SkyTrak 6036 Service Manual - Manual (Page 267)

Section 10. Electrical System
Model 6036/6036T S/N 9B0500 thru 14833 10-5
10.3 WIRING HARNESSES
The forklift has harnesses (Fig 10.5) for cab and
engine wiring. A forklift with an optional lighting
system will have a separate lighting harness (1,
Fig 10.30 or 10.30A). Each wire within a harness
is identified by a wire number on the electrical
schematic and on both ends of each wire.
a. Removal
1. Remove a wiring harness only if damaged or
unusable.
2. You may prefer to install the new harness as
you remove the old harness.
3. Tag the terminal locations of all wires, harness
clips and tie wraps as you remove the old
harness as required to permit identical installa-
tion of the new harness.
b. Disassembly
When replacing wires, it is important that the
correct gage size be used. Never replace a wire
with one of a smaller gage size.
c. Cleaning and Drying
Clean a wiring harness using a natural bristle
brush and the same detergents you would use to
clean the forklift. Allow to air dry with surface
temperatures not to exceed 300 °F (149 °C).
d. Inspection and Replacement
Replace a harness only if damaged or unusable.
If you must splice a wire or repair one that is
broken, always use rosin core solder to bond the
splice. Use insulating tape to cover all splices or
bare wires.
e. Installation
The harnesses are held securely in place by clips
or other devices to prevent chafing or wearing of
the insulation due to vibration. Be careful to install
harness clips and tie wraps in the locations tagged
on the forklift and the old harness in step a.
10.4 CIRCUIT BREAKERS
AND/OR FUSES
10.4.1 Circuit Breakers
S/N 9B500 thru 1882
Circuit breakers, (Fig 10.5) protect the electrical
system. The breakers are mounted inside the
right console on the outside cab wall below the
fork and frame tilt control lever. A breaker will trip
if there is a shorted or grounded wire in the
applicable circuit. It will automatically reset once it
cools.
A circuit breaker has a bimetallic arm and a pair of
contact points. When the current exceeds preset
limits, the arm gets hot, bends, and opens the
contact points. This shuts off the current through
the circuit and protects against damage or fire.
If a breaker continually trips, check the system for
shorts, grounds or defective components.
Under normal operating conditions a circuit
breaker should never require replacement.
However, if a breaker doesn’t automatically reset,
the breaker is defective and must be replaced.
The ignition switch feed for the entire electrical
system is protected by a 40 A circuit breaker (4,
Fig. 10.5), the horn, backup alarm and optional
cab heater fan by a 10 A circuit breaker (2), and
the control circuits by two 6 A circuit breakers (1
and 3). A forklift with an enclosed cab has an
additional 6 A circuit breaker (5) that protects the
windshield washer/wiper switch and the circulation
fan.
An optional light package includes head lights and
a rear work light, and stop, directional, hazard
(emergency flasher) and tail lights in a circuit
which is protected by a 15 A circuit breaker (6).