KENWORTH DDEC II R115 Wiring Schematics Manual

R115-4725.FM 115 RED BLK YEL GND WHT P118SD RED/GRN LOW COOLANT LEVEL MODULE C108DB BLU/BLK CL109DB BLU/LT BLU + - ELECTRONIC FOOT PEDAL 916 RED/BLK 417 BLU 952 BLK 16-LIGHT WARNING LAMP MODULE DDEC POWER HARNESS BATTERY CABLES 15A FUSE LOCATED IN BATT BOX 135A BATTERY COOLANT LEVEL SENSOR LOCATED IN TOP TANK OF RADIATOR DDEC ENGINE HARNESS DDEC ENGINE HARNESS VEHICLE SPEED SENSOR CAB GND PD BOX PD BOX CAB ROOF HARNESS CHASSIS HARNESS CAB SECT CHASSIS HARNESS CAB SECT DDEC CAB HARNESS DDEC ENGINE HARNESS CAB ROOF HARNESS DDEC ENGINE HARNESS DIAGNOSTIC JUMPER DIAGNOSTIC CONNECTOR STOP ENGINE OVERRIDE SWITCH (OPTIONAL) LOCATED IN KEY SWITCH PANEL INSTRUMENT PANEL HARNESS DDEC CAB HARNESS DDEC CAB HARN DDEC CAB HARNESS BRAKE SWITCH HARNESS CRUISE CONTROL SET/RES SWITCH LOCATED ON DASH CRUISE CONTROL ON/OFF SWITCH LOCATED ON DASH ENGINE RETARD RELAY (OPTIONAL) LOCATED BEHIND LH GAUGE PNL DDEC CAB HARNESS DDEC CAB HARN P118SD RED/GRN 901 GRN 901 GRN 901 GRN 901 GRN 900 GRN/YEL 900 GRN/YEL 900 GRN/YEL P118SD RED/GRN P118SD RED/GRN P118SD RED/GRN 556 LT BLU/BLK 557 LT BLU/ORN P118SD RED/GRN P118SD RED/GRN P118SD RED/GRN 901 GRN 900 GRN/YEL GND WHT GND WHT GND WHT GND WHT GND WHT GND WHT GND WHT P118SD RED/GRN GND WHT P118SD RED/GRN GND WHT 451 LT GRN 451 LT GRN 451 LT GRN 451 LT GRN 528 BRN/RED 528 BRN/RED 528 BRN/RED 419 PUR/WHT 419 PUR/WHT 509 PUR 509 PUR L158WL BRN/YEL L159WL BRN/WHT P18WL L GRN 524 GRY/BLK 524 GRY/BLK 524 GRY/BLK 543 BRN 543 BRN 543 BRN 531 LT BLU 531 LT BLU 531 LT BLU 541 YEL/RED 541 YEL/RED 541 YEL/RED 544 BRN/WHT 544 BRN/WHT 544 BRN/WHT 545 LT BLU/YEL 545 LT BLU/YEL 545 LT BLU/YEL 542 YEL 542 YEL 542 YEL 908 WHT 508 GRY 508 GRY 508 GRY 908 WHT 916 RED/BLK 417 BLU 555 TAN GND WHT 558 WHT ORN C118SD RED/GRN 240 RED 241 RED 150 BLK COOLANT LEVEL HARNESS 15A 15A P113BB RED/BRN SEE KEY SWITCH AND SPARE CIRCUIT BREAKER DIAGRAM CHECK ENGINE STOP ENGINE DIP SWITCH DDEC II ELECTRONIC CONTROL MODULE LOCATED ON LEFT HAND SIDE OF ENGINE CAB ROOF HARNESS CAB ROOF HARNESS 952 BLK 953 BLK/WHT C97CS LT BLU/GRN C97CS LT BLU/GRN 916 RED/BLK 417 BLU 952 BLK C 85 86 87 87A 30 11 12 14 13 13 15 16 17 18 19 26 20 21 23 23 20 25 16 26 28 27 29 30 31 31 C BLU CAB GROUND SHIFT MODULATOR CONTROL RELAY LOCATED BEHIND RH GAUGE PANEL SHIFT MODULATOR SOLENOID LOCATED BEHIND RH GAUGE PANEL SHIFT MOD CNTRL HARN 908 WHT GND WHT 24 PARK BRAKE SWITCH MOUNTED ON AIR JUNCTION BLOCK CRUISE CONTROL RELAY