Wiring Harnesses; Removal And Replacement; Disassembly; Cleaning And Drying - JLG sky trak mmv Service Manual

2. When an electrical component (8) is to be grounded,
eliminate paint and rust from around the stud, bolt or
capscrew (9), install a flat washer (10), tooth type or
slot-type lockwasher, or locking nut with slotted type
lockwasher (11) and nut or locknut (12).
12
11
9
10.5

WIRING HARNESSES

Wiring on the vehicle is contained within five separate
wiring harnesses, the engine harness, cab harness, light-
ing harness, boom worklight harness and load moment
indicator harness. A harness consists of black-nylon wo-
ven braiding, providing a protective cover to bundle nu-
merous wiring groups, splices, terminals, connectors,
and, where applicable, diodes. Each harness is identified
with a JLG part number when the vehicle leaves the fac-
tory.
Each wire is identified by a wire number on each end of
the individual wire, and by the color and gauge size of the
wire. The wire numbers are also identified on the appro-
priate electrical schematic. All circuits have been electri-
cally tested for continuity, and all diodes have been
tested for correct biasing. Where several individual con-
nectors appear, the wiring leading to a particular connec-
tor can help identify the specific circuit. For some circuits,
a colored band (tie wrap) is present, affixed to the con-
nector wiring and used as a color-code indicator. If wiring
ever needs to be replaced, use the correct gauge size
wiring. NEVER replace a wire with a smaller gauge wire.
Model MMV Rev. 12/04
10.5.1
Remove a wiring harness only if damaged or unusable.
Install a new harness one terminal at a time as the old
harness is removed. Label or tag the terminal locations of
all wires, harness clips, tie wraps and conduit as the old
harness is removed to allow correct installation of the
new harness.
10.5.2
10
Disassembly of the wiring harness is not recommended
due to the precise arrangement of wires and splice re-
8
quirements. If it becomes necessary to replace wires, use
the correct gauge size wiring, and NEVER replace a wire
with a smaller gauge wire.
MA0881
10.5.3
Clean a wire harness with a natural bristle brush and the
same detergent used to clean the vehicle. Allow the har-
ness to air dry. DO NOT allow surface temperatures to
exceed 300° F (149° C).
10.5.4
Replace a harness only if it is damaged or unusable. If a
splice or repair must be made to a wire, always use rosin
core solder to bond wires together. Use heat-shrink tub-
ing or insulating electrical tape to cover all splices or bare
wires.
10.5.5
The wiring harnesses are held securely in place by wire
tie wraps, clips or other devices to help prevent chafing or
wearing of the insulation and entanglement with moving
parts. Sections of ribbed plastic conduit have been in-
stalled where wiring or harnesses pass through openings
in the vehicle frame. Always install tie wraps, clips, con-
duit, etc., in their original locations to help prevent dam-
age to the wiring or harnesses.
Electrical System

Removal and Replacement

Disassembly

Cleaning and Drying

Inspection and Repair

Installation

10.9