When is the last time you pulled the battery out and checked the water level? What is the battery voltage dropping to under a load? While you have it out you might as well check voltage on each cell.

The battery I was dealing with did not drop an excessive amount of voltage when load tested. Have you load tested yours? Does it drop a lot of voltage under load?

Hi there, I have a Raymond EASI 4D R45TT. I read this thread and it is somewhat related to mine. My forklift battery percentage changes all the time. At one point, it shows 100% after it is charged, and when I turn it of, it goes to 7%. When I turn it back on it goes to 90, do the same thing and will then show 57 for example or even 0 (and then back to a random number)I can drive it for some time too. After I fully charged it, I checked the voltage of the leads on the battery and it showed 36.9V (it's a 36v battery). And suggestions to fix this issue or could it be the battery? Thanks

Hey guys,

It turns out it was just a programming issue. Had Raymond come out, they adjusted parameters and BDI is now working as it should. Thanks for all your help.

We set up Raymond to come out on Monday. Will post back with fix. Hopefully it's nothing silly that was over looked by me.

hey marcos,
ok that makes sense, yes like brewski said the 24v signal your reading is just the power supply for the display itself. The BDI monitors the actual battery voltage through a different circuit and displays it through the monitor display.
They explanation you gave sounded like you were checking the battery voltage at the bdi and it was 24v.
Now since the battery is 36v as you say you should check that voltage at the battery and see what it is, a 36v battery charged should ready 37.5 to 39v fully charged, depending on the condition of the battery acid and age of the battery, Older batteries tend to read on the lower side.
In either case you can try to lower the reset voltage on the BDI controller and it should reset, as batteries do get older it may be necessary to adjust that reset voltage to compensate for lower voltages on older batteries because they do not reach the higher voltage they once did when they were new.

I'm sure since you may be calling a tech out he may have to resort to this to make the BDI operate correctly for that battery or hopefully it's just a poor connection in the harness somewhere keeping the BDI from reading the battery voltage correctly.

We are coordinating with Raymond to see when they can come out. Thanks for the help guys.

My recommendation: plug ur batt into charger for 5 mins or so. Then plug the battery into the truck while the surface voltage on the battey is still high. It might just need an extra little bit to reset. If no luck there have your local dealer come with a laptop and reset your truck.

These trucks are garbage I'm sorry to say. It's half Italian half German and branded American. Nothing but problems that's why they stopped making them and use Toyota now.

I do, there's a 6 pin connector, but only 5 pi s are used which are 2 negative wires, can h, can l and positive. Negatives are present, positive 24v present and cans are there. On the wiring diagram it shows 24v also. This is what's kicking my ace.

The 24 volt is to power the display. It should also have a battery voltage present. Do you have a wiring diagram? It might communicate with the main controller through Canbus. Check the voltage at the main controller.

Well it's a 36V system, but the voltage to the display is only 24V. I guess the display doesn't need that much power. Checked the manual and that is the correct voltage to the display. This is why I'm struggling with it. If it's got the correct voltage 24v going to it, why is it showing only one bar? The other thing was I tried a different battery just to re out the battery and same issue. Thanks!

is that voltage reading just 24v?
for a 24v system a fully charged 24v battery should read anywhere between 25 to 27 volts depending on how old it is, older batteries may read on the lower end of that scale but its got to have enough voltage to reset the BDI so the gauge will reset to 100%. The battery has to be at least 80 to 90% charged according to how the reset voltage in the control card settings is set before the BDI will reset.