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1. TRUCK MODELS COVERED
This Service Manual furnishes servicing and maintenance information for the following trucks:
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SENB8596 GENERAL INFORMATION

2. NAMEPLATE AND SERIAL NUMBER LOCATIONS
SENB8596 GENERAL INFORMATION
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3. TECHNICAL DATA
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SENB8596 GENERAL INFORMATION

4. DIMENSIONS (APPROXIMATE)
SENB8596 GENERAL INFORMATION
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5. 7 7
SENB8596 GENERAL INFORMATION

6. SPECIFICATIONS
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SENB8596 COOLING SYSTEM

7. SENB8596 COOLING SYSTEM
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DESCRIPTION
The radiator with a tube-and-fin type core comes
standard. The fins are corrugated. The cooling fan is of
pusher type and has eight blades to provide high
cooling efficiency. The lower tank has a built-in
transmission oil cooler which, in operation, is constantly
removing heat from the transmission oil returning from
the torque converter.

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SENB8596 COOLING SYSTEM
REMOVAL AND INSTALLATION
Start by:
a) Remove the gas-filled cylinder and engine hood.
b) Remove the radiator cover.
c) Loosen the radiator drain cock to drain coolant
from the radiator.

9. Suggestions for removal
(1) Fasten a hoist to the radiator and sling the
radiator.
(2) Remove the radiator mounts (at 4 places) and lift
off the radiator.
Inspection
(1) Blow dirt and bugs, if any, from the radiator fins
with compressed air. Be careful not to bend the
fins because this will decrease cooling efficiency.
(2) Replace the radiator if the fins are damaged
beyond repair.
(3) Check the rubber cushions of the radiator mounts
for condition. Replace them if damaged or
deteriorated.
(4) Check the radiator hoses, upper and lower, for
condition. Replace them if defective.
Installation
To install, follow the reverse of removal sequence.
(1) Slide the hoses on to the tubes of the radiator and
tighten all the clamps. Make sure the hoses are
properly clamped at flared portions of the tube.
(2) Fill the cooling system with coolant to the correct
level. Start the engine and, with the engine
running at low idle, listen for any abnormal noise.
Check to be sure the coolant level in the reserve
tank is correct.
SENB8596 COOLING SYSTEM
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10. TROUBLESHOOTING
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SENB8596 COOLING SYSTEM

11. SPECIFICATIONS
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SENB8596 ELECTRICAL SYSTEM

12. LOCATION OF COMPONENTS
For the components to which harnesses A, B and C are connected, see the pages which follows.
SENB8596 ELECTRICAL SYSTEM
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13. Harness A
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SENB8596 ELECTRICAL SYSTEM

14. Circuit numbers and color codes of harness A
SENB8596 ELECTRICAL SYSTEM
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15. Harness B (on the left side of engine room)
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SENB8596 ELECTRICAL SYSTEM

16. Harness C (on the right side of engine room)
SENB8596 COOLING SYSTEM
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17. DESCRIPTION
Console Box
1 Engine coolant temperature gauge
2 Torque converter oil temperature gauge
3 Fuel gauge
4 Hour meter
5 Central vehicle monitoring system
6 Starter switch
7 Lighting switch
8 OK monitor check switch
9 Fuse box
10 Speed selector switch
Central vehicle monitoring system
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SENB8596 ELECTRICAL SYSTEM

18. Components in console box
SENB8596 ELECTRICAL SYSTEM
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Spare power source (terminal)
The spare terminal is located on the lead from the fuse
box in the control box. (Another spare terminal is
located on the main harness side of the chassis.)
Cord color: LG (yellow/green)
The step required to gain access to the spare terminal
is to remove the rear panel of the control box. The
terminal is taped to the harness protector.

