B30C ADT Electrics

B30C ADT

ELECTRICAL

COPYRIGHT REFERENCE PAGE

BELL TRAINING 2000 ELECTRICAL 1

SPECIFICATIONS

The electrical system on the BELL machine is a very simple 24 V system with the

electrical supply from 2 x l2 V batteries or a 24 V alternator driven by the engine. The

power output from the alternator is regulated and maintains the batteries in a fully

charged state. The two batteries are connected in series to give 24 V

The specification data for the electrical system on the C SERIES ADT are as follows:

Electrical System

Voltage 24V

Battery Type 2X12 V, maintenance free

Battery capacity 100Ah

Starter motor capacity 4kW

Alternator voltage rating 24V

Alternator amperage rating 55A

Power Ratings (bulbs)

Headlight 24V75/70W

Front park light 24V2W

Front indicator light 24V21W

Number plate light 24V5W

Stop/tail light 24V21/5 W

Rear indicator light 24V21W

Reverse light 24V75W

Interior light 24V18W

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ELECTRICAL



OPERATOR CONTROLS AND INSTRUMENTS

The following figure details the layout of the controls and instruments in the cab for the

B25C:

ITEM DESCRIPTION ITEM DESCRIPTION

1 Centre Panel (Instruments) 11 Trainer Seat

2 Right Panel (Controls) 12 Retarder pedal

3 Gear Shift Control lever 13 Document holder

4 Park/ Emergency brake control valve 14 Steering Column Switch

5 Bin Tip Control Lever 15 Electrical Distribution Box Cover plate

6 Air Conditioner Control Panel 16 Steering Wheel Adj Lever

7 Windscreen Washer Bottle 17 Air/ Air Conditioner Vent

8 Accelerator Pedal

9 Service Brake Pedal

10 Operators Seat

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ELECTRICAL



The following figure details the electrical distribution box front panel:

1. 20 A circuit breaker (CB9) 5. 15 A circuit breaker (CB5)




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ELECTRICAL



CONTROLS AND INSTRUMENTS

All the gauges, indicators, switches and controls are described in this chapter.

1. SPEEDOMETER.

The speedometer monitors the machine speed in kilometers per hour (km/h).

2. MAIN WARNING INDICATOR

The main warning indicator flashes to warn the operator of one or more of the following

conditions or problems with a machine system.

Low coolant level, High hydraulic fluid temperature, Low pneumatic system pressure,

Brake system failure, Emergency steering system in operation, Park/emergency brake

If one or more of the above faults occur, the respective warning indicator on the

dashboard will also flash when the main warning indicator flashes.

A warning buzzer also sounds when the main warning indicator flashes if the engine is

running (except for the park/emergency brake ON condition).

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ELECTRICAL



3. ENGINE OVERSPEED WARNING INDICATOR

The engine over speed warning indicator flashes and a warning buzzer sounds when the

engine speed exceeds 2 850 rev/min.

If the operator continues to over speed and the engine speed exceeds 2 950 rev/min the

following occurs:

The engine over speed warning indicator ceases flashing but stays illuminated.

The exhaust brake is automatically applied by the MFA 10

A caution symbol (D) flashes on the tachometer.

A louder buzzer sounds.

The error is logged into the MFA 10

4. TRANSMISSION DISPLAY SCREEN

The screen displays the transmissions current operation mode, the current gear selection

and error codes.

5.TACHOMETER

The tachometer monitors the engine speed in revolutions per minute rev/min).

Incorporated on the face of the tachometer is an LED caution sign (D). This sign is not

visible until an over speed situation is caused.

6. BRAKE SYSTEM LOW PRESSURE WARNING INDICATOR

The indicator flashes if the brake systems hydraulic pressure drops below 11mpa

(110bar)

Note: The main warning indicator and the warning buzzer are also activated with the

brake system low pressure warning indicator.

7. EMERGENCY STEERING WARNING INDICATOR

The emergency steering warning indicator flashes if there is an engine or main hydraulic

pump failure and the emergency steering is activated.

Note: The main warning indicator and the warning buzzer are also activated with the

emergency steering warning indicator.

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ELECTRICAL



8. DIRECTION INDICATOR

The direction indicator will flash when the steering column switch is moved to indicate a

right turn.

If the hazard switch is ON, both direction indicators flash.

