Hitachi Construction Truck Manufacturing Ltd.

[ Dash 3 ]

Electrical Training Manual

3/20/2007
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 Table of Figures
Starting Circuit ................................................................................................................................ 1
Engine Control – Vehicle................................................................................................................ 2
Accelerator Pedal ...........................................................................................................................................................2
Air Filter Sensor Switch ..................................................................................................................................................2
Coolant Level Switch ......................................................................................................................................................2
Transmission Control – CAB ......................................................................................................... 3
Shift Lever ......................................................................................................................................................................3
Transmission Control – Vehicle .................................................................................................... 5
Monitoring Circuits – Comb-meter ................................................................................................ 7
Engine Oil Pressure Light (L1) .......................................................................................................................................7
Engine Coolant Level (L2)..............................................................................................................................................7
Engine Error (L3) ............................................................................................................................................................7
Battery Charging (L4) .....................................................................................................................................................7
T/M Error (L5) .................................................................................................................................................................7
T/M Oil Pressure (L6) .....................................................................................................................................................7
Check Filter (L7) .............................................................................................................................................................7
Steer System Temperature (L8).....................................................................................................................................8
Steer System Pressure (L9) ...........................................................................................................................................8
Brake System Pressure (L10) ........................................................................................................................................8
Park Brake (L11) ............................................................................................................................................................8
Lamps for Options ..........................................................................................................................................................8
Speedometer ..................................................................................................................................................................8
Odometer........................................................................................................................................................................9
Service Meter: ................................................................................................................................................................9
Hi Beam & Turn Signals .................................................................................................................................................9
Body Up (L17) ................................................................................................................................................................9
Gauges ...........................................................................................................................................................................9
Monitoring Circuits - Gauges....................................................................................................... 10
Horn Circuit ................................................................................................................................... 11
Diagnostic Circuit ......................................................................................................................... 12
Load/Dump Brake Circuit ............................................................................................................. 13
Parking Brake Circuit.................................................................................................................... 14
Steer System Monitor ................................................................................................................... 15
Hoist Circuit................................................................................................................................... 16
Steer Bleed Down Circuit ............................................................................................................. 18
Marker Lamp Circuit ..................................................................................................................... 19
Headlamp Circuit – Halogen ........................................................................................................ 20
Turn Signal & Hazard Warning .................................................................................................... 21
Brake Lamp Circuit ....................................................................................................................... 22
Reverse Lamp / Alarm Circuit ...................................................................................................... 23
Dome Lamp Circuit ....................................................................................................................... 24
Windshield Wiper & Washer Circuit ............................................................................................ 25
Accessories / Customer Power Supply Circuit .......................................................................... 26
Front Brake Disable Circuit.......................................................................................................... 27
Haultronics Circuit (Optional) ...................................................................................................... 28
Service Lamp Circuit (Optional) .................................................................................................. 29
ATC/EDSC Circuit (Optional) ....................................................................................................... 30
Air Seat / Heated Seat / Heated Mirror Circuit (Optional)........................................................... 31
Air Conditioner Circuit (Optional)................................................................................................ 32

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Figure 1: Starting Circuit .................................................................................................................. 1
Figure 2 : Engine Control Circuit ...................................................................................................... 2
Figure 3: Transmission Control - Cab Circuit ................................................................................... 4
Figure 4: Transmission Control Circuit - Vehicle .............................................................................. 6
Figure 5: Monitoring Circuits - Comb Meter ..................................................................................... 9
Figure 6: Monitoring / Gauge Circuit .............................................................................................. 10
Figure 7: Horn Circuit ..................................................................................................................... 11
Figure 8: Diagnostic Circuit ............................................................................................................ 12
Figure 9: Load/Dump Brake Circuit ................................................................................................ 13
Figure 10: Parking Brake Circuit .................................................................................................... 14
Figure 11: Steer System Monitor Circuit ........................................................................................ 15
Figure 12: Hoist Circuit.................................................................................................................... 17
Figure 13: Steer Bleed Down Circuit .............................................................................................. 18
Figure 14: Marker Lamp Circuit...................................................................................................... 19
Figure 15: Headlamp Circuit .......................................................................................................... 20
Figure 16: Turn Signal & Hazard Warning Circuit ........................................................................... 21
Figure 17: Brake Lamp Circuit ....................................................................................................... 22
Figure 18: Reverse Lamp / Alarm Circuit ....................................................................................... 23
Figure 19: Dome Lamp Circuit ........................................................................................................ 24
Figure 20: Windshield Wiper & Washer Circuit .............................................................................. 25
Figure 21: Accessories / Customer Power Supply Circuit .............................................................. 26
Figure 22: Front Brake Disable Circuit ........................................................................................... 27
Figure 23: Load Weigh Circuit – Haultronics.................................................................................. 28
Figure 24: Service Lamp Circuit..................................................................................................... 29
Figure 25: ATC/EDSC Circuit......................................................................................................... 30
Figure 26: Air Seat / Heated Seat / Heated Mirror Circuit .............................................................. 31
Figure 27: Air Conditioner Circuit ................................................................................................... 32

