Flaky ignition on aerocab trucks

Discussion in 'Kenworth Forum' started by Pirate_Freder, Feb 25, 2025.

  1. Pirate_Freder

    Pirate_Freder Light Load Member

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    To my knowledge this is a fact of life with these trucks so I've just lived with it, but I'm fed up now and wanna figure it out. What I'm talking about is on W900s, T660s, and I imagine T600s and T800s. The problem being where you go to start the engine and nothing happens, you keep turning the key back and forth, one time it might turn over a tiny bit and stop, the next it does absolutely nothing, and after a few or several tries it starts perfectly. But most of the time it works just fine on the first try, it never leaves me unable to start it either. I just started doing some digging online and I'm hardly finding anything, although I did see something about a starter interrupt relay, is that the likely cause? That would make sense as I don't hear the solenoid click when it doesn't turn over. Have any of y'all experienced and solved this?

    To clarify, this is on a 2019 W9 glider with a 3406E, but I've experienced it on other W9s as well as T660s.
     
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  3. unloader

    unloader Road Train Member

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    Sounds like your starter is going out to me. The next time it happens take a rubber mallet and gently tap the starter. If it fires up right after you do that, you'll have your answer.

    unloader
     
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  4. Pirate_Freder

    Pirate_Freder Light Load Member

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    I appreciate the input, although I'm familiar with that sort of issue and the remedies, hammer included. I've driven KWs with this issue ongoing over hundreds of thousands of miles in each truck. Never have I found it to relate to a starter, or more specifically a starter solenoid. E.g. the W9 I drive now, it's at 434k, ~350k of which I've done and it's had that issue since I got in it. Same deal with the W9 I was driving before I switched from 3 to 4 axles, and so on and so forth.

    Years ago when I was green and first encountered this, I asked people who had been around the block about it and they said it's just a KW thing. I've brought it up to other people over the years and gotten the same answer, although some people assume it's the ignition switch, but they've never bothered to try fixing it.
     
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  5. unloader

    unloader Road Train Member

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  6. Claytonbigsby

    Claytonbigsby Bobtail Member

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    I’m convinced it’s a KW thing too, don’t matter if it’s a Cat or Isx- W9 or T800. We have about a dozen Pete’s and a dozen KWs and only KWs are the problem children
    Click. Click…. Click…
    I’ve sistered on an additional wire going from back of key switch starter terminal down to the small wire terminal on the starter solenoid, to bypass the interrupt circuit. It will crank every time you turn the key.
    I’ve changed starters, key switches, tested batteries, cleaned cables and found that’s the only reliable fix when you get a truck that cranks on occasion while every thing else is working good.
     
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  7. Pirate_Freder

    Pirate_Freder Light Load Member

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    There we go, I knew someone else here must have experienced this lol. So it is the interrupt circuit after all, sweet. You ran the wire from the start position on the ignition switch to the solenoid's control signal input? I'll look at the wiring and see if I can figure out how the interrupt circuit works. Hopefully there's a direct way to bypass it, maybe just a jumper in place of a relay in the fuse box. If not, I've got your solution in my back pocket, thank you. I'll let you know if I come up with a more direct solution.
     
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  8. D.Tibbitt

    D.Tibbitt Road Train Member

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    I had this problem on a 2016 386 pete ... never could figure out what it was. Ran it that way for 4 years. Never knew if the truck was gonna start again when I shut it off.. lol
     
  9. Judge

    Judge Road Train Member

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    Wire a push button up. How I gotta start my t660
     
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  10. Dave1837

    Dave1837 Road Train Member

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    The 386 I drove did the same thing
     
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  11. Claytonbigsby

    Claytonbigsby Bobtail Member

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    Yes, that’s how I ran the wire. The center wire behind key switch is the signal wire for starter crank.
    There is a way to bypass the interrupt relay with a jumper wire down by the floor fuse panel but I haven’t had time to play with it. I believe it’s pin 30 and 87 that gets a jumper, on 389’s it’s the two fat pins to bypass. There’s supposed to be a bypass relay available from paccar to eliminate the starter interrupt.
    If you have paccar ESA software you can disable and tweak some of the starter functions in the program section on it if you want to explore more in solving it
    IMG_5955.jpeg
     
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