9. ALTERNATOR (CHARGE) WARNING INDICATOR

The warning indicator illuminates if the alternator is not charging the batteries or if the

engine is not running and the ignition switch is ON.The normal operating voltage is 24V.

10. DO NOT SHIFT WARNING INDICATOR

The do not shift warning indicator illuminates when there is a transmission problem or

failure.

Note: The do not shift warning indicator flashes briefly on start-up when the ignition key

is turned to the ON position.

If the do not shift warning indicator illuminates, check for error codes on the gear shift

control.

11. LOW PNEUMATIC PRESSURE WARNING INDICATOR

The low pneumatic pressure-warning indicator flashes when the air pressure in the

pneumatic tank is below 500 KPa (72.5 psi).

Note: The park/emergency brake cannot be re-leased until the air pressure in the tank is

allowed to build up to approximately 550 kPa (79.8 psi) and the low pneumatic pressure

indicator extinguishes.

12. Blank (Spare)

13. Blank (Spare)

14. HIGH HYDRAULIC FLUID TEMPERATURE WARNING INDICATOR

The high hydraulic fluid temperature warning indicator flashes when the hydraulic fluid

temperature exceeds 120C (248F).

If overheating occurs stop the machine, engage neutral and allow the engine to run at

1500 rev/min until the hydraulic temperature returns to normal temperature and the

warning indicator extinguishes.

Note: The main warning indicator and the warning buzzer are also activated with the high

hydraulic fluid temperature warning indicator.

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ELECTRICAL



15. LOW ENGINE COOLANT LEVEL WARNING INDICATOR

The warning indicator flashes when the engine coolant requires replenishing immediately.

Note: The main warning indicator and the warning buzzer are also activated with the low

engine coolant level warning indicator.

Note: The low engine coolant level warning indicator may flash briefly on start-up when

the ignition key is turned to the ON position.

16. Blank (Spare)

17. High Beam Indicator

The indicator illuminates when the high beam mode on the headlights is selected on the

steering column switch.

18. Blank (Spare)

19. ROTATING BEACON WARNING INDICATOR

Note: The rotating beacon is optional equipment. (The wiring is standard)

The rotating beacon warning indicator illuminates when the warning beacon on top of the

cab is switched on.

20. BIN RAISED WARNING INDICATOR

CAUTION

When the bin is raised the machine can only operate in 1st gear and the exhaust

brake and retarder are inoperable.

The bin raised warning indicator will not extinguish until the bin is fully lowered.

21. EXHAUST BRAKE/ RETARDER WARNING INDICATOR

The exhaust brake/retarder warning indicator illuminates when the exhaust brake is

applied.

Note: The exhaust brake is automatically applied when the accelerator pedal is fully

released (and transmission lock-up is engaged). The exhaust brake is de-activated when

the accelerator pedal is re-applied (or the machine is out of lock-up mode). The exhaust

brake warning indicator then extinguishes.

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ELECTRICAL



22. INTER-AXLE DIFFERENTIAL LOCK INDICATOR

The inter-axle differential lock indicator illuminates when the longitudinal differential lock is

engaged.

Note: The engine rev/min must be lower than 900 rev/min and the output shaft rotation

must be lower than 60 rev/min before the inter- axle will engage.

23. COLD START WARNING INDICATOR

The cold start function is automatic. When the ignition is switched on and the engine

coolant temperature is below 15C (59F), the warning indicator illuminates.

Note: The cold start warning indicator illuminates briefly on start-up, when the ignition key

is turned to the ON position.

When it is safe to start the engine, the cold start warning indicator extinguishes.

24. DIRECTION INDICATOR

The direction indicator will flash when the steering column switch is moved to indicate a

left turn.

If the hazard switch is ON, both direction indicators flash24P

25. PARK/EMERGENCY BRAKE WARNING INDICATOR

The park/emergency brake warning indicator illuminates when the park/emergency brake

is applied and extinguishes when it is released.

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ELECTRICAL



MASTER DISPLAY UNIT

trip+ -

1

2

3

S005094

4

The MFA 10 (1) is located on the right side panel on the dashboard. The MFA 10

comprises of the digital display screen (2), two rows of buttons (3) and two rows of light

emitting diodes (LED) (4).

The buttons are manually operated to monitor the condition of machine systems and the

results of the selected monitoring function are displayed on the digital display screen.

