Service Manual: Electrical System

15 15-Electrical KM815001 4/24/02
Department Customer Service

Category Service Manual
Section Electrical
Title Electrical System
Number KM815001
Service Date
Model
06/18/03
All
Manual Page 1 of 70
Electrical System
Table of Contents Meters 8

Test Light 12
Theory Of Operation 3 Hydrometer 12
Generating Electricity 3 Diagnosis / Testing 14
Voltage, Current, Resistance 4 Systematic Plan 14
Types Of Circuits 4 Common Point Analysis 14
Electrical System Failures 6 Substitution Test 14
Troubleshooting Tools 8 Voltage Tests 14
Wiring Diagrams 8 Open Circuit Test 17
Page 2 of 70
Electrical: Electrical System Number KM815001
Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Relay Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Data Bus Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Wiring Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
How To Read This Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Circuit Color / Circuit Number Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Battery Cable Volt Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Solenoid Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Charging Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Cable Voltage Loss Test - 24 Volt Cranking With Series-Parallel Switch . . . . . . . . . . . . . . . . 53
Wiring Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Page 3 of 70
Theory Of Operation For alternators equipped with brushes, the rotor is electri-
cally magnetized by a small current flowing through the
Theory Of Operation is divided into three sections. brushes installed on smooth slip rings. The rotor isn't
magnetized until current actually passes through the
1. Generating Electricity rotor. See Figure 15-2.
a. Alternator
• Voltage
• Current
• Resistance
2. Circuits
a. Series Circuits
• Voltage and Current
b. Parallel Circuits
• Voltage
• Current
• Resistance
3. Series/Parallel Circuits Figure 15-2 Brushes and Slip Rings
a. Circuit Composition For a brushless alternator, current is produced by the
rotor rotating between a stationary magnet and the sta-
Generating Electricity tionary field/stator windings. See Figure 15-3.
Alternator
An alternator produces alternating current that is rectified

into direct current for use in truck circuitry. Some alterna-
tors are equipped with brushes and some are brushless.
Current is produced by rotating a magnet inside a station-

ary winding. The rotating magnet is called a rotor and the
stationary winding is called a stator. See Figure 15-1.
Figure 15-3 Brushless Alternator
Brushless alternators or alternators equipped with

brushes produce alternating current. However, the bat-
tery stores direct current only. A rectifier assembly con-
verts the alternating current to direct current. See Figure
15-4 on page 4.
A regulator controls the alternator output by adjusting the

magnetic field of the alternator. This regulates the bat-
tery's state of charge. See Figure 15-4 on page 4.
Figure 15-1 Rotor and Stator
Page 4 of 70
Figure 15-5 Water Pressure and Voltage
Current
Figure 15-4 Rectifier Assembly
The flow of electricity through a wire is called current.
Electrical current cannot be seen moving. However, a Without voltage, or pressure, the current will not flow.
meter can display the flow of current. A successful tech- Current is measured in amperes.
nician knows how to read the meters that allow him or her
to diagnose malfunctions and to maintain the electrical NOTE: Voltage is the electrical pressure that causes the
system at maximum operating efficiently. current to flow. Current may be thought of as the rate of
flow.
Voltage, Current, Resistance Example:
Voltage 30 Ibs. of pressure at the water supply will force 150

gallons of water per minute through a fire hose. For
Voltage is the electrical pressure, or force, that causes electricity, let's say 12 volts at the power supply will
the current to flow. The force is the difference in electrical force 30 amperes of electricity through a wire.
pressure between two points (+) (-) in a circuit. Voltage is
measured in volts. NOTE:
Voltage = pressure.
The principle for current flow is the same as for water.
Water flows through a hose because there is greater Current = flow.
pressure at the water supply than at the outlet of the
hose. Current flows through a wire because there is Resistance
greater pressure (voltage) at the electrical supply (alter-
Resistance to current flow may be thought of as a restric-
nator) than at the component (lamp, motor, etc.). See
tion. Resistance is measured in ohms.
Figure 15-5
Types Of Circuits
Basic types of circuits:
• Series Circuit—1 current path.
• Parallel Circuit—2 or more current paths.
• Series/Parallel Circuit—A circuit composed of series
and parallel circuits.
Page 5 of 70
Series Circuits Figure 15-7 shows a parallel circuit with 2 current paths,
I1 and I2. To find the total current IT in the parallel circuit,
A series circuit has 1 current path. The same current
add the current in I1 and I2.
flows through each component. All components oppose
the flow of current. Think of each component as a resis- I1 + I2 = IT
tance to current flow. To find total resistance of a series
circuit, add all resistances. If there is a break anywhere in Voltage
the circuit, no current will flow. See Figure 15-6.
In a parallel circuit, all branches are connected in parallel
with the power supply. The voltage produced by the
power supply is the same at each branch.
Current
In a parallel circuit, current flowing through each branch

is determined by the resistance.
In a branch:
High resistance = low current. Low resistance = high
Figure 15-6 Series Circuit current.
Voltage and Current As branches are added:
In a series circuit, the same current flows through all Total resistance decreases. Total circuit current
components. How much current is determined by the increases.
voltage supply and total resistance of the circuit compo-
nents. Resistance
NOTE: The more the resistance, the less the current Resistance is measured in Ohms. Total resistance in a
flow. The less the resistance, the more the current flow. parallel circuit is less than the least branch resistance.
Example:
Parallel Circuits
See Figure 15-8
A parallel circuit has more than one path for current flow.
See Figure 15-7. If the branch with least resistance (R1) is 3, total resis-
tance will be less than 3. Refer to formula for determining
resistance.
Figure 15-7 Parallel Circuit

Page 6 of 70
Figure 15-10 Series/Parallel Circuit
Electrical System Failures

Most electrical system wiring problems can be grouped
into four major areas:
Figure 15-8 Resistance • Opens
Series/Parallel Circuits • Shorts

• Short to ground
Circuit Composition
• High circuit resistance
A series/parallel circuit consists of both types of circuits,
series and parallel. Open Circuit: An open circuit occurs any time there is
not a complete circuit, as is the case when there is a bro-
NOTES: ken wire, blown fuse, or defective switch. See Figure
15-11.
• A series circuit has 1 current path.
• A parallel circuit has 2 or more current paths.
The result of an open circuit is:
• A series/parallel circuit is composed of series and
parallel circuits. • No operation from the circuit.
• No current flow through the circuit.
See Figure 15-9 and Figure 15-10.
• No continuity through the circuit.
• There will be voltage up to the point of the open.
Figure 15-9 Series/Parallel Circuit
Figure 15-11
Page 7 of 70
Short Circuit: A short circuit is defined as any time two

conductors are touching, as is the case when someone
overloads a circuit and the insulation melts between two
wires in a loom, allowing those wires to touch each other.
See Figure 15-12.
The result of a short circuit is:

• Either slow, erratic, or no operation from the circuit.
• Higher than normal current flow through the circuit.
• Lower than normal circuit resistance. Figure 15-13
High Current Resistance: High resistance acts as a

restriction to flow and is usually caused by poor or loose
connections, dirt or corrosion on wires and terminals,
incorrect gauge wire, to long a wire length, and excessive
heat. See Figure 15-14.
The result of high resistance is:

Illustrates exposed wires • Slow, erratic, or no operation.
touching each other.
• Higher than normal voltage drop.
• Lower than normal current flow.
• May produce heat at the source of the problem.
Figure 15-12
Short to Ground: A short circuit to ground is different

than a short. It occurs any time a conductor is exposed
and touches a piece of metal that acts as part of the
ground circuit, like the frame, firewall, or engine. If a fuse
with a glass or plastic window is used, a short to ground
is indicated by rapid burning of the fuse, and a smoke
stained window appears. Remember, electricity takes the
shortest path to ground. See Figure 15-13.
Poor Or Loose Corroded Connections Damaged Wires
The result of a short to ground is: Connections
• Excessive high amp flow. Figure 15-14
• No complete circuit operation.

Page 8 of 70
Troubleshooting Tools • Reversing polarity with a digital meter will simply

result in a negative reading (minus sign). If polarity is
1. Tools For Troubleshooting reversed with an analog meter, it could damage the
meter.
a. Wiring Diagrams
• If analog meters are not read directly facing the
b. Meters:
meter, inaccuracies may result.
• Voltmeter
• Digital multimeters combine a voltmeter, ammeter
• Ammeter and ohmmeter in one instrument, eliminating the
need for separate meters.
• Ohmmeter
• Multimeter—combines a voltmeter and
ohmmeter.
c. Hydrometer
d. 12 volt test light
e. Self powered test light
Wiring Diagrams
A wiring diagram is a map of electrical circuits. A suc-

cessful technician uses a diagram to find out where in the
circuit the action should or should not appear.To succed
in understanding the operation of Kenworth’s electrical
system, a technician must be able to read a Kenworth
wiring diagram and wiring key. For additional information
see How To Read This Wiring Diagram on page 27.
Meters
Meters are the "eyes" that allow the technician to look at

the action of the electrical circuit. The technician should
become familiar with the operation and use of the follow-
ing types of meters:
• Volt Meter
• Ammeter
• Ohmmeter
While analog meters were the "standard" years ago, the

use of digital multimeters is highly recommended on
today's trucks. See Figure 15-15. Here's why:
• Digital meters are generally more accurate than ana-
log (needle type) meters.
• Digital meter readings need no interpretation - every-
one sees the same numbers.
• Digital meters are usually auto-ranging; they auto-
matically select the proper scale. Figure 15-15
Page 9 of 70
How To Use A Multimeter

Measuring Voltage
A voltmeter is designed to measure the voltage, or differ-

ence of potential, between points. Voltage exists between
two points and as a result a voltmeter is connected
across or in parallel with the points across which the volt-
age appears.
Figure 15-17
Measuring Amperage
Before using the ammeter, always check the fuses to

make sure they are good. To do this, turn the rotary
switch to Ohms (Ω). See Figure 15-18. With the test lead
in the Volt/Ohm terminal, insert the red probe into the 10
A terminal. A reading of <.5 ohms indicates the fuse is
good. An OL reading indicates a bad fuse that must be
replaced before using this scale.
Repeat the process for the 300 mA scale. The ohmmeter

reading should be between 4-8 ohms. An OL reading
indicates a bad fuse. The 10 A terminal is protected by a
15 amp fuse, the 300 mA terminal is protected by a 630
Figure 15-16 mA fuse.
To measure voltage:
1. Select the VAC or VDC (V~ or V-) symbol by turning
the meter's rotary switch. See Figure 15-16.
2. Connect the Black (-) COM meter test lead to the
ground (-) location in the circuit.
3. Connect the Red (+) V Ω meter test lead to the power
(+) location in the circuit.
4. Read the meter display to determine the available
voltage at that point.
CAUTION: If the meter is connected with

wrong polarity, the meter will read minus volt-
age.
To read voltage drop or voltage loss, connect the voltme-

ter across the section of wiring or component while
observing correct polarity (positive lead closest to the
power source). In order to read voltage drop, the circuit
Figure 15-18
must be energized while reading the display. See Figure
15-17.
Page 10 of 70
An ammeter is an instrument calibrated to measure cur- Measuring Resistance

rent flow in amperes. Unless an inductive pickup
(clamp-on) ammeter is used, the circuit must be opened The resistance of a circuit or component (load) can be
and the ammeter connected in series in order to take measured by using an ohmmeter. An ohmmeter mea-
measurements. sures resistance by applying a known voltage to a circuit
or component under test, and measuring the resulting
To measure amperage: current. Batteries or a built in power source usually sup-
plies the voltage for the ohmmeter. With a constant volt-
1. Select the AC or DC (A~ or A-) symbol by turning the
age applied to the meter circuit, the current and thus the
meter's rotary switch. See Figure 15-19.
reading varies with the resistance being measured. The
2. For measurements up to 320 mA, connect the meter meter scale is calibrated in ohms (Ω).
test leads into the 300 mA and COM terminals. To
measure between 300 mA and 10 amps, connect the CAUTION: Before connecting the ohmmeter
leads to the 10 A and COM terminals. to a circuit, disconnect the power source. To
verify the circuit is without voltage, connect a
NOTE: The meter test leads can be connected voltmeter to the circuit before connecting the
with the circuit current flowing through the meter ohmmeter.
from - to + or + to -. The connection can also be
made anywhere in the circuit since the current is NOTE: When measuring the resistance of a sin-
the same at all points. gle component, disconnect one end of the com-
ponent from the circuit. This will eliminate
3. Observe the amperage reading on the meter display. parallel paths that could give incorrect readings.
ALWAYS ISOLATE THE COMPONENT OR CIR-
In order to measure total current flow in a parallel circuit,
CUIT BEING TESTED.
the meter test leads must be connected to measure total
current flow through the meter. This can be done by con- To measure resistance:
necting the meter leads to the common ground side of
the parallel circuit, or the power side, before the parallel 1. Select the Ohms (Ω) symbol by turning the meter's
branches split. rotary switch. See Figure 15-20.
2. Connect the meter test leads across the component
or part of the circuit to be tested.
3. Observe the resistance reading on the meter display.
NOTE: If the display reading is followed by a KΩ

symbol, it indicates Kilo Ohms. A MΩ symbol
indicates Mega Ohms. An OL symbol means an
infinite resistance was measured. This would
indicate an open circuit between the test leads
and the component or circuit being tested.
Figure 15-19
Page 11 of 70
Continuity Testing
The ohmmeter can also be used for continuity testing.

