Raymond® Walkie Pallet Truck Maintenance Manual

Wiring Harness

All wires in the harness are marked every 1 to 1.5 in. (2.54 to 3.81 cm) with a wire identification number. These numbers correspond to wire identification given in the schematic. See “Schematics” on pageA-9.

Terminology

The term “connector JPx” means a mated connector consisting of two connector halves. One half contains male connectors, or pins (P); the other half contains female connectors, or jacks (J).

When you disconnect a mated JP connector, you will have two connector halves. The individual connector halves are designated by “Jx” and “Px.”

For example, connector JP2 is the mated connector in the control handle. J2 represents the jack connections. P2 represents the pin connections.

To locate electrical connectors on the truck refer to the electrical schematic located in the Appendix or see “Electrical Connector Locator Chart” on page5-12.

Component Procedures

Wiring

Wiring Harness

Inspection

Whenever working on the truck, use care around wiring harnesses.

•Do not pull on wires.

•Carefully mate and un mate all connectors.

•Do not pry apart connectors with unspecified tools.

•Examine and maintain any added materials used to dress or protect the wire. This includes spiral wrap, brackets, cable ties, fasteners, flexible conduit, etc.

•Check harness wires for abrasions, scrapes, nicks in the wire, damage from overheating or burns, or other general insulation damage.

•Replace terminations with exposed wire visible at the connectors. Damaged terminations, exposed wires, or damaged connectors can cause operational failure of the truck.

During troubleshooting and repairs, it is sometimes necessary to unmate a connector, move a harness, cut a cable tie, or remove the wire from a bracket. Note carefully the location of the wire and all protective or securing attachments before moving the harness.

After repair, return or replace all protective and/or securing hardware to its original condition. Protective materials are necessary to provide reliable performan ce of the interconnect system.

In addition to the wire identification number printed every 1 to 1.5 in. (2.54 to 3.81 cm) on the wire, there should be a wire marker at each termination. If the marker is missing or unreadable, remark the wire to allow easier identification.

NOTE: It is normal to find unused connectors for uninstalled options that have had heat shrink applied over them and have been strapped to the harness.

Diodes Test

Check diodes with a digital multimeter or use a Simpson 260 multimeter or its equivalent. Use the diode testing feature on the digital multimeter. Use the RX1 ohm scale on the Simpson 260 multimeter.

Caution

Unless otherwise directed, disconnect the battery connector when you check electrical circuits or components with an ohmmeter. Electrical curren t can damage the ohmmeter.

Replace the entire assembly if defective diodes are found.

Fuses

Test/Inspection

Examine the fuse for signs of overheating, discoloration, cracking, or other physical damage. Replace the fuse if you find damage. See Figure6-8.

To test a fuse, remove it or isolate it from the electrical circuit. Do this by removing the fuse from the truck or by removing all the connections from one side of the fuse.

Use an ohmmeter set to Rx1 scale and measure the resistance across the fuse. The resistance should be less than 1 ohm.

Circuit Breaker

Under extreme operating conditions the current demand on the battery may exceed the rating for the main circuit breaker and force it open. This will cause the truck to become inoperable until the circuit breaker automatically resets itself.

Test/Inspection

Examine the circuit breaker for signs of overheating, discoloration, or other physical damage. See Figure6-8. Replace the circuit breaker if you find damage.

To test a circuit breaker, remove it or isolate it from the electrical circuit and allow it to cool (or reset itself). Do this by removing the circuit breaker from the truck or by removing all the connections from one side.

Use an ohmmeter set to Rx1 scale and measure the resistance across the circuit breaker. The resistance should be less than 1 ohm.

Switches (General)

Switches (General)

Refer to the electrical schematic in the Appendix to identify the electrical circuit location of the switch.

Test/Inspection

Examine the switch for signs of arcing, overheating, discoloration, cracking, or other physical damage. Replace the switch if you see such damage.

To test a switch, isolat e it from the electrical circuit. Do this by removing all the connections from the switch, making sure all wires are labeled and identified for reconnection.

Use an ohmmeter set to a low resistance scale to measure the resistance across the switch. In a closed position, the switch should be less than 1 ohm. In an open position, the switch should show a resistance greater than 10 megohms.