Club Car 2007 XRT 800, Maintenance Service Manual

Page: 446 / 516

BATTERIES: ELECTRIC VEHICLES Battery Replacement
Page 24-8 2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
24
*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.
BATTERY REPLACEMENT
See General Warning on page 1-1.
ý
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.
4. Before removing batteries, note the orientation of the batteries and the connecting wires. Disconnect the
battery cables as instructed. See WARNING “To avoid unintentionally starting...” in General Warn-
ing on page 1-2. Remove remaining wires and batteries. See Wiring Diagram on page 21-2.
5. Visually inspect the new batteries for any damage that may have occurred in transit. New batteries will
not deliver their full capabilities until they have been discharged and recharged 20 to 50 times. To obtain
the maximum service life from new batteries, restrict vehicles with new batteries to one hour of operation
between charges for the first two months vehicle is in service. Batteries should be fully charged before
first use of new vehicle, before first use of a vehicle after storage, and before use each day.
6. 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.
7. 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.
8. Install batteries in the proper orientation (Figure 24-4, Page 24-9) . 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.
9. Install wires in proper sequence (Figure 24-4, Page 24-9) . Install black wire to negative post of battery
no. 4 last. Tighten all connections to 110 in-lb (12.4 N·m). Coat all terminals with Battery Terminal Pro-
tector Spray (CCI P/N 1014305) to minimize future corrosion.
10. Give the batteries a full charge prior to operation. This ensures all the batteries are fully charged and the
cells are equalized prior to use.