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Wiring repair and replacement
Wiring 54.01 Wiring Repair and Replacement Repair and Replacement IMPORTANT: Before repairing or replacing any dam- aged electrical system parts, find and correct the cause of the damage; otherwise, it could occur again. Wiring insulation can be damaged by internal or external heat, chafing, kinking, breaking, cracking, or saturation with oil or grease. Discolored wire insulation (brown) is caused by long- term overheating of the wire itself. Melted insulation is usually caused by an external heat source. Repair or replace damaged wiring. Whether you repair or 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 Worn or missing insulation Repair Discolored insulation Replace * Repair the break by soldering the two broken ends together if there is enough 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 wire underneath is also damaged. Remove and replace the damaged section. 2. If the insulation is chafed, find the source of chafing 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 tubing to protect the insulation. 3. Cover the repaired section of wiring with plastic convoluted tubing. Replacing Damaged Wire CAUTION Never replace a wire with a smaller gauge wire. Wire gauge is selected by electrical load and current 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 only solder splices. IMPORTANT: If the damaged wire is 12 gauge or larger, do not replace a section of it, replace the entire wire. 2. If the insulation has been discolored, find out what is causing the wire to overheat and correct it. 3. If the insulation has been melted, check the routing of the wiring and find the problem. Reroute the wiring if possible and secure it with clamps. If rerouting is not possible, use a heat shield to protect the wire. Repairing Electrical Connections 1. Find the cause of the damage or corrosion and correct the problem. 2. Using a solution of baking soda and water, clean corroded connectors with a wire brush, then dry the area. Replace any damaged connectors. 3. Spray any exposed connectors, such as ground terminals, with dielectric red enamel. See Table 2. Business Class M2 Workshop Manual, Supplement 10, September 2006 100/1 54.01 Wiring Wiring Repair and Replacement Approved Dielectric Red Enamel Protectant Material Approved Brands Spray-On Application MMM 1602 IVI–Spray 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 done using solder repair kit ESY ES66 404 and is for 14- or 16-gauge wire. Do not repair wire that is 12 gauge or larger, 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. Make sure the stripped ends are 3/8- to 1/2-inch (10- to 13-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 Wiring 54.01 Wiring Repair and Replacement f540392a 1 2 1 3 4 A A 11/04/94 A. 3/8 to 1/2 Inch (10 to 13 mm) 1. Wire End 2. Crimp Splice 3. Solder Sleeve 4. Heat Shrink Fig. 1, Exterior Wire Repair 3. Slip a solder sleeve from kit ESY ES66 404 over one end of the wire. See Fig. 1. 4. Using a suitable crimp tool and a crimp splice from the kit, crimp the ends of the wire as follows: 4.1 Insert a stripped wire end into the crimp splice until it touches the wire stop in the middle of the crimp splice. 4.2 Center the crimping tool between the wire stop and the end of the crimp splice, then crimp the wire. See Fig. 2. 4.3 Repeat the two substeps above for the other wire end. 5. Check the crimp, making sure the crimping tool impression is on both ends of the crimp splice. 6. Slide the solder sleeve over the crimp splice so the solder ring is over the center of the crimp splice. See Fig. 3. Then apply 250 F (121 C) heat until the solder flows into the splice crimp and the plastic sleeve has shrunk completely against the wire. 7. Slide the heat shrink over the splice, then apply 250 F (121 C) heat to it until completely shrunk against the wire insulation. Some of the sealant material should be bubbling out from the ends of the 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 or smaller dual-wall heat shrink at the end of the wire to prevent water intrusion. Business Class M2 Workshop Manual, Supplement 10, September 2006 100/3 54.01 Wiring Wiring Repair and Replacement f540395a 1 2 3 11/04/94 A A A. Center crimping tool here. 1. Wire Stop 2. Wire 3. Crimp Splice (shown crimped) Fig. 2, Centering the Crimping Tool 1 2 3 4 3 11/04/94 f540394a 1. Solder 2. Crimp Splice (shown crimped) 3. Wire 4. Solder Sleeve Fig. 3, Wire Ready for Soldering 2. Slide the heat shrink over the wire end, leaving about 1/4 inch (6 mm) hanging off the end of the wire to allow the heat shrink to seal completely to prevent water intrusion. 3. Apply 250 F (121 C) heat to it until it has com- pletely shrunk against the wire insulation. Some of the sealant material should bubble out from the ends of the heat shrink. 4. Clamp the end with pliers as needed to seal the end of the heat shrink. Business Class M2 Workshop Manual, Supplement 10, September 2006100/4 Wiring 54.01 Specifications 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 Auxiliary 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/Driver’s Display/Data Record/1587+/ 1939– Green DK-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/Horn/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 Circuit Number 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 Circuit Numbers and Descriptions Circuit Number 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 Business Class M2 Workshop Manual, Supplement 10, September 2006 400/1 54.01 Wiring Specifications Circuit Numbers and Descriptions Circuit Number 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 Circuit Numbers and Descriptions Circuit Number 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 Business Class M2 Workshop Manual, Supplement 10, September 2006400/2 Wiring 54.01 Specifications Circuit Numbers and Descriptions Circuit Number 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 Circuit Numbers and Descriptions Circuit Number Circuit Description 223 Transmission controls, auto shift (axle shift, see 209) 224 Transmission controls (axle shift, see 209) 225 Air pressure gauge, primary 226 Air pressure gauge, secondary 227 Air pressure gauge, application 228 Oil pressure electronic gauge, engine 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 271 Oil pressure electronic gauge, engine 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 controls 286 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 Business Class M2 Workshop Manual, Supplement 10, September 2006 400/3 54.01 Wiring Specifications Circuit Numbers and Descriptions Circuit Number 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 Circuit Numbers and Descriptions Circuit Number 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) 380 Daylight running lights (DRL) 381 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 Business Class M2 Workshop Manual, Supplement 10, September 2006400/4 Wiring 54.01 Specifications Circuit Numbers and Descriptions Circuit Number Circuit Description 408 Emergency vehicle accessory and warning lights 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 controls 440 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 Circuit Numbers and Descriptions Circuit Number 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 for crash system (SPACE) 455 Instrument left/right side selection control 457 Dash controls, datalink, (BPU) 459 Steering pump controls 460 Transmission, automatic, Aisin Seiki, cab controls 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 system 467 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/expansion multiplex module 482 Emergency firetruck pump controls 483 Engine control module and controls Business Class M2 Workshop Manual, Supplement 10, September 2006 400/5 54.01 Wiring Specifications Circuit Numbers and Descriptions Circuit Number Circuit Description 487 Electronic engine emissions detection and monitoring 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 Business Class M2 Workshop Manual, Supplement 10, September 2006400/6 . Wiring 54.01 Wiring Repair and Replacement Repair and Replacement IMPORTANT: Before repairing or replacing any dam- aged electrical system parts, find and correct the cause. heat source. Repair or replace damaged wiring. Whether you repair or replace the wiring depends on the type of damage. See Table 1. Wiring Damage Type of Damage Remedy Broken wire Repair or replace* Kinked. Manual, Supplement 10, September 2006 100/1 54.01 Wiring Wiring Repair and Replacement Approved Dielectric Red Enamel Protectant Material Approved Brands Spray-On Application MMM 1602 IVI–Spray Sealer,