Not my usual day (forklift project)

We had a catastrophic battery meltdown on our stand-up forklift a week ago and today I finally dug into it. An old Lewis Shepard stand up. I have been told we purchased it in the late '80s used from a local factory. We think its from late '60s or early '70s. The battery has been giving us fits over the last 2 years and it finally popped. Battery was tagged installed in 1981. We could get a new battery that fits for around $4000 or buy a whole new walkie-stacker for just under $7k. So boss says chuck it. The battery weighs around 1500# dry, so says the paperwork, but with almost 35 years of buildup on the plates, much more. Ill be dropping it off tomorrow at the yard and ill update with prices. Hate to see the old girl go.... we named her "Sally"

http://i.imgur.com/vP8Lgw2.jpg?1

http://i.imgur.com/ElvXGt8.jpg?1

http://i.imgur.com/cB31Y0c.jpg?1

BYE Sally

R.I.P. Sally :(

Dropped that battery off this morning.

steel cased batteries = $0.24 / lbs

scale said just over 1200#s = $290

a little extra for the company x-mas party fund

Conclusion of project.

Drained and pulled hydo pump, tank, and pluming. Pulled lift chains and secondary mast out of main mast assembly. Pulled lift ram and all hoses. Dropped drive assembly out the bottom for disassembly at a later time. I plan on taking the hydro pump motor and drive motor in once I get them tore down. Chassis and main mast is all heavy welded and my company doesn't own gas torches, so I needed to just try to unbolt as much as I could to make it as light as possible. Stuffed it in the shop van and across town I went.

Chassis was around 2200#s
Drive motor assembly is around 150#s
Mast assembly not sure yet, probably around 250 or 300#s
Battery came in at 1200#s

Total so far ~$450

Overall it was a cool project. Most likely will never do one again but I would if I needed to.

heavy duty breakers with large silver tab points
http://i.imgur.com/v42ibeN.jpg?1

Internals
http://i.imgur.com/TLXV3yx.jpg?1

Hydro pump and assembly
http://i.imgur.com/PfkPszZ.jpg?1

internal mast assembly
http://i.imgur.com/fEZnSCK.jpg?1

Doors wouldn't close. Looked a bit sketchy but it got there.

http://i.imgur.com/TUlb6pY.jpg?2

Thanks for looking guys ;)

very interesting
thanks for the informative pics