Section

Wiring Harness Repair

Make sure the truck is OFF and the battery connector disconnected before working on harnesses. When pulling a wire out through a bundle, cut off the pin or socket so it does not snag. When replacing wires, in some cases you can tape or solder one end of a new wire to one end of the failed wire. Then you can pull the old wire out of the bundle and pull the new wire into the bundle, all at the same time. Make sure to disconnect the old wire from the new wire.

In other cases, it is easier to secure a new wire to the outside of the existing wire bundle with cable ties of an appropriate size. The failed wire can be left in the bundle, or can be pulled by one end to remove it from the bundle.

When replacing wires, follow these guidelines:

•Use the appropriate tools to remove and insert terminations at each connector.

•Remove damaged terminations and discard. Never reuse a termination from a wire.

•Do not cut away a terminal lug and reuse the wire strands that were crimped into the original lug.

•When stripping wire, use new wire strands for new terminations. Make sure to use a new wire with extra length to allow for cutting and stripping of the ends to install new terminations.

•Use a new wire that is the same gauge (typically gauge 18 AWG), size, type, and color as the wire it is replacing.

•Use a hand stripper capable of stripping by wire gauge number. Use care not to nick or cut any of the wire strands. Discard and replace a wire with damaged strands. Insert the correct length wire strands into the termination before crimping.

Wiring Harness Soldering Procedures

To prevent damage from excessive heat when soldering small components in assemblies, follow these guidelines:

•Make sure the soldering tip is clean. A dirty tip does not transfer heat well and encourages long dwell time and greater pressure. Apply light pressure on the terminal.

•Flux: rosin base

•Solder: 60/40 rosin core or equivalent

•Solder Iron: 15-20 watt “pencil-type” maximum

•Tip Size: 3 mm (0.118 in.) diameter x 30mm (1.182 in.) long screwdriver tip. Make sure the tip is clean.

•After soldering, clean the terminals with a brush dampened with an alcohol-based cleaner (P/N990-600/FOF). Do not allow any cleaner to seep into the switches or potentiometers, or contact contamination may occur.

Electrical Components Fuses

Fuses

Under extreme operating conditions, fuses (FU1, FU2, and FU3) protect the electrical circuits and components from excessive current or voltage overloads. Fuse FU1 is a 400 Amp fuse and is used to protect the truck’s traction system. Fuse FU2 is a 350 Amp fuse and is used to protect the truck’s lift system. Fuse FU3 is a 15 Amp fuse and is used to protect the truck’s control system. See Figure7-62.

Fuse FU3

Fuse FU1

Fuse FU2

Fuse Test/Inspection

Examine each fuse for signs of overheating, discoloration, cracking, or other physical damage. Replace the fuse if you find damage.

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 to measure the resistance across the fuse. The resistance must be less than 1 ohm.

Publication: 1146947, Revised: 12 Jan 2017 7-49

Section 7.Component Procedures

Horn

Horn

The horn is located below the Traction Amplifier (TA) in the left side electrical compartment.

Horn Removal

1.If equipped with the optional keypad, press the red OFF ( O ) key. Place the Main ON/OFF Switch in the OFF position. Disconnect the battery connector from the truck.

2.Remove the tractor covers.

3.Disconnect the wires from the horn. See Figure7-63

Model 6210 Maintenance Manual

Components

Horn Installation

1.Attach the horn to the contactor panel and tighten the mounting bolt.

2.Attach the wires to the horn terminals.

3.Connect the battery connector.

4.Place the Main ON/OFF Switch in the ON position. If equipped with the optional keypad, enter your PIN-key code, press the green ON ( | ) key, and test the operation of the horn.

5.If equipped with the optional keypad, press the red OFF ( O ) key. Place the Main ON/OFF Switch in the OFF position. Disconnect the battery connector from the truck.

6.Install the tractor covers.

7.Reconnect the battery connector.

Horn (behind bumper)

4.Remove the horn mounting bolt.