LOCATED NEAR AIR JUNCTION BLOCK SERVICE BRAKE SWITCH MOUNTED ON AIR JUNCTION BLOCK BRAKE SWITCH HARNESS P118SD RED/GRN GND WHT GND WHT P118SD RED/GRN 558 WHT 558 WHT ORN C118SD RED/GRN C118SD RED/GRN GND WHT 524 GRY/BLK 543 BRN 531 LT BLU TAN ORN JUMPER WIRE C 85 86 87 87A 30 GND WHT WARN LAMP ELEC ENG (SHTDN) 22 TORQUE CONVERTER LOCKUP SWITCH (OPTIONAL) LOCATED RH FRONT UNDER TRANSMISSION (SEE DETAIL "E" FOR TRANS W/ RETARDER) C118SD RED/GRN C118SD RED/GRN BLOCKING DIODE LOCATED IN HARNESS ABOVE PD BOX A B C D E F H G C 85 86 87 87A 30 J K B1 M L C1 NONE J.M.GROVE N WONG N WONG 03-26-91 REI I9289 P 1 4 WILHOYTE MERTENS X X DIAGRAM DDEC II OF 2 SHT 1 SIGNATURE ON FILE SIGNATURE ON FILE SIGNATURE ON FILE SIGNATURE ON FILE R115-4725 497-91 R115-4725 DIST B C D E F G H I J K L M N O f 1) USE ON W900B/S/L T800/H/M T602A AND C500B/550B WITH DDC SERIES 60 DDEC II ENGINES WITH NON ATEC ALLISON TRANSMISSIONS W/ OR W/O TRANSMISSION RETARDER. GENERAL NOTES: B VJJ DRK 11-08-91 EWO 37136J EPR 37029E RAM DRK DISP = N-RI NDA = N 1) ELEC ENG WAS SHTDN 2) SEE SHT 2 3) SEE SHT 2 JW G8 PCR 971-90-07 C2 C THN NKW 12-13-91 EWO 37236S RAM NKW DISP = N-SR NDA = N 1) ADD "SEE DETAIL E..." 2) ADD "W/ OR W/O TRANS RETARDER" 3) SEE SH 2. JW A4 G2 PCR 971-90-11 D DDH DRK 10-30-92 DLD DRK DISP = R-EC NDA = N 1) SEE SHT 2 2) SEE SHT 2 3) SEE SHT 2 PCR 1471-92 JW DDEC II R115-4725 D 01

R115-4725.FM IGNITION BYPASS RELAY LOCATED NEAR AIR JUNCTION BLOCK IDLE STOP HARNESS PARK BRAKE SWITCH MOUNTED ON AIR JUNCTION BLOCK BRAKE SWITCH HARNESS P118SD RED/GRN GND WHT P118SD RED/GRN C118SD RED/GRN A B C 524 GRY/BLK GND WHT IDLE STOP RELAY LOCATED NEAR AIR JUNCTION BLOCK GND WHT 524 GRY/BLK C118SD RED/GRN 15A BRAKE SWITCH HARNESS IDLE STOP RELAY LOCATED NEAR AIR JUNCTION BLOCK IDLE STOP HARNESS GND WHT 524 GRY/BLK C118SD RED/GRN B A 524 GRY/BLK GND WHT ENGINE "IDLE STOP" OIL PRESSURE SWITCH MNTD ON AIR JUNCTION BLOCK DETAIL "A" SEE NOTE 7. ENGINE IDLE STOP C 85 86 87 87A 30 C 85 86 87 87A 30 C 85 86 87 87A 30 C 85 86 87 87A 30 C ENG RET ON/OFF SWITCH MOUNTED IN DASH SEE KEY SWITCH AND SPARE CIRCUIT BREAKER WIRING DIAGRAM ENGINE RETARD 10 A BATTERY BUSS BAR ENG RET RELAY LOCATED BEHIND LH GAUGE PANEL C97SW LT.BLU/GRN C96JH LT.GRN/YEL C98JF LT.GRN/BLK ENGINE RETARDER SOLENOID FORWARD CYLINDER HEAD ENGINE RETARDER SOLENOID CENTER CYLINDER HEAD ENG RET MODE SELECTOR SWITCH MOUNTED IN DASH ENGINE HEAD 508 C C ENGINE RETARDER SOLENOID REAR CYLINDER HEAD INSTR PANEL HARN ENGINE