SkyTrak 6036 Service Manual - Manual (Page 223)

Section 10. Electrical System
Model 6036 S/N 9B0499 and Before 10-29
10.6.2 Batteries
All lead-acid batteries generate hydrogen gas
which is highly flammable. If ignited by a spark
or flame, the gas may explode violently, caus-
ing spraying of acid, fragmentation of the
battery, and possible severe personal injuries.
Wear safety glasses when working near batter-
ies. In case of contact with acid, flush immedi-
ately with water.
a. Description
The batteries supply power to the starter and
ignition systems to crank the engine. They supply
the extra power required when the electrical load
requirements of the forklift exceed the supply from
the charging system in case of a alternator or
charging failure, and acts as a voltage stabilizer in
the electrical system, smoothing out or reducing
temporarily high voltage.
With the correct cables properly attached, and with
the batteries properly mounted, the batteries never
need periodic maintenance.
When starting the forklift, crank for a maximum of
15 seconds, then rest for two minutes to avoid
burning up the starter. Do not idle excessively.
Keep the batteries from freezing by maintaining a
full charge. A completely discharged battery will
freeze at 18 °F (8 °C).
When winterizing the forklift, test the start/charge
system in accordance with the diagnostic proce-
dures supplied with Generator Tester Model J-
26290 (refer to paragraph 10.6.1.a). Required
diagnostic equipment includes a variable carbon
pile battery tester (500 A minimum with ammeter);
a separate digital voltmeter that is calibrated
frequently, and an inductive (clamp-on) ammeter.
Test areas are: batteries, starter motor replacement
test, starter circuitry and battery cable test, sole-
noid circuit test, magnetic switch control circuit
test, alternator wiring test, and a alternator output
test.
Water never has to be added to the batteries.
There are no filler caps. Each battery is sealed,
except for small vent holes in the cover. The vents
allow what small amount of gasses that are pro-
duced in the battery to escape. The special
chemical composition inside the battery reduces
gassing to a very small amount at normal charging
Warning !
VOLTMETER
BATTERY
RESISTOR
TEST AMMETER
ALTERNATOR
CARBON PILE
BATTERY TESTER
Fig. 10.36 Connections for Bench Check of Alterna-
tor
o. Service Test Specifications
The JLG Alternator, Part Nos. 8270217 and
8270219, are also identified by Delcotron Alternator
Model 1101228, Series 12SI, Type 100, Specifica-
tion No. 7236. It has the following service test
specifications:
• Negative ground. When connected to a
battery, the ground polarity of the alternator
must be the same as the ground polarity of
the battery.
• Clockwise rotation viewing from drive end.
• 2.4 to 2.8 field ohms at 80 °F (27 °C). A high
ohmmeter reading indicates excessive
resistance, and a low reading indicates
shorted field windings, which can cause
regulator failure.
• 4.2 to 5.0 A field current at 80 °F (27 °C) and
12 V. A low ammeter reading indicates
excessive resistance, and a high reading
indicates shorted field windings.
• Cold output of 23 A at approximately 1600
rpm, 66 A at 6500 rpm. These outputs are
with the alternator at 80 °F (27 °C).
NOTE: A voltmeter is not needed for output check.
Load battery with carbon pile battery tester to
obtain maximum output. Refer to paragraphs b and
n for test procedures.
MA1191