I have a similar but different problem. My battery was overhauled, regenerated, and the modules on my forklift replaced, but the charger now only charges to 25% capacity. What could be the problem?

No Edward, in this case, the card is the problem.
the original card was configured previous to be change.
i put this card in another truck and the problem move it to that truck.

this is a configuration in the card, and usually does not mean the card is bad, but that it needed to be configured for that truck and it's battery.

well, it was easy. the oscilator card (new from factory) was the problem.
this card was changed and the problem was solved.
charge at 100% and the forklift work 8 hrs.

Resulto ser la tarjeta osciladora, se reemplazo por una usada, (la que traia es la que llego de fabrica con el equipo), por lo que asumo que esa tarjeta trae un problema, que genera que el indicador marque de esa manera la descarga de la bater'ia

pero afortunadamente ya quedo resuelto.

parece que siempre si se de esto!!! jejeje

Necesito:
Modelo de Clark.
Amperios de la bateria.
Y sobre todo medir la densidad de la bateria una vez cargada y despues de que indique la maquina que esta descargada. Esto es fundamental para saber por donde seguir investigando.

Federico:
esa parte no la verifique.
Este equipo es nuevo, se entrego hace un mes, solo ha trabajado cerca de 30 hrs.
la bateria es nueva, el cargador es HF "alta frecuencia", se hizo el cambio con otra bateria nueva y un cargador ferroresonante.
y el resultado fue igual (la carga de la bateria solo dura 3 hrs. maximo).
tuve una experiencia similar hace 3 años en el que un stockpicker crown se descargaba casi de la misma manera, y el problema lo encontre en el IGBT (nunca supe a que se debio) pero al reemplazarlo se corrigio el problema, al 1/2 año se daño el IGBT y cuando lo reemplaze por otro nuevo regreso esa falla, y solo al reemplazar ese IGBT nuevamente se corrigio el problema, no se a que se deba o en que influya pero solo asi se corregia ese detalle (que se "descargara" la bateria en poco tiempo).

espero tu me puedas dar alguna idea de que injerencia tiene el IGBT en la duracion de la batería.

lo que si es que esta interesante el problema....

saludos.

How many amps is the battery?

When the battery indicates that 20% of electrolyte density has

*Cuando la bateria indica el 20% que densidad de electrolito tiene*

tks. to all. i very appreciate your support.
we try using another new battery and the ressult was no different.
and stil drop the charge.
if i can resolve this, maybe really i'm a technician..... jejeje

Raul, you can tell a lot by loading the battery with hydraulic relief and checking the voltage drop at each cell. I'll bet you'll find at least two or more of the cells drop below 2 volts which will severely deplete your battery charge in short time. That's a quick way to check a battery in the field but the proper way to test a battery is at the battery repair shop using a discharge load bank along with very specific criteria for testing. In my opinion poor connections are not very likely. Good luck

Might want to add - check the truck/battery connector halves for cracking & the contacts for excessive pitting/burning. Replace cracked connector halves &repair or replace the contact tips. While you are at it check the charger connector for the same - these tend to get broken quicker as they get thrown to the ground often - plastic & concrete don't mix.

I believe the point Ed was getting to and what we need to know is from fully charged 2.12 VPC after 3 hours what is the VPC. You say you monitered the lift but how did you do this? If you are just going off the BDI how do you know it's reading properly? Also would like to know the condition of the battery and all other cables (both visual and resistance) if you have a broken or corroded cable it may be causing an abnormally high amp draw causing your battery to discharge quicker.

2.12 Volts per cell is 100% charged, 1.75 VPC is 80% discharged. If you have a 36 volt battery times your VPC by 18, if it is a 24v battery times your VPC by 12. 2.12 VPC assumes your battery is perfect, 2.08 VPC may be more realistic. How is the battery being charged and discharged?

Tks. Edward,
the battery works only for 3 hrs. (and i say because i was monitoring the forklift during these time and the percent of charge was from 100 to 20%)
the tilt stall proof. i didn't performance.
the spec. grav. is in the range of 1.2 per cell and the volts are in the range of 2.35 to 2.15 per cell

the forklift are a NPR20 with the EV100 system with IGBT.

how are you deciding the battery only works for 3 hours (battery gage? lift cut out? reading battery voltages?) when it seems "dead" to you, ave you taken voltage readings at rest and with the hydraulics stalled about 3 seconds?
when you say "battery it's ok (volts, specific gravity, water level)" please describe the 'ok' water level is, and tell us the numbers for the spec. grav. and volts, at rest and when the tilt is stalled, and what control system is fitted and serial number of the truck is.