Model 6210 Maintenance Manual

Electrical Components

12.Install the lower and grille covers.

13.Reconnect the battery connector, and the place the Main ON/OFF Switch in the ON position. If equipped with the optional keypad, enter your PIN-key code and then press the green ON ( | ) key.

14.Test the operation of the truck.

Speed Sensor (Encoder) Replacement

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 lower and grille covers.

3.Remove the bumper.

4.Disconnect the connector from main harness to the speed sensor and the temperature sensor.

5.Remove the connector [38] from the bracket [35] on the drive unit.

6.De-pin the connections for the speed sensor cable.

7.Remove the screw [22] securing the speed sensor [24] to the speed sensor cover [21].

8.Remove the speed sensor and carefully pull the speed sensor cable through the grommet.

9.Install the socket head cap screw [22] to secure the replacement speed sensor [24] to the speed sensor cover assembly [21]. Torque the screws to 39.8 in. lb. (4.5 Nm).

10.Route the cable of the replacement speed sensor through the grommet.

11.Re-pin the connector. Refer to Figure7-76 for pin locations and wire colors.

Section 7.Component Procedures

12.Install the connector [38] on the bracket [35] on the drive unit.

NOTE: Make sure the speed sensor cable is correctly seated in the grommet to prevent damage from contact with the linkage when the drive unit turns.

13.Reconnect the main harness to the speed sensor.

14.Install the bumper.

15.Install the lower and grille covers.

16.Reconnect the battery connector, and the place the Main ON/OFF Switch in the ON position. If equipped with the optional keypad, enter your PIN-key code and then press the green ON ( | ) key.

17.Test the operation of the truck.

Publication: 1146947, Revised: 12 Jan 2017 7-65

Section 7.Component Procedures

Model 6210 Maintenance Manual

Traction MotorElectrical Components

Terminal Block Replacement

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 lower and grille covers.

3.Disconnect the power cables from the traction motor to the terminal block [31] on the drive unit, noting their correct position.

4.Remove the screws [32] and washers [37] retaining the terminal block [31] to the drive unit housing.

5.Secure the replacement terminal block [31] to the drive unit housing with washers [37] and screws [32]. Torque screws to 47.8 in. lb. (5.4 Nm).

6.Reattach the traction motor power cables and electromagnetic brake wiring connections to the terminal block. Torque power cable securing nuts to 26.5 in. lb. (3Nm).

NOTE: Check the traction motor cable routing. Make sure the wires are not near the drive tire. Secure wires with cable ties to prevent damage.

Figure 7-78.

Motor Power Cable Terminations

7.Before testing operation, move the handle from extreme left to right and down into the operating position and back several times. Check for any wire and cable interference. Repair or adjust as necessary.

8.Install the lower and grille covers.

9.Reconnect the battery connector, and the place the Main ON/OFF Switch in the ON position. If equipped with the optional keypad, enter your PIN-key code and then press the green ON ( | ) key.