Toro 04042 - Inspecting the Wire Harnesses and Component Connector Assemblies; Repairing Harness Wire Insulation

InspectingtheWireHarnesses
andComponentConnector
Assemblies
Figure19showsthethreewireharnesses.
g030844
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3
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Figure19
1.Mainharness3.Batteryharness
2.Batteryadapterharness
Thewireharnessesandelectricalcomponentsincludethe
following:
•Electricalconnectors
•Connectorpins
•Electricalterminals
•Insulatedwire
Whileyouaretroubleshooting,inspectthepartsforwear
anddamage.
Commonelectricalproblemsinclude:
•Open,shorted,orburnedwires
Note:Debris,suchaswetgrassclippings,canactasa
conductor.
•Corrodedterminalsorpins
•Waterintheconnector
•Connectorpinsthatareloose,bent,ormispositioned
•Connectorsthatarenotfullyseated
•Wiresthatarepinched,frayed,oraremissinginsulation
•Damagedconnectorlocks,clips,orhousings
•Missingorinadequatedielectricgrease
Note:Dielectricgreaseisusedinallunsealedwire
harnessconnectors.
RepairingHarnessWire
Insulation
Ifdamageextendsthroughtheinsulationandstrandsofthe
wirearebroken,repairorreplacethewireharness.Contact
yourToroServiceRepresentativeforguidancewhenrepairing
wires,terminals,pins,and/orconnectors.
Ifthereisdamagetotheouterinsulationonly,orifthe
damagetotheshieldingisabrasionordeformationonlywith
nobrokenstrands,repairthewireharnessasfollows:
1.Cleanthedamagedareaofthepartwithisopropyl
alcohol.
2.Drythepartwithacleanlint-freecloth.
3.Wrapthedamagedareawith2layersofall-weather
electricaltapeoranequivalent.
Note:Ensurethatthetapeextendspastthedamagebya
minimumof1.3cm(1/2inch).
Note:Heatshrinktapeproperlyinstalledinthesamemanner
aselectricaltapeisacceptable.Installtheheatshrinktape
accordingtothemanufacturer’sinstructions.
AttachingWireHarnesses
Properlyattachingthewireharnessestothemachinehelps
keeptheconnectorsfrombecominglooseandprotectsthe
harnessesfromaccidentaldamagecausedbyvibration.
•Ensurethatnodeviceusedtoattachawireharnesstothe
machinecanrotateorslidefreelyonthewireharness.
•Forwiresnotcontainedinconvolutedtubing,securethe
wireswithelectricaltapeoracabletieevery10to15cm
(4to6inches).
•Forsplit-loom,convolutedtubing,ensurethatthetapeor
cabletiesare1.3cm(1/2inch)awayfromanyconnectors
orlabels.
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