CHAPTER 3 REPAIR INSTRUCTIONS - TM-10-3930-609-350032

TM 10-3930-609-35

CHAPTER 3

REPAIR INSTRUCTIONS

Section I. REPLACEMENT OF WIRING HARNESS

3-1. General

m. Disconnect wiring harness leads 13A-1 and 84

Removal of the wiring harness is not ordinarily required

from screw-type terminals on horn.

during overhaul of the truck. Usually, repair of the

n. Disconnect wiring harness leads 91 and 92 from

harness can be accomplished with the harness in place.

screw-type terminals on seat switch.

However, if repair is required in an inaccessible place,

o. Disconnect wiring harness leads 78 and 98 from

the harness may be removed from the truck and

screw-type terminals on pump switch.

reinstalled as described in paragraphs 3-2 and 3-3.

p. Disconnect wiring harness leads 69-1, 69-4, and

93 from screwtype terminals on battery connecting

3-2. Removal of Wiring Harness

switch.

a. Release handle on battery connector and

q. Remove three clamps which secure thermal

disengage battery connector.

relays to hydraulic oil tank, to travel motor frame, and to

b. Remove floor plate- (TM 10-3930-609-12).

pump motor frame. After disengaging thermal relays,

c. Remove valve cover (TM 10-3930-609-12).

replace clamps to prevent loss of parts.

d. Remove four screws, nuts, and flatwashers

r. Starting at front of truck, remove all clamps and

which secure cover to bottom of truck frame below

clips which secure wiring harness branches and main

battery compartment and withdraw cover.

trunk to structural members. After disengaging harness

e. Disengage terminals on harness leads 99 and

from clamps and clips, reattach clamps and clips to

13A-2 from terminals on wires extending from headlight

prevent loss of parts.

flexible conduit.

s. Remove control panel cover (TM 10-3930-609-

f. Remove two terminal covers from steering

12).

column and disconnect harness lead 83 and 84 from

t. Disengage two plugs on wiring harness from

screw-type horn button terminals.

receptacles connected to internal wiring of control panel.

g. Disengage plug on harness (containing leads

u. Unscrew conduit fitting (through which wiring

33, 69-3, 71, 72, and 74) from receptacle on cable

harness passes) from front wall of control panel

extending from direction control switch.

compartment. Fitting is located in lower left hand corner

h. Disengage harness terminals on leads 92 and

of control panel compartment.

93 from push-on terminals of panic switch.

v. Carefully withdraw wiring- harness from control

i. Disengage harness terminals on leads 13A-4

panel compartment. Straighten out branches in harness

and 82 from push-on terminals on hourmeter.

as required and work bulky items through holes and

around corners as. required. Avoid undue strain on

j. Disconnect harness leads 19, 86-1, 86-2, and 99

plugs, terminals, and thermal relays.

from screw-type terminals on light switch.

k. Disengage plug on wiring harness (containing

3-3. Installing Wiring Harness

leads 13A-3, 29A, 45, 49, 69-2, 69-3, 70, and 71) from

Installation of the wiring harness is essentially the

recptacle on cable extending from accelerator master

reverse of the removal procedure. Plugs are keyed to

switch.

prevent improper orientation. After securing

I. Disengage plug on wiring harness (containing

leads 35, 70, 86-1, and 94) from plug on cable

extending from brake and stoplight switch.

3-1