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Got this forklift at work. I guess someone ran over a metal grate and tore out the main wiring harness. So now, I will more than likely be tasked to make some sort of sense out of this spaghetti of wiring. I think I have identified most of the major players in this electrical system:
Although this looks like a wiring disasterpiece, I am devising a way to tackle this mess. My first strategy will be just to get 1 circuit to work; preferably one that will actually start the forklift. If I can make it this far, I will then apply power (using my new power probe 🙂 ) to various lines going towards the hydraulic cylinders to see if I can get any forks to move. Then, from the control side, I will probably perform continuity testing to see if any of the forklift controls induce an open or a close in the circuit. There appears to be a lot of solenoids and relays and what not in the mix which will surely make things interesting. There might be circuits designed to be (or inhibited by) safety interlocks that I will also need to account for. :dry:
If anyone has ever been down this road, I am open to suggestions.
Wish I had a wiring diagram.
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Can you call the maker of the fork truck to get the wiring
or service manual? no luck on line for wiring? I’m jealous
about the power probe. 😛 Stupid airplane being late. :ohmy:I love working on fork lifts! I work at a Nissan dealer and I get Nissan forklifts all the time. But I have wiring diagrams and service manuals which help me a lot. Just take it slow and easy and just like ToyotaKarl said. Have fun with that power probe. I sadly don’t have one yet so I don’t get many opportunities to use them. 🙁
Good luck you can do it. There’s nothing magic about electricity. Electrons have to follow the physical laws of this planet just like everything else.
I haven’t had a lot of time to work on this… it is kinda low on the list of priorities in the shop. I think I’ll get some time to get it going this week though.
Here is probably the worst wiring diagram I have ever seen in my life:
I think I made better progress just based on my own observations:
Kids, stay in school and pay attention, so when you design these electrical schematics they will hopefully offer some sort of helpful information.
That first diagram made me laugh! Yours it pretty good. It seems like every wiring diagram in any service manual I have seen leaves a lot to be desired meaning they fall short of a proper electrical schematic. I don’t know if this is because they are holding back on information or the people releasing them don’t know what proper schematics are.
I am currently in my own electrical nightmare as well troubleshooting an electronics circuit that’s fairly gnarly. Sometimes it just takes pure perseverance. It will get done.
[quote=”college man” post=70212]The more beer you drink the clearer the diagram gets. ;)[/quote]
You are possibly correct. But I can’t handle my alcohol so I avoid it, but I walk at lunch time everyday with my wife for 2 miles and many times things come into clarity regarding my electrical issues I am working on. Just stepping away I thing helps.
I work on circuits everyday and one big issue is that we over think these circuit issues preventing us from getting to root cause. No matter how complicated the circuit is, 99.9% of the time the root cause will be very simple- a short, open, partial short, partial open. This is true even on the die level of semiconductors.
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