HARNESS C96JH LT.GRN/YEL E G H F DETAIL "B" SEE NOTE 5. GRN ORN SEE NOTE 4. ENGINE IDLE STOP WITH IGNITION BYPASS DETAIL "C" JACOBS BRAKE P21AL BLK P95ER BLK/LT GRN C 85 86 87 87A 30 ENG RET RELAY 1 IN PD BOX C 85 86 87 87A 30 ENG RET RELAY 2 IN PD BOX P95ER BLK/LT GRN POWER DISTR BOX INSTR PANEL HARN INSTR PANEL HARN DDEC HARN CAB SECT P95ER BLK/LT GRN C96JB LT.GRN/YEL C98JB LT.GRN/BLK INSTR PANEL HARN SWITCH PANEL HARN L95ER BLK/LT GRN L95ER BLK/LT GRN C95ER BLK/LT GRN L95ER BLK/LT GRN 16-LIGHT WARNING LAMP MODULE CAB GND CAB ROOF HARN CAB ROOF HARN CAB ROOF HARN INSTR PANEL HARN TO "ACC" FEED CB, SEE GAUGE & ACCESSORY DIAGRAM PCB1 BLK P21AL BLK PD BOX SPARE CB HARN PCB1 BLK IDLE STOP HARN SEE KEY SWITCH & SPARE CB DIAGRAM P52AF WHT/BLK 22 32 33 22 34 37 20 35 36 38 13 39 C97SW LT.BLU/GRN GND WHT C118SD RED/GRN D PARK BRAKE SWITCH MOUNTED ON AIR JUNCTION BLOCK C118SD RED/GRN D P118SD RED/GRN C PCB1 BLK C98JF LT.GRN/BLK C96JH LT.GRN/YEL C98JF LT.GRN/BLK C96JB LT.GRN/YEL C98JB LT.GRN/BLK C96JB LT.GRN/YEL C98JB LT.GRN/BLK C96JB LT.GRN/YEL C98JB LT.GRN/BLK A J K DETAIL "D" COOLANT LEVEL SENSOR WITH INTEGRAL CONNECTOR SEE NOTE 42. B2 B3 DETAIL "E" ALLISON TRANS WITH RETARDER ORN 20 JUMPER WIRE C118SD RED/GRN M L C118SD RED/GRN POWER FROM PARK BRAKE SWITCH POWER TO CRUISE CONTROL RELAY DDEC CAB HARN SHIFT MOD CNTRL HARN RED JUMPER TO ENGINE RETARD RELAY TORQUE CONVERTER LOCKUP SWITCH (OPTIONAL) LOCATED RH FRONT UNDER TRANSMISSION. C3 WHT JUMPER AIR PRESS SWITCH, N.C., MOUNTED IN AIR JUNCTION BLOCK, IN SAME AIR LINE AS RETARDER CONTROL. SWITCH WILL OPEN WHEN AIR IS APPLIED, CUTTING THE POWER TO THE CRUISE CONTROL. D3 D2 D2 D3 D1 D1 NONE J.M.GROVE N WONG N WONG 03-26-91 REI I9289 P 1 4 WILHOYTE MERTENS X X DIAGRAM DDEC II OF 2 SHT 2 SIGNATURE ON FILE SIGNATURE ON FILE SIGNATURE ON FILE SIGNATURE ON FILE R115-4725 497-91 R115-4725 DIST B C D E F G H I J K L M N O f GENERAL NOTES: 1) USE WITH W9B/S/L, T8/H/M, T602 AND C5/550B MODELS WITH DDC SERIES 60 DDEC II ENGINES WITH NON ATEC ALLISON TRANSMISSIONS. NOTE: THE PTO WITH CRUISE FEATURE MUST REMAIN PROGRAMMED "NO" FOR THIS COMBINATION 40) SUPERSEDES R115-4369 PROD SERV f 41) SUPERSEDES R115-4233 PROD SERV f 2) ALL SWITCHES SHOWN ON THIS DIAGRAM ARE SHOWN WITH THE KEY OFF WITH AIR SYSTEM AT ZERO PRESSURE. 3) GROUNDING CIRCUIT 451 WILL CAUSE THE DIAGNOSTIC CODES TO FLASH VIA THE CHECK ENGINE LIGHT. SEE DDEC II TROUBLE SHOOTING GUIDE FOR CODE DEFINITION. SEE NOTE 18. 