Most digital multimeters have a rotary switch position that
provides an "audible" tone when there is circuit continuity.
A continuous tone sounds if the resistance between the
terminals is less than approximately 150 ohms (100
counts in the display). In Touch Hold, two continual beeps
indicates circuit continuity.
When testing a diode, use the "audible" tone switch posi-

tion instead of the Ohm (Ω) switch position. See Figure
15-21.
Figure 15-20
Figure 15-21
VAT Tester
A volt amp tester or VAT is a multipurpose tester that con-

sists of a voltmeter with internal and external voltage
leads, an ammeter with an inductive pickup, and a carbon
pile. The carbon pile is a variable resistor designed to
carry high current flow for a short duration. This unit is an
effective tool for testing batteries, starting circuits and
charging circuits.
To use a VAT tester, connect the large tester leads to the

battery, starter, or alternator terminals. This is dependent
on the component test being performed. The ammeter
inductive pickup should be clamped securely around the
wire that you want to read current flow in. Ensure the
arrow on the inductive pickup is pointing in the direction
of current flow. The voltage selector switch should be in
the internal voltage position to read voltage at where the
large tester leads are connected. The voltage selector
Page 12 of 70
switch should be in the external voltage position to read • A glass tube containing a weighted and calibrated
voltage using the separate external voltage leads that float.
plug into the VAT tester. See Figure 15-22.
• A rubber suction bulb on the upper end of the glass
tube.
NOTE: Because the carbon pile uses up the
voltage and converts it to heat, limit the use of • A rubber tube on the lower end of the glass tube.
the carbon pile to a very short duration (15 sec-
onds).
Figure 15-23 Hydrometer
NOTE: Some hydrometers are equipped with a ther-

mometer to aid in determining specific gravity.
Each cell of a battery contains a solution called electro-

lyte. Electrolyte is sulfuric acid diluted with water. The
Figure 15-22 specific gravity of the electrolyte varies with the state of
charge of the cell. A hydrometer measures the specific
Test Light gravity of the electrolyte.
Because the use of a test light could cause damage to How To Use A Hydrometer
electronic components if not properly connected, or
cause long term performance issues if the wire insulation CAUTION: Wear appropriate eye protection.
is pierced, we recommend that the use of this tool be
replaced with a voltmeter. A voltmeter will give a much • Avoid dripping the electrolyte from the hydrome-
more accurate indication of voltage present than a test ter. The electrolyte is very corrosive.
light. 1. Squeeze the rubber suction bulb on the top end of
the glass tube.
Hydrometer
2. Insert the rubber tube on the lower end of the glass
tube into the cell of the battery.
A hydrometer is a tool for estimating the state of charge
in a battery by measuring the specific gravity of the elec- 3. Release the rubber suction bulb and the electrolyte
trolyte. See Figure 15-23. will be drawn into the glass tube.
A hydrometer consists of: 4. Read the specific gravity of the electrolyte where the
electrolyte meets the calibrated scale on the float.
Page 13 of 70
IMPORTANT: When reading specific gravity, the float NOTE: Variations in specific gravity from battery cell to
must be freely suspended in the electrolyte, not touching battery cell should not exceed.025.
the walls, top or bottom of the glass tube.
Temperature affects specific gravity readings. Some
Your eye must be approximately on a level with the elec- hydrometers are equipped with thermometers which tell
trolyte in the glass tube. Readings taken at a sharp angle how much should be added to or subtracted from the
may be inaccurate. See Figure 15-24. specific gravity as a result of temperature variations.
When electrolyte has been gassing freely, allow sediment As a general rule, do not adjust for temperature differ-
and gas to escape from the sample before taking a read- ences between 60° F and 100° F. To adjust for large dif-
ing. ferences in electrolyte temperature:
Add .004 to the specific gravity reading for every 10°
above 80° F.
Subtract .004 from the specific gravity reading for
every 10° below 80° F.
Example 1:
You have obtained a specific gravity reading of 1.24
with the electrolyte at 120° F. Because the tempera-
ture is 40° above the standard 80° F, add .004 x 4 =
.016 to the specific gravity reading. The correct read-
ing is 1.256.
Example 2:
You have obtained a specific gravity reading of 1.25
with the electrolyte at 0° F. Because the temperature
is 80° below standard, subtract .004 x 8 = .032 from
the specific gravity reading. The correct reading is
1.218.
NOTE: For Centigrade conversion, 80° F = 27° C For

every 5.5° C above 27° C, add .004. For every 5.5° C
below 27° C, subtract .004.
Figure 15-24 Hydrometer With Readings Specific Gravity and Percentage of Charge
In a fully-charged battery, the specific gravity of the elec- 1.280 Sp. Gr. 100% Charged
trolyte is 1.280 at electrolyte temperature of 80° F. This
1.250 Sp. Gr. 75% Charged
specific gravity causes the float to “ride high”. As the
charge of the battery decreases, the specific gravity of 1.220 Sp. Gr. 50% Charged
the electrolyte decreases, and the float in the hydrometer
1.190 Sp. Gr. 25% Charged
floats at a lower level in the electrolyte. See Figure 15-25.
1. 160 Sp. Gr. Very little useful capacity
In a discharged battery, the specific gravity of the electro-
lyte is 1.150 or less, at 80° F. This specific gravity causes 1.130 Sp. Gr. Discharged
the float to “ride low”. Figure 15-25 Hydrometer Chart
Page 14 of 70
A Plan For Finding Electrical • Corroded contacts

Malfunctions • Blown fuse
• Loose alternator belts
Diagnosis / Testing
Observe All Symptoms
Electricity can't be seen, nor can it be heard. It's evasive
Observe all symptoms, especially in related circuits.
nature is the main reason electrical troubleshooting
Diagnosis time can be substantially shortened if you
appears difficult. However, if you use a systematic plan to
observe what doesn't work as well as what does work.
analyze electrical problems, a quick solution can often be
found. Testing
Systematic Plan Most people think of the testing phase as troubleshoot-

ing, when in fact it is only one of the six steps listed on
A systematic plan should be followed in order to analyze page one of this section. The basic tests that will be
electrical system problems. The plan should include the described in this section are:
following steps:
• Common Point Analysis
1. Verify the complaint
• Substitution Test
2. Visual inspection
• Jumper Wire Test
3. Observe all symptoms
• Voltage Tests
4. Testing
• Continuity Test
5. Repair the defect
• Relay Tests
6. Performance test
• Data Bus Tests
Verify Complaint 1. Common Point Analysis
Before troubleshooting, verify the customer complaint. This technique will enable you to pinpoint the most
Report of a malfunction may be caused by incorrect oper- likely cause of the problem, beginning with a careful
ation of controls or the customer may expect the system analysis of the circuit. Remember, you have already
to do something it isn't designed to do. Verify that: performed a visual inspection of the system and
• The component controls are operated properly. observed all symptoms, gathering as much informa-
tion as possible.
• The operator's expectations do not go beyond the
design of the component or system. The first step in common point analysis is to locate the
inoperative component(s) using the appropriate wiring
Visual Inspection diagram as a reference tool. When you have located
the circuit on the diagram, search out the common
It is always a good idea to visually inspect the circuit or point between the defective components. If one com-
component before testing. Look for: ponent malfunctions in a system with more than one
• Defective components component, begin testing at the malfunctioning com-
ponent. In the example in Figure 15-26 on page 15,
• Loose connections
the problem could be: a burnt out bulb, an open in the
• Damaged wires circuit providing power to the bulb, or a bad ground for
the bulb.
Page 15 of 70
Using common point analysis can also be used for

ground circuits. The common point in Figure 15-28 is a
bad ground to the inoperative components. Narrowing
the problem down to a common point shortens the overall
time it will take to correct the problem.
Figure 15-26
In the next example, Figure 15-27, several components in

the same system are inoperative. Begin testing at the
common source of power shared by all of the inoperative
components.
Figure 15-28
2. Substitution Test
Substitution is by far the simplest testing procedure. It

consists of replacing the suspected component with a
known good component. Use this method when:
a. You are reasonably sure the component is defec-
tive.
b. When the suspected component is easily acces-
sible.
Figure 15-27
Page 16 of 70
3. Jumper Wire Test Frequently, the jumper wire is used to jump power
directly from the battery to the load as a means of iso-
The jumper wire test is equally simple and effective. lating an open circuit, or simply to determine if the
The jumper wire can be used to temporarily by-pass problem is in the load or the circuit. To isolate a prob-
low resistance components such as switch contacts lem in the circuit, move the free end of the jumper wire
and wires you suspect may be open. If the circuit from point to point, back from the component to the
works when this is done, the problem has been identi- source. By noting the points at which the component
fied. See Figure 15-29. works and when it doesn't isolates the problem. See
Figure 15-31.
Lamp Off Lamp On
Figure 15-31
4. Voltage Tests
The voltage tests include checks for power, open cir-

Figure 15-29 cuits and voltage drops.
In addition, the jumper wire must be large enough to
NOTE: Although power checks can be made
handle circuit current.
with either a test light or voltmeter, we recom-
CAUTION: NEVER use a jumper wire to mend the use of a voltmeter. A test light can
bypass a load or resistance component. This tell when voltage is present, but not how
lowers the resistance which increases the much voltage is present. For some electronic
current flow. This could result in blown fuses, circuits, the specific voltage must be deter-
melted wiring or a fire. See Figure 15-30. mined to correctly diagnose the problem. A
test light can not provide exact voltage.
Figure 15-30
Page 17 of 70
• Power Check
To perform a power check, place the meter in

parallel with the circuit. The meter will read the
amount of voltage differences between the con-
nection points. See Figure 15-32.
Figure 15-34
• Voltage Drop Test
Figure 15-32 NOTE: Checking for voltage drop can only be
• Open Circuit Test done with a voltmeter.
When testing for an open circuit on the power Performing this test will tell you whether a circuit
side of the circuit, start from the component and is operating at peak efficiency or not. Poor con-
work back to the source. See Figure 15-33. nections or corroded wiring will build up resis-
tance in a circuit, and since additional resistance
requires the use of voltage to push the current
through, you get voltage drop.
Voltage drop can adversely affect the operation

of the component when it is more than the allow-
able for that circuit. The maximum allowable cir-
cuit voltage drop is as follows:
External Lights 0.25 volts
Cranking Control 1.0 volts
Cranking Circuit
12 v system 0.576 volts
Figure 15-33 24 v system 2.4 volts
When testing for an open circuit on the ground All Other Circuits 0.25 volts
side of the circuit, start from the ground and work
back to the component. See Figure 15-34. There should be full voltage drop across the
Remember, voltage should be present on the component in the circuit. See Figure 15-35. If
ground side of the component because the cir- not, we have to look for extra resistance in the
cuit is not complete. circuit which could be wanted or unwanted resis-
tance.
Page 18 of 70
NOTE: A voltmeter measures the differ-

ence in voltage between the two points.
Figure 15-35
To check voltage drop on the power side of the

circuit:
1. Measure the battery voltage.
2. Measure the voltage at the component.
3. Subtract battery voltage minus component Figure 15-37
voltage.
If the voltage drop on the power side of the circuit
This will give you total voltage drop for that por- is satisfactory, then the negative side of the cir-
tion of the circuit. See Figure 15-36. cuit must be checked. See Figure 15-38 and Fig-
ure 15-39. The same techniques are used.
Figure 15-36
Figure 15-38
Another method of obtaining the same informa-
tion as above is to connect a low scale voltmeter
from the battery positive terminal to the compo-
nent. See Figure 15-37.
Page 19 of 70
To check for voltage at the relay socket, remove

the relay. Using a voltmeter, check for battery
voltage at the common (power side) of the
socket. See Figure 15-41.
30
Power
86
85
87A
87
Normally Normally
Closed Open
Figure 15-39
• Continuity Test
An ohmmeter or self-powered test light can be used to