The digital display screen displays two values, one value on the top line of the screen and

the other on the bottom line of the screen, in accordance with the top and bottom rows of

buttons.

The LEDs are red warning indicators or indicators for the relevant system being

monitored.

When the ignition is switched on the unit performs a brief self-test. If there is a problem

with one of the systems tested the relevant LED flashes and the relevant value is

displayed on the digital display screen.

Note: Every error which is encountered by the master display unit is logged and stored in

the units computer. The computer can store 250 errors per function (system).

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ELECTRICAL



DEFAULT DISPLAY

When the ignition switch is turned on and the self-test is completed, the digital display

screen displays two values as follows:

trip+ -

1

S005095

2

The amount of fuel in the fuel tank is displayed on the top of the screen (1). The amount of

fuel is displayed in litres.

Note: The fuel tank capacity is 215 litres (56.8 USGAL).

The number of hours that the engine has been in operation is displayed on the bottom

line of the screen (2).

Note: The engine operation hours are also referred to as the SMR (Service Meter

Reading) and it is this reading which is used to determine the service intervals as detailed

in the service guide. (RSG Recommended Service Guide)

When one of the buttons on the top row is pressed, the value for that particular system is

displayed on the top line of the screen.

When one of the buttons on the bottom row is pressed, the value for that particular system

is displayed on the bottom line of the screen.

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The relevant LED illuminates to indicate which system button has been pressed and thus

which system is being monitored.

Pressing a button again will cause the display to revert to the default display.

When a critical value of any of the monitored functions is reached, its value on the LCD

screen overrides any other function displayed at that time. In conjunction with the

displayed value, the critical functions LED is activated together with a warning buzzer to

alert the operator to the problem.

The buttons and their functions are as follows:

trip+ -

1

S005095

2

TOP DISPLAY

BOTTOM DISPLAY

4

5

678

9

10

11

12

3

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1. TOP DISPLAY

This indicates the value of the relevant button pushed on the top row.

2. BOTTOM DISPLAY

This indicates the value of the relevant button pushed on the bottom row.

3. AIR PRESSURE SYSTEM BUTTON

When the system air pressure button is pressed the air pressure is displayed in bars on

the top line of the digital display screen and the relevant LED illuminates.

The normal operating pressure is 8 bar (800 kPa or 116 psi).

When the system air pressure button is pressed again the display for the air pressure is

cancelled and default is displayed.

The operator is warned of a low system air pressure as follows:

If the air pressure reaches 5 bar (500 kPa or 72.5 psi):

The pressure displayed on the screen flashes.

The LED flashes.

A warning buzzer sounds intermittently.

If the air pressure reaches 4.5 bar (450 kPa or 65psi):

The display and the LED cease flashing but re-main illuminated.

The warning buzzer sounds continuously.

The error is logged in the units computer and stored in its memory.

4. FUEL BUTTON

When the fuel button is pressed the amount of fuel in the fuel tank is displayed in litres on

the top line of the digital display screen and the relevant LED illuminates.

The fuel tank capacity is 215 litres (56.8 USGAL).

The operator is warned of low fuel as follows:

If the fuel in the tank reaches a level of 20 litres (5.3 USGAL):

The fuel level displayed on the screen flashes.

The LED flashes.


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ELECTRICAL



If the fuel in the tank reaches a level of 10 litres (2.6 USGAL):




5. SPARE

6. TRIP BUTTON

When the trip button is pressed the display at the bottom of the digital display screen is

zeroed for the trip meter mode and the relevant LED illuminates.

The number of kilometer traveled (since zeroing) is counted up as the machine is

travelling. When the trip button is pressed again the trip meter mode is cancelled and the

default is displayed.

7. SYSTEM VOLTAGE BUTTON

When the system voltage button is pressed the electrical system voltage is displayed on

the bottom line of the digital display screen and the relevant LED illuminates.

The systems operating voltage is 24V. If the charge is low, check the battery charge

indicator, the alternator and the alternator drive belts.

8. BOTTOM ROW LEDS (Indicates a problem with a corresponding button or circuit)

9. ENGINE OIL PRESSURE BUTTON

When the engine oil pressure button is pressed the engine oil pressure is displayed in

bars on the bottom line of the digital display screen and the relevant LED illuminates.

