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

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.

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.

Thanks for the video. Took apart my 5A 56v battery that would not charge. On the charger it was just solid red. Had 46v on the battery. Checked the contacts looked black. Took out the contact board so I could get to clean them better. Filed down a wooden paddle (lolly pop stick) put some alcohol on it and cleaned those puppies right up. The stick turned black as. Put the pack together and PTL we got it charging. Thanks for your help.

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

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.

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

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

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. 👍 Looooong 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 😒

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.

I ORIGINALLY POSTED THIS ONE YEAR AGO. I AM REPOSTING IT IN CASE ANYONE HASN'T TRIED, "THE BANG TRICK WORKED .SO glad I saw the comments about banging the battery from about a foot off the ground and dropping it. IT WORKED I had THREE bad batteries. ALL THREE have been working GREAT since May and I recharge and use the OFTEN. HOLY GUACAMOLE. Those three bad ones were here for over a year. I bought two news ones for 200 bucks a piece but something told me NOT to throw those bad ones out. THREE bad batteries now working PERFECTLY for five months with CONSTANT charging. I have the lawn mower, leaf blower and snow blower and I use the blower daily and the lawn mower once per week. HUGE area. SO glad I was the comments about BANGING the batteries. THANK YOU THANK YOU THANK YOU"

WARNING: When pulling apart the end with the power button, be careful to do this gently. Mine would not budge, then let loose, pulled off some of the wires which subsequently shorted and now I have a bit more complicated project on my hands.

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.

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.

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.

Thank you for these videos, I'm gonna watch them to try to diagnose my Ego battery (it's an intermittent fault). If you don't have small enough 40 A fuses, you might solder two 20 A fuses in parallel...

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.

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

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.

LOVE THIS CHANNEL. New Subscriber in Austin Texas! Currently looking to replace a Mod# BA2240 Ego battery (56V, 4.0 AH) that turned my mower into a lonely sculpture. Seems 4.0 AH was discontinued. Grr. Looking at "investing" $250 in a 5.0 AH ($250 for A BATTERY!) Now, my tinker heart wants to crack open my old 4.0 AH and see if it only needs a $2 fuse!!!! I know soldering. And the old battery was heading to a recycling bin, anyway. Nothing to lose and $245 to save! YES. I will be cautious. Daddy taught me well. I will plan to touch-back with a debrief for you. --- Rock on!

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