Figure 15-41
test for continuity. Both pieces of equipment put a
small amount of current through the circuit. This test is If there is no voltage at the relay socket power
used to check fuses and other similar low resistance terminal, check for any of the following:
components as well as checking wires for opens.
• Blown circuit breaker or fuse.
• Relay Tests
• Broken wire between the safety device and
A voltmeter or self-powered test light and a jumper power terminal socket.
wire are needed to test each individual relay circuit. A • Bad or corroded connection.
typical relay circuit is shown in Figure 15-40.
If there is battery voltage at the power terminal
socket, connect a jumper wire across the switch
portion of the relay between the power terminal
87A Normally Closed
Power 30 87 Normally Open and the normally open position on the relay
socket connections (#87 & #30) at the block. The
component should operate. See Figure 15-42.
86 85
Relay
Figure 15-40
Page 20 of 70
Power
30
30 85 86
86 87A
Jumper 85
87A 87
87
Normally Open
Figure 15-42
If there is voltage at the component, check for a

problem in the:
• Relay control circuit.
• Defective relay.
If there is no voltage at the component, check for:

• Continuity in the wire from the relay to the
component.
• Bad or corroded connection.
Relay Control Circuit Figure 15-43
If there is a voltage reading, check for a defective

To check the relay control circuit, connect a volt-
relay.
meter across the relay control terminal socket
connections (#85 & #86) at the block. Note: If no voltage reading is observed, connect the
Ensure the meter is connected observing proper voltmeter positive (+) lead to the power side of
polarity. the relay control circuit socket (#85). Connect the
negative (-) lead to the vehicle ground. See Fig-
With the ignition switch in the ON position and
ure 15-44.
the control switch closed, check the voltage. See
Figure 15-43.
NOTE: You should see voltage with the control

switch on, no voltage with the control switch off.
Page 21 of 70
30
30 86
85 86 87A
85
87
87A
87
Figure 15-45
Figure 15-44
If there is voltage at the power side of the relay control

circuit, use a self-powered test light, jumper wire or ohm-
meter to check for a faulty ground, a defective control
switch or an open wire in the control coil ground circuit.
See Figure 15-45 and Figure 15-46.
Figure 15-46
Page 22 of 70
• Data Bus Tests If both the E108DB and E109DB voltage checks
in steps 2 and 3 above indicate no voltage or
J1587 Data Bus Tests very low voltage, one of the electronic compo-
nent circuits that share the data bus may be
The J1587 data bus is used to transmit informa- shorted out, causing the entire data bus to
tion between different electronic components on become corrupted. To determine whether it is
the vehicle. A DDR plug under the dash allows the data bus or an electronic circuit, disconnect
the technician to connect diagnostic equipment all data bus circuits, expect for the engine and
that can be used to monitor component opera- DDR plug. If the data bus starts to transmit infor-
tion, access fault code information, etc. See. Fig- mation with everything disconnected (except
ure 15-47. The J1587 data bus uses a twisted engine and DDR plug), start reconnecting each
pair of wires to communicate between electronic electronic component until the data bus circuit
components. The circuit designations are goes dead. This will tell you which component is
E108DB (+) and E109DB (-). corrupting the data bus.
When a diagnostic tool is connected to the DDR If you are still unable to communicate with the
plug-in under the dash, no message or the mes- diagnostic tool plugged into the DDR plug or if
sage "Failure to Communicate" could mean there the meter reading still shows 0 or low voltage, try
are several problems. To determine if the prob- isolating the engine. If the engine will communi-
lem is related to the DDR plug, data bus or cate by itself, then the data bus is the problem
something else, follow the trouble-shooting pro- and should be checked for a short, open or short
cedure below. to ground.
1. With the ignition switch ON, set the voltmeter
to the DC volts position.
2. Connect the meter positive (+) lead to the
E108DB terminal and the meter negative (-)
lead to the GND terminal on the DDR plug.
You should see a reading of between 3.0 and
4.5 DC volts that are constantly changing.
E109DB terminal and the meter negative (-)
lead to the GND terminal on the DDR plug.
You should see a reading of between 0.4 and
1.5 DC volts that are constantly changing.
P120DG or P82BB terminal and the meter
negative (-) lead to the GND terminal on the
DDR plug. You should see a reading of bat-
tery voltage. If you do not read battery volt-
age, find the source of the problem and repair
it.
Terminal Circuit Description

A E108DB Data Link +1587/1708
B E109DB Data Link - 1587/1708
C P120DG Battery Power +
E GND - M Ground -
Figure 15-47
Page 23 of 70
J1939 Data Bus Tests Repair Defect And Performance Test
To test the J1939 data bus to determine if the cir- When the malfunction has been determined, make the
cuit is good, connect an ohmmeter to pin "C" necessary repairs to the circuit or replace the defective
(J1939 +) and pin "D" (J1939 -) at the 9 pin DDR component. All operations should be tested to ensure no
plug under the dash. See Figure 15-48. With other problems are present.
both terminating resistors in the data link, a read-
ing of approximately 60 ohms should be dis-
played on the meter. If one resistor is removed,
an ohmmeter reading of approximately120 ohms
should be obtained. A meter reading of "OL"
would indicate the J1939 data bus is either open
or both terminating resistors have been removed.
To check for reversed wires, check from pin "C"

of the data plug-in to the appropriate terminal on
the component ECM and then from pin "D" of the
plug-in to the appropriate terminal on the compo-
nent ECM.
/
Terminal Circuit Description

A GND - M Ground -
B P120DG Battery Power +
C YEL J1939 + Data Link
D GRN J1939 - Data Link
E SHLD J1939 Shield
F E108DB Data Link + (J1587/1708)
G E109DB Data Link - (J1587/1708)
Figure 15-48
Page 24 of 70
Diagrams See Figure 15-49 on page 25 for Symbols In Wiring Dia-

grams.
A wiring diagram is a map of electrical circuits. A suc-
cessful technician uses a diagram to find out where in the See Figure 15-50 on page 27 to view a tutorial on how to
circuit the action should or should not appear. To suc- trace a typical Kenworth electrical circuit. Click on How
ceed in understanding the operation of Kenworth's elec- To Read This Wiring Diagram on page 27.
trical system, a technician must be able to read a
Kenworth wiring diagram and wiring key. A wiring dia-
gram and wiring key will show:
• Circuit function
• Circuit number of all wires in a circuit
• Color of all wires in a circuit
• Destination of wire or purpose of circuit
• Location of:
• -Terminals
• -Splices
• -Connections
• -Plugs
• -Grounds
• -Fuses and circuit breakers
• Relation of components on chassis in Cab and Chas-
sis wiring diagrams
Page 25 of 70
P81BB,RED/L_BLU,CUMMINS/DDEC ONLY P81BB,RED/L BLU,CUMMINS/DDEC ONLY TO ENGINE DIAG
P81BB,RED/L_BLU P81BB,RED/L BLU, ALL ENGINES TO ENGINE DIAG
P82BB,ORN/RED
Symbol For Splice
C19SR,TAN C19SR,TAN C19SR,TAN EXTERIOR LIGHTING DIAG
P51KS, RED/YEL
P82BB,ORN/RED TO ENGINE DIAG
P82KS, ORN/RED IGN_BUSS
2
P113BB, RED/BRN 1
3 4 5 6 7 P113BB, RED/BRN TO ENGINE DIAG
P113BB, RED/BRN
P113BB, RED/BRN
P113BB, RED/BRN
P113BB, RED/BRN
BATT_BUSS
P113BB,RED/BRN
2
2 1 ACC_BUSS
STR_RELAY ACC_RELAY IGN_RELAY 2
ERET1 3 4 5 1
P51KS, RED/YEL TO ENGINE DIAG
P82BB,ORN/RED
P82BB,ORN/RED
P82BB,ORN/RED
87 30 87 30 87 30 3 4 5 6 7 8 9 10
C17SR,ORN P82KS, ORN/RED P82KS,ORN/RED
Example: S3
C19SR,TAN
86
c
85 86
c
85
GND,WHT
86
c
85
GND,WHT
P51KS, RED/YEL
P51KS, RED/YEL
P51KS, RED/YEL
P51KS, RED/YEL
P51KS, RED/YEL
P51KS, RED/YEL
P51KS, RED/YEL
P51KS, RED/YEL
ON CEP ON CEP ON CEP
This wire has a Symbol For Fuse

C17SR,ORN
C19SR,TAN
GND,WHT
code of C17SR
GND,WHT
C19SR,TAN
KEY_SWITCH 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
ERET,WHT/BLU
1
P51KS, RED/YEL
2
IGN
ACC
STR
3 P113KS, RED/BRN P113KS, RED/BRN
2 30A2 30A2 30A 2 15A2 15A2 15A2 15A2 15A 2 30A2 30A2 30A2 30A2 30A2 30A2 30A2 30A
Identifies
P82KS,RED/ORN
Application
BAT 4
3 G1
1 1
P113BB, RED/BRN
P113BB, RED/BRN
P113BB, RED/BRN
P113BB, RED/BRN
P82BB,ORN/RED
P82BB,ORN/RED
P82BB,ORN/RED
P51KS,RED/YEL
P51KS,RED/YEL
P51KS,RED/YEL
P51KS,RED/YEL
P51KS,RED/YEL
P51KS,RED/YEL
P51KS,RED/YEL
P51KS,RED/YEL
1 2 DEH1F6 5 4559 DASH HARN NOTES:
1) USE ON T2000 WITH 12 - 12 CHARGE
IGN1C,ORN
DASH HARNESS GROUND
6 5 4559 AND START SYSTEM.
ENGINE HARNESS
1 2 DEHIM
2) THIS DIAGRAM APPLIES TO CHASSIS BUILT
4
ERET,WHT/BLU
C1 STARTING APPROX: OCT 1996

GROMMET
C19SR,TAN 1 1 ENDING APPROX: XXX XXXX
P81BB,RED/L_BLU
CEP1
J1
RADSOK C19SR,TAN SPARE
CONN CIRCUIT
Symbol For Single Wire Plug BLOCK

ON CEP
C17SR,ORN
P82BB, ORN/RED
GND,WHT
1
CLEAN MAXI FUSE IN 5A
POWER BATTERY BOX 15O AMP
MEGA FUSE
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
GND,WHT
2 50A
LOCATED ON LH
CORNER OF ENGINE
P81BB, RED/L_BLU
6 C2
5A Symbol For Terminal
P21AL, BLK
5B
P117GA,RED
Symbol For Diode P81BB,RED/L BLU

