15 15qElectrical KM815055 03/11/03

Department Customer Service

Category Service Manual
Section Electrical
Power Distribution Box (for chassis
Title
built after 12/03/01)

Service Number

Date
KM815055
03/11/03

Manual
W900, T800, T600, C500 (excluding
Model
T800 City Cab and T800 Work Cab)
Page 1 of 20

Power Distribution Box

(for W900, T600, T800 C500 chassis built after 12/03/01)
 Page 2 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Component Location

Figure 15-1
 Page 3 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Table of Contents

Component Location on page 2

Manufacturing Start Dates on page 4

Diagrams on page 5
Wiring on page 5

Routing on page 5

System Description on page 6

Central Electrical Panel (CEP) Fuse Layout on
page 6

CEP Circuit Identification on page 8

PD Box Connectors - Pinout Locations on page 9

Spare Circuits on page 10

Adding Spare Circuits on page 10

Option # 1: PD Box Spare PWR/GND Sockets on

page 10

Option # 2: Spare Circuit Bullet Connectors on

page 12

Option # 3: Spare Circuit Relays (For loads exceed-

ing 20 amps) on page 12

Servicing on page 15
Tips for Easier PD Box Servicing on page 15

Power Distribution Box Removal on page 16

Fuse/Relay Module Replacement on page 18

 Page 4 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Manufacturing Start Dates

This information applies to W900, T600, T800 and C500
(excluding T800 City Cab & T800 Work Cab) chassis built
from:
12/03/01 - Renton
12/10/01 - Chillicothe
1/14/02 - KenMex
 Page 5 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Diagrams Park and Tail Lamps P94-1384 A 01

Charge and Start P94-1385 A 01

NOTE: The following diagrams are provided as
an introduction to this product. Future diagrams
Ether Start P94-1390 A 01
will be added to ServiceNet but will not be added
to this list. The procedure to determine the
Cummins Engine Fan Interlock Instructions P95-1576 01
proper diagram for a chassis is to start with the
diagrams link in ECAT (Refer to Cat/DDEC Engine Fan Interlock Instructions P95-1577
Web ECAT - Diagrams). 01
Wiring Windshield Wipe & Wash P94-1331 - 01
Instrument Panel Harness, Cat and Cummins Engines Cab HVAC P94-1391 - 01
P92-2040 - 01
Accessory Power, 38-in Sleeper P94-1392 - 01
Instrument Panel Harness, DDEC Engines P92-2041 -
01 Accessory Power, 62-in/72-in Sleeper P94-1393 - 01

Trailer ABS P94-1311 01 Accessory Power, 86-in Sleeper P94-1394 - 01

Fog Lamps P94-1338 A 01 Power Windows P94-1396 A 01

Trailer ABS P94-1349 01 Stop and Turn Lamps P94-1399 - 01

Trailer ABS P94-1353 01 Radio or CB Radio P94-1400 A 01

Trailer ABS P94-1355 01 Clearance and ID Lamps P94-1413 A 01

Trailer ABS P94-1356 01 Interior Lighting P94-1414 A 01

Trailer ABS P94-1357 01 Routing

Trailer ABS P94-1358 01 Instrument Panel Harness R414-1260 A 01

Trailer ABS P94-1359 01 Chassis Harness - Cab Section & PD Box Power
R414-1261 A 01
Trailer ABS P94-1360 01
Trailer Harness Options R414-1262 A 01
Trailer ABS P94-1361 01
Headlight Harness, T800H R414-1274 01
Trailer ABS P94-1362 01
Firewall - Wire & Cable Entry Locations R414-1275 01
Headlamps P94-1379 01
Headlamp Harness, T6 w/SMC Hood R414-1265 A 01
Headlamps, w/ MUX Wheel P94-1380 01
Headlamp Harness Routing R414-1266 - 01
Headlamps, w/DRL P94-1381 01
Air Dryer Harness, RH Front Mounted R414-1278 - 01
Headlamps, w/MUX & DRL P94-1382 01
 Page 6 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

System Description
The new Power Distribution Box includes the box hous-
ing, instrument panel harness and 20 separate fuse and
relay modules locked together to form the Central Electri-
cal Panel (CEP). The system was designed to improve
overall system reliability, simplify power distribution wiring
and connections, and make servicing easier. The CEP is
the heart of the vehicle electrical system, providing 72
circuits (twice as many as the previous PD box design) to
meet todays electrical system demands and those of the
future.

Central Electrical Panel (CEP) Fuse Layout

All circuits are protected with fuses and/or circuit break-
ers and relays are used to carry most high amperage cur-
rent loads. A 135 amp circuit breaker in the battery box
provides circuit protection for the CEP. Each electrical cir-
cuit is color coded and identified with a circuit number.
Wiring and routing diagrams applicable to the new PD
box design are available in ServiceNet. See Manufactur-
ing Start Dates on page 4 and Routing on page 5.

