Repair Procedure for Damaged Harness Wiring {1408} Caterpillar


Repair Procedure for Damaged Harness Wiring {1408}

Usage:

MT700 018


Caterpillar Products
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Introduction

This Special Instruction will aide in repairing damaged or broken wires in a wire harness used in Cat ® applications.

Important Safety Information

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, procedure, work method, or operating technique is not recommended by Caterpillar: The user is responsible for ensuring the safety of using said tool, procedure, work method, or operating technique.

Ensure that the product will not be damaged, or be made unsafe, by the operation, lubrication, maintenance, or repair procedures that are used.

Repair Procedure for Damaged Harness Wiring

The following is applicable to:

  • 50V or less

  • Individual wire repair only

The purpose of these instructions is to provide proper necessary information to repair damaged or broken 18 AWG to 12 AWG wires in a harness.

Note: Internal harnesses such as, but not limited to, transmission, engine, differential and multi conductor cables, shall be replaced not repaired.

Do not perform any of the procedures or order any parts until you read and understand the information contained within these instructions.

Individual or multiple damaged or broken wires 18 AWG to 12 AWG, can be repaired, using the components listed in table 1.

Types of Damage

The damage to harness can vary from a small nick on braid or wire insulation to harness severely damaged with wires broken.

Note: The person performing the repair will determine the type of damage.

Type 1 Damage

Type 1 damage is considered to be minor damage. This damage may include damage to the braid and damage to wire insulation but no exposed conductors. Refer to illustrations 1, 2, and 3 for this type of damage.



Illustration 1g02642998


Illustration 2g02643056


Illustration 3g02643136

Type 2 Damage

Type 2 damage is considered to be braid and wire insulation damage with exposed or broken conductors. Refer to illustration 4 and 5 for this type of damage.



Illustration 4g02643156


Illustration 5g02643177

Table 1
Single Wire Splice Only 
Usage  Jiffy Splice  Butt Splice 
Can be used reliably in most application Can be used reliably in non-signal application only 
Part Number  115-8109  128-2800  370-2156  136-4878  136-4877  136-4876 
Wire Size (AWG)  18  "X"      "X"     
16   "X"      "X"   
14   "X"      "X"   
12     "X"      "X" 
Insulation Strip Lengths  6.4 mm (0.25 inch) to 7 mm (0.27 inch)  6 mm (0.24 inch) to 10 mm (0.39 inch)  10 mm (0.39 inch) to 13 mm (0.51 inch) 
Heat Source Required        "X"  "X"  "X" 
Fuel & Oil Resistance        "X"  "X"  "X" 
Temperature Rating  −55° C (−67° F) to 120° C (248° F)  −55° C (−67° F) to 105° C (221° F) 
Addition Parts Required  Pins  9X-3401  126-1767  7T-0093  None 
Sockets 9X-3402  126-1768  7T-0094 
Tools Required  1U-5804 Crimp Tool  9S-9150 Terminal Crimp Tool As 9U-6070 Heat Gun Gp 
Braid Removal Tool  Harness Braid Cutter 377-6198 
Electrical Tape  6V-4592 Tape 

If a section of harness needs to be replaced consider using the following pre-braided harness for replacement:

  • 3 Wire Harness 366-8856 Wiring Harness As

  • 6 Wire Harness 366-8857 Wiring Harness As

  • 9 Wire Harness 394-6873 Wiring Harness

  • 12 Wire Harness 394-6874 Wiring Harness

Type 1 Damage Repair

Use the following steps for type 1 damage.

  1. Identify damaged area of the harness.

  2. Identify root cause of damage.

    Note: Prior to implementing repair consider how to reposition harness or protect harness from repeat of damage.

  3. Inspect the area to ensure that there are no exposed conductors.

  4. Use electrical tape to cover damaged area and then secure tape with a tie strap.

Type 2 Damage Repair

Use the following procedure to ensure proper repair for type 2 damage.



    Illustration 6g02646471

  1. Identify the damaged area of harness. Refer to illustration 6.

  2. Identify the root cause of damage.

    Note: Prior to implementing repair consider how to reposition harness or protect harness from repeat of damage.



    Illustration 7g02646475

    Note: Note the orientation of the tool.

  3. Remove the braid using the recommended tool 377-6198 Cutter and expose the wires at the damaged area. Refer to illustration 7.

    Remove enough braid so that wires have enough length available to be repaired and do not have any undue tension after the repair is complete.

    If additional length of wire or harness section is needed, use pre-braided:



    Illustration 8g02646502


    Illustration 9g02646516

  4. Isolate the damaged or broken wires to be repaired and clean adequately to prepare for sealed splice. Refer to illustration 8 and 9.


    Illustration 10g02646519

  5. Remove the damaged section of each wire. Ensure to cut back enough to a point where all of the strands are intact. Refer to illustration 10.

  6. Refer to table 1 to determine which splice method to use and the appropriate insulation strip lengths. Verify that there is no nick or damage to the wire strands.

    If you are using a jiffy splice, proceed to step 7.

    If you are using a butt splice, proceed to step 22.



