Steps for adding distilled water to lead-acid batteries used in forklifts

Time：2025-07-25 14:51:02

Browse：622

This article will provide a detailed introduction to the steps for adding distilled water to lead-acid batteries used in forklifts and answer common questions in practical operation.

As an important piece of equipment in industrial production and logistics transportation, the performance of lead-acid batteries, the power source of forklifts, directly affects the operational efficiency. During the charging and discharging process of lead-acid batteries, the water in the electrolyte will gradually evaporate. If distilled water is not replenished in time, it will lead to exposed plates, reduced capacity, and even shortened battery life. Therefore, it is of vital importance to master the correct method of adding distilled water. This article will provide a detailed introduction to the steps for adding distilled water to lead-acid batteries used in forklifts and answer common questions in practical operation.
1. Preparations Before adding distilled Water
Before starting to add distilled water, adequate preparations should be made to ensure the safety and effectiveness of the operation.
First of all, you need to prepare appropriate materials and tools, including distilled water that meets the standards (do not use tap water, mineral water, etc. The reasons for this will be explained in detail later), protective equipment (acid-resistant gloves, goggles, masks), a special funnel, and a clean cloth.
Secondly, it is necessary to choose a safe operating environment. Operations should be carried out in a well-ventilated area away from fire and heat sources, avoiding direct sunlight. At the same time, ensure that there are no open flames, sparks or flammable items around to prevent the risk of explosion or fire.
Finally, it is necessary to check the condition of the battery in advance. Observe whether there is any damage or leakage on the battery's appearance. If there is any damage or leakage, the fault should be dealt with first. Check whether the connection lines of the battery are firm, loose or corroded. If there is corrosion, wipe it clean with a cloth dipped in soda water.
2. Specific steps for adding distilled water
Step 1: Disconnect the battery. First, turn off the power of the forklift. Then, in the order of "removing the negative terminal first, then the positive terminal", use a wrench to loosen the nuts on the battery electrode terminals, remove the connection wires, and keep the connection wires away from the electrodes to avoid short circuits.
Step 2: Open the liquid filling hole cover. Locate the liquid filling hole cover on the battery (usually a black or transparent plastic cover; for some batteries, the liquid filling hole cover is an integral type while for others, it is an independent small cover). Gently pry open or unscrew the liquid filling hole cover by hand or with a suitable tool, and place it in a clean area.
Step 3: Observe the liquid level height. Observe the electrolyte level inside the battery through the filling hole. Under normal circumstances, the electrolyte level should be 10 to 15mm higher than the plates. If the liquid level is lower than or close to the plates, distilled water needs to be added.
Step 4: Add distilled water. Insert the funnel into the liquid filling hole and slowly pour in distilled water. Pay attention to controlling the addition speed to avoid the distilled water overflowing. During the addition process, constantly observe the liquid level. Stop adding when the liquid level reaches the standard of 10-15mm higher than the plate.
Step 5: Cover the liquid filling hole cover. After the addition is completed, put the liquid filling hole cover back to its original position and make sure it is tightly closed to prevent the electrolyte from overflowing and impurities from entering.
Step 6: Reconnect the battery. Connect the connecting wires back to the electrode terminals in the order of "connect the positive terminal first, then the negative terminal", and tighten the nuts with a wrench to ensure a firm connection.
Step 7: Clean and organize. Wipe the surface of the battery with a clean cloth, especially the electrode terminals, to ensure there is no electrolyte residue. Sort out the tools and materials and clean up the operation site.
3. Frequently Asked Questions and Answers
Question 1: How should the frequency of adding distilled water be controlled?
Answer: The frequency of adding distilled water should be determined based on the usage frequency of the forklift and the condition of the battery. Generally speaking, the battery level should be checked once a week. If the level is found to be lower than the standard value, distilled water should be added in time. For frequently used forklifts, the inspection frequency can be appropriately increased, such as once every 3 to 4 days. In addition, after the battery has undergone multiple charge and discharge cycles, the liquid level should be checked in a timely manner and distilled water should be replenished.
Question 2: What impact will there be if too much distilled water is accidentally added, causing the liquid level to be too high?
Answer: If too much distilled water is added, causing the liquid level to be too high, during the charging and discharging process of the battery, the electrolyte will expand due to heat and may overflow from the filling hole. The spilled electrolyte is corrosive and can corrode the battery casing, electrode terminals and surrounding components. At the same time, it will also cause a decrease in the concentration of the electrolyte, affecting the charging and discharging performance of the battery, reducing its capacity and service life. Therefore, when adding distilled water, it is essential to control the amount. If too much is accidentally added, the excess electrolyte can be sucked out with a pipette or syringe.
Question 3: Why can't distilled water be added during the charging process of the battery?
Answer: During the charging process of a storage battery, chemical reactions occur in the electrolyte, causing the temperature to rise and the electrolyte to expand. Adding distilled water at this time will cause a sudden drop in the concentration of the electrolyte, affecting the charging effect. At the same time, the high-temperature electrolyte may splash out, causing burns to people. In addition, when charging, gas will be produced inside the battery. If the liquid filling hole cover is opened at this time to add distilled water, the gas may mix with air, posing a safety hazard. Therefore, distilled water must be added only after the battery is fully charged and cooled to room temperature.
4. Summary
Correctly adding distilled water to lead-acid batteries used in forklifts is a key operation to ensure the stable performance of the batteries and extend their service life. Operators must strictly follow the above steps to operate, make adequate preparations, standardize each operation link, and at the same time pay attention to answering the common questions mentioned in the operation to avoid damage to the battery due to improper operation. Regular inspection and maintenance of the battery can keep the forklift in good working condition at all times, improve operational efficiency and reduce the occurrence rate of equipment failures.

Statement: The articles on this site are written by the GSGT team or reprinted from other media or compiled by AI.No reproduction without permission.For copyright or other issues, please contact:gsgtpower@163.com.

News

Steps for adding distilled water to lead-acid batteries used in forklifts

24V/VCF6A lead-acid battery NICHIYU FBR9 forward forklift battery factory direct supply

24-7PBS/560M Forklift Battery for Hyster E40XN 48V 560Ah Excellent in Both Price and Quality

24V/4HPzS620 Lead-Acid Battery for ForkLifts and Hyster N30XMR3 Special Battery for ForkLifts

24V/VGF370 Hyster P2.0 Pallet Truck Battery Factory Direct Supply