34-081 Service Bulletin/Repair Instructions

TIB 34-081 - Electrical Harness Damage Diagnosis and Repair Path
Page 1 of 5
Technical Information Bulletin

34-081
Section

Wiring and Lighting - 34
Subject

Electrical Harness Damage Diagnosis and Repair Path
Release Date

8/6/2019
Revision

08/30/2019: Added a "Reference" section in the Procedure section. Added links to related bulletins in the Reference section.
Condition

Damaged wire harness
Chassis Affected

All Kenworth Chassis
Action

Information Only

This bulletin provides guidance to determine the proper repair path for harness damage. See procedure below.
Warranty

For repairs made while the chassis is covered by Kenworth Warranty, refer to Kenworth Warranty bulletin Wire Harness Warranty and Claim
https://eportal.paccar.com/dealer/uskw/en/service/vehiclebulletins/vehiclefieldservice/Pages... 9/3/2019
TIB 34-081 - Electrical Harness Damage Diagnosis and Repair Path
Page 2 of 5
Filing Requirements C-C-065 for claim filing instructions.

For visual defects and repairs, provide photos clearly showing the defect and the repair with your warranty claim. Providing the

photos greatly expedites the claim processing.
Parts

Some parts are available from PACCAR Parts. See the table and references below. Parts not included in the table and references below can be

sourced locally.

Part Number

Description

Butt-splices, ring terminals, butt Source locally. Must have integral heat shrink or 2 layers of heat

connectors

shrink must be used over the connection

Some repair connectors can be found in the following kits:

PACCAR MX-13 & MX-11 EPA2013 Wiring Repair Kit

PACCAR MX-13 EPA2010 Wiring Repair Kit
Procedure

References

The following references provide additional wiring repair related information:

34-044 Electrical Connectors Disassembly/Assembly

34-050 Required Wire Crimper Kits

34-051 Guide for Properly Probing Electrical Connections on T680 and T880
Wire Damage

Coroplast tape and wire insulation has completely worn, resulting in:

Damaged wire insulation

Wire is exposed but not damaged

Wire is exposed, damaged, and/or corroded
Actions

Refer to the guidelines below to repair or replace the harness. If replacing the harness has been determined to be the appropriate repair path,

and a replacement harness is not immediately available, contact your DSM for optional repair guidance until the harness can be replaced.

Refer to the Wire repair method extracted from Kenworth Training Course 302 for repair procedures.

Refer to the warranty policy bulletin Wire Harness Warranty and Claim Filing Requirements C-C-065 for information on which harnesses

CANNOT be repaired and MUST be replaced.

Is there corrosion or other damage present?

Is the damage limited to a small segment of the wire or harness or does it appear to encompass a large area?

Is it possible to fully remove the compromised section of wire?

If so, then the harness can be repaired.

If not, can the harness be temporarily repaired while waiting for a new harness?

Is the connector damaged?

Is the connector wiring damaged?

Can the connector be replaced?

Can the affected wiring be repaired or section replaced?

Are only pins in the connector damaged?

Are the pins or terminated leads available?

What is the cost of replacing the harness versus repairing the harness?

Major harnesses are to be repaired whenever possible.

Minor harnesses can be serviced as assemblies, depending on availability.

CAUTION

Refer to Kenworth Warranty bulletin Wire Harness Warranty and Claim Filing Requirements C-C-065 for

a list of harnesses that cannot be repaired and must be replaced. Failure to do so may result in

personal injury or death.
https://eportal.paccar.com/dealer/uskw/en/service/vehiclebulletins/vehiclefieldservice/Pages... 9/3/2019
TIB 34-081 - Electrical Harness Damage Diagnosis and Repair Path
Example of harness damage
Explanation of

harness

damage
Page 3 of 5
Possible repair

path
Permanent

or

Temporary

repair
Harness wrap

compromised

and the grey

wire has

shorted,

resulting in the

wire being

burned through

and damage to

the insulation

of the green

and blue wires.

Very little

corrosion is

present on the

exposed wires

of the grey

wire.
Cut out the damaged Permanent

section of the grey

repair

wire and splice in a

new section.

Depending on how

far the damage to

the green and blue

wires is from a

connector, the repair

could be one of the

following:
Harness wrap

compromised,

bare wires are

exposed, likely

shorted, and

extensive

corrosion is

visible.
Replace the

Permanent

harness.

repair

It is unlikely that all

of the corroded

sections of the

harness can be

removed.

It is unlikely that all

of the harness

damage can be

found. It is very likely

that there is more

damage in the

harness that is not

visible.
Harness wrap

compromised,

bare wires

exposed,

significant

corrosion is

present.

There is also a

significant

amount of

moisture

present on this

harness.
You are unlikely to

find the extent of all

the corrosion in the

two red wires.

You may be able to

cut out the corroded

section of the red

wires and splice in a

new section, but

there is no

guarantee that all of

the corroded wire

has been removed.
Depending

on how far

the wire is

from the

connector,

the wire

could be

removed

from the

connector

and the

damaged

area covered

with

weatherproof

heat shrink.

Cut the wire

at the

damage and

repair with a

butt splice

with integral

heat shrink

and an

additional

layer of

weatherproof

heat shrink.
Temporary

repair until

a new

harness is

available.
https://eportal.paccar.com/dealer/uskw/en/service/vehiclebulletins/vehiclefieldservice/Pages... 9/3/2019
TIB 34-081 - Electrical Harness Damage Diagnosis and Repair Path
Page 4 of 5
Replace the

harness, but a

temporary repair can

be attempted while

waiting for a new

harness.
Damaged

communication

cable. Bare

wire is

exposed, but

no corrosion is

visible.

Note: Any other

cable that is

damaged as

shown can be

repaired

similarly.
Cut the wire at the

Permanent

exposed wire. Install repair

a butt splice with

integral heat shrink.

If the wire is an area

outside of the cab,

also cover with

weatherproof heat

shrink.
Connector has

heat related

damage. The

wiring on the

other side of

the connector

may be ok, but

the terminals

are damaged.
If there is no

Permanent

damage to the

repair

wiring, and either a

bare connector and

individual terminated

leads or new

terminals are

available, then

replace the

connector and

terminals.

If the connector

and/or terminated

leads or terminals

are not available,

then the harness

may need to be

replaced.

Refer to the KW

Wiring Diagrams

extracted from

Kenworth Training

Course 302 for

guidance in finding

the connector and or

terminal lead part

numbers.
A single

terminal is

damaged.

(This is an

extreme

example. Likely

the component

connector is

showing signs

of corrosion

and/or other

damage at the

mating location

of the orange

wire.)
If there is a

Permanent

terminated lead

repair

available, replace

the terminal.

If only a terminal is

available, replace

the terminal. A small

section of wire can

be added to the

terminal as needed

to remove any

corroded section of

the harness.

Refer to the KW

Wiring Diagrams

extracted from

Kenworth Training

Course 302 for

guidance in finding

the connector and or

terminal lead part

numbers.
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TIB 34-081 - Electrical Harness Damage Diagnosis and Repair Path
Page 5 of 5
Attachments

Wire repair method extracted from Kenworth Training Course 302

KW Wiring Diagrams extracted from Kenworth Training Course 302
Authored by: OF
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