CLAMP ON
AMMETER
P119GA,BRN
P52AF, WHT/RED
GND, WHT GND,WHT
C17SR,ORN
FIREWALL
(Reference Only)
P82BB, ORN/RED
BATTERY CBL,RED
BATTERY CBL,RED
1 3 TO DASH GND
2 TO SLEEPER GND
FRAME TO R CHASSIS GND
GND TO TAIL LP GND
ALTERNATOR
GND,WHT
5/16"_GND_STUD TO FR CHASSIS GND

STARTER TO CAB MT GND
12 VOLT
GND,WHT AMMETERREAR CH
GND,WHT
4-12V HARNESS HARNESS

C
#10 ALT1
BATTERY
P117GA,RED 1 1 TO INSTRUMENTATION DIAGRAM
ENGINE P119GA,BRN 2 2 TO INSTRUMENTATION DIAGRAM
BLOCK GND, WHT 3 3 TO INSTRUMENTATION DIAGRAM
P52AF, WHT/RED 4 4 TO INSTRUMENTATION DIAGRAM
ALT2
7
BATTERY CBL,BLK
BATTERY CBL,BLK GND,WHT
C3 6
BATT GND,WHT
ERET,WHT/BLU
BATTRET GND,WHT RET,WHT/BLU
C988, WHT
BATTRET,WHT
INSTRUMENTATION DIAGRAM
ENGINE DIAGRAM (CUMMINS ONLY)
ENGINE DIAGRAM (CAT ONLY)
Symbol For Connector
150A, WHT ENGINE DIAGRAM (DDECIII ONLY)
150B, WHT ENGINE DIAGRAM (DDECIII ONLY)
Symbol For Ground 953,BLK/WHT

151, WHT ENGINE DIAGRAM (DDECIII ONLY)
ENGINE DIAGRAM (DDECIII ONLY)
Figure 15-49 P94-1113

Page 26 of 70
Wiring Key Example: C 17 SR
Wiring Code Definition List Function . . . . . . C = Components

Circuit
Example: C17SR Number . . . . . . . 17 = Starter Solenoid
C -- Function See Function Destination or
Description Below. Purpose. . . . . . . SR = Starter
17 -- Circuit Number See “Circuit Descrip-
tion” on page 28. Explanation:
SR -- Destination or See “Destination or C17SR = Starter Solenoid to Starter

Purpose Purpose” on page 33.
Wiring Code, Spare Circuit Breaker
Example: PCB 33
PCB -- Function Power from Spare

FUNCTION Circuit Breaker.
LETTER DESCRIPTION
33 -- Circuit Breaker Tells location of
C Components Number circuit breaker.
E ECU / Electronic Control
G Gauges
GND Ground
H Heating / Air Conditioning
L Lighting
P Power
PCB Power from Spare Circuit Breaker
R Relay
S Spare
Page 27 of 70
How To Read This Wiring Diagram

HOLE IN J01
PD BOX
COVER
P51KS RED/YEL WIRE0553 1
5
ACC
2
C19SR TAN WIRE0001 KEY USAGE NOTE:
STR SWITCH
P82KS ORN/RED WIRE0555 4 BAT
USE ON W9/T6/T8/C5 CHASSIS
KEY SW IGN WITH 12-12V ELECTRICAL SYSTEMS.
FUSE P113KS RED/BRN WIRE0002 3
USE WITH UPGRADED PD BOX.
6
P82BB ORN/RED WIRE0492 1 1 P82KS ORN/RED WIRE0555
10A INSTR
PANEL
HARNESS SEE DETAIL "B" FOR USE
WITH PUSH BUTTON START
3
IGN BUS
RELAY C
E J32
GND WHT WIRE0065

83
P113KS RED/BRN WIRE00021 C 1 GND WHT WIRE0637 GND WHT WIRE0065 02 SEE DETAIL "A" FOR USE WITH
1 STARTER J05 P04 NUETRAL START SWITCH
C19SR TAN WIRE0591
SENSE
P82BB ORN/RED WIRE0003 1 1 5 5 5 5
1 1 1 1
GND WHT WIRE0636
D 6 6 6 6
DETAIL "A"
J03 A USE WITH NEUTRAL
J02 2 2 7 7 C19SR TAN WIRE0005 7 7 C19SR TAN WIRE0006 START SWITCH (OPT)
C19SR TAN WIRE0046 C19SR TAN WIRE0024
P82BB ORN/RED WIRE0492
ACC BUS
A P05
RELAY 1 1 4 4 4 4 P05
TRANS
1
F HARNESS
3 3 3 3 3 3 J07
P51KS RED/YEL WIRE0553 1 1 TRANS 1
C HARNESS
P113BB RED/BRN WIRE0066 SEE FIREWALL 6 6 2 2 2 2 B
J07
APPROPRIATE GROUND
P82BB ORN/RED WIRE0378 1 1 P51KS RED/YEL WIRE0343 SYSTEM STUD C19SR TAN WIRE0008 8 8 C19SR TAN WIRE0004 8 8 C19SR TAN WIRE0007
DIAGRAM B NEUTRAL START SWITCH
39 39 P03 J06 (SHOWN IN NEUTRAL
ENGINE CHASSIS CHASSIS TRANSMISSION POSITION)
40 40 HARNESSHARNESS HARNESS HARNESS
5 5
67 P01 P02
P82BB ORN/RED WIRE0044 INSTRUMENT ENGINE
PANEL ENGINE HARNESS SEE DETAIL "F" FOR USE WITH
HARNESS HARNESS ENGINE HARNESSES WITH
P82BB ORN/RED WIRE0089 ENGINE MOLDED STYLE CONNECTORS
4 J04 HARNESS
J08
A
ENGINE BATTERY
1
POWERJ09 HARNESS BOX HARN
FEED P06
POWER STARTER
HARNESS
DISTRIBUTION RELAY
BOX P21AL BLK WIRE0025 C19SR TAN WIRE0009 2 2 C19SR TAN WIRE0011 J13
GND WHT WIRE0014 1 1 GND WHT WIRE0012 C

J14
P07 J11 J15
C17SR ORN WIRE0015
J10 C17SR ORN WIRE0017
J16
DETAIL "B" J12
USE WITH PUSHBUTTON START (OPT)
P84SR BLK/ORN WIRE0026
PUSH BUTTON
START SWITCH ENGINE
GROUND
IF CIRCUIT PCB33A IS STUD
UNAVAILABLE, USE PCB33B,
STRT BTN 34A OR 34B INSTEAD J19
FUSE
P84SR BLK/ORN WIRE0026
P21AL BLK WIRE0025 1
1 1 1 135A
PCB_33A BLK WIRE0088
F J30 J29 1 J20
10A MAIL SLOT IN
SEE AREA H11 J21
FOR J17 BATTERY BOX
P113BB RED/BRN WIRE0087 1 1
JUMPERBLK WIRE0052
JUMPERBLK WIRE0058
CONTINUATION INSTR
PCB_33B BLK WIRE0090
XXX PANEL J31

OF CIRCUIT 1 1 1 JUMPERRED WIRE0040 JUMPERRED WIRE0040
HARN
JUMPER J18 BATTERY CABLE WIRE0019
P09
JUMPERBLK WIRE0052
ALTERNATOR
POWER
DISTRIBUTION BATTERY CABLE WIRE0077
BOX BATTERY CABLE WIRE0050
JUMPERWHT WIRE0041
J33
1
C
J23
1
CUT THIS CIRCUIT

AT KEY SWITCH, C
INSULATE AND TIED BACK J22
M
C19SR TAN WIRE0063
SEE P97-1013, -1014 & -1015

FOR BATTERY CONFIGURATIONS.
STARTER
INSTR
SEE DETAIL "C" FOR USE WITH AMMETER
PANEL JUMPER
SEE DETAIL "D" FOR USE WITH BATTERY DISCONNECT SWITCHES
HARNESS
SEE DETAIL "E" FOR USE WITH BATTERY DISCONNECT SWITCHES AND AMMETER
J32
E
65 2
1 C19SR TAN WIRE0061 1 3 JUMPERBLK WIRE0058 BATTERY CABLE WIRE0051
4 BATTERY CABLE WIRE0078
P08
C19SR TAN WIRE0062
Figure 15-50 P94-1385

