SportsTran - Battery Care

By: Sportstran  11-11-2011
Keywords: Batteries, Waste Water, Golf Cart

Read and Understand all Disclaimers, Warnings, Cautions and Danger items below.

BATTERIES — ELECTRIC GOLF CART OR UTILITY VEHICLE

NOTE: Recycle or dispose of discarded batteries in accordance with local, state, and federal regulations.

  • The batteries in DS V-Glide 36-Volt electric vehicles are 6 volts each.
  • The batteries in PowerDrive System 48 and IQ System electric vehicles are 8 volts each or 12 volts each depending on the make, model and year model of the golf cart or utility vehicle.

Both the 6- and 8-volt batteries are deep-cycle batteries, specially built for electric golf cart or utility vehicle application. Automotive batteries should never be used. 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 PowerDrive System 48 and IQ System vehicles with new batteries to 36 holes of use between charges in the first two months of operation; V-Glide 36-volt vehicles should be limited to 18 holes between charges in the first two months. Batteries should be fully charged before first use of new golf cart or utility vehicle, before first use of a golf cart or utility vehicle after storage, and before releasing golf cart or utility vehicle for use each day.

BATTERY CARE

To keep batteries in good working condition, follow this maintenance program on a regular basis:

  1. The batteries should be kept clean and free of corrosion. Wash tops and terminals of batteries with a solution of baking soda and water (1 cup (237 ml) baking soda per gallon (3.8 L) of water). Rinse solution off of the batteries. Do not allow this solution to enter the battery. Be sure terminals are tight. Let the terminals dry and then coat with Battery Terminal Protector Spray (CCI P/N 1014305). See following NOTE.

    NOTE: Dispose of waste water properly.

  2. The electrolyte level in the batteries should be checked weekly (Figure 22). Add water only after charging unless the electrolyte level is below the top of the plates. In this case, add just enough water to cover the plates, charge and then check the level again. Never charge batteries if plates are exposed above electrolyte level. For best battery life, add only distilled water. See following NOTE.

    NOTE: A battery watering gun or bottle is available at many auto parts dealers.

  3. The hold-down straps should be tight enough so that the batteries do not move while the golf cart or utility vehicle is in motion, but not so tight as to crack or buckle the battery case. Tighten hold-down retaining nuts to 40 in lb (4.5 N·m). The terminal connections should be clean and tight, and any worn insulation or frayed wires should be replaced. Tighten battery terminals to 110 in-lb (12.4 N·m).
  4. After use, the batteries should be placed on charge. The batteries should never be left discharged any longer than absolutely necessary (do not leave discharged overnight).

BATTERY CHARGER — ELECTRIC GOLF CART OR UTILITY VEHICLE

NOTE: Because the golf cart or utility vehicle's onboard computer (OBC) has a storage charge feature that automatically checks and recharges the batteries as necessary every 15 days, the charger can remain plugged to a PowerDrive or IQ System vehicle throughout the storage period.

Shortly after charging begins, the PowerDrive Charger will shut off in order to run a self-diagnostic program (ammeter will drop to zero). Charging will resume in a few moments (ammeter returns to previous rate of charge). This will be repeated at one hour and at two hours into the charge cycle.

Each electric golf cart or utility vehicle is supplied with a fully automatic battery charger as standard equipment. The AC cord to each charger is to be connected to a source capable of supplying 10 amperes minimum per charger. To reduce the risk of electric shock, the battery charger must be grounded. The charger is equipped with an AC electric cord having an equipment-grounding conductor and a grounding type plug. The AC plug must be connected to an appropriate receptacle that is properly installed and grounded in accordance with the National Electrical Code and all local codes and ordinances. See the owner's manual supplied with the charger for specific operating instructions before using the charger. The use of an extension cord with the charger should be avoided. If an extension cord must be used, use a three-conductor no. 12 AWG (American Wire Gauge) or no. 14 SWG (British Standard Wire Gauge), heavy duty cord with ground, properly wired and in good electrical condition. Keep it as short as possible (no more than 12 feet (3.7 m)). Place all cords so they will not be stepped on, tripped over, or otherwise subject to damage or stress. Ensure that the charger ventilation slots are unobstructed and that there is adequate ventilation.

CHARGING BATTERIES

NOTE: When temperatures fall below 65 °F (18.3 °C), batteries charged in unheated areas should be placed on charge as soon as possible after use. Batteries are warmest immediately after use, and cold batteries require more time to fully charge.

