Model 8210/8250 Maintenance Manual Section 7. Component Procedures
Electrical Components Wiring Harness
Publication: 1146945/001, Revised: 25 Sep 2018 7-69
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
30 mm (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/N 990-600/FOF). Do not allow
any cleaner to seep into the switches or
potentiometers, or contact contamination
may occur.
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