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Controls / Indicators

Cradle Power Button and Status Indicator​

The cradle features a power button located on its side, used to manually turn the cradle on or off. The button is surrounded by a green indicator ring that shows the current status of the cradle:

  • Off – Cradle is powered down.

  • Blinking – Cradle is powered on and attempting to connect to a battery.

  • Solid On – Cradle is powered on and has successfully connected to a battery.

Using the Power Button:

  • If the status indicator is off, the operator can power on the cradle by pressing the button momentarily.

  • If the status indicator is blinking or solid, the operator can power off the cradle by pressing and holding the button for approximately 2 seconds. The indicator ring will turn off when the power-down sequence begins.

The cradle utilizes an internal control board and 12V, 5Ah battery to facilitate several functions relating to the system. If the Cradle has been idle for more than 6 hours or has had a battery removed for more than 10 minutes , the cradle will shut down to preserve the energy in the cradle’s small keep-alive battery.

If the power button light-ring does not start flashing, the system will need to be serviced. In most cases, this is due to a manually loaded battery not fully seated in the cradle, but in some other instances it can be due to a faulty.

Battery Display Indicator (BDI)​

The Battery Display Indicator (BDI) is installed on the forklift and provides the operator with real-time information about the status of the battery and cradle system. It uses a combination of indicator lights and audible beeps to communicate important conditions, such as when the forklift is ready to drive, needs charging, or requires maintenance.

Operators should monitor the BDI during normal operation and be alert to any changes in status indicators or sounds. Responding promptly to warnings—such as low battery or fault conditions—helps ensure safe and uninterrupted forklift operation.

The diagram below identifies each indicator on the BDI and its function.

Normal Operation​

Cradle Power Up​

When the cradle is powered on via the cradle power button, the BDI performs a brief lamp and sound test. During this test, all indicator lights illuminate orange, and the BDI emits a short beep.

This indicates that the system is initializing and confirms that the BDI’s indicators and audio function are operational.

Connecting to Battery​

The cradle continuously attempts to establish communication with an installed battery. During this process:

  • The BDI flashes the Drive Power indicator green, and

  • The Battery SoC gauge flashes alternating orange segments.

This connection attempt continues until either:

  • A successful connection is established, or

  • The connection attempt fails due to timeout or error.

Connected to Battery​

When the cradle successfully connects to a battery and the battery is supplying power to the forklift:

  • The BDI displays a solid green Drive Power indicator, and

  • The Battery SoC gauge shows the battery’s current state of charge (SoC).

If the battery’s SoC is within a usable range, all segments of the SoC gauge will appear green.

Cradle Power Down​

The cradle will power down under 3 different conditions:

  • If the cradle power button is pressed for 2 seconds.

  • If a battery is not present or cradle is faulted for more than 10 minutes.

  • If a battery is connected and the truck is not used for more than 6 hours.

At the start of the cradle power-down sequence, the BDI illuminates all indicators orange and emits a short beep. It then begins a 10-second countdown using the Battery SoC gauge, turning off one segment at a time.

After the final segment of the SoC gauge turns off, the cradle completes the shutdown process, removes power to the BDI, and all indicators turn off.

Charging​

In-Truck Charging​

On models equipped with charger communication features, the cradle may be connected to an approved charger to initiate a charging session.

warning

Never connect the cradle to a lead-acid or unapproved battery charger, as this may result in battery damage or fire.

When a charging session begins:

  • The Drive Power indicator displays solid orange, and

  • The highest illuminated segment of the Battery SoC gauge flashes orange to indicate active charging.

When charging is complete or the session is terminated, the cradle will automatically return to the normal Connected state.

Warnings and Fault Conditions​

Stop Condition​

If a fault occurs that requires the cradle or battery to disconnect power from the forklift, the system will enter a Stop condition. In this state:

  • The Stop indicator flashes red rapidly,

  • The Maintenance indicator illuminates orange, and

  • The BDI emits three short beeps every 2 seconds.

The operator will have a minimum of 30 seconds to bring the forklift to a safe stop or complete any unloading before power to the forklift is automatically removed.

Fault​

If the cradle and battery are unable to provide power to the forklift due to a fault, the BDI will indicate the condition as follows:

  • The Drive Power indicator displays solid red, and

  • The Maintenance indicator illuminates orange.

