I belive that the controller is in the box. I think that one of our techs has had issues with the wiring harness rubbing throught where it enters the box.
s in model number designates space saver model with shorter counterweight and I am not quite sure what controller in battery box does unless unit is equipped with TWC system for emissions and is silver in color. I would imagine that alternator is your problem or harness itself damaged.
I think you and I are looking at the problem from two different points of view, you have stated that you have nine volts constant and Im asking what is the current draw its the current draw thats flatening the battery not the voltage, I respect your thirty years in the lift truck bussiness, Ive had thirty six years mainly on electric truck.
Titus
I noticed the S in the model #- is this a safety rated truck? If you disconnect the little box in the battery box but leave the alternator hooked up I understand you still have a voltage draw, but will the truck still run? Does the alternator still charge? What electrically is affected?
generally if there is a draw on the system through the alternator its most likly caused by a shorted regulator, if its internal to the alternator and not that little box on the battery u spoke of earlier then have the alternator checked and repaired.
If indeed that little box has something to do with the regulator then replace that too.
Just my guess
Is there any accessories on the machine, like a Shock Watch? Looking at a schematic the only things "powered up" with the key off are the light relays, horn, cable to the starter, cable to the alternator, and the S terminal on the plug that goes in the alternator (5 amp alt. fuse in the fuse box).
Titus,
We have already verified the amperage draw. The battery has been checked as this would be the first thing to do. Been i this buisness for over thirty years. Appreciate the suggestion but haave been there. My biggest concern is replacing just the alternator will not reduce the draw. Want to make sure we are not missing something that has happened before. Thanks.
Im not familliar with this truck but Ive given it some thought and i think at this stage you need to put your digital meter on the amps range and check the current draw from the battery insert it between the battery positive post and the cable terminal and read of the current draw if its ten amps you have a problem if its.0100 amps then theres no problem and the battery is past its best and needs replacing. Better still charge the battery up and do a load test on it How old is the battery. I think you need to check the battery capacity before you go looking for current and earth leakage.
Titus