7) SEE DETAIL "C" FOR USE WITH ENGINE RETARDER. CIRCUIT 508 GOES TO GROUND. WHEN THE THROTTLE PEDAL IS UP, WITH THE TORQUE CONVERTER LOCKED (LOCKUP SWITCH CLOSED, LOCKUP RELAY ENERGIZED), THE RETARDER RELAY CLOSES CONNECTING CIRCUITS C97CS AND C97SW. THE BLOCKING DIODE IN ZONE D5 ON PAGE 1 PREVENTS CIRCUIT 508 FROM BACKFEEDING THE CRUISE CONTROL AND IDLE STOP RELAYS WHEN DDEC IS FUELING THE ENGINE. 6) WITH THE ON/OFF SWITCH "ON", SERVICE BRAKE RELEASED (SWITCH CLOSED) AND TORQUE CONVERTER LOCKED (SWITCH CLOSED), THE CRUISE CONTROL RELAY CLOSES. THIS COMPLETES CIRCUIT 543 TO GROUND ENABLING CRUISE CONTROL. APPLYING SET OR RESUME WILL ACTIVATE CRUISE CONTROL (RESUME IF POWER HAS NOT BEEN INTERRUPTED SINCE LAST SET). APPLYING SERVICE BRAKE (OPEN SWITCH) OR TORQUE CONVERTER UNLOCKING (OPEN SWITCH) DE-ENERGIZES THE CRUISE CONTROL RELAY. THIS COMPLETES CIRCUIT 531 TO GROUND DISABLING CRUISE CONTROL. THE CLASSIFICATION OF THE CIRCUIT APPLIES TO ALL CHARACTERISTICS OF THAT CIRCUIT AS IT PERTAINS TO THIS HARNESS, INCLUDING BUT NOT LIMITED TO: WIRE GAUGE, CONNECTORS, POSITION IN CONNECTORS, TERMINALS. CLASSIFICATION OF CHARACTERISTICS THIS DRAWING/SPECIFICATION USES SYMBOLS TO CLASSIFY CHARACTERISTICS. THESE SYMBOLS ARE DEFINED IN QMS002 "CLASSIFICATION OF CHARACTERISTICS". 4) SEE DETAIL "A" FOR USE WITH ENGINE IDLE STOP. SETTING THE PARK BRAKE OPENS THE PARK BRAKE SWITCH. THIS DE-ENERGIZES THE IDLE STOP RELAY COMPLETING CIRCUIT 524 TO GROUND INITIATING THE IDLE STOP TIMER. 5) SEE DETAIL "B" FOR USE WITH ENGINE IDLE STOP WITH IGNITION BYPASS. SETTING THE PARK BRAKE OPENS THE PARK BRAKE SWITCH. THIS DE- ENERGIZES THE RELAYS COMPLETING CIRCUIT 524 TO GROUND AND CIRCUIT P118SD TO PCB1. WHEN CIRCUIT 524 SENSES GROUND THE IDLE STOP TIMER IS INITIATED. CIRCUIT PCB1 BACKFEEDS P118SD PROVIDING POWER TO THE DDEC MODULE BYPASSING THE IGNITION SWITCH. THIS ALLOWS THE OPERATOR TO TURN THE IGNITION OFF AND REMOVE THE KEY FROM THE SWITCH. WHEN THE IDLE TIMER SHUTS THE ENGINE DOWN THE OIL PRESSURE SWITCH OPENS CUTTING POWER TO THE DDEC MODULE. 9) 10) DESIGNATES POINT OF REFERENCE ON DIAGRAM OR DETAIL. 8) NON ELECTRONIC AUTO TRANSMISSIONS UTILIZE THE SHIFT MODULATOR CONTROL RELAY AND SOLENOID VALVE. CIRCUIT 908 GOES TO GROUND WHEN THE THROTTLE POSITION IS GREATER THAN 80% AND IS OPEN WHEN THE THROTTLE POSITION IS LESS THAN 65%. THE RELAY OPENS AND CLOSES CORRESPONDINGLY ENERGIZING AND DE-ENERGIZING THE SHIFT MODULATOR CONTROL VALVE. 