Ch 6 page 1 ELECTRICAL SYSTEM Chapter 6 Electrical system SHOP MANUAL
Ch 6 page 2 ELECTRICAL SYSTEM Electrical system Safety instructions............................................................................... 4 Welding on the dump truck..........................................................................................................4 Battery hazard prevention............................................................................................................5 Diagnostic..................................................................................
Ch 6 page 3 ELECTRICAL SYSTEM Body float sensor.........................................................................................................................40 TPMS (optional)...........................................................................................................................41 Tire sensor...................................................................................................................................41 Heater (Optional Webasto)............................
Ch 6 page 4 ELECTRICAL SYSTEM Safety instructions Voltage The trucks have a 24V system. The battery ÷ 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. Battery main switch A main switch is connected on the battery + supply cable.
Ch 6 page 5 ELECTRICAL SYSTEM Battery hazard prevention NOTE - Never shut off main switch when engine is running. Keep the batteries in good condition. Battery power assistance: see Operating and Maintenance manual. When exchanging electrical components always turn off the battery main switch. Remember that a open circuit symptom in a warning light circuit might be a broken bulb. WARNING Never turn off battery main switch when ignition is on.
Ch 6 page 6 ELECTRICAL SYSTEM Diagnostic Overview tools CanPc Installing CANPC • Double-click the CANPC setup file to open the installation wizard. • Choose if you want to have a desktop shortcut created. • Click “Next” to proceed. • Click “Install”. The program will by default be installed on the computers “C:/”Drive. Folder name will be CANPC. Figure 4 Complete the installation by clicking “Finish”.
Ch 6 page 7 ELECTRICAL SYSTEM CanPc setup Before use it is recommended that the CANPC diagnostic program is set up to make sure that the connection, CANlogging and software updating are working properly. 1. Launch the CANPC diagnostic program from the shortcut on the computer desktop. 2. Click file and select “Settings” on the dropdown window that appears. Figure 6 1. Interface selection. Select CANPC(comport) for old version CANPC interface with serial port connection to the laptop.
Ch 6 page 8 ELECTRICAL SYSTEM Adding additional VCU software. • CANPC will always have the latest software VCU software embedded at the time of release. If new VCU software is released before it is included in the CANPC update version, it can be manually added. • Right-click the VCU software you have received and select “copy”. • Locate the folder which the “CANPC.exe” file is installed on and paste the new VCU software directly into the same folder.
Ch 6 page 9 ELECTRICAL SYSTEM With the CIF2 connected, launch the CANPC program from the shortcut created on the desktop. A new window will appear. Figure 10 When properly connected the following will be visible: 1. All connected controllers/components will have a green square displayed in the first column. 2. Status symbol shows that the interface is connected. 3. CAN load is visible. 4. Bottom bar shows connection between computer and interface. Figure 11 CIF2 firmware upgrade.
Ch 6 page 10 ELECTRICAL SYSTEM Update procedure: Connect the CIF2 interface to the laptop with the USB cable. WARNING The interface must NOT be connected to the ADT diagnostic port when performing the firmware upgrade. 1. Open the CANPC program. 2. Open the Extra tab and select “CIF2 firmware upgrade”. 3. Select the upgrade tab to install the newer version into the interface. • Verify the update by confirming that the current and the new software are the same. 4.
Ch 6 page 11 ELECTRICAL SYSTEM Software update VCU software update procedure Updating VCU software: • Connect the CANPC interface. 1. Launch the CANPC program and select VCU CAN1 from the initial window. • Click the “Download software” button. 2. A new window will appear. Select the desired software and click the “Download” button. 3. A warning will appear. Carefully read and select the “YES!” button to start or the “No,cancel” button to abort. Figure 14 VCU software update procedure.
Ch 6 page 12 ELECTRICAL SYSTEM Failed update. In case the update should fail because of reasons like laptop runs out of battery or lost connection. The status bar will turn red and show “Error”. On the initial CANPC window all the devices will show a red symbol or not show at all. The VCU symbol will show with a yellow symbol, indicating that no software is installed into it. The truck will then be rendered useless until a succesful update is performed.
Ch 6 page 13 ELECTRICAL SYSTEM 1. Connect the CIF2 to diagnostic port. The CIF2 unit is made with a integrated OBDII plug and can be plugged directly into the OBDII diagnostic port in the cab. For earlier DA models, use the included OBDII to UMNL mini 12P cable. For MT - series use the UMNL mini 6P connector. 2. Connect the USB cable from the CIF2 into a free USB port on the computer. 3. Turn the ignition to ON. All 3 LED’s on the CIF2 unit should illuminate.
