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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.
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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.
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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
Circuit Numbers and Descriptions
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
Circuit Numbers and Descriptions
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
Circuit Numbers and Descriptions
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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Wiring 54.01Specifications
Circuit Numbers and Descriptions
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
Circuit Numbers and Descriptions
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
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 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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54.01 WiringSpecifications
Circuit Numbers and Descriptions
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
Circuit Numbers and Descriptions
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)
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
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Wiring 54.01Specifications
Circuit Numbers and Descriptions
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
Circuit Numbers and Descriptions
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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54.01 WiringSpecifications
Circuit Numbers and Descriptions
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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