(DASH 2 )

ELECTRICAL TRAINING
MANUAL

7/3/2007
 Table of Contents
STARTING CIRCUITS..................................................................................................................1
CUMMINS .................................................................................................................................1
Detroit Diesel.............................................................................................................................1
Engine Control - Vehicle ............................................................................................................2
Throttle Pedal............................................................................................................................2
Retard Pedal .............................................................................................................................2
Load/Dump Brake .....................................................................................................................2
Park Brake ................................................................................................................................2
Hydraulic Filters 1 and 2............................................................................................................2
Air Filter 1, 2, 3, and 4 ...............................................................................................................3
Steer Filter.................................................................................................................................3
Steer Oil Temperature Sensor ..................................................................................................3
Brake Coolant Temperature Sensor..........................................................................................3
Fuel Level Sensor .....................................................................................................................3
Axle Oil Level Switches .............................................................................................................4
Engine Coolant Level (Optional) ...............................................................................................4
Control Cabinet...........................................................................................................................5
Gate Unit Power Supply ............................................................................................................5
Inverter A...................................................................................................................................5
Inverter B...................................................................................................................................5
Motor Speed Sensors................................................................................................................5
Bearing Temperature Sensors ..................................................................................................5
Lights ...........................................................................................................................................6
Right Front Turn Signal .............................................................................................................6
Left Front Turn Signal................................................................................................................6
Right Rear Turn Signal..............................................................................................................6
Left Rear Turn Signal ................................................................................................................6
Hazard Signal............................................................................................................................6
Headlights – Low Beams...........................................................................................................7
Headlights – High Beams..........................................................................................................7
Windshield Wipers and Washer ................................................................................................8
Windshield Wipers ....................................................................................................................8
Windshield Washer ...................................................................................................................8
Heater / Airconditioning (A/C)....................................................................................................9
Hoist Controller.........................................................................................................................10
Hoist Lever ..............................................................................................................................10
Proximity Switch ......................................................................................................................10
Body-up Switch .......................................................................................................................10
Propulsion Override Switch .....................................................................................................11
Load Weigh System..................................................................................................................12
Strut Sensors ..........................................................................................................................12
Load Weigh Lights ..................................................................................................................12
Horns .........................................................................................................................................13
SCHEMATICS ............................................................................................................................15

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THIS PAGE LEFT INTENTIONALLY BLANK
 Starting Circuits
STARTING CIRCUITS
Cummins
The ignition is connected to a 24VDC battery supply through a 10amp fuse FU1 as long as the
cutoff switch is in the closed position. When the ignition switch is set to the IGN position it
supplies 24VDC to relays RE9, RE10 and RE17 causing them to energize and close contacts
allowing for the ignition switch activated 12VDC and 24VDC supply paths to supply power to
their components.

When the ignition switch is turned to the START position it supplies 24VDC to relay RE1 and
solenoid S1E energizing them, providing 24VDC to relay RE2 through relay RE1 and sends
24VDC to the control cabinet through solenoid S1E, illuminating the IGNITION ON lamp. The
shift controller must be in the neutral position and the park brake must be engaged for power to
be supplied to the pre-lube timer solenoid from relay RE2 to the pre-lube timer solenoid. The
pre-lube timer solenoid will supply 24VDC to the pre-lube motor in starter #2 which will build oil
pressure prior to starting the power pack. Once the timer has run its course it energizes the
relays ESMR#1 and ESMR#2 supplying power to starter #1 and #2.

(Refer to Schematic 10/20)

Detroit Diesel
The ignition is connected to a 24Vdc battery supply through fuse FU1 as long as the cutoff
switch is in the closed position. When the ignition switch is set to the IGN position is supplies
24Vdc to relays RE9, RE10, and RE17 causing them to energize and close contacts allowing for
the ignition switch activated 12Vdc and 24Vdc supply paths to supply power to their components.

When the ignition switch is turned to the START position it supplies 24Vdc to relay ESMR #2
which energizes the relay and closes. Relay ESMR #2 then allowes the relay in STARTER #2
to energize and close providing 24Vdc to the starting motor in STARTER #2.

Also when the ignition switch is turned to the START position it supplies 24Vdc to relay ESMR
#1 which energizes the relay allowing it to close and supply power to the relay in STARTER #1
that closes the circuit path for the starting motor in STARTER #1.

