Battery Replacement - Club Car 2009-20011 Electric Precedent Maintenance And Service Manual

BATTERIES

BATTERY REPLACEMENT

See General Warnings on page 1-1.
WARNING
• To prevent electrolyte leakage from the battery vents, batteries must be kept in an upright position.
Tipping a battery beyond a 45° angle in any direction can allow a small amount of electrolyte to leak
out the vent hole. Do not exceed this 45° angle when lifting, carrying, or installing batteries. Battery
acid can cause severe personal injury to skin or eyes, and can damage clothing.
• When replacing batteries in the Single Point Watering System, place the battery cap from the new
replacement battery onto the used battery being removed from the car. Important safety warnings on
the battery cap must remain with the battery after it has been removed from the car
1. Before removing batteries, note the orientation of the batteries and the connecting wires. Disconnect the battery
cables and discharge the controller as instructed. See Disconnecting the Batteries – Electric Vehicles on
page 1-3. Remove remaining wires and batteries (Figure 18-6, Page 18-16) (Figure 18-7, Page 18-16).
2. Visually inspect the new batteries for any damage that may have occurred in transit. New batteries will not deliver
their full capabilities until they have been discharged and recharged 20 to 50 times. To obtain the maximum
service life from new batteries, restrict vehicles with new batteries to one hour of operation between charges for
the first two months vehicle is in service. Batteries should be fully charged before first use of new vehicle, before
first use of a vehicle after storage, and before use each day.
3. If the battery cables are to be reused, inspect them for broken or frayed wires, damaged terminals, or worn
insulation. Remove any corrosion on the connectors. A solution of baking soda and water (1 cup (237 mL) baking
soda per 1 gallon (3.8 L) of water) does an excellent job of neutralizing and removing the corrosion. Be careful
not to allow the baking soda solution to enter the battery.
4. Check and clean the battery rack and hold-downs. The nuts and bolts on the hold-downs may corrode. It is
therefore advised they be cleaned periodically and replaced as necessary.
5. Install batteries in the proper orientation (Figure 18-6, Page 18-16) (Figure 18-7, Page 18-16). Install battery
hold-downs. The hold-downs should be tight enough so batteries do not move while vehicle is in motion, but not
so tight as to crack or buckle battery case. Tighten hold-down retaining nuts to 72 in-lb (8.1 N·m), alternating
between hold-down bolts.
6. Install wires in proper sequence. Install black wire to negative post of battery no. 4 (4 x 12-Volt battery set) or
battery no. 6 (6 x 8-Volt battery set) last. Tighten all connections to 110 in-lb (12.4 N·m). Coat all terminals with
Battery Terminal Protector Spray (P/N 1014305) to minimize future corrosion.
7. Give the batteries a full charge prior to operation. This ensures all the batteries are fully charged and the cells are
equalized prior to use.
2009-2011 Electric Precedent Maintenance and Service Manual
Battery Replacement
Page 18-15
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