So I have a Hyster W40z. I kept getting complaints of the battery going dead way too quickly. Strange as I replaced the Batteries 6 months ago, back in July. These are Trojan T105's.
So I plug it in, the power light comes on and then the Yellow charging light comes on and flashes once every second. It stays like like for hours. I came in the next day and the Red Shutdown light and the Green Done light was flashing 3 times
This is the thing. Right now it shows 25 Volts. I checked each battery and they are in the 6.2 to 6.3 range. I put my Harbor freight load tester on them and they're right on the edge of weak and good. The day before the batteries were weaker, I had hooked the batteries up to our Toyota Pallet Jack charger for an hour and it had no problem charging the batteries up. The charger was working as it should.
I figured maybe with a boosted charge that the charger built in would start working right. But nope!!! Looking at the charger manual, well I have a couple, they talk about dip switch settings. Well mine was set 4 up and 1 down at the end. I'm getting mixed settings on what it should be for these Trojan T105 batteries. I tried the 13 up, 4th down an 5th up instead. Hasn't changed anything.
Right now it shows Fully changes on the gauge of the Hyster. The battery pack is showing 25 volts. I'm now such on what to do. The batteries seem good. They are also only 6 months old and are quality batteries. It's why I got these as they were recommended. Still, I just don't know if it's the batteries and I'm missing something, or there is an issue with the charger. I don't want to spend $500 on a new charger, only to find out the new one does the same thing.
I do have to say these do et banged around a lot. They are used in a food factory. They do tend to get a little wet, or at least a bit of moister. Everything looks dry. It hasn't been used since Monday until it died and it's now Thursday. I'm just not sure where to go from here.
Does anyone have any ideas?
One last question. This has to do with the Strut in the Steering column. It was broken and so I ordered a new one, but it is weak. It doesn't really want to spring the handle back up like the old one. It had a Stabilus 029614 1045N installed. Where can I get one of these? Or a 3rd party version of this? I'm getting complaints about the current one. People don't like it. Yet that was the part number listed when I ordered it.
Showing items 1 - 11 of 11 results.
yeah i had a feeling :o)
good deal, glad you got it fixed
and yeah, that's a pretty good price on that charger for sure.
I just replaced the charger. It looks like it's charging good. No flashing lights. It's a solid Yellow charging light and power light. The fan is powered on. So it looks like it was a failed charger all this time. New charger is on sale for $418 plus tax. So not too bad.
Now I'm just waiting for it to finish and the green light to pop on and be solid. People should be surprised tomorrow when they come into work and see they finally have another pallet jack to use. We are expecting 3 new Toyota's in a week or 2. It's been a very long wait. We want to sell off our 3 crowns, which all have new batteries. 2 of them are freezer versions.
yep, sounds like it to me
you've charged the batteries to an acceptable charge, the charger should see this and reset back to start charging. since it is still flashing the code then i believe it would be safe to say the charger has some internal issue and should be repaired or replaced. I don't know of anyone that repairs them so the replacement is your only other option.
So the crown finished charging with the Hyster connected to it. The Hyster is now showing 26.15 Volts measuring from the terminals the 2 charger wires are connected at. It's still doing the 3 flash thing with the Shutdown and Charged lights.
I checked each battery and they're all over 6-volt. I did a load test on each battery and they all passed. Really, all I have left at this point is the charger.
Ummm, well right now I've had it rigged to our Crown Pallet jack which is broken down and won't go UP. But the charger works and so I rigged it to the Hyster to charge those batteries. Checking the voltage as it is being charged on the Hyster I'm getting around 29.3 volts. So it's been running for around 4 hours now. The Crown charging both battery packs in parallel.
I normally don't have a spare pallet jack like this to do this. But since the Crown is broken down yet again, I had the chance to use it for charging. I'll see what happens soon when I disconnect it.
well the only other scenario i can think of that might make the charger think there are low power or no batteries hooked up would be the charger itself is bad.
These chargers did have issues with the wiring where it comes out of the charger at that strain relief plug. I remember one of the other tech's i work with having this same issue and he found the wires burned on the inside of the charger, he couldn't get that harness and fix it. They made him replace the whole charger.
If you have another charger maybe you can rig it up to that battery pack and see if it will charge them?
That is what I don't get. I'm showing around 25 volts on the battery pack. I'm load-testing them and they are still showing ok, they're on the borderline of weak. The batteries are Trojan T105's that are 6 months old. I replaced the batteries in our Toyota also at the same time with the same type of batteries and zero issue with those charging up. People like the Toyota better and so it sees more use than the Hyster. Both still busy when working.
I'm going to hook each battery back up to my 6 volt charger for a few hours and try again I guess. 2 hours per battery is an all day thing. We are already low on pallet jacks as it is. One of our crowns we are waiting on a part. Now sure why it's taking so long. Another one once again are having issues. We have 3 crown pallet jacks, 2 are freezer versions, and those crowns are always breaking down for one reason or another. Complete garbage!!!! Out Crown Fork lift is just as unreliable. All the Crown stuff is being replaced. We've had it with that garbage.
based on the service literature on this model/serial lift if the shutdown and charged lights are flashing it is indicating the batteries are 100% discharged.
The description of this fault is:
"Batt Is 100% Discharged: Based on 1.75Vdc / cell, this error is produced when cell voltage falls below this value (example: 21Vdc for 24V Battery Pack). A.C. Power should be connected to charger and charging initiated immediately."
Now in this case the charger will not start up at all until it sees the voltage it wants above the 21vdc. There is only one way to achieve this, get the voltage higher by either replacing the batteries or you can find a good charged battery pack and connect it in parallel and fake out the charger so it will start up in normal mode and start charging. I would leave it on for a few minutes till it brings up the lower set of batteries enough so the charger will be able to continue on it's own, THEN you remove the jumper pack so it can continue.
I would monitor the charging periodically as it may error out again with an over heat code if the charger is charging too hard.
Once you get the batteries charged up enough you can run a load test on each battery and see if any of them have any bad cells or if they all are just not capable of charging due to old age or something along those lines.
So the gauge is showing a full charge. I doubt it's full. It's still Flashing the Shutdown and Charged lights. They are both doing 3 flashes and repeating that over and over again. The serial# is B218N28235L.
I have worked on a lot of w40z pallet jacks the built in chargers were not that good they would go bad after about three years in truck usually the charger would not turn on most were not repairable and very expensive some over thousand dollars at dealer. what l would do is wait till the truck is ready for charge than plug into another charger and let it charge over night untill it shuts off than plug the battery back into the pallet jack and see if the gauge comes back to full if so the charger is bad if not the batteries are dropping down over night and the truck will not reset the gauge. Most 24volt charges will take the charger to about 32volts before it shuts down or about around 11hours than shut off but if the batteries are weak as it sits with no charge the voltage will drop overnight and will not reset the bdi gauge when you plug back in.hope this helps
it sounds to me like the charger is overheating and shutting down.
the service book does give certain flash codes and if the charger has changed from one year to the next then you need to make sure you have the correct literature based on the serial number of the unit.
What is that serial number and i may can help.
Forkliftaction.com accepts no responsibility for forum content and requires forum participants to adhere to the rules. Click here for more information.