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 STARTING CIRCUIT
Starting Circuit
The starting circuit is powered with Unswitched 24Vdc. When the Key Switch is set to the START
position (ST) it provides 24Vdc through Fuse F1 to the Computer Control Unit (CCU). The CCU
sends a 24Vdc signal to the Engine Start Relay (RY1) if the engine is not already started (must be
less than 600RPM) charging the coil and closing the contact between pin 30 and 87.

The Engine Start Relay, when activated by the Key Switch, provides Unswitched 24Vdc from Fuse
F1 to the Park Brake Switch Pin 6. The Park Brake Switch must be closed (closed contact
between Pin 5 and 6) to provide power to energize the ESMR relay that is connected to Pin 5 on
the Park Brake Switch. The ESMR Relay, when charged by 24Vdc provides switched 24Vdc to the
coil of the Starter Motor Relay. When the Starter Motor Relay is charged by the ESMR relay it
provides Switched 24Vdc to the Starter Motor, cranking the diesel engine.

Figure 1: Starting Circuit

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 ENGINE CONTROL - VEHICLE
Engine Control – Vehicle
The Engine Control Unit (ECU) is powered with Unswitched 24Vdc through fuses F14, F15, F16
and F18.

Accelerator Pedal
The computer control unit provides 5Vdc to the Accelerator Pedal pin C. When the Accelerator
Pedal is pressed it divides the 5Vdc provided by the CCU proportionally to the position of the pedal.
The divided voltage is returned to the CCU as a signal from the Accelerator Pedal pin B. The CCU
also provides a path to ground that is connected to Accelerator pin A.

Air Filter Sensor Switch

The air filter switch is a normally open switch that is powered with 24Vdc from the Computer
Control Unit (CCU). The air filter switch will close when the air filter becomes clogged, causing a
warning light to flash in the dash panel.

Coolant Level Switch

The coolant level switch is powered with the engine control unit (ECU). When the coolant level is
low, the switch closes and sends a signal to the ECU which will send a signal to the Computer
Control Unit (CCU) through the J1939 data-link and a warning light will illuminate in the dash panel.

Figure 2 : Engine Control Circuit

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 TRANSMISSION CONTROL
Transmission Control – CAB
The Transmission Control Unit (TCU) is powered with Unswitched 24Vdc through fuse FU-19.

Shift Lever
The Shift Lever is powered with 24Vdc from the Transmission Control Unit (TCU). The illumination
of the shift lever is controlled by the rheostat in the dash panel.

If the body is raised to a body angle of >10%, the TCU restricts the transmission forward
movement to first gear if moving from a stopped position. If the machine was not stopped but the
body is up ( >10% ) the TCU will prevent any up shifting capabilities but will allow downshifting.

(The transmission receives a signal from the Body Up Relay (RY9) to indicate the body is up). The
Body Angle sensor sends a signal proportional to the body angle back to the CCU. The CCU will
energize the Body Angle Relay should the body angle be at >10%.

If the hoist lever is in the RAISE position or the body is up (body angle >10%) the vehicle will shift
into neutral if currently in reverse gear. If the transmission is in forward gear the forward motion
speed is limited. In the described conditions the CCU energizes the Neutral Dump Relay (RY14)
that sends an electrical signal to the TCU to perform the restrictions.

