D6N hydraulic cylinder rebuild question

[Nige]

Here's another thought. It's obvious from the damage to the screws that someone has been in there before. What if they reconnected the switch wiring wrong.?
Compare the wiring on the illustration below with how the wires are connected to the terminals on the switch.
Start at the machine harness and make sure that the wires are Grey-to-Grey, Orange-to-Orange, and Pink-to-Pink at the 3-pin connector. Then move to how the wires are connected to the switch.



The terminals on the switch will be either marked 1, 2, 3 as per the illustration, or possibly COM, NO, and NC. I can't tell from your photo. Terminal 2 is COM, Terminal 1 is NC, and Terminal 3 is NO.

 

[DmanD6N]

Com 1 is pink, NO3 is orange and NC2 is grey. Wires do match colorswithmachineharness.

 

[DmanD6N]

1) Resistance measured between grey and pink reads up to 17 then goes down to 8. B and C have continuity. A to C is open.
2) In reverse A and C have continuity.
3) When moved back to neutral from reverse continuity is lost between grey and pink unless I go to forward position first and then neutral. After that there is again continuity in neutral.

Measuring resistance again after these tests shows only 1 no matter what forward, neutral or reverse position or multimeter setting.

 

[Nige]

If the contacts were fully closed resistance should measure less than 1 ohm, ideally less than 0.1 ohm if the contacts are in really good condition.
The variable resistance readings sound like the switch is playing silly buggers. I'd replace it as a start and go from there.

At least you have confirmed that the switch is wired correctly.

 

[DmanD6N]

Switch is in stock and the price is $51.94. 2 1/2 hour round trip to get it so not sure if I'll do it today. Thanks Nige!

 

[Nige]

Switch is in stock and the price is $51.94. 2 1/2 hour round trip to get it so not sure if I'll do it today. Thanks Nige!

At least that price is better than $4600...!!
Fingers crossed that it sorts the problem for you.

 

[DmanD6N]

I installed the switches and tried it out. Not exactly the Nebraska test but pushed and changed direction a lot for an hour and a half. No dreaded buzzer and no service code displayed. So far so good.
What would I do without you Nige? Thanks!

 

[Nige]

Where do I send the invoice for $4,600..?

 

[DmanD6N]

Manitoba Canada