Underneath the vehicle as well
as the outside of the vehicle
Rinse corrosion, dirt, grass, etc. from top of batteries
Rinse between batteries and vehicle frame.
Clean Batteries with mixture of Baking soda and water
Recommend 20 PSI
Battery Water Levels
Check water levels monthly,
bi-monthly or weekly depending on frequency of use.
Use distilled water Only in batteries.
Only fill when needed - do not over fill.
Only fill after vehicle has been fully charged
*If levels are low or empty, the battery plates will dry out
and batteries will no longer take a full charge.
*If levels are overfilled, the battery acid will overflow
and will cause corrosion.
At the end of each day, even
with minimal use
Firmly plug in charger cord, make sure amp gauge needle on
the charger switches on.
Amp gauge will register 0 when batteries are fully charged.
Yellow light on vehicle dash may remain on for 10 seconds
after unplugging unit.
We do want to remind you
of the following safety items:
- These Vehicles are not allowed on public roads.
Except Tomberlin Models
- Check with your agent for insurance on your
- When not in use leave the vehicle in neutral,
remove the key from the ignition and
engage the parking brake.
- Buzzer will sound when vehicle is in reverse.
- Before using the vehicle, be sure to read and
understand operating instructions on the
- Before using the vehicle, be sure the driver
and riders read and understand the safety
warnings on the dash panel.
- Caution: when washing battery
compartment and maintaining batteries,
wear appropriate gloves, protective eyewear and
protective clothing as battery acid can be harmful
to skin and clothing.
Storage - Winter or
Store in cool environment, not Necessarily heated.
Recommend tire pressure at 20 PSI.
Do not latch parking brake.
put into long term storage run the risk of battery
damage if not stored correctly.
Batteries are the most critical and most
expensive component of an electric car.
Fully charged batteries will not freeze.
Low charged batteries could freeze and
crack. Batteries would need replacement.
The car's on-board computer (OBC) operates
the charger, it continually takes battery readings and
then talks to the charger telling it what kind of charge and
how long to charge the batteries. The OBC
only allows the charger to cycle a specific number of times
before it will not allow it to come
on again. After that time, the computer will begin to
discharge the batteries by continuing to take
battery readings causing possible battery freeze and
36V Vehicle - full charge,
batteries full and unplug charger from outlet and vehicle -
disconnect black wire from - (negative) terminal on battery
#6 located on the driver rear side. Disconnect thick red
wire from + (positive) terminal battery #1 located on
passenger rear side - If green wire on battery #4,
disconnect from + (positive) terminal - reconnect wire to
negative terminal before connecting to positive terminal.
– Powerdrive & IQ Chargers:: Fully charge the
batteries, unplug charger from outlet and vehicle - if unit
has a tow/run switch, put switch in tow position and leave
in tow until you reconnect the battery wires - disconnect
black wire from - (negative) terminal on battery #6 on
driver rear side - disconnect thick red wire from +
(positive) terminal on battery #1 on passenger rear side -
reconnect wire to negative terminal before connecting to
If you have a Battery Life Saver
it must be disconnected for the winter.
If it is not disconnected it will discharge the batteries
and they can Freeze.
a. First make sure all the batteries have sufficient water (more on this later), that the battery caps are securely in place and the car has been fully charged. Then take a hard look at the battery support racks and battery holddown brackets & J-bolts. Will the battery racks last another year? Do you need to remove the batteries to repair the racks from which a battery or two is hanging at a 45 degree angle? If so you can skip this part till the racks are fixed. Most times it's not so drastic but look the racks over from above and from beneath the car. Advanced cases of corrosion are usually accompanied by a white powdery looking crystal that can be very difficult to remove. If the following procedures do not virtually eliminate all of the corrosion, then the batteries may need to be removed for a more thorough cleaning & corrosion prevention treatment. Sometimes you will find a clean, corrosion-free rack that has become so rusted it is about to collapse. We have replacement racks if needed.
b. Unplug the charger and drive the car to a convenient place where you can wash the batteries & battery racks with Neuralizer and lots of water (a garden hose is OK). Lock the hill brake.
c. If you have a ‘Regen’ electrical drive system (automatically brakes going down hill), turn the master switch under the seat to ‘Tow’ or ‘Tow/Maintenance’. This turns the car completely off. Be sure to turn the switch back to the "RUN" position after the cleaning is done or the car will appear dead and not run. If you do not have a ‘Regen’ system, then just put the Forward/Reverse (F/R) switch into the Neutral position (straight up) and turn the key to 'OFF'. Thisalsoturns the car off…no battery current can run to the motor.