The operating pressures are 3 bar (300 KPa or 43.5 psi) @ idle (650 rev/min) rising to 5

bar (500 KPa or 72.5 psi) @ 1 500 rev/min. At engine speeds higher than 1 500 rev/min

the pressure remains constant at 5 bar.When the engine oil pressure button is pressed

again the display for the engine oil pressure is cancelled and default is displayed.

The operator is warned of a low engine oil pressure as follows:

If the engine oil pressure reaches 100 KPa (14.5 psi):

The pressure displayed on the screen flashes.

The LED flashes.


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If the engine oil pressure reaches 50 kPa (7.25 psi):




10. TRANSMISSION FLUID TEMPERATURE BUTTON

When the transmission fluid temperature button is pressed the transmission fluid

temperature is displayed in degrees Celsius (C) on the top line of the digital display

screen and the relevant LED illuminates.

When the transmission fluid temperature button is pressed again the display for the

transmission fluid temperature is cancelled and default is displayed.

The operator is warned of a high transmission fluid temperature as follows:

If the transmission fluid temperature reaches 135C (275F):

The temperature displayed on the screen flashes.

The LED flashes.


If the transmission fluid temperature reaches 145C (293F):




11. ENGINE COOLANT TEMPERATURE BUTTON

When the engine coolant temperature button is pressed the engine coolant temperature is

displayed in degrees Celsius (C) on the top line of the digital display screen and the

relevant LED illuminates.

The normal operating temperature range is 85C to 95C (185F to 203F)

When the engine coolant temperature button is pressed again the display for the engine

coolant temperature is cancelled and default (fuel reading) is displayed.

The operator is warned of a high engine coolant temperature as follows:

If the engine coolant temperature reaches 98C (208F):

The temperature displayed on the screen flashes.

The LED flashes.

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If the engine coolant temperature reaches 105C (221F):




12. TOP ROW LEDS (Indicates a problem with a corresponding button or circuit)

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ELECTRICAL



MFA 10 INSTUMENTATION THRESHOLDS AND WARNINGS

FIRST

THRESHOLD

FLASHING LED

INTERMITTENT

ALARM

SECOND

THRESHOLD

CONTINOUS

LED

CONTINOUS

ALARM

Transmission Temp. (converter out) C 134 144

Engine Temp. C 98 104

Fuel Level L 19 10

Engine Oil Pressure BAR 0.7 0.5

Air Pressure BAR 5 4.5

Remove and acknowledge warning by pressing the appropriate button for 5 seconds.

All second threshold warning occurrences (except fuel) are logged in the MFA 10 event

memory for later access.

ENGINE SPEED THRESHOLDS AND WARNINGS

FIRST

THRESHOLD

FLASHING LED

INTERMITTENT

ALARM

SECOND

THRESHOLD

CONTINOUS

LED

CONTINOUS

ALARM

Engine Speed RPM 2600 2700

Engine Over speed warning indicator

Main Warning Alarm

Automatic Application of Exh. Brake

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WARNING LIGHT THRESHOLD AND INFORMATION

Cont.

Light

Flashing

Llight

Main

Warning

Alarm

Main

Warning

Indicator

1. Indicator Left

2. Cold start (if fitted)

3. Exhaust Brake

4. Rotating Beacon (if

fitted)

5. Park Brake

6. Diff. Lock

7. Bin-up

8. High beam

9. Accumulator Press. Bar 110

10. Emergency Steering Bar 5

11. Low Water Level

12. Hyd. Oil Temp. (B25

only)

C 120

13. Indicator Right

14. Charge Light

15. Do-Not-Shift

16. Air Pressure Bar 4.5

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SWITCHES

A row of switches is located on the right side panel on the dashboard. There are nine

positions for switches on the panel. Each switch is manually operated to select a required

function.

Note: There are blanking plates fitted to the three end switch positions.

The switches and their functions are as follows:

S002398

1 2 3 4 5 6 7 8 9

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1. INTERIOR LIGHT SWITCH

The interior light switch is used to operate the interior light on the roof of the cab.

The switch has two positions:

OFF; switch in the normal position.

ON; switch in the down position.

2. LIGHTS SWITCH

The light switch is used to operate the headlights, park lights, tail lights and number plate

light.

