Using a Forklift Battery Watering System vs. Watering By Hand

February 12, 2025 | Categories: Blogs, Batteries, Chargers, Efficiency, Safety

Every electric forklift needs regular battery watering. A “dry" battery cannot charge safely or effectively, which means a lower lifespan for the unit (and frequent overheating). Too much watering can also be a problem: Overwatered batteries can boil over, creating a serious safety risk for employees.

That’s why many operations invest in forklift battery watering systems that automate the process. A well-designed watering system can simplify operations in any battery room — but for smaller fleets, hand watering may make more sense.

In this article, we’ll discuss the advantages of forklift battery watering systems, along with a few alternatives that can keep your operation running smoothly if you can’t justify the investment.

What Is a Forklift Battery Watering System?

A forklift battery watering system streamlines maintenance by automatically delivering water to each individual battery after a full charge. Essentially, it’s doing exactly what your workers are doing — but with a greater degree of precision, since the system works in conjunction with the battery charger.

BHS’s Integrated Watering System (IWS) connects directly to battery charger cabinets, with a module connected into the DC output of each charger. Hoses are threaded through forklift battery system stands to allow for a footprint-free watering system.

This approach has a few major advantages:

Efficiency: The IWS allows you to water multiple batteries simultaneously from a single water supply, significantly reducing labor time.
Low Footprint: A battery watering system eliminates the need for watering carts and other manual equipment.
Precise and Consistent Watering: With an automated system, you get dependable results — no over-watering — which means a longer lifespan for lift truck batteries.
Enhanced Safety: Battery watering systems eliminate the ergonomic hazards associated with manual watering and greatly reduce the risk of boil-overs.
Scalability: If your fleet grows, you can easily add chargers to an integrated battery watering system.

Should I Invest in a Battery Watering System?

A full forklift battery watering system is an excellent investment for larger fleets, but it may be overkill for an operation with two or three lift trucks.

That’s particularly true if you don’t have an appropriate water supply within your battery room (or if you don’t have a dedicated battery room, period). The BHS Integrated Watering System requires a water supply with a minimum of 25 psi (1.7 bar) and a flow minimum of 5 gallons per minute (18.9 L/min).

And while watering forklift batteries by hand introduces some risks, you can limit those risks with well-designed manual watering equipment:

Battery Watering Guns with Automatic Shutoff: The primary problem with manual battery watering is precision — but this is a problem that gas stations solved decades ago by incorporating automatic shutoffs. The BHS Water Gun (WG-X) features a non-electric, automatic shutoff to make watering easier, more efficient, and much more precise.
Ergonomic Battery Watering Equipment: The BHS Water Gun is compact, lightweight, and ergonomically designed. A 45-degree nozzle allows workers to fill batteries without bending or twisting.
Low-Footprint Battery Water Carts: BHS Battery Water Carts (BWC) are easy to maneuver and store. For small to midsize fleets, they’re an excellent solution for on-the-floor watering.

The bottom line: You should invest in a full forklift battery watering system if you have a larger fleet, you expect your fleet to grow, or you’re already noticing efficiency issues related to manual battery maintenance. If you’ve got a smaller fleet, however, you can still work efficiently by simply investing in the right equipment.

To learn more, read: Watering Forklift Batteries: The Complete Guide for Battery Room Operators

Find the Perfect Battery Room Solutions for Any Fleet

Proper battery watering is essential for maximizing the performance and longevity of your forklift batteries. While manual watering may be suitable for smaller operations, larger fleets can significantly benefit from the efficiency, safety, and cost savings of an automated system like the BHS IWS.

To determine the best watering solution for your specific needs, contact the experts at BHS. We can help you optimize your battery maintenance program and ensure your forklifts operate at peak performance.

Call 1.800.247.9500 to speak with a member of our sales team.