Kenworth SmartWheel KM816010 User manual

(01/02) KM816010
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
0Kenwor th SmartW heel Troubleshoot-
ing Guide KM816010 01/02
16
CONTENTS
TITLE PAGE
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Service Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TIBs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
How to use this Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Tools for Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
A. Start - No Functions Work or Operation is Intermittent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
A1. Possible cause: Open circuit in BA11 or Gnd circuit to elect. module (circuits PCB 1, 2, 3, or 4 and G N D). . .5
A2. Possible cause: Bad electrical connection to hub or slip rings.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
A2. Possible cause: Bad electrical connection to hub or slip rings.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
A3. Possible cause: Bad electronics module or steering wheel hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
B. Horn Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
B1. Possible cause: No power or ground in horn circuit.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
B2. Possible cause: Bad horn relay in power distribution box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
B3. Possible cause: Problem in circuit R11HN.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
B4. Possible cause: Bad electronics module or steering wheel hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
C. Engine Retarder Does Not Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
C1. Symptom: Engine retarder will not turn on (1994 Cummins only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
C2. Symptom: Engine retarder will not turn on (all engines). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
C3. Symptom: Retarder works only when button held down or does not turn on.. . . . . . . . . . . . . . . . . . . . . . . . . .21
D. Cruise Control Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
D1. Symptom: Cruise Control will not turn on.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
D2. Symptom: Cruise SET will not work.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
D3. Symptom: Cruise RESUME will not work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
E. Headlight Flash Does Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
E1. Symptom: Headlights do not turn on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
E1. Symptom: Headlights do not turn on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
E2. Symptom: Headlights do not flash on with SmartWheel switch.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
E3. Symptom: Headlights do not blink off with SmartWheel switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
F. Marker Lamp Flash Does Not Work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
F1. Symptom: Marker lights do not turn on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
F1. Symptom: Marker lights will not turn on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
F2. Symptom: Marker lights do not flash on with SmartWheel switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
F3. Symptom: Marker lights do not blink off with Smart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide
(01/02) KM816010 Page 1 of 44
16
16Kenworth SmartWheel Troubleshooting
Guide KM816010 01/02
16
Related Documents
Service Manuals
Kenworth SmartWheel Troubleshooting Guide,
KM816010.
TIBs
15-16A T2000 Multiplex Steering Wheel Operation
15-17 SmartWheel / Multiplex Steering Wheel Controls
Wiring Diagrams
SmartWheel Multiplex Switch Module K301-415 01
Headlamps w/Multiplex (SmartWheel) Steering Wheel
P94-1191 - 01
Horn Multiplex Steering Wheel R115-5453 01
Headlamps w/ Multiplex R115-5450 01
Headlamps w/ MUX Wheel P94-1335 01
Clearance & ID Lamps w/ Multiplex (SmartWheel)
P94-1197 - 01
Clearance & ID Lamps, T800A Cabs w/Multiplex Steering
Wheel R115-5452 01
Clearance & ID Lamps, BII Cabs w/Multiplex Steering
Wheel R115-5451 01
Headlamps, w/ MUX Wheel P94-1380 01
Multiplex W/94 CAT R115-5456 A 01
Cummins Plus, MUX, Smartwheel R115-6017 01
T2000 DDEC III Engine Wiring P94-1009 A 01
DDEC III W/Multiplex R115-5457 A 01

Page 2 of 44 KM816010 (01/02)
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
Wiring
Figure 16-1

