DMF RW-1016, Parts & Service Manual

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DIVERSIFIED METAL FABRICATORS, INC. RW-1016
5-8 © 2017 DMF, Inc. All Rights Reserved.
5.2 ELECTRICAL SYSTEM
5.2.1 Locating Electrical Components
 Determine location under the hood for the circuit breakers and terminal strip. It should
be accessible and protected from road spray. High on the firewall, along the inside of the
fender, and attached to the battery box are typical locations. The terminal strip can also
be located inside the cab.
 When installing the terminal strip in an area subject to moisture, such as under the
hood, the large connector on the wireless control box must be oriented DOWNWARDS to
prevent water intrusion.
 The pump solenoid should be protected from accidental contact with loose tools or cargo
with covers if necessary. See section 5.1.2 for additional information on pump locations.
5.2.2 Routing Wires
 Route the electrical harness according to 5.3 Electrical Schematics. Observe the
following guidelines:
o
We recommend running the wires in split loom.
o
Route wires away from the drive train, exhaust, and any moving parts.
o
Ensure that wires do not interfere with Railgear motion.
o
Wires can be routed inside the frame.
o
Support and restrain wires with wire ties or wire clips as necessary.
 All electrical terminations should be protected with liquid electrical tape or
other means.
 Heat shrink terminals are provided and should be used wherever possible.
 Run wires from chassis locations to the terminal strip under the hood.
 All bulkhead or firewall penetrations must be protected with grommets.
 Attach wires to the terminal strip as shown in 5.3 Electrical System.
 Attach the (2) Battery Source leads and the (1) Ignition Source Lead. The ignition
source is made using the provided mini-ATO fuse tap.
 Where possible attach grounds to the battery posts or remote ground provided.
 The hydraulic pump requires a dedicated ground to the frame, 4 GA welding cable
minimum. Tapped holes on the aluminum pump block provide an easy and secure
attachment point.
5.2.3 Electrical Insulation
All Electrical terminations should be protected with a spray or brush-on electrical insulation
product. This includes pump grounds, solenoid connections, terminal strip connections and the
terminal strip ground. Failure to adequately protect the electrical components can lead to
corrosion and system malfunction. The manufacturer does not warranty the installation of a
third party installer. This is the installer’s responsibility.