Section 7. Component Procedures Model 8210/8250 Maintenance Manual
Wiring Harness Electrical Components
7-68 Publication: 1146945/001, Revised: 25 Sep 2018
Wiring Harness
Use correct electrostatic discharge
precautions. See “Static Safety” on
page 2-13.
N
OTE: For replacement parts information refer
to the Parts Manual.
The wiring harness is designed to connect the
electrical components of the pallet truck.
All wires in the harness are marked with a wire
identification number. These numbers
correspond to wire identification given in the
Electrical Schematics.
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 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.
• Carefully connect and disconnect all
connectors.
• Do not pry apart connectors with
unspecified tools.
• 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.
• Check harness wires for abrasions,
scrapes, nicks in the wire, damage from
overheating or burns, or other general
insulation damage.
• 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.
N
OTE: 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.
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