11 MOLDED (GREEN) 8 WAY CONNECTOR LOCATED AT PD BOX. 12 MOLDED (BLACK) 16 WAY CONNECTOR LOCATED AT PD BOX. SEE R115-4012 FOR PIN CONFIGURATION. 13 MOLEX 12 WAY CONNECTOR LOCATED ON WARNING LAMP MODULE. 14 MOLDED (BLACK) 6 WAY CONNECTOR LOCATED IN ENGINE COMPARTMENT NEAR PD BOX. 15 PACKARD 2 WAY WEATHER PACK LOCATED AT REAR OF TRANSMISSION. 16 PACKARD 4 WAY WEATHER PACK LOCATED IN ENGINE COMPARTMENT ABOVE STEERING COLUMN. 17 PACKARD 3 WAY METRI PACK LOCATED BEHIND DASH AT STEERING COLUMN. 18 PACKARD 2 WAY 56 SERIES CONNECTOR LOCATED ABOVE LEFT HAND UNDER DASH PANEL. 19 PACKARD 12 WAY METRI PACK CONNECTOR LOCATED AT FRONT EDGE OF LEFT HAND DOOR. 20 6.35 (1/4") SLIDE TERMINALS LOCATED ABOVE CLUTCH. 21 PACKARD 2 WAY WEATHER PACK LOCATED BEHIND DASH AT PD BOX. FOR ELECTRONIC DASH DATA BUS ONLY. 22 PACKARD 2 WAY METRI PACK LOCATED BEHIND THE DASH NEAR THE AIR JUNCTION BLOCK. 23 PACKARD 4 WAY METRI PACK LOCATED BEHIND DASH NEAR THE AIR JUNCTION BLOCK. 24 PACKARD 2 WAY METRI PACK CONNECTOR LOCATED BEHIND DASH AT PD BOX. 25 PACKARD 3 WAY WEATHER PACK CONNECTOR LOCATED ABOVE FOOT THROTTLE. 26 DEUTSCH 14 WAY CONNECTOR MOUNTED IN FIREWALL. 27 PACKARD 3 WAY WEATHER PACK LOCATED TOP FRONT OF ENGINE. 28 PACKARD 6 WAY METRI PACK LOCATED BEHIND DASH AT STEERING COLUMN. 29 LOCATED IN BATTERY BOX. 30 PACKARD 6 WAY METRI PACK LOCATED IN DDEC MODULE. 31 PACKARD 30 WAY METRI PACK LOCATED IN DDEC MODULE. 32 MOLDED (RED) 8 WAY CONNECTOR LOCATED AT PD BOX. 33 MOLDED BULLET CONNECTOR LOCATED BEHIND DASH NEAR PD BOX. 34 MOLDED (BLUE) 8 WAY CONNECTOR LOCATED AT PD BOX. 35 MOLDED (BLACK) 16 WAY CONNECTOR LOCATED BY HEATER BOX IN THE FIREWALL. SEE R115-4015 FOR PIN CONFIGURATION. 36 PACKARD 2 WAY WEATHER PACK LOCATED AT REAR OF ENGINE HEAD. 37 MOLDED (RED) 8 WAY CONNECTOR LOCATED BEHIND SWITCH PANEL. 38 MOLDED (BLACK) 8 WAY CONNECTOR LOCATED BEHIND DASH AT PD BOX. 39 MOLEX 8 WAY CONNECTOR LOCATED ON WARNING LAMP MODULE. OF ENGINE AND TRANSMISSION TO PREVENT POSSIBLE DAMAGE TO TRANSMISSION. 42) SEE DETAIL "D" FOR COOLANT LEVEL SENSOR WITH INTGRAL CONNECTOR. C THN NKW 12-13-91 EWO 37236S RAM NKW DISP = N-SR NDA = N 1) SEE SH 1 2) SEE SH 1 3) ADD DETAIL "E" JW E5 PCR 971-90-11 B VJJ DRK 11-08-91 EWO 37136J EPR 37029E RAM DRK DISP = N-RI NDA = N 1) SEE SHT 1 2) ADD DETAIL D 3) ADD NOTE 42 JW D3 B3 PCR 971-90-07 D DDH DRK 10-30-92 DLD DRK DISP = R-EC NDA = N 1) WAS: P95ER (2 PLACES) 2) WAS: C98JB LT GRN/BLK (2 PLACES) 3) WAS: C96JB LT GRN/YEL (2 PLACES) PCR 1471-92 JW B6,B7 C6,C7 B6,B7 DDEC II R115-4725 D 02