wiring repair and replacement.pdf

8/11/2019 wiring repair and replacement.pdf

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Wiring 54.01Wiring Repair and Replacement

Repair and Replacement

IMPORTANT: Before repairing or replacing any dam-aged electrical system parts, find and correct thecause of the damage; otherwise, it could occur again.

Wiring insulation can be damaged by internal orexternal heat, chafing, kinking, breaking, cracking, orsaturation with oil or grease.

Discolored wire insulation (brown) is caused by long-term overheating of the wire itself. Melted insulation isusually caused by an external heat source.

Repair or replace damaged wiring. Whether you repairor replace the wiring depends on the type of damage.

See Table 1.

Wiring Damage

Type of Damage Remedy

Broken wire Repair or replace*

Kinked wire Replace

Oil-soaked insulation Replace

Cracked insulation Repair if minor, replace if not

Melted insulation Replace

Wor n or missing insulation Repair

Discolored insulation Replace

* Repair the break by soldering the two broken ends together if there isenough slack in the wire; otherwise solder in a new section of wire. See"Repairing Broken Wire" for instructions.

Table 1, Wiring Damage

Repairing Damaged Wire Insulation

1. Using heat shrink, cover the damaged area. Over-lap the damaged area at least 3/4 inch (20 mm)on both sides.

IMPORTANT: Do not repair the insulation if the wireunderneath is also damaged. Remove and replace thedamaged section.

2. If the insulation is chafed, find the source ofchafing and route the wiring away from it. If this is

not possible, cover the sharp edge with protective

vinyl trim (18-02188-001) or use convoluted tubingto protect the insulation.

3. Cover the repaired section of wiring with plasticconvoluted tubing.

Replacing Damaged Wire

CAUTION

Never replace a wire with a smaller gauge wire.Wire gauge is selected by electrical load andcurrent capabilities. Overheating may occur if a

wrong gauge wire is used.1. Replace damaged wire using a solder splice. See

"Repairing Broken Wire" for instructions. Use onlysolder splices.

IMPORTANT: If the damaged wire is 12 gauge orlarger, do not replace a section of it, replace the entirewire.

2. If the insulation has been discolored, find out whatis causing the wire to overheat and correct it.

3. If the insulation has been melted, check the routingof the wiring and find the problem. Reroute thewiring if possible and secure it with clamps. If

rerouting is not possible, use a heat shield toprotect the wire.

Repairing Electrical Connections

1. Find the cause of the damage or corrosion andcorrect the problem.

2. Using a solution of baking soda and water, cleancorroded connectors with a wire brush, then drythe area. Replace any damaged connectors.

3. Spray any exposed connectors, such as groundterminals, with dielectric red enamel. See Table 2.

Business Class M2 Workshop Manual, Supplement 10, September 2006 100/1


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54.01 WiringWiring Repair and Replacement

Approved Dielectric Red Enamel

Protectant Material Approved Brands

Spray-On Application MMM 1602 IVISpray Sealer, Red Electric Grade; order from the PDC

Brush-On Application Glyptal 1201EW Low VOC, Red; order at www.glyptal.com or 1-800-GLP-1201

Table 2, Approved Dielectric Red Enamel

Repairing Broken Wire

IMPORTANT: The following procedure is the only ap-proved method of repairing broken wires on Freight-liner vehicles. This procedure (solder splicing) is doneusing solder repair kit ESY ES66 404 and is for 14- or

16-gauge wire. Do not repair wire that is 12 gauge orlarger, replace it instead. The kit contains:

connector ESY 2B14 (PAC PG000638)

sleeve ESY RTS110 0182 (PAC PG000637)

tube 48-02461-038

1. Strip the ends of the wire to be repaired. Makesure the stripped ends are 3/8- to 1/2-inch (10- to13-mm) long.

2. If repairing an exterior wire, slip a 3-inch (75-mm)long piece of heat shrink over one end of the wire.See Fig. 1.

Business Class M2 Workshop Manual, Supplement 10, September 2006100/2


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Wiring 54.01Wiring Repair and Replacement