Page 28 of 70
Circuit Circuit
Circuit Description Color Code Circuit Description Color Code
No. No.
Gnd Ground ATA White 32. Service Brake Sense Yellow/Green
1. Tail and Park Lamps ATA Brown 33. Left Front Directional Signal Lamp Yellow/Black
2. Stop Lamps ATA Red 34. Right Front Directional Signal Lamp Green/Black
3. Marker & Clearance Lamps ATA Black 35. Left Rear Directional Signal Lamp ATA/Yellow
4. Hot Wire for Auxiliary Devices on Trailer ATA Blue 36. Right Rear Directional Signal Lamp ATA/Green
5. Head Lamps Lt. Blue 37. Idle Validation Off Brown/Black
6. Low Beam Red/Black 38. Idle Validation Signal Yellow/Red
7. High Beam Blue/White 39. Hot Feed Line to Pressure Auxiliary Switch Red/Pink
8. Control Circuit for Accessory Relays Red/Gray 40. Return Line from Pressure Auxiliary Switch Red/Violet
9. LH Road or Fog Lamp Purple 41. Sanders Brown/White
10. RH Road or Fog Lamp Purple/White 42. Radio Receiver Green/Red
11. Horn Relay Ground White/Green 43. Radio Transmitter Green/Orange
12. Horn Relay Hot Green/White 44. Differential Lock Lt. Blue/Brown
13. Panel Lamps Gray 45. Fifth Wheel Lock Brown/Green
14. Flood or Loading Lamp Red/Tan 46. Low Air Green/Tan
15. Battery Charging Gray/Yellow 47. Two Speed Axle Yellow/Blue
16. Post Spot Lamp Gray/Red 48. Idle Increment Red/White
17. Starter Solenoid Orange 49. Idle Increment Red/Blue
18. Hot Line to Buzzer and Warning Devices Lt. Green 50. Circuit Breaker to Terminal Strip Pink/Blue
19. Starter Switch to Solenoid Tan 51. Accessory Term. of Ignition Switch to Circuit Red/Yellow
Breaker
20. Windshield Washer Motor Lt. Blue/Yellow
52. Ignition Circuit Breaker to Accessories White/Black
21. Battery to Ammeter - Main Charge and Dis- Black
charge Line 53. Horn Relay to Horn Pink/Black
22. Regulator Battery Term to Ammeter Charg- Black 54. Acc. Circuit Breaker to Accessories White/Red
ing Line
55. Check Engine Light Blue/Yellow
23. Ether Start Tan/Green
56. Low Coolant Lt. Green/Blue
24. Engine Heater Blue/Pink
57. Electric Water Temp. Purple/Yellow
25. Engine Oil Temperature Pink
58. High Water Temp. Low Oil Press. Green/Brown
26. Main Trans. Oil Temp. Violet
59. Remote Throttle Enable Tan
27. Aux. Trans. Oil Temp. Gray/Black
60. Remote Throttle Signal Input Gray/Pink
28. First or Single Rear Axle Temp. Gray/Black
61. Ground White
29. Second Rear Axle Temp. Gray/Black
62. Defroster Fan Yellow/Red
30. Heater - Pass. Side Lt. BLue/Black
63. Switched Tri-State Derate Gray/Lt. Blue
31. Clutch Position Yellow/Purple
64. Turn Signal Feed Orange/Blue
Page 29 of 70
Circuit Circuit
No. No.
65. Courtesy Lamps Pink/Green 97. Engine Retard Switches Lt. Blue/Green
66. Dome Lamp - Front Violet/White 98. Jake Brake Full Lt. Green/Black
67. Dome Lamp - Sleeper Tan/Yellow 99. Fuel Heater or Filter Lt. Green/Red
68. Voltage Regulator Energizing Control Line Red/Blue 100. Interaxle Diff. Lock Indicator Lamp White/Red
69. Switch Common Gray 101. General Purpose Exterior Lamps Green/Lt. Blue
70. Turn Signal Flasher to Switch Volt Reg. or Yellow/Green 102. Air Conditioner Clutch Control Lt. Green/White
Press. Switch
103. Spare Relay Power Contact - Normally Blue
71. Windshield Wiper Black/Green Open
72. Fuel Gauge Tan/Black 104. Spare Relay Power Contact - Normally Blue
Closed
73. Fuel Gauge - LH Tank with Two Senders Tan/Red
105. Spare Relay Power Contact - Common Blue
74. Fuel Pressure Orange/Green
106. Spare Relay Coil (+) Blue
75. LH Windshield Wiper Black/Green
107. Spare Relay Coil (-) Blue
76. RH Windshield Wiper Green/Black
108. Data Link Buss + Blue/Black
77. Sleeper Heater Blue/Orange
109. Data Link Buss - Blue/Lt. Blue
78. Sleeper Relay Controls to Sleeper Heater Blue/Gray
Motor 110. DRL Power Brown/Lt. Blue
79. Backup Lamp Pink/White 111. DRL Sense Orange/Black
80. Sign Lamp Red/Orange 112. Remote PTO Enable Black/White
81. Clean Power Red/Lt. Blue 113. Feed from Ignition Term. of Key Switch to Red/Brown
Circuit Breaker
82. Cab Feed Line Between Circuit Breakers Orange/Red
and Key Switch 114. Audio System Tan/White
83. Mirror Motor Brown/Tan 115. Alt. Sensing Circuit (Regulator Term or 1 of Black/White
3 Alt. AC Terms)
84. Starter Relay Feed Black/Orange
116. Sleeper Accessories and Cigar Lighter Pink/Red
85. Reversible Motor - Up or Forward Lt. Blue/Tan
117. Charging Circuit - Alternator to Ammeter Red
86. Reversible Motor - Down or Reverse Tan/Lt. Blue
118. Cummins to PT Pump; 8V-71 & Cat. to Fuel Red/Green
87. Air Conditioning or Cooler Yellow/White Shutdown
88. Glow Plug Orange/White 119. Shunted Ammeter Brown
89. Mirror Heat Brown/Yellow 120. Diagnostic CONN Battery Power Red/Blue
90. Expello Valve - Air Tank Heat - Air Dryer Purple/Red 121. Diagnostic Test Switch Yellow
91. VARASHIELD Indicator Lt. Blue/Red 122. Alternator Warning Lamp Lt.
Green/Orange
92. VARASHIELD Down Tan/Lt. Blue
123. Sleeper Air Control Red
93. VARASHIELD Up Lt. Blue/ Tan
124. Sleeper Box Air Conditioning Control Circuit Lt. Green/White
94. Transmission Lockup Green/Pink
125. Park Brake Sense for DRL Lt. Green/Yellow
95. Engine Retard Black/Lt. Green
126. Batt. Ckt. Breaker - DRL Red/Violet
96. Jake Brake Half Lt. Green/Yellow
Page 30 of 70
Circuit Circuit
No. No.
127. Throttle Power Brown/Gray 159. Stop Engine Lamp Brown/White
128. Throttle Sense Position Brown/Red 160. Anti-Lock Solenoid, Left Front Axle Orange/White
129. Throttle Position Brown/Green 161. Anti-Lock Solenoid, Right Front Axle Orange/Yellow
130. not used 162. Anti-Lock Solenoid, Left Rear or Left For- Violet/Green
ward Rear Axle
131. C.B. Speaker Wiring (-) White/Gray
163. Anti-Lock Solenoid, Right Rear or Right For- Violet/Blue
132. C.B. Speaker Wiring (+) Brown/Gray ward Rear Axle
133. Radio Speaker Ground Circuit RH Speaker Orange/Gray 164. Anti-Lock Solenoid, Left Rear Rear Axle Violet/Orange
134. Radio Speaker Ground Circuit LH Speaker Gray/Orange 165. Anti-Lock Solenoid, Right Rear Rear Axle Violet/Yellow
135. Radio RH Speaker Circuit (Sleeper) Green/Gray 166. Anti-Lock Wheel Speed Sensor, Left Front Yellow/Black
136. Radio LH Speaker Circuit (Sleeper) Gray/Lt. Green 167. Anti-Lock Wheel Speed Sensor, Right Front Yellow/White
137. Radio RH Speaker Circuit (Cab) Black/Gray 168. Anti-Lock Wheel Speed Sensor, Left Rear or Yellow/Orange
Left Forward Rear
138. Radio LH Speaker Circuit (Cab) Gray/Green
169. Anti-Lock Wheel Speed Sensor, Right Rear Yellow/Blue
139. Cruise On/Off Orange/Brown or Right Forward Rear
140. Cruise Set Orange/Green 170. Anti-Lock Wheel Speed Sensor, Left Rear Yellow/Lt. Green
Rear
141. Cruise Resume Orange/Red
171. Anti-Lock Wheel Speed Sensor, Right Rear Yellow/Tan
142. J1922 Data Link (+) Yellow
Rear
143. J1922 Data Link (-) Orange
172. Anti-Slip Solenoid Orange/Purple
144. Fan Clutch Control White/Lt. Green
173. ECU/Electronic Control Switched Circuit Gray/Blue
145. Dump Gate Front White
174. Motor Common Mirrors White/Brown
146. Dump Gate Rear White
175. Power Mirrors Left/Right White/Orange
147. Torque Limiting Circuit, PT Pump to Pres- Red/Green
sure Switch 176. Power Mirrors Up/Down Gray/Violet
148. Electric Tach. Sending Circuit Black/Red 177. Power Windows Up Gray/Lt. Blue
149. Hobbs Hour Meter Gray/Yellow 178. Power Windows Down White/Lt. Blue
150. Electric Speedo Sending Circuit Blue/Red 179. Power Windows Common White/Tan
151. Smart Sensor Yellow/Violet 180. Power Door Locks White/Purple
152. Check Fluids Lamp Green/Orange 181. Auxiliary Battery Red
153. Anti-Lock Brake System Monitor Feed Pink/Purple 182. Proprietary Bus (-) Gray/Red
154. Anti-Lock Brake System Power Purple/Pink 183. Proprietary Bus (+) Red/Gray
155. Anti-Lock Brake System Warning - Fail Cir- Violet/Brown 184. C.B. and AM/FM Radio Power Lt. Green/Pink
cuit
185. J1939 Data Link (High) Yellow
156. Anti-Lock Brake System Diagnostic Circuit Brown/Violet
186. J1939 Data Link (Low) Green
157. Pyrometer (Australia only) Green
187. J1939 Data Link (Shield) White
158. Check Engine Lamp Brown/Orange
188. not used
Page 31 of 70
Circuit Circuit
No. No.
189. not used 223. Auto Trans Man Override Tan/Blue
190. Door Lock Actuator Feed Wire “B” Blue/Red 224. not used
191. Door Lock Actuator Feed Wire “A” Green/Red 225. not used
192. Door Unlock Black/Red 226. Engine Governor Switch Orange/Blue
193. Door Lock White/Red 227. not used
194. Door Unlock Relay Ground Brown/Red 228. Collision Warning Power Red/Purple
195. Door Lock Relay Ground Black/Red 229. Collision Warning Bus Positive Orange/Lt. Blue
196. Air Bag Warning Lamp Blue/Yellow 230. Collision Warning Bus Negative Black/Tan
197. Air Bag Battery Power Red/Yellow 231. Collision Warning Side Sensor Power, Red/Lt. Green
Primary
198. Air Bag Ignition Power Orange/Yellow
232. Collision Warning Side Sensor Ground, Violet/Lt. Green
199. Air Bag Firing Circuit Yellow/Pink Primary
200. Seat Belt Switch Yellow/Brown 233. Collision Warning Side Sensor Signal, Purple/Lt. Green
Primary
201. Aux Input Gray/Green
234. Collision Warning Side Sensor Power, Red/White
202. Aux Output Gray/Yellow Secondary
203. Transmission Shift Modulation Purple/Lt.Blue 235. Collision Warning Side Sensor Ground, Violet/White
Secondary
204. Transmission In Gear Purple/Green
236. Collision Warning Side Sensor Signal, Purple/White
205. Low Coolant Low Blue/Black
Secondary
206. Low Coolant High Blue/White
237. Collision Warning Driver’s Display Unit Purple/Tan
207. +5 VDC Blue/Red Power
208. Return Blue/Green 238. Collision Warning Side Sensor Display Green/Purple
Signal, Primary
209. not used
239. Collision Warning Side Sensor Display Gray/Purple
210. Maintenance Indicator Lamp Green/Red Signal, Secondary
211. Water-In-Fuel Indicator Lamp Green/Yellow 240. Collision Warning Front Sensor Power Red/Yellow
212. Proprietary Can Bus (High) Red 241. Collision Warning Front Sensor Ground Violet/Yellow
213. Proprietary Can Bus (Low) Black 242. not used
214. Proprietary Can Bus (Shield) White 243 not used
215. PTO Lamp Brown/Blue 244 Engine Condensation Actuator Orange/Lt. Green
216. Remote PTO Set Brown/Lt. Green 245 Engine Turbo Control Actuator Pink/Brown
217. Remote PTO Resume Brown/Lt. Yellow 246 Engine EGR Actuator Green/Violet
218. not used 247 Engine EGR Bypass Actuator Blue/Orange
219. Input Sensor Common #1 White/Purple 248 Engine Oxygen Sensor Yellow/Brown
220. Input Sensor Common #2 White/Orange 249 Engine Mass Air Flow Sensor Pink/Lt. Blue
221. Trans Shift Solenoid Tan/Purple
222. Trans Position Sensor Tan/Lt. Green

Page 32 of 70
Circuit CIRCUIT DESIGNATOR TABLE "C"

Circuit Description Color Code
No.
Circuit Circuit Circuit Description
250 not used Name Color Code
through
300. ACC Yellow Spare Accessory Circuits
301. Spare Circuit Black/White ALTI Black Alaternator “I” Terminal Feed
302. Spare Circuit Black/Yellow BAT Red Spare Battery Circuits
303. Spare Circuit Black/Red CAP Yellow/Gray Noise Suppressing Capacitor
304. Spare Circuit Black/Green ERET White/Pink Electronic Return
305. Spare Circuit Black/Orange GND White Ground (ATA)
306. Spare Circuit Black/Lt. Blue EGN Orange Spare Ignition Circuits
307. Spare Circuit Black/Pink OAT1 White/Viloet Outside Air Temperature (+)
308. Spare Circuit Brown/Blue OAT2 White/Yellow Outside Air Temperature (-)
309. Spare Circuit Brown/Lt. Blue PCB Black Spare Power Circuit Breakers
310. Spare Circuit Brown/Lt. Green PWR Red Battery (+)
311. Spare Circuit Lt. Blue/Green RET White/Blue Instrument Return
312. Spare Circuit Brown/Yellow SPC Blue/Tan Spare Passthrough Chassis Circuits
313. Spare Circuit Lt. Blue/Lt. SPE Brown/Pink Spare Passthrough Engine Circuits
Green
SPR Pink Spare Passthrough Roof Circuits
314. Spare Circuit Lt. Blue/Orange
SPS Yellow/Lt Spare Passthrough Sleeper Circuits
315. Spare Circuit Lt. Blue/Pink Blue
316. Spare Circuit Lt. Blue/Purple V White 24 Volt Charging Wire
317. Spare Circuit Lt. Green/Gray
318. Spare Circuit Lt. Blue/White
319. Spare Circuit Lt. Green/Purple
320. Spare Circuit Lt. Green/Brown