WARNING! Several circuits in the Central Elec-

trical Panel are designated as "Fuse Only" cir-
cuits. Do not install a circuit breaker in place
of a fuse for the following circuits:
RADIO M
RADIO P
CB PWR
SLPR ACC
FOG LPS
and whenever a spare circuit is used to supply power
for an additional cigar lighter and/or ACC power well.
 Page 7 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

View Rotated 90 From Actual Installation

Bottom Top
(near floor) (near dash)

CAT Only

DDEC Only

Figure 15-2 CEP Fuse Cover Decal

 Page 8 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

CEP Circuit Identification

Driver Passenger
Side Side

Figure 15-3 CEP Circuit Identification

 Page 9 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

PD Box Connectors - Pinout Locations

PD Box Deutsch Connectors

(mates with chassis harness)
Wire Number Circuit Term Function
WREO425 L7HBR 1 High Beam Lamp Right
WREO517 P79BL 2 Backup Lamps
WREO204 C2AX 3 Stop Lamps
WREO580 L7HBL 4 High Beam Lamp Left
WREO316 L6LBL 5 Low Beam Lamp Left
WREO315 L6LBR 6 Low Beam Lamp Right
WREO496 L9FG 7 LH Fog Lamp
WREO537 L33LT 8 Left Front Directional Turn Signal & Trailer
WREO538 L34RT 9 Right Front Directional Turn Signal & Trailer
WREO161 L35LT 10 Left Turn
WREO162 L36RT 11 Right Turn
WREO510 L1PL 12 Tail & Park Lamps
Chassis and Trailer Harness
WREO446 L3ML 13 Marker Lamps
Connectors Located Behind
WREO503 L14FL 14 Flood Lamp Windshield Washer Reservoir
WREO518 P118SK 15 Engine Shutdown
WREO641 C102FC 16 Air Conditioner Clutch Control
WREO521 H90AT 17 Air Tank
WREO427 G278U 18 Aux Trans Oil Temp
WREO117 C20WW 19 Windshield Washer Motor
WREO426 G28SU 20 FF or Single Rear Axle Temp
WREO489 C53HN 21 Horn Relay To Horn
WREO190 C71HI 22 Windshield Wiper High
WREO429 G29SU 23 RR Axle Temp
WREO430 G72SU 24 Fuel Gauge Sender
WREO191 C71LW 25 Windshield Wiper Low
WREO397 P20WW 26 Windshield Washer Motor
WREO192 C71WM 27 Windshield Wiper Motor
WREO 28 Plug
WREO 29 Plug
P20-1134-29-5-0 (chas)

PD Box Deutsch Connectors

(mates with trailer harness)
Wire Number Circuit Term Function
WREO447 P181TR R Aux Battery see note 10
WREO452 L2TR S Stop Lamp Trailer
WREO539 P4TR T Hot Wire For Aux Devices On Trailer
WREO454 P154TR U Trailer ABS Power
WREO509 L1PL V Park Lamp P20-1134-29-5-0 (ABS01)
WREO536 L34RT W Right Front Directional Signal Lamp
WREO540 L155TR X ABS Trailer Warn Lamp
WREO535 L33LT Y Left Front Directional Signal Lamp
WREO559 L3TR Z Marker Lamps Trailer

Figure 15-4
 Page 10 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Spare Circuits Option # 1: PD Box Spare PWR/GND

Sockets
The CEP has a total of 26 spare circuits (3 of which can
1. Remove 3 fasteners securing the courtesy lamp
be connected to spare relays on the CEP).
mounting plate under the dash.
They include: 2. Allow plate to hang loose. See Figure 15-5.
11 spare battery circuits
10 spare accessory circuits
5 spare ignition circuits

Adding Spare Circuits

The CEP has 3 different options available for tapping into
spare BATT, ACC or IGN power.

Courtesy Lamp Mounting Plate

Figure 15-5
3. From under the dash, install a P92-1969-1 power
jumper wire into one of the top row of 6 spare BATT,
ACC, or IGN sockets not currently being used. See
Figure 15-6.

