SBU54-048
Service Bulletin Details
Public Details for: SBU54-048
Service bulletin for guidelines for repairing or replacing an electrical harness. Use the guidelines in this bulletin to determine if a damaged electrical harness should be repaired or replaced.
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Models from 2020
2020 FCCC MT45 |
2020 FCCC MT55 |
2020 FCCC S2C |
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2020 FCCC S2RV |
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2020 FCCC XCR |
Models from 2019
2019 FCCC MT45 |
2019 FCCC MT55 |
2019 FCCC S2G |
2019 FCCC S2RV |
2019 FCCC XCL |
2019 FCCC XCM |
2019 FCCC XCP |
2019 FCCC XCR |
2019 FCCC XCS |
Models from 2018
2018 FCCC MT45 |
2018 FCCC MT55 |
2018 FCCC S2G |
2018 FCCC S2RV |
2018 FCCC XCL |
2018 FCCC XCM |
2018 FCCC XCP |
2018 FCCC XCR |
2018 FCCC XCS |
Models from 2017
2017 FCCC MT45 |
2017 FCCC MT55 |
2017 FCCC S2G |
2017 FCCC S2RV |
2017 FCCC XCL |
2017 FCCC XCM |
2017 FCCC XCP |
2017 FCCC XCR |
2017 FCCC XCS |
Models from 2016
2016 FCCC MT45 |
2016 FCCC MT55 |
2016 FCCC S2G |
2016 FCCC XCL |
2016 FCCC XCM |
2016 FCCC XCP |
2016 FCCC XCR |
2016 FCCC XCS |
Models from 2015
2015 FCCC MT45 |
2015 FCCC MT55 |
2015 FCCC S2G |
2015 FCCC XCL |
2015 FCCC XCM |
2015 FCCC XCP |
2015 FCCC XCR |
2015 FCCC XCS |
Guidelines for Repairing or Replacing an Electrical Harness > Recreational Vehicle > School Bus > Shuttle Bus 54-048 Freightliner Custom Chassis Service Bulletin > Walk-In Van > S2 Description of Revisions: This bulletin replaces the version dated February 2016. Sewing Seam Ripper tool part and TwistTube® part list are added in the bulletin and convolute tubing has been removed. General Information Use the guidelines in this bulletin to determine if a damaged electrical harness should be repaired or replaced. Refer to the wiring section in Group 54 of the applicable workshop manual for detailed wire repair instructions. Table 1 describes general guidelines for repairing or replacing a harness. There may be cases when more than one factor determines the course of action. For example, repairing a harness is recommended if shipping times for the replacement harness exceed one week. However, replacement may be the only option if damage to the harness is too extensive. NOTE: When a harness is repaired, the source of the damage must also be identified and repaired. Table 2 is a quick-reference for specific wire and terminal conditions. IMPORTANT: Damaged connectors and seals can be replaced without replacing the harness. A drag test should be performed to make sure that the terminal can retain proper tension to the mating terminal. Refer to "Terminal Drag Test" in this bulletin for instructions. Discolored wires or melted insulation should be replaced before any other repairs are performed on the harness. Repairing or Replacing a Harness Repair Less than 20% of the harness is damaged. If the wire damage is greater than 6 inches (15 cm), an overlay harness can be added to replace the section of damaged wire. Wire is smaller than 12-gauge. The harness is not readily available, or shipping will take longer than one week. Wire insulation is cracked due to excessive heat from an external source. Repair is recommended if the damage is isolated to one section of the wire. There is a clean cut to the wire, corrosion is wicked no more than 1 inch (2.5 cm) from the terminal end. If the damaged area is over 6 inches (15 cm), the harness can be repaired by adding overlay wiring over the damaged area. Replace More than 20% of the harness is damaged. Wire is 12-gauge or larger. The harness can be obtained in less than a week. Wire insulation is cracked due to age, or damage is extensive and spread throughout the wire. The harness is proprietary, such as a datalink with sheathing NOTE: If damage exceeds 1 inch (2.5 cm) from the terminal over a twisted pair, or a WABCO sensor and solenoid wiring. end, a quality repair may require adding a jumper wire to create enough slack in the wire. If adding extra splices stretches the wire too tightly it can