Ch 6 page 14 ELECTRICAL SYSTEM Updating transmission software: 1. Open the CANPC program. 2. Select the TCU by left-clicking it once. 3. Select the “Download software” button. This will open the update menu. Figure 20 4. Select the software to install. Only the software valid for the actual type of transmission will be displayed. NOTE On some units both the current and new software will be available for download. 5. Make sure all the criterias for safe start of the download are fulfilled.
Ch 6 page 15 ELECTRICAL SYSTEM 6. When the download is complete, the action bar will display “Done” and the download progress bar will display 100%. Select the close button to finish. Figure 22 NOTE If the update should for any reason fail, repeat the steps 1 to 6.
Ch 6 page 16 ELECTRICAL SYSTEM Components Front wagon 2 3 BRAKE CIRCUIT 1 21 ? 4 20 5 4 6 SUSP 19 TRANS 18 11 7 17 16 SUSP 14 SUSP / FRAME 15 8 12 9 13 Figure 23 Position Item Position Item 1 Marking light 12 Main light 2 Sensor (Cooling brake tank) 13 Direction light 3 Sensor (Hydraulic tank) 14 Direction light 4 Temperature sensor 15 Main light 5 Marking light 16 Horn 6 Batteries 17 Horn 7 Ultrasonic level sensor 18 Temperature sensor 8 Control unit
Ch 6 page 17 ELECTRICAL SYSTEM Rear wagon 4 3 2 5 BRAKE CIRCUIT 6 1 7 8 Figure 24 Position Item 1 Temperature sensor 2 Body status indicator 3 Reverse alarm 4 Rear view camera 5 Work light rear 6 Led rear lamp 7 Tilting sensor 8 Temperature sensor SHOP MANUAL
Ch 6 page 18 ELECTRICAL SYSTEM Overview on the inside of the cabin 1 3 Posistion Item 1 LCD display 2 Keypad 3 USB 4 Gear selector 5 Tip lever 6 Cigarette lighter 7 Switch 8 Switch 9 Throttle pedal 10 Electric park brake switch 11 Mirror adjustment switch 12 Buzzer 13 Ignition switch 5 4 2 13 12 7 6 11 8 9 Figure 25 SHOP MANUAL 10
Ch 6 page 19 ELECTRICAL SYSTEM Overview on the outside of the cabin Posistion Item 1 Interior light 2 HVAC control unit 3 Radio 4 Wiper motor 5 Rotating beacon 6 Speakers 7 Door switch 5 1 2 6 3 4 7 Figure 26 SHOP MANUAL
Ch 6 page 20 ELECTRICAL SYSTEM Battery The truck has 2x EXIDE batteries installed. PERFORMANCES Voltage (V): 12 V C20 (Ah): 105.0 20 h Rc (min): 0 Cranking (A) 950 EN Vibration: Manufactured Specific Endurance: VDA Requirement Charge: CHARGED Technology: AGM Grid: Ca/Ca Figure 27 DIMENSIONS Battery Weight (kg): 28.8 Volume acid (l): 5.
Ch 6 page 21 ELECTRICAL SYSTEM Cabin VCU3 The VCU powers the control panel and the HVAC unit. It can also activate the A/C compressor clutch when the control panel signals this and both pressure and evaporator temperature allow it.
Ch 6 page 22 ELECTRICAL SYSTEM HVAC Figure 29 There are several electrical parts involved in controlling the temperature and air stream in the cabin. There are: 1. HVAC unit. Inside are the heater core, evaporator, water valve, re-circulation flap motor, blower + control, pressure sensors, temperature sensors and the A/C thermostat. The electrically operated water valve is used to regulate the amount of engine coolant coming into the heater core. In this way the amount of heat is controlled. 2.
Ch 6 page 23 ELECTRICAL SYSTEM The pressures, temperature, engine rpm, AC clutch signals and evaporator temperature, can be viewed on the VCU diagnostic page on the display in the cabin. There are a few items related to A/C on the diagnostic page, such as: • • • • • A/C LP. Gives the pressure in the low pressure part of the A/C system. A/C HP. Gives the pressure in the high pressure part of the A/C system. A/C clutch input.
Ch 6 page 24 ELECTRICAL SYSTEM Flap motor The flap motor is a reversal polarity electric motor. This is used to close the HVAC unit from the outside air when the recirculation button is pressed on the control panel. It is a two wire motor that uses two external switches and parallel diodes to limit the movement in both directions. When the flap is in one of the end positions, one switch will be open and the diode will make sure that only movement in the opposite direction is possible.
Ch 6 page 25 ELECTRICAL SYSTEM Radio Radio installed on the ADT: • Continental TR7412UB-OR. FM(Standard) • Continental TRD7412UB-OR DAB(Option) Figure 36 General Power supply Maximum power output 4 x 41 W Suitable speaker impedance 4 ohm Fuse spec 10 A Weight 0.7 kg Dimensions (WxDxH) 188x116.3x58.5 mm Figure 37 TROUBLESHOOTING Problem Possible cause Solution The unit will not switch on. Car ignition is not on. Cable is not properly connected. Fuse is burnt.
