hahaha.
I can't belive!
I just went on-line at my customer to search for the same problem!

Thanks for the info!

Thanks replaced batteries and all is working fine now.

possibly voltage drop in the control circuit
edit -site doesn't like linking to itself?
you will need to cut and paste link into new window
www.forkliftaction.com/forum/discussion_11685.htm

Thanks will go through all the batteries again in the morning
will post back my findings
thanks for all your help ;)

well the problem with GEL batteries is they can take a surface charge and fool the BDI into thinking they are good voltage wise but when you load test them that will tell the real story. AGM batteries are the same way.

Those type batteries are great because they hold a strong charge for longer than lead acid batteries, but thier falloff point even tho is longer than lead acid batteries are they fall off real quick when they do. The Pro's being longer stronger discharge rate before falloff but the Con's are when they go bad its not gradual, they usually just go suddenly.
At least from my experience anyway...

Thanks for the reply the batteries are Gel ones Champion I will load test them once again. the one thing that I cant understand is that the BDI drops from full to nothing ?

hi phil,
it does sound as if you have a battery issue
swaping out the bdi proves it is not bad

when you checked the batteries did you test each one individually?
load test them each to see if you have one or two that may be bad dragging down the whole pack?

what kind of battery are these? lead acid? AGM? Gel?

just some thoughts to ponder ;o)