ES START (EASY & SMOOTH START SYSTEM) BR04–1

ES START (EASY & SMOOTH START SYSTEM)

BR04

BR04-001

ES START .................................................BR04-2
DESCRIPTION ................................................ BR04-2
DIAGRAM ........................................................ BR04-4
SPECIAL TOOL ............................................... BR04-5
INITIAL SETTING OF ES START ................... BR04-6

ES START CONTROL VALVE ................BR04-12

COMPONENT LOCATOR ............................. BR04-12
OVERHAUL ................................................... BR04-13
INSPECTION AND REPAIR .......................... BR04-15

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BR04–2 ES START (EASY & SMOOTH START SYSTEM)

ES START
DESCRIPTION
EN06Z0804C100001

ES START CONTROL VALVE

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SHTS06Z080400001

CLUTCH FLUID PRESSURE SWITCH

SHTS06Z080400002
ES START (EASY & SMOOTH START SYSTEM) BR04–3

CLUTCH PEDAL STROKE SENSOR

SHTS06Z080400003

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STOP LIGHT SWITCH

SHTS06Z080400004
BR04–4 ES START (EASY & SMOOTH START SYSTEM)

DIAGRAM
EN06Z0804J100001

SYSTEM DIAGRAM

ES MAIN SWITCH

RELEASE TIMING
SWITCH

ES START CONTROL
BRAKE AIR VALVE
PRESSURE SWITCH
ES START
CONTROLLER
NEUTRAL SWITCH

COURTESY SWITCH

SPRING BRAKE ES START

SWITCH SLOPE INDICATOR LIGHT
SENSOR

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BUZZER CANCEL
SWITCH

BUZZER
BACK-UP LIGHT
SWITCH

CLUTCH FLUID
PRESSURE SWITCH

CLUTCH PEDAL
STROKE SENSOR

SPEED SENSOR

DIAGNOSIS MONITOR

SHTS06Z080400005
 ES START (EASY & SMOOTH START SYSTEM) BR04–5

PIPING DIAGRAM

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SHTS06Z080400006

SPECIAL TOOL
EN06Z0804K100001

Illustration Part number Tool name Remarks

FOR DIAGNOSING AND

09630-1370 DIAGNOSIS MONITOR
SETUP OF ES START

SPECIAL WIRING HARNESS

FOR CONNECTING
09630-2300 FOR INTENSIVE DIAGNOSIS
DIAGNOSIS MONITOR
CONNECTOR
BR04–6 ES START (EASY & SMOOTH START SYSTEM)

INITIAL SETTING OF ES START

EN06Z0804H300001

INITIAL SETTING
NOTICE
When replacing a controller of "ES Start", be sure to execute this
OFF
initial setting.

1. CHECK "ON" OF POWER SUPPLY WHEN SWITCHING THE

STARTER KEY "ON".
(1) Turn "OFF" ES main switch while turning "ON" the starter key.

SHTS06Z080400009

(2) Check the operation of "ES start" indicator in the meter and also
the buzzer.
Standard:
After the indicator light is lit for a second, the buzzer to
switch off the light beeps one time.
NOTICE

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Unless the buzzer beeps, the indicator is not lit. When it does not
turn off even after one second, inspect the electrical circuit.

SHTS06Z080400010

(3) Turn "ON" the ES main switch.

ON

SHTS06Z080400011

2. CHECK OF INSTALLING CONDITION OF CLUTCH STROKE

SENSOR.
NOTICE
OFF • When replacing clutch stroke sensor, execute this inspection
without fail.
• Execute this under the condition that clutch adjustment (for
normal clearance of clutch pedal) completed.
(1) Turn "ON" starter key and turn "OFF" the ES main switch.

SHTS06Z080400012
 ES START (EASY & SMOOTH START SYSTEM) BR04–7

(2) White color connector, one of two intensive diagnosis connectors,

FIXING DAMMY CONNECTOR located at lower part of right side of the instrument panel, should
be connected to the specific harness and the diagnosis monitor
be connected to the connector with a tag of "ES start".
SST:
Dedicated Harness (09630-2300)
Diagnosis Monitor (09630-1370)

WHITE CONNECTOR

BLACK CONNECTOR
SHTS06Z080400013

NOTICE
As intensive diagnosis connector is normally connected to the
fixed dummy connector, pull it out from the dummy connector to
use. Also, couple it with the fixed dummy connector while not
using it.

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SHTS06Z080400014

(3) Turn on "FAST" release timing switch three times within 5 sec-
onds.

SHTS06Z080400015

(4) Checking function of sensor installation condition starts and check

that indicator is flashing as shown in the figure.
NOTICE
When indicator not flashing, inspect the electrical circuit.
(5) Check sensor installation condition with the buzzer beeping when
clutch pedal is free.
Standard: The buzzer beeps continuously.
NOTICE
INDICATOR
OPERATING When not beeping the buzzer, inspect clutch stroke sensor and its
PATTERN relating circuit.
SHTS06Z080400016
BR04–8 ES START (EASY & SMOOTH START SYSTEM)

(6) After turning again release timing switch on "FAST", remove diag-
nosis monitor.

