EGO 56V 5Ah Battery Repair (2P pack repair #1) FUSE

In this video we have a EGO 5Ah Battery on the bench. I purchased this item as a non-working for parts from ebay for around $55 USD. I just wanted to find out what the differences in the larger capacity battery may be and see what failed inside. It ended up being similar and it was a very fortunate easy fix. I will keep you up to date if the 30A fuse holds up under heavier loads in the near future. I may have to get creative with a 40 or 50A fuse replacement if I do have any issues. Hope it helps and Thanks for watching!
* update 4-14-2020: I have not had any issues with the 30A fuse in any tool I have. it's been holding up well!
*update 8-6-20: I ended up soldering in a 40A metal fuse links in this pack as a permanent fix and have not had any issues!
this is a link to a similar fuse link, cut down and soldered in place with 200W soldering iron:

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[suitersautomotive]

Dude, awesome! Thanks for posting this. It's always interesting to see how a company built something and the simple fixes to what would otherwise be expensive replacements.

[peteewing]

Thanks for the video on how to disassemble the 56V 5Ah battery. Mine is used for the mower and wouldn't go through the charge cycle with the fan starting. Opened it up and everything looked OK. Started cleaning the contacts with emery paper and some film came out. Cleaned the 4 contacts best I could by sliding the emery paper between the contacts. Also, used a que-tip and rubbing alcohol on the charger contacts. Put it onto the charger and the fan started and its charging again. Not the first time li-ion batteries gave me trouble from the charging contacts. As the unit gets older may need to be cleaned more frequently.

[georgeavargas]

I like to say TY I have and EGO 56V and by watching your video I fix it. It was blinking red and found it was a dirty contacts. TY again great information. I'm 67 years old and always wanted to work on electronics and your video give me that insight.

[danmortimer]

Thank you for helping me fix a 4Ah ego battery with this technique. I had a blown fuse and replaced with a 30A automotive.

[annespacedroid]

I had repaired a 1st gen 2.5ah all cells out of service. Replaced all cells, spot welded👌. Green led flashes once each second, cells discharging. Replaced Mjd117 on bms, now have a fully functioning 2.6ah with all new cells & nickel strips (I used 0.2mm pure nickel) 👍 A 4ah 1st gen came back to life after finding corrosion on a bms connector & plug. 👍

Watching your videos certainly helped accomplish this. So thank you for your time & effort uploading your videos/sharing your findings. Much appreciated.

I won't be selling any packs, I'll be using them myself & seeing how long my repairs last. 🙄

I only have 2 more packs to work on. Both 1st gen 4.0ah, with different bms in each. One pack was subject to the owner "dropping" it on the ground until it worked. Which led to a connector breaking away from its solder. New connector might solve that. While I was waiting for said connector I decided to start work on the other 4ah. All cells dead, no longer in service. 28 new 2600mah cells later & all new spot welded nickel, I now have a 5.2ah battery. 😁

I had charge balanced each cell & tested the battery, worked perfect. 👍 runtime.

Placing in either standard or rapid charger results in them both reporting the battery is already fully charged. It isn't. Couldn't swap out the BMS from other 4ah, different connectors.

1st gen 2.5ah (now 2.6ah) I repaired had the same connections, so swapped that in, both chargers charge battery properly now, rapid charger shows correct charging levels progress. Rapid charger gets to 100% & then shows one solid red led (over temp, which it isn't) & I'm suspecting that has something to do with the 2.5ah bms having different (lack of?) circuit/software for the 4ah temp sensors.

So can I assume the 4ah BMS is at fault? Everything about it works except charging. After only a few seconds the charger shows battery full.

Any common parts that fail causing this situation?. Anything I can test?.

Or do I need to wait for a donor bms 😒

[Guitrum]

Just did the fuse replacement with a 30amp automobile fuse just like in the video. Worked like a charm!

[invisi-bill]

Thanks for the video. Nice to have the disassembly explained. My one year old 5ah battery had intermittent faults where the red light would come on after around 10 minutes of mowing. Letting it cool for 5 minutes gave me another 10 minutes of mowing. Turned out to be a scorched contact on the plus terminal inside the battery . Upon disassembly I noticed that the plastic around this contact had some carbon soot, making the diagnosis a bit more obvious. Anyway, cleaning up the contacts (as Pete says below) did the trick.

[nigelc]

Thanks for the video, I also cleaned the contacts ( 2000 sandpaper ) and it's going way better, I've never leaf blown the section without running out of power & after cleaning the contacts it never skipped a beat.

[codystonehill]

Thanks for this video! All i could find was a 30amp fuse for my mower, hoping it'll hold up! For the first time in a year... My battery is finally charging. I am so happy.

[brilwiljeff]

I got the red flash. Watched this, disassembled completely, still 53v. cleaned the contacts and now have green. Thumbs up.

[flynpnda]

Thanks for the disassembly video. I have a couple of batteries that exhibit the same behavior after a multi-head tool (assuming) shorted out the batteries. Both batteries illuminate when pressing the buttons but will not take a charge. I'll definitely use this as a reference for a diagnosis

[mlongpine]

Thanks for the video, I have a 4.0 amp hour battery and it had the exact same symptoms. Taking it apart I couldn't find any remnants of a fuse, maybe at never had one and the board was defective from the beginning. I got this battery 2+ yrs ago as part of an open box from Home Depot with my chainsaw. I don't think it even went with that chainsaw because he had to find the battery over to the side, that is why I didn't try to warranty through Ego, and it was marked "as is" from Home Depot. Soldered in a fuse an it now works.

[NickConteSC]

Wish I had your tech skills and logical calm thinking brain sir!

[jonk]

Thanks for your videos. I have many EGO power tools and a 2000w power station with four 7.5ah battery. I recently started using one of my 7.5ah battery to power my custom electric recumbent trike. This EGO 7.5ah battery performs better than my 48v ebike battery. I’m glad u do tear downs on these packs. It gives me clues on what these batteries can handle. Keep sharing and posting your videos. They really help a lot.

[icebmwpower]

Wow! Just Wow man. What a video! Deep bow for your time and effort! Keep doing the good work.

[InexplicableBill]

Excellent video man thank you for doing this. I have 4 batteries for 3 different devices that are still under warranty one which is giving me errors and charging issues. I'm looking forward to whatever EGO is going to do for me but as soon as I'm out of warranty on these expensive things I'm going to be coming back to this video! My little DIY solder gun won't be up to the task tho so I guess I'll need an upgrade! Thanks again!

[firehawk]

Thank you for posting this. I have two dead batteries I picked up free in the recycle bin at work and will see if they failed in the same way.

[narref]

The new ones still go bad... after 7 uses. Customer service have been useless.. Thank you for the video, I may be able to salvage it.

[timwelch]

I have a 7.5 ah that when on the charger the charger says it is 100%. The battery off the charger only lights 2of5, and gives me the equivalent of run time. Any idea what the issue could be?

[paulstanley]

Super helpful. I have the same fuse out on my 5 Ah. Very clever use of the car fuse.