Ch 6 page 26 ELECTRICAL SYSTEM Interior light MiniOval LED 24V. Figure 39 Figure 38 Cigarette lighter Figure 40 12V Universal cigarette lighter. • Type of connection: blade coupling 6.3mm. • Installation opening: Ø23.5 mm • Control panel thickness: max. 2.5 mm.
Ch 6 page 27 ELECTRICAL SYSTEM Speakers Dual Blaupunkt Performance GTx 402 SC speakers are installed in the truck cabin. Figure 42 Figure 41 Peak power handling 140 W RMS power handling 30 W Impedance 4 Ohms Frequency response 90 - 20.000 Hz Sensitivity 90 dB (2.83 V/m) Doorswitch Proximity door switch from Assemtech Europe. Switching capacity Max. 10 W/VA Switching voltage max. 200 VDC/AC Switching Current Max. 0.5 A Contact resistance Max. 200 mOhms Switching distance Min.
Ch 6 page 28 ELECTRICAL SYSTEM Tip lever Parker IQAN-LSL tip lever is a single-axis joystick, 0.5 - 4.5 Vdc, intended for the proportional control of one doubleacting hydraulic function. The lever has several options including a manual neutral detent and a switch in the top of the handle. The IQAN-LSL is a spring centered, dual sensor device. The optional switch in the top of the handle can be used to detect operator presence. The dual sensors provide 0.5 - 4.5 Vdc and 4.5 - 0.
Ch 6 page 29 ELECTRICAL SYSTEM Gear selector Gear selector from ZF. Nominal Voltage 24 V Operating Voltage 20 - 32 V Testing Voltage 28 ± 0.5 V Max. Supply Current 4 A max. Output Current 1 A max. Operating Temperature -40°C - +80°C Figure 46 Wiper motor DOGA wiper motor. Figure 48 Figure 47 Connector pin Terminal Color Electrical wiper function. 1 53 Red Positive Speed n1 feed switch. 5 31 Black Negative, earth. 6 31b Green Park feed. 3 53a Yellow Park (auxiliar feed).
Ch 6 page 30 ELECTRICAL SYSTEM Throttle pedal This is a throttle pedal assembly with a solid-state rotary position sensor that provides a dual linear output voltage proportional to absolute shaft rotation in either direction from a reference angle. It operates from +5V power typically supplied by a vehicle engine control unit (ECU). This device’s two outputs are independent and electrically isolated, supporting the implementation of highly fault tolerant and reliable systems. Supply Voltage 5±0.
Ch 6 page 31 ELECTRICAL SYSTEM TMS The Q-Pro is a small, rugged, enviromentally-sealed module with numerous customization options including operating network, inputs/outputs, memory, CAN bus and antenna detection. 0.49 12.5 2.00 50.8 4.81 122 3.89 98.9 0.87 22 0.32 8.1 PIN 1 PIN 12 2 J18 5 4.18 106.2 PIN 1 5.74 145.8 3 2 4 PIN 12 0.64 16.1 148.000 to 150.050 MHz Receive Freq. 137.000 to 138.000 MHz Transmit Power 5W min. - 10W max. Data Rates 2400 bps Uplink/ 4800 bps Downlink 6.
Ch 6 page 32 ELECTRICAL SYSTEM Electric mirrors (optional) Glass size (WxH) 185 x 363,5 mm Radius of curvature 1200mm Heating system Unheated or heated 12 or 24V Adjustment Manual or electrical, 12 or 24V Adjustment range up/down: > ± 7°C and left/right: > ± 13°C Mirror mounting bracket interface Clamp for 18-28mm tube diameter On-board power supply connection 2- or 6-lead flange socket, direct contacting upon request Material Figure 55 Shock-proof ABS plastic, black, UV resistant Buzzer
Ch 6 page 33 ELECTRICAL SYSTEM DC - DC converter Part number PV12s Cont/Int Power 12A/18A non-isolated Nominal Voltage 24Vdc input, 12Vdc output Dimensions 127 x 87 x 50 mm Weight 405g Input voltage range 17-32 Vdc Output voltage 13.6 Vdc +15% -20% at extremes of temperature, load and input tolerance.
Ch 6 page 34 ELECTRICAL SYSTEM Park brake switch HELLA ignition switch with lock 6.pole. Figure 60 Figure 59 Mirror adjustment switch Mekra mirror adjustment switch with LED. Rated voltage DC 12/24 V Test Voltage DC 14/28 V Operating voltage DC 10 - 30 V Max.
