Wiring repair and replacement

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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

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.

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Wiring Repair and Replacement

Approved Dielectric Red Enamel

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.

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f540392a

1

2

1

3

4

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.

other wire end

5 Check the crimp, making sure the crimping tool

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 250F (121C) 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

250F (121C) 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

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(50-Wiring Repair and Replacement

f540395a

1

2

3

11/04/94

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

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 250F (121C) 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

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Standard Wiring Color Coding

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

Circuit Numbers and Descriptions Circuit

Number

16 Alternator, main power cables, ammeter

18 Air pressure warning/indicator

19 Voltage, meter/alarm

20 Headlamp, left

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Circuit

Number

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

Number

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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Circuit

Number

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

Number

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

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 controls

286 Fuel/water separator indicator/warning, Racor (RAI)

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

295 Radio, AM/FM/CB

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Circuit

Number

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

Number

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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Circuit

Number

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

441 Engine control module, alternative fuel vehicles

442 Data recorder, Data Logger Unit (DLU)

443 Door lock

Number

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

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

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Circuit

Number

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

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