Maintenance Centre

Electric Golf Buggy Hydrometer and Equalisation Charging

Using a Hydrometer

A hydrometer is used to test the state of charge of a battery cell. This is performed by measuring the density of the electrolyte, which is accomplished by measuring the specific gravity of the electrolyte. The greater the concentration of sulphuric acid, the more dense the electrolyte becomes. The higher the density, the higher the state of charge.

Hydrometer Testing Procedure

1. Draw electrolyte into the hydrometer several times to permit the thermometer to adjust to the electrolyte temperature and note the reading. Examine the colour of the electrolyte. A brown or grey coloration indicates a problem with the battery and is a sign that the battery is nearing the end of its life.
2. Draw the minimum quantity of electrolyte into the hydrometer to permit the float to float freely without contacting the top or bottom of the cylinder.
3. Hold the hydrometer in a vertical position at eye level and note the reading where the electrolyte meets the scale on the float.
4. Add or subtract four points (.004) to the reading for every 10° F (6° C) the electrolyte temperature is above or below 80° F (27° C). Adjust the reading to conform with the electrolyte temperature, e.g., if the reading indicates a specific gravity of 1.250 and the electrolyte temperature is 90° F (32° C), the 1.250 which gives a corrected reading of 1.254. Similarly if the temperature was 70° F (21° C), subtract reading of 1.246.four points (.004) from the 1.250 to give a corrected.
5. Test each cell and note the readings (corrected to 80° F or 27° C). A variation of fifty points between any two cell readings (example 1.250 - 1.200) indicates a problem with the low reading cell(s).

As a battery ages the specific gravity of the electrolyte will decrease at full charge. This is not a reason to replace the battery providing all cells are within fifty points of each other.

Since the hydrometer test is in response to a vehicle exhibiting a performance problem, the vehicle should be recharged and the test repeated. If the results indicate a weak cell, the battery or batteries should be removed and replaced with a good battery of the same brand, type and approximate age.

! WARNING !
To prevent battery explosion that could result in severe personal injury or death, never insert a metal thermometer into a battery. Use a hydrometer with a built in thermometer that is designed for testing batteries.

Specific gravity is the measurement of a liquid that is compared to a baseline. The baseline is water which is assigned a base number of 1.000. The concentration of sulphuric acid to water in a new golf car battery is 1.280 which means that the electrolyte weighs 1.280 times the weight of the same volume of water. A fully charged battery will test at 1.275 - 1.280 while a discharged battery will read in the 1.140 range.

! NOTE !
Do not perform a hydrometer test on a battery that has just been watered. The battery must go through at least one charge and discharge cycle in order to permit the water to adequately mix with the electrolyte.

The temperature of the hydrometer reading must be corrected to 80° F (27°C). High quality hydrometers are equipped with an internal thermometer that will measure the temperature of the electrolyte and will include a conversion scale to correct the float reading. It is important to recognize that the electrolyte temperature is significantly different from the ambient temperature if the vehicle has been operated.

Equalisation Charging

An equalization charge is a controlled over-charge of the battery set to allow the electrolyte to mix properly and to promote equal cell voltages and specific gravity readings.

1. Perform all periodic maintenance checks (fluid level, clean batteries, and good terminal connections, proper charging).
2. Make sure that the buggy was charged the night before and that the charger has cycled off.
3. Unplug the charger from the car.
4. Inspect the DC plug of the charger and the receptacle of the car for any damage.
5. Plug the charger back in to the car to restart the charger.
6. Allow the charger to run until it cycles off.
7. Unplug the charger and re-plug immediately after the previous charger cycle.
8. Repeat for three consecutive charge cycles.
9. Allow batteries to cool.
10. Inspect and / or correct the electrolyte level in all battery cells.
11. Return the car to service.