Battery Replacement - Club Car Turf 252 2007 Maintenance And Service Manual

25

Battery Replacement

BATTERY REPLACEMENT
See General Warning 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.
1. Before removing batteries, note the orientation of the batteries and the connecting wires. Disconnect the batteries
and discharge the controller. See Disconnecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
Remove remaining wires and batteries. See Wiring Diagrams on page 22-2.
2. Visually inspect the new batteries for any damage that may have occurred in transit.
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.
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1. Place Tow/Run Switch in TOW before disconnecting or
connecting battery cables.
2. Remove negative battery cable.
3. Remove positive battery cable.
Connect battery cables in reverse order.
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Figure 25-1 Battery Configuration
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 25-1, Page 25-2). 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 to 40 in-lb (4.5 N·m), alternating between hold-down bolts.
6. Install wires in proper sequence (Figure 25-1, Page 25-2). Install black wire to negative post of battery no. 8 last.
Make sure all connections are tight. See Connecting the Batteries – Electric Vehicles, Section 1, Page 1-4.
7. Give the battery set a full charge prior to operation to ensure all the batteries are fully charged and the cells are
equalized prior to use.
Page 25-2 2007-2009 Turf 252, Carryall 252 and XRT 900 Maintenance and Service Manual
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BATTERIES: ELECTRIC VEHICLES