(01/02) KM816010 Page 3 of 44
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
Purpose
The purpose of this guide is to locate malfunctions in the
• wiring
• connectors
• power distribution box relays
• steering wheel hub
• multiplex electronics module
• slip rings
If the wiring, connectors, and relays are functioning prop-
erly, it is reasonable to assume that the malfunction is in
the multiplex wheel system (hub, module, or slip rings).
IMPORTANT: Verify a malfunction in the SmartWheel
steering wheel hub or the multiplex electronics module
before replacing them. The only way to check these
components is with the Kenworth SmartWheel Multi-
plex Steering Wheel Tester. Replacing these compo-
nents will not correct the malfunction if the problem is due
to open wires, poor connections, or bad relays.
CAUTION: Do not attempt to disassemble the elec-
tronics module or the steering wheel hub. Disassem-
bly will void warranty.
How to use this Troubleshooting
Guide
Check the multiplex wheel for proper operation according
to the Kenworth Multiplex Steering Wheel Operating
Manual.
If none of the functions on the steering wheel work or
they work erratically, go to Section A, Start.
If some of the functions on the steering wheel work, go to
the Section for the function that doesn't work.
Tools for Troubleshooting
• Kenworth SmartWheel Multiplex Steering Wheel Tes-
ter (strongly recommended). - Volt-ohmmeter rated
at 20,000 ohms per volt. For proper connections, see
Figure 16-2.
• Wiring diagrams. See Appendix of this manual.
• Operating Manual for Kenworth SmartWheel Multi-
plex Control System.
NOTE: Excellent basic troubleshooting procedures are
described in the Kenworth Electrical Troubleshooting
Manual. This manual is useful if you are unfamiliar with
how to use an ohmmeter or need suggestions for electri-
cal troubleshooting techniques.
CAUTION: Before connecting an ohmmeter to a cir-
cuit, disconnect the power source. Then verify that
the circuit is without voltage by connecting a voltme-
ter to the circuit. Ohmmeter may be damaged if con-
nected to a voltage source.
Figure 16-2

Page 4 of 44 KM816010 (01/02)
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
Figure 16-3

(01/02) KM816010 Page 5 of 44
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
Troubleshooting Charts
A. Start - No Functions Work or Operation is Intermittent
A1. Possible cause: Open circuit in BA11 or Gnd circuit to elect. module (circuits PCB 1, 2, 3,
or 4 and G N D).
Check Result What To Do Next
A1-1
Unplug the 6-way connector from
the multiplex electronics module.
Check voltage between pin 6 and
pin 3.
Voltmeter reads battery voltage.
No voltage.
Go to A1-2.
Go to A1-3.
A1-2
Check connector pins to make sure
they are not corroded, bent, or
unseated.
Connector pins OK.
Connector pins bad.
Go to A1-4.
Repair or replace connector/ pins. If
problem is corrosion, eliminate
source of moisture.
A1-3
Check circuit breaker or fuse in
power distribution box position
Spare 1,2,3, or 4.
Circuit breaker good. There is a broken wire or connector
in the harness or in the power distri-
bution box. Look at the multiplex
steering wheel headlamp wiring dia-
gram and trouble-shoot circuit PCB
1,2,3, or 4 and GND.
Circuit breaker bad. Replace circuit breaker.
A1-4
Visually check the 2-way connector
just behind the steering column in
the dash (twisted pair circuit from
steering wheel).
Connector OK.
Connector unplugged, broken, cor-
roded.
Go to A2.
Repair/Replace connector. If prob-
lem is corrosion, eliminate source of
moisture.

Page 6 of 44 KM816010 (01/02)
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
Figure 16-4

(01/02) KM816010 Page 7 of 44
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
A. Start - No Functions Work Or Operation is Intermittent
A2. Possible cause: Bad electrical connection to hub or slip rings.
Check Result What To Do Next
A2-1
Remove 4 screws holding hub to
steering wheel and check wire con-
nections to hub.
Wires/connections OK.
Wires or connectors disconnected,
broken, corroded.
Go to A2-2.
Repair/replace terminals or wires.
Be careful to observe polarity on
wires.
A2-2
Check continuity of ckts IPX SIG and
IPX GND through brushes and slip
rings (yellow and brown wires). Mea-
sure from hub to 2 way metri-pack
connector at base of steering col-
umn and from 2 way connector to 6
way connector (pins 1 and 2) at mul-
tiplex module. Also check polarity of
circuits. If reversed, no functions will
work and module may be damaged.
Each circuit has continuity.
No continuity in one or both circuits.
Continuity is intermittent in one or
both circuits as steering wheel is
turned.
Go to A3-1.
Go to A2-3.
Go to A2-4.
A2-3
Extend steering column to full tele-
scoped position. Remove side cov-
ers from steering column and
inspect slip rings, brushes & contact
springs. Turn steering wheel while
observing brush and slip ring opera-
tion.
Brushes not contacting slip rings. Adjust, repair or replace affected
parts
Wires not making good connection
to brushes. Replace brushes.
Inner and/or outer springs not mak-
ing contact to slip rings or to con-
tacts under gap hider cover.
Adjust, repair or replace affected
parts.