The lights switch has three positions:


Park lights, taillights, number plate light and instrument panel lighting ON; switch in the

central position.

Headlights ON; switch in the down position.

Note: The park, tail, number plate and instrument panel lights will illuminate when the

lights switch is in the central position, even if the ignition switch is OFF. However the

ignition switch must be ON for the headlights to operate from the ignition switch in the

down position.

3. WINDSCREEN WIPER/WASHER SWITCH

The windscreen wiper/washer switch is used to operate the windscreen wiper motor and

the windscreen washer pump on the water bottle.

The switch has three positions:


Windscreen wiper ON; switch in the centre position.

Windscreen washer ON; switch held in the down position.

Note: The switch is spring-loaded from the washer position to the central position.

4. ROTATING BEACON SWITCH

The rotating beacon switch is used to operate the warning beacon on the roof of the cab.




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5. INTER-AXLE DIFFERENTIAL LOCK SWITCH

The inter-axle differential lock switch is used to apply the longitudinal lock in the transfer

case.




Note: When the inter-axle differential lock is engaged the inter-axle differential lock

indicator on the instrument panel illuminates.

Note: The engine rev/min must be lower than 900 rev/min and the output shaft rotation

must be lower than 60 rev/min before the inter- axle will engage.

6. Hazard Indicators Switch

The hazard indicators switch is used to operate the direction indicators.




When the switch is ON, both of the rear direction indicators and both of the front direction

indicators will flash.The two direction indicators on the instrument panel will also flash

when the hazard indicator switch is ON.

Note: The hazard indicators switch will operate the direction indicators and the direction

indicators when the ignition switch is ON or OFF.

7. SPARE

8. SPARE

9. SPARE

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BATTERY DISCONNECT SWITCH

The battery disconnect switch (1) is located inside the battery box.The battery disconnect

switch is used to isolate the electrical power from the batteries to the machine.

CAUTION

Always switch OFF the battery disconnect switch when the engine is shut down

and the machine is left unattended. If the switch is left ON for long periods while the

engine is shut down, the batteries may become discharged.

CAUTION

Always switch OFF the battery disconnect switch before any maintenance or repair

is per-formed on the machines electrical system or any welding work is performed.

The battery disconnect switch has two positions, OFF and ON, the switch position is

clearly marked on the switchs face plate.

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IGNITION SWITCH

The ignition switch (1) is located on the right panel on the dashboard.

The ignition switch is key operated and has two positions, OFF and ON.

Note: The ignition switch will only operate if the battery disconnect switch is ON. Refer to

previous description.

When the ignition switch is switched ON, the following indicators illuminate or flash:

Main warning indicator.

Park/emergency brake indicator.

Emergency steering warning indicator.

Alternator warning indicator

Do not shift warning indicator.

Low pneumatic pressure warning indicator.

Low engine coolant warning indicator (flashes briefly).

Cold start indicator (optional).

Note: Transmission digital display unit, will display neutral (N)

Note: The park/emergency brake warning indicator will extinguish when the

park/emergency brake is re-leased. The other warning indicators will extinguish

when the engine is started.

When the ignition switch is switched OFF, the kill lever on the injection pump is activated

causing the engine to stop.

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START BUTTON

The start button (1) is located on the right panel on the dashboard.The start button is used

to activate the starter motor when starting the engine. Whenever the start button is kept

depressed the starter motor will be activated. Releasing the start button will de-activate

the starter motor.

CAUTION

Do not hold in the start button (operate the starter motor) for more than seventeen

seconds. If the engine does start during this period, wait one minute before

attempting again to start the engine. If the engine does not start after two attempts,

investigate the cause.

Note: The start button will only operate if the batteries disconnect switch and the ignition

switch are ON. The transmission also has to be in neutral. Refer to previous description.

BATTERY CIRCUIT BREAKER

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The battery circuit breaker (1) is rated at 60 A and is located inside the batteries box.

The circuit breaker protects the machines electrical circuits from a possible overload

condition or fault from the batteries.

S002364

GEAR SHIFT CONTROL

The gear shift control is located on the right hand side of the cab.

The gear shift control comprises of the gear shift control lever (1), the automatic / manual

selector button (2) and gear selection identification plate.

The selector button is used to switch between manual and automatic modes.

The gear selection identification plate is a graphical representation of the gear shift gate.

V ( Forward ) , is used to select a forward gear.

