In the United States, forklift batteries are rated to deliver their full available amps over 6 hours if they are placed under continuous load for that whole time.  In order to create this test, we take the total amps the battery is rated for, and draw 1/6 of those each hour.  This continuous draw simulates a forklift using the battery.  It is important to see the full test because cells that look strong initially can drop off suddenly after three or four hours. 

 Some companies will do accelerated tests where they increase the draw and decrease the time.  The most common accelerated test is a 3-hour test, but we have seen tests as short as 15 minutes.  Companies that do these tests will argue that “Peukert’s law” allows for reliable testing at higher rates and shorter time.  Unfortunately, that is unreliable.  While all batteries SHOULD follow this law, we have found that passing an accelerated test does not mean it will hold up during the longer test.  Make sure you see the full test.

Important question, and everybody seems to have a different definition.  We put each battery through a decision tree to determine exactly what needs to be done to restore its capacity.  We have strict protocols and scrap any battery that exhibits the potential of failing once it is in your facility.

We put each battery though a receiving evaluation, acid adjustment, desulfation, cycling, 6-hour load testing, cell replacement if necessary (followed by confirmation testing), and detailed cosmetics. We spend multiple days on each battery, and once it has completed the reconditioning process, we recharge every battery after 30 days and cycle it every 90 days to keep it at peak condition.

Well, maybe.  Unfortunately, there are some causes battery failure that cannot be reversed.  For example, when active material (lead) sheds off the plates and settles at the bottom of the cell, a short-circuit is formed that fries that cell for good.  Another problem we see is that cells have not been watered regularly.  When that happens, the lead plates are no longer submerged in the water-acid electrolyte and the lead plates oxidize which renders them useless.  Another consideration is age.  While some manufacturers last longer than others, there comes a time when the battery is too old and we can’t trust that it will perform well at the customer’s location.  When that happens, we simply scrap it. 

Yes.  Once you know which battery goes into your truck, you will find that all battery manufacturers can provide that same battery.  However, be prepared – the model number will be slightly different depending on the manufacturer.  This is partly due to marketing, but it also has to do with the construction of the battery.  There are different variations that will fit in your truck (waterless, high power, fast charge, gel cell, etc.), so you want to explore options before buying.

The best way to determine this is to find out the physical dimensions of the battery compartment in the truck and the voltage, and then talk with a knowledgeable battery provider.  There are many guides online that allow you to search for your truck and find out which battery is required.  While these are a good start, we have seen these guides be incorrect too often.  Dimensions and voltage are the best way to get the right battery the first time.

Practice proper maintenance and avoid abuse!  We receive thousands of used batteries so we have seen it all.  We see batteries that are 8 years old that have been well maintained outperforming batteries that are 3 years old that have been abused.

Proper maintenance includes watering your battery when it is dry (and also fully charged!), as well as utilizing proper charging.  A single-point-watering-system is the best way to ensure regular watering.  Proper charging includes having the right charger for the battery and making sure the battery gets an equalize charge once a week.  Additionally, allowing the battery to cool after charge will greatly extend battery life.

Abuse generally relates to overuse of the battery.  Constantly using and charging batteries creates a lot of heat, and heat kills batteries.  The hotter the battery, the weaker the lead plates are and the more “shedding” occurs.  Shedding, the process of lead falling off the plates and settling at the bottom of the battery, is a naturally occurring process that is dramatically accelerated by excessive heat.

Sulfation occurs when sulfuric acid changes from its liquid state into solid crystals on the lead plates in the battery.  Sulfation decreases overall battery capacity in two ways.  First, since batteries generate electricity through a chemical reaction between the acid and the lead plates, there is less liquid available in the electrolyte to interact with the lead plates.  Second, the remaining sulfuric acid has a harder time getting to the lead plates because the sulfate crystals form a barrier on the plates.

Desulfation is the process of converting sulfate crystals that have built up on the lead plates back into the electrolyte.  The best way complete desulfation is through micro pulse electronic waves.  We use a patented technology that sends electronic pulses into the battery – no chemicals are added.  Just like an opera singer shattering a wine glass, we use electronic waves at a specific frequency that dissolve the sulfate crystals and return them back to the electrolyte. 

Conventional chargers follow a cadence of: discharge battery 80% of total capacity.  Charge for 8 hours.  Allow battery to cool for 8 hours.  In general, the start rate of the charger delivers about 15% - 20% of the battery’s total amps per hour.  The charge curve then tapers off to a finish rate of delivering approximately 5% of the battery’s total rated amps per hour.

