Crown WAVE60-118:
Battery drop 0%

Hi guys! So this started to happens recently, never did that before. I have a wave60 that start at 100% battery after plugged/charged all night long. after 3-4 hours of use it have dropped to 76% (100% then 92%, 84% then 76%). I left the wave on here without using it for 5min, then when I use it back after 5min and try to go forward (or reverse) the bdi from instantly from 76% to 0% witht he "charge battery" message. So.. it goes 100% to 0% in like 4 hours... normally I can do 4-5 days and its not even at 20% lol!

There is a crown tech that checked the batteries, and out of the 4 batteries this is only 1 battery that is a little bit weaker so he said the 3 other batteries need to push more to compensate for the small loss the weaker battery have. Well... is this normal? even if there is 1 battery that is a bit weaker its not suppose to drop from 100% to 0% in like 3-4 hours of use! Whats the problem? I heard to check the battery voltage when the wave will be at 0% because maybe the battery could still be full after 3 hours but the wave sees them at 0% is this true? if yes then its the bdi that is faulty? If not then I don't see how it can goes drastically to 0% in 4 hours and also going from 76% to 0% in an instant??

Thanks in advance!
  • Posted 7 Jul 2024 03:12
  • Discussion started by Djaztek
  • Quebec, Canada
Showing items 1 - 15 of 16 results.
Alright no thanks for the help. Will just replace all batteries so all will be brand new ;)
  • Posted 10 Jul 2024 03:50
  • Reply by Djaztek
  • Quebec, Canada
Yeah that is 100% a battery issue. With the issue with rekeying and changing charge percentages that is a major symptom of a bad battery. A 6v battery should never drop to 4.85v. I recommend replacing all 4 in this situation but replacing only one should solve the problem as well, im just not 100% positive that the one battery didn't cause damage to the others.
  • Posted 10 Jul 2024 03:38
  • Reply by DyslexicNerd_01
  • Wisconsin, United States
Ok... so I checked again individually each batteries when the wave was 0% with « charge battery » message. Every battery was at around 6.30v and the weaker one was 4.85v

So... battery issue and replacing all 4 batteries should fix that?

Also, I find it quite weird that I was now at 43% and in an instant just by power off and power on again it dropped to 0%, without even starting to drop and losing some percentage every few minutes. Its like if I stay on it goes down to 0% fast but gradually but the moment I shut it down and restart now its already 0%
  • Posted 10 Jul 2024 03:29
  • Reply by Djaztek
  • Quebec, Canada
Thanks so much. Will check again when wave will be 0%. Will let you know ;)
  • Posted 8 Jul 2024 23:28
  • Reply by Djaztek
  • Quebec, Canada
With the lower voltage spread you probably can get away with only changing one. If you are going to change the amp hourage you will have to swap all 4 batteries so they are all the same amp hourage. While the lift will still run with different amp hourage batteries it will start to cause more issues pretty soon down the road and it could possibly kill all the batteries or even internal components depending on the spread of amperage.

The reason the one battery gets up to 6.02v when idling is because it stealing power from the other healthy batteries, that is what can cause the others to go bad. Typically a voltage spread of 0.05v or more between each battery indicates that the battery is bad. They should all be close in voltage especially after coming off a charge or near 100%.
  • Posted 8 Jul 2024 23:11
  • Reply by DyslexicNerd_01
  • Wisconsin, United States
Alright but that 5.95v is when raising the platform almost at the highest. Without doing anything it was around 6.02v.

Should I replace all 4 batteries like you said was better or simply the faulty one?

Also, now they are 6v - 215ah batteries. Can I put 190ah? I have 190 and 230. No 215 in stores :(
  • Posted 8 Jul 2024 23:05
  • Reply by Djaztek
  • Quebec, Canada
Yes that one battery at 5.95v is most likely dying. When it drops below 6v it pulls power from the other batteries to try and get above 6v causing the lift to have issues. Luckily you've caught it early. Currently the drop is around 10%. If you wait for the battery to drop lower then it will make this issue more visible. With it at 100% and the one battery at 5.95v that is a huge red flag. I recommend replacing that battery asap before it causes damage to th3 other 3 batteries.