Page 33 of 70
Destination or Purpose
Circuit Designations
A
Circuit Circuit Circuit Description
Name Color Code ABS Anti-Lock Brake
AC Air Conditioning
ACC Yellow Spare Accessory Circuits
AD Air Dryer
ALTI Black Alternator “I” Terminal Feed
AF Accessories Feed
BAT Red Spare Battery Circuits AH Aux. Heater
CAP Yellow/Gray Noise Suppressing Capacitor AL Alternator
ERET White/Pink Electronic Return AM Actuator Motor

AO Automatic Override
GND White Ground (ATA)
AR Acc. Relay
IGN Orange Spare Ignition Circuits
AT Air Tank
OAT1 White/Violet Outside Air Temperature (+) AU Automatic
OAT2 White/Yellow Outside Air Temperature (-) AX Auxiliary
PCB Black Spare Power Circuit Breakers AXL Auxiliary Left

AXR Auxiliary Right
PWR Red Battery (+)
AXT Axle Temperature
RET White/Blue Instrument Return
SPC Blue/Tan Spare Passthrough Chassis Circuits B

BA Back Up Alarm
SPE Brown/Pink Spare Passthrough Engine Circuits
BB Buss Bar
SPR Pink Spare Passthrough Roof Circuits
BL Backup Lamp
SPS Yellow/Lt.blue Spare Passthrough Sleeper Circuits
BR Breaker
V White 24 Volt Charging Wire BS Binary Switch
BZ Buzzer
C
CA Collision Warning
CB C.B. Radio
CC Charging Circuit
CCT Cruise Control
CG Cigar Lighter
CH Cab Heater
CK Clock
CL Clearance Lamps
CLP Cellular Phone
CM Common
CP Clean Power
CS Clutch SW
CT Control
CTS CTIS
Page 34 of 70
Destination or Purpose Destination or Purpose

GP Glow Plug
D
DB Data Buss H
DC Door Courtesy Lamp HB High Beam
DCL Door Courtesy Left HC Horton Fan Clutch
DCR Door Courtesy Right HH High Heat
DF Defroster Fan HI High
DG Diagnostic HL Headlamps
DK Door Lock HM Hobbs Hour Meter
DL Diff Lock HN Horn
DM Dome Lamp HP High Pressure
DMF Dome Floor HS Heat Sensor
DML Dome Left HW High Water - Low Oil
DWR Dome Right
I
DRL Daytime Running Lamp
IGB Ignition Bus Bar
DS Dimmer Switch
D1 Diagonal 1 (Antilock)
J
D2 Diagonal 2 (Antilock)
JB Jacob’s Brake
JF Jacob’s Brake Full
E
JH Jacob’s Brake Half
EF Engine Fan
EG Engine Gauge
K
EH Engine Heater
KS Key Switch
EM Engine ECM
ER Engine Retard L
ES Ether Start LA Low Air
EV Expello Valve LB Low Beam
LC Low Coolant
F
LH Low Heat
FC Freon Compressor
LI Lights - Instrument
FF Fuel Filter
LO Low Oil
FG Fog Light
LP Low Pressure
FH Fan Hub
LT Left Turn
FL Flood Lamp
LV Left Valve (ASR)
FL2 Flood Lamp, 2nd set
LW Low
FP Fuel Pressure
FT Fuel Tank Heater M
FW Fifth Wheel Lock MH Mirror Heat
MHL Mirror Heat Lamp
G
ML Marker Lamp
GA Gauge
MM Motorized Mirror
GD Gear Display
MN Manual
Page 35 of 70
Destination or Purpose Destination or Purpose

MO Manual Override SL Spot Lamp
MR Motor SN Sign Lamp
MT Medium Temp SO Solenoid Valve - Outlet
MW Multiplex Wheel SP Speedometer
SR Starter
N
SS Sleeper Speaker
NC Normally Closed
ST Stop Lamp
NO Normally Open
SU Sending Unit
NS Neutral Start
SV Solenoid Valve
SW Switch
P
PB Park Brake
T
PI Position Indicator
TC Tachometer
PL Park Lamps
TCT Traction Control
PTO PTO
TK Trip Tracker
PW Power Window
TL Tail Lamp
PWB Power Bus Bar
TM Terminal Strip
PWL Power Windows, Left
TN Turn Signal
PWR Power Windows, Right
TR Trailer
PY Pyrometer
TRE Transmission ECU
TRS Transmission Shifter
R
TS Throttle Switch
RC Roof Condenser
TV Television
RCC Rear Vision Camera
RD Rear Directional Lamp
U
RF Refrigerator
US Unitary Switch
RL Road Lamp
USW Unswitched
RM Radio Memory
RP Radio Power V
RR Radio Receiver VR Voltage Regulator
RS Radio Speaker VS VARASHIELD
RT Right Turn
W
RV Right Valve (ASR)
WD Wiper Delay
RY Relay
WL Warning Lamp
S WM Wiper Motor
S Splice WS Wheel Sensor
SA Sleeper Accessories WW Windshield Washer
SC Sleeper Control
SD Engine Shutdown
REF: R076-3315 Rev R
SG Safety Gauges
SH Sleeper Heat
SI Solenoid Valve - Inlet
Page 36 of 70
Circuit Color / Circuit Number Matrix Example:

What kind of circuit is a white wire with a green
For Matrix, see next page. stripe?
To identify circuit number and description: 1. Find White in the solid color row.
1. Find the solid color of the wire in the row at the top of 2. Find Green in the stripe column.
the page. 3. White and Green intersect at circuit number 11.
2. Find the stripe color of the wire in the column at the 4. Find Number 11 in the Circuit Number / Circuit
left of the page. Description table.
NOTE: A red wire with a red stripe is a solid red wire. A 5. Circuit number 11 is: Horn Relay Ground.
black wire with a black stripe is a solid black wire, etc.
3. The circuit is identified by the number at the intersec-
tion of the stripe column and the solid color row.
4. To identify the circuit description, find the circuit num-
ber in the table that begins with the Circuit Number /
“Electrical Circuit Matrix” on page 37.
R076-3315 Rev P
Page 37 of 70
Electrical Circuit Matrix

See “Electrical Circuit Matrix” on previous page for instructions on how to identify circuit number and name.
Stripe Solid Color

Lt. Lt.
Black Blue Brown Green Gray Orange Pink Purple Red Tan Violet White Yellow
Blue Green
Black 3 108 37 34 27 30 98 111 53 6 72 52 33
21 76 28 49 166
22 29
ALTI
PCB
Blue 4 215 173 56 64 50 68 223 163 RET 47
103 308 226 120 169
104
105
106
107
Brown 1 58 44 320 139 245 113 155 174 200
119 248
Green 71 208 45 36 138 97 74 65 204 147 23 162 11 32
75 129 157 201 140 118 70
304 186
Gray 137 78 127 135 13 311 317 133 8 131 CAP
132 69 183
Lt. Blue 306 109 309 101 63 5 229 249 203 81 86 178 SPS
110 177 92
Lt. Green 95 205 310 136 313 18 244 233 231 222 232 144 170
216
Orange 84 77 158 43 134 314 122 17 80 164 175 168
305 247 152 143 220
IGN
Pink 307 24 SPE 94 60 315 184 25 154 39 ERET 199
SPR
Purple 238 239 316 319 172 153 9 228 221 180 31
219
Red 148 150 128 42 16 91 99 82 116 90 2 73 54 38
192 190 194 191 182 141 117 100 62
195 207 210 181 193
303 BAT
123
Tan 230 SPC 83 46 93 237 14 19 179 171
85 59
Violet 156 246 176 40 26 OATI 151
126
White 112 7 159 12 318 124 160 79 10 48 114 66 61 167
115 206 41 102 88 236 234 235 145 87
301 146
GND
V
187
Yellow 302 55 89 211 149 20 96 161 57 51 67 165 OAT2 35

196 217 15 125 198 197 241 121
312 202 240 142
ACC
185
Page 38 of 70
Servicing Battery Cable Volt Drop Test
• Starting Circuit (See Figure 15-51)

• Battery Cable Voltage Drop
Positive Battery Cables
• Starter Solenoid Circuit Testing
1. Ensure the parking brake is set and the transmission
• Charging Circuit Testing is in neutral.
• Series-Parallel Testing 2. Disable the engine so it won't start.
• Wiring Repairs 3. Connect the voltmeter positive (+) lead to the battery
positive (+) terminal.
Starting Circuit
4. Connect the voltmeter negative (-) lead to the starter
Slow cranking or no cranking can be caused by low bat- solenoid battery terminal.
teries, defective cranking motor, defective component in 5. Crank the engine and measure the positive cable volt
the control circuit, or a problem in the wiring and connec- drop. Stop cranking as soon as the reading is
tions. As with any electrical problem, the technician obtained.
should take a systematic approach to troubleshooting the
problem. For battery service information, refer to Batter- NOTE: If two sets of batteries and cables are
ies, KM815006 in ServiceNet. used, repeat this process for the other set of
cables.
Battery Cables
Negative Battery Cables
Slow or sluggish cranking may be caused by high resis-
1. Connect the voltmeter positive (+) lead to the starter
tance in the battery cables and connections, especially in
ground stud on the starter.
cold weather. After all batteries test good and the termi-
nals are clean and tight, check the battery cables. The 2. Connect the voltmeter negative (-) lead to the battery
voltage drop in the positive cables, plus the voltage drop negative (-) terminal the cable fastens to.
in the negative cables equals the total voltage drop, or
3. Crank the engine and measure the negative cable
the difference between battery voltage and starter volt-
volt drop. Stop cranking as soon as the reading is
age.
obtained.
ADD
Positive Cable Volt Loss ______ volts (Meter 1)
Negative Cable Volt Loss ______ volts (Meter 2)

_______________________________________
Total Volt Loss ______ volts (0.5 max)
(Meter 1)
(Meter 2)
Figure 15-51
Page 40 of 70
Starter Control Circuit
When the starter solenoid circuit has excessive voltage

loss, the starter pinion sometimes may not engage the
flywheel. If it does engage, it quite often drops out too
soon when the battery voltage lowers. The solenoid cir-
cuit consists of either a starter relay or a series-parallel
switch.
Solenoid Circuit Test
(See Figure 15-52)

is in neutral.
2. Disable the engine so it won't start.
3. Connect the voltmeter positive (+) lead to the SW ter-
minal on the starter solenoid. (Meter 1)
ground terminal. (Meter 1)
5. Have an assistant turn the ignition key to the start
position. The starter relay should close.
NOTE: If the relay does not close, perform the

