Club Car Precedent Villager 2, Maintenance And Service Manual

Page: 183 / 414

ELECTRIC VEHICLE - BATTERIES Battery Replacement
14
BATTERY REPLACEMENT
See General Warnings on page 1-2.
WARNING
• Wear steel-toe shoes when replacing batteries.
• 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.
• When replacing batteries in the Single Point Watering System, place the battery cap from the new
replacement battery onto the used battery being removed from the car. Important safety warnings on
the battery cap must remain with the battery after it has been removed from the car
CAUTION
• To prevent degradation of battery performance and life, never mix batteries of different part numbers
or brands/model numbers. Anytime a different model of battery is used, the charging algorithm must
be changed to match it. For vehicles with PowerDrive charger, the vehicles' onboard computer must
be changed to one that is specific to the battery installed. For vehicles with high-frequency charger
(e.g. ERIC or QuiQ), the charger must be reprogrammed with the appropriate algorithm specific to
the battery installed.
1. Before removing batteries, note the orientation of the batteries and the connecting wires. Disconnect the battery
cables and discharge the controller as instructed.
See Disconnecting the Batteries – Electric Vehicles on
page 1-4. Remove remaining wires and batteries.
2. 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 50 to 70 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.
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.
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. Regroup batteries as required. See Battery Regrouping on page 14-3.
6. Install regrouped or new batteries in the proper orientation (Figure 1-1, Page 1-4) . 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 hold-down retaining nuts to 72 lb·in (8.1 N·m), alternating between
hold-down bolts.
7. Install wires in proper sequence. Install black wire to negative post of battery no. 6 (6 x 8-Volt battery set) last.
See Connecting the Batteries – Electric Vehicles on page 1-4.
8. If replacement batteries have a different part number than the batteries removed, either replace the vehicles'
onboard computer or reprogram the high-frequency charger.
See preceding CAUTION.
9. 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.
2019 Precedent Villager 2 Maintenance and Service Manual Page 14-5