d. We recommend that youDO NOTdisconnect any terminals unless it is necessary to clean them. Regen cars require that the 'Tow/Maintenance' switch be in the 'Tow' position and that a specific sequence of battery cable disconnect & reconnect be followed. There is some other maintenance to do here and we will cover cables later.
e. Be sure your car is in a location where the neutralized acid water, grass and mud you are about to wash off will safely wash away. Be sure you are NOT wearing your best pair of jeans or any other cotton clothing. Hydrosulphuric acid just loves cotton. It’s fond of skin too, so you might want long sleeves and gloves. Polyester clothing resists the acid.
f. Start on one side of the car and spray our environmentally-friendly Battery Acid Neutralizer (Available through us or Most auto parts stores.) all over the tops & terminal posts of the batteries. Be sure to spray between the batteries, on the battery racks and the inside walls of the body panels, especially if they are metal. Now use an old paintbrush to scour all the nooks and crannies of the battery tops and sides. Use a little extra water if you need.
Follow the directions on the bottle in applying and rinsing the Neutralizer. This liquid will change color to signify that it is neutralizing any acid present. Allow this to sit and work for a few moments then wash the entire compartment thoroughly with lots of water, being careful to avoid any acid splash on you.
NOTE: Water from a garden hose with a pressure nozzle, or even a commercial pressure washer, will not hurt the electrical parts of the car. Do not let the pressure washer beat on the vital parts but a good thorough washing is fine. Many golf clubs wash the battery compartment out every day…this is great! Several times a month is good, once a month is ok, and certainly at seasons end at a very minimum. Hey, it’s your investment!
Step 2 Maintaining the Battery Terminals:
WARNING 1: For your personal safety always, always, always remove all metal rings from fingers, watchbands or bracelets from wrists and any loose hanging necklaces. If the jewelry becomes a short circuit between batteries, it will ruin your day…not to mention that cherished family jewel!
WARNING 2: Eye safety is a vital concern too. Wear eye protection! A spark from a cigarette (NO! NO! NO!) or an inadvertent battery short, such as a dropped tool (or ring), can cause a battery to explode, spew battery acid and possibly catch fire (I know this from ‘lucky’ personal experience, thank you). Extreme caution is required. At best an exploding battery will put the hurt to your ears and a twitter to your heart. Should you ever drop a wrench or other tool onto a battery top—BACK AWAY IMMEDIATELY!!!!! It’s a whole lot better, and cheaper, to replace a battery than have an Emergency Room visit. Retrieve the tool after the smoke clears.
a. This is an excellent time to check, clean, tighten & treat all of the battery terminal connections. Battery cable looseness, weakness, oxidation and corrosion all interfere with the flow of electricity, create excess heat and decrease the efficiency of your Electric Golf Car. This looseness can occur and must be checked for anywhere the thick battery cables attach; battery to battery, at the F&R switch, at the motor, controller or old fashioned wiper contact & speed board, the resistor coils or the solenoid(s). Loose connections create a lot of heat; look for discoloration in the cable end or on the stud and base plate to which the cable is attached. Then perform these simple checks.
b. Firmly wriggle each cable end side-to-side and then flex up & down. There should be no looseness or movement sideways. If there is, the nut that secures the cable end to the battery post needs to be tightened some more. Use an adjustable wrench to tighten the nut, clockwise, just a little. If the cable end will not tighten, even if the nut feels tight, there may be a problem with the battery post stud. Chronic looseness of any cable end, anywhere in the electrical system, will cause a heat buildup. Enough heat can ‘freeze’ the nut on the battery stud making it impossible to tighten the cable end. Over time the heat can cause the lead post to melt away from the cable end. You can see the melted lead on the side of the post, much like melted candle wax…sometimes even a pool on the battery top...sometimes little beads of lead splatter onto the battery top, melt through the case and allow acid to jostle out as the car moves along. Be sure the cables are tight to the post. Don’t overtighten but they should be good and snug...no wriggle! Club car calls for 110 ft lbs of torque on your cables.