degrade the integrity of the harness. Freightliner Custom Chassis Service Bulletin, 02/04/2020 Page 1 54-048 Guidelines for Repairing or Replacing an Electrical Harness Freightliner Custom Chassis Service Bulletin > Recreational Vehicle > School Bus > Shuttle Bus > Walk-In Van > S2 Repairing or Replacing a Harness Repair Replace Two harnesses are affected. For example, M2 24 pin lever lock connector (23-13144-010 and 23-13144-009) is corroded on both sides. Also, if the harness has minimal corrosion wicked up the wire, the connectors can be reExtensive damage to the harness caused by foreign material pinned. such as DEF fluid, diesel fuel, or road/deicer fluid. If the damaged area is over 6 inches (15 cm), the harness can be repaired by adding overlay wiring over the damaged area. Table 1, Repairing or Replacing a Harness Wire Damage Quick Reference Description Remedy Kinked Wire Repair Melted Insulation, Major. Replace Melted Insulation, Minor Repair Worn or Missing Insulation. See Fig. 1. Repair Discolored or Cracked Insulation, Major. Replace See Fig. 2. Discolored or Cracked Insulation, Minor. Repair Datalink, Twisted Wire NOTE: If only the terminals are damaged, the terminals can be replaced without replacing the twisted pair. Corrosion in the Wire* Corrosion in the Connector Failed Terminal Pair Drag Test Molded Cable† Replace Repair Repair Replace Terminal Replace * Corrosion is wicked no more than 1 inch (2.5 cm) from the terminal end, and no corrosion is wicked into the wire. † An example is Meritor WABCO ABS sensor wiring. Table 2, Wire Damage Quick Reference How to Identify a Repairable Wire Page 2 Freightliner Custom Chassis Service Bulletin, 02/04/2020 Guidelines for Repairing or Replacing an Electrical Harness > Recreational Vehicle > School Bus > Shuttle Bus 54-048 Freightliner Custom Chassis Service Bulletin > Walk-In Van > S2 12/16/2014 02/16/2015 f546121 f546138 Fig. 2, Insulation Discoloration, Major Fig. 1, Worn Insulation, Major See Table 3 to identify a repairable wire. Condition Corroded Terminal Identifying a Repairable Wire Description Example If there is no further corrosion in the wire, and it is not blackened from corrosion, the wire can be repaired by cutting off the corroded terminal and stripping away the wire insulation. A new terminal can then be installed and inserted into the connector. NOTE: If the repair causes the wire to be pulled tight, or results in tension at the connector, a short piece of wire and new terminal can be added to reduce the tension. Otherwise, all terminals must be replaced. A 10/29/2014 f546107 A. Corroded terminal. Freightliner Custom Chassis Service Bulletin, 02/04/2020 Page 3 54-048 Guidelines for Repairing or Replacing an Electrical Harness Freightliner Custom Chassis Service Bulletin Condition Corroded Wire > Recreational Vehicle > School Bus > Shuttle Bus Identifying a Repairable Wire Description > Walk-In Van > S2 Example Corroded wires can be repaired by cutting out the damaged section. The wire needs to be cut until only clean wire is found for repair. It may be necessary to add a jumper wire to create slack and avoid wire tension. Refer to the instructions in this bulletin to install a jumper wire. The example shows a small amount of corrosion at the end of the wire. Cut Wire (clean) or Worn Insulation 12/16/2014 f546117 10/29/2014 f546106 If the wire shows no sign of corrosion, the wire can be repaired with a splice kit. Table 3, Identifying a Repairable Wire Broken or Corroded Wires Whether or not a broken or corroded wire, or cracked insulation should be repaired or replaced depends on the extent of the damage. A broken wire can be soldered together only if enough slack remains to avoid wire tension. If there is not sufficient slack, a new section of wire must be soldered between the two broken ends. This technique can also be used with small sections of corroded wire. Overlay wiring can also be used in the damaged area, however the entire harness must be replaced if the corrosion exceeds 6 inches (15 cm). If terminals are corroded at the connector, the terminal can be replaced. However, the entire wire must be overlayed if corrosion exceeds 6 inches (15 cm). A jumper wire can be used in the case, if necessary. Installing a Jumper Wire 1. Remove the terminal from the connector. 