FH00020R00H

Parts-Service Gram 6/29/15

See Models Below

TO: DEALER PRINCIPALS, BRANCH MANAGERS, SERVICE MANAGERS,

PARTS MANAGERS and TRAINERS

SUBJECT: Charger and Battery Diagnostics

MODELS AFFECTED: B218 (W40Z), B495 (W25-30ZA2), A419 (W45ZHD)

DESCRIPTION:
Due to field complaints of a “bad charger” or “charger that won’t turn on”, the following
information for validating charger operation and battery condition has been developed.
One bad battery in the pack can affect proper operation of the charger. Therefore it is
imperative that both the batteries and the charger are properly troubleshot when issues
are encountered.

First and foremost, all precautions, safety equipment and practices should be followed
as identified in the unit Operator Manual or the Periodic Maintenance Service Manual.

First step and important for effective troubleshooting process:

Verify electrolyte level is above the plates before charging. If level is below the plates,
add distilled water until the tops of the plates are covered.
The batteries should be charged overnight before testing using an automotive style
charger or appropriate device.

Note: If the batteries are physically damaged, they should be replaced before
proceeding.

Once on site check for any damage to terminals, battery cases, charger, cables and
connectors. Verify battery voltage is available at the motor controller while in operation.
If there is any damage, repair or replace any damaged parts before proceeding. Plug in
the charger. If charger is already plugged in, unplug, wait for 20 seconds and plug back
in. Does the charger power up and the charging light LED come on? This could take up
to 1 minute. If the charger comes on correctly, jump to Step 5 of the charger
troubleshooting. If the charger does not come on, go to Step 1 of the charger
troubleshooting.

NOTE: In March 2014 (Software Rev A11), the voltage drop point has been decreased
from 17.4 volts to 12 volts. The charger should not go into “self-protection” mode unless
the voltage drops below 12 volts for more than 1 – 2 seconds. Further, as long as the
battery volts are above 12 volts, it can be reset with just AC being disconnected for 30
seconds. The charger will also self-reset without AC being disconnected once voltages
return to an acceptable level of >17 volts for at least 10 seconds.

This Parts-Service Gram is confidential and for use by NMHG employees and authorized Hyster® dealers only. Do not copy or
distribute to unauthorized parties. We reserve the right to change the design of our products without incurring an obligation to modify
previously manufactured products.
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Chargers built prior to March 2014 (Software Rev A09 or earlier), the reset occurs by
disconnecting the AC power from the charger (unplugging it from the wall) and also
removing the negative charger wire from the battery. The AC & DC need to be removed
from the charger for a minimum of one minute.

Software Revision

Reference: Gram FH00018

Charger Troubleshooting

1. Is the total voltage of the battery pack higher than 12 volts? If yes, go to Step 2. If
no, replace all 4 batteries.
2. Note any Displayed Error Code (LED flash pattern other than yellow Charging LED)
and record.
3. Disconnect the charger from its power source and on chargers with A09 or earlier
software, remove the negative lead from the batteries. Allow the charger to sit for at
least 1 minute. Reconnect the negative lead of the charger. Let the charger sit for
30 seconds and then plug it in to a power source. Does the charger power up? If
yes, skip to Step 5. If no, go to Step 4.
4. Verify wall outlet receptacle measures a minimum voltage of 108 Volts AC, if no
Repeat Step 3, but with a different wall outlet. Does the charger come on? If yes, go
to Step 5 since the previous receptacle may be defective. If outlet measures a
minimum Voltage of 108 Volts AC and the charger doesn’t come on, possible
defective charger or power cords. Replace power cord or charger.
Even if your charger is faulty, proceed with verifying the condition of the batteries as
per the battery procedure.
5. Determine the charger mode and the corresponding absorption voltage from Chart 1
used in the Latest Revision software: A11.1.
6. If the charger has finished charging (green LED is ON) the voltage across battery
pack should measure 26.4 ± 0.5 Vdc.

Note: If the charger has an error code flashing after replacing the batteries or while
replacing the charger that has been described below, the charger maybe suspect and
should be replaced.

Confidential - For use by NMHG employees and authorized dealers only.

