Yeah, that is exactly what happen, someone mind was on the four day holiday weekend and not what they were doing when they plugged it in.

I will ask the battery folks about the lockout keys. thanks to you both.

OK, I was thinking about a physical preventative measure should be available. Thanks for the info.

cambox i am not aware of any changes made to the IFB as of the last time i checked on it. The most common issue that causes this is plugging the charger into the truck instead of the battery and what partsguy suggested is the most surefire way to keep it from happening again.
Consult you local industrial battery company and ask them about a charger plug lockout kit which as suggested consists of a couple of blocks that bolt to the charger connector and the connector on the truck itself to prevent from being able to plug the charger plug into the truck connector.

Assuming that truck has standard SB style battery connectors on it. The easy way is to install what they call charger keys on the connectors. Basically it is a flat piece of steel that gets bolted to the connectors that does not allow the charger to be plugged into the truck.

swoop223... Do you know specifically what they did to protect the IFB from the mistake of charging the forklift? I have the third instance of this occurring in a year and a half. Now they are looking at a way to fix this issue. A year after I suggested making a fix. any info would be appreciated.

well that makes all the difference in the world
yes most newer chargers are called 'smart chargers' and should not start up unless it see's a certain voltage before it starts.
The only problem with some forklifts is some of the components do store voltage in their capacitor circuits and they sometimes feeds back through the battery circuit... this would be why the charger may have kicked in just long enough to blow the card or damage it to the point that it self destructed when trying to run the truck.
Schaeff trucks had this problem until schaeff figured that out and put a circuit in place to prevent that... those control card dash displays for those things were very expensive :o)

Again, thanks for the help with this. Plugged in the new fuse card and unit now works.
While interviewing the client, operators and managers about this failure i was informed this card failure/fuse blowing has occurred when the charger was accidentally plugged into the forklift instead of the battery. Unit has smart charger and will not operate without battery connected. Must be coincidence, charger now cannot be plugged int lift.

Thanks that is great info, will be very helpful.

done...
let me know how it goes
if that doesn't work i'll look for more info

hey tom, if you can get to your profile find the signature part and put it there, it will show up then every time you post like mine and several others do :o)

Both the Dealer and Area Service Rep are cautious about commenting on this failure. **** [email address removed]-----

hyster made a vague reference?
hyster the mfg engineering dept? or hyster the dealer?
a vague reference just means they don't know and just threw something at you so they wouldn't look totally incompetent ;o)

post your email addy in your profile signature or put it here, do not put it in regular format or forum will detect it and blank it out... add spaces or something, i'll figure it out ;o)

Client has sourced a new card from Hyster, i am reluctant to plug in without confirming loads on fuse card circuits. Would anyone have a wiring diagram specifically for the fuse card circuit inputs and outputs. Hyster has made a vague reference to problems with the mast wiring causing fuse blowing and card failure. Tests on this circuit are OK.
Thanks in advance for all the help.

Part Number sourced from Hyster, thanks for the advise, will insist on OEM part.

that HY part number you gave is not OEM, it is TVH so its aftermarket parts.
I would definatly try an OEM part or you can keep throwing those aftermarket boards on there till one holds up... your choice :o)

btw... where did you get that part number you listed from? off the board? or from the dealer?

No shorts, is a 36 volt lift and all cards are OEM installed by Hyster dealer. Add ons all factory.

that a 24v truck or 36v truck?
the part number you give is for the 36v truck, there is a service gram out on this part also defining which one goes with which serial number range and according to that the A265 series trucks came with a 24v or 36v IFB.
According to serial number this truck should have come with this part number for this IFB, 2089014 and flight systems/TVH reman number should have been 1706682 (OEM) or 1706682R (reman).
The number you gave does show up but is not the one highlighted per serial number range.

and have you thought about trying an OEM hyster part instead of those TVH/flight systems reman parts?

plus i notice this board has fuses for accessories like lights etc, what do you have connected to this truck? are there any addon lights not part of the hyster design? aftermarket lights?

and lastly have you checked for voltage to the frame?
you might have a shorted circuit elsewhere causing this, you have have to back probe the circuit to find it.

20 amp fuse on fuse card. Card components have now burnt off due to repeated fuse changes. No shorts, card has been isolated and still blows fuse.

What is the amperage of this fuse is it a main power fuse of 350 amps or so??? I would check your power cables for a short to ground between fuse and motor.....

Model N40ZRS-16.5 ser#A265N01712E Card # HY2109344 has been changed several times.