f540392a1

2

1

3

4

A

A

11/04/94

A. 3/8 to 1/2 Inch (10 to 13 mm)

1. Wire End2. Crimp Splice

3. Solder Sleeve4. Heat Shrink

Fig. 1, Exterior Wire Repair

3. Slip a solder sleeve from kit ESY ES66 404 overone end of the wire. See Fig. 1.

4. Using a suitable crimp tool and a crimp splice fromthe kit, crimp the ends of the wire as follows:

4.1 Insert a stripped wire end into the crimpsplice until it touches the wire stop in themiddle of the crimp splice.

4.2 Center the crimping tool between the wirestop and the end of the crimp splice, thencrimp the wire. See Fig. 2.

4.3 Repeat the two substeps above for theother wire end.

5. Check the crimp, making sure the crimping toolimpression is on both ends of the crimp splice.

6. Slide the solder sleeve over the crimp splice sothe solder ring is over the center of the crimpsplice. SeeFig. 3. Then apply 250

F (121

C) heatuntil the solder flows into the splice crimp and theplastic sleeve has shrunk completely against thewire.

7. Slide the heat shrink over the splice, then apply250

F (121

C) heat to it until completely shrunkagainst the wire insulation. Some of the sealant

material should be bubbling out from the ends ofthe heat shrink.

Terminating A Wire End

1. Terminate a cut wire end by installing a 2-inch (50-mm) long piece of 1/4-inch (6-mm) diameter orsmaller dual-wall heat shrink at the end of the wireto prevent water intrusion.



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54.01 WiringWiring Repair and Replacement

f540395a

1

2

3

11/04/94

A

A

A. Center crimping tool here.

1. Wire Stop2. Wire3. Crimp Splice (shown crimped)

Fig. 2, Centering the Crimping Tool

1

2

3

4

311/04/94 f540394a

1. Solder2. Crimp Splice (shown crimped)3. Wire4. Solder Sleeve

Fig. 3, Wire Ready for Soldering

2. Slide the heat shrink over the wire end, leavingabout 1/4 inch (6 mm) hanging off the end of thewire to allow the heat shrink to seal completely toprevent water intrusion.

3. Apply 250

F (121

C) heat to it until it has com-pletely shrunk against the wire insulation. Someof the sealant material should bubble out from theends of the heat shrink.

4. Clamp the end with pliers as needed to seal theend of the heat shrink.



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Wiring 54.01Specifications

Specifications

Standard Wiring Color Coding

Color Abbr Typical Usage

Black BK Ground, General

Black-White BK-W Ground, Clean or Isolated

Blue DK DKBL Backup/Wiper/Trailer Auxil iary

Blue LT LTBL HVAC/Circulation Fans/1922+

Blue LT-White LTBL-W Water, Oil Gauge, and Indicator (engine and transmission)

Brown BR Marker, Tail, and Panel Lamps

Gray GY Electronic Engine (or TXL Insulation)

Green DK DKG Turn Signal, Right-side/Drivers Display/Data Record/1587+/1939

GreenDK-White

DKG-W Starting Aids/Fuel Heaters/Material Control/Winch/Tailgate

Green LT LTG Headlamp/Roadlamp/DRL

Green LT-White LTG-W Axle Controls and Indicators/Suspension/Fifth Wheel

Orange O ABS/EBS/1587

Pink PK Start Control/Ignition/Charging/Volt and Ammeter/1922

Pink-White PK-W Fuel Control and Indicators/Shutdown/Speed Limiter

Purple PRP Engine Fan/PTO/Auto Lube and Oil

Purple-White PRP-W Utility/Spot/Ad/Interior/Emergency Lighting

Red R Power Distribution, Constant

Red-White R-W Brake/Pneumatic/Hydraulic/Retarder/Stop

Tan T mph, rpm Signals/Hor n/Flasher/Pyro/Turbo

Tan-White T-W Audio/Video/Security/Window/Computer/Seat/Mirror/Cab-Tilt

White W Transmission (or SXL insulation)

Yellow Y Turn Signal, left/1939+ (or GXL insulation)

