Repair wiring harness

AR54.18-D-0100FA

Repair wiring harness

4.5.15

Model

909

Front frame wiring harness

1

Front frame wiring harness

 Danger !

Risk of explosion from explosive gas. Risk of poisoning and caustic burns from swallowing battery electrolyte. Risk of injury through burns to skin and eyes from battery acid or when handling damaged lead-acid batteries

No fires, sparks, open flames or smoking. Wear acid-resistant gloves, clothing and glasses. Only pour battery acid into suitable and appropriately marked containers.

AS54.10-Z-0001-01A



Notes on battery

AH54.10-P-0001-01A



Disassemble

1

Remove front bumper

AR88.20-D-2000F

2

Remove battery

3

Remove battery box

4

Disconnect front frame wiring harness (1) from consumer points

5

Cut through front frame wiring harness (1) at an easily accessible point underneath battery box

 Cut through the individual lines at separating points which are offset by approx. 45 mm relative to each other.

6

Unclip cable ties and remove front frame wiring harness (1)



Assemble

7

Connect new front frame wiring harness (1) at consumer points, route to separating point and fix in place using cable tie

 Danger !

Risk of injury caused by burns to skin and eyes. Risk of poisoning caused by inhaling fumes when working with heat-shrinkable tubing.

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

AS00.19-Z-0001-01A

 Danger !

Risk of injury caused by burns to skin and eyes, risk of poisoning caused by inhaling fumes during soldering.

Wear protective gloves, protective clothing and safety glasses. Ensure that the work area is adequately ventilated. Secure power supply cables. Avoid sources of fire in working area.

AS00.19-Z-0002-01A

8

Repair wiring harness using cable connectors

AR54.18-D-0100-03F



000 588 00 84 00 Heat gun

WS54.00-P-0049B

 Only use cable connectors with heat-shrinkable tubing.
Select the cable connector according to the cable cross-section.
When connecting the lines, make sure that the insulation of both line pairs is the same color.

 Wiring harness repair kit

*220589019900

9

Install battery compartment

10

Install battery

11

Perform function test

12

Install front bumper

AR88.20-D-2000F

13

Set time on instrument cluster

14

Set time on timer for auxiliary heater

MODEL 909 with CODE H12 (Auxiliary heater (warm water)) MODEL 909 with CODE H86 (Timer for auxiliary heater) MODEL 909 with CODE HZ5 (10kW auxiliary water heater with timer)