To clear the fault and attempt reconnection, the cradle must be power-cycled. If the fault persists after a power cycle, contact maintenance personnel or refer to the troubleshooting section.

State of Charge Behavior​

Return State of Charge​

When the battery’s state of charge (SoC) begins approaching a low level, the bottom three segments of the Battery SoC gauge will illuminate orange and will emit a short beep every 60 seconds. This indicates that the battery should either:

  • Be returned to a PowerHive and swapped with a charged battery, or

  • Be connected to a charger stand-alone charger for charging.

Operators should plan to take action before the battery reaches a critical low state that could disable drive power.

Low State of Charge​

When the battery’s state of charge (SoC) becomes low:

  • The bottom two segments of the Battery SoC gauge illuminate red.

  • The BDI emits a long beep every 30 seconds.

If the SoC continues to drop:

  • The second-lowest red indicator begins to flash slowly.

  • The BDI emits two short beeps every 10 seconds.

Operators should return to a PowerHive for a battery swap or connect the forklift to a standalone charger as soon as possible to avoid disruption.

Critically Low State of Charge​

If the battery reaches a critically low state of charge:

  • The cradle will initiate the Stop condition and remove power to the forklift after 30 seconds.

  • The lowest SoC indicator will flash red rapidly.

To temporarily restore power and allow limited movement:

  • The operator may power-cycle the cradle to reinitialize the system and move the forklift to a charging location.

During this recovery state:

  • The lowest SoC indicator continues flashing red, and

  • The BDI emits two short beeps every 5 seconds.

If the battery discharges further, the Stop condition will reinitiate, and the battery will remain disabled until connected to a charger.

(Old Stuff – Rewrite and include information above) 5.2.7.1 Control Lights​

Three lights are used on the left side of the display.

• Power (Green / Red) o Red: Cradle powered but no battery is connected o Green: Cradle powered, and battery is communicating • Maintenance (Yellow) o Cradle is requesting a power limit from the truck. o Reduce load and return to the swap station to change the battery. • Stop (Red) o Fast-flash: The system is shutting down o Solid: The system is shut down

SOC Lights​

A stack of 13, 2-color LEDs capable of making red, yellow, or green colors.

When the stack of LEDs is all on, the battery is full. When the State of Charge of the battery is low the BDI LEDs will turn yellow, then red and begin flashing. Operation in the yellow or red zone of the BDI indicates that the battery may not have enough power to supply a very intense load from the vehicle – operation should be limited if possible.

When the BDI shows yellow or red and begins beeping, the battery should be changed for a charged battery as soon as practical.

Sounds​

Startup: Short Chirp – Startup sound-test

Operation – 3 yellow LEDs: Slow-Beep, short

  • Indicates entering low-SoC region.

  • Limit power and return for swap.

Operation – 2 Yellow LEDs: Slow Beep, short Operation – 2 Red LEDs: Slow-Beep, short

  • Extremely low SoC region

  • Limit power and return for swap.

  • Battery will shut off, can be turned on.

Operation – 1 Red Flashing LED: Fast Beep, Continuous

Returning Early​

While the system will attempt to limit operation that reduces the life of the battery, the operator may choose to return the battery to the Hive at any time before the yellow zone (3 LEDs) to extend the lifespan of the battery even longer.

Since these are Lithium-ion batteries, they DO NOT suffer from the effects of charging memory or not fully discharging them before charging. In fact, over-discharge of batteries leads to a reduced lifespan.

Battery Lifespan Considerations​

When operating the battery in the yellow or red zones of the BDI forklift drive and lift speed can be tempered to extend the lifespan of the batteries.

If your vehicle has a CAN communication connection, it will automatically limit the forklift power based on the capabilities of the battery and thus improve the lifespan automatically. In this situation, you can still return the battery to the Hive as soon as the BDI indicates 3 yellow LEDs to maintain optimal conditions for long battery lifespan.

Battery Power Button​

The battery will stay powered for up to 6 hours if unattended or idle (charge / discharge current less than 10A). If the battery turns off and the forklift is without power (no light on the power button on the side of the cradle), the operator can press the silver button on the side of the cradle to turn on the system battery.

If the battery is out of the vehicle for over a week, the battery will disable its communication board to prevent excessive discharge. This can be seen by checking the silver power button on the side of the battery. If the button’s ring is not slowly flashing green, the battery is shut down and should be re-enabled if it needs to be used.