Yellow-White Y-W Air Bag and SPACE

Table 1, Standard Wiring Color Coding

Circuit Numbers and Descriptions

CircuitNumber

Circuit Description

1 Battery cable, ground

2 Battery cable, 6v positive

3 Battery cable, 6v negative

6 Battery cable, 12v positive

14 Cab power, main

15 Starter, engine


CircuitNumber

Circuit Description

16 Alternator, main power cables, ammeter

18 Air pressure warning/indicator

19 Voltage, meter/alarm

20 Headlamp, left

21 Headlamp, right

22 Headlamp, low beam, left/right



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54.01 WiringSpecifications


CircuitNumber

Circuit Description

23 Tail lamps

24 Horn, electric

25 Horn, air, electronically controlled

26 Horn, electric, supply

27 Roadlamp/foglamp

28 Roadlamp/foglamp

29 Panel/instrument lamps

30 Transmission oil temperature

31 Transmission oil temperature, auxiliary

34 Oil pressure, engine

35 Oil temperature, engine

36 Stop lamp

37 Turn signal flasher supply

38 Turn signal

39 Stop/turn combination lamp

40 Fan, windshield/sleeper

41 Dome lamp, interior

42 Axle oil temperature, forward

43 Axle oil temperature, rear

44 Axle oil temperature, center auxiliary

45 Receptacle, trailer

46 Marker/parking lamps

47 Fuel level

48 Fuel control and level, natural gas

52 Ignition switch and controls

55 Data recorder, speed and tach graph

57 Outlet, 12v power receptacle/cigar lighter

58 Heater, auxiliary

60 Turn signal, left cab

61 Turn signal, right cab

71 Ignition switch and controls

73 Utility lamp, back of cab

74 Starter mag switch/solenoid

75 Starter mag switch, ground, thermal protection

76 Mirror heat

77 Mirror heat, right mirror supply


CircuitNumber

Circuit Description

78 Spot lamp

80 Mirror heat, switch and controls

81 Ignition switch control devices

82 Starter mag switch, power supply

83 Alternator ground

84 Starting aid, glow plug heater

85 Starting aid, glow plug heater

87 Axle lock

88 Lubrication system, automatic

90 Sander, road

91 Heater, diesel-fired auxiliary

94 Air dryer, heated

95 Speaker, radio

96 Oil level warning

97 Air conditioner

98 Heater A/C motor, blower

99 Fuel solenoid, engine run

102 Parking lamps

103 Parking lamps, right

108 Door activated lamps, courtesy

109 Door control dome lamp, right

113 Baggage compartment lamps

117 Speed sensor "+", vehicle, mph/km/h

118 Speed sensor "", vehicle, mph/km/h

119 Coolant temperature, engine

120 Back up/reverse lamp

121 Brake, engine/retarder/compression

122 Back up/reverse alarm

123 Alternator, voltage regulator/rectifier

125 Park brake indicator/warning

131 Alternator NO CHANGE indicator/warning

132 Alternator charging system monitor

137 Alternator NO CHANGE indicator/warning

138 Starter lockout, alternator, ADLO

139 Starter lockout, alternator, ADLO

140 Oil pressure electronic gauge, engine



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CircuitNumber

Circuit Description

149 Fan manual controls, engine

150 Engine protection, shutdown/warning

154 Auxiliary air pressure

155 Axle lift controls

157 Mirror remote power controls

162 Tach sensor "+", engine, rpm

163 Tach sensor "", engine, rpm

166 Starting aid, engine, ether

168 Hour meter, engine

170 Fifth wheel slide lock indicator

171 Brakesaver, CAT

172 Clock

173 Coolant level, engine coolant

178 Idle timer, delayed shutdown, cool down

182 Fuel pressure

183 Air cleaner restriction indicator/warning

191 Starting aid, glow plug, heater

193 Cab tilt pump

196 Fuel/water separator heater

197 Transmission lockup sensor

198 Axle, two-speed shift control

200 PTO controls

203 Exhaust brake

206 Heater A/C with oil pressure controls

208 Axle control, triaxle, steer lock

209 Axle, two-speed shift control

210 Power distribution module (PDM), outside cab

211 Security system, Rockwell

212 Refrigerator, power, (no outlet)

214 Generator, auxiliary

215 Heater, diesel-fired auxiliary, Webasto

218 Pyrometer, gauge

219 Turbo pressure gauge

221 Suspension dump controls

222 Headlamp dimmer controls


CircuitNumber

Circuit Description

223 Transmission controls, auto shift (axle shift, see209)

224 Transmission controls (axle shift, see 209)

225 Air pressure gauge, primary

226 Air pressure gauge, secondary

227 Air pressure gauge, application


232 Transmission controls, power harness

234 Fan controls, engine

236 Transmission neutral indicator

240 Fuel/water separator indicator/warning

241 Data recorder, Sangamo tacho graph

242 Seat controls

244 Speed limiter, vehicle, Hewitt

246 Fuel pump, electric

250 Cruise control, Bendix (BW)

253 Cab tilt indicator

254 Emergency lamp, beacon, roof-mounted

255 Advertising lamp

256 Optional power wire

261 Axle lock, controlled differential

262 Retarder, transmission (Allison)

266 PTO controls, transfer case


274 Transmission oil temperature

276 Oil fill system, leveler, Webb (WEI), engine

278 Wiper control, right

279 Wiper control, left

281 Oil filter change indicator/warning, engine

285 Suspension electronic/air controls286 Fuel/water separator indicator/warning, Racor

(RAI)