    Illustration 11g02646531


    Illustration 12g02646538

  7. Strip 6.4 mm (0.25 inch) to 7 mm (0.28 inch) (N) of insulation from the wire.

    Note: Be careful not to cut or nick the copper wire strands. A properly stripped wire will have the strands visible through inspection hole (M). The insulation will be within 1.5 mm (0.06 inch) of the back of the terminal when wire is properly inserted. Refer to illustration 11 and 12.



    Illustration 13g02646554
    (G) Wire Selector Gauge
    (H) Lock Clip
    (J) Selector Knob

  8. Make sure the wire selector gauge (G), on 1U-5804 Crimp Tool is set to the wire size being crimped. If the selector gauge setting does not match the wire size being crimped, proceed as follows:

    1. Remove lock clip (H).

    2. Raise selector knob (J) and rotate knob until the arrow is aligned with the wire size to be crimped.

    3. Lower the selector knob (J) and insert the lock clip (H).


    Illustration 14g02646594
    (K) Locknut
    (L) Adjusting Screw

  9. Loosen locknut (K) and turn adjusting screw (L) in until the screw stops. Refer to illustration 14.


    Illustration 15g02646604


    Illustration 16g02646609
    Wire or Crimp End is Flush with Tool Face

  10. Insert terminal (6) and turn adjusting screw (L) until the wire or crimp end of the terminal is flush with the tool face. Tighten locknut (K).


    Illustration 17g02646614

  11. Insert the wire into the terminal. The terminal must be centered between crimp fingers . Make sure that all wire strands are in the crimp barrel.

  12. Crimp the wire in the terminal by squeezing the handles of the crimp tool together until the handle hits the stop and automatically releases.

  13. Remove the crimped terminal from 1U-5804 Crimp Tool.


    Illustration 18g02646615
    Good Quality Crimp, Correctly Positioned.


    Illustration 19g02646659
    Bad Crimp. Not Centered on Length of Pin.

  14. Inspect the terminal to make sure that all wire strands are in the crimped barrel. Verify the crimp indent falls in the center of the terminal crimp barrel. Refer to illustration 18 and illustration 19.


    Illustration 20g02646560


    Illustration 21g02646668


    Illustration 22g02646672

  15. Use electrical tape to cover neatly the ends of frayed braid only. Refer to illustration 21 and illustration 22.


    Illustration 23g02646741


    Illustration 24g02646746

  16. Engage pin and socket into Jiffy Splice. A slight tug on the wires will confirm the pin and socket are properly engaged. Refer to illustration 23 and illustration 24.

  17. If more that one wire is damaged or broken repeat the process.

  18. Perform electrical / functional check on circuit to ensure that repair is effective.


    Illustration 25g02646752


    Illustration 26g02646756

  19. Use electrical tape to cover neatly the ends of any frayed braid. Refer to illustration 25 and 26.


    Illustration 27g02646766

  20. Use electrical tape to ensure that all the splices are secured in place and are not loose. Refer to illustration 27.


    Illustration 28g02646777

  21. Secure tape with tie strap, using 4C-5877 Installer Tool. Refer to illustration 28. Tensioning specifications may be found in table 2.

    Table 2
    Cable Strap
    Part Number 
    4C-5877
    Installer Tool
    Setting 
    326-8203
    Installer Tool
    Setting 
    Estimated Tensioning Force (N) 
    8L-8413 Cable Strap  80-100 
    7D-0874 Cable Strap  120-130 
    3S-2093 Cable Strap  120-140 
    6L-7008 Cable Strap  150-170 
    6K-0806 Cable Strap  180-210 
    7K-1181 Cable Strap  250-290 
    9X-6772 Cable Strap  250-290 
    193-3973 Cable Strap
    204-2281 Cable Strap 
    250-290 

    Repair for option A is complete.



    Illustration 29g02647618

    Note: Use the Following for Repair Using a Butt Splice.

  22. Strip 6.4 mm (0.25 inch) to 7 mm (0.28 inch) of insulation from the wire being repaired. Refer to illustration 29.

    Note: Be careful not to cut or nick the copper wire strands.



    Illustration 30g02647637

  23. Use table 1 to identify correct sized butt splice in accordance with proper wire gauge size.


    Illustration 31g02647847

  24. Crimp butt splice on stripped ends of wire using 9S-9150 Terminal Crimp Tool As. A slight tug on the wires will confirm the splice is properly crimped. Refer to illustration 31.


    Illustration 32g02647857


    Illustration 33g02647862

  25. Perform electrical/ functional check on circuit to ensure that repair is effective.

  26. Heat shrink the butt splice insulation using 9U-6070 Heat Gun Gp. Confirm visually that there is no opening and adhesive is properly sealing onto wire insulation. Refer to illustration 32 and 33.

  27. If more that one wire is damaged or broken repeat the process.


    Illustration 34g02647867


    Illustration 35g02647875

  28. Use electrical tape to ensure that all the splices and frayed braid are secured in place and are not loose. Refer to illustration 34 and 35.


    Illustration 36g02647896


    Illustration 37g02647898
    (1) Tie Strap

  29. Secure tape with tie strap, using 4C-5877 Installer Tool. Refer to illustration 36 and 37. Tensioning specifications may be found in table 2.

  30. Repair for option B is complete.

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