If the brake oil temperature exceeds 93 ºC (200 ºF) the TCU will switch into the Accelerated
Downshift Mode and it will shift gears at a higher engine RPM than in the normal operating mode
helping to cool down the brake system oil while increasing the effect of engine braking. If the TCU
is in the Accelerated Downshift Mode and the brake oil temperature drops to 88 °C or bellow the
TCU will shift back to normal operating mode if there is no other restriction. Switching to the
accelerated downshift mode is triggered by the Max Cool Relay (RY10) through a signal from the
CCU.

If the transmission oil filter is clogged or the transmission oil is exceptionally thick the filter switch
opens, sending a “floating signal” (Floating meaning not a voltage or ground signal) to the CCU to
activate T/M Filter Blocked Relay (RY15). Relay RY15 will signal the TCU to prevent any up-
shifting while the transmission continues to operate with normal downshifting. If the transmission is
in the neutral gear, the operation is limited to first gear (forward) or reverse gear only.

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Figure 3: Transmission Control - Cab Circuit

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 TRANSMISSION CONTROL
Transmission Control – Vehicle
The engine speed, turbine speed and output speed sensors provide speed information to the
Transmission Control Unit (TCU). The engine speed signal is generated by the gear teeth on the
top Power Take-Off (PTO) gear. The turbine speed signal is generated by serrations on the tone
wheel attached to the splitter low drum. The output speed sensor is generated by a toothed
member attached to the output shaft.

The speed ratios between various speed sensors allow the TCU to determine if the transmission is
in the selected range.

The sump temperature sensor in the lock up body sends information to the TCU, prohibiting
operation at extreme hot or cold temperatures.

The transmission electro-hydraulic valve body contains various solenoids to control pressure.
Various transmission ranges are achieved through the combination of various states of these
solenoids. Solenoids A through G are connected to the TCU through the main connector while
solenoid J is connected through the trim boost connector and solenoid K is connected through the
lock up connector.

The transmission filter sensor switch is a normally closed switch and is powered with the 24V CCU
Sensor supply. When the filter is clogged the switch will open and a warning light will flash in the
dash panel.

The transmission oil temp sensor monitors the transmission oil temperature. A warning light flashes
in the dash panel when the transmission oil temperature exceeds the normal preset value. The
transmission oil pressure sensor monitors the transmission oil pressure. A dash panel warning
light will illuminate when the pressure drops below the normal preset value.

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Figure 4: Transmission Control Circuit - Vehicle

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 MONITORING CIRCUITS
Monitoring Circuits – Comb-meter
Engine Oil Pressure Light (L1)
The Engine Control Unit (ECU) sends the engine oil pressure information to the CCU through a
J1939 data-link. The CCU turns ON the warning light L1 when the engine oil pressure is low. If the
CCU can’t read the engine oil pressure lamp L1 will flash, indicating an error.

Engine Coolant Level (L2) The ECU sends the engine coolant level information to the CCU
through a J1939 data-link. The CCU turns ON the warning light L2 when the engine coolant level is
low. If the CCU can’t read the engine coolant level lamp L2 will flash, indicating an error.

Engine Error (L3)

When the ECU encounters any error condition it will turn ON the warning light L3.

Battery Charging (L4)

If the alternator voltage is < 25.5Vdc OR > 31Vdc, the CCU turns ON warning light L4.

T/M Error (L5)

If the Transmission Control Unit (TCU) encounters any error condition it will release the ground
from output pin S31 (TCU), turning ON warning light L5.

T/M Oil Pressure (L6)

If the engine speed is >1000 rpm and the Transmission oil temperature is >38 ºC (100 ºF) and the
T/M oil pressure is <965 kPa (140 psi) for 5 seconds the CCU will turn ON warning light L6.

Check Filter (L7)

Warning light L7 will be activated by any of the following four filter switches: air filter, T/M oil filter,
steer oil filter or hoist oil filter. Lamp L7 can be either solid ON or flashing with a pattern, as
described in the following table considering all filters clogged to highlight the display priority:

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The described priority order will dictate which flashing pattern will be first observed when
more than one filter is clogged.

