c. Attach jumper harness ground wire terminal to hex bolt and reinstall hex bolt.
Vehicles After SN 809269.
a. Loosen and remove existing ground bolt with ground connections and nut. See Figure 14.
b. Add jumper harness ground wire to ground bolt and existing ground connections.
c. Reinstall ground bolt and nut. Final tighten ground bolt and nut to 35 ft. lbs.
Prior to SN 809269

SN 809269 and later

Figure 14

27.

Close and secure cab electrical cabinet door.

28.

Reinstall clipboard holder with two screws and washers removed in Step 16. See Figure 15. Final tighten

9

screws to 75 in lbs.

Clipboard Holder

Figure 15

29.

Reconnect connecter C18 removed in Step 15 to side console joystick.

30.
Reinstall console cover with fifteen screws and washers removed in Step 14. See Figure 16. Final tighten
screws to 75 in. lbs.

Console Cover

Figure 16

10

31.
Secure Grayhill display (A001K952) to mounting bracket (A000W179) with four screws and washers
removed in Step 12. See Figure 17. Final tighten screws to 10 in. lbs.
32.

Install inserts (A000F010) in display bracket. See Figure 17.
Insert

(A000F010)

Bracket

(A000W179)

Display

(A001K952)

Figure 17

33.

Slide display and bracket assembly into overhead console through display opening. See Figure 18.

34.

Connect jumper harness connector C1538 to port A on back of display.

35.

Connect jumper harness connector C1529 to port B on back of display.

36.
Secure display bracket to overhead console with four screws, and flat washers removed in Step 12. See
Figure 18.
Display Port A
Connector
C1529

Connector
C1538

Display Port B

Figure 18

37.

Mark and drill two 3/16 inch holes in bottom of overhead console per dimensions in Figure 19.
2.06

4.118

3.37

2X Ø 0.188

Figure 19

11

38.
Loosen and remove right rear speaker mounting screw and nut. See Figure 20. Save screw and nut for
reinstallation.
39.
Remove paint from area around where speaker mounting screw and nut was removed in the overhead
console. See Figure 20.
40.

Place TCU (A001K385) in overhead console through radio panel opening. See Figure 20.

41.
Secure TCU module to overhead console through holes drilled in Step 37 with screws (A000W843),
washers (A000V858), and acorn nuts (A001C246). See Figure 20. Install screws from top and washers and
acorn nuts from the bottom, acorn nuts to be visible from driver’s seat. Final tighten hardware to 17 in lbs.
42.

Connect jumper harness (A001F369) to connector C1530 and TCU. See Figure 20.

43.

Connect cellular and GPS cables disconnected from Micronet display to TCU. See Figure 20.

44.
Reinstall right rear speaker mounting screw with jumper harness ground terminal on speaker mounting
screw, and install nut removed in Step 38. Final tighten to 17 in. lbs.
TCU

(A001K385)

TCU Mounting
Hardware

Cellular Cable

GPS Cable
Ground
Connector C1530

Jumper Harness
(A001F369)

Figure 20

45.
Locate connector C311 and DVI connector, that were disconnected from the Micronet display, through the
right-hand overhead console access panel, See Figure 21.
46.

Connect jumper harness connector C1549 to DVI connector. See Figure 21.

47.

Remove the two thumb screws from connector C311. Thumb screws will not be reused.

48.

Connect jumper harness connector C1531 to connector C311. See Figure 21.

12

49.
Install connector plate (A001B842), screws (A001B897), washers (A000V859), and nuts (A000F374) to
secure connector C311 to C1531. Do not over tighten hardware and bend connector plate. See Figure 21.

NOTE

The USB connector previously connected to
the Micronet display will not be used with the
Grayhill display.
Screws (A001B897)
Washers (A000V859)
Nuts (A000F374)

Connector
C1549

USB Connector

DVI
Connector

Connector
C1531
Connector Plate
(A001B842)

Connector
C311

Figure 21

50.

Secure all cable routings and excess cable lengths with cable ties (A000C018). See Figure 22.

Cable Ties
(A000C018)

Figure 22

51.
Turn vehicle ignition switch ON and make sure Grayhill display and TCU lights turn on. If display or TCU
do not power on turn ignition switch OFF and check connectors. Repeat process of checking the display and
TCU lights turning on.

13

52.
Reinstall right-hand access panel with seven screws and washers removed in Step 13. See Figure 23.
Final tighten screws to 75 in lbs.

Right-Hand
Access Panel

Figure 23

53.
Reinstall overhead console access panel with four screws and washers removed in Step 9. See
Figure 24. Final tighten screws to 75 in lbs.

Access Panel

Figure 24

14

54.

Reconnect harness connector and antenna to back of radio.

55.
Reinstall radio panel to overhead console with four screws and washers removed in Step 7. See Figure
25. Final tighten screws to 75 in lbs.
Screws and
Washers

Radio Panel

Figure 25

56.

Remove lockout/tagout and tire chocks.

Front Control Module Update
Contact S-Series service for information on required software updates.
57.

Update front control module (FCM) to v9.2.51 using the following procedure.

a. Disconnect rear control module (RCM) connector C373A to prevent inadvertently updating the wrong
control module. See Figure 26.

Connector
C373A

Rear BCM
Figure 26

15

b. Plug in PCAN adapter cable to laptop. Remove terminating resistor receptacle and connect PCAN
adapter to green connector C12 near driver’s left foot area in cab. See Figure 27.

