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Yah, we need more details...

If it has ev100LX then the bdi is controlled through the traction card, and can be adjusted somewhat.
A straight ev100 non-lx will have a curtis bdi assembly that can also be adjusted for cutout and reset.

(the difference is the display, only the LX trucks have the little led display that shows hours, codes etc.)

I suspect the problem is simply the reset voltage.
The bdi's won't reset to 100% until the battery goes over a certain voltage. If that voltage is too high, or the charger shut-off too many hours before, the guage won't reset.
Just reset the charger, and after a short time (10-30 seconds) unplug the charger and quickly plug the battery into the truck.

If that fails to solve the problem, we'll definatley need more info...
  • Posted 28 Jul 2006 14:19
  • By mike_n
  • joined 11 Feb'06 - 138 messages
  • Alberta, Canada

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Global Industry News
edition #1243 - 14 August 2025
In this week’s Forkliftaction News , we look at more financial reports with one major producer recording a “significant” decline in Q2 bookings to report an operating loss of USD8.5 million, while another had a strong quarter “despite increased trade tensions and a challenging geopolitical landscape”... Continue reading
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The black box flight recorder was invented by Australian scientist David Warren in the mid-1950s. While initially met with indifference in Australia, his invention gained international recognition, particularly in the UK, and is now a mandatory piece of safety equipment on all commercial aircraft.