How To Recondition Electric Forklift Batteries SAVE $6,000.00 by Walt Barrett





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Published on Apr 30, 2011

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Video Transcript:
How to recondition a very old forklift battery: First, we do tests with a voltmeter, on the overall voltage of the battery. This is a 36-volt battery, so it should read at least 36 volts. The battery has just come off the battery charger, and is reading 38 volts. The extra two volts is a surface charge and it will bleed off very quickly.

Now we check the condition of each cell. First we remove all of the battery caps. The 36 volts at 2 volts per cell means that 18 caps must be removed. Hoses are on here because it includes a self-watering system. Note that when we removed the battery filler caps we did not have to detach the watering hoses. This saved us a great deal of labor, which can vary from battery to battery.

Next, we check the condition of each cell individually. We test cells with a DC voltmeter and a pair of metal probes. Cell testing is the most important step.

After removing all the caps, we start to test the cells. We use a hydrometer to check specific gravity of the cells. The technician reads the cells using a voltmeter and two metal probes. He inserts the metal probes from one open cell to the next open cell. The voltage on the meter is about 2 volts. The meter should read 2 volts to 2.5 volts, or the cell is weak. You must check all 18 cells in this manner and make sure that each cell reads more than 2 volts.

Every cell must be tested. Ideally, each cell should read 2 volts to 2.5 volts. That would be perfect by the book. Anything else is a gamble. You might add your chemicals but not get a good result. That's why 2 volts or more is preferable in each cell. There's no guarantee that a cell will come back if it doesn't read at least 2 volts when starting the project.

Both probes must be dipped down thoroughly into the electrolyte. Always check the water level, and use distilled water in the battery. You only need about a quarter of an inch of water over the top of the battery plates. Do not overfill the battery.

We are now finished checking the cells, and they are all over 2 volts. That means that this battery is a very good candidate for reconditioning.

Here is a view of the meter and the probes. Next, we're going to check a few cells with the hydrometer. And as you can see, the flow is going to be in the red, which means that these cells are really in weak condition. This battery is not holding a charge.

The owner of this battery said that this battery only ran 30 minutes before it went flat dead. The hydrometer is in the red. It should be up in the middle of the green.

After we recondition the battery, we will retest it with the voltmeter and a hydrometer. We are now going to add one-third of a cup of Battery Chem™ to each cell. Then we put the battery back on the charger and begin the reconditioning process. This should take 24 hours.

If you are not familiar with using a hydrometer, refer to our earlier training videos on how to recondition automotive batteries. You will also learn how to use a load tester. You can review in other lessons how to test each cell in the battery.

Technician John adds one third of a cup of Battery Chem™ to each cell in the battery. Once the chemicals are added and the battery caps and hoses are replaced, the process of reconditioning the battery is complete. Now place it on the battery charger overnight.

Interested in earning from $500 to $5,000 a week? Contact me [info above] and I'll show you how to get started in this profitable business. Thousands of electric forklifts are in the U.S.. If you spend the time, advertise, get the customers, and do the work, you can make incredible money in this business.

Become an exclusive Battery Chem™ dealer with our unique product. You will not have any competition in your area because no one else has Battery Chem™. We have saved batteries for over 25 years. We are worldwide. Dealerships are available in any country.

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