Do not copy or redistribute to unauthorized parties.
 FH00020R00H
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Condition LED1 LED2 LED3 LED4 LED5

Data Base Integrity Flash Off Off Flash Flash

CHARGE 1 MODE TABLE

Switch Setting: 0 = Switch Up 1 = Switch Down

Mode Battery Description AH Range Absorption Switch Setting (5-key left to right)
Voltage 1 2 3 4 5
01 Exide Flooded 180-225AH 28.8V 0 0 0 0 0
02 US Battery Flooded 180-225AH 29.4V 0 0 0 0 1
03 Trojan Flooded 180-225AH 28.6V 0 0 0 1 0
04 US Battery AGM 180-225AH 29.4V 0 0 0 1 1
05 Exide Flooded 225-300AH 28.8V 0 0 1 0 0
06 US Battery Flooded 225-300AH 29.4V 0 0 1 0 1
07 Trojan Flooded 225-300AH 28.6V 0 0 1 1 0
08 Full River AGM 225-300AH 29.4V 0 0 1 1 1
09 Exide Flooded 60-100AH 28.8V 0 1 0 0 0
10 US Battery Flooded 60-100AH 29.4V 0 1 0 0 1
11 Trojan Flooded 60-100AH 28.6V 0 1 0 1 0
12 Full River AGM 60-100AH 29.4V 0 1 0 1 1
13 East Penn Gel 80-225AH 28.0V 0 1 1 0 0
14 Full River AGM 180-225AH 29.4V 0 1 1 0 1
15 BMZ LiFePO4 150-200AH 29.4V 0 1 1 1 0
16-32 Empty – Do Not Use

7. With the charger charging and the Charging LED illuminated continuously, test the
voltage at the Battery Terminal where the charger connects. Does the voltage
measurement match the absorption voltage? If yes, the charger has reached the
proper absorption voltage. Continue to the Battery Troubleshooting section. If no, go
to Step 8.
8. Use a Current Clamp Meter, set to Adc, to measure output charging amps from the
charger. Is the charge current value 20 ± 1 Adc? If yes, let the charger run for 15
minutes and go back to Step 6. If you have already gone back to Step 6 once go to
battery troubleshooting. If the current is less than 20 amps, (± .25V) the voltage at
connector is higher / lower than targeted absorption, and the charging LED is on,
replace charger. If the “complete” LED is illuminated, unplug wait 20 seconds
reconnect and redo Step 6.

NOTE: Do not bypass the interlock wiring to the ignition switch when troubleshooting
charger issues. This will aversively effect the charger operation and could damage the
charger and batteries.

Confidential - For use by NMHG employees and authorized dealers only.

Do not copy or redistribute to unauthorized parties.
 FH00020R00H
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Battery Troubleshooting

1. Have the batteries been charged overnight and are the electrolyte levels at proper
level? If yes, proceed to Step 2. If no, add distilled water. The electrolyte level
should be ¼ inch from the bottom of the vent well. Charge the batteries overnight.
Return the next day to test.
2. After the batteries have been charged and allowed to sit for four hours, verify that
the electrolyte level is correct. If at the proper level, check Open Circuit Voltage
(OCV), if less than 6 volts it is a bad battery. Check specific gravity, if one or two
cells are less than 1.200, it is a defective battery. If all cells are below 1.200,
continue charging until all cells are above 1.260. If the variance between the three
cells is greater than .015 the battery is defective. If all three steps are identified as
acceptable proceed to Step 3.
3. Unplug the battery pack from the truck. Disconnect the negative lead of the charger.
4. Attach the ‘load tester’ to one battery.
Note: Load Tester Tool must reach 208A for a 6 volt battery.
5. Adjust the current of the load tester to 208 A.
6. Run a 15 second load test. Does the voltage drop below 4.8V? If yes, replace
battery. If no, battery is good.
7. Perform test on all four batteries culling out the ‘suspect ‘batteries.
8. Tag issue batteries with battery test findings as noted in Step 2-6 along with the unit
serial number.
9. Contact your local US Battery Representative as identified in the Batteries &
Chargers Aftermarket site located in Material Handling Central website.
10. The US Battery return process, terms and conditions are accessible via the link
embedded in the Direct Ship Deep Cycle Battery Program document.

WARRANTY REIMBURSEMENT:
This Parts-Service Gram is for information purposes only.

Confidential - For use by NMHG employees and authorized dealers only.

Do not copy or redistribute to unauthorized parties.