PDF Electrical Service Manual Kenworth Truck KM815001 - 597 KB
Troubleshoot and repair the electrical systems on your Kenworth truck with this specialized service manual.
It contains detailed wiring diagrams, schematics, and diagnostic procedures.
This guide is indispensable for technicians working on complex electrical issues, from lighting to engine control modules.
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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
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Page 11 of 70
Electrical: Electrical System Number KM815001
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 (β¦) 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
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Page 21 of 70
Electrical: Electrical System Number KM815001
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
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Page 31 of 70
Electrical: Electrical System Number KM815001
Circuit Circuit
Circuit Description Color Code Circuit Description Color Code
No. No.
189. not used 223. Auto Trans Man Override Tan/Blue
190. Door Lock Actuator Feed Wire βBβ Blue/Red 224. not used
191. Door Lock Actuator Feed Wire βAβ 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 Driverβs 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
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Meter 1
Meter 2
Figure 15-52
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Page 51 of 70
Electrical: Electrical System Number KM815001
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)
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Meter 2
5
1 Meter 3
2
7
Meter 1
Meter 4
Figure 15-63