292 Fuel tachometer, Flowscan (FOS), Argo (ARG)

295 Radio, AM/FM/CB

299 Air temperature, outside cab

300 Radio line level signals

302 CB Radio



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CircuitNumber

Circuit Description

303 Air pressure, low

304 Back up/reverse lamp

305 Ignition switch, accessory

306 Ignition switch, run position

309 Park brake indicator/warning

310 Axle lock

311 Ignition accessory option block

312 Radio

313 Turn signal flasher supply

314 Turn signal switch supply

315 Wiper

316 Wiper motor low speed

317 Wiper motor park

318 Wiper motor high speed

319 Wiper motor park

320 Wiper washer

324 Lightbar high coolant temperature

325 Lightbar, engine oil pressure

326 Lightbar turn signal flasher control

331 Datalink power, diagnostics, SAE J1708

332 Datalink return, negative

333 Air dryer, heated

334 Door-activated dome lamp

337 Roadlamp switch

338 Heater A/C electronic controls

339 Lightbar/cluster power

342 Ammeter gauge

343 Starting aid, glow plug switch, heater

344 Starting aid, glow plug pressure switch, heater

345 Starting aid, glow plug solenoid, heater

346 Speaker, radio, ground

347 Shutter, engine fan

349 Shutter, engine fan

350 Lightbar, turn signal flasher timing

351 Speed limiter, vehicle, lightbar

359 Headlamp ON signal, lightbar/cluster


CircuitNumber

Circuit Description

363 Window power

364 Window power, up

365 Window power, down

368 Coolant temperature gauge, Kysor VIP

372 Receptacle #2, trailer 7-way, ISO 3731

373 Fuel solenoid, engine run

376 Antilock brake system (ABS) controls

377 Antilock brake system (ABS) sensors

378 Antilock brake system (ABS) valves

379 Daylight running lights (DRL)



382 Daylight running lights (DRL), left headlamp

383 Daylight running lights (DRL), right headlamp

384 Daylight running lights (DRL), program

385 Daylight running lights (DRL), controls

386 Daylight running lights (DRL), left headlamp

387 Daylight running lights (DRL), right headlamp

388 Hydraulic brake power and controls

389 Hydraulic brake relay

390 Hydraulic brake lamp

391 Hydraulic brake relay

392 Hydraulic brake motor

393 Hydraulic brake flow/relay

394 Hydraulic brake, park brake lamp

395 Hydraulic brake fluid sensor

396 Hydraulic brake buzzer/alarm

397 Hydraulic brake cab door signal

398 Hydraulic brake motor sense

399 Optional wire, cab/chassis, customer furnished

400 Optional wire, cab/chassis, customer furnished

402 Engine start/stop system, Temp-A-Start (TAS)

404 Data recorder, ARI trip

405 Data recorder

406 Emergency lamp, alternating flashing

407 Emergency lamp, cross-fire lights



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CircuitNumber

Circuit Description

408 Emergency vehicle accessory and warninglights

409 Emergency lamp, bin lights

410 Emergency siren

411 Emergency fire truck miscellaneous lighting

412 Data recorder, Isspro (ISP)

414 Tracking system, vehicle, Sony Geostrat RGSS

416 Refrigerator/television power, (no outlet)

417 Phone power, mobile

418 Tool box lamp, left

419 Tool box lamp, right

420 Military 24v lighting, blackout

421 Military 24v lighting and devices, blackout

422 Military auxiliary 24v heater

