23 - 1
Wiring Harness
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
JCB 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.
!
CAUTION
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
!
WARNING
In addition to the warnings incorporated into the
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
!
CAUTION
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
Tools Required
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
Repair Procedure
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 above, the
dimension is 7mm.
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
X
, part number
892/00349.
Note that each of the splices detailed is colour-coded
to make size and range readily visible. They are
secured using the corresponding size and matching
colour-coded jaws of the crimp tool to ensure joint
security. This tool also incorporates a ratchet closing
mechanism which will not release until the splice is
fully closed to the correct compression size.
3
With the Butane heater assembly, 892/00350, seal the
connection using the procedure on the next page.
....continued
Section C
9803/3280
Section C
23 - 1
Issue 1
Service Procedures
S189530
7
X