ENGINE RUNNING
FILTER SW FLASH PRIORITY
Air ON One 1

T/M OFF Two 2

Steer OFF Three 3

Hoist OFF Four 4

ENGINE STOPPED
FILTER SW LAMP PRIORITY
Air ON One -
T/M OFF Two -
Steer OFF Three -
Hoist OFF Four -

Steer System Temperature (L8)

The CCU will turn ON L8 when the steer oil temperature is <93 ºC (200 ºF).

Steer System Pressure (L9)

If the steer oil pressure is <12.41 MPa (1800 psi), the CCU turns warning light L9 ON, if after 2 sec
if the engine speed is less than 700 min-1(rpm) the stop light L20 and the buzzer become active or
after 5 sec if the engine speed is less than 1900 min-1(rpm). Otherwise if L9 is ON, L20 and the
buzzer become active immediately.

Brake System Pressure (L10)

If the brake oil pressure is <11.376 MPa (1800 psi) the CCU turns ON the warning light L10 and if
the engine is running it will also activate the Caution Lamp L15, the Stop Lamp L20 and the buzzer.

Park Brake (L11)

This light turns ON when the park brake is requested and applied. It will flash if the park brake is
requested but not applied, otherwise it will be OFF. The park brake will be applied when requested
if the engine speed is 0 min-1(rpm) or the vehicle speed is less than 2km/h and T/M in Neutral. If
park brake is requested and not applied after 2 seconds the stop lamp L20, the caution lamp L15
and the buzzer become active.

Lamps for Options

Lamps L12, L13 and L14 (ATC Applied, EDSC Applied and ATC/EDSC Error) are applicable if the
truck has an ATC and EDSC option.

Speedometer
Indicates the vehicle speed based on the transmission output shaft speed.

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Odometer
The CCU runs the odometer and it is powered with 12V DC through Relay RY11.

Service Meter:
The service meter keeps track of the total engine running time.

Hi Beam & Turn Signals

L18 indicates when the high beam is ON. L16 and L21 indicate the left and right turn signals or the
hazard signal.

Body Up (L17)
When the body angle is >10%, the CCU activates relay RY6, closing the circuit for Lamp L17.

Gauges
Transmission, coolant and brake temperature gauges are driven by CCU pulse width modulation
(PWM) signals.

Figure 5: Monitoring Circuits - Comb Meter

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Monitoring Circuits - Gauges
The steer oil pressure sensor mounted on the Relief Check Bleed (RCB) Valve is powered with
24Vdc from the Central Control Unit (CCU) Analog Sensor Output supply. The pressure is
converted into an analog signal which is sent to the CCU and then converted to a pulse width
modulated (PWM) signal to drive the steer pressure gauge.

The fuel level sensor sends an electrical signal proportional to the fuel level to the CCU. The CCU
converts the fuel level sensor signal to a PWM signal that drives the fuel level gauge.

The engine speed signal is broadcast by the Engine Control Unit (ECU) received by the CCU and
converted to a PWM signal that drives the tachometer to indicate the current engine RPMs.

All of the gauges are illuminated with lamps controlled by a rheostat for light intensity. The
Rheostat receives 24Vdc and lowers the 24Vdc by increasing the series resistance of the lighting
circuit, dimming the lights.

Figure 6: Monitoring / Gauge Circuit

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 HORN CIRCUIT
Horn Circuit
The horns (Hi & Lo) are powered with Unswitched 24Vdc through fuse F10 and relay RY16. Relay
RY16 is energized when the Horn Switch is closed (Horn is pushed).

Figure 7: Horn Circuit

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 DIAGNOSTIC CIRCUIT
Diagnostic Circuit
Diagnostic connectors are available for all the 3 controllers (CCU, TCU and ECU) in order to
troubleshoot the system and monitor broadcast data on the CAN type data-links (J1939 and J1708).
A COM type serial port connection is available to upload and download information to and from the
CCU. Two key switches are available, one to set the CCU to rewrite mode and the other to turn the
Transmission into manual mode (for diagnostic purposes only). Both switches are located in the
rear electrical compartment. All three controllers (CCU, ECU and TCU) communicate with each
other through a J1939 communication data link. Each data-link line is ended with a 120 Ohms
resistor in order to minimize impedance mismatch communication losses.

