Repair Procedure For Damaged Harness Wiring (1408) : Special Instruction

1/10/2019 Media Search - REHS7215 - Repair Procedure for Damaged Harness Wiring {1408}
Previous Screen
Welcome: r080ev1
Product: NO EQUIPMENT SELECTED
Model: NO EQUIPMENT SELECTED
Configuration: NO EQUIPMENT SELECTED
Special Instruction
Repair Procedure for Damaged Harness Wiring {1408}
Media Number -REHS7215-03 Publication Date -24/01/2013 Date Updated -02/11/2018
i07177426
Repair Procedure for Damaged Harness Wiring {1408}

SMCS - 1408
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:
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledpage=… 1/19
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
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.
Table 1
Single Wire Splice Only
Jiffy Splice Butt Splice

Usage Can be used reliably in most Can be used reliably in non-signal
application application only
Part Number 115-8109 128-2800 370-2156 136-4878 136-4877 136-4876

Wire Size 18 "X" "X"
(AWG)
16 "X" "X"
14 "X" "X"
12 "X" "X"
10 mm
6.4 mm (0.25 inch) to 7 mm 6 mm (0.24 inch) to (0.39 inch) to
Insulation Strip Lengths
(0.27 inch) 10 mm (0.39 inch) 13 mm
(0.51 inch)
Heat Source Required "X" "X" "X"

Fuel & Oil Resistance "X" "X" "X"
−55° C (−67° F) to 120° C

Temperature Rating −55° C (−67° F) to 105° C (221° F)
(248° F)
Addition Parts Pins 9X-3401 126-1767 7T-0093

None
Required Sockets 9X-3402 126-1768 7T-0094
9S-9150 Terminal Crimp Tool As 9U-

Tools Required 1U-5804 Crimp Tool
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
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.
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.
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:
4. Isolate the damaged or broken wires to be repaired and clean adequately to prepare for sealed splice. Refer
to illustration 8 and 9.
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.
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.
(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:
a. Remove lock clip (H).
b. Raise selector knob (J) and rotate knob until the arrow is aligned with the wire size to be crimped.
c. Lower the selector knob (J) and insert the lock clip (H).
(K) Locknut
(L) Adjusting Screw
9. Loosen locknut (K) and turn adjusting screw (L) in until the screw stops. Refer to illustration 14.
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).
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/mediasearch/mediaheaderinfoframeset.jsp&calledpage… 10/19
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.
Good Quality Crimp, Correctly Positioned.
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.
15. Use electrical tape to cover neatly the ends of frayed braid only. Refer to illustration 21 and illustration 22.
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.
19. Use electrical tape to cover neatly the ends of any frayed braid. Refer to illustration 25 and 26.
20. Use electrical tape to ensure that all the splices are secured in place and are not loose. Refer to illustration
27.
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
4C-5877 326-8203
Cable Strap
Installer Tool Installer Tool Estimated Tensioning Force (N)
Part Number
Setting Setting
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
8 8 250-290
204-2281 Cable Strap
Repair for option A is complete.
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.
23. Use table 1 to identify correct sized butt splice in accordance with proper wire gauge size.
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.
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.
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.
(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.
Copyright 1993 - 2019 Caterpillar Inc. Tue Oct 01 2019 09:28:03 GMT-0500 (hora estándar de Perú)
All Rights Reserved.
r080ev1
Private Network For SIS Licensees.

Repair Procedure For Damaged Harness Wiring (1408) : Special Instruction

Uploaded by

Copyright:

Available Formats

You might also like

Repair Procedure For Damaged Harness Wiring (1408) : Special Instruction

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Repair Procedure For Damaged Harness Wiring (1408) : Special Instruction

Uploaded by

Copyright:

Available Formats

1/10/2019 Media Search - REHS7215 - Repair Procedure for Damaged Harness Wiring {1408}

Repair Procedure for Damaged Harness Wiring {1408}

Important Safety Information

Repair Procedure for Damaged Harness Wiring

Individual wire repair only

Jiffy Splice Butt Splice

Part Number 115-8109 128-2800 370-2156 136-4878 136-4877 136-4876

Heat Source Required "X" "X" "X"

−55° C (−67° F) to 120° C

Addition Parts Pins 9X-3401 126-1767 7T-0093

9S-9150 Terminal Crimp Tool As 9U-

Braid Removal Tool Harness Braid Cutter 377-6198

Electrical Tape 6V-4592 Tape

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

1. Identify damaged area of the harness.

2. Identify root cause of damage.

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

Type 2 Damage Repair

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

2. Identify the root cause of damage.

Note: Note the orientation of the tool.

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

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

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

a. Remove lock clip (H).

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

7D-0874 Cable Strap 3 3 120-130

3S-2093 Cable Strap 3 4 120-140

Repair for option A is complete.

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

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

30. Repair for option B is complete.

You might also like