Code 218 just means that the throttle pot is seeing voltages that are out of the calibrated range. That pot could be going bad, but there are alot of other checks that can be done to narrow the issue down further.
  • Posted 8 Jul 2024 22:50
  • Modified 8 Jul 2024 22:52 by poster
  • Reply by DyslexicNerd_01
  • Wisconsin, United States
Ok so I just tested total and individual batteries. Total was around 25v while the wave is at 100%. For individual batteries and while raising/lowering the hydraulic platform each battery goes around 6.05v but there is one that goes to 5.95v. I assume this is the faulty battery and the problem?

Should I also check when the wave will be 0%?
  • Posted 8 Jul 2024 22:38
  • Reply by Djaztek
  • Quebec, Canada
Alright good!

Mmm.. well, generally when the code 218 appears is right when I start the wave without even touching the hands control. I go on the wave, turn the key to power on and then "code 2018 call service".
  • Posted 8 Jul 2024 05:16
  • Reply by Djaztek
  • Quebec, Canada
218 is typically thrown because the operator controls were touched before the self test was completed. Rekeying is the only way to reset that code. They shouldn't have any relation, or it would throw more than just one code if it was a battery voltage issue.
It definitely sounds like you have one battery or more that is dying and needs replacement
  • Posted 8 Jul 2024 05:06
  • Reply by DyslexicNerd_01
  • Wisconsin, United States
Ok thanks for the help!

Yes, the problem just happened few weeks ago, it was all good before then one day I unplugged the wave, it was at 100% (left charging all night long) and after 3-4 hours it dropped instantly to 0% and since then its like that almost every day.

I don't know if it can help but this happened almost at the same time than the code 218 that randomly appears from time to time when I power on the wave. I have to either mess with the hands (move back and forth) or simply power off and power on again to make the code 2018 go away. Do you think this could be all linked to the battery drop issue?
  • Posted 8 Jul 2024 05:01
  • Modified 8 Jul 2024 05:02 by poster
  • Reply by Djaztek
  • Quebec, Canada
Yeah with the issue you are explaining it could either be a weak fuse or a bad battery. I see wave batteries go bad all the time. Encore doesn't always replace batteries unless they are causing issues while in the shop. I recommend replacing all 4 but it sounds like you caught this issue early so it shouldn't have caused any damage to the other 3 yet, but there still is a chance that just installing 1 will only temporarily fix your issue.
You can check the battery manufacture year by looking for the silver stick with a letter and 2 numbers on it next to the recycling logo. The 2 numbers are the manufaure year.
  • Posted 8 Jul 2024 04:42
  • Reply by DyslexicNerd_01
  • Wisconsin, United States
Alright thanks! So, ff the problem is one batterie that is a bit weaker its normal to drop from 100% to 0% in 2-3 hours?

I bought an "Encore" model, kind of refurbished. Battery was supposed to be replace by all new. We bought the wave in May 2023 and since then it is used everyday. Many hours a day. Should I just replace the weaker battery or put all 4 new? Find it suck to buy 4 battery when only 1 is weaker....
  • Posted 8 Jul 2024 04:37
  • Reply by Djaztek
  • Quebec, Canada
A full charge should be around 25.00v to 25.50v. When the bdi displays 0% it should be around 23.80v to 24.10v. Make sure to measure the voltage at the battery connector before the main contactor to get the most accurate reading.
At a full charge each individual battery should sit around 6.35v. At 0% they should all be around 6.02v.
If the individual batteries drop below 6v that is a sign there is an issue with one or more of the batteries.
If the battery voltage is not matching with the bdi, then there is a voltage drop somewhere in the system and you may need to start testing components. Fuses and contactor are the best places to start.
  • Posted 8 Jul 2024 04:16
  • Modified 8 Jul 2024 04:18 by poster
  • Reply by DyslexicNerd_01
  • Wisconsin, United States
I asked someone to test the overall voltage for all 4 batteries but thats when the wave was powered on and at 100%. The overall was around 25v. If I check back when the wave is dead at 0% then if batteries overall are still at 24-26v then the problem is not the batteries but a misreading from the wave?
  • Posted 8 Jul 2024 04:12
  • Reply by Djaztek
  • Quebec, Canada

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