Figure 8: Diagnostic Circuit

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 LOAD/DUMP BRAKE CIRCUIT
Load/Dump Brake Circuit
The Load Dump Brake Solenoid is used to activate the rear brakes when the Load Dump Switch is
pushed or when the Hill Hold feature is active.

When the Load Dump Switch is pressed, the Computer Control Unit (CCU) receives Switched
24Vdc through the Load Dump switch and fuse F24. When the Load Dump Brake is requested the
CCU sends a signal to the load dump solenoid that directs pilot pressure to the rear brake cartridge
applying the rear brakes.

The load dump solenoid is also activated by the Hill Hold logic built into the CCU software,
engaging or disengaging the rear brakes accordingly. When the load dump switch is ON, the Hill
Hold logic is ignored. The Hill Hold feature is hardware activated (by the installation of the
inclinometer). If the inclinometer is not installed the Hill Hold feature is disabled.

Figure 9: Load/Dump Brake Circuit

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 PARKING BRAKE CIRCUIT
Parking Brake Circuit
The Park Brake switch is a double contact switch where one contact is normally closed while the
other is normally open. The Park Brake Switch receives Switched 24Vdc through fuse F12. With
the Park Brake Switch deactivated the CCU receives a “float” input and senses that the park brake
switch is activated. The reason for the float activation logic is that if fuse F12 blows it will not
prevent the park brake from being activated.

When park brake is requested, the CCU will energize the Park Brake Solenoid which activates the
park brake, but only if the vehicle speed is less than 2 km/h and the transmission is in the Neutral
gear. The reason for these conditions is to protect the park brake from accidental application.

When the park brake is applied, relay RY13 will energize causing the transmission controller to
lock the transmission in the Neutral gear to protect the park brake from damage in the attempt to
run the truck with the park brake applied. In this case the Transmission lamp will flash indicating a
shift restriction. When the park brake is applied the park brake lamp found in the dash panel and
the switch LED will turn ON.

The park brake oil pressure is monitored to indicate application of the park brake and control the
park brake LED.

Figure 10: Parking Brake Circuit

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 HYDRAULIC TANK CIRCUIT
Steer System Monitor
Fuse F24 supplies switched 24Vdc to the Steer Filter Switch. The Steer Filter switch, mounted in
the filter head, is normally closed and will open when the steer filter is clogged. If the steer filter
switch is open for more than 25 seconds while the engine is running the CCU will send a flashing
pattern signal to the filter warning lamp found on the dash panel. The Steer Oil Pressure sensor,
mounted in the relief check bleed (RCB) valve, is powered from the 24Vdc Analog Sensor CCU
output. When the engine is running the CCU converts the steer oil pressure signal coming from the
steer oil pressure sensor into a pressure value.

The Steer Oil Temp Sensor is a thermistor where the resistance decreases with temperature
increase. The CCU sends a voltage to the Steer Oil Temp Sensor and a current signal is returned
to the CCU. The current signal is converted to a numerical value by the CCU using an internal
Analog to Digital Converter (A/D Converter).

Figure 11: Steer System Monitor Circuit

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 HOIST CIRCUIT
Hoist Circuit
The hoist lever and the body angle sensor are powered with 5Vdc from the Computer Control Unit
(CCU) sensor output supply. The hoist lever sends an analog signal that is proportional with the
position of the lever back to the controller. When the hoist lever is in the RAISE position the body
up solenoid is activated by a pulse width modulated (PWM) signal with the duty cycle from 60% to
100%, proportional to the lever angle. When the hoist lever is in the HOLD position, both body up
and body down solenoid are de-energized. When the hoist lever is in the FLOAT position, the
body down solenoid valve is activated with a duty cycle of 54%.