The up & down flex motion at the cable end should not cause much flex. The end should be rigid to the post. The cable can flex but the metal terminal end should not. If it does easily flex or, worse, it’s downright floppy, then you have a battery cable end about to give it up. Fix it before it leaves you, where you least expect it! Replace that cable or crimp on a new end. If you intend to repair your own cables & ends, you must use a good Crimping tool,quality cableand the right sizecable ends(or lugs). One of the most common problems I see on battery cable repairs is a poor crimp of the cable end onto the cable. The crimping method is very important! If the cable is not adequately secured to the terminal end it becomes just another weak link in the electrical system of the car, subject to failure at any moment. If this situation exists when new batteries are installed, that connection will give it up. Guaranteed! Better yet Replace the cables with New ones to insure proper connection.
c. If your battery cables have the old lead'Banjo' style terminalsthat encircle the battery post (which are just about obsolete), then follow this tip: Remove and examine the inside of each terminal connector in turn. The lead should be shiny and bright on both the outside of the post and inside the lead terminal. If there is any dullness, it is beginning to oxidize and you will need to clean the lead surface, preferably with a sharp knife or battery tool , until it's shiny and clean.
There are commercialbattery terminal cleaner toolsand if used regularly, they can do a good job. The sharp edged tools are usually more effective than the wire brush kind. A tough, crusty oxidation can build up that is difficult to remove, especially after a long storage. The wire type terminal cleaners are ok if you do this procedure several times a year, but they are largely ineffective on built up, crusted oxidation. The positive terminal of a battery seems to be the most susceptible to the oxidation and corrosion. Lots of people think their batteries need to be replaced when they will no longer push the car the required distance. The owners are usually very surprised to learn that the batteries are fine, but the terminals had become so corroded that current could not flow. There's a lot of current trying to flow to an electric golf car motor and it needs a clean circuit.
d. The type of terminal oxidation mentioned above looks fundamentally different from battery rack corrosion. Although both are caused by the acid atmosphere in and around the batteries, rack corrosion is much more sinister. The crust and/or cable looseness can cause the car to stop. Corrosion eats the car frame alive. Aluminum and steel frames alike! Aluminum frames can handle salt air much better than steel but both are the vegetable de jour to battery acid. This rack corrosion frequently looks like a white flakey powder buildup on aluminum or steel racks, and, in severe cases, any other metal parts in the immediate vicinity including the brake cables. It is very tenacious and may require that the batteries be removed to adequately remedy the problem.
Getting back to the battery cable ends & posts, the positive terminals generally take the brunt of the corrosion but the negative posts will corrode too. If they arebadlycorroded, you will need to do some serious cleaning. You will probably need to remove the corroded cable end from the battery, soak it in neutralizer, wire brush the metal ends and then carefully inspect them. If the ends are ok, firmly wire brush the battery post clean, reinstall the cable on the battery and tighten the nuts securely to the battery post (are the nuts clean too? Don’t contaminate a clean cable end with a corroded nut). Don't leave a cleaned battery cable end & post susceptible to future corrosion. Once finished all terminal should have a Heavy coat of terminal Protectant applied, Again you can get this from us or Most auto parts stores.
CAUTION: Some electrical systems, especially 'regen' systems, require a certain sequence when disconnecting & reconnecting the batteries. Be sure to put the car in the TOW position before loosening any battery terminals. Consult your service manual.
Corrosion can appear as thick yellow goop (sometimes gooey, sometimes hard), white powdery fluff or as a bluish goo. Sometimes these different kinds are on the same terminal or post or battery rack. This is never a good thing, as corrosion seems to beget more corrosion. Real trouble comes when it starts to get on the frame of the car. Wave goodbye to the battery racks…and car frame in severe cases. And it is so easy to prevent! Just hose off those batteries and racks several times a year. No big deal!
e. Recheck the water levels in each cell. Take the hassle out of this task by using aBattery Fill system . Use distilled water only (lead acid batteries can be damaged by certain elements found in some tap water even though it is safe to drink). Be sure the electrolyte (water) in each battery cell is, at a minimum, above the plates (the straight lines you can see when looking straight down into the battery cell). See Chart above on Battery Maintenance , For regular everyday use the battery water level should be just slightly below the cell collar, or about 1" below the top of the battery. Be careful not to overfill the cells. This is an extremely common mistake that results in shortened overall battery life, acid getting everywhere and it requires much more maintenance. For a full discourse on batteries and battery care see above Maintenance chart.
In cold climates, when the car will be left uncharged for several months, leave the water level a little low (but above the plate tops). This raises the specific gravity of the acid, which will help prevent freezing. Lead acid batteries keep much better in the cold than in the heat, as long as the charge stays up. A fully charged battery will not freeze until 60 to 70 BELOW zero, whereas a discharged battery can freeze at 20 degrees ABOVE zero. As a battery becomes discharged, the acid turns into water by the basic chemical nature of the lead acid battery. As the charge is restored the water turns back into acid. A detailed description his chemical process is beyond the scope of this presentation.