Insert the charger DC plug into the vehicle receptacle. The charger will turn on two to ten seconds later. When inserting the DC plug, align the raised guide on the plug with the guide slot in the receptacle and push straight in slowly. The PowerDrive Charger interacts with an onboard computer on PowerDrive System 48 and IQ System vehicles. The computer records the amount of energy consumed during vehicle use. While the charger is plugged in, the vehicle's control circuit is locked out, preventing operation of the golf cart or utility vehicle as well as the possibility of consequent damage to the charger and the golf cart or utility vehicle. Once the lockout is actuated, the charger turns on. The onboard computer then records the amount of energy being returned to the batteries. When the optimum amount of energy needed to replenish the batteries is returned, the charger will shut off. The control circuit lockout remains activated until the charger plug is disconnected from the golf cart or utility vehicle. Only PowerDrive System 48 and IQ System vehicles are compatible with PowerDrive chargers. Other Club Car models or vehicles made by other manufacturers are not compatible. As long as the charger is allowed to shut off by itself, the batteries will be fully charged. Overcharging and undercharging will normally be prevented. The charger is automatic and will turn off when batteries are fully charged. If the charger does not seem to be operating properly, or if the batteries seem weak, contact your local Club Car distributor/dealer.

PLUG AND RECEPTACLE

The charger cord, plug, and receptacle are wear items and should be inspected daily. Visually inspect them for cracks, loose connections, and frayed wiring; they must be replaced when worn or damaged. If charger plug or receptacle show signs of corrosion or the plug is difficult to insert or remove, the receptacle contacts and plug terminals should be cleaned with a good electrical contact cleaner or lightly sprayed with WD-40® brand spray lubricant. The plug should then be inserted and removed several times to ensure ease of insertion, ease of removal, and good electrical contact.

NOTE: If the warning tag has been damaged or removed from the DC cord, have it replaced immediately.

RECEPTACLE FUSE LINK

As an additional feature to protect the batteries and charging circuit from an overload, the electric golf cart or utility vehicle is equipped with a receptacle fuse link. If the charger does not come on when the vehicle is placed on charge, visually inspect the fuse link.

BATTERY — GASOLINE GOLF CART OR UTILITY VEHICLE

The battery in the Club Car gasoline golf cart or utility vehicle is a 12-volt, low maintenance battery that requires infrequent watering. Any corrosion around the positive (+) or negative (—) terminals should be washed off with a solution of baking soda and water (1 cup (237 ml) per gallon (3.8 L) of water). Rinse solution off the battery. Do not allow this solution to enter battery. Be sure terminals are tight (battery terminals should be tightened to 20 ft-lb (27.1 N·m)). Let the terminals dry and then spray them with Battery Terminal Protector Spray (CCI P/N 1014305).

Be sure battery clamp is properly tightened. Tighten to 12 ft-Ib (16.3 N·m). A loose battery clamp may allow the battery to become damaged from vibration or jarring. If battery appears weak, have it charged by a trained technician. The battery should never be left discharged any longer than absolutely necessary (do not leave discharged overnight).

DANGER:

  • Battery — Explosive gases! Do not smoke. Keep sparks and flames away from the golf cart or utility vehicle and service area. Ventilate when charging or operating golf cart or utility vehicle in an enclosed area. Wear a full face shield and rubber gloves when working on or near batteries.
  • Charge batteries in a well-ventilated area only. Batteries emit hydrogen while being charged. Hydrogen is an explosive gas and must never exceed a level of 2% of the air.
  • 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 followed with milk of magnesia or vegetable oil. Call a physician immediately.
    • Eyes: Flush with water for 15 minutes. Call a physician immediately.
  • Tools, wires, and metal objects can cause sparks when shorted across a battery.

WARNING:

  • Wear safety glasses or approved eye protection when servicing the golf cart or utility vehicle or battery charger. Wear a full face shield and rubber gloves when working on or near batteries.
  • Use insulated tools when working near batteries or electrical connections. Use extreme caution to avoid shorting of components or wiring.
  • The charging area must be ventilated. Hydrogen level in the air must never exceed 2%. The total volume of air in the charging area must be changed five times per hour. Exhaust fans should be located at the highest point of the roof. Contact a local HVAC engineer.
  • Do not charge the golf cart or utility vehicle batteries with the golf cart or utility vehicle covered or enclosed. Any enclosure or cover should be removed or unzipped and pulled back when batteries are being charged. An accumulation of hydrogen gas could result in an explosion.
  • Only trained technicians should repair or service the charger. Contact your nearest Club Car distributor/dealer.
  • Each charger should have its own dedicated 15 or 20 ampere separately protected (circuit breaker or fuse) single phase branch circuit, in accordance with all applicable electrical codes for the location.
  • Connect the charger AC supply cord to a properly grounded, three-wire outlet of the proper voltage and frequency as shown on the charger.
  • Do not use an adapter to plug the charger with a three-prong plug into a two-prong outlet. Improper connection of the equipment-grounding conductor can result in a fire or an electrical shock.
  • An extension cord or electrical outlet must accept a three-prong plug. Extension cord should be a three-wire No. 12 AWG, and be as short as possible. The use of improper extension cord could result in fire or an electrical shock.
  • Do not operate the charger if it has received a sharp blow, was dropped, or otherwise damaged in any way.
  • Have worn, cut, or damaged power cords or wires replaced immediately.
  • Do not use near fuels, grain dust, solvents, thinners, or other flammables. Chargers can ignite flammable materials and vapors.
  • Do not expose to rain or any liquid. Keep the charger dry.
  • Never push objects of any kind into the charger through cabinet slots. They may touch dangerous voltage points or cause an electrical short circuit that could result in fire or electrical shock.
  • Do not connect a stationary charger to the receptacle if the charger cord, plug, or the golf cart or utility vehicle receptacle is broken, damaged, or does not make a good electrical connection. Fire or personal injury can result. Have a qualified technician replace the parts.
  • 36-Volt Accu-Power Charger: Do not disconnect the DC output plug from the golf cart or utility vehicle receptacle when the charger is on. The resulting arcing and burning could damage the plug and receptacle and could cause batteries to explode. If the charger must be stopped, disconnect the AC supply plug from the wall outlet before disconnecting the charger DC cord from the golf cart or utility vehicle receptacle.
  • 48-Volt PowerDrive Charger: When the charger is on, the charger DC cord may be disconnected from the golf cart or utility vehicle receptacle slowly. Jerking or pulling the DC cord out quickly could cause arcing and burning that could damage the plug and receptacle and could cause batteries to explode.
  • Do not block or cover the charger ventilation slots. The slots provide ventilation and protect the charger from overheating.
  • Do not allow clothing, blankets, or other material to cover the charger.
  • Do not allow the charger to operate for more than 30 minutes at 19 or more amperes.
  • 36-Volt Accu-Power Charger: Do not leave the DC cord plugged into a vehicle receptacle while unattended for more than two consecutive days. Severe overheating and damage to the batteries may result if the charger does not turn off.
  • Install surge arrestors on incoming AC power lines. Surge arrestors will help protect electrical components in the charger and on the golf cart or utility vehicle from all but direct or close lightning strikes.
  • Be sure all wire connections at the receptacle and the fuse link are clean and tight.
  • Do not rock or bend the plug. To connect the charger plug to the vehicle receptacle, grasp the plug handle and push the plug straight into the receptacle.
  • Do not pull on the DC cord. Do not twist, rock or bend the plug. To disconnect the charger plug from the vehicle receptacle, grasp the plug by the handle and pull the plug straight out of the receptacle.
  • Do not connect a charger to the receptacle if the charger cord, plug, or the vehicle receptacle is broken, damaged in any manner, or does not make a good electrical connection. Fire or personal injury can result. Have it replaced by a qualified service person immediately.
  • Failure to follow these instructions could result in damage to the charger cord, the plug, and (or) the vehicle receptacle.
  • Do not use a charger if:
    • The plug is too loose or does not make a good connection.
    • The plug and receptacle feel hotter than normal during charge.
    • The plug pins (PowerDrive Chargers), blades (Accu-Power Chargers), or receptacle contacts are bent or corroded.
    • The plug, receptacle, or cords are cut, worn, have any exposed wires or are damaged in any way.
  • Using the charger with any of the above symptoms could result in a fire, property damage, personal injury, or death.
  • If the receptacle fuse link is blown, determine the source of the electrical problem and correct it before replacing the fuse. Contact your nearest Club Car distributor/dealer.
  • Do not jump start a dead battery using another battery and jumper cables.

CAUTION:

  • On all vehicles, turn off all accessories before charging batteries.
  • If battery wire terminals are damaged or corroded, they should be replaced or cleaned as necessary. Failure to do so may cause them to overheat during operation.
  • If battery wire terminals are damaged or corroded, they should be replaced or cleaned as necessary. Failure to do so may cause them to overheat during operation.

DISCLAIMER:

The material provided above is solely for informational purposes only, and is not intended to supplement, modify or act as a substitute for the manufacturer's owners manual. This information is of a general nature and may not apply to specific makes and models. Consult your owner's manual for golf cart or utility vehicle specific information, or contact a trained service technician. Sports Transportation, LLC expressly disclaims any and all liability for claims, rights, demands, expenses, actions, and/or causes of action whatsoever (including without limitation, negligence, gross negligence, breach of statutory duty or any tortious liability), arising out of or in any way related to any loss, damage, or injury, including without limitation death, that may be sustained by individuals or entities, or any property of individuals or entities, as a result, directly or indirectly, of the information provided herein.

Keywords: Baking Soda, Batteries, Battery Terminal Protector, Golf Cart, Utility Vehicle, Waste Water,

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