2. Cut out the damaged section of wire. Page 4 Freightliner Custom Chassis Service Bulletin, 02/04/2020 Guidelines for Repairing or Replacing an Electrical Harness > Recreational Vehicle > School Bus > Shuttle Bus 54-048 Freightliner Custom Chassis Service Bulletin > Walk-In Van > S2 3. Crimp and solder the new terminal with a new seal (if required) on to the new section of wire. NOTE: Make sure the wire is the same gauge and quality as the wire being replaced. 4. Insert the terminal into the connector. See Fig. 3. 5. Run the wire along the harness up to the section of wire that is being replaced. See Fig. 4. 6. Splice the wires using a Daimler splice kit ESY ES66 404, or Phillips STA-DRY® Crimp and Solder connector parts. See Fig. 5. Refer to Table 4 for a list of connector parts. 7. Inspect the harness and make sure there is enough slack. See Fig. 6. 8. Wrap the harness with TwistTube® fiber wrap. See Fig. 7. 12/16/2014 f546126 Fig. 4, Section of Wire to be Replaced 12/16/2014 f546120 Fig. 3, Terminal Inserted Into the Connector Freightliner Custom Chassis Service Bulletin, 02/04/2020 Page 5 54-048 Guidelines for Repairing or Replacing an Electrical Harness Freightliner Custom Chassis Service Bulletin > Recreational Vehicle > School Bus > Shuttle Bus > Walk-In Van > S2 A 02/16/2015 f546135 Fig. 5, Splicing the Wires 12/16/2014 f546124 A. The wire should be slack so that there is no tension. Fig. 6, Slack in the Connector Repairing a Harness Wrapped in Fiber IMPORTANT: Do not use a hook razor blade to cut fiber wrap. Use a sewing seam ripper to cut the fiber tape ( Fig. 8), taking care not to cut the harness wires. 1. Locate damaged area and carefully make an opening in the fiber wrap using a sewing seam ripper. See Fig. 10. Page 6 Freightliner Custom Chassis Service Bulletin, 02/04/2020 Guidelines for Repairing or Replacing an Electrical Harness > Recreational Vehicle > School Bus > Shuttle Bus Freightliner Custom Chassis Service Bulletin > Walk-In Van > S2 01/21/2020 54-048 f547094 11/08/2019 Fig. 7, Harness Wrapped with TwistTube® f547053 Fig. 8, Sewing Seam Ripper 2. Flip the tool over so the blunt end is facing wiring, then cut enough length to allow the fiber to be unwrapped. See Fig. 9. 11/08/2019 f547054 Fig. 9, Cutting an Opening into the Fiber Wrap 11/08/2019 f547055 Fig. 10, Cutting the Fiber Using the Blunt End of the Seam Cutter 3. Unwrap the fiber until a sufficient area is exposed to make the repair. See Fig. 11. 4. If an overlay is necessary, remove just enough fiber to allow for a splice into the damaged wire. See Fig. 12. Freightliner Custom Chassis Service Bulletin, 02/04/2020 Page 7 54-048 Guidelines for Repairing or Replacing an Electrical Harness Freightliner Custom Chassis Service Bulletin 02/16/2015 > Recreational Vehicle > School Bus > Shuttle Bus f546139 Fig. 11, Unwrapping the Harness > Walk-In Van > S2 02/16/2015 f546143 Fig. 12, Overlay Added to the Damaged Area of the Harness 5. Overlay the wire, then wrap the entire length to cover the overlay and integrate it with the harness. 6. Repair the wire as necessary. See Fig. 13. 02/16/2015 f546142 Fig. 13, Wire Repaired with Shrink Tubing 7. Wrap the harness with fiber tape. Refer to Table 5. Make sure enough tape is used to overlap the starting point. See Fig. 14. 8. When the harness is completely wrapped, secure both ends of the fiber wrap with electrical tape. See Fig. 15. Page 8 Freightliner Custom Chassis Service Bulletin, 02/04/2020 Guidelines for Repairing or Replacing an Electrical Harness > Recreational Vehicle > School Bus > Shuttle Bus 54-048 Freightliner Custom Chassis Service Bulletin > Walk-In Van > S2 1 02/16/2015 f546136 1. Fiber Wrap Secured with Electrical Tape 02/16/2015 f546144 Fig. 15, Fiber Wrap Secured with Electrical Tape Fig. 14, Wrapping the Harness with Fiber Tape Terminal Drag Test A drag test is performed between a single male and female terminal to determine if the engagement and retention forces between them are sufficient. Individual terminals that fail the drag test can be replaced. If the repair causes the wire to be pulled tight, or results in tension at the connector, a short piece of wire and new terminal can be added to reduce the tension. Otherwise, all terminals must be replaced. 