Electrical System Troubleshooting Guide: Kaiyi 24V Equipment (EN)

GROUP 3 ELECTRICAL SYSTEM 1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR · Before disconnecting the connector, always turn the starting switch OFF. · Before carrying out below procedure, check all the related connectors are properly inserted and short of fuse No.12. · After checking, insert the disconnected connectors again immediately unless otherwise specified. 6-24 Cause Remedy YES Check voltage Defective cluster Replace YES between CN-56 (1) and chassis Disconnection in Repair or replace NO wiring harness or (After clean) Check voltage poor contact between CN-5(3) and chassis between CN-5(3) -CN-56(1) Starting switch : ON Voltage :

20~32V Repair or replace Disconnection in (After clean) NO wiring harness or poor contact between CN-5(3) -and fuse No.12 CLUSTER FUSE POWER IG(24V) 1 3 NO.12 GND 2 9 RX TX CN-56 CN-5 Check voltage YES 20 ~ 32V NO 0V Cause Remedy Defective cluster Disconnection in wiring harness or poor contact between CN-5(3) -CN-56(1) Disconnection in wiring harness or poor contact between CN-5(3) -and fuse No.12 Replace Repair or replace (After clean) Repair or replace (After clean) YES 20 ~ 32V NO 0V

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· Before disconnecting the connector, always turn the starting switch OFF. · Before carrying out below procedure, check all the related connectors are properly inserted. · After checking, insert the disconnected connectors again immediately unless otherwise specified. Check voltage CONTROLLER 29 30 CN-50 CLUSTER POWER IG(24V) GND *12V 2 9 TX RX *4V 4 CN-56 3 10 11 CN-5 29076ES02 6-25 2.

COMMUNICATION ERROR FLASHES ON THE CLUSTER YES Check voltage YES between CN-56 (3,4) and chassis Check voltage NO between CN-5 (10,11)and chassis KEY ON NO Cause Remedy Defective controller Disconnection in wiring harness or poor contact between CN-56 (3,4) CN-5(10,11) Disconnection in wiring harness or poor contact between CN-5 (10,11)-CN-50 (29,30) Replace Repair or replace (After clean) Repair or replace (After clean) YES * 4V *12V NO 0V 0V

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3. BATTERY CHARGING WARNING LAMP LIGHTS UP (Starting switch : ON) · Before disconnecting the connector, always turn the starting switch OFF. · Before carrying out below procedure, check all the related connectors are properly inserted. · After checking, insert the disconnected connectors again immediately unless otherwise specified. Check voltage 45076ES01 6-26 YES Check voltage YES between CN-51 (9) and chassis Check voltage NO YES between CN-3 (7) and chassis Check voltage NO between alternator terminal "I" and chassis Voltage : 20~32V Engine :

Running NO Cause Remedy Defective controller Disconnection in wiring harness or poor contact between CN-51(9) -CN-3(7) Disconnection in wiring harness or poor contact between CN-3(7)-alternator terminal "I" Defective alternator Replace Repair or replace (After clean) Repair or replace (After clean) Replace YES 20 ~ 32V NO 0V

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4. WHEN COOLANT OVERHEAT WARNING LAMP LIGHTS UP (Engine is started) · Before disconnecting the connector, always turn the starting switch OFF. · Before carrying out below procedure, check all the related connectors are properly inserted. · After checking, insert the disconnected connectors again immediately unless otherwise specified. 12th step Check Table 1 st step RESISTOR A A RESISTOR A A ECM CN-50 CN-2 8007A6ES02 6-27 YES Is the CAN YES communication between MCU and ECM? Starting switch : ON YES Check resistance Does the gauge between CN-173 light up and down at lamp NO (A-B) & CN-174 (A-B). check? NO Starting switch : ON Spec :

120Ω NO Cause Remedy Disconnection in wiring harness or poor contact between ECM-coolant temp sensor Defective controller or ECM Defective wiring harness Defective cluster Repair or replace (After clean) Replace Replace Replace Range 1st step 2nd~10th step 11th~12th step Temperature ~29。C 30~105。C 105。C ~ 36 46 37 27 25 26 3 4 5

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