In the busy golf season, especially in hot climates, it is recommended to keep a close eye on the water level, especially in older batteries, and NEVER let it get below the plates. Also a dirty, acid covered battery will self discharge at a faster rate than a clean treated battery, even in cooler temperatures. The heat of a Florida summer can cause a battery to self-discharge in as few as 30 days. Of course freezing is not a risk but a discharged battery will sulfate, which basically means hard crystals of lead sulfate clog up the tiny sponge-like cavities of the battery plates. The longer the state of discharge lasts the more this hard-to-dissolve crystalline structure builds up and the result is less capacity in the batteries. It is a harmful, and costly, condition if left untended. Adequate charging avoids this situation.
f. OK, we have washed and cleaned and inspected and tightened and neutralized. Let the car drip dry for a while and then apply some sort of protection on the battery terminals to inhibit future corrosion. When used on a new or clean terminal, proper protection can last for years with little care. If the terminals are corroded, treatment does little but add to the mess. Don’t believe the claims that a little spray here and there takes care of badly corroded batteries. Clean them thoroughly with a neutralizer. After they dry put a protective coating on the terminals. If the batteries are fully charged you can run the car. If not, put the car on charge and allow the charger to run its full course. It will take 10 or so charge/discharge cycles to bring the batteries up to full capacity after a long layover
g. After the charge is done, unplug the charger from the car and from the wall. If you have a ‘ReGen’ model electric (1995 and newer), be sure to turn the switch under the seat from ‘Tow’ or ‘Tow/Maintenance’ to the 'RUN' position. This electrically reactivates the car for use after off-season storage.
This is a very important step when preparing the car for seasonal use. If left in the ‘TOW’ or 'Tow Maintenance' mode, the electronic speed controller stays dormant and will not permit the car to move. Conversely, if the 'TOW' switch has been left in the 'RUN' mode, then the controller capacitors stay energized by drawing off the limited battery juice. This can run the battery voltage below the critical charger 'cut-on' voltage leaving open the possibility of excessive lead sulfate buildup on the plates and the batteries freezing if the temperature drops too low.
Step 3 Finalizing the Spring Prep:
a. Check the tire pressure and inflate to 20–25 psi. If you have had any problems with a slow leaking tire, don't waste your time with the foam 'fix-a-flat' stuff that comes in aerosol cans. Usually it does not work permanently and can damage aluminum wheels. I recommend taking the tire to a professional and having it plugged (it's only about $5) or, if the tread is still pretty good, have a tube installed. While you are down there filling the tires, look at the tread and sidewalls. The tire tread wear should be even across the entire width of the tire. If the center of the tread is worn too much the tire may be over inflated. If the outer edges are worn away then a chronic air leak is indicated, maybe due to weather-cracked sidewalls or a pesky nail or golf tee. (Sidewall cracks are very common and the cracks may or may not be the cause of the air leak. Apply soapy water with a brush over the sides & tread of the tire and look for bubbles caused by escaping air.) If one front tire is worn a lot more than the other, or the tread has signs of feathering or scrubbing in one direction, then a front-end inspection & alignment may be needed. It is somewhat normal for a tire to lose 5 to 10 pounds of air pressure over a long storage. Low tire pressure makes the battery pack have to work a lot harder to power the car around especially in grass or loose dirt & gravel.
b. In order to keep your steering system working smoothly and to prevent any metal-to-metal deterioration, it is recommended that your front end be greased at least once a year. For those that use the car year round or use the car above and beyond 'normal' usage', you may need to do this more often. A simple grease gun with a flexible delivery hose is recommended for this step. With the key 'OFF' and the F&R shifter in Neutral, jack up the front end.
CAUTION: Always use jack stands or blocks of some kind when you are under the car. Never trust a jack to hold fast and you can never be too safe. The minute you let your guard down in situations under the car, bad things can happen.