1. Perform a drag test on a known good terminal pair. 1.1 Select a mating female and male terminal pair that have the same part numbers as the affected female and male terminal pair. 1.2 Manually insert, and then remove, the test mating male terminal into the test female terminal three times. On the known good test terminal pair, the mating terminal will fit securely when inserted into the terminal in the connector. There will be significant resistance (drag) when the mating terminal is removed. 2. Compare the amount of resistance to the affected terminal pair by performing the same test on the affected terminal pair. If the mating terminal does not have the same resistance as the good terminal pair, the terminal pair and the seals (if required) should be replaced. Parts Repair wires using a Daimler splice kit ESY ES66 404, or Phillips STA-DRY Crimp and Solder Connectors Parts. See Table 4 for a list of STA-DRY solderless connector parts. See Table 5 for polyester cloth tape part numbers. See Table 6 for TwistTube® part list. See Table 7 for sewing seam ripper tool part number. Freightliner Custom Chassis Service Bulletin, 02/04/2020 Page 9 54-048 Guidelines for Repairing or Replacing an Electrical Harness Freightliner Custom Chassis Service Bulletin Wire Size: gauge (mm) 20 to 18 (0.5 to 0.8) 16 10 14 (1 to 2) 12 to 10 (3 to 5) 8 or larger (5 or larger) > Recreational Vehicle > School Bus > Shuttle Bus > Walk-In Van > S2 Phillips STA-DRY Crimp and Solder Connectors Parts Connector Part Shrinkable Tubing (Daimler Part Number) Number* PHM 1 1863 1/4 inch with internal adhesive coating (48-02461-025) PHM 1 1862 1/4 inch with internal adhesive coating (48-02461-025) PHM 1 1861 3/8 inch with internal adhesive coating–4 foot length (48-02461-038) Replace the terminal or Use adhesive lined red for positive cables and black for negative the entire cable cables. * Twenty-five connectors per pack. Table 4, Phillips STA-DRY Crimp and Solder Connectors Parts Tape-Polyester Cloth, Adhesive Backed Roll Length Width 82 feet (25 meters) 0.75 inch (19 mm) 82 feet (25 meters) 1 inch (25 mm) 82 feet (25 meters) 2 inches (50 mm) Part Number 48-25910-002 48-25910-003 48-25910-004 Table 5, Tape-Polyester Cloth, Adhesive Backed DTNA P/N DTNA Description 48-26131-000 TubeTwistTube®,PES,BK,DIA5 TubeTwistTube®,PES,BK,DIA8 TubeTwistTube®,PES,BK,DIA13 TubeTwistTube®,PES,BK,DIA19 TubeTwistTube®,PES,BK,DIA25 TubeTwistTube®,PES,BK,DIA38 TubeTwistTube®,PES,BK,DIA51 48-26131-001 48-26131-002 48-26131-003 48-26131-004 48-26131-009 48-26131-011 Vendor (Bentley Harris / Federal Mogul Twist tube 2420) P/N BEN 2421000503SCM Reference Diameter BEN 2421000803SCM DTNA Recommended Bundle Size Min Max 5 mm 6 mm_1/4" 8 mm 1 mm_18GA Wire 6 mm_1/4" BEN 2421001303SCM 13 mm 8 mm_5/16" 14 mm_9/16" BEN 2421001903SCM 19 mm 14 mm_9/16" 22 mm_7/8" BEN 2421002503SCM 25 mm 21 mm_13/16" 31 mm_1 1/4" BEN 2421003803S 38 mm 31 mm_1 1/4" 45 mm_1 3/4" BEN 2421005103S 51 mm 45 mm_1 3/4" 60 mm_2 3/8" 9 mm_3/8" Table 6, TwistTube® Chart Tool Part Number DKI0CHA17002-13 Description Sewing Seam Ripper Tool Table 7, Sewing Seam Ripper Tool NOTE: The tool part number DKI0CHA17002-13 is a part of the tool kit DDE DKI0CHA17001. For more information refer to Tool Letter 18TL-3. Page 10 Freightliner Custom Chassis Service Bulletin, 02/04/2020 Guidelines for Repairing or Replacing an Electrical Harness > Recreational Vehicle > School Bus > Shuttle Bus > Walk-In Van > S2 54-048 Freightliner Custom Chassis Service Bulletin Warranty This is an informational bulletin. Warranty does not apply. Freightliner Custom Chassis Service Bulletin, 02/04/2020 Page 11