Guideline for Visual Inspection and Repair of Foam Wiring Harness {0649, 1408, 1408, 1408, 1408} Caterpillar


Guideline for Visual Inspection and Repair of Foam Wiring Harness {0649, 1408, 1408, 1408, 1408}

Usage:

769C 01X


Caterpillar Products
All Cat Engines

Introduction

Table 1
Revision  Summary of Changes SEBF9305 
08  Added new serial number prefixes for New Product Introduction (NPI) 

© 2019 Caterpillar® All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information



Illustration 1g02139237

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 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, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.



Illustration 2g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

This guideline provides the visual inspection and repair procedure for a rigid foam wiring harness. The rigid foam harness consists of a wiring harness encased in a robust and solid rigid foam. Failure of a rigid foam harness is rare and would happen if the internal wires are damaged.

Service Letters and Technical Information Bulletins


NOTICE

The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.


Tooling and Equipment

Table 2
Required Tooling and Equipment 
Part Number  Description 
303-9339  Lint Free Shop Towels 
08609  3M Windo-Weld Super Fast Urethane 
Isopropyl Alcohol 

Visual Inspection

Complete the following to perform a visual inspection:

  1. If necessary, clean the harness using isopropyl alcohol or electrical cleaner.

  2. Visually inspect the harness for damage.


    Illustration 3g02928496
    Air bubble holes.


    Illustration 4g02981603

  3. Illustrations 3 and 4 show small imperfections of the harness material that are insignificant and can be disregarded.


    Illustration 5g02928645
    Repairable harness damage.

  4. Larger damage penetrating into the wire cavity can be repaired and the harness can be salvaged.


    Illustration 6g03277099
    Non-reparable damage exposing copper wire through the insulation.

  5. Damaged insulation under the foam is not repairable. The harness must be replaced.

Repair Procedure

Note: If avoidable do not perform repairs in temperatures below 4.4° C (40° F). Cure time varies depending on temperature and relative humidity.

Complete the following to repair the rigid foam wiring harness.

  1. Thoroughly inspect the damaged portion to ensure that the damage does protrude into the wires. Damage to the foam portion of the harness can be repaired with 3MWindo-WeldSuper Fast Urethane #08609.

  2. Clean the damaged site using isopropyl alcohol or electrical cleaner.


    Illustration 7g02928897

  3. Completely fill the damaged area using 3MWindo-WeldSuper Fast Urethane #08609.

    Note: Once product is applied, there are only 10-15 minutes of working time available.



    Illustration 8g02928899

    Note: Ensure that you wear personal protective equipment such as a glove when handling a solvent-based material.

  4. Wipe the area smooth with a fingertip or putty knife.

  5. Allow repair to cure undisturbed at least 6 hours.

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