Golf Car Battery Use and Maintenance

Intro

The batteries in your golf car or maintenance vehicle require a minimal, but important amount of care to achieve maximum utility and life.  They are a substantial portion of your overall investment so understanding proper operation and maintenance will maximize long term use before replacement is necessary.

This guide is meant to provide the minimum information necessary and is presented in non-technical terms.  There are numerous internet sources for more detailed information and “how-to” guides.  Please read through this guide and follow the important safety guidelines.

Function

Just what is a battery and what does it do?  The battery bank is a storage reservoir of electrons (direct current electricity).  When called on for work, the electrons flow from the reservoir to the device requiring electricity to perform work.  In our case, this is the electric motor driving the cart.

Like a water reservoir, once depleted the reservoir needs to be refilled.  The battery charger takes power from a common electrical outlet and puts electrons back into the battery for use again later.  The total amount of energy available is determined by the size of the batteries (again, much like the water reservoir).  The measurement unit is “amp hours.”  The more amp hours, the bigger the storage capacity and the longer the motor can run.

Operation

The type of battery typically installed in these vehicles is what’s known as a flooded, lead acid, deep cycle battery.  They are designed for the demands of these cars and substitutes should never be used.  Fire and/or acid leaking may result.  You should also never exchange batteries from another golf car as their lifecycle will be in a different stage.

The amp hours available for work is not a fixed number.  It is highest (at rating) when brand new and slowly diminishes over time.  These batteries have a finite number of discharge cycles and ultimately need to be replaced.

As such, in order to maximize their lifespan, the operator can be mindful of good operating practices.  The “bad” practices listed should be used only when absolutely necessary and not as a regular matter of operation.  The good practices will help insure longest possible battery life between charges and longest overall life.

Hard acceleration = bad Full throttle = bad Deep discharge (dead) = bad Frequent starts = bad Sitting after discharge = bad Partial recharge = bad

Gentle acceleration = good Up to 2/3 throttle = good Partial discharge (to 50%) = good Constant speed = good Recharge after use = good Complete recharge = good

In many ways the golf car is much like an automobile in this way.  Stop and go or going 80 both result in poor fuel economy.  A constant moderate speed is where efficiency is achieved.

Charging

Charging is important.  The batteries will perform best when used at a full state of charge.  They will also last longer when left on a charge as the charger automatically delivers the amount of charge required.  It constantly monitors the batteries and provides only what they need. 

The best practice is to leave the car plugged in until it needs to be used and then plug it back in at the end of the day, allowing it to completely charge.

The process of charging creates hydrogen gas, which is highly explosive.  Charging should always be done in a well-ventilated area away from flames or anything that can create a spark.

Charging procedure for “Powerwise” EZGO brand chargers:

• Verify charger condition by plugging into the wall receptacle and by inserting the charger handle into the car. LED lights will flash red or green (Powerwise QE) or the ammeter will indicate 21 amps (Powerwise 1&2) based on depth of discharge.
• Allow the charger to complete the charge process by turning off on it’s own.
• Short charging will promote unbalanced batteries and needless battery replacement.
• Equalization charges are recommended monthly with daily use, bi-annually with periodic use.  Equalization is an overcharge performed on flooded lead-acid batteries after they have been fully charged. It helps eliminate stratification and sulfation, two conditions that can reduce the overall performance of a battery.

     Visual LED Display Information, LED Operation Codes:

     SHORT LED flash green = less than 80% charged
     LONG LED flash green = more than 80% charged
     SOLID LED green = 100% charged
     RED LED flash = fault code

Equalization Charging

An equalization charge is a controlled over-charge of the battery set to allow the electrolyte to mix properly and to promote equal cell voltages and specific gravity readings.

Perform all periodic maintenance checks (fluid level, clean batteries, good terminal connections, and verify proper charging).  Make sure that the car was charged the night before and that the charger has cycled off.

• Unplug the charger from the car.
• Inspect the DC plug of the charger and the receptacle of the car for any damage.
• Plug the charger back in to the car to restart the charger.
• Allow the charger to run until it cycles off.
• Unplug the charger and re-plug immediately after the previous charger cycle.
• Repeat for three consecutive charge cycles.
• Allow batteries to cool.
• Inspect and / or correct the electrolyte level in all battery cells.
• Return the car to service.

Maintenance

BATTERIES CAN KILL.  Golf car batteries have enough voltage and current to stop the heart.  It is important when working around batteries that nothing conductive (like metal or body parts) can cross the terminals.  Also, wearing rubber gloves and safety goggles are absolutely necessary.

Regular maintenance involves inspection and water management.  The batteries are filled with a solution of acid and water (electrolyte).  The charging and operation process evaporates the water so it is necessary to maintain water at the proper level.

Once a month, remove the battery caps and inspect the water level.  It should be just covering the top of the lead plates.  Fill ONLY using distilled water.  Be sure it says “distilled” as most bottled waters have a high level of minerals which are bad for the plates.  Distilled water can be found in any grocery store and is usually in the “laundry or cleaning solution” area.  Do NOT fill to the top of the case as the electrolyte needs room for expansion and over filling will result in this corrosive fluid being pushed out of the battery and into the surrounding area.  The plates need to be covered so they will not oxidize and become less effective.

While adding water, inspect the batteries for any signs of bulging, cracks or other problems.  Inspect the connections for unusual corrosion or loose connections.  Contact a trained technician if there is anything that looks out of the ordinary.  Automatic watering systems are available.  Ask an All Cal representative about this if you are interested.

Every 12 months the connections should be removed, terminals and connection cables cleaned with a battery brush and retightened.  This requires working with conductive tools so it is necessary the technician is trained and capable of these requirements.  If not, please call All Cal and one of our technicians can come out to service the vehicle batteries, check brakes and perform other routine maintenance items.

If you have any questions about your golf car battery use or maintenance, please don’t hesitate to contact All Cal.