Before adding or replacing chargers, it is important to know whether your electrical supply is single phase or three phase, and whether the AC voltage is 208, 240, or 480.  Additionally, look at the corresponding maximum rated amp draw listed on the charger’s nameplate to make sure you won’t be blowing fuses when you power up the charger. 

Equalize charge is an important maintenance step to do at least once every two weeks.  Over the course of usage, the different cells in the battery become somewhat imbalanced with some being more charged than others.  If left to continue unchecked, minor imbalances can become big problems.  Equalize charge takes care of this problem by continuing a slow trickle charge for several hours after the normal charge process has completed.

In general, if an 80% reconditioned battery goes into the right application, we would expect it to last another two or three years.  However, it depends on make, age, usage environment, and maintenance. 

Make

Not all manufacturers are the same.  Batteries from top-tier manufacturers last a lot longer than those from bottom-tier manufacturers.  Knowing the difference between high-quality and low-quality batteries is essential.  A battery that is five years old may have the same remaining life as a battery that is three years old, depending on the make.

Age

Most batteries last about 1500 cycles, with one cycle being a period of usage, followed by a charge and cooling.  While this does not translate directly into years, most facilities will use 260 to 300 cycles per year.  This translates to about 5.5 years.  In reality, we often see 7- and 8-year-old batteries still testing well.

Usage Environment

Cold storage and excessive heat environments are the most detrimental on batteries and will shorten how long the battery is good for.  Any operation that runs the battery more than one shift per day will also reduce the battery’s life.  Lastly, if the forklift is used to push or pull objects instead of lifting and driving with them, or if the operator has to drive up ramps repeatedly, those things will put excessive strain on the battery and will also shorten it’s life.

Maintenance

The main reason we put a 6-month warranty on reconditioned batteries is not because we don’t think they will last beyond 6 months.  It is because any company can destroy a battery rapidly by abusing it or not maintaining it properly.  The battery MUST be watered regularly (when it is fully charged) or it will be scrap before long. 

Yes.  Evergreen has a broad selection of forklift batteries available and is one of the nation’s leading providers of weekly and monthly rentals.  We also offer brand new batteries for long-term rental at very low rates.

Single point watering systems are a clean, safe, and easy way to water an entire battery in less than one minute.  As you know, a battery has many cells that must each be watered.  Traditionally, you have to gain access to the top of the battery and then remove each of the vent caps.  Then, you must pour water into the cells, being careful not to overfill them.  Finally, you screw the vent caps back on and put the battery back into place.

With a single point watering system, there are inserts that go into the tops of each cell, and small hoses that connect each insert.  At the end of the system, there is a connection to the water supply.  When the water supply is turned on, the water flows through the hoses to each of the cells, and the inserts automatically shut off the flow when the cell is full.  Best of all, the watering system stays in place so you don’t have to mess with it after it’s installed!  It is a huge time saver and it completely eliminates sliding stand-up batteries half way out of the truck one way, and then back out the other way.

No.  Evergreen does not install the charger at your facility.  You must have a certified electrician make the installation.

Fast charging is similar to opportunity charging in that the battery is plugged into the charger during breaks and in between shifts.  The start rate of the charger can be up to 60% of the battery’s total rated amps per hour.  State of charge for the battery will hover between 30% and 80% during the day.  Standard batteries cannot be fast charged; there are specific batteries that have been designed to handle the increased amperage and have been outfitted with double cables.

In contrast to conventional charging where the battery is used until it reaches 20% state of charge and then recharged for 8 hours, opportunity charging is a frequent volley of usage and quick charges during breaks and shift changes.  Operators do not change batteries during shifts, and instead repeatedly plug the battery into charge when the truck is not being used.  State of charge for the battery remains between 30% and 80% during the day.  To get the most out of these short charging windows, the charger is designed to deliver a higher rate of charge.  The start rate for opportunity chargers is up to 30% of the battery’s rated amps per hour. 

All temperatures are corrected to 77 degrees Fahrenheit.  Below that temperature, the specific gravity and thus the voltage of the cells reads falsely higher than it really is.  Modern day chargers detect the voltage of the battery, adjusting their output and shutting off accordingly.  In cold storage, since the voltages read higher than they actually are, the charger sees a fully charged battery and shuts off before the battery is actually fully charged.  This results in a battery that never gets fully charged before the next shift and keeps getting run lower and lower.

It is important to consider where the forklift will need to go and to get a forklift with a collapsed height lower than the shortest entry.  Whether there are doorways in your warehouse or the truck enters freight trailers or shipping containers, make sure to know the lowest height required and the collapsed height of the forklift you are considering purchasing. 

