Forklift Alternator + Rewire

I couldn't find a place for posts like this so this is a brand new section for stuff that doesn't fit into the other categories in the Tools + Equip section.

The forklift generator went south so the fun started in trying to get a basic old GM alternator on it. It was way past time for the old Prestolite and regulator to go and I want something common on there with a lifetime warranty on it. It wont fit down where the other one was so it has to be moved up a little above the steering pump, more fun lol.

The coil is getting changed to do away with the ballast resistor and it's getting rewired to get rid of the mess back there. The ammeter is also going away and will be changed to a volt gauge instead.

The alternator is on and everything is working good. It's a 1 wire self energizing GM alternator made for tractors so the only wire it needs is one from the charging post to the battery, when it hits a certain rpm it kicks in automatically. The ballast resistor is bypassed and the new volt gauge is also in and working.

On another note... I started checking and disconnecting wires that were no longer needed because it no longer has a generator + regulator system, and there are some heavy wires that went from the starter solenoid bat post to the front and through the ammeter for that gauge that were no longer needed. Then I got digging around and there are wires all over that are just taped up going to nothing, wires spliced to other wires and taped up, empty spots in the old glass fuse block with wires on both sides of the fuse holder that used to do something, and a lot of wires coming off of the ignition switch that do or used to do who knows what.. I was getting ready to make an even larger mess on top of the mess that is already there.

I depend on this thing being ready most of the day every day, sooooo, tomorrow I'm pulling the floor pan to get a better look at what's going on. What it really needs with all of the changes made over the years to a 49 year old forklift (1972 model) it should be totally updated and rewired. I'm thinking the alternative is something will go wrong when I really need it...

I like the one wires, but Delco makes crap Alternators. :goodjob

I always had good luck out of them, as long as they are the Duralast Professional or Gold lines, never had any luck from anyone elses.

I thought I would make it fancy and got out a waterproof fuse + relay block and a grounding buss bar this morning (1st pic), then I thought that's kinda crazy and extremely time consuming for just 2 relays so I got out a small 6 fuse marine block with a grounding block and am using it with a single Delphi waterproof fuse holder kit at the rear for the main feed. Wiring takes too long the way I do it as it is lol.

There's not much wiring in the rear now and it's simplified a lot more than it was, with all the extra parts and brackets removed it looks bare in the back compared to what it was. I hoped to get it done today but there were too many interruptions so maybe I can wrap it up tomorrow and get my butt back to work.

Geno wrote: I always had good luck out of them, as long as they are the Duralast Professional or Gold lines, never had any luck from anyone elses.

I thought I would make it fancy and got out a waterproof fuse + relay block and a grounding buss bar this morning (1st pic), then I thought that's kinda crazy and extremely time consuming for just 2 relays so I got out a small 6 fuse marine block with a grounding block and am using it with a single Delphi waterproof fuse holder kit at the rear for the main feed. Wiring takes too long the way I do it as it is lol.

There's not much wiring in the rear now and it's simplified a lot more than it was, with all the extra parts and brackets removed it looks bare in the back compared to what it was. I hoped to get it done today but there were too many interruptions so maybe I can wrap it up tomorrow and get my butt back to work.

Great job but where is the USB port and GPS oh and satellite radio where oh where...you have to keep up with the times even on a forklift....... :sorry :computer

Don't get me started Nappy, I have all the stuff here to do that with but need to refrain...

The little Wheel Horse lift is back up and running.

I could do a little more touch up with the covering in the front but I gotta get back to work.

Here's a before and after of what really needed redoing.