Model 9600/9700 Swing-Reach ® Lift Truck
Section 7. Component Procedures Wiring and Harness Connectors
Wiring and Harness Connectors
Electrical Components •
Remove damaged terminations and discard. Never reuse a termination from a wire.
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Do not cut away a terminal lug and reuse the wire strands that were crimped into the original lug.
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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.
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Use a new wire that is the same gauge (typically gauge 18 AWG), size, type, and color as the wire it is replacing.
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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 wire strands the correct length into termination before crimping.
General Repair Procedures See “Electrical Troubleshooting” on page 5-2. Whenever working on the lift truck, use care around wiring harnesses. •
Carefully connect and disconnect all connections.
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Do not pry connectors apart with unspecified tools.
There should be a wire marker at each termination. If the marker is missing or unreadable, remark the wire to allow 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.
Repair
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.
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Flux: rosin base
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Solder: 60/40 rosin core or equivalent
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Solder Iron: 15-25 watt “pencil-type” maximum
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Tip Size: 3 mm (0.118 in.) diameter x 30 mm (1.182 in.) long screwdriver tip. Make sure the tip is clean.
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After soldering, clean the terminals with a brush dampened with an alcohol-based cleaner (P/N 990-600/FOF). Do not allow any cleaner to seep into the switches or potentiometers, or contact contamination may occur.
Use correct electrostatic discharge precautions. See “Static Precautions” on page 2-8. When pulling a wire out through a bundle, cut off the pin or socket so it does not snag. When replacing wires, tape or solder one end of a new wire to one end of the failed wire. Pull the new wire into the bundle. 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. Leave the failed wire in the bundle, or pull it by one end to remove it from the bundle. When replacing wires, follow these guidelines: •
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Use the appropriate tools to remove and insert terminations at each connector.
Publication: 1089040, Issued: 08 Apr 2016
