Model 6210 Maintenance Manual
Section 7. Component Procedures
Electrical Components
Wiring Harness Use correct electrostatic discharge precautions. See “Static Safety” on page 2-11. The wiring harness is designed to connect the electrical components of the truck. All wires in the harness are marked with a wire identification number. These numbers correspond to wire identification given in the electrical schematic.
Wiring Harness 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 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 find electrical connectors on the truck, refer to the Electrical Schematics.
Wiring Harness
Wiring Harness Inspection Make sure the truck is OFF and the battery connector disconnected before working on harnesses. Whenever working on the truck, use care around wiring harnesses. •
Do not pull on wires.
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Carefully connect and disconnect all connectors.
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Do not pry apart connectors with unspecified tools.
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Examine and maintain any added materials used to dress or protect the wire. This includes spiral wrap, brackets, cable ties, fasteners, flexible conduit, and so forth.
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Check harness wires for abrasions, scrapes, nicks in the wire, damage from overheating or burns, or other general insulation damage.
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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 performance of the interconnect system. In addition to the wire identification number printed every 1 to 1.5 in. (25.4 to 38.1 mm) on the wire, there is a wire marker at each termination. If the marker is missing or unreadable, remark the wire to permit 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.
Publication: 1146947, Revised: 12 Jan 2017
7-47