On each tie rod end, steering gear box and king pins, there is usually a grease 'nipple'. Wipe it clean with a rag and then press the end of the grease gun onto the nipple (also called a zerk fitting). Be sure the end seats correctly. Squeeze the trigger two or three times into each fitting. Do not fill to the point where grease is running out everywhere. If this happens clean the excess right away. Grease is a magnet for dirt and if there is grease all over the tie rod ends, dirt will follow. Most older golf cars have grease fittings with only a few exceptions. Don't waste your time looking for grease fittings on most Yamaha cars, or on some of the most modern cars...there isn't a single one. They have a closed system which never needs grease (it actually works pretty well).
c. The beginning of the season is also a good time to be sure your brakes, brake cables and hill brake catch mechanism are all working. It doesn't do a lot of good to have a great running golf car that you can't stop and keep stopped. A hill brake lock mechanism that unexpectedly pops off is a mortal danger to anyone downhill from you. Thoroughly inspect and test your brakes regularly. Begin (with the key off and on flat ground) by pressing the brake pedal. Feel to be sure the pedal doesn't feel mushy or weak. If the pedal tension does feel weak, you may have a frayed, kinked or broken brake cable, need to disassemble & clean the brake shoe adjuster mechanisms, or perform an adjustment to the turnbuckle or compensator spring assembly where the cables attach to the pedal underneath the floorboard. Carefully check the cables for battery corrosion, rust, kinks or signs of fraying or unraveling. You can purchase new cables from us we always have them in stock. If the pedal tension feels ok, but you still have to press extra hard on the pedal for adequate stopping, you may need to replace the shoes or inspect the brake drums. You can purchase new brake shoes from us as well. Any of these components or combinations thereof may need replacing or adjusting to achieve the proper brake feel. With the vast array of shoes and cables out there, I have seen all kinds of jury-rigged combinations. The correct shoes, installed & adjusted the proper way, with the correct brake cables & drums helps insure proper braking and personal safety.
The hill brake catch mechanism is hard to inspect on any car. There are two parts; the notch (usually found on the hill brake pedal) and the catch plate (usually attached to the frame of the car). Either or both can wear and unexpectedly pop off creating a dangerous rollaway situation. The best way to check this is to get down with a flashlight and carefully look at both components for wear. The other way is to lock the hill brake down as you normally would, then reach down with your hand and try to dislodge the catch mechanism by shaking & pulling at it. It should hold very firmly. If it seems to pop off too easily then there may be need of closer inspection. Consult your service manual for complete instructions...or seek a Professional, we have full spring prep services available.
d. Check the differential gear oil. This is often overlooked for years and lack of oil will cause the diff gears to start clashing, which leads to an audible gear whine noise as you accelerate, cruise or coast. Lots of older cars have both a drain & a fill hole but on more modern cars the drain hole has gone away. All of the modern Dana brand differentials take regular 30 weight motor oil but other brands may take a heavier 90 weight gear oil. It is always best to consult your service or owner's manual. If the oil is determined to be low; add to the bottom of the fill hole. Be sure you are adding oil to the actual fill hole and that you are not overfilling because this can lead to other problems such as blown wheel seals and oily brakes. I always look carefully for signs of oil leaks around the differential cover plate and at the end of the axle tubes where the wheels attach. If things look oily or caked with damp looking dirt chances are you have a leak somewhere.
e. Check your reverse buzzer! OK, OK, everybody hates these loud obnoxious intrusions while concentrating on backing up. I find many cars that have a wire pulled or cut off. Others that just don't work. I also find cars accidentally left in the reverse position, standing quietly, ominously, waiting to unexpectedly go into reverse when the gas pedal is pushed. Don't do this! That buzzer is for everyone's safety. With the modern 'regen' cars the buzzer functions as the 'roll away protection' warning signal as well. In today's market, where the majority of golf cars are used for personal transportation and where parking areas are crowded with other golf cars and people standing around, a disabled or broken reverse buzzer is inviting disaster. And perhaps a lawsuit! If the buzzer is too loud, locate where it is located on the car and partially cover the buzzer hole with a piece of duct tape. This will cut down on the high pitch while still making enough noise to warn the driver, and those standing around, that the car is in reverse. If you walk past an unattended car accidentally left in reverse, do your neighbor a kind deed and shift it to Neutral. The legs you save may be your own!
f. The last thing to really take a close look at is how tight the battery cable connections are throughout the car. I mentioned loose battery cables at the battery posts proper but anywhere the heavy cables are attached--the motor, the F&R switch, the wiper-style speed switch with the fixed copper contacts (older pre-electronic speed controller cars, 1990 & before), the newer electronic speed controller terminals and especially on the solenoid (the most common failure)--must have a clean tight connection. Looseness=Heat. Heat=Failure...sooner or later. Again, if you can wriggle the cable end under the nut that secures it, it is loose! If the entire contact moves on the board to which it is attached, then the contact is loose on the board. If the cable end or the stud & nuts look oxidized, rusted or discolored compared to other nearby connections, it indicates a heat buildup and impending failure. Deal with these problems while you have the vehicle where it can be repaired. Otherwise you will be dragging that bad boy home.