Isuzu N-Series. Manual - part 1073

8-4 CAB AND CHASSIS ELECTRICAL

Never insert the circuit tester test probes into the con-
nector open end to test the continuity. Broken or open
connector terminals will result.

Waterproof Connector Inspection
It is not possible to insert the test probes into the con-
nector wire side of a waterproof connector.
Use one side of a connector 1 with its wires cut to make
the test. Connect the test connector 2 to the connector
to be tested. Connect the test probes to the cut wires to
check the connector continuity.

Connector Pin Removal
Connector Housing Tang Lock Type

1. Insert a slender shaft into the connector housing

open end.

2. Push the tang lock up (in the direction of the arrow

in the illustration). Pull the wire with pin free from
the wire side of the connector.

Pin Tang Lock Type

1. Insert a slender shaft into the connector housing

open end.

2. Push the tang lock flat (toward the wire side of the

connector). Pull the wire with pin free from the wire
side of the connector.

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CAB AND CHASSIS ELECTRICAL 8-5

Connector Pin Insertion

3. Check that the tang lock is fully up.
4. Insert the pin from the connector wire side.

Push the pin in until the tang lock closes firmly.

5. Gently pull on the wires to make sure that the con-

nector pin is firmly set in place.

Parts Handling
Be careful when handling electrical parts. They should
not be dropped or thrown, because short circuit or other
damage may result.

Cable Harness
When installing the parts, be careful not to pinch or
wedge the wiring harness.
All electrical connections must be kept clean and tight.

Use a grommet or guard tube to protect the wiring har-
ness from contacting a sharp edge or surface.

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8-6 CAB AND CHASSIS ELECTRICAL

Position the wiring harness with a enough clearance
from the other parts and guard the wiring harness with a
vinyl tube and clips to avoid direct contact.

The wiring harness between engine and chassis should
be long enough to prevent chafing or damage due to
various vibrations.

Splicing Wire

1. Open the Harness

If the harness is taped, remove the tape. To avoid
wire insulation damage, use a sewing “seam rip-
per” (available from sewing supply stores) to cut
open the harness.
If the harness has a block plastic conduit, simply
pull out the desired wire.

2. Cut the wire

Begin by cutting as little wire off the harness as
possible. You may need the extra length of wire lat-
er if you decide to cut more wire off to change the
location of a splice. You may have to adjust splice
locations to make certain that each splice is at least

1-2/2

″ (40 mm) away from other splices, harness

branches, or connectors.

3. Strip the insulation

When replacing a wire, use a wire of the same size
as the original wire. Check the stripped wire for
nicks or cut stands. If the wire is damaged, repeat
the procedure on a new section of wire. The two
stripped wire ends should be equal in length.

4. Crimp the Wires

Select the proper clip to secure the splice. To de-
termine the proper clip size for the wire being
spliced, follow the directions included with your
clips.
Select the correct anvil on the crimper. (On most
crimpers your choice is limited to either a small or
large anvil.) Overlap the two stripped wire ends
and hold them between your thumb and forefinger.
Then, center the splice clip under the stripped
wires and hold it in place.

• Open the crimping tool to its full width and rest

one handle on a firm flat surface.

• Center the back of the splice clip on the proper

anvil and close the crimping tool to the point
where the back of the splice clip touches the
wings of the clip.

• Make sure that the clip and wires are still in the

correct position. Then, apply steady pressure
until the crimping tool closes.

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CAB AND CHASSIS ELECTRICAL 8-7

Before crimping the ends of the clip, be sure that:

• The wires extend beyond the clip in each direc-

tion.

• No strands of wire are cut loose, and
• No insulation is caught under the clip.

Crimp the splice again, once on each end. Do not
let the crimping tool extend beyond the edge of the
clip or you may damage or nick the wires.

5. Solder

Apply 60/40 rosin core solder to the opening in the
back of the clip. Follow the manufacturer's instruc-
tions for the solder equipment you are using.

6. Tape the Splice

Center and roll the splicing tape. The tape should
cover the entire splice. Roll on enough tape to du-
plicate the thickness of the insulation on the exist-
ing wires. Do not flag the tape. Flagged tape may
not provide enough insulation, and the flagged
ends will tangle with the other wires in the harness.

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