Repair Procedure for Damaged Harness Wiring {1408} Caterpillar

Caterpillar Products

All

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 1	g02642998

Illustration 2	g02643056

Illustration 3	g02643136

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 4	g02643156

Illustration 5	g02643177

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.

Show/hide table

Illustration 6	g02646471

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.

   Show/hide table

   Illustration 7	g02646475

   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:

   • 3 Wire Harness 366-8856 Wiring Harness

   • 6 Wire Harness 366-8857 Wiring Harness

   • 9 Wire Harness 394-6873 Wiring Harness

   • 12 Wire Harness 394-6874 Wiring Harness
   Show/hide table

   Illustration 8	g02646502

   Show/hide table

   Illustration 9	g02646516

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

   Illustration 10	g02646519

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.

   Show/hide table

   Illustration 11	g02646531

   Show/hide table

   Illustration 12	g02646538

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.

   Show/hide table

   Illustration 13	g02646554
   (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).
   Show/hide table

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

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

   Illustration 15	g02646604

   Show/hide table

   Illustration 16	g02646609
   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).
    Show/hide table

    Illustration 17	g02646614

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.
    Show/hide table

    Illustration 18	g02646615
    Good Quality Crimp, Correctly Positioned.

    Show/hide table

    Illustration 19	g02646659
    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.
    Show/hide table

    Illustration 20	g02646560

    Show/hide table

    Illustration 21	g02646668

    Show/hide table

    Illustration 22	g02646672

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

    Illustration 23	g02646741

    Show/hide table

    Illustration 24	g02646746

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.
    Show/hide table

    Illustration 25	g02646752

    Show/hide table

    Illustration 26	g02646756

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

    Illustration 27	g02646766

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

    Illustration 28	g02646777

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

    Table 2

    Cable Strap Part Number	4C-5877 Installer Tool Setting	326-8203 Installer Tool Setting	Estimated Tensioning Force (N)
    8L-8413 Cable Strap	2	2	80-100
    7D-0874 Cable Strap	3	3	120-130
    3S-2093 Cable Strap	3	4	120-140
    6L-7008 Cable Strap	4	5	150-170
    6K-0806 Cable Strap	5	6	180-210
    7K-1181 Cable Strap	8	8	250-290
    9X-6772 Cable Strap	8	8	250-290
    193-3973 Cable Strap 204-2281 Cable Strap	8	8	250-290

    Repair for option A is complete.

    Show/hide table

    Illustration 29	g02647618

    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.

    Show/hide table

    Illustration 30	g02647637

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

    Illustration 31	g02647847

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.
    Show/hide table

    Illustration 32	g02647857

    Show/hide table

    Illustration 33	g02647862

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.
    Show/hide table

    Illustration 34	g02647867

    Show/hide table

    Illustration 35	g02647875

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.
    Show/hide table

    Illustration 36	g02647896

    Show/hide table

    Illustration 37	g02647898
    (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.