N ( Neutral ) , is used to select neutral gear.

R ( Reverse ), is used to select reverse gear.

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AIR CONDITIONER

Note: The air conditioner is optional equipment.

F002139

2

1

The air conditioner (1) and the filter housing (2) are located on the right side of the cab.

The air conditioners control panel is located on the right of the cab and enables the

following functions:

Switch (1) controls the fresh air vent. When the switch is pressed the air vent is opened to

allow fresh air into the cab. When the fan speed knob (2) is turned in a clock-wise

direction, the fan speed is increased. A counter clockwise turn of the fan speed knob

decreases the fan speed. Air conditioner switch (3) switches the air conditioner on or off.

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Note: The air conditioner switch is optional. If an air conditioner is not fitted, the face plate

does not have the cut-out for the switch.

When the air conditioner switch is ON, and the fan switch is also ON, conditioned air is

circulated through the air vents.

When the temperature control knob (4) is turned in a clockwise direction, the air circulated

through the air vents is progressively warmed. When the temperature control knob is

turned in a counter clockwise direction, the air circulated through the air vents is

progressively cooled.

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ELECTRICAL



ELECTRICAL EARTHING CONNECTIONS CHASSIS

Incorrect earth procedure is a major cause of electrical faults on machines.

It is of major importance to clean off all paint and rust at the earth points.

Bare shiny metal must be visible where the earth connector ring lug touches

the machine chassis. This especially important at points where a bolt is used

through a thin steel plate and there is no direct thread contact from the bolt to

the chassis. If a threaded boss is available as an earth point, it should be

used in preference to a hole through a plate.

The contact face of the boss should be cleaned off as for any other earth

point. Do not rely on just the bolt thread maintaining the contact.

Where possible use a sealer varnish to seal the completed earth point from

corrosion. A small amount of copper slip grease can be used on the bolt

thread if no sealer is available. This has a high metal content. Do not use

normal grease for the application as it is non-conductive.

Symptoms of bad earthing can be electrical problems such as no selection of

gears or erratic functioning, solenoid/relays that do not hold in properly, lights

glowing dully when other lights are operated.

EG: 1

Park lights glow when the brake lights are switched on:

It is noticed that the brake lights are also dull. This is due to a bad rear earth.

The brake lights find the path to earth through some other component-in this

case the park lights earthed on the front of the machine.

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EG: 2

An ignition solenoid will not switch on properly and makes a clattering sound:

When the ignition key is turned it gives an earth to the ignition solenoid coil. If there is

paint between the earth lug and the chassis a very small area of metal makes

contact. This area has electrical resistance causing a volt drop. The coil of the

solenoid sees a voltage level which borderline with its minimum operating

specification causing the spring to overcome the coils magnetic field opening the

contacts again. This operation repeats its self causing the solenoid contacts to open

and close repeatedly until the ignition switch is switched off.

SOLUTION:

In both cases clean the paint or corrosion off the offending earth point and ensure

maximum metal to lug contact. Apply suitable corrosion prevention material to maintain

contact integrity.

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FAULT FINDING

Some general hints:

Equipment: All that is normally required is a multi-meter.

Never look at the whole wiring on a machine. There are enough wires on a

BELL machine to confuse most people. If the indicators are not working, forget

about the other circuits and concentrate only on the indicators. Try to picture

how the current should flow through the circuit. E.g. Current flows from positive

to a circuit breaker to the loaded to earth.

A component is more likely to give trouble than a wire. Dont try swapping

around. If the machine was working with the wires connected that way, then

connections must be correct.

Check connectors for loose or corroded connections. A quick squirt with Q20

(anti corrosion solvent ) will often cure this.

An alternator has 2, 3 or 4 connections, depending on the vehicle. These are:

D + Terminal : a yellow wire that comes form the dash warning light.

W Terminal :an unrectified stator terminal that operates the revcounter.

B+ Terminal : the main charge wire to the battery.

B- Terminal : an extra earth terminal. This is necessary when thealternator is rubber mounted.

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CIRCUIT BREAKERS

The circuit breakers used by bell are of the thermal type. When they heat up

due to current flow they trip. A 15 AMP circuit breaker will continuously handle

the amount of heat generated by a 15 AMP current without tripping.

