Toyota Orderpicker Model 7BPUE 15 Service Manual Section 5. Troubleshooting
Battery Discharge
Indicator (BDI)
Theory
Battery Discharge Indicator (BDI) is a feature
that monitors and remembers the charge level
of the battery connected to the lift truck and
helps to prevent excessive discharging of that
battery. Operating a lift truck using a
discharged battery can damage both the battery
and the electrical components of the lift truck.
At power
-
up, BDI tests the battery to determine
if it is the same battery that was installed at
power
-
down.
If
it is the same battery, it
continues to monitor the battery for discharge
and updates the Operator Display as required.
If
a different battery is detected, BDI tests to
determine the state
-
of
-
charge of the
replacement battery. The replacement battery
must meet both of the following criteria before
the display will be reset and lift restored.
1. The replacement battery must have a
charge level at least 50% different from the
previously installed battery,
2. The charge value of the replacement
battery must be greater than or equal to
the configured BDI setting.
The criteria are determined in this way:
1. BDI compares the charge of the battery
that was connected to the lift truck with
the new battery's charge. A charge
difference of at least 50% between the two
batteries resets BDI to show the
state
-
of
-
charge of the replacement battery,
that is, the measured state
-
of
-
charge of
the replacement battery minus the
remembered state
-
of
-
charge of the old
battery must equal or exceed 50%. This
reset can be higher or lower than the old
battery.
a. Example 1:
A
battery in the lift truck is
at 10% charge; the replacement battery
is at 95%. With more than a 50%
difference in the charge levels, BDI
Battery Discharge lndicator (BDI)
resets the Operator Display to show the
replacement battery's charge.
b. Example 2:
A
battery in the lift truck is
at 20% charge and lift cutout has not
occurred. The replacement battery has
a state
-
of
-
charge equal to 50%.
Because the difference is only
30%, the
display will remain at 20% until the
replacement battery has discharged to
20%. Then the display will begin
counting down.
c. Example 3:
A
battery in the lift truck is
at 20% charge and lift cutout has
occurred. The replacement battery has
a state
-
of
-
charge equal to 50%.
Because the difference is only
30%, the
display will remain at 20% and lift
cutout will remain in effect until a
battery with a charge of at least 70%
and a state
-
of
-
charge exceeding the
configured BDI setting is installed in
the lift truck.
2. BDI looks at the configured reset point.
BDI reset is programmable from 55% to
100% of total battery charge and can be
changed by entering the Configure Mode
using the Superword. The new battery
must be equal to or greater than the
configured percent of charge before the
BDI will change.
Example
-
BDI
configured at 95%. Plugging in a battery at
anything below 95% charge will not
change the Operator Display. Older
batteries or applications providing
inadequate charging time could require a
lower configured value for BDI since older
batteries might be unable to reach a
higher percent charge. Therefore, some
batteries could require BDI configured as
low as 55% before lift cutout will reset and
the Operator Display shows the charge of
the replacement battery.
The following example describes installing a
new battery when the Operator Display does
not reset. Assume the following:
BDI configured at 95%, the battery
connected is at 45% charge, and the new
battery is at 92% charge.
00700
-
CL222
-
05,
1
5 March 2005
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