“Starter Relay Circuit Test” on page 42
6. Measure the voltage at the switch terminal on the
starter solenoid. Release the ignition key once the
reading is obtained. The voltage reading should be
approximately the same as battery voltage. If the
voltage reading is less than 9 volts, the solenoid con-
tacts may not operate correctly. If this is the case,
check the starter relay circuit wiring for loose or cor-
roded connections and repair as necessary. Then
re-test.
7. Connect the voltmeter positive (+) lead to the battery
positive terminal on the starter solenoid. (Meter 2)
solenoid motor terminal. (Meter 2)
9. Have an assistant turn the ignition key to the start
position. Observe the voltage drop across the sole-
noid contact disk. Maximum voltage drop should not
exceed 0.2 volts.
NOTE: Battery voltage should be observed

when the meter test leads are first connected.
Voltage should be less than 0.2 volts when the
engine is being cranked.
Meter 1
Meter 2
Figure 15-52
Page 42 of 70
Starter Relay Circuit Test
(See Figure 15-53)
The starter relay control circuit seldom fails. However, the

following test procedure is especially important if the cir-
cuit does fail completely, and the starter relay does not
close.
is in neutral.
3. Connect a voltmeter to the battery cable ends on the
starter. (Meter 1)
4. Turn the ignition key to the crank position. You should
hear the starter relay close. If not, continue to pro-
ceed.
5. Measure battery cable voltage. Release the ignition
switch once the reading is obtained.
6. Connect the voltmeter to the control coil terminals on
the starter solenoid (switch terminal). If the solenoid
has only one small terminal, connect the voltmeter
negative (-) lead to the battery negative lead on the
starter. (Meter 2).
7. Turn the ignition key to the crank position. Measure
starter relay voltage. Release the ignition switch once
the reading is obtained.
SUBTRACT
Battery Cable Voltage ____ volts (Meter 1)
- Starter Relay Voltage _____ volts (Meter 2)
_______________________________________
Control Circuit Loss ______ volts (0.5 max)
If circuit loss is 0.5 volts or less and the starter relay

switch closes, end the test.
If circuit loss is 0.5 volts or less, but the starter relay

switch does not close, replace the relay and repeat the
test above.
If circuit loss is more than 0.5 volts, continue testing the

control circuit.
Meter 1
Meter 2
Figure 15-53
Page 44 of 70
If the circuit voltage loss is 1.0 volt or less, the solenoid

circuit is adequate. Continue to the starter relay circuit
test.
If the circuit voltage loss is more than 1.0 volt, the loss is
excessive. This loss may be caused by loose connec-
tions, corrosion, too small a wire, a switch located too far
from the starting motor, or a worn out starter relay. To
locate the section causing the problem, follow the steps
below. See Figure 15-54.
is in neutral.
3. Connect the voltmeter positive (+) lead to the battery
terminal on the starter solenoid. (Meter 1)
4. Connect the voltmeter negative (-) lead on the bat-
tery side of the starter relay. (Meter 1)
NOTE: If the meter registers voltage, connect the

meter to the other large terminal on the starter
relay.
5. Crank the engine and measure the volt drop.
Release the switch once the reading is obtained.
6. Connect the voltmeter positive (+) lead to the sole-
noid side of the starter relay. (Meter 2)
7. Connect the voltmeter negative (-) lead to the SW
terminal on the starter solenoid. (Meter 2)
8. Crank the engine and measure the volt drop. Stop
cranking as soon as the reading is obtained.
9. Connect the voltmeter positive (+) and negative (-)
leads to the starter relay as shown in the diagram.
(Meter 3).
NOTE: The meter will display system voltage

until the ignition switch is turned to the start posi-
tion.
10. Crank the engine and measure the volt drop.
Release the switch once the reading is obtained.
First Cable Loss ______ volts (0.4 max) (Meter 1)

Second Cable Loss ____ volts (0.4 max) (Meter 2)
Starter Relay Loss _____ volts (0.2 max) (Meter 3)
11. Repair or replace the cable(s) or starter relay if nec-
essary.
Meter 3
Meter 1
Meter 2
Figure 15-54
Page 46 of 70
If the starter relay circuit test has indicated high resis-

tance in the circuit, perform the following test to deter-
mine where the problem lies. Use the diagram in Figure
15-55 for determining meter polarity if you are not sure.
With the starter relay connected:
is in neutral.
3. Connect a low scale voltmeter to the connection
points shown in the diagram for the areas that need
to be tested.
4. Crank the engine long enough to obtain the volt drop
reading at each of the following locations:
• Solenoid "Bat" terminal to ignition switch - (Meter 1)
• Across the ignition switch - (Meter 2)
• Ignition switch to starter relay - (Meter 3)
• Starter relay to starter - (Meter 4)
ADD
Meter 1____ volts
Meter 2____ volts
Meter 3____ volts
Meter 4____ volts

_______________________________________
Total Voltage Loss____ volts (0.5 max)

Meter 2
Meter 3
Meter 1
Meter 4
Figure 15-55
Page 48 of 70
Charging Circuit
When a charging system problem is suspected, it is usu-
ally because of a slow cranking problem, a gauge read-
ing too high or too low, or excessive odor detected from
the battery box area. There are two ways to determine if
the charging system is working properly. Both methods
are based on measuring maximum voltage output and
maximum amperage output. It is recommended that
when ever possible, the technician check both.
Amperage Output Test
NOTE: Conduct the following test at shop temper-

ature.
1. Connect a VAT tester to the vehicle batteries by
hooking up the machine's positive (+) and negative
(-) leads to the battery positive (+) and negative (-)
terminals. Clamp the inductive lead around the alter-
nator positive (+) wire with the arrow of the inductive
pickup facing away from the alternator. See Figure
15-56.
2. Increase engine rpm until the alternator is turning at
rated speed (in most cases, alternator rated speed is
approximately 1500 engine rpm). Figure 15-56
3. Turn on and adjust the carbon pile until the ammeter

reads its highest value without letting battery voltage
drop below 12.6 volts. Record the reading. Remove
the load from the carbon pile and idle down the
engine.
Page 49 of 70
Voltage Output Test • If voltage exceeds 15.5 volts, replace the alternator. If
the alternator uses an external regulator, check the
1. Connect the voltmeter positive (+) and negative (-)
regulator wiring and replace the regulator if the wiring
leads to the alternator positive (+) and negative (-)
is good.
terminals. See Figure Figure 15-57.
• If voltage reading at the batteries is low, check the
2. Ensure all vehicle loads are turned off and the volt-
charging circuit wiring.
meter is reading battery voltage.
3. Fast idle the engine until the voltage stabilizes (does Alternator Wiring Test
not increase) for 2 minutes.
The output of the alternator must reach the batteries and
4. Record the alternator output voltage. accessory loads with a minimum amount of voltage loss.
Any loss slows the rate of charge to the batteries and
could cause the batteries to remain in a state of dis-
charge. Low output voltages can also have an affect on
electrical components designed to run at higher voltages.
Alternator output is controlled by the voltage regulator

and preset to operate at a 13.5 - 14.8 range. This maxi-
mum voltage is available at the alternator output terminal.
However, if any voltage is lost in the wiring, something
less will reach the load. Before proceeding with the fol-
lowing tests, make sure the batteries have been tested
and the terminals have been cleaned and tightened. Use
the diagram in Figure 15-58.
is in neutral.
2. Connect a voltmeter across the batteries and bring
the engine up to a fast idle. Record the reading after
the voltage has stabilized for 2 minutes. (Meter 1)
3. Connect a voltmeter across the output terminals on
the alternator and bring the engine up to a fast idle.
Record the reading after the voltage has stabilized
for 2 minutes. (Meter 2)
Figure 15-57 SUBTRACT

Battery Voltage Reading_____volts (Meter 1)
Charging System Results
- Alternator Voltage Reading_____ volts (Meter 2)
_______________________________________
• If no amperage output was obtained - try polarizing
the alternator momentarily and repeat steps 2 and 3 Voltage Drop_____ (0.5 max)
of the amperage output test.
If system voltage drop is 0.5 volts or less, tighten mount-
• If amperage output is not 90% of the rated output ing bolts (including ground). Stop test.
(stamped on alternator case), replace the alternator.
If system voltage drop is more than 0.5 volts, perform
“Volt Drop Test” on page 51.
Meter 2
Meter 1
Figure 15-58
Page 51 of 70
Volt Drop Test
Use the diagram in Figure 15-59.

1. With the engine running at a fast idle, connect the
voltmeter positive (+) lead to the alternator battery or
positive (+) terminal. Connect the voltmeter negative
(-) lead to the positive (+) terminal on the battery.
(Meter 1)
2. Record the meter reading.
3. Connect the voltmeter positive (+) lead to the ground
terminal on the alternator. Connect the voltmeter
negative (-) lead to the negative (-) terminal on the
battery. (Meter 2)
4. Run engine at fast idle and record meter reading.
ADD
Positive Cable Volt Loss_____ volts (Meter 1)
Negative Cable Volt Loss_____ volts (Meter 2)
_______________________________________
Total System Loss_____ (0.5 max)
Meter 1
Meter 2
Figure 15-59
Page 53 of 70
Cable Voltage Loss Test - 24 Volt Cranking With

Series-Parallel Switch
1. Check the battery cable connections to the starter
solenoid and starter. Tighten and clean if necessary.
is in neutral.
4. Attach a remote start switch from the #2 terminal to
the #7 terminal on the series-parallel switch. See Fig-
ure 15-60.
5. While pressing the remote start switch, measure the
voltage across both sets of batteries (voltmeter leads
should be connected to battery terminal nuts or ter-
minal posts). (Meter 1)
6. Release the start switch and record the meter read-
ing.
7. Connect the voltmeter to the starter solenoid "Bat"
terminal and starter ground. (Meter 2)
voltage at the starter.
9. Release the remote start switch and record the meter
reading.
SUBTRACT
Battery Voltage Reading_____volts (Meter 1)
- Starter Voltage Reading_____ volts (Meter 2)
_______________________________________
Total Cable Voltage Loss______ (1.8 max)
5
1
Meter 1
2
7
Meter 2
Figure 15-60
Page 55 of 70
The recommended maximum acceptable voltage loss for 9. Release the remote start switch and record the meter
a 24-volt cranking system is 1.8 volts. reading.
10. Connect the voltmeter from the series-parallel switch
If the battery cable voltage loss is acceptable, proceed to
#2 terminal to the #1 terminal of the series-parallel
the starter solenoid test.
switch. (Meter 4)
If the battery cable voltage loss is excessive, proceed as 11. While pressing the remote start switch, measure the
follows to determine which circuit has the excessive loss. volt loss.
1. With the engine still disabled and the remote start 12. Release the remote start switch and record the meter
switch still connected, connect a low scale voltmeter reading.
from the starter solenoid "Bat" terminal to the battery
positive (+) terminal on the "B" set of batteries. 13. Connect the voltmeter from the series-parallel switch
(Meter 1) See Figure 15-61. #1 terminal to the battery negative (-) terminal on the
"B" set of batteries. (Meter 5)
positive (+) cable volt loss. 14. While pressing the remote start switch, measure the
negative (-) cable volt loss.
reading. 15. Release the remote start switch and record the meter
reading.
4. Connect a voltmeter from the starter motor ground
terminal to the battery negative (-) terminal on the "A" ADD
set of batteries. (Meter 2)
Battery Pos. Cable Loss_____ volts (Meter 1)
negative (-) cable volt loss. Battery Neg. Cable Loss_____ volts (Meter 2)
reading. Series-Parallel Pos. Loss_____ volts (Meter 3)
7. Connect the voltmeter from the battery positive (+) Series-Parallel Loss ______volts (Meter 4)
terminal of the "A" set of batteries to the #2 terminal
of the series-parallel switch. (Meter 3) See Figure Series-Parallel Neg. Loss_____ volts (Meter 5)
15-61. _________________________________
8. While pressing the remote start switch, measure the Total Voltage Loss ____ volts (1.8 max)
positive (+) cable volt loss.
Repair or replace cables or the series-parallel switch with
excessive resistance.
5
Meter 1
Meter 2
Figure 15-61
Meter 4
1
Meter 5
2
Meter 3
Figure 15-61 continued

Page 58 of 70
The preceding procedure should show which circuit has

excessive voltage loss. Repair or replace the problem
portion of the circuit.
• If the wiring circuit is now adequate, adjust the alter-
nator belts, tighten the mounting bolts and ground
wire.
• If the wiring is adequate, but there are still charging
problems, test the alternator per the alternator output
check. If necessary, replace the alternator.
Alternator Wiring Test

