Trojan batteries are deep-cycle lead-acid batteries designed for motive applications requiring sustained high-current output, such as electric forklifts, golf carts, and floor scrubbers. Their thick lead plates and durable construction support daily deep discharges (up to 80% DoD) with 1200+ cycles. Trojan’s T-1275 model delivers 150Ah at 6V, commonly used in series configurations (e.g., 48V systems). Pro Tip: Equalize flooded Trojan batteries monthly to prevent sulfation and extend lifespan beyond 5 years.
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What defines Trojan batteries in motive power applications?
Trojan batteries in motive applications are defined by rugged lead-calcium plates and high cycle durability, engineered for deep discharges. Their thick grids minimize corrosion, while absorbent glass mat (AGM) or flooded designs cater to varied operational needs. They dominate in electric forklifts due to sustained torque delivery even below 50% charge.
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Trojan’s motive batteries use lead-calcium alloy grids, which resist corrosion better than standard lead-antimony models. A 6V T-1275 flooded battery weighs 58 lbs, delivering 150Ah for 1,200 cycles at 50% DoD. AGM variants (e.g., T-1275-AGM) reduce maintenance but cost 25% more. For example, a warehouse forklift running 8-hour shifts uses eight 6V T-105 batteries (48V system) to power 2.5kW motors. Pro Tip: Keep flooded batteries watered with distilled water—exposing plates to air accelerates degradation. Practically speaking, Trojan’s design prioritizes durability over energy density, making them ideal for stop-start industrial use.
| Model | Voltage | Ah Capacity |
|---|---|---|
| T-105 | 6V | 225Ah |
| T-1275 | 6V | 150Ah |
| T-1900 | 6V | 200Ah |
Why choose Trojan over lithium-ion for industrial equipment?
Trojan batteries offer lower upfront costs and extreme temperature tolerance, critical for industrial settings. While lithium-ion provides 3x faster charging, Trojan’s flooded variants cost $150/kWh vs. $450/kWh for LiFePO4. They operate reliably in -20°C to 50°C ranges without BMS shutdowns.
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In motive applications like airport baggage tractors, Trojan batteries withstand vibration and partial discharges better than most lithium packs. For example, a 48V system using eight T-105s costs $2,400 versus $6,500 for equivalent lithium. But what about total cost of ownership? Over 5 years, Trojan may require 2-3 replacements versus lithium’s single lifespan—yet still save 15% for budget-focused operations. Pro Tip: Use AGM Trojans in humid environments to prevent terminal corrosion. Transitioning to lithium? Ensure your charger profiles match—mismatches risk thermal events.
| Metric | Trojan Flooded | LiFePO4 |
|---|---|---|
| Cost/kWh | $150 | $450 |
| Cycle Life | 1,200 | 3,000 |
| Temp Range | -20°C–50°C | 0°C–45°C |
How to maintain Trojan batteries for maximum lifespan?
Key maintenance steps include monthly equalization charges and regular watering. Check electrolyte levels every 15 charging cycles, topping up with distilled water post-charging. Keep terminals clean using a baking soda mix to prevent sulfation-induced resistance spikes.
Battery maintenance impacts lifespan dramatically. A forklift fleet neglecting equalization saw 40% capacity loss within 18 months. Equalizing at 7.4V per 6V cell for 3 hours dissolves sulfate crystals—restoring up to 12% capacity. Pro Tip: Use a refractometer to test specific gravity monthly; 1.277 is ideal for flooded Trojans. Transitioning from charging to storage? Always charge to 100% first—sitting at 50% charge induces stratification. For example, a golf cart dealer increased Trojan T-875 lifespans from 4 to 6 years by implementing biweekly equalization. Why risk premature failure when simple routines add years?
What are common motive applications for Trojan batteries?
Trojan batteries power electric forklifts, golf carts, and floor scrubbers due to high surge currents. Golf courses use 48V setups (eight 6V) for 25–35 mph speeds, while floor scrubbers need stable 36V systems (six 6V) for 6-hour runtime.
Beyond common uses, Trojan batteries excel in niche applications like electric ferries and mining haulers. A ferry in Washington uses 144V (24x6V) systems pushing 400Ah for 10-hour operations. Pro Tip: Over size battery banks by 20% if equipment runs multiple shifts—this reduces DoD and extends cycles. What’s often overlooked? Trojan’s compatibility with legacy charging infrastructure, unlike lithium requiring upgraded units. For example, a 2012 forklift fleet upgraded to T-1275s without charger replacements, saving $15k per vehicle.
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FAQs
Yes, if voltage matches—but ensure chargers switch to lead-acid profiles. Lithium chargers’ higher voltages (58.4V vs. 57.6V for 48V Trojans) risk overcharging.
How long do Trojan batteries last in daily use?
Properly maintained flooded Trojans last 5–7 years at 5 cycles/week. AGM lasts 4–5 years with minimal upkeep.
Are Trojans suitable for solar storage?
Not ideal—deep-cycle solar batteries prioritize different discharge profiles. Trojans excel in short, high-current bursts, not slow, steady draws.
