Flooded lead-acid batteries rely on an electrolyte mixture of sulfuric acid and water to function. During charging, electrolysis occurs, converting water into hydrogen and oxygen gas. This gassing process leads to the gradual loss of water from the battery cells over time. If the electrolyte level drops too low, the internal lead plates become exposed to air, which causes sulfation and permanent damage that reduces battery capacity. Maintaining the correct water level sustains the battery’s capacity and overall lifespan.
Essential Tools and Safety Precautions
Maintenance requires gathering the correct materials and prioritizing personal protection due to the corrosive nature of battery acid. The only liquid acceptable for replenishment is distilled water, as tap water contains minerals and impurities that contaminate the electrolyte and interfere with chemical reactions. Protecting the eyes and skin requires ANSI-approved safety glasses and chemical-resistant gloves to shield against accidental acid splashes.
A solution of baking soda and water should be mixed to neutralize any acid residue present on the battery terminals or surrounding components. Terminals can be gently cleaned with this solution and a non-metallic brush before the caps are opened. Batteries release flammable hydrogen gas during charging and while caps are removed, requiring work in a well-ventilated area away from open flames or sources of spark. Working with batteries requires a non-metallic tool set to prevent accidental short circuits across the terminals.
Step-by-Step Battery Watering Procedure
The process of adding water requires careful attention to timing and level to prevent damage or overflows. Ensure the golf cart is powered off, the key is removed, and the charging cord is disconnected before accessing the battery compartment. Once the compartment is open, carefully remove all vent caps from the cells, noting their position for proper replacement.
A general rule is to add water only after the battery has completed a full charging cycle. The charging process naturally expands the electrolyte volume, and filling beforehand would lead to overflow and acid spillage. If the lead plates are visibly exposed, add just enough distilled water to cover the plates before initiating a charge cycle. This minimal addition prevents immediate plate damage from oxidation.
The final level adjustment must be made accurately after the charge is complete and the electrolyte level has stabilized. When the battery is fully charged and the caps are off, use a specialized battery filler tool or a clean funnel to introduce the distilled water into each cell. The proper fill level is 1/8 to 1/4 inch above the top of the internal plates or up to the indicator ring found in some cell designs.
Overfilling the cells leads to electrolyte leakage when the battery is subsequently charged, which promotes corrosion and reduces the lifespan of the battery tray and surrounding components. Once the correct level is reached in every cell, securely replace all the vent caps. Any spilled electrolyte should be immediately neutralized using the prepared baking soda solution and then wiped clean to prevent corrosion. Checking the water level once a month is a good general practice, though high-usage carts or those frequently charged in hot weather may require checks every two weeks.