1. Connect a voltmeter to the alternator positive (+) and
negative (-) terminals. (Meter 1) See Figure 15-62.
2. With the engine running, measure alternator voltage
and record the reading.
3. Connect a voltmeter to the “A” set of battery positive
(+) and negative (-) terminals. (Meter 2) See Figure
15-62.
4. With the engine running, measure battery voltage
SUBTRACT
Alternator Voltage ______volts (Meter 1)
- Battery Voltage (“A” set) ______volts (Meter 2)
_______________________________________
Voltage Loss (“A” set) ______volts
5. Connect a voltmeter to the “B” set of battery positive
(+) and negative (-) terminals. (Meter 3) See Figure
15-62.
6. With the engine running, measure battery voltage
SUBTRACT
Alternator Voltage ______volts (Meter 1)
- Battery Voltage (“B” set) ______volts (Meter 3)
_______________________________________
Voltage Loss (“B” set) ______volts
7. Add the voltage losses for the “A” and “B” set batter-
ies as recorded in steps 4 and 6 above.
If the total system voltage drop is 0.5 volts or less, tighten

the alternator mounting bolts and ground. Stop test.
If the system voltage drop is more than 0.5 volts, con-

tinue test on page 60.
Meter 1
5
1
Meter 3
2
7
Meter 2
Figure 15-62
Page 60 of 70
1. With the engine running, connect a low scale voltme- 8. Measure the negative circuit voltage loss and record
ter to the alternator positive (+) terminal and the pos- the reading.
itive (+) terminal of the "A" set of batteries. (Meter 1).
See Figure 15-63. ADD
2. Measure the positive (+) circuit voltage loss and Positive Circuit Loss _____ volts (Meter 1)
record the reading.
3. Connect the voltmeter across the series-parallel Series-Parallel Switch Loss_____ volts (Meter 2)
switch terminals #2 and #5. (Meter 2)
#5 Wire Loss _____ volts (Meter 3)
4. Measure the series-parallel switch voltage and
record the reading. Negative Circuit Loss _____ volts (Meter 4)
__________________________________________
5. Connect the voltmeter from the series-parallel switch
Total System Loss _____ volts (0.5 max)
terminal #5 to the positive (+) terminal of the "B" set
of batteries. (Meter 3) If the total system voltage loss exceeds 0.5 volts, check
6. Measure the #5 wire voltage loss and record the for high resistance in wiring, or loose and/or corroded
reading. connections. Repair as necessary.
7. Connect the voltmeter from the alternator negative (-)
terminal to the starter motor ground terminal. (Meter
4)
Meter 2
1 Meter 3
2
7
Meter 1
Meter 4
Figure 15-63
Page 62 of 70
Wiring Repairs
Broken Wire
For how to find a broken wire or splice, see “Continuity
Test” on page 19.
How To Repair A Broken Wire

1. With wire strippers, strip 1/2 inch of insulation from
broken end of each wire.
2. Slide plastic heat shrink tube over wire end 6-8
inches away from area of splice.
3. Position metal splice around each end of broken
wire.
NOTE: Metal splice must cover all of exposed wire.

4. Crimp metal splice. See Figure 15-64 Figure 15-65 Soldering of Splice
6. Position plastic heat shrink tube over splice. See Fig-
ure 15-66.
NOTE: Splice may also be protected with electrical

tape.
7. Apply heat to shrink tube. See Figure 15-67 on page
63.
Figure 15-64 Wire Strippers

5. Solder splice. See Figure 15-65
Figure 15-66 Position of Heat Shrink

Page 63 of 70
1. Before removing connector, identify each terminal by

affixing a tag with a letter to the wire of the terminal.
See Figure 15-68.
Figure 15-67 Heating of Heat Shrink

Figure 15-68 Replacing a Connector
Replacing An Electrical Connector
2. Identify each terminal of the new plug by affixing a
tag with a letter to the wire of the terminal.
Several different types of wiring connectors are used in
Kenworth electrical systems. The 8-way molded connec-
NOTE: Verify that terminals A through H of new connec-
tor, illustrated in Figure 15-68 is commonly used, as well
tors are like terminals A through H of connector to be
as hard-shell and Deutsch style connectors. When
replaced.
replacing individual terminals or a complete connector,
the following general replacement guidelines should be 3. With appropriate tool, cut wire A of connector to be
followed to ensure that each wire terminal is installed in replaced.
the correct replacement connector pinout location.
4. Splice wire A of connector to be replaced with wire A
of new connector.
How To Replace An Electrical Connector.
NOTE: Follow procedure in this section for How To
IMPORTANT: Each terminal of the new connector must
Repair A Broken Wire.
be connected with the same wire to which the terminal of
the old connector was connected.
Repeat steps 3 and 4 for each wire of connector.
In addition to the general terminal and connector replace-

ment guidelines above, the following connector replace-
ment procedures for several different types of Deutsch
connectors is provided on pages 64-69.
Additional information covering Deutsch, Molex and

Packard connectors, terminals, and tools are available on
the internet at:
Manufacturer Website
Deutsch laddinc.com
Molex molex.com
Packard delphiauto.com/connect
Page 64 of 70
Deutsch Connectors
DRC SERIES
Contact Crimping
1. Strip ¼" (6.3 mm) insulation from wire.
2. Raise selector knob and rotate until arrow is aligned Figure 15-72
with wire size to be crimped.
NOTE: Tool must be readjusted for each type/size
3. Loosen lock nut, turn adjusting screw in until it stops. of contact.
Contact Insertion
1. Grasp contact approximately 1.00" (25.4 mm) behind
the contact crimp barrel.
Figure 15-69
4. Insert contact with barrel up. Turn adjusting screw
counter clockwise until contact is flush with indentor
cover. Tighten lock nut.
Figure 15-73
2. Hold connector with rear grommet facing you.
Figure 15-70
5. Insert wire into contact. Contact must be centered Figure 15-74
between indicators. Close handles until crimp cycle
is completed. 3. Push contact straight into connector grommet until a
positive stop is felt. A slight tug will confirm that it is
6. Release handles and remove crimped contact. properly locked in place.
7. Inspect terminal to insure that all strands are in crimp
barrel.
Figure 15-75
Figure 15-71
Page 65 of 70
Contact Removal
1. With rear insert toward you, snap appropriate size
extractor tool over the wire of contact to be removed.
Figure 15-77
NOTE: Do not twist or insert tool at an angle.
Figure 15-76 3. Pull contact-wire assembly out of connector.

2. Slide tool along wire into the insert cavity until it
engages contact and resistance is felt.
Figure 15-78
Page 66 of 70
DT SERIES Contact Removal
Contact Insertion 1. Remove orange wedge using needlenose pliers or a

hook shaped wire to pull wedge straight out.
1. Grasp crimped contact approximately (25.2 mm) one
inch behind the contact barrel.
Figure 15-83
2. To remove the contacts, gently pull wire backwards,
Figure 15-79
while at the same time releasing the locking finger by
2. Hold connector with rear grommet facing you. moving it away from the contact with a screwdriver.
Figure 15-80 Figure 15-84

3. Push contact straight into connector grommet until a 3. Hold the rear seal in place, as removing the contact
click is felt. A slight tug will confirm that it is properly will displace the seal.
locked in place.
Figure 15-85
Figure 15-81
Once all contacts are in place, insert orange wedge

will arrow pointing toward exterior locking mecha-
nism. The orange wedge will snap into place. Rect-
angular wedges are not oriented. They may go in
either way.
NOTE: The receptacle is shown - use the same

procedure for plug.
Figure 15-82
Page 67 of 70
DTM SERIES Contact Removal

1. Remove orange wedge using needlenose pliers to
Contact Insertion
pull wedge straight out.
1. Grasp crimped contact approximately 1.0" (25.4 mm)
behind the contact barrel.
Figure 15-89
2. To remove the contacts, gently pull wire backwards,
Figure 15-86 while at the same time releasing the locking finger by
2. Hold connector with rear grommet facing you. moving it away from the contact with a screwdriver.

3. Push contact straight into connector grommet until a 3. Hold the rear seal in place, as removing the contact
click is felt. A slight tug will confirm that it is properly will displace the seal.
locked in place.
Once all contacts are in place, insert orange wedge:

receptacles - with half holes aligning with contacts.
Plugs - with contacts aligning behind full holes. The
orange wedge will snap into place.
NOTE: The receptacle is shown - use the same

Figure 15-91
procedure for plug.
Figure 15-88
Page 68 of 70
HD10 SERIES Contact Removal

1. With rear insert toward you, snap the appropriate
Contact Insertion
size plastic tool over the wire of the contact to be
1. Grasp the contact-wire assembly between the thumb removed.
and forefinger on the wire approximately one inch
behind the contact crimp barrel.
Figure 15-95
2. Slide the tool along the wire into the insert cavity until
Figure 15-92
it engages the contact and resistance is felt. The con-
2. Hold the connector with the rear grommet facing you. tact retaining clip will be in the unlocked position.

3. Push the contact straight into the connector grommet 3. Pull the contact-wire assembly out of the connector.
until a positive stop is felt. The retaining fingers in the
connector will snap behind the shoulder of the con-
tact and lock it in place. A slight tug will confirm that it
is properly sealed.
Figure 15-97
Figure 15-94
Page 69 of 70
HD30 and HDP 20 SERIES
Contact Insertion
1. Grasp contact approximately (25.4 mm) one inch
behind the contact crimp barrel.
Figure 15-100
Contact Removal
1. With rear insert toward you, snap appropriate size
extractor tool over the wire of contact to be removed.
Figure 15-98
2. Hold connector with rear grommet facing you.
Figure 15-101
2. Slide tool along into the insert cavity until it engages
Figure 15-99 contact and resistance is felt.
3. Push contact straight into connector grommet until a
positive stop is felt. A slight tug will confirm that it is
properly locked in place.
NOTE: For unused wire cavities, insert sealing

plugs for full environmental sealing
Figure 15-102
3. Pull contact-wire assembly out of connector.
NOTE: Do not twist or insert tool at an angle

Page 70 of 70

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15 15-Electrical KM815001 4/24/02

Department Customer Service

Table of Contents Meters 8

Electrical: Electrical System Number KM815001

Voltage Drop Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Electrical: Electrical System Number KM815001

An alternator produces alternating current that is rectified

Current is produced by rotating a magnet inside a station-

Figure 15-3 Brushless Alternator

Brushless alternators or alternators equipped with

A regulator controls the alternator output by adjusting the

Electrical: Electrical System Number KM815001

Figure 15-5 Water Pressure and Voltage

Voltage, Current, Resistance Example:

Voltage 30 Ibs. of pressure at the water supply will force 150

Electrical: Electrical System Number KM815001

In a parallel circuit, current flowing through each branch

Figure 15-7 Parallel Circuit

Electrical: Electrical System Number KM815001

Figure 15-10 Series/Parallel Circuit

Electrical System Failures

Series/Parallel Circuits • Shorts

Figure 15-9 Series/Parallel Circuit

Electrical: Electrical System Number KM815001

Short Circuit: A short circuit is defined as any time two

The result of a short circuit is:

High Current Resistance: High resistance acts as a

The result of high resistance is:

Short to Ground: A short circuit to ground is different

• Excessive high amp flow. Figure 15-14

• No complete circuit operation.

Electrical: Electrical System Number KM815001

Troubleshooting Tools • Reversing polarity with a digital meter will simply

A wiring diagram is a map of electrical circuits. A suc-

Meters are the "eyes" that allow the technician to look at

While analog meters were the "standard" years ago, the

Electrical: Electrical System Number KM815001

How To Use A Multimeter

A voltmeter is designed to measure the voltage, or differ-

Before using the ammeter, always check the fuses to

Repeat the process for the 300 mA scale. The ohmmeter

CAUTION: If the meter is connected with

To read voltage drop or voltage loss, connect the voltme-

Electrical: Electrical System Number KM815001

An ammeter is an instrument calibrated to measure cur- Measuring Resistance

NOTE: If the display reading is followed by a KΩ

Electrical: Electrical System Number KM815001

The ohmmeter can also be used for continuity testing.

When testing a diode, use the "audible" tone switch posi-

A volt amp tester or VAT is a multipurpose tester that con-

To use a VAT tester, connect the large tester leads to the

Electrical: Electrical System Number KM815001

Figure 15-23 Hydrometer

NOTE: Some hydrometers are equipped with a ther-

Each cell of a battery contains a solution called electro-

Electrical: Electrical System Number KM815001

NOTE: For Centigrade conversion, 80° F = 27° C For

Electrical: Electrical System Number KM815001

A Plan For Finding Electrical • Corroded contacts

Systematic Plan Most people think of the testing phase as troubleshoot-

Electrical: Electrical System Number KM815001

Using common point analysis can also be used for