Connector
C12

Figure 27

c. Turn vehicle ignition switch to ON position.
d. Turn vehicle battery disconnect switch OFF.
e. On laptop open Orchestra. See Figure 28.
f.

Select the Downloaders Tab followed by the Firmware Download tab. See Figure 28.

g. Select Grid Connect radio button. See Figure 28.
h. Set Select Baud rate to 500k. See Figure 28.
i.

Click Start button. See Figure 28.

Figure 28

j.

Turn vehicle battery disconnect switch ON.

16

k. In Orchestra click Stop.
l. Select the Connect button. See Figure 29. When connected the keypads blink and the dome lights turn
off. If keypads are not blinking and dome lights are not off, select Connect button again.
m. Enter 450 in Filter field to search for CL-450-101-00. See Figure 29.
n. Double click on CL-450-101-00 from module list to select. See Figure 29.
o. Browse to the computer drive or flash drive location where the controller update programming files are
located and select the file to you want to load by clicking on it. See Figure 29.
p. Click Start button. See Figure 29. Status will say downloading to approximately 5 minutes.
q. Click OK when finished

Figure 29

58.
Make sure the vehicle’s rear work lights function as intended after FCM software update is complete. If
rear work lights do not function as intended repeat Step 57.
59.

Disconnect PCAN device from connector C12 and reinstall terminating resistor.

60.

Reconnect rear PDM connector C373A disconnected in Step 57a.

17

Display Setup
61.

Setup Grayhill display using the following procedure.

a. Power on display and log in as service manager.
Settings -> User Access -> User Name & Password -> Continue -> Return to Settings Screen

▼

▼

▼

18

b. Verify/enter vehicle option selections recorded in Step 1.
Settings -> Options
c. Set time to appropriate time zone, daylight savings status, and preferred format (12 vs 24 hour).
d. Verify/enter lifetime drum revs recorded in Step 2.

▼

▼

e. Verify/enter lifetime gallons recorded in Step 3.

▼

▼

19

f.

Create slump profiles to match slump profiles recorded in Step 4.

▼

▼

▼

▼

g. Return to User Access screen and log out.
h. Press home button to return to main screen.
i.

Turn vehicle ignition OFF to complete display setup procedure.

20

ClearSky™ Verification
62.
Make sure truck is in a location with adequate cellular and GPS service. Truck may need to be outside for
adequate service.
63.

Turn truck ignition switch to ON position and wait until overhead display shows home screen

64.
Log into ClearSky (https://clearsky.mcneiluscompanies.com) See Figure 30. If an account needs to be
created contact ClearSky support ([email protected]).

Figure 30

65.

Search for truck serial number (last six digits of truck VIN) in ClearSky search window. See Figure 31.

Figure 31

66.
Make sure the truck’s serial number appears in the search results Assets window and select the truck
from the search results. See Figure 32.

Figure 32

67.
Make sure the truck VIN displayed in the information box in the upper left corner of page is correct. See
Figure 33.

Figure 33

21

68.
Check the GPS by clicking on the SUMMARY tab and making sure the map shows the current location of
the truck. The time stamp displayed should be within 2 minutes of the current time. See Figure 34.

Figure 34

69.
Check the ClearSky data by clicking on the TRUCK GAUGES tab and making sure the ClearSky gauges
match what is shown on the gauges in the truck. See Figure 35. Gauges include fuel level, front air tank
pressure, rear air tank pressure, odometer, and engine hours.

Figure 35

22

70.
Click UNIT DATA tab and make sure a report named IGNON appears near top of REPORTS sub-tab with
a DATE/TIME with the vehicle’s ignition turned ON.

Figure 36

71.

Click CONTROLLER INFO tab and make sure information for the following eleven parameters exist.
• VIN
• IMEI
• ICCID
• ENGINE SERIAL/SOFTWARE VERSION
• ABS SOFTWARE VERSION
• DISPLAY SOFTWARE VERSION
• FCM SOFTWARE VERSION
• RCM SOFTWARE VERSION
• TRANSMISSION SOFTWARE VERSION
• INSTRUMENT PANEL SOFTWARE VERSION
• ENGINE REFERENCE TORQUE

Figure 37

23

ClearSky™ Troubleshooting
1. Make sure TCU version number populates in overhead display ABOUT screen. If TCU version is not
populated the TCU is not communicating.
a. Check for a solid red LED and flashing green LED on front of TCU. See Figure 38. No lit LEDs on front of
TCU indicates no power to TCU.
b. Make sure TCU connectors are fully seated and there are no bent or damaged pins.
2. Make sure GPS antenna and cellular cables are connected correctly.
Cellular Connection

LEDs display here
through TCU housing

GPS Antenna Connection
Figure 38

3. Turn vehicle’s battery disconnect switch OFF and wait until LEDs on front of TCU turn off, the TCU has an
internal battery which can take up to 3 hours to fully drain before LEDs go out.
4. Turn vehicle’s battery disconnect switch ON.
5. Turn vehicle ignition switch ON and recheck if TCU is operating and populates the version number in
overhead display ABOUT screen.
6. Contact S-Series service if these troubleshooting steps do not correct TCU operation.

Continuous Improvement:

The change included in this document is part of the
McNeilus Continuous Improvement Process.
McNeilus’s quality policy is providing customer satisfaction
through innovative products, dedicated service, and a
constant focus on continuous improvement.
24

(888) 686-7278
www.streetsmartparts.com