Lead-acid Battery Refill SOP

Purpose:

Provide practical guidance for protecting workers from injury while refilling water levels in lead-acid batteries used in forklifts, aerial lifts and related equipment.

Equipment required:

• PPE: face shield, acid-resistant gloves (butyl, latex, nitrile, neoprene), rubber apron, long pants, and closed-toed shoes.
• Water gun or container with a funnel, full of distilled water.
• Lead-acid battery & vehicle or equipment
• Battery spill kit or baking soda with a scrubbing device and towel
• Head lamp or flashlight, or hydrometer
• 

Hazards:

• acid splashes & spills.

Important considerations:

• Use only distilled water. Tap water and other liquids contain salts, minerals and other contaminants that may react with the acid, shorten the life of battery, or both.
• Use weak bases like baking soda to neutralize acids. Strong bases with strong acids can cause violent chemical reactions. Mix weak base into acid well, before wiping up a spill.
• Overfilling batteries can cause acid to bubble up and create hydrogen gas while charging.
• Vehicle use affects battery life. Follow the maintenance schedule and all other necessary recommendations as specified by the manufacturer.

Preparation

1. Locate and consult operator’s manual for additional precautions not mentioned.
2. Park and turn off the device, remove and (if applicable) hold onto key to prevent ignition.
3. Bring battery to full charge to prevent boiling over. Charging batteries causes electrolyte levels to rise. Filling a battery with little or no charge to right fill level can cause a boil over when charged again.
   1. If it is slightly below full charge, you will have to fill slightly below fill level (just barely cover plates).
4. Disconnect the battery from the vehicle and charging equipment. Inspect for any damage to the battery.
   1. 
5. Put on required PPE for visual inspection of battery and refill. Grab all other required equipment.
   1. 

Inspect water level

6. Open battery compartment and locate vent caps (fill holes) on batteries (often found on top of many batteries), then remove vent caps to look inside.
   1. 
7. Check water level. Water level should cover lead plates completely and should not be above the designated level. This can be done visually or with a hydrometer.
   1. 

Refill battery

8. Using a water gun, pump, or container and funnel, slowly add distilled water to the manufacturer’s designated level, or if not visible, add almost exactly enough to cover lead plates inside. Do not overfill; if water is at appropriate levels, do not add water.
   1. 

Return to use

9. Reinstall vent caps or plugs securely, closing battery compartment cover.
10. Reconnect battery.
11. Reconnect battery.
    1. If battery was below full charge, charge for a few minutes.
       1. Disconnect battery again and check fill levels.
       2. Do not charge again if at or close to designated fill level and electrolyte levels drop naturally.
          1. Warn others not to charge again until electrolyte lowers to safe levels.
12. Wipe off excess water from the top of battery casings. If electrolyte is in the splash water, neutralize the acid with baking soda.