19. Side Instrument Panel
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SENB8596 ELECTRICAL SYSTEM

20. Fuses
SENB8596 ELECTRICAL SYSTEM
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Optional fuses

21. Major Components
Electronic control unit (ECU)
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SENB8596 ELECTRICAL SYSTEM
The electronic control unit (ECU) has a built-in 1-chip
microcomputer. This computer processes signals from
the travel speed sensor for actuating the speed selector
system.
The ECU has “self-diagnostic” failure indicator lights
which come on when any problem occurs in the
electrical system, thereby allowing the operator to
locate the problem. It has the following fail-safe
systems so that failure of power, control circuit, or other
components will not endanger the operator.
Fail-safe system

22. Starter switch (anti-restart type)
This switch has a built-in mechanical lockout. This
lockout restrains the key from turning to START
position from ON position (as when the engine is
SENB8596 ELECTRICAL SYSTEM
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running) help to prevent damage to the starter pinionor
flywheel ring gear. The ON position of the switch is for
energizing the air heater.
Light Switch

23. LIGHT BULB SPECIFICATIONS
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SENB8596 ELECTRICAL SYSTEM

24. Combination Meter
Disassembly
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SENB8596 ELECTRICAL SYSTEM
Assembly
Follow the reverse of disassembly sequence.

25. Indicator bulb replacement
1. Rear panel removal (on machine)
(1) Remove the screws (four) that hold the rear
panel, and separate the rear panel from the
meter panel and front panel.
(2) Remove the bulbs from the printed circuit
board by turning them counterclockwise.
2. Location of bulbs (on printed circuit board)
1 Brake fluid level indicator
2 Fuel filter indicator (option)
3 Air heater indicator
4 Alternator indicator
5 Engine oil pressure indicator
6 Turn signal indicator
7 Air cleaner indicator (option)
8 Fuel level indicator (option)
9 Engine coolant level indicator (option)
10 Working light indicator (option)
11 High-beam indicator (option)
12 Instrument panel light
SENB8596 ELECTRICAL SYSTEM
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26. Side Instrument Panel
Disassembly
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SENB8596 ELECTRICAL SYSTEM

27. Assembly
Follow the reverse of disassembly sequence.
SENB8596 ELECTRICAL SYSTEM
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28. BATTERIES
1. Electrolyte specific gravity (S.G.) reading and battery condition
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SENB8596 ELECTRICAL SYSTEM
To check the battery for charging, take hydrometer
readings on its electrolyte: the battery may be deemed
to be fully charged if the readings are between 1.260
and 1.280 at normal temperature. The tendency of the
charging system can be told from the way the
electrolyte level goes down to expose cell plates. If
refilling (with distilled water) is necessary every month
or so, the system is tending to over-charge the battery.
If refilling is not required for over 3 months, it is likely
that the system is inadequately charging.
2. Precautions for battery charging
(1) In slow-charging a dead battery, the charging
current should be about 1/10 the capacity of
the battery to be charged.
(2) In quick-charging the battery, the battery
capacity in ampere should not be exceeded.
(3) During charging, adjust the charging current to
prevent the battery electrolyte temperature
from rising beyond 45°C (113°F).
(4) When connecting the cables to the battery,
begin with the cable for the positive (+)
terminal. When disconnecting them from the
battery, begin with the cable for the negative
(–) terminal.

29. Installation of automatic engine stop solenoid
1. Install the solenoid switch and levers in position on
the bracket.
2. Push plunger (1) in all the way. Move stop lever (2)
(engine side) all the way to STOP position. Under
this condition, adjust the length of solenoid rod (3)
and connect it to the lever.
3. After installing the switch, move the engine stop
lever to RUN position by hand to make sure the
plunger end is not projecting from the solenoid
switch.
SENB8596 ELECTRICAL SYSTEM
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30. TROUBLESHOOTING
Starter System
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SENB8596 ELECTRICAL SYSTEM

31. Lighting System
SENB8596 ELECTRICAL SYSTEM
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SENB8596 ELECTRICAL SYSTEM

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