SHTS06Z080400017

3. INITIAL SETTING FOR RELEASING POSITION

NOTICE
Execute initial setting of releasing position without fail when
replacing clutch.
(1) Confirm the following condition of the vehicle.
• Starter key: ON
• ES main switch: OFF
• Clutch pedal: Free position

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• Parking brake: Operating
(2) Starting engine, check that idling revolution is normal.
(3) White color connector, one of two centralized diagnosis connec-
FIXING DAMMY CONNECTOR tors located at lower part of right side of the instrument panel,
should be connected to the dedicated harness and diagnosis
monitor be connected to the connector with a tag of "ES start".
SST:
Dedicated Harness (09630-2300)
Diagnosis Monitor (09630-1370)

WHITE CONNECTOR

BLACK CONNECTOR
SHTS06Z080400018

NOTICE
As centralized diagnosis connector is normally connected to the
fixed dummy connector, pull it out from the dummy connector to
use. Also, couple it with the fixed dummy connector while not
using it.

SHTS06Z080400019

(4) Put release timing switch on "FAST" for more than 3 seconds.
(5) Initial setting function of release position starts. Check that buzzer
and indicator are working as it follows.
• Buzzer: 1 long beeping continuously.
• Indicator: Flashes in synchronization with the buzzer beeping.
(6) When buzzer does not beep, check the following points:
• Relating circuit with parking brake (buzzer cancel switch)
• Relating circuit with "ES start" switch.
• Controller
(7) Depress the clutch pedal and shift the gear to 3rd speed.
SHTS06Z080400020 (8) Release slowly the pedal for clutch engagement.
 ES START (EASY & SMOOTH START SYSTEM) BR04–9

(9) When tachometer needle descends and then comes back again,
put again release timing switch on "FAST". At this moment, con-
troller memorizes signal of clutch stroke sensor.
(10) Once controller memory completed, buzzer stops after it beeps
one time. Indicator light goes off.
(11) Remove diagnosis monitor from the coupler.

SHTS06Z080400021

4. INITIAL SETTING OF SLOPE SENSOR AT "0" POINT.

NOTICE
When any style of body mounted on the chassis of vehicle and the
vehicle level changed, implement this initial setting without fail.
(1) Confirm that the following condition of the vehicle.
• ES main switch: OFF
• Road surface condition: Flat (±1 deg)
• Parking brake: Operating

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(2) White color connector, one of two intensive diagnosis connectors,
FIXING DAMMY CONNECTOR located at lower part of right side of the instrument panel, should
be connected to the dedicated harness and the diagnosis monitor
be connected to the connector with a tag of "ES Start".
SST:
Dedicated Harness (09630-2300)
Diagnosis Monitor (09630-1370)

WHITE CONNECTOR

BLACK CONNECTOR
SHTS06Z080400013

NOTICE
As intensive diagnosis connector is normally connected to the
fixed dummy connector, pull it out from the dummy connector to
use. Also, couple it with the fixed dummy connector while not
using it.

SHTS06Z080400014

(3) Put release timing switch on "SLOW" for more than 3 seconds.
(4) Initial setting function of slope sensor starts. Check that buzzer
and indicator are working as it follows:
• Buzzer: 2 short beeping continuously.
• Indicator: Flashes in synchronization with the buzzer beeping.
(5) When not beeping nor flashing as mentioned above, check the fol-
lowing points:
• Relating circuit with parking brake (buzzer cancel switch)
• Relating circuit with "ES start" switch
• Controller
SHTS06Z080400022
BR04–10 ES START (EASY & SMOOTH START SYSTEM)

(6) Put again release timing switch on "SLOW". At this moment, con-
troller memorizes signal of slope sensor.
(7) Once controller memory completed, buzzer stops after it beeps
one time.
(8) Indicator light goes off.

SHTS06Z080400023

CHECKING PROCEDURE OF OPERATION

1. PREPARATION
(1) Confirm that the vehicle is under the following condition:
• The road surface is not at down hill.
• Starter key: ON
• Parking brake released
• The both doors of the cab at driver's and the other side are

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closed.
NOTICE
• Operation check can be done, even though the engine is not
in motion.
• In case of operation checking while the engine is in motion,
you will need to perform a starting operation by paying much
attention not to start out the vehicle suddenly.

2. OPERATION OF "ES START"

(1) Free clutch pedal by shifting the gear to the neutral position.
(2) Turn "ON" ES main switch.
(3) Once continuing to depress the brake pedal, "ES start" will start to
work within about one second.
ON (4) Confirm the operation of "ES start" with the following points.
• Buzzer beeps one time.
• Indicator light is lit.
• The braking force will be retained, even though setting your leg
free from the brake pedal.