In the POWER DOWN position a 0.8 volt signal is directed to the hoist controller. The hoist
controller then interprets this as the POWER DOWN position and will send a pulsed voltage signal
to the Lower PWM valve of the hoist control valve. The Lower PWM valve shuttles to allow
hydraulic piloting pressure of 1720 kPa (250 psi) to the end of the hoist control valve spool. The
valve spool shifts to allow a reduced amount of system hydraulic pressure approximately 10343
kPa (1500 psi) to flow to the rod end of the hoist cylinders, to hydraulically collapse the cylinders
and force the body down.

The Body Angle sensor sends an analog signal to the CCU proportional to the position of the body.

The hoist cooling oil filter switch is a normally closed switch and is supplied power from the
switched 24Vdc power supply through fuse F24. If the switch is closed it indicates that the filter is
good and if the switch is open it indicates that the filter is bad. While the engine is running if the oil
filter switch is closed and the hoist oil temperature is greater than 43 ºC (109 ºF), after 25 seconds
the CCU will indicate the filter is clogged. If the engine is stopped there is a delay of 5 seconds
and no temperature condition is required to indicate a filter clogged condition.

The Hoist/Brake Cooling Temp Sensor switch supplies a variable electrical signal proportional to
the oil temperature to the CCU which converts this signal into a temperature value.

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Figure 12: Hoist Circuit

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 STEER BLEED DOWN CIRCUIT
Steer Bleed Down Circuit
The Steer Bleed down Relay (RY4) is activated and deactivated through fuse F12 connected to the
switched 24Vdc power supply. The Steer Bleed Down Solenoid will be activated by the Unswitched
24V DC battery supply through fuse F5 and relay RY4 (when RY4 is not energized). While the
truck is running, relay RY4 is energized, cutting power from the bleed down solenoid.

When the truck is not running (switched power supplies are off), relay RY4 is not energized,
supplying power to the bleed down solenoid and the timer from Unswitched 24Vdc supply through
fuse F5. When the truck is not running the timer will engage the solenoid for 200 seconds in order
to bleed down the system pressure soted in the steer accumulator (if the main Unswitched 24V DC
supply is not cut off). After 200 seconds the timer will disengage the solenoid.

Typically the steer system needs 90 seconds to bleed down completely.

Figure 13: Steer Bleed Down Circuit

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 MARKER LAMP CIRCUIT
Marker Lamp Circuit
The marker lights are supplied by the Switched 24V DC supply through fuse F20 and the head light
switch. There are two distinct electric circuits. The first circuit has a rheostat in series with all the
interior marker lights, allowing the operator to vary the light intensity. The second circuit is without
a rheostat and is connected to all the outside marker lights including the “customer options
connector” located on the horse collar. This connector can be used to power up any additional
marker lamps installed by customer.

Figure 14: Marker Lamp Circuit

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 HEADLAMP CIRCUIT
Headlamp Circuit – Halogen
The Headlamp Controls Relay RY28 provides power to the Hi Beam lamps when energized and to
the Low Beam lamps when not. The Hi Beam Switch pulls the Headlamp Controls circuit to ground,
energizing the Headlamp Controls relay.

There are two groups of head lights, upper and lower headlights. Both groups have high and low
beam lamps and they work together. The Low beam lamps are controlled by relay RY21 and relay
RY22 and the Hi beam lamps are controlled by relay RY25 and relay RY26. The head lights are
powered by the Switched 24Vdc supply. Fuse F20 delivers power to the command circuits while
fuse F27 delivers power to the Low beam lamps and fuse F26 delivers power to the Hi beam lamps.
The headlamp control relay RY28 controls the Hi and the Low beam circuits.

When the head light switch is turned ON and if the Hi beam switch is OFF, RY28 is disengaged
causing the Low beam circuit to be active.

Figure 15: Headlamp Circuit

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 TURN SIGNAL & HAZARD WARNING

Turn Signal & Hazard Warning

The Turn / Hazard lamps are powered by the 24V DC Unswitched supply through fuse F8, the
flasher and the Turn / Hazard switch combination. When the signal light is switched it will close
contact 6 and 7 (Right Hand Turn) or contact 6 and 2 (Left Hand Turn). If the Hazard Light is used,
contacts 2 and 7 will be closed to contact 6 allowing for both left and right turn lights to blink
simultaneously.