Installing P92-1969-1 Power Jumper Wire

Figure 15-6
 Page 11 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Option # 1: PD Box Spare PWR/GND

Sockets (continued)
1. Connect the other end of the jumper wire positive (+)
and negative (-) leads to the accessory. If the acces-
sory is to be controlled by a dash switch, connect the
negative (-) lead to a spare dash switch, then to the
accessory.
2. Install the correct rated fuse, or circuit breaker, into
the fuse socket directly below the jumper harness
installed in step 3.
 Page 12 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Option # 2: Spare Circuit Bullet Connectors Option # 3: Spare Circuit Relays (For loads
1. Remove the LH gauge panel above ignition key exceeding 20 amps)
switch. 1. Remove the LH gauge panel above ignition key
2. From behind the gauge panel, locate one of the 20 switch.
spare BATT, ACC, or IGN bullet connectors not cur- 2. From behind the gauge panel, locate one of the 3
rently being used. See Figure 15-7. spare relay connectors not currently used. See Fig-
ure 15-9.

Spare Bullet Connectors

Figure 15-7
3. Plug one end of a K333-127-2 pigtail harness into the Spare Relay Connectors
appropriate spare circuit bullet connector. See Figure
15-8. Figure 15-9
3. Plug one end of a spare relay harness (PN
P92-1947-X) into the appropriate spare relay circuit
K333-127-2 connector. See Figure 15-10 on page 13.

NOTE: Use a P92-1947-1 or -3 harness for a

Normally Open (NO) spare relay circuit. Use
a P92-1947-2 or -4 harness for a Normally
Closed (NC) spare relay circuit.
Figure 15-8
4. Connect the other end of the pigtail harness to the
accessory. If the accessory is to be controlled by a
dash switch, connect a ground wire to the switch,
then to the accessory.
5. Install the correct rated fuse, or circuit breaker, into
the fuse socket that corresponds to the spare circuit
selected in step 2.
 Page 13 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Option # 3: Spare Circuit Relays (For loads

exceeding 20 amps) (continued)

Common (Power) Common (Power)

R105CM R105CM

R103NC
Normally Open Normally
R104NO Closed

P92-1947-1 P92-1947-2 R107RY

Switch Switch
R107RY

Normally Open Normally Closed

R104NO R103NC

Common Common
(Power) (Power)
R105CM R105CM

P92-1947-3 P92-1947-4
Switch Switch
R107RY R107RY

Figure 15-10
 Page 14 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Option # 3: Spare Circuit Relays (For loads

exceeding 20 amps) (continued)
4. Connect the spare relay harness end labeled NOR-
MALLY OPEN or NORMALLY CLOSED to the acces-
sory.

5. Connect the spare relay harness end labeled

SWITCH (a ground wire) to a spare dash switch.
Ensure the switch is properly grounded. Next, ground
the accessory to a known good ground source (i.e.
cab, engine, frame).

6. To provide power to the relay, connect a power

source to the spare relay harness end labeled COM-
MON. To accomplish this, follow the procedure
below:
a. Locate one of the spare IGN, ACC, or BATT bul-
let connectors located behind the LH gauge
panel. See Figure 15-7 on page 12.

b. Using a K333-127-2 jumper harness, plug one

end of the jumper harness into one of the spare
bullet connectors. Connect the other end of
the jumper harness to the spare relay jumper
harness end labeled COMMON.

c. Install the correct amperage fuse in the appropri-

ate spare fuse socket. Install a K301-179 or
VF4-15F11-S01 relay into the socket that corre-
sponds to the spare relay circuit selected in step
2.
 Page 15 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Servicing Tips for Easier PD Box Servicing

Power Distribution Box And Fuse/Relay Replace damaged P20-1000-040 yellow module
locking wedges before reassembly.
Module Removal
Double-check each terminal wire removed during dis-
The new P D Box includes: assembly to assure it is re-installed and locked in the
correct pin-out location on the new module.
housing
Inspect for possible loose terminals on the backside
instrument panel harness
of other modules.
20 separate fuse and relay modules
Check the power feed cable and stud inside the PD
box housing to assure it is properly tight (10 to12
The modules lock together to form the Central Electrical
ft/lb.) and free of corrosion.
Panel. Each fuse and relay module can be replaced sep-
arately by releasing the locking wedges that fasten each During CEP reinstallation, make sure none of the
module together. harness wires are pinched behind or around the
sides of the PD box housing. Secure the harness
wires with plastic ties to minimize potential pinching.
Assure that the threaded thumbscrew inserts remain
attached to the housing during disassembly.
Before reinstalling the upper PD box cover, position
the pinchweld strip to prevent the harness from chaf-
ing on the cover edges.
Replace the reusable housing gasket only if it is
damaged.
Torque values:
PD box housing firewall fasteners = 5 to 7 ft/lbs.
Battery power feed cable outside the PD box
housing = 8 to 13 ft/lbs.
Battery power feed cable inside the PD box
housing = 10 to 12 ft/lbs.
The CEP can be disassembled from inside the cab,
but workspace is limited. For this reason, Kenworth
Figure 15-11 recommends removing the PD box housing from the
engine side of the firewall to service the CEP as
described in the next section.
 Page 16 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Power Distribution Box Removal

1. Disconnect the batteries.
2. If applicable, remove any air intake piping blocking
access to the PD box on the engine side of the fire-
wall.
3. Remove the windshield washer reservoir attached to
the PD box. See Figure 15-12.

