With lack of daylight, crap weather, being back at work (from home admittedly) full time and having my son at weekends I've not had much time to tinker, let alone use the JCB.
But I've continued to fiddle about with the lights and wiring to get everything working...ish...
When the JCB arrived the headlights had been replaced with a pair of Hella driving lamps that were only wired to come on main-beam, they also seemed to be pointing at the backs of the pallet forks :/ The beacon on the roof didn't work and neither did the number plate lights or interior light, an indicator wasn't working on the offside (right) front and the nearside (left) front side/indicator lamp was wrapped in electrical tape.
Working my way through everything I found corroded connectors on the power supply wires for the interior light and beacon at the connector to the right of the steering column tucked up under the body tub rail. The ends of the wires had broken off the bullets and fallen out of the connector block and lord knows how they hadn't shorted on anything, because typically in getting to them I did short them and blew the fuse! Always disconnect the battery first
The number plate lights were a bit bashed about and the bullets corroded so I pulled them out gave them a thorough clean up, added some aluminium foil tape to the backs of the glass for refectors, replaced the bulbs for LED's and decided to run a dedicated earth to each rather than relying on fortuitous earthing through rusty bolts on rusty bodywork. In running the dedicated earths I also spliced in some additional power feeds off the halogen worklights to run some additional LED work lamps that I'd picked up off the 'bay of e'; 5 work lamps for 15quid delivered...
The Durite Lamps arrived, and I wasn't exactly impressed with the quality, the housing is made from the thinest steel which I sware the powder coat is thicker on, and the lamp guards are purely decorative
I opened them up took the halogen lamp units out of the bezels and offered up the 5" LED headlights, I ended up having to glue some 1mm rubber around the lip of the lamps to get clearance between the polycarbonate lens and the 'guards', I also had to trim the securing clips down a lot to seat the lamps in the bezzels because the lip on the lamp units was so thick.
Connector wise I'd bought some 2 and 3 pin waterproof connectors and I replaced all the connectors on lamps exposed to the weather. On the LED headlamps the headlight element has the conventional dip, main and earth connections plus a connection for a 'halo' sidelamp and a second colour for the 'halo'. I wired the halo to the sidelight and the second colour to the indicator.
I took the front sidelight/indicator units apart, repairing the nearside unit where the tape had been covering a smashed up plastics with some aluminium shaped, bonded and riveted to it to hold it all together. Frustratingly the lamp holder inside that lamp was rather corroded, and fell apart while I was putting it back on the JCB. Just like the number plate lights I lined the inside with aluminium foil tape, replaced the sidelight bulbs with LED's and ran dedicated earths.
I repeated the same process as I did on the sidelight/indicator units on the taillights, except without running the dedicated earths at the moment as I need to work out where I can run them to.
The additional LED worklights have been attached to the mounts halfway up the front and rear pillars and I also fitted the now redundant driving lamps on the underside of those same mounts. At the rear I drilled through the pillar below each mount to feed the power cables up to cab mounted work light.
Because of the extra light I've put higher rated fuses in on the lamp circuits.
All the wiring connections spliced in, properly insulated using adhesive lined heatshrink wherever possible, and lamps mounted I reconnected the battery and...only the headlights and indicators would work, no sidelights, work lights or tail lamps. I discovered in this that the second halo colour on the headlights wasn't amber, it was blue. Bugger. They're now disconnected. Back to the wiring diagram to see if I'd missed something, blown something or got the LED's wired in backwards. This is when I discovered that the headlights are wired direct through the light switch, meanwhile the sidelights, tail lights and worklights all go through a relay...odd...Found the relay, took it out checked it for signs of damage and opened it up to see if the contactors were dirty or burnt. Nothing. Plugged it back in. No difference. Hmmm
A few days later decided to take another look and everything worked fine
So all looks good...except a tail light bulb has now blown, the front neraside sidelight holder has fallen apart and the brake lights don't seem to work