Page 8 of 44 KM816010 (01/02)
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
Figure 16-5

(01/02) KM816010 Page 9 of 44
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
A. Start - No Functions Work Or Operation is Intermittent
A2. Possible cause: Bad electrical connection to hub or slip rings.
A3. Possible cause: Bad electronics module or steering wheel hub.
Check Result What To Do Next
A2-4
Check condition of lubrication on
contact surfaces of dual brass slip
ring.
No grease exists.
Grease very thin (brass is dry in
places).
Apply contact ring grease (available
from DSM) according to prescribed
method. Use only this type of
grease.
Check Result What To Do Next
A3-1
Connect the multiplex steering
wheel tester to the module and the
truck harness. Follow the steps in
the tester manual for testing the
“Truck Module”.
Module tests OK.
Module fails test.
Go to A3-2.
Replace module.
A3-2
Follow the steps in the tester manual
for testing the “Truck Hub”.
Hub fails test. Check all wiring and connections
between module and steering wheel
hub (ckts IPX SIG and IPX GND). If
no problems are found, replace
steering wheel hub.

Page 10 of 44 KM816010 (01/02)
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
Figure 16-6

(01/02) KM816010 Page 11 of 44
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
B. Horn Does Not Work
NOTE: Use this section only if horn does not work. If none of the SmartWheel functions work, go to Section A.
B1. Possible cause: No power or ground in horn circuit.
B2. Possible cause: Bad horn relay in power distribution box.
Check Result What To Do Next
B1 -1
Horn circuit breaker or fuse in cab
power distribution box.
Circuit breaker or fuse OK.
No continuity.
Go to B1-2.
Determine cause for fuse to blow
(shorted wire, etc.). Replace circuit
breaker or fuse. If horn still does not
work, go to B1-2.
B1 -2
Horn wiring/ connections leading to
horn (ckt C53HN). Use multiplex
steering wheel horn wiring diagram
R115-5453.
Wires OK, connectors clean and
tight. Go to B2.
Wires broken, frayed, or connectors
loose, damaged, corroded. Repair or replace wires and/or con- nectors.
Check Result What To Do Next
B2-1
Press horn button on steering wheel.
Listen for relay click in power distri-
bution box.
Click heard. Remove horn relay. Use jumper wire
from terminal marked + to terminal
directly across from it. Horn should
come on. If horn works, replace
relay. If horn does not work, it may
be defective or problem exists in
truck wiring. Troubleshoot ckt
C53HN.
No click heard. Go to B3.

Page 12 of 44 KM816010 (01/02)
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
Figure 16-7

(01/02) KM816010 Page 13 of 44
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
B. Horn Does Not Work
B3. Possible cause: Problem in circuit R11HN.
B4. Possible cause: Bad electronics module or steering wheel hub.
Check Result What To Do Next
B3-1
Unplug the 8 way connector from the
multiplex module. Check continuity
of ckt R11 HN from pin 1 of the con-
nector to terminal marked S at horn
relay position in power distribution
box.
Ckt has continuity.
No continuity.
Go to B4.
There is a break in the circuit
between the module and the power
distribution box. Trace ckt R11 HN.
Check Result What To Do Next
B4-1
Plug 8 way connector back into mod-
ule. Locate one way slide terminal in
ckt R11 HN and disconnect.
Check for continuity between R11
HN leading to module and ground
when horn button is pressed.
Continuity to gnd when button
pressed.
No continuity.
Problem is in truck wiring. Recheck
circuits R11 HN and C53HN.
Go to A3.