Windshield Washer Reservoir

Chassis Battery Power
Trailer Harness1 Feed Cable
Harness

PD box shown with windshield washer reservoir removed.

Figure 15-12
4. Remove the battery power feed cable at the PD box.
See Figure 15-12.
5. Remove the chassis and trailer harness Deutsch
connectors at the bottom of the PD box. See Figure
15-12.
 Page 17 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Power Distribution Box Removal (continued) 10. Using a pair of needle-nosed pliers, compress the
two lower lock fingers that secure the CEP inside the
6. Remove 12 fasteners securing the PD box housing to box housing. See Figure 15-15. At the same time,
the firewall. See Figure 15-13. pull the bottom of the CEP out slightly to ensure the
lock fingers stay released.

Compress Lower CEP Lock Fingers

Figure 15-15
11. Apply slight downward pressure to the CEP while
continuing to angle the bottom of the CEP out and
down. This will disengage the upper lock fingers from
the housing and allow the CEP to be removed.
Figure 15-13 12. Move the housing to the side so that access to the
7. Unseat the PD box housing from the firewall and CEP is unobstructed. See Figure 15-16.
allow the box to hang free.
8. Rotate the PD box housing enough to remove the
lower PD box cover. The cover is held with a thumb-
screw at the bottom and a flange at the top. See Fig-
PD Box
ure 15-14.
Housing CEP
Thumbscrews Upper Cover Thumbscrews

Lower Cover Figure 15-16

Thumbscrew 13. Carefully pull the CEP out of the PD box housing.
(not shown)
NOTE: It is not necessary to remove the power
feed cable or the two Deutsch connectors inside
the PD box housing in order to separate the CEP
from the housing.

Steps 1 through 13 above make the CEP accessible

Figure 15-14 enough to allow replacement of individual fuse or relay
9. Remove 4 thumbscrews securing the upper PD box modules.
cover, then remove the cover. See Figure 15-14.
 Page 18 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Fuse/Relay Module Replacement

Single module replacement is easier when a section of
the CEP is separated first, freeing one side of the dam-
aged module from the CEP and then releasing the lock-
ing wedges on the opposite side and end of the module
being replaced.

The following example describes the replacement of a

high current relay module, but the same procedure
applies to all 20 modules. The only difference is the size
or type of terminal connectors used with some modules.
1. With a small screwdriver, pry the red cover (if appli-
cable) off the defective module. See Figure 15-17.

Use a 3mm screwdriver to release the module locking

wedge tabs. At the same time, apply downward pres-
sure to the module to ensure the locking tabs stay re-
leased.

Figure 15-18

Use A Screwdriver To Pry Cover Off

Figure 15-17

NOTE: In steps 2a and 2b next, apply downward

pressure to the modules at the same time as the
tabs are released. This will assure the tabs stay
released and allow the modules to be separated.
2. To separate a section of the CEP:
a. With a 3mm screwdriver, release the 6 yellow
locking wedge tabs on one side of the defective
module and the module next to it. See Figure
15-18.
b. Release the 4 remaining lock wedge tabs on the Module To Be Replaced
module being replaced. See Figure 15-19 and
Figure 15-19
Figure 15-20 on page 19.
 Page 19 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Fuse/Relay Module Replacement (continued) 4. Using a terminal extraction tool, release each termi-
nal wire lock finger. See Figure 15-22 and Figure
15-23.

Figure 15-20

NOTE: Before performing steps 3 through 5

Use a terminal extraction tool to release each terminal lock finger
next, assure proper reassembly by writing down (relay module shown).
each wires circuit number and location.
Figure 15-22
3. When replacing a fuse module, remove the red
spacer between the lock fingers before releasing the
terminal lock fingers. See Figure 15-21.

Use a terminal extraction tool to release each terminal lock finger

(fuse module shown).

Fuse modules only: The terminal lock spacer must be removed Figure 15-23
prior to releasing the terminal lock fingers.

Figure 15-21
 Page 20 of 20

Electrical: Power Distribution Box (after 12/01) Number KM815055

Fuse/Relay Module Replacement (continued)

5. Pull each wire out from the backside of the module.
See Figure 15-24.

Figure 15-24
6. The defective module can now be replaced.
7. For reassembly, follow the R & R procedures in
reverse order.