SkyTrak 6036 Service Manual - Manual (Page 198)

Section 10. Electrical System
10-5 Model 6036 S/N 9B0499 and Before
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
Circuit breakers, (1 thru 6, Fig 10.6) 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. 10.6), 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).
a. Removal of Individual Circuit Breaker and
Circuit Breaker Bracket
1. Disconnect negative (–) cable (2, Fig. 10.38)
from batteries.
2. Tag and disconnect wiring from circuit breaker
by removing hex nuts and lock washers.
3. Each circuit breaker is held in the circuit
breaker bracket by spring tension only. Re-
move circuit breaker by inserting small slot
screwdriver between circuit breaker bracket and
left edge of circuit breaker and tilt breaker out
of bracket
10.2.4 Warning Lights
There are four warning lights in a cluster between
the hourmeter and fuel gauge. When you turn the
ignition key to the RUN position the Engine Oil
Pressure and Alternator Charge indicators will light.
This is a normal condition. While the engine is
running, all lights should be OFF. However, if any
of the lights go ON a potentially dangerous condi-
tion exists.
Directly to the right of the instrument cluster is a
warning light bulb test button. With ignition switch
in RUN and the engine OFF, depress this button to
test all four warning lights. If any of the lights are
burnt out, replace the bulb(s) immediately. You will
find the bulb number in the Electrical Specifications
Table at the end of this section.
10.3 WIRING HARNESSES
The forklift has harnesses (1 and 2, Fig 10.5) for
cab and engine wiring. A forklift with an optional
lighting system will have a separate lighting
harness (1, Fig 10.53). 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 tempera-
tures 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.