Braking axle when operating "ES Start"

SHTS06Z080400024 Axle position
Model
Front-front Front-rear Rear-front Rear-rear
FS X —


FY X X

: Operating, X: Not operating, —: Not available

ES START (EASY & SMOOTH START SYSTEM) BR04–11

(5) When "ES start" does not work, check the following points:
a. Indicator light is not lit.
• Inclination of road (when at down hill, shift the gear to "R", it does
not work unless the clutch pedal is depressed.)
• Neutral switch and its relating circuit
• Stop light switch and its relating circuit
b. Indicator flashes and the buzzer beeps.
• Check it through diagnosis function.
c. Indicator light is lit. But the buzzer beeps.
• Courtesy switch and its relating circuit.
d. Braking force is not retained.
• ES start valve and brake air circuit
• Controller

3. RELEASE OF "ES START"

(1) Depressing deep and surely the clutch pedal, shift the gear for
moving forward.
(2) Release the pedal for clutch engagement.
(3) "ES start" will be released at the partial clutch engagement.
Check the following conditions:
• Indicator light is not lit.

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• Release of braking force.
(4) When "ES start" not released, check the following points:
a. Indicator light does not turn out.
• It will not be released by mis-handling (when the clutch pedal is
not deeply depressed at shifting the gear)
• Neutral switch and its relating circuit
• Clutch pedal stroke sensor and its relating circuit.
b. Braking force is not retained.
• "ES start" valve and the brake air circuit.
• Controller
BR04–12 ES START (EASY & SMOOTH START SYSTEM)

ES START CONTROL VALVE

COMPONENT LOCATOR
EN06Z0804D100001

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SHTS06Z080400025

1 Hose 11 O-ring 21 O-ring

2 Bolt 12 Piston 22 Valve seat
3 Bracket 13 O-ring 23 O-ring
4 Cover 14 Screw 24 Valve
5 O-ring 15 Solenoid assembly 25 Spring
6 Spring 16 Spring 26 Filter
7 Inlet valve 17 Plunger 27 Body
8 Straight pin 18 Rod 28 Cover
9 Spring seat 19 Coil cover 29 O-ring
10 Spring 20 O-ring

Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 4.0-6.0 {40-60, 2.9-4.3} B 1.3-1.7 {13-17, 0.49-1.22}
 ES START (EASY & SMOOTH START SYSTEM) BR04–13

OVERHAUL
EN06Z0804H200001

IMPORTANT POINT - DISMOUNTING

NOTICE
• When dismounting and storing parts, place a cap on all ports
so not dirt or dust enters.
• Be careful so water, dirt, or dust does not enter inside the
harness connector to prevent solenoid short circuits or
faulty connections.

IMPORTANT POINT - ASSEMBLY

NOTICE
Apply an adequate amount of grease to each O-ring before assem-
bly.

1. ASSEMBLING ES START CONTROL VALVE

(1) Insert the spring in the valve and assemble it in the body.

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SHTS06Z080400026

NOTICE
Assemble the valve and the spring as shown in the figure.

SHTS06Z080400027

(2) Align and attach the O-ring to the groove of the inside valve seat
VALVE SEAT HOLE correctly and install it in the body.
NOTICE
Align the valve seat holes and body holes to perform the assem-
bly.

BODY HOLE

SHTS06Z080400028

(3) Assemble the O-rings (2 units) in the piston and lubricate the
inside diameter of the piston with grease.
NOTICE
Verify the diameter of the O-ring (small one) because there are
multiple settings and then assemble the unit.
Dimension "D" and "d"= 22 mm {0.87 in.}

SHTS06Z080400029
BR04–14 ES START (EASY & SMOOTH START SYSTEM)

(4) Assemble the spring, piston and inlet valve. Press in the inlet
valve and install the straight pin.
NOTICE
Align the inlet valve pin hole and piston pin hole and assemble the
parts. After the assembly is completed, do not rotate the inlet
valve to align the pin holes.

SHTS06Z080400030

(5) Position the spring seat collar so it faces the rear side and install
the unit.
(6) Apply grease to the outer surface of the O-ring installed in the pis-
ton.

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SHTS06Z080400031

(7) Apply grease to the inner surface of the body.

(8) Insert the piston inlet valve assembly in the body.
NOTICE
Do not turn the piston when inserting it.

SHTS06Z080400032
 ES START (EASY & SMOOTH START SYSTEM) BR04–15

INSPECTION AND REPAIR

EN06Z0804H300002

NOTICE
Isopropyl alcohol should only be used to wash the ES start con-
trol valve components.

Inspection item Standard Limit Remedy Inspection procedure

Valve body inside, piston, — — Replace, Visual check

valve, valve seat, spring if necessary.
and inlet valve:
Wear and damage

O-ring: — — Replace, Visual check

Crack and damage if necessary.

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