Shop Manual: Kaiyi Dump Truck — Electrical System Diagnostics (EN)

Ch 6 page 1 ELECTRICAL SYSTEM Chapter 6 Electrical system SHOP MANUAL

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Ch 6 page 2 ELECTRICAL SYSTEM Electrical system Safety instructions............................................................................... 4 Welding on the dump truck..........................................................................................................4 Battery hazard prevention............................................................................................................5 Diagnostic.............................................................................................

6 Overview tools...............................................................................................................................6 CanPc............................................................................................................................................6 CanPc setup..................................................................................................................................7 CIF2 interface................................................................................................................................8 Software update..........................................................................................................................11 VCU software update procedure.................................................................................................11 Transmission software update.

With CANPC...............................................................................12 Components.......................................................................................

16 Front wagon.................................................................................................................................16 Rear wagon..................................................................................................................................17 Overview on the inside of the cabin..........................................................................................18 Overview on the outside of the cabin.......................................................................................19 Battery..........................................................................................................................................20 Cabin............................................................................................................................................21 VCU3...........................................................................................................................................21 HVAC...........................................................................................................................................22 A/C compressor...........................................................................................................................22 Blower control..............................................................................................................................23 Water valve..................................................................................................................................23 Flap motor....................................................................................................................................24 Temperature sensors...................................................................................................................24 Evaporator temperature sensor...................................................................................................24 Pressure sensors.........................................................................................................................24 Radio...........................................................................................................................................25 Interior light..................................................................................................................................26 Cigarette lighter...........................................................................................................................26 Speakers......................................................................................................................................27 Doorswitch...................................................................................................................................27 Tip lever.......................................................................................................................................28 Driver seat...................................................................................................................................28 Gear selector...............................................................................................................................29 Wiper motor.................................................................................................................................29 Throttle pedal...............................................................................................................................30 LCD Display.................................................................................................................................30 TMS.............................................................................................................................................31 Electric mirrors (optional).............................................................................................................32 Buzzer..........................................................................................................................................32 DC - DC converter.......................................................................................................................33 USB charger................................................................................................................................33 Park brake switch.........................................................................................................................34 Mirror adjustment switch..............................................................................................................34 Steering column switch................................................................................................................34 Retarder lever .............................................................................................................................35 Diagnostic connector...................................................................................................................35 Electrical parts involved in hydraulic control...........................................................................36 Test block.....................................................................................................................................36 Steering valve..............................................................................................................................37 Main valve....................................................................................................................................38 Parking brake sensor...................................................................................................................39 SHOP MANUAL

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Ch 6 page 3 ELECTRICAL SYSTEM Body float sensor.........................................................................................................................40 TPMS (optional)...........................................................................................................................41 Tire sensor...................................................................................................................................41 Heater (Optional Webasto).........................................................................................................42 Webasto Thermo Pro 90..............................................................................................................42 Lubrication pump........................................................................................................................43 PM1...............................................................................................................................................44 Sensors........................................................................................................................................45 Clogged air filter sensor ..............................................................................................................45 Hydraulic level sensor..................................................................................................................45 Level sensor.......................................................................................

46 Proximity sensor..........................................................................................................................46 Temperature sensor.....................................................................................................................47 Rear view camera........................................................................................................................47 Lights...........................................................................................................................................48 Main lights....................................................................................................................................48 Rear lights....................................................................................................................................48 Beacon light.................................................................................................................................49 Direction/Marking Lights..............................................................................................................49 Work lights...................................................................................................................................50 Marking light for mirrors...............................................................................................................51 Electrical circuits...............................................................................

51 CAN bus.......................................................................................................................................51 Wiring routing..............................................................................................................................52 Front frame..................................................................................................................................52 Rear frame...................................................................................................................................53 Cabin...........................................................................................................................................54 Electrical diagrams.....................................................................................................................56 Cabin...........................................................................................................................................56 Front and rear..............................................................................................................................57 Power, engine and options...........................................................................................................58 HVAC unit VCU3..........................................................................................................................59 SHOP MANUAL

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Ch 6 page 4 ELECTRICAL SYSTEM Safety instructions Voltage The trucks have a 24V system. The battery ч is used as ground connection. Supply Two 12V/105Ah batteries are connected together in serial connection to provide the system with 24V. The batteries are located on the left hand side of the fender. A 28V/100A alternator is used to charge the batteries. The alternator is located on the front of the engine. 3 2 Battery main switch A main switch is connected on the battery + supply cable. The battery main switch is located in the left hand side fender. 1 4 Fuses The fuses are located on the VCU3 inside the cab, behind the cover on the back wall + “junction” box in front left fender.

WARNING Never turn off battery main switch when engine is running. Never turn off battery main switch when ignition is on. Leave battery main switch in ON position as long the lamp (4) is on or flashing. When the lamp(4) is off the main switch can safely be turned to OFF position. 1.Main switch. 2.Emergency stop of engine. 3.External power supply output. 4.Indicator lamp. Figure 1 Welding on the dump truck The transmission and the engine are equipped with electronic control units. Before welding on the dump truck: 1. Disconnect batteries. 2. Unplug the connector on the electronic control units for the engine and the transmission. The control units are located in the wall behind the seat. 3.

Ground point should be less than 1 m from welding point. 4. There should not be sealings, bearings or wiring harness between the welding point and the ground point. SHOP MANUAL

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