Battery Troubleshooting Examples - Club Car DS Villager 4 Maintenance And Service Manual Supplement

BATTERIES

BATTERY TROUBLESHOOTING EXAMPLES

The following information represents a few examples of troubleshooting battery problems.
Example 1
Vehicle no. 68 was suspected of having a bad battery due to its performance. As a result, the battery charger
test was performed. After a full charge, the battery charger ammeter read 8.0 amps. Next, the on-charge volt-
age test was performed and the following results were recorded:
BATTERY NO.
On-Charge Voltage
*Battery no. 3 appears suspect. Batteries no. 1 and 4 are also suspect. Next, a hydrometer test should be
conducted on all batteries.
Hydrometer test results:
CELL NUMBER
Cell 1 (Positive Post)
Cell 2
Cell 3
Cell 4 (Negative Post)
*After the hydrometer test, it appears that battery no. 1 is the problem. Next, the discharge test was per-
formed.
Discharge test results:
BATTERY NO.
Discharge Voltage
*After a discharge test which lasted 45 minutes, battery no. 1 is clearly shown to be the problem. Battery no.
4 should be watched a little more closely but appears to be okay. Battery no. 1 should be replaced with a bat-
tery that has about the same age and usage as the other batteries in the set.
Example 2
Vehicle no. 70 was also suspected of having a bad battery due to its performance. The battery charger test
showed 7.0 amps after a full charge. After confirming there were no problems with the electrical system,
charger or brakes, the on-charge voltage was recorded as follows:
BATTERY NO.
On-Charge Voltage
*Battery no. 2 was immediately suspected as the problem. After checking battery no. 2 with a hydrometer, it
was discovered that the negative post cell was completely dead. Battery no. 2 should be replaced with a bat-
tery that has the same age and usage as the other batteries in the set.
1 2
10.15 V 10.60 V
1 2
1.200* 1.265
1.285 1.275
1.265 1.270
1.275 1.270
1 2
5.44* V 7.33 V
1 2
10.48 V 9.77* V
2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
3 4
9.80* V 10.16 V
BATTERY NUMBER
3 4
1.300 1.250
1.290 1.270
1.275 1.265
1.285 1.265
3 4
7.73 V 7.15 V
3 4
10.53 V 10.57 V
Battery Testing – 8 Volt
5 6
10.56 V 10.61 V
5 6
1.280 1.260
1.295 1.265
1.280 1.275
1.275 1.275
5 6
7.43 V 7.41 V
5 6
10.55 V 10.33 V
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