Replacing Batteries - Club Car Gasoline Service Manual

REPLACING BATTERIES

22
DANGER
E
• BATTERY - EXPLOSIVE GASES! DO NOT SMOKE. KEEP SPARKS AND FLAMES AWAY. VEN-
TILATE WHEN CHARGING OR USING IN AN ENCLOSED SPACE. ALWAYS WEAR FULL FACE
SHIELD AND RUBBER GLOVES WHEN WORKING WITH BATTERIES.
• USE EXTREME CAUTION WHEN USING TOOLS, WIRES, OR METAL OBJECTS NEAR BAT-
TERIES! A SHORT CIRCUIT AND (OR) SPARK COULD CAUSE AN EXPLOSION.
• 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 MAG-
NESIA OR VEGETABLE OIL. CALL A PHYSICIAN IMMEDIATELY.
- EYES: FLUSH WITH WATER FOR FIFTEEN MINUTES. CALL PHYSICIAN IMMEDIATELY.
WARNING
• TURN KEY SWITCH OFF, PLACE FORWARD AND REVERSE LEVER IN THE NEUTRAL POSI-
TION, AND REMOVE KEY PRIOR TO SERVICING.
• DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES, CHAINS,
ETC. BEFORE SERVICING VEHICLE.
• ALWAYS USE INSULATED TOOLS WHEN WORKING NEAR BATTERIES OR ELECTRICAL CON-
NECTIONS.
• TO AVOID UNINTENTIONAL STARTING OF THE VEHICLE, DISCONNECT BATTERIES AS
SHOWN IN FIGURE 22-5 OR FIGURE 22-6, AND THEN DISCHARGE THE CONTROLLER ON
POWERDRIVE SYSTEM 48 VEHICLES AS FOLLOWS:
- TURN THE KEY SWITCH TO ON AND PLACE THE FORWARD AND REVERSE LEVER IN THE
REVERSE POSITION .
- SLOWLY DEPRESS THE ACCELERATOR PEDAL AND KEEP IT DEPRESSED UNTIL THE
REVERSE WARNING BUZZER CAN NO LONGER BE HEARD. WHEN THE BUZZER STOPS
SOUNDING, THE CONTROLLER IS DISCHARGED.
• 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 DIREC-
TION 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. BAT-
TERY 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. First, discon-
nect the batteries and discharge the controller as described in the WARNING above. Then remove
remaining wires and batteries.
• See Figure 22-5 for 36 volt V-Glide 36 volt Vehicle battery wiring.
• See Figure 22-6 for PowerDrive System 48 and PowerDrive Plus Vehicle battery wiring.
2. Visually inspect the new batteries for any damage that may have occurred in transit.
3. If the old battery wires are going to be reused, inspect them for broken or frayed wires, damaged termi-
nals, or worn insulation. Remove any corrosion on the connectors. One cup of bicarbonate of soda
(baking soda) in a gallon of water and a bristle brush do an excellent job of neutralizing and removing
the corrosion. Be careful not to allow this baking soda solution to enter the battery.
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