If a circuit breaker is a little over its it will not trip immediately. The further over

its limit it becomes, the faster it will trip.

In the event of a short circuit the breaker will trip almost instantaneously due to

the almost instantaneous heat generated by a large current.

These facts can be used to advantage trouble shooting. I.e. if the circuit breaker

trips after 5 minutes or only a while after things are switched on, then the

problem is that of an overloaded circuit. This is usually where non-factory fitted

electrical components have been installed, or a device such as a wiper motor

has jammed allowing a moderate current flow but not a dead short.

If the circuit breaker trips within a few seconds the problem is that of a dead

short positive wires direct to machine chassis. In this case look for broken

wires on the relevant circuit or external damage. To the harness causing

internal shorts or disconnected terminals touching a metal part of the machine.

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RELAYS

Relays can be referred to as a remote switch, which can handle a highercurrent flow. A relay has five pins:

30- Ignition or battery positive or this can be a earth.

87a- Load normally closed.

87 - Load normally open.

85 - Signal or trigger.

86 - Signal or trigger.

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ELECTRICAL



ELECTRICAL EQUIPMENT TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSE REMEDY

Right turn indicator does notwork.

Bulb defective.Loose or brokenconnections.Indicator stalk switchdefective.

Change the bulb.Change the indicator stalkswitch.Tighten or repairconnections.

Left turn indicator does notwork.

Bulb defective.Loose or brokenconnections.Indicator stalk switchdefective.

Change the bulb.Change the indicator stalkswitch.Tighten or repairconnections.

Windscreen wiper does notoperate.

Wiper arm jamming motor.Wiper switch defective.Wiper motor defective.Loose or brokenconnections.

Release arm and blade.Change the wiper switch.Change the wiper motor.Tighten or repairconnections.

Charge warning light not onwith master switch on andengine stopped.

Warning light bulb defective.Wiring and connectorsdisconnected.Regulator on alternatordefective.

Change the bulbCheck/repairChange the alternator.

Charge warning light not offwith engine running

Alternator drive belt loose orbroken.Regulator on alternatordefective.

Adjust drive belt tension or fitnew drive belt.Change the alternator.

Charge warning light not offwith engine running.

Alternator drive belt loose orbroken.Regulator on alternatordefective.Alternator defective.Poor battery connections.

Adjust drive tension or fitnew drive belt.Change the alternator.Change the alternator.Clean and check batteryconnections.

Batteries do not hold charge. Battery cells dry.Battery defective.Short running times withlights in use.

Check battery electrolyteand top up.Change the battery.Remove and charge thebatteries or install fullycharged batteries.

Batteries boiling dry fromover charging.

Regulator on alternatordefective.

Change the alternator andtop up the electrolyte in thebatteries.

B30C ADT

ELECTRICAL



ELECTRICAL EQUIPMENT TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSE REMEDY

Starter motor does not turnor turns very slowly.

Flat batteries.Worn brush gear.Batteries defective ordamaged.Battery terminals loose orcorroded.Starter motor defective ordamaged.Starter button defective ordamaged.Starter bushes worn grinding rotor on field coils.

Recharge or change thebatteries.Change the batteries.

Tighten and/or clean thebattery terminals.Change the starter motor.

Change the starter button.

Starter motor turns but doesnot turn the engine.

Starter motor defective ordamaged (solenoid stickynot engaging.

Change the starter motor.

Starter motor does notdisengage after the enginehas started.

Starter motor defective ordamaged (jammed bendixgear)Starter button defective ordamaged.

Change the starter motor.

Change the starter button.

Starter motor does not turn(shift lever in neutral).

Gear shift faulty.neutral switch/neutral relay.

Check gear shift and changeor repair as necessary.Check in-line fuse andreplace.

Gauge not working properly. Loose or brokenconnections.Sender defective.Gauge defective.

Tighten or repair theconnection.Change the sender.Change the gauge.

Switch not working properly Loose or brokenconnections.Switch defective.Component defective.

Tighten or repair theconnection.Change the Switch.Change the component

Warning light not workingproperly.

Warning light bulb defective.

Circuit breaker tripped.Loose or brokenconnections.

Change the warning lightbulb.Investigate cause and reset.Tighten or repair theconnection.