423 Military, winch controls

424 Headlamp wiper/washer

425 Battery cutoff switch controls and bypass

426 Air inside/outside indicator

427 Tracking system, vehicle, satellite

428 Battery isolator protection system

429 Pyrometer alarm/warning

430 Wiper heater

431 Starting aid, engine preheater, grid/flame

432 Seat controls

433 Data recorder, Data Hub (DDE)

434 Suspension controls, ECAS

435 Seat belt indicator/warning

436 Camera, rear and side view

437 Instrumentation control unit (ICU), dash display

439 Engine control module and controls440 Engine control module and controls

441 Engine control module, alternative fuel vehicles

442 Data recorder, Data Logger Unit (DLU)

443 Door lock

444 Obstacle detection system (ODS), VORAD

445 Body controls, dump lock


CircuitNumber

Circuit Description

446 Tire inflation, Central Tire Inflation System(CTIS)

447 Battery cutoff protection system, Hewitt (HEW)

448 Tailgate controls, material

449 Fueling data recording and transmitter

450 Mirror dimming controls (MSI)

453 Body builder/customer furnished wiring

454 Air bag and seat pretensioner activation forcrash system (SPACE)

455 Instrument left/right side selection control457 Dash controls, datalink, (BPU)

459 Steering pump controls

460 Transmission, automatic, Aisin Seiki, cabcontrols

461 Transmission, automatic, Aisin Seiki, chassis/transmission controls

462 Headlamp, left auxiliary, snow plow

463 Headlamp, right auxiliary, snow plow

464 Transmission SmartShift control

465 Headlamp flashing control

466 Lane departure indicator/tracking system467 Coolant flow, engine

468 Obstacle detection system (ODS), VORAD

469 Level control power, body/chassis

470 Datalink transmit

471 Datalink receive

472 Engine control module and controls

473 Multifunction turn signal switch

474 Smart switch, resistance identified

475 Engine idler controls

477 Hazard lights for US Postal Service

479 CB antenna

480 Switched auxiliary air pressure for body builder/customer

481 Address strapping for chassis/expansionmultiplex module

482 Emergency firetruck pump controls

483 Engine control module and controls



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CircuitNumber

Circuit Description

487 Electronic engine emissions detection andmonitoring

500 Hydraulic brake ECU, brake signal

502 Oil level warning, engine low

503 Starting aid, engine preheater, flame start

505 Gauge sender, optional

516 Starting aid, engine preheater, flame start

1587 Datalink, diagnostics, SAE J1587

1922 Datalink, controls, SAE J1922

1939 Datalink, controls, SAE J1939

BAT Main battery power

GND Ground, miscellaneous cab/chassis

OPT Optional wiring, spare or customer furnished

B### Bendix antilock brake system (ABS)

C### Caterpillar electronic engine

D### Detroit Diesel electronic engine (DDE)

E### Allison electronic transmission

N### Cummins electronic engine

S### Spicer AutoMate transmission

T### Twin Disc automatic transmission

W### Eaton Ceemat/AutoShift transmission

X### WABCO anitlock brake system (ABS); see 376,377 and 378

Table 2, Circuit Numbers and Descriptions


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wiring repair and replacement.pdf