ar5418d0100c

Repairing wiring harness

Type ar · topic 54.18 · version 0103 · 2006-07-26

Applies to: MODEL WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7 Front frame wiring harness MODEL 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada Front frame wiring harness MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA MODEL 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico

Where it sits

Function group 2 Chassis › 54 Electrical system, equipment and instruments › 54.18 Cable harnesses — Series 903 (models 61*, 62*, 66*, 67*) · Series 904 (models 61*, 62*, 66*)

EinPAS 25 On-board/network/multifunction › 25.25 Main wiring harness › 25.25.30 Repair wiring harness — Series 903 (models 61*, 62*, 66*, 67*) · Series 904 (models 61*, 62*, 66*)

AR54.18-D-0100C

Repairing wiring harness

1.2.01

MODEL WD1, WD2, WD3, WD6, WD7, XD1, XD2, XD3, XD4, XD5, XD6, XD7, YD1, YD2, YD3, YD4, YD5, YD6, YD7
Front frame wiring harness

MODEL 903.61 /66 /67, 904.61 /66 with CODE (ZU7) National version for Canada
Front frame wiring harness

MODELS 903.61 /66 /67, 904.61 /66 with CODE (ZU8) National version for USA

MODEL 903.61 /62 /66 /67, 904.61 /62 /66 with CODE (ZU9) National version for Mexico

Repairing wiring harness

D54.18-1118-06

1 Front frame wiring harness

Dismantling

Danger!

Risk of injury. This work may result in burns to skin and eyes. Risk of poisoning. Inhaling fumes when working with heat-shrinkable tubing may cause poisoning.

Work only in well ventilated rooms. Wear safety glasses with side protection and protective glove.

AS00.19-Z-0001-01A

1

Remove front bumper

AR88.20-D-2000NA

2

Remove battery

3

Remove battery tray

4

Disconnect frame wiring harness (1) at front consuming points

5

Disconnect front frame wiring harness (1) at an easily accessible place below the battery tray

Use cable shears to cut the wires. Always cut the individual cables at the cut to different lengths.

6

Unclip cable straps and remove old frame wiring harness (1)

Assembling

7

Connect new frame wiring harness (1) to the front consumer points, route to below the battery recess and attach with cable strap

8

Repair wiring harness using
cable connectors

Only use cable connectors with shrink hose. Select cable connectors that match cable cross-section. When joining the cables, ensure that the insulation sheaths are the same color.

AR54.18-D-0100-03A

*220589019900

Hot-air gun

*WH58.30-Z-1004-20A

9

Install battery recess

10

Install battery

11

Perform function check

12

Reinstall front bumper

AR88.20-D-2000NA

Repairing wiring harness

Wiring harness repair kit

220 589 01 99 00

Commercially available tools

Number

Designation

WH58.30-Z-1004-20A

Hot-air gun

Referenced documents