Replacing Batteries - Club Car 1998 Maintenance And Service Manual Supplement

13
BATTERIES

REPLACING BATTERIES

Read DANGER and WARNING on page 13-1.
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. First, place the
Tow/Run switch in the TOW position. Disconnect the batteries and discharge the controller as described in
the WARNING on page 13-1. Then remove remaining wires and batteries. See Figure 13-5, Page 13-4 for
PowerDrive Plus Vehicle battery wiring.
2. Visually inspect the new batteries for any damage that may have occurred in transit.
3. If old battery cables are going to be reused, inspect them for broken or frayed wires, damaged terminals, 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.
4. Check and clean the battery rack and hold-downs. The nuts and bolts on the hold-downs may corrode. It is
therefore advised that they be cleaned periodically and replaced as necessary.
5. Install batteries in the proper orientation (Figure 13-5, Page 13-4). 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.
Page 13-4 1998/1999 PowerDrive Plus Maintenance and Service Supplement
FRONT
OF VEHICLE
5
REMOVE NEGATIVE
6
CABLE FIRST
Figure 13-5 PowerDrive Plus Battery Configuration
2
1
3
4
PLACE TOW/RUN SWITCH IN THE
TOW POSITION BEFORE
DISCONNECTING BATTERY
CABLES
Replacing Batteries