(Refer to schematic 19/20)

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 Engine Control - Vehicle
Engine Control - Vehicle
Throttle Pedal
The throttle pedal receives a voltage signal from the Traction Control Unit (TCU). That voltage
is then divided in proportion to the position of the pedal. That divided voltage is then returned to
the TCU where it will be converted to an electrical signal that will control the throttle of the
vehicle.

(Refer to Schematic 17/20)

Retard Pedal
The retard pedal works in the same way as the throttle pedal. It receives a voltage level from
the TCU. That voltage is then divided in proportion to the position of the pedal and returned to
the TCU where it is converted to an electrical signal that will control the retarder.

(Refer to Schematic 17/20)

Load/Dump Brake
The load/dump brake receives 24VDC from the activated ignition supply through fuse FU34. If
the brake is applied, the pedal will supply power through diode D11 to the load/dump brake
solenoid.

(Refer to Schematic 17/20)

Park Brake
The park brake is supplied with 24VDC from the ignition key switch. When the park brake
switch is depressed it sends a voltage signal to the Electronic Control Unit (ECU). The ECU will
then de-energize the park brake solenoid causing the park brake to apply as well as illuminating
the park brake indicator light.

(Refer to Schematic 6/20)

Hydraulic Filters 1 and 2

The hydraulic filter switches are supplied with 24VDC from the ignition key switch and are
protected by fuse FU24. When the filter flow is restricted (dirty filter) the ECU receives a voltage
signal from the sensor and sends a signal to the filter restriction lamp indicating that the filters
will require replacement soon. The filter restriction lamp will also illuminate during start-up when
the ignition switch is on but the engine is off and there is no input from the filter restriction switch.

(Refer to schematic 6/20)

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Air Filter 1, 2, 3, and 4
The air filter switches are supplied with 24VDC from the ignition key switch and are protected by
fuse FU24. When the filter flow is restricted (dirty filter) the ECU receives a voltage signal from
the sensor and sends a signal to the filter restriction lamp indicating that the filters will require
replacement soon. The filter restriction lamp will also illuminate during start-up when the ignition
switch is on but the engine is off and there is no input from the filter restriction switch.

(Refer to Schematic 6/20)

Steer Filter
The steer filter switches are supplied with 24VDC from the ignition key switch and are protected
by fuse FU24. When the filter flow is restricted (dirty filter) the ECU receives a voltage signal
from the sensor and sends a signal to the filter restriction lamp, indicating that the filters will
require replacement soon. The filter restriction lamp will also illuminate during start-up when the
ignition switch is on but the engine is off and there is no input from the filter restriction switch.

(Refer to Schematic 6/20)

Steer Oil Temperature Sensor

The Steer Oil Temperature Sensor is a resistance temperature detector (RTD) that provides a
resistance proportional to the surrounding temperature. When the RTDs are heated by the steer
oil they become less resistant. The ECU reads this resistance and interprets it as a temperature.
If the steer oil temperature becomes too hot the STEER TEMP indicator lamp will illuminate.

(Refer to Schematic 6/20)

Brake Coolant Temperature Sensor

The Brake Coolant Temperature Sensor is a resistance temperature detector (RTD) that
provides a resistance proportional to the surrounding temperature. When the RTDs are heated
by the brake/hoist oil returning from brake cooling circiut they become less resistant. The ECU
reads this resistance and interprets it as a temperature. If the temperature becomes too hot the
BRAKE COOLANT TEMP indicator lamp will illuminate.

(Refer to Schematic 6/20)

Fuel Level Sensor

The Fuel Level Sensor is located on the fuel tank and it sends an electrical signal back to the
ECU that is proportional to the fuel level in the fuel tank. The fuel level is then displayed on the
Contronic LCD display as a percentile.

(Refer to Schematic 6/20)

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Axle Oil Level Switches
The Axle Oil Level Switches are located on the rear axle of the vehicle. These switches receive
24VDC from the ignition key switch through fuse FU14

(Refer to Schematic 6/20)

Engine Coolant Level (Optional)

Secondary circuit mounted in the radiator.

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 Control Cabinet
Control Cabinet
The control cabinet receives DC three phase rectified power from the alternator through the
main rectifier. This rectified voltage is then passed through the K104/204 DCL SWITCH and
filtered with the capacitor bank (c101, c102 and c103)

(Refer to Schematic 11/20 and 15/20)

Gate Unit Power Supply

The gate unit power supply receives 24VDC from the battery supply. Its primary function is to
provide timed gate pulses to the inverters and choppers to control motor speeds and power duty
cycles frequencies.

