This is an overview on how to weld the innercell connectors on a forklift battery. I already pulled the bad cell out and put the good cell in. I will post a more detailed video on the welding process soon.
Super helpful normally put around the battery connector wet rag to prevent the mealt the cell is to much work you make very easy course is experienced time thanks for you video hope have the flame need to practice in the torches
Hello please do you have idea what the weight of the actual battery is after removing the iron case. I buy decommissioned batteries for recycling but it is based on the actual weight. I'm wondering if you can help with that info
i have a forklift battery that has been left unused for years... the liquid inside is all dried up... think i can still have someone come and recondition it or simply pour those liquid inside it shall work again?
12 psi oxygen 7 psi acetylene I have a small victor torch with a 00 tip. ***FOR ME*** I adjust the psi so that the valves on the torch are not "touchy". Meaning I have to turn the valves on the torch a little more to get the right flame point. Not too sharp, but not too rounded.
What brazer you use? I try before to reconnect the lead head but some not strong enough,some people say need solder grease and some people say need calbulator brazing...
I had the same problem at first. The issue was cleanliness. You have to have shiny lead. My tip is a victor 00 size. You also may not have the flame set right. When you adjust the flame point, it needs to have a rounded point about 3mm long with the rest of the flame jetting out 15 or 20 cm. The flame should be limp and it should be fairly quiet. If it sounds like a torch it's too hot. I have never used solder grease or flux or anything like that. Just clean shiny lead.
Also, you may be adding lead too quick. The post you melt down should be liquid and the lead you add should be liquid. Maybe keep your torch in the middle for a little longer and allow the pool of lead to expand a little bit more before you connect to the side walls of the intercell connector.
Is it a more recommended that the forklift battery is completely replaced with all new cell packs, or is it the norm to just reweld a new single 2v cell pack to the defected one?
Lots of factors to consider. 1. Age 2. Condition of the remaining cells 3. How battery is cared for (or not cared for) 4. Customer's budget. 5. How many cells need replaced It takes 3 new cells in a less than 5 year old battery to make the value proposition of that repair not worth it. Usually 1 or 2 new cells or 3 used cells is the sweet spot for most repairs for most customers. More than that and 95% of my customers will buy a new battery. I don't replace cells in batteries over 5 years old unless the customer can't buy a new battery or the battery runs really good and I think it will last at least 2 years or more. I've ran into the problem where I replace a cell and 2 weeks later another cell goes bad followed by another after a short time. Customer gets mad and I loose money. A battery degrades over time obviously and after 5 years on a good battery you're looking at 80% or worse run time in a forklift. And that 80% drops 10% or more each year after that. To replace every cell in a battery with new would cost 3 or 4 times more than a new battery.
ryanburbridge I've been waiting to run out of lead sticks so I could make more. I just ran out the other day so the video should be up in the next couple of days. Thanks for your comment!
@@ParamjitandMichael I have it filmed and the editing process started. I think I just have to write a script and voice the narration. I've got a bunch of excuses for why it's not done yet, lol. I do plan on finishing it one day. I hope you get to see it and find it helpful when it's done.
I have never know there are lead-acid batteries with welded interconnectors... Can't even remember ever hearing about them in the Netherlands/Europe. Is this mainly a USA-thing?
Yes. All the major US battery brands are welded. Although since the lockdowns all major battery brands are really delayed in manufacturing so more euro style batteries are being sold than before. I've sold a couple dozen euro style batteries over this year and I'm happy with them so far. They have the bolted connectors and cables instead of welded. Also super thick steel cases too. I've sold the eternity brand batteries. The traditional style brands I sold before were Douglas and crown.
@@Korcregus Ah ok, that explains it ;) There is only one benefit to welded interconnectors I can think of: no 'cauliflower' problems ;) (usually, bolted interconnectors start to corrode somewhere at some point, which can grow into a cauliflower appearance of whitish/greenish/yellowish 'stuff' ;) Pretty funny to think about the fact that the Hyster-forklift we used to have at the company where I work has an 'euro-style' battery ;)
@@weeardguy welding has its issues for sure. Enersys brand batteries has thicker lead connectors but at the factory they only weld a small amount of lead at the top of the connection. You can see from my video I'm welding from the bottom to the top of each connector. At the factory the cells positive and negative posts are way bigger and take up more space inside the connector hole. Plus they have to be fast so they end up only making 2 or 3 passes at the top of the connection. This allows for acid and dirt to get in between the post and connector and cause corrosion of the lead and eventually the connector will split. If the batteries get cleaned more often I assume the lead connectors would probably be the better choice. It'll be interesting to see how the bolt style works out over the years.
@@uhp100 Same here. I switched to 00 and I stopped melting down. Make sure you use a wet paper towel too. Sometimes I form the wet paper towel to the outside of the inter cell connector and that helps with melt downs too.
@@uhp100 Practice will help you get a feel for how long you can stay in before the melt down happens. With a 0 tip I melted down 1 out of 5 connectors. With 00 I melt maybe 1 out of 200/300 connectors. It was a game changer for me.
Michael Engelman I'm assuming you're asking about the lead intercell connectors. You need a special drill bit that only drills a ring out. That way you're left with a post on the cell and an intercell connector with a big enough hole to weld to a post.
Here is the tool you need.. Its around 100 usd... www.ebay.com/itm/Durite-Hollow-Battery-Post-Drill-Cd1-0-107-00/322978526059?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2055119.m1438.l2649
00 torch tip. The flame should be about 8 inches or 20 cm long. The end of the flame should be feathered or limp. The inner blue flame should be about 1/8 inch or 3 mm long and it should be a rounded triangle shape.
@@Korcregus Ok thanks for the information. I'm fond of batteries, especially those of forklifts. I see that you know enough of batteries, I would like to learn more about this ... if you can.
@@edoscar83 I try to make a useful video every now and again. You gave me an idea to make a video about how to set the torch. It seems simple but it's actually pretty complicated. And a properly set torch makes welding way easier.
Yes, a correct torch is very important. Because if it is not correct it can damage the connection bridge, and that is serious, or it can burn the plastic cover of the cell ... I see that your torch is so tight that you do not use protection molds.
RLEESTUDIO You do whatever you think is safe. I know what's safe and what's not safe (because of experience) and I act accordingly. I've blown up 2 cells and 1 golf cart battery, it's not fun. I don't do those things anymore that caused the explosions. I don't need to take off all the caps. You do. So you do what you want and I'll do what I want. Battery work isn't for a DIYer who watches a RU-vid video. I'm not saying you are. I'm saying this isn't a diy thing. It takes specialised tools and skill that a DIYer doesn't have and it's impractical for them to obtain.
IngmecIng Ingeniería You just need to blow the cells out with compressed air. The liquid isn't what explodes, the gas that is produced by charging and using the battery is what explodes. Once the gas is cleared, you shouldn't have any issues.
Nick, who needs background music. We are more interested in what you are saying and the music makes hearing you worse. Suggestion if you must have music add it at the beginning AND END WHEN YOU'RE NOT SAYING ANYTHING.
ML Howard I know... Everyone who watched it before I posted it told me to cut out the music or turn it way down but I didn't listen. It's a learning process. Thanks for caring enough to offer the constructive criticism.