Page 14 of 44 KM816010 (01/02)
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
Figure 16-8

(01/02) KM816010 Page 15 of 44
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
C. Engine Retarder Does Not Work
C1. Symptom: Engine retarder will not turn on (1994 Cummins only).
C1-1. Possible cause: No power or ground to retarder circuit.
C1-2. Possible cause: Problem in retarder circuits C96JH or C98JF.
Check Result What To Do Next
C1-1A
Engine retarder (ENG RTD) circuit
breaker or fuse in cab power distri-
bution box.
Circuit breaker or fuse OK.
No continuity.
Go to C1-1B.
Determine cause for fuse to blow
(shorted wire, etc.).
Replace circuit breaker or fuse. If
retarder still does not work, go to
C1-1B.
C1-1B
Continuity in ground circuit for
retarder relays (ckt C97CS) from
relay coil to cab ground.
Connector OK, continuity to cab
ground. Go to C1-2.
Connection loose, broken, corroded. Repair or replace connector(s),
tighten ground stud.
Check Result What To Do Next
C1-2A
Retarder wiring/ connections
leading to engine brake solenoids
(ckts C96JH and C98JF). Use multi-
plex steering wheel Select engine
wiring diagram.
Wires OK, connectors clean and
tight. Go to C1-3.
Wires broken, frayed, or connectors
loose, damaged, corroded. Repair or replace wires and/or con- nectors.

Page 16 of 44 KM816010 (01/02)
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
Figure 16-9

(01/02) KM816010 Page 17 of 44
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
C. Engine Retarder Does Not Work
C1-3. Possible cause: Bad retarder relay(s) in power distribution box.
C1-4. Possible cause: Problem in circuits C96JB or C98JB.
Check Result What To Do Next
C 1-3A
Turn on ignition. Press the retarder
buttons on steering wheel.
Listen for relay clicks in power distri-
bution box.
Click heard. Determine which relay was clicking.
Remove this relay.
Use jumper wire from terminal
marked + to terminal directly across
from it (common to normally open).
This retarder setting should now
work. If it does, replace relay.
Repeat for other relay if it also
clicked.
If retarder settings do not work with
jumper in place, Go to C1-4.
No click heard. Go to C1-4.
Check Result What To Do Next
C1-4A
Unplug the 14 way connector from
the multiplex module.
Check continuity of ckts C98JB and
C96JB from pins 9 and 11 of the
connector to top terminal (coil-power
side) of each retarder relay position
in power distribution box.
Ckt has continuity. Go to C2.
No continuity. There is a break in the circuit
between the module and the power
distribution box. Trace each circuit,
checking connectors and wiring.

Page 18 of 44 KM816010 (01/02)
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
Figure 16-10

(01/02) KM816010 Page 19 of 44
MAINTENANCE MANUAL
Kenworth SmartWheel Troubleshooting Guide 16
C. Engine Retarder Does Not Work
NOTE: Use this section only if retarder does not work. If none of the SmartWheel functions work, go to Section A.
C2. Symptom: Engine retarder will not turn on (all engines).
C2-1. Possible cause: No accessory power to electronics module.
C2-2. Possible cause: Problem in retarder wiring.
o
Check Result What To Do Next
C2-1A
Unplug 14-way connector from elec-
tronics module. Turn on ignition.
Check voltage between connector
pin 12 and a cab ground.
Voltmeter reads battery voltage.
No voltage. Go to C2-1 B.
Go to C2-2.
Go to C2-1B.
C2-1B
Check circuit breaker or fuse in
power distribution box position
Spare 19, 20, or 21.
Circuit breaker/fuse OK. An open circuit exists between the
power dist box & the electronics
module. Trace circuits PCB 19, 20,
21.
Circuit breaker bad/fuse Replace circuit breaker or blown.
fuse. Determine cause for fuse to
blow.
Check Result What To Do Next
2-2A
Check retarder circuits between
electronics module 14-way connec-
tor pins 9,11, 14 and engine ECM.
DDEC: 953, 979, 583. CAT: C993,
E716, E717. Cummins: 588, C96JH,
C98JF.
Wiring, connectors OK all circults
have continuity. Go to C3-2.
Wire broken, connector unplugged,
loose or corroded. Repair or replace wires and/or con- nectors.