OPERATOR'S MANUAL MAINTENANCE

Section C - Electrics
Service Procedure
Wiring Harness Repair
C-174 C-174
9803/9880-3
Wiring Harness Repair
TC-004
Introduction
Instances do occur where it is necessary to incorporate
auxiliary electrical components into existing electrical
circuits and, although unlikely with present wiring
harnesses, repair or replace specific individual wires within
a harness. This will also apply to other machines in
addition to those of manufacture.
To ensure that either the inclusion of an auxiliary electrical
component or a repair within a harness is completed to an
acceptable standard it is strongly recommended that the
following tools, equipment and procedures are always
used. Note that JCB harnesses have an International
Protection rating of 67 (I.P.67).
The sheath covering of the recommended splice is heat
shrunk onto the original wire insulation. This results in a
seal and corresponding joint to IP 67 specifications.
!MCAUTION
When installing Auxiliary Electrical Components
always ensure that the additional load rating is
suitable for that particular circuit. It is unacceptable to
simply increase the fuse rating as this can cause
overloading and consequential failure of wiring, along
with failure of integral circuit components, which the
fuse is protecting.
ELEC-2-1
!MWARNING
In addition to the warnings incorporated into this
procedure, extreme care should be taken when
handling the gas heating tool to ensure that the flame
does not damage or set fire to any items in the vicinity
of the repair, i.e. other wires, floor panels, floor mats,
sound proofing, paintwork, etc. This tool should not
be used in any restricted location prohibiting the use
of "Naked Flames" or where risk of explosive gas or
similar safety parameters apply. No other heat source
should be used to attempt a sealed joint.
ELEC-2-2
!MCAUTION
When the heater is in use, the reflector and the air
coming out are extremely hot. Keep away to avoid
accidental burns. Do not touch the reflector until it has
had time to cool down after switching off. If flame
reappears at the reflector when the heater is in use, the
catalytic element is damaged or used up. Stop work
immediately and replace the heater.
ELEC-2-3
Repair Procedure
Table 3. Tools Required
1 Cut the wire and remove the protective insulation for
a suitable distance dependent upon the size of wire
and splice to be used. For the splices detailed in
K Table 3. ( T C-174), the dimension is 7mm.
Fig 11.
2 Using the correct sized splice, attach the new section
of wire required or auxiliary flying lead to the existing
harness and secure using the crimp tool.
K Fig 11. ( T C-174). Note that each of the splices
detailed is colour-coded to make size and range
Part No. Description Qty
892/00350 Butane Heater assembly 1
892/00349 Crimp tool 1
892/00351 Splice 0.5-1.5 mm (Red) 50
892/00352 Splice 1.5-2.5 mm (Blue) 50
892/00353 Splice 3.0-6.0 mm (Yellow) 50