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Topic: Wire Harness Short Shut Engine Off? (Read 427 times) previous topic - next topic

Wire Harness Short Shut Engine Off?

Yesterday, we had a scary incident on I 75. Engine shuddered then shut down at 65 mph. Had to get towed to a campground with another tow set up for Monday to bring us to Cummins service. 
I was able to contact Paul Yasbeck on the phone. He suggested I test the ignition solenoid. A soon as I turned the key for the test I noticed a puff of smoke and stopped.

Today I turned the key to the run position and voila all the lights on the dash came on.  I then pulled the dash apart and started searching. The ISC turned over and started. I also turned on the wipers because they were on when this happened. Staring into the mess of wires I noticed a small spark, turned it off.
The wire harness had been rubbing up against the the windshield wiper motor which moves ever so slightly from the torque of the arms turning. It rubbed a hole through at least one wire in the harness and probably a few more. The wires were black from heat.
I hope to cut the ty-wraps and use electrical tape to cover the burnt insulation on every wire I can find that even turned a little brown from the heat. Is this ok to do?  And if I can read the wires, will I be able to know which systems might be affected.

Thanks
Ed

Ed and Michele
2000 U295  36'  (Build #5600)
8.3 ISC 350HP.
2012 Jeep Grand Cherokee (Toad)
2001 Lance Truck Camper (Sold)
2001 Lazy Daze (Class C). RK Floor Plan (Sold)

Re: Wire Harness Short Shut Engine Off?

Reply #1 –
Quote from: Lance Camper –

The wire harness had been rubbing up against the the windshield wiper motor which moves ever so slightly from the torque of the arms turning. It rubbed a hole through at least one wire in the harness and probably a few more. The wires were black from heat.
I hope to cut the ty-wraps and use electrical tape to cover the burnt insulation on every wire I can find that even turned a little brown from the heat. Is this ok to do?  And if I can read the wires, will I be able to know which systems might be affected.

Thanks
Ed


As long as the wire isn't burnt through just protect it with some electrical tape, then dress the harness so it doesn't rub against the wiper motor.  Do whatever makes you comfortable with the tape.  Nice save!
1992 Foretravel Grand Villa
U225 SBID Build No. 4134
1986 Rockwood Driftwood
1968 S.I.A.T.A. Spring
1962 Studebaker Lark
1986 Honda VF700C
1983 Honda VF750C
Charlie, the Dog was broken out of jail 24 Oct 2023
N1RPN
AA1OH (H)e who must be obeyed.

Re: Wire Harness Short Shut Engine Off?

Reply #2 –
Since, the wire experienced a short from the worn insulation, one or more strands, may be burned through essentially making it a smaller wire not able to safely carry the load it was designed for.  A possible fix is to cut the wire at the burn mark and use a crimp connector to reattach the wires.  A solder type connector could also be used.  While the wire is cut heat shrink tubing can be placed on the wire to insulate the new connection after it is reconnected.
Jerry Whiteaker former owner 96 U270  36' #4831 Austin,TX-Owner Mods LCD TV w/front cabinet rebuild - LCD TV bedroom - Dual Central AC, either can cool coach w 30 amp - Skylights at roof AC openings - Drop ceiling for ducting of AC - Shower skylight white gelcoat/wood/epoxy frame - Air Springs/Shocks replaced - 2014 CRV - 8K Home Solar - Chevy Volt

Re: Wire Harness Short Shut Engine Off?

Reply #3 –
Agree, a good idea to remove enough of the insulation to verify that the wire is not damaged.  And if it is cut out the bad section.  If a short section and enough slack, use a butt connector or solder/heat shrink.  If the damaged section is longer, splice in a wire.

We really can't tell the extent of the wire damage from the photo.
Brett Wolfe
EX: 1993 U240
Moderator, ForeForum 2001-
Moderator Diesel RV Club 2002-
Moderator, FMCA Forum 2009-2020
Chairman FMCA Technical Advisory Committee 2011-2020

Re: Wire Harness Short Shut Engine Off?

Reply #4 –
Thanks to all, today I will run the engine for about an hour to see if my repair holds up.

Different subject but related.
When Daniel's Tow and Recovery (Lake City Fl) removed my axels I lost quite a bit of gear oil. Since, I probably won't need to be towed to Jacksonville Cummins. I need to replace both axels and the gear oil. Is this something I can do myself? Is it difficult to line up the splines when the axels go in? How much torque applied to the nuts?
Now would be the time to change to Amsoil 75W140. How do I know how much to add? Stick my finger in the hole? How much do I need? I see it comes in quart packages. 

And finally do you like my Fred Flintstone Hub Caps ( see photo)

Thanks
Ed
Ed and Michele
2000 U295  36'  (Build #5600)
8.3 ISC 350HP.
2012 Jeep Grand Cherokee (Toad)
2001 Lance Truck Camper (Sold)
2001 Lazy Daze (Class C). RK Floor Plan (Sold)
 

Re: Wire Harness Short Shut Engine Off?

Reply #5 –
Quote from: Lance Camper –
  And if I can read the wires, will I be able to know which systems might be affected.


Answered my own question, Wire 103A got the worst of it. It reads "IGN Relay to IGN Power Relay"
Based on my brief conversation with Mr Yasbeck, I'm deducing this caused my relay to go bonkers and shut me down.
Ed and Michele
2000 U295  36'  (Build #5600)
8.3 ISC 350HP.
2012 Jeep Grand Cherokee (Toad)
2001 Lance Truck Camper (Sold)
2001 Lazy Daze (Class C). RK Floor Plan (Sold)