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01
Wiring
Remedy
Broken wire
Repair or replace*
Kinked wire
Replace
Oil-soaked insulation
Replace
Cracked insulation
Melted insulation
Worn or missing insulation
Discolored insulation
* 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.
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.
1. Using heat shrink, cover the damaged area. Overlap the damaged area at least 3/4 inch (20 mm)
on both sides.
100/1
54.01
Wiring
Approved Brands
Spray-On Application
MMM 1602 IVISpray Sealer, Red Electric Grade; order from the PDC
Brush-On Application
100/2
54.01
Wiring
1
A
11/04/94
f540392a
3. Solder Sleeve
4. Heat Shrink
Fig. 1, Exterior Wire Repair
4.2
4.3
100/3
54.01
Wiring
A
2
f540395a
11/04/94
A.
1.
2.
3.
2
4
3
Solder
Crimp Splice (shown crimped)
Wire
Solder Sleeve
11/04/94
1.
2.
3.
4.
f540394a
3. Apply 250 F (121 C) heat to it until it has completely 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.
100/4
54.01
Wiring
Specifications
Specifications
Standard Wiring Color Coding
Color
Abbr
Typical Usage
Black
BK
Ground, General
Black-White
BK-W
Blue DK
DKBL
Backup/Wiper/Trailer Auxiliary
Blue LT
LTBL
HVAC/Circulation Fans/1922+
Blue LT-White
Brown
BR
Gray
GY
Green DK
DKG
Green
DK-White
Green LT
LTG
Headlamp/Roadlamp/DRL
Orange
ABS/EBS/1587
Pink
PK
Pink-White
PK-W
Purple
PRP
Purple-White
PRP-W
Utility/Spot/Ad/Interior/Emergency Lighting
Red
Red-White
R-W
Brake/Pneumatic/Hydraulic/Retarder/Stop
Tan
Tan-White
T-W
Audio/Video/Security/Window/Computer/Seat/Mirror/Cab-Tilt
White
Yellow
Yellow-White
Y-W
Circuit Description
Circuit Description
16
18
19
Voltage, meter/alarm
20
Headlamp, left
14
21
Headlamp, right
15
Starter, engine
22
400/1
54.01
Wiring
Specifications
Circuit Description
Circuit Description
23
Tail lamps
78
Spot lamp
24
Horn, electric
80
25
81
26
82
27
Roadlamp/foglamp
83
Alternator ground
28
Roadlamp/foglamp
84
29
Panel/instrument lamps
85
30
87
Axle lock
31
88
34
90
Sander, road
35
91
36
Stop lamp
94
37
95
Speaker, radio
38
Turn signal
96
39
97
Air conditioner
40
Fan, windshield/sleeper
98
41
99
42
102
Parking lamps
43
103
44
108
45
Receptacle, trailer
109
46
Marker/parking lamps
113
47
Fuel level
117
48
118
52
119
55
120
57
121
Brake, engine/retarder/compression
58
Heater, auxiliary
122
60
123
61
125
71
131
73
132
74
137
75
138
76
Mirror heat
139
77
140
400/2
54.01
Wiring
Specifications
Circuit Description
149
150
154
155
157
162
163
166
168
170
171
Brakesaver, CAT
172
Clock
173
178
182
Fuel pressure
183
191
193
196
197
198
200
PTO controls
203
Exhaust brake
206
208
209
210
211
Circuit Description
223
224
225
226
227
228
232
234
236
240
241
242
Seat controls
244
246
250
253
254
255
Advertising lamp
256
261
262
266
271
274
276
278
279
281
285
286
212
214
Generator, auxiliary
215
218
Pyrometer, gauge
292
219
295
Radio, AM/FM/CB
221
299
222
300
302
CB Radio
400/3
54.01
Wiring
Specifications
Circuit Description
Circuit Description
303
363
Window power
304
364
Window power, up
305
365
306
368
309
372
310
Axle lock
373
311
376
312
Radio
377
313
378
314
379
315
Wiper
380
316
381
317
382
318
383
319
384
320
Wiper washer
385
324
386
325
387
326
388
331
389
332
390
333
391
334
392
337
Roadlamp switch
393
338
394
339
Lightbar/cluster power
395
342
Ammeter gauge
396
343
397
344
398
345
399
346
400
347
402
349
404
350
405
Data recorder
351
406
359
407
400/4
54.01
Wiring
Specifications
Circuit Description
Circuit Description
408
446
409
447
410
Emergency siren
448
411
449
412
450
414
453
416
454
417
418
455
419
457
459
460
461
420
421
422
423
424
Headlamp wiper/washer
462
425
463
426
464
427
465
428
466
429
Pyrometer alarm/warning
467
430
Wiper heater
468
431
469
432
Seat controls
470
Datalink transmit
433
471
Datalink receive
434
472
435
473
436
474
437
475
439
477
440
479
CB antenna
441
480
442
481
443
Door lock
444
482
483
445
400/5
54.01
Wiring
Specifications
Circuit Description
487
500
502
503
505
516
1587
1922
1939
BAT
GND
OPT
B###
C###
D###
E###
N###
S###
T###
W###
X###
400/6