Figure 16: Turn Signal & Hazard Warning Circuit

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 BRAKE LAMP CIRCUIT

Brake Lamp Circuit

The brake lamps are activated using the 24V DC switched power battery supply through fuse F20
and relay R18. The brake lamps are turned ON when either brake pedal is pushed or when the
EDSC feature is active. The brake or retard pedals, when pushed, will engage the brake or retard
pedal switch causing RY18 to turn ON.

When the EDSC feature is active it will also cause RY18 to turn ON. Diodes D5 and D6 are in
place to prevent the EDSC 24Vdc output from the Computer Control Unit (CCU) from signaling the
brake or retard pedal inputs on the CCU.

Figure 17: Brake Lamp Circuit

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 REVERSE LAMP / ALARM CIRCUIT

Reverse Lamp / Alarm Circuit

The reverse lamp and reverse alarm are powered with the switched 24Vdc battery supply through
fuse F28 and relays RY27 and RY23. When the vehicle is in reverse gear (R1 or R2), the
Computer Control Unit (CCU) will energize relays RY23 and RY27 causing them to close contacts
30 and 87.

Figure 18: Reverse Lamp / Alarm Circuit

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 DOME LAMP CIRCUIT

Dome Lamp Circuit

The Dome light is powered with Unswitched 24Vdc through fuse F8. The Dome light switch will
directly turn the dome light ON of OFF.

Figure 19: Dome Lamp Circuit

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 WINDSHIELD WIPER & WASHER CIRCUIT

Windshield Wiper & Washer Circuit

The windshield wiper and washer circuit is powered with switched 24Vdc through fuse F13. The
wiper switch has 4 positions: OFF, HI, LO & Intermediate speed to alter the speed of the wiper
motor. Intermediate speed is attained by the use of the wiper relay.

Activating the washer pump button on the wiper switch sends a 24Vdc signal to activate the
windshield wiper motor and pump that is mounted on the windshield washer bottle.

Figure 20: Windshield Wiper & Washer Circuit

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 ACCESSORIES / CUSTOMER POWER SUPPLY CIRCUIT

Accessories / Customer Power Supply Circuit

When the key switch is in ON position, Switched 24Vdc is available through fuse F23 to power the
cigar lighter. This cigar lighter also has an auxiliary 24Vdc power and this can be used for
customer switched 24V option. At the same time this switched 24V is also available on pin 1 of the
customer options connectors. There are 3 customer options connectors located on the truck. The
first one is located in the electrical compartment in the cab rear, 2nd one is located in the overhead
dash in the cab and the 3rd connector is located on the horse collar. Any customer options should
be powered using these 3 connectors only. Un-switched 24V DC ( key switch off) power is
available on pin 2 of all the connectors.12VDC battery power is available on Pin 4 of customer
options connector in overhead dash and pin 3 of connector in cabin. There is a 12Vdc power port
in the console which is powered through fuse F9 and it supplies 12V only if the key switch is in the
ON position or in the ACC position.

Figure 21: Accessories / Customer Power Supply Circuit

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 FRONT BRAKE DISABLE CIRCUIT

Front Brake Disable Circuit

The front brake disable circuit is powered with switched 24Vdc through fuse F24 and the normally
open front brake disable switch. The front brake disable switch will turn the front brake cutoff
solenoid ON or OFF. This solenoid cuts-off the front brakes only when the brake pressure is less
than or equal to 1850 psi. If the solenoid is engaged (cutting off the front brakes) but the brake
pressure exceeds 1850 psi the front brakes will apply through a hydraulic bypass valve.

Figure 22: Front Brake Disable Circuit

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 FRONT BRAKE DISABLE CIRCUIT

Haultronics Circuit (Optional)

The Haultronics circuit is divided in two sections. The first section contains the sensors which are
supplied 5Vdc by the Computer Control Unit (CCU) and return a signal proportional to the
increased pressure in the strut when the body is being filled. The sensors are the strut pressure
sensors (four) and the inclinometer. The second section contains the load weigh lights and the
relays that control them. There are two types of lights: red and yellow. They are found in the dash
panel inside the cab and outside on the left and right side of the deck. The yellow light can turn ON
or OFF through RY19 based on the payload calculated by the CCU, indicating if the payload is
close to the nominal truck payload. The red light can be ON or OFF through RY20 and can also
flash through RY17 based on the calculated payload, indicating if the payload has reached or
exceeded the nominal truck payload.

