Main Cab Wiring Harness Replacement
TM 9-2320-363-34-1 · Chapter 4 — Electrical System Maintenance
This task covers: a. Removal b. Cleaning c. Inspection d. Installation
Tools and Special Equipment: Equipment Condition:
Shop Equipment, SC 4910-95-CL-A31 Reference Condition Description
Tool Kit, SC 5180-90-CL-N05
TM 9-2320-363-20 Batteries Disconnected
References:
TM 9-2320-363-20
l Wiring harness and leads are secured in place by clips, wire ties, cushion clamps, and screw terminals.
l Only remove hardware securing harness or lead to be removed.
1. DISCONNECT RELAY AND FUSE PANEL (1).
2. DISCONNECT 42-PIN CONNECTOR (2), 34-PIN CONNECTOR (3), 32-PIN CONNECTOR (4), 6-PIN SEALED CONNECTOR (5), AND FOUR RING TERMINALS (6).
3. DISCONNECT THREE RING TERMINALS (6), 12-PIN CONNECTOR (7), FEMALE TERMINAL BLADE (8), 6-PIN FEMALE CONNECTOR (9), 3-PIN SEALED CONNECTOR (10), TWO 3-PIN FEMALE CONNECTORS (11), 1-PIN MALE CONNECTOR (12), AND SIX 1-PIN FEMALE CONNECTORS (13).
4 DISCONNECT THREE RING TERMINALS (6), 6-PIN FEMALE CONNECTOR (9), TWO 3-PIN FEMALE CONNECTORS (11), 1-PIN MALE CONNECTOR (12), 1-PIN FEMALE CONNECTOR (13), 12-PIN DIAGNOSTIC CONNECTOR (14), 3-PIN MALE CONNECTOR (15), TWO 2-PIN CONNECTORS (16), AND 2-PIN FEMALE CONNECTOR (17).
4.1 DISCONNECT 2-PIN MALE CONNECTOR (6.1).
4.2 REMOVE EIGHT SCREWS (14.1) AND REMOVE 6-PIN DIAGNOSTIC CONNECTOR (14.2) AND 9-PIN DATA LOGGER CONNECTOR (14.3).
4-24 Change 1
5. DISCONNECT RING TERMINAL (6), 6-PIN FEMALE CONNECTOR (9), FOUR 3-PIN FEMALE CONNECTORS (11), TWO 1-PIN MALE CONNECTORS (12), TWO 1-PIN FEMALE CONNECTOR (13), 2-PIN MALE CONNECTOR (16), 12-PIN LIGHT SWITCH CONNECTOR (18), AND 32-PIN CONNECTOR (19).
6. DISCONNECT FIVE 6-PIN FEMALE CONNECTORS (9), 3-PIN SEALED CONNECTOR (10), THREE 1-PIN FEMALE CONNECTORS (13), THREE 2-PIN MALE CONNECTORS (16), THREE 2-PIN FEMALE CONNECTORS (17), FOUR 4-PIN MALE CONNECTORS (20), THREE 4-PIN FEMALE CONNECTORS (21), AND 2-PIN SEALED CONNECTOR (22).
7. USCONNECT TWO RING TERMINALS (6), 2-PIN MALE CONNECTOR (16), THREE 4-PIN MALE CONNECTORS (20), AND THREE 6-PIN MALE CONNECTORS (23).
8. REMOVE MAIN CAB WIRING HARNESS (24).
Use general cleaning methods to clean all parts (page 2-30).
Inspect all parts for wear or damage.
Wiring harness and leads are secured in place by clips, wire ties, cushion clamps, and screw terminals. Make sure wiring harness is secure and all hardware is tight.
1. CONNECT RELAY AND FUSE PANEL (1),
2. CONNECT 42-PIN CONNECTOR (2), 34-PIN CONNECTOR (3), 32-PIN CONNECTOR (4), 6-PIN SEALED CONNECTOR (5), AND FOUR RING TERMINALS (6).
3 . CONNECT THREE RING TERMINALS (6), 12-PIN CONNECTOR (7), FEMALE TERMINAL BLADE (8), 6-PIN FEMALE CONNECTOR (9), 3-PIN SEALED CONNECTOR (10), TWO 3-PIN FEMALE CONNECTORS (11), 1-PIN MALE CONNECTOR (12), AND SIX 1-PIN FEMALE CONNECTORS (13).
3.1 INSTALL 9-PIN DATA LOGGER CONNECTOR (14.3) AND 6-PIN DIAGNOSTIC CONNECTOR (14.2) WITH EIGHT SCREWS (14.1).
3.2 CONNECT 2-PIN MALE CONNECTOR (6.1).
4. CONNECT THREE RING TERMINALS (6), 6-PIN FEMALE CONNECTOR (9), TWO 3-PIN FEMALE CONNECTORS (11), 1-PIN MALE CONNECTOR (12), 1-PIN FEMALE CONNECTOR (13), 12-PIN DIAGNOSTIC CONNECTOR (14), 3-PIN MALE CONNECTOR (15), TWO 2-PIN CONNECTORS (16), AND 2-PIN FEMALE CONNECTOR (17).
5. CONNECT RING TERMINAL (6), 6-PIN FEMALE CONNECTOR (9), FOUR 3-PIN FEMALE CONNECTORS (11), TWO 1-PIN MALE CONNECTORS (12), TWO 1-PIN FEMALE CONNECTOR (13), 2-PIN MALE CONNECTOR (16), 12-PIN LIGHT SWITCH CONNECTOR (18), AND 32-PIN CONNECTOR (19).
6. CONNECT FIVE 6-PIN FEMALE CONNECTORS (9), 3-PIN SEALED CONNECTOR (10), THREE 1-PIN FEMALE CONNECTORS (13), THREE 2-PIN MALE CONNECTORS (16), THREE 2-PIN FEMALE CONNECTORS (17), FOUR 4-PIN MALE CONNECTORS (20), THREE 4-PIN FEMALE CONNECTORS (21), AND 2-PIN SEALED CONNECTOR (22).
7. CONNECT TWO RING TERMINALS (6), 2-PIN MALE CONNECTOR (16), THREE 4-PIN MALE CONNECTORS (20), AND THREE 6-PIN MALE CONNECTORS (23).
8. SECURE MAIN CAB WIRING HARNESS (24).
Connect batteries (TM 9-2320-363-20).