Watering Tips
In most electric forklifts, lead-acid batteries rely on water in each cell to keep the right balance of chemicals that power the equipment. If the water level gets too low, it can lead to unnecessary damage, shorten the battery’s lifespan, and reduce the time it holds a charge. This not only makes the forklift less effective but can also drive up energy and maintenance costs. Let's discuss how you can prevent this damage.
How to Correctly Water your Forklift Battery
How to know when to water your forklift battery?
Visual Inspection: Regularly inspect the electrolyte levels in each battery cell. If the electrolyte level is below the recommended level or the lead plates are exposed, it's time to water.
Float / Eye Indicator: If your battery is equipped with a float or eye indicator in the vent caps, you will be able to look at those. These indicators change color or position when there is a need for watering.
What supplies are needed?
Watering gun: A specialized tool designed for controlled and accurate filling of each cell.
Water: Distilled or deionized water should be the only water added to your battery. Other water types can affect battery lifespan and performance.
Personal Protection Equipment (PPE): To protect yourself from acid spills or splashing, the following PPE is necessary to protect yourself:
Goggles
Gloves
Long Sleeves
Long Pants
Closed Toe Shoes
Battery Water System (optional but recommended): This is a series of tubes and nozzles that are inserted into each forklift cell, completely automating the watering process. Connect to your water source to the system, turn on water, then once each cell is full, the water will automatically shut off--minimizing overfilling the battery.
The Watering Process
Ensure that you are wearing proper PPE.
Locate the battery's fill holes or vent caps, typically found on top of each battery cell.
Remove vent caps.
Pour distilled water into each cell, ensuring even distribution (watering jug or watering gun can be used).
If filling with a watering jug--fill cells until the electrolyte reaches the recommended level. Do not overfill. This can cause spillage during charging.
If using a watering gun--most watering guns have a pressure sensor that will stop once the correct level is reached.
When finished watering, place vent caps back on securely.
Frequently Asked Questions
Q: Why is it important to water forklift batteries?
A: Forklift batteries need water to work properly. As the battery charges, some of that water naturally evaporates. If the water level gets too low, the internal plates can be exposed and start to get damaged. Adding water keeps the plates covered, protects the battery, and helps it last longer.
Q: What if the battery runs out of water?
A: When the water level is too low and the lead plates are exposed, it can create a reaction that gives off a lot of heat. This heat causes even more water to evaporate, which can speed up wear and shorten the overall life of the battery.
Q: What if there is too much water in the battery?
A: Overfilling a battery can cause it to boil over during charging, which means some of the corrosive battery acid can spill out. This not only reduces the battery’s electrolyte levels but can also damage equipment, eat away at floors or racking, and even cause serious injury if it comes into contact with skin.