B30C ADT

ELECTRICAL



EARTH POINTS R3

B30C

ELECTRICAL



STARTING & CHARGING CIRCUIT R3

B30C

ELECTRICAL



VEHICLE INTERFACE UNIT WARNING CIRCUIT R3

B30C

ELECTRICAL



MFA 10 & OVERREV CIRCUIT R3

B30C

ELECTRICAL



HEADLIGHT CIRCUIT R3

B30C

ELECTRICAL



INDICATOR / HAZARD CIRCUIT R3

B30C

ELECTRICAL



REVERSE / STOP LIGHT & HORN CICUITS R3

B30C

ELECTRICAL



AIRCON / BLOWER CIRCUIT R3

B30C

ELECTRICAL



BLOWER AND WIPER CIRCUIT R3

B30C

ELECTRICAL



COLD START / ROTATING BEACON / CIG. LIGHTER CICUIT R3

B30C

ELECTRICAL



RADIO CIRCUIT ( OPTIONAL ) R3

B30C

ELECTRICAL



BIN / PARK BRAKE / KICK DOWN CIRCUITS R3

B30C

ELECTRICAL



EST 37 ELECTRICAL CIRCUIT R3

12

70

08

17

12

-BP

00

99

99

TRAN

SMISS

ION

EST 3

7M

ICRO

PROC

ESSOR

TRAN

SMISSIO

N

11

410

1114

83

12

112

RETA

RD

ER / EX

HA

UST

BR

AKEDIFF

LOC

KS

OLEN

OID

LOC

K UP V

ALVE

LOA

D SEN

SOR

(TPS) DIFFER

ENC

E PRESS

URE FILTER

SWITC

H

SEN

SO

R RETA

RD

ER

TEMP

INTER

NA

L GE

AR

CH

AIN

SPEED

PIC

K U

P

TUR

BINE SP

EED P

ICK UP

ENG

INE SPE

ED P

ICK

UP

OU

TPU

T SPEED

SENSO

R

DIA

GN

OSTIC

PLU

G

CA

N IN

TERFA

CE

37 W

AY CANNO

N C

ONNEC

TOR

DISP

LAY SC

REE

N

A7

A5

A6

B4

B6 Y7

Y8

Y9

S10 B9 B3

B2

B1

SHIFT LEVER

(VTS-3)

A2

VP

VNRT+T-OPTIO

NA

L B3

10

37

19

39

B3

31

42

43

R2

74

1

GN 0.5

BL 1

.5P...........

IGN

ITION

NEU

TRA

L SIGN

AL

REV

ERSE

SIG

NA

L

DIFF

LOC

K S

WITC

HB

ATTE

RYB

ATTE

RYB

IN U

P RELA

YD

O N

OT SH

IFT LIGH

T

EA

RTHE

ARTH

KIC

KD

OW

N SW

ITCH

SPEED

O

RD

1.5

RD

1.5

IGN

ITION

BN

/RD

1.5

WH

/RD

1.5

GN

/BL 1.5

GN

1.5

GN

1.5

BN

/BL 1.5

GY 1.5

BK 2

.5B

K 2.5

BK/W

H 1.5

WH

1.5

800

804

808

820

828

83

68

40

84

4

85

68

52

86

0

87

28

76

83

2

12346 5789101

11

21

31

41

51

61

71

81

92

02

12

2

12346 5789101

11

21

31

41

51

61

71

81

920212

2

Y8

Y9

PAR

K BRA

KE SW

ITCH

OR/G

N 1.5

P3

B30C

ELECTRICAL



ELECTRIC MIRROR CIRCUITS R3

B30C

ELECTRICAL



HYDRAULIC COOLER AND REV WARNING CIRCUITS R3

B30C

ELECTRICAL



CONNECTORS P01 R3

B30C

ELECTRICAL



CONNECTORS P02/03 R3

B30C

ELECTRICAL



CONNECTORS P04/P05/P06/P07 R3

B30C

ELECTRICAL




B30C

ELECTRICAL



CONNECTORS P12/P13/P14 R3

B30C

ELECTRICAL



CONNECTORS P15/P16/P17 R3

B30C

ELECTRICAL




B30C

ELECTRICAL



CONNECTORS P26/P27/P28/P29/P30 R3

B30C

ELECTRICAL



CONNECTORS P31/P32/P33/P34/P35/P36 R3

B30C

ELECTRICAL




Documents

B30C ADT Electrics