| Parameter | Specification | Testing Standard |
|---|---|---|
| COGENG Part Number | COGENG-WH-61/62 | Internal Quality Standard QS-502 |
| Replaces OEM Part No. | 86978861 86978862 | Direct OEM Replacement |
| Wire Gauge Range | 0.5 mm² - 35.0 mm² | SAE J1128 |
| Temperature Rating | -40°C to +125°C (-40°F to +257°F) | ISO 16750-4 |
| Insulation Material | Cross-linked polyethylene | UL 224 |
| Protective Conduit | Corrugated nylon | SAE J2031 |
| Voltage Rating | 12V/24V DC | SAE J551 |
| Current Capacity | 5A - 200A (circuit dependent) | ISO 3780 |
| Insulation Resistance | >100 MΩ at 1000V DC | IEC 60851 |
| Dielectric Strength | 2500V AC for 60 seconds | ISO 1456 |
| Connector System | Case-specific weatherproof | USCAR-2 |
| Waterproof Rating | IP67 (connectors) | IEC 60529 |
| Vibration Resistance | 10-2000 Hz, 20G RMS | ISO 19453 |
| Circuit Function | Wire Gauge | Color Code | Connector Type | Application |
|---|---|---|---|---|
| Main Power Distribution | 35.0 mm² | Red | Heavy-duty lugs | Battery to main relay |
| Starter Circuit | 25.0 mm² | Red/White | Copper lugs | Starter motor |
| Alternator Output | 16.0 mm² | Orange | Ring terminals | Charging system |
| Engine ECU | 4.0 mm² | Red/Black | 12-pin weatherproof | Engine management |
| Hydraulic Solenoids | 2.5 mm² | Blue/Yellow | 8-pin connector | Valve control |
| Lighting System | 2.0 mm² | White/Black | 6-pin connector | Work lights |
| Operator Controls | 0.5 mm² | Various | 16-pin connector | Joystick & switches |
| Monitoring Sensors | 0.75 mm² | Various | 4-pin weatherpack | Temperature/pressure |
| Safety Systems | 1.0 mm² | Green/White | 4-pin connector | Emergency stops |
| CAN Bus System | 0.75 mm² | Orange/Brown | Twisted pair shielded | Data communication |
| Equipment Type | Model Series | Specific Models | Model Years |
|---|---|---|---|
| Case Excavators | CX Series | CX130, CX160, CX180 | 2008-2014 |
| Case Loaders | 4x1 Series | 421, 431, 441 | 2007-2013 |
| Case Dozers | 6 Series | 650, 750, 850 | 2006-2012 |
| Case Skid Steers | 4x4 Series | 445, 455, 465 | 2008-2015 |
| Case Backhoes | 5x0 Series | 580, 590 | 2005-2011 |
| Pos. | Part No | Parts name | Qty |
| 1 | 8702622 | WIRE HARNESS | [1] |
| 86978861 | WIRE HARNESS | [1] | |
| 86978862 | WIRE HARNESS | [1] | |
| 2 | 529068 | BULB,#1156, 12V, 21W | [1] |
| 3 | 80700 | WASHER,0.56" ID x 1.38" OD x 0.11" Thk | [1] |
| 4 | 853709 | GASKET,1.65mm Thk | [1] |
| 5 | 280963 | NUT,Nut, 1/2-20 GR 5 ZND | [1] |
| 6 | 574820 | GROMMET | [3] |
| 7 | 853765 | CLAMP,7.9mm, Coat, 10.3mm Bolt Hole, P Type | [4] |
| 8 | 86538829 | BRACKET | [2] |
| 9 | 300383 | BOLT,Hex, M10 x 1.5 x 16mm, Cl 8.8, Full Thd | [4] |
| 10 | 140045 | BELLEVILLE WASHER,M10 Bolt Size x 22mm OD x 1.6mm Thk | [4] |
| 11 | 86536572 | LAMP | [1] |
| 12 | 80679 | LOCK WASHER,1/20.507 CST ZND | [1] |
| 13 | LENS | [1] | |
| 14 | 86837775 | RESISTOR | [1] |
| 15 | 86606228 | COVER | [1] |
| 16 | 120098 | BOLT,Hex, M5 x 20, 8.8, Full Thd | [4] |
| 17 | 322356 | BELLEVILLE WASHER,M5 Bolt Size x 12mm OD x 1.85mm Thk | [4] |
| 18 | 84037188 | O-RING,3mm Thk x 34.2mm ID, 70 Duro | [1] |
| 19 | 86508813 | NUT,M5, Cl 8 | [4] |
| Parameter | Minimum | Typical | Maximum |
|---|---|---|---|
| Starter Voltage Drop | N/A | <0.4V | <0.6V |
| Signal Circuit Resistance | N/A | <0.1Ω | <0.2Ω |
| CAN Bus Termination | 110Ω | 120Ω | 130Ω |
| Insulation Resistance | 100 MΩ | 500 MΩ | N/A |
| Voltage Drop (Power) | N/A | <0.3V | <0.5V |
| Maintenance Activity | Interval | Parameters | Test Equipment |
|---|---|---|---|
| Visual Inspection | 250 hours | Check for abrasion, damage | Visual assessment |
| Connector Check | 500 hours | Verify IP67 seal integrity | Connector test tool |
| Resistance Test | 1000 hours | Circuit resistance < 0.2Ω | Digital multimeter |
| Insulation Test | 2000 hours | >100 MΩ at 1000V DC | Megohmmeter |
| Function Test | 4000 hours | Full system operational check | Diagnostic software |
Q1: Which Case equipment models use the 86978861 and 86978862 wire harnesses?
A: These premium wire harnesses are designed for specific Case construction equipment models requiring OEM part numbers 86978861 and 86978862. Please verify compatibility with your machine model and serial number before ordering.
Q2: What is the difference between 86978861 and 86978862?
A: These are two different harness assemblies – typically one may be for the main cab harness and the other for an auxiliary or attachment harness. Please confirm your specific application requirements with your machine details.
Q3: What makes these "premium" wire harnesses?
A: They feature OEM-grade connectors, heavy-duty construction with high-temperature resistant wiring, abrasion-resistant sheathing, and sealed terminals for reliable performance in harsh job site conditions.
Q4: Are these harnesses plug-and-play?
A: Yes, both harnesses are designed for direct plug-and-play fitment with OEM-spec connectors – no cutting, soldering, or modifications required.
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