SkyTrak 6036 Service Manual - Manual (Page 217)

Section 10. Electrical System
Model 6036 S/N 9B0499 and Before 10-23
If indicator lamp operates normally, proceed to "B.
ABNORMAL CHARGING SYSTEM OPERATION.”
Otherwise, proceed to either one of the following
three abnormal conditions.
1. Switch Off, Lamp On. In this case, disconnect
the two leads from the alternator No. 1 and
No. 2 terminals. If the lamp stays on, there is
a short between these two leads. If the lamp
goes out, replace the rectifier bridge as
covered in paragraph 10.6.1.g. This condition
will cause an undercharged battery.
2. Switch On, Lamp Off, Engine Stopped. This
condition can be caused by the defects listed
in step 1 above, or by an open wire in the
circuit. To determine where an open exists,
proceed as follows:
(a) Check for an open circuit breaker, a
burned out bulb, defective bulb socket, or
an open in No. 1 lead circuit between
alternator and ignition switch.
(b) If no defects have been found, proceed to
“B. ABNORMAL CHARGING SYSTEM
OPERATION.”
OFF OFF STOPPED
ON ON STOPPED
ON OFF RUNNING
Ignition Switch Lamp Engine
The other method follows:
A basic wiring diagram showing lead connections
is shown in Fig. 10.26. To avoid damage to the
electrical equipment, always observe the following
precautions:
• Do not polarize the alternator.
• Do not short across or ground any of the
terminals in the charging circuit, except as
specifically instructed herein.
• Make sure the alternator and batteries
have the same ground polarity.
• When connecting a charger or a booster
battery to the forklift batteries, connect
negative to negative and positive to
positive. The correct jump start procedure
is covered in paragraph 10.6.2.g.
Trouble in the charging system will show up as
one or more of the following conditions:
A. Abnormal indicator lamp operation.
B. Abnormal charging system operation.
A. Abnormal Indicator Lamp Operation.
Check the indicator lamp on the control console
for normal operation as shown below:
3. Switch On, Lamp On, Engine Running. Check
for an open circuit breaker between indicator
lamp and switch. Other possibilities are
covered in “B. ABNORMAL CHARGING
SYSTEM OPERATION”.
If a defect has been found and corrected at this
point, no further checks need be made.
B. Abnormal Charging System Operation
1. Check that discharged batteries weren’t
caused by accessories left ON for extended
periods.
2. Check alternator drive belt for proper slack
adjustment.
3. If a battery defect is suspected, refer to
Section 10.6.2 Battery.
4. Inspect the wiring for defects. Check all
connections for tightness and cleanliness,
including the slip connectors at the alternator
and connections at the batteries.
5. With ignition switch ON and all wiring harness
leads connected, connect a voltmeter from:
(a) Alternator BAT TERMINAL to ground.
(b) Alternator NO. 1 TERMINAL to ground.
(c) Alternator NO. 2 TERMINAL to ground.
A zero reading indicates an open between voltme-
ter connection and batteries. Repair wiring
harness if required.
6. With all accessories turned off, connect a
voltmeter across the batteries. Operate
engine at moderate speed. If voltage is 15.5 V
or more on a 12 V system, remove alternator
for repair.
Fig. 10.27 Grounding Alternator Field Winding
(Wiring Connections Are Not Shown)
TAB
INSERT SCREWDRIVER IN
THIS HOLE TO GROUND
TAB TO END FRAME
MA1101