SkyTrak 6036 Service Manual - Manual (Page 195)

Section 10. Electrical System
Model 6036 S/N 9B0499 and Before 10-2
10.1.1 Service Warnings
and Recommendations
• DO NOT disconnect the battery while the
engine is running. This will cause a voltage
surge in the alternator charging system that
will immediately ruin the diodes or transistors.
• DO NOT disconnect any wiring without first
stopping the engine, turning all electrical
switches to the OFF position and disconnect-
ing the battery ground cable from the battery.
• DO NOT cause a short circuit by connecting
leads to incorrect terminals. Always identify
a lead to its correct terminal. A short circuit
or wrong connection giving reverse polarity
will immediately and permanently ruin
transistors and diodes.
• DO NOT connect a battery into the system
without checking for correct polarity and
voltage.
• DO NOT “flash” connections to check for
current flow. No matter how brief the contact
the transistors may be ruined.
• Wear safety glasses when working near
batteries.
• All lead-acid batteries generate hydrogen gas
which is highly flammable. If ignited by a
spark or flame, the gas may explode violently
causing spraying of acid, fragmentation of the
battery, and possible severe personal
injuries, particularly to the eyes.
• Avoid battery acid. In case of contact with
acid, flush immediately with water.
• Charge batteries only in a well-ventilated
area. Always be sure battery chargers are
OFF when connecting to or disconnecting
from batteries.
• See Delco Remy Service Bulletin 1B115 and
1B-116 for additional safety information and
procedures.
These instructions assume that all wires are
connected and routed as designed. Take into
account any disconnected and rerouted wires
before you begin any diagnosis. By referring to
the wiring diagrams, you can test circuits for
continuity or shorts by using a conventional test
light, ohmmeter, multimeter or low reading voltme-
ter.
Warning !
A. The area around the base of the stud (the outside
diameter of lock washer (5)) shall be free of paint.
B. Stud, bolt, or capscrew
1. Hex nut or lock nut
2. Tooth or slot type lock washer
3. Flat washer
4. Electrical ground or grounds
5. Tooth type lock washer
Fig. 10.1 Recommended Sequence of Parts for
Electrical Wire Grounding
10.1 SYSTEM COMPONENTS
The electrical system produces, stores, distributes
and uses electricity in the operation of the forklift.
Electricity is produced by an engine-driven alterna-
tor which has a solid state voltage regulator.
Current from the alternator charges the battery
and powers components.
The battery provides power for starting the engine
and supplements the output of the alternator
during periods of peak demand.
Other electrically powered components include a
horn, neutral start switch, steer select valve; park
lock release valve, reverse switch and backup
alarm; an hourmeter, a fuel level sender and
gauge, and a cluster of warning lights.
A forklift may have the following electrical options:
• a lighting system with headlights, tail lights,
directional signals, emergency flashers and
rear work light;
• an enclosed cab with air circulating and
heater fans and a windshield washer and
wiper
NOTE: Forklifts built thru Serial Number 9B0499
have an electrically powered hydraulic pump. This
pump maintains hydraulic pressure for power
steering and service and park lock brakes if
engine oil pressure falls below a predetermined
level. The pump is actuated by an oil pressure
switch which actuates a solenoid which in turn
starts the pump if engine oil pressure falls below 4
psi (0,3 bar).
A
B
2
1
4
3
5
MA0871