Club Car Carryall 500 2015 Maintenance And Service Manual page 291

TROUBLESHOOTING AND ELECTRICAL
SYSTEM: PEDAL-START GAS VEHICLE
TEST PROCEDURE 1 – Battery
See General Warnings on page 1-1.
DANGER
• Due to the danger of an exploding battery, wear a full face shield and rubber gloves when working near
a battery.
• Battery – Explosive gases! Do not smoke. Keep sparks and flames away from the vehicle and service
area. Ventilate when charging or operating vehicle in an enclosed area. Wear a full face shield and
rubber gloves when working on or near batteries.
• Battery – Poison! Contains acid! Causes severe burns. Avoid contact with skin, eyes, or clothing.
Antidotes:
– External: Flush with water. Call a physician immediately.
– Internal: Drink large quantities of milk or water. Follow with milk of magnesia or vegetable
oil. Call a physician immediately.
– Eyes: Flush with water for 15 minutes. Call a physician immediately.
NOTE: The battery must be properly maintained and fully charged in order to perform the following test procedures.
Battery maintenance procedures, including watering information and allowable mineral content, can be found
in section Electrical Components: Pedal-Start Gas Vehicle on page 20-1 of this manual. See Battery
on page 20-32.
1. Place the Forward/Reverse handle in the NEUTRAL position and the neutral lockout switch in the MAINTENANCE
position. Chock the wheels.
2. Check for loose or corroded battery terminal connections. Remove the negative (–) cable first and clean, tighten,
and replace connections as necessary.
Hydrometer Test
A hydrometer (CC P/N 1011478) measures the specific gravity. The greater the specific gravity, the greater the state of
charge of the battery. A fully charged battery should read between 1.250 and 1.280 at 80 °F (27 °C). Never add acid to
the battery to obtain a higher specific gravity (Figure 18-7, Page 18-18).
CAUTION
• Do not allow battery acid from battery caps or hydrometer to drip onto the body. Battery acid will
cause permanent damage. Wash off immediately.
Performing the Hydrometer Test
1. Be sure that the battery has sufficient water to cover the plates by approximately 1/2 in. (12.7 mm) and is
fully charged prior to beginning the test. If water must be added, recharge the battery before performing the
hydrometer test (Figure 18-8, Page 18-18).
2. Remove the vent cap.
3. Using a battery thermometer (CC P/N 1011767), record the electrolyte temperature of a center cell.
4. Squeeze the rubber bulb of the hydrometer and insert into the cell. Slowly release the bulb, drawing electrolyte
up into the glass tube of the hydrometer.
2015 Carryall 500 and 700 Maintenance and Service Manual
18
Test Procedures
Page 18-17