For your reference, here are some standard heights to consider when purchasing:

• Standard Freight Trailer (used to carry most common freight)
• 40’: 92” door height
• 43’: 92” door height
• 48’: 98” door height
• 53’: 94” door height
• Shipping containers: (used to transport freight internationally)
• 20’: 90” door height
• 40’: 90” door height
• 45’: 102” door height
• 48’: 102” door height
• 53’: 102” door height

Absolutely.  Because of Evergreen’s ability to recondition and resell used forklift batteries, we share some of the gain with you the supplier.  We match any competitive scrap pricing in the market, and even pay more than scrap if a battery tests at least 4 hours.  Selling your used or scrap batteries to Evergreen is the best option for getting top dollar and quick payment for your batteries.

Since forklift batteries are considered hazmat, there are specific ways you must fill out the bill of lading.  Evergreen is glad to work with you, your shipping department, or your freight company to eliminate the headache of shipping.  Additionally, Evergreen will gladly provide you with a quote for us to handle the freight so you can compare against your own options.  Whether you use Evergreen’s freight or not, we are glad to advise on what goes on the BOL.

Evergreen has each and every forklift it sells inspected and repaired before it is available for sale.  We do not sell forklifts “as-is.”  We want to make sure you have a forklift that will work well the moment you press the pedal.

Ultimately, there is no substitute for a 6-hour load test when determining if a battery will last for an entire shift.  While there are a few ways to see if a battery is BAD, the load test is the only reliable method of confirming if a battery is GOOD.  Some indicators of a bad battery include:

• Significant variance in open circuit voltage of the cells.  If you are seeing open circuit voltages vary by more than .03 volts (i.e. 2.05, 1.93, 2.03, 1.96…), then there is a problem.  Those lower voltage cells will be the first cells to fail under load. 
• Extremely low voltage.  A fully discharged battery will read approximately 1.90 volts per cell when it is sitting and not under load or on charge.  If the battery is showing voltages of 1.50 volts or less, you should be concerned that the battery is severely discharged.
• Excessive corrosion on top of battery.  Some minor corrosion is acceptable and is fairly common.  However, if the battery is caked with inches of corrosion, it is a clear sign of abuse.  Furthermore, it can cause short circuiting which can lead to permanent failure.
• Bone dry.  If you open up the vent caps and it looks like the Mojave Desert inside, you’ve got a problem.  Lack of watering can cause permanent cell failure, so be on the lookout for this.

Luckily, Evergreen Industrial Batteries provides a complete test report with each battery.  If you buy an electric forklift from Evergreen, you will get a full warranty and the peace of mind that comes with reliable power.

It depends on whether the unit is electric or internal combustion.  If it is electric, there are several hour readings – key hours, traction motor hours, hydraulic motor hours, and steering motor hours.  When you turn on the forklift, you will see the hour readings cycle through.  The most telling indicator of usage is the traction hour reading.  Traction hours relate to how long the forklift has been moving forward or backwards, and is the best overall guage of wear on the forklift.  Be careful, however, if you see a very low hour reading.  It is possible that the meter has reached its limit and has turned over and started counting from zero again.   For internal combustion trucks, there is only one hour reading because the motor is always running even while the truck idles.

The number of stages refers to the number of vertical components on each half of the mast.  Some forklifts only have two components – the base and one section that extends – while others have up to four such segments.  There is a tradeoff between lift height and visibility when considering which stage mast to get.  The obvious drawback of the two-stage mast is that it can only extend so far.  However, it provides great visibility since there is very little metal in the operator’s field of view.  On the other hand, while the four-stage mast can reach great heights, all of that metal greatly reduces operator visibility.  The most common mast configuration is three-stage, offering a combination of lift height and visibility. 

This is a test answer 

The decision to buy new or reconditioned should be based both on your own application/usage, and on the supplier of the battery.  First, your usage.  We would never recommend a reconditioned forklift battery to a company that runs multiple shifts, operates in cold storage, or utilizes opportunity or fast charging.  Any such application requires new batteries and specialized equipment. 

When considering the capacity that a battery will deliver, keep in mind that a new battery is rated to deliver 6 hours of continuous usage before recharge, which covers an 8-hour shift (1-hr lunch, two 15-minute breaks, and 30 other minutes of downtime).  The capacity of a reconditioned battery from Evergreen ranges anywhere from 50% to 100% of new, but we recommend putting them into applications that will not require more than 5 hours of usage in a single shift.  In other words, if you have somebody who’s entire job is operating a forklift, you should probably go new.  If, however, your forklift operators are also doing other things during the day, a reconditioned battery might make sense for you.

Second, who you buy from makes a big difference.  You will want to see a full 6-hour load test, and you should see specific gravity and initial open circuit voltage information as well.  These readings tell you if there are any bad cells, and whether the acid levels are where they are supposed to be.