Raymond 8210 - Wire Harness Installation

Model 8210/8250 Maintenance Manual Section 7. Component Procedures
Electrical Components Lithium-Ion Battery
Publication: 1146945/001, Revised: 25 Sep 2018 7-59
8. For a high capacity lithium-ion battery,
disconnect the communication connector
from the second Cell Module Assembly.
9. Do not pull on the wires to remove the
connector.
10. Disconnect the Charger I/O connector by
pinching the tabs and pulling the
connector out.
11. Do not pull on the wires to remove the
connector.
12. Pinch the two tabs on the charger DC
output housing and remove the cover.
13. Unscrew and remove the charger DC
output B+ and B– terminals.
14. Remove the lithium-ion battery display
port from the cubby (male end).
15. Remove the Accessory Power connector
from the cubby (male end).
16. Remove the Service CAN port from the
cubby (female end).
17. Remove the Truck CAN connector from the
lithium-ion battery (male end).
18. Remove the Cooling Fan connector from
the lithium-ion battery (male end).
19. Remove harness assembly.
Wire Harness Installation
Perform the following steps to install the
Harness:
1. Plug the BMC I/O and Power Connector to
the BMC.
2. Plug the Cell Module Assembly
communication connector to the Cell
Module Assembly. If a second Cell Module
Assembly is present, plug the Cell Module
Assembly communication connector to the
Cell Module Assembly.
3. Plug the Charger I/O Connector into the
charger.
4. Install the DC output ring terminals into
the appropriate terminal on the charger.
5. Install fasteners. Torque fasteners to
3.3 ft. lb. (4.5 Nm).
6. Snap the DC output housing over the
terminals.
7. Install the cooling fan connector onto the
lithium-ion battery.
8. Install fasteners. Torque fasteners to
6.6 ft. lb. (9 Nm).
9. Place the wire clips on the standoff on the
lithium-ion battery.
10. Install the truck CAN connector onto the
lithium-ion battery.
11. Install the Accessory Power connector
(male end) into the cubby.
12. Install fasteners. Torque fasteners to
1.7 ft. lb. (2.3 Nm).
13. Install the lithium-ion battery display
connector into the cubby wall.
14. Install fasteners. Torque fasteners to
1.7 ft. lb. (2.3 Nm).
15. Install the service connector into the
cubby wall.
16. Install fasteners. Torque fasteners to
0.7 ft. lb. (0.9 Nm).
17. Add zip ties to the cable mounting posts
and the harness.
18. Install the front cover. See “Front Cover
Installation” on page 7-50.
19. Install the top cover. See “Top Cover
Installation” on page 7-49.
20. Reconnect the battery connector. 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.
21. Test the operation of the truck.
Do not reverse the polarity on the DC
output side on the AC charger during
installation. This could result in sparks,
fire, or explosion; and damage to
property and/or injury to personnel
could occur.
Property of American Airlines