(Refer to Schematic 11/20 and 15/20)

Inverter A
Inverter A is a 3phase inverter. It receives a rectified and filtered DC voltage from the main
rectifier (see sheet 14/20) and converts that DC voltage back to an AC voltage that has a
controlled frequency from the gate pulses by the gate unit power supply. This controlled
frequency allows speed control for MOTOR A (MA)

(Refer to Schematic 11/20 and 15/20)

Inverter B
Inverter B is a 3phase inverter. It receives a rectified and filtered DC voltage from the main
rectifier (see sheet 14/20) and converts that DC voltage back to an AC voltage that has a
controlled frequency from the gate pulses by the gate unit power supply. This controlled
frequency allows speed control for MOTOR B (MB).

(Refer to Schematic 11/20 and 15/20)

Motor Speed Sensors

Both motor A and motor B have a pulsed speed sensor attached to them internally. These
sensors send a pulsed signal to the traction control unit (TCU). Each revolution of the motor
generates a short electrical pulse.

(Refer to Schematic 11/20 and 15/20)

Bearing Temperature Sensors

Both motor A and motor B have bearing temperature sensors attached to them. These sensors
are near the motor speed sensors mentioned above.

(Refer to Schematic 11/20 and 15/20

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 Lights
Lights
Right Front Turn Signal
The right front turn signal receives 24VDC from the 24V battery supply through fuse FU8, the
flasher, and the turn/hazard switch box. The TURN/HAZARD INDICATOR is illuminated by
power being supplied to it in parallel to the right front turn signal through diode D13. The flasher
provides the pulsed voltage for the blinking.

(Refer to Schematic 5/20)

Left Front Turn Signal

The left front turn signal receives 24VDC from the 24V battery supply through fuse FU8, the
flasher, and the turn/hazard switch box. The TURN/HAZARD INDICATOR is illuminated by
power being supplied to it in parallel to the left front turn signal through diode D14. The flasher
provides the pulsed voltage for the blinking.

(Refer to Schematic 5/20)

Right Rear Turn Signal

The right rear turn signal receives 24VDC from the 24V battery supply through fuse FU8, the
flasher, and the turn/hazard switch box. The flasher provides the pulsed voltage required for
light flashing.

(Refer to Schematic 5/20)

Left Rear Turn Signal

The left rear turn signal receives 24VDC from the 24V battery supply through fuse FU8, the
flasher, and the turn/hazard switch box. The flasher provides the pulsed voltage required for
light flashing.

(Refer to Schematic 5/20)

Hazard Signal
The hazard signal receives 24VDC from the 24V battery supply through fuse FU8, the flasher
and the turn/hazard switch box. When the hazard button is activated it shorts the right and left
front signal lights and the right and left rear signal lights together and connects them to the
24VDC battery supply. The flasher provides the pulsed voltage for the blinking.

(Refer to Schematic 5/20)

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Headlights – Low Beams
The MAIN LIGHT switch receives 24VDC from the battery supply through fuse FU3. The MAIN
LIGHT switch must be on to supply power through fuses FU11, FU12 and FU10 to power the
marker lights, tail lights, and left and right switches. The gauge lamps are also powered by this
switch and regulated with a rheostat to control the intensity of the light.

(Refer to Schematic 4/20)

Headlights – High Beams

The high beams receive 24VDC from the battery supply through fuse FU3. The MAIN LIGHT
switch must be on as well as the HIGH BEAM switch. When both switches are on relay RE11 is
energized causing it to change contact poles and send power to the HIGH BEAM INDICATOR
light and the right and left upper HIGH BEAM HEADLIGHTS.

(Refer to Schematic 4/20)

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 Windshield Wipers and
Washer

Windshield Wipers and Washer

Windshield Wipers
The windshield wiper motor is powered by 24Vdc from the battery supply and is protected by
fuse FU13. The speed of the wipers is varied by the Windshield Wiper switch (3 speeds). The
Windshield Wiper/Washer switch is a variable resistance switch that takes 24Vdc and converts
that signal to a voltage that is proportional to the speed setting. This signal is passed on to the
ECU where it is converted to a pulsed DC voltage that energizes and de-energizes relay RE6
causing the wipers to move back and forth intermittently.

