Adding water to your forklift is an important maintenance task that will ensure the longevity and performance of your forklift battery. Below is a step-by-step guide from the LTMG Team on how to safely add water to your forklift battery:

1. Understand the working principle of lead-acid batteries:

First of all, it is necessary to understand the working principle of lead-acid batteries and their possible problems during use, such as short life span, low specific energy, gassing from charging and discharging, long charging time with high energy consumption, and easy to lack of water. This information will help to take the correct hydration measures.

2. Ensure safety:

Before you start, make sure you are wearing appropriate personal protective equipment, such as gloves and safety glasses. Also, make sure the vehicle is at a standstill and disconnect the power to the battery. Locate the lead plug on the battery, usually on the top or side of the battery cover. Use a tool to open the plug cover and open it fully to allow gas to escape.

3. Check fluid level:

Use a level gauge or tilt the battery cover to check the water level. If the level is below the proper marking line (usually the predetermined level inside the battery cell), water will need to be added.

4. Add Water:

Using a clean water filler gun or spray bottle, pour distilled water slowly and evenly into the battery cells. Make sure there is enough water in each cell, but do not overfill. Top up with deionized or distilled water to between the highest and lowest levels; do not top up with raw battery fluid or tap water. Battery liquid will dilute or enhance the original specific gravity of the electrolyte, causing a decline in battery performance; tap water contains too many impurities, which will lead to a dilute battery response, long-term addition of tap water may cause short-circuit, damage to the battery of the electric forklift.

5. Timely water replenishment:

lead-acid batteries will gradually lose water in the process of use, so it is very important to check the battery status regularly and replenish water in time. This can not only prevent the battery from being damaged due to lack of water but also keep the battery in the best working condition.

6. Pay attention to the water quality: 

The water used for rehydration should be pure, preferably distilled or deionized water. This is because any impurities may affect the performance and life of the battery. Therefore, make sure the water source used is clean and unpolluted before rehydrating.

7. Avoid excessive water replenishment:

Although water replenishment is necessary, if too much water is added, the battery of the electric forklift may overflow when charging and moving, resulting in a decrease in the overall specific gravity of the battery, performance degradation, water accumulation in the case and corrosion, and severe cases, it may even cause a short-circuit of the battery.

8. Anti-corrosion and anti-leakage technology:

Although no specific anti-corrosion and anti-leakage technology details are provided, in practice, measures should be taken to protect the battery from corrosion and moisture leakage. This may include using leak-proof sealing materials and ensuring that the battery is installed in a dry, well-ventilated environment.

The key to correctly rehydrating forklift batteries is to use the appropriate tools and methods, checking regularly and replenishing water promptly, as well as ensuring that the water used is pure and not over-hydrated. In addition, taking appropriate anti-corrosion and anti-leakage measures is also an important factor to ensure the long-term stable operation of the battery.

How to test whether the forklift battery needs to be rehydrated?

To check whether the forklift battery needs to be rehydrated or not, you can do it by the following methods:

1. Use a coulometer:

You can use a coulometer designed for electric forklift trucks to detect the battery status. This kind of coulometer can judge the charging and discharging status, display the remaining power, and control the output when the voltage is low. Through these functions, you can indirectly determine whether the battery needs to be recharged. If the power meter shows that the battery power is too low or has a tendency to discharge, it may mean that the battery has insufficient internal water and needs to be rehydrated.

2. Battery Monitoring System (BMS):

VRLA batteries are equipped with a battery monitoring system that can monitor the state of the battery in real time, including the state-of-charge model, alarm conditions, and data storage. By monitoring the battery's state of charge temperature and other parameters, it can determine whether the battery needs to be rehydrated. For example, if the temperature of the battery is monitored to be abnormally high or the charging efficiency is reduced, it may be caused by insufficient electrolytes, and then it is necessary to replenish water.

3. Regular inspection and maintenance:

In addition to the use of professional equipment, regular inspection and maintenance of forklift batteries is also necessary. This includes checking the battery casing for cracks or leaks, as well as observing whether the battery fluid level is below the minimum scale. If these problems are detected, the battery should be replenished immediately with distilled water or other suitable non-corrosive liquid.

Detecting whether a forklift battery needs to be rehydrated can be done in several ways, including the use of a charge gauge, a battery monitoring system, regular inspection and maintenance, and professional judgment. Each of these methods has its focus, but all are designed to ensure that the battery is in optimal working condition for forklift safety and efficiency.

What are the specific steps for rehydrating a forklift battery using distilled or deionized water?

The specific steps for rehydrating a forklift battery with distilled or deionized water can be summarized as follows:

1. Prepare pure distilled water or deionized water:

First of all, you need to make sure that the water used is pure. Distilled water and deionized water are pure water, but their preparation process is different. Distilled water is prepared through a distillation process while deionized water is prepared through an ion exchange technique. Both methods are effective in removing impurities and ions from the water to ensure the purity of the water.

2. Testing water quality:

Before using distilled or deionized water, its quality should be tested to ensure that its purity meets the standard of battery use. The purity of distilled water can be measured by simple test methods.

3. Replenishment of electrolytes:

For acidic batteries (such as TG type and GN type), it is necessary to replenish distilled water or deionized water regularly due to the continuous evaporation of water in the electrolyte during daily maintenance. When replenishing, pure water should be poured into the battery slowly to avoid air bubbles, which may lead to a short circuit inside the battery.

4. Adjusting electrolyte concentration:

After replenishing water, it may be necessary to adjust the concentration of the electrolyte. This usually involves adding sulfuric acid or other electrolytes to achieve the correct specific gravity. This is essential to maintain optimum battery performance.

5. Check and clean battery terminals:

During the rehydration process, the battery terminals should also be checked for cleanliness, and any substances that could cause poor contact should be removed. Maintaining good electrical connections is important for battery performance and longevity.

6. Test battery performance:

After rehydrating and adjusting the electrolyte concentration, it is recommended to perform a simple performance test on the battery to ensure it is working properly.

In conclusion, using distilled or deionized water to rehydrate forklift batteries is a relatively simple process, but attention needs to be paid to the purity of the water, the correct method of replenishment, and subsequent maintenance measures. In terms of performance and price, lead-acid battery forklifts can offer great value, but do require a bit of maintenance By following the above steps, you can effectively extend the service life of your batteries and keep them performing well.