> A fellow who has lots of experience with electric vehicles tells me it
> costs about $1000 to replace a lead-acid battery pack in a forklift or >a golf cart. We were discussing the gradual reduction of the batteries
> ability to hold charge due to sulphation of the plates. This means
> every 3-5 years, you'd have to replace your battery pack(s).
<SNIP>
Hi Jerry!
I spoke to a diesel truck mechanic who worked over 32 years on
electrical systems of the Big 10-4 trucks, including reviving seemingly
dead batteries. He explained that batteries that were NOT subjected
to high current over-charging due to defective charging system
regulators, etc., (which in turn caused electrolyte temperatures to
exceed 120 degrees F., which in turn caused the internal lead plates to
warp and short out) could be made in most cases, useful for a few more
years of service by the following restoration and TLC remedy:
1. Put one teaspoon of Caustic Soda in EACH CELL.
2. Trickle charge (with all caps off) for 2 hours or until all cells
are "fizzing".
3. Disconnect leads and invert battery to dump contents.
4. Fill battery full with distilled water and shake for a few minutes.
5. Invert and empty battery again.
6. Repeat steps 4 & 5 if you wish.
7. Refill all cells with fresh battery acid (H2SO4 + distilled water)
to proper level marks.
8. Trickle charge for 24 hours. (with caps off)
9. View all cells with flashlight to ensure lead plates have changed
colour from Gray to Brown. (Indicates no shorted cells and that its
fully charged)
10.Check each cell for proper specific gravity using hydrometer and
top off if necessary.
11.Perform final check for proper voltage.
12.Check for leaks!
WARNING NOTE: DO NOT clip on or off charger lead clips to battery posts
while charger is turned on. Doing this will create a spark that can
ignite the hydrogen gas vapours from the electrolyte, thereby causing an
EXPLOSION, a free trip to the hospital, and time off work!
IMHO, this is always worth a try before considering purchasing a new
one!