(Refer to Schematic 5/20)

Windshield Washer
The windshield washer circuit is powered by 24Vdc battery supply and is protected by fuse
FU13. When the windshield wash switch is closed it supplies power to the windshield washer
motor to pump out washer fluid and also provides a signal to the ECU to automatically run the
windshield wipers at a set speed for roughly five seconds to clean with fluid from the windshield.

(Refer to Schematic 5/20)

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 Heater / Airconditioning
Heater / Airconditioning (A/C)
The heater/air conditioner (A/C) is powered by a 12Vdc supply protected by fuse FU42. The
speed dial of the unit is powered by a 24Vdc supply that is protected by fuse FU20. The speed
of the blower motor is varied increasing or decreasing the resistance by using a 3 pole switch
with a high resistance on the LO setting, a medium resistance on the M setting and no resistor
on the HI setting. The higher the resistance causes a lower field voltage in the motor and slows
the revolutions per minute (RPM), creating less air flow.

(Refer to Schematic 5/20)

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 Hoist Controller
Hoist Controller
The hoist controller is powered by 24Vdc ignition key switch power supply and is protected by
fuse FU18. The hoist controller receives signals from the hoist lever and the proximity switch
and it sends signals to the ECU raise and lower pulse width modulation (PWM) valves when the
lever is in RAISE position it energizes the solenoid on the brake cooling diverter valve.

(Refer to Schematic 7/20)

Hoist Lever
The hoist lever is powered by 5Vdc from the hoist controller. The hoist lever returns a signal to
the hoist controller ranging from 0.5 to 4.3Vdc depending on lever position. If the proximity
switch is not open the hoist controller will send a signal to either the raise, or lower PWM valve.

(Refer to Schematic 7/20)

Proximity Switch
The proximity switch is a normally closed (N.C.) infrared switch mounted on the back of the
vehicle. When the body is raised it cuts the infrared beam from the switch, the switch will open
and stop the body from being raised any further by sending a signal back to the hoist controller.
The switch must be set to stop the body from rising beyond maximum allowable cylinder
extension.

(Refer to Schematic 7/20)

Body-up Switch
The body up switch is connected to the 24Vdc ignition power supply, the traction control unit
(TCU) and the body up lamp indicator. The body up switch has two contacts, one that is the
contact for the connection to the TCU (normally closed) and one that is the contact for the body-
up indicator lamp (normally open). When the body is down on the frame, the body-up switch is
sending a voltage signal to the TCU and is preventing a voltage signal to be sent to the body-up
indicator lamp. When the body-up switch is not sending a signal to the TCU (body is up), the
TCU limits the hauler to only forward motion and at a user preset speed limit. The body-up
indicator lamp is illuminated while the body is up.

(Refer to Schematic 7/20)

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Propulsion Override Switch
The propulsion Overdrive Switch is supplied power by the 24Vdc ignition switch supply through
fuse FU39 and is a safety mechanism that will override the limit put on speed when the body is
up. Pressing this switch down and holding it, you are no longer speed restricted. This should
only be used in an emergency situation as movement at higher speeds while the body is up can
cause damage to the hauler. Override speed is a user adjustable parameter.

(Refer to Schematic 7/20)

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 Load Weigh System
Load Weigh System
Strut Sensors
Each ride strut on the vehicle is fitted with a pressure sensor that sends a signal back to the
electronic control unit (ECU) that is proportional to the weight of the hauler. The ECU then
sends a signal to the LOAD WEIGH LIGHTS based on the signal from the strut pressure
sensors. The pressures are displayed on the Contronic LCD.

(Refer to Schematic 7/20)

Load Weigh Lights

The load weigh lights are located on the sides of the hauler. There are three lights on either
side of the hauler, each with a different color: green, amber and red. The green light indicates
that the hauler is filled to 25% capacity. The amber light indicates that the hauler is filled to 80%
capacity. The red light indicates that the hauler is filled to 100% capacity. These parameters
can be changed using the Contronic Service Tool.

(Refer to Schematic 7/20)

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 Horns
Horns
The LEFT HIGH, LEFT LOW, RIGHT HIGH, and RIGHT LOW horns are all connected in parallel.
Relay RE3 receives 24VDC from the battery supply through fuse FU4. When the HORN switch
is activated it energizes relay RE3 so the contact switches poles and closes the circuit causing
the horns to sound

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Schematics

SCHEMATICS

7/3/2007
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 HTT4500(2)-20-0707

7/3/2007