Figure 23: Load Weigh Circuit – Haultronics

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 SERVICE LAMP CIRCUIT
Service Lamp Circuit (Optional)
The service lamp circuit is powered with Unswitched 24Vdc through fuse F6 and the normally open
service lamp switch. When the service lamp switch is closed it closes the circuit, illuminating all
service lamps.

Figure 24: Service Lamp Circuit

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 SERVICE LAMP CIRCUIT
ATC/EDSC Circuit (Optional)
The Automatic Traction Control (ATC) / Electronic Downhill Speed Control (EDSC) circuit is divided
into two sections, the command section and the sensor section. Fuse F24 delivers switched 24Vdc
to both the ATC and EDSC switch. The ATC switch has three positions: OFF, continuous ON and
BOOST. The BOOST position remains engaged as long the switch is pressed. When released the
switch returns to the second position (continuous ON). The sensor section contains two speed
sensors mounted on the rear axle on the left and right side to monitor the speed of each rear wheel.
If the ATC switch is further pressed into the third position (then released) it will activate the ATC
Boost feature for a short period of time (about 10 seconds). After ATC boost ends ATC remains
active (if the ATC switch is still ON). The ATC feature will restrict the speed difference between the
left and right rear wheels to maximum 50%, applying the brake (in a dynamic mode) on the faster
turning wheel. The ATC Boost will restrict the difference between the rear wheels to maximum
10% using the same method. The concept of the EDSC feature is to prevent the vehicle from
gaining speed while going downhill. This effect is achieved by dynamically applying the rear brakes
(to slow the vehicle down) in order to prevent the transmission to up-shift gears when the engine
speed is at its maximum limit (~2000 rpm).

Figure 25: ATC/EDSC Circuit

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 AIR SEAT / HEATED SEAT / HEATED MIRROR CIRCUIT

Air Seat / Heated Seat / Heated Mirror Circuit (Optional)

The air seat/heated seat and heated mirror circuit is powered with switched 24Vdc through fuse
F25. Each of these circuits has its own ON/OFF switch, allowing individual activation. The air seat
switch powers the air compressor built in the seat to deliver the operator all features associated
with air seat. The heated seat and mirror have built-in thermostats to control heat.

Figure 26: Air Seat / Heated Seat / Heated Mirror Circuit

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 AIR CONDITIONER CIRCUIT

Air Conditioner Circuit (Optional)

The Air Conditioner (A/C) system is powered with switched 24Vdc through fuse F21. The A/C unit
has its own electronic control unit that allows turning ON/OFF the unit and distributing the air.

Relay RY8 controls the defrost section and relay RY12 controls the fresh air and recirculation
section. All the actuators are powered with 12Vdc obtained from 24V using 47 Ohms resistors in
series with each actuator circuit. There are 4 temperature sensors (inside, outside, de-icing and
after-coil) used by the control unit to monitor and control the A/C system. The A/C compressor is
driven by the vehicle engine through an electronic clutch actuated by the compressor pressure
switch. The compressor pressure switch will engage and disengage the clutch while maintaining
the A/C system pressure in the established limits. The following signals are sent to the Computer
Control Unit (CCU) in order to control other vehicle components that service the A/C system.

1. Defrost ON – currently not used by the CCU.

2. Low Pressure – request for more vehicle engine rpm to increase the A/C system pressure. As
a response, when the vehicle is in neutral gear, the CCU will request an alternate idle from the
engine controller which will raise the idle speed to 1200 rpm.

3. Fan Clutch ON – request to engage the vehicle cooling fan in order to speed up cooling of the
A/C system thermal exchange agent. As a response the CCU will send a request to the engine
controller to turn ON the engine fan clutch.

Figure 27: Air Conditioner Circuit

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 HTT750(3)-20-1106 (REVISION 0)

3/20/2007