Ch 6 page 35 ELECTRICAL SYSTEM Retarder lever Standard retarder setting is 100 % and can be reduced by the retarder lever (up or down) from 100% to 25%. Figure 63 Diagnostic connector 4.0 mm pitch, OBD-II wire-to-wire receptacle housing panel mount. Rated Voltage Max. 30 V Ambient temperature range -40 °C to 85 °C Circuits Max.
Ch 6 page 36 ELECTRICAL SYSTEM Electrical parts involved in hydraulic control Test block 145 - Tilt Cylinder Pressure 142 - Front Brake Pressure 144 - Park Brake Pressure 143 - Rear Brake Pressure Figure 65 SHOP MANUAL 140 - Pump 1 Pressure
Ch 6 page 37 ELECTRICAL SYSTEM Steering valve 147 - Emergency steering Figure 66 SHOP MANUAL
Ch 6 page 38 ELECTRICAL SYSTEM Main valve 146 - Park brake output 184 - Brake charge valve 182- Fan drive Figure 67 SHOP MANUAL
Ch 6 page 39 ELECTRICAL SYSTEM Parking brake sensor 191 - Park brake valve Figure 68 SHOP MANUAL
Ch 6 page 40 ELECTRICAL SYSTEM Body float sensor 192 - Body Float Figure 69 SHOP MANUAL
Ch 6 page 41 ELECTRICAL SYSTEM TPMS (optional) Tire sensor Figure 70 Continental tire pressure sensor. All 6 wheels got a tire pressure sensor installed on the inside of the rims.
Ch 6 page 42 ELECTRICAL SYSTEM Heater (Optional Webasto) Webasto Thermo Pro 90 The webasto heats up the engine very quickly to optimum starting temperatures. Both fuel consumption and exhaust emissions are therefore reduced in the starting phase. This webasto has automatic altitude compensation as standard. Figure 71 Heat output max. 9.1 kW Heat output control range 1.8 - 7.6 kW Rated voltage 12/24 V Operating voltage range 10.5 - 14.
Ch 6 page 43 ELECTRICAL SYSTEM Lubrication pump Groeneveld automatic Twin-3 greasing system. The system keeps all greasing points of the machine greased automatically at the correct time with the correct dose. Optimum grease distribution over the hole greasing surface is achieved because the greasing takes place while the machine is in operation.
Ch 6 page 44 ELECTRICAL SYSTEM PM1 Main switches panel 1. Main switch on battery. To disconnect the battery turn the switch to OFF position To connect the battery turn the switch to ON position. • 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. is on or flashing. When the lamp(4) is off the main switch can safely be turned to OFF position. 3 2 4 2.
Ch 6 page 45 ELECTRICAL SYSTEM Sensors Clogged air filter sensor Air cleaner sensor from Mann + Hummel. Figure 75 Figure 76 Operational pressure range 0 - 100 mbar (0 - 10 kPa) Media Air Supply voltage Normal 5 - 30 Vdc, sensor can be powered directly from vehicle up to 30 Vdc. Accuracy ± 2.5% Output voltage 0.5 - 4.
Ch 6 page 46 ELECTRICAL SYSTEM Level sensor Packed ultrasonic level sensor Operating voltage (oil level measurement) 9 - 16V Operating voltage (temperature measurement) 6 - 16V Reverse-polarity voltage -14 V / 60s Overvoltage 15s at 28V 250ms at 32V Measurement range (static and dynamic) 18 - 118.8mm Operating temperature -40°C to +160°C Current consumption 4 mA Max.current consumption during measuring 50 mA Weight 76g ± 3% Figure 78 Proximity sensor Omron proximity sensor.
Ch 6 page 47 ELECTRICAL SYSTEM Temperature sensor M14 PT1000 JTcon temperature sensor Measuring resistor PT 1000 Accuracy temperature range: -50°C to 15°C 15° to 125° 125°C to 150°C ±3°C ±1,5°C ±3°C Resistance value 0°C: 1000 ohm 100°C: 1385 ohm Measuring current ≤ 1,0 mA Power supply constant current or constant voltage Dielectrical strength per VDE 0160/500 VAC, 50Hz, 1 min Insulation resistance with respect to housing per VDE 0100/ > 10 Mohm/500 VDC Figure 80 Rear view camera Mekra MCC
Ch 6 page 48 ELECTRICAL SYSTEM Lights Main lights Bi-halogen Hella Halogen low beam and high beam in one headlight. Right-hand traffic, H7 bulb, 24 Volt. Figure 82 Rear lights DureLED Combi Hella Figure 83 Design Voltage Nominal Voltage Nominal Power Rear Position Lamp 8 LEDs 13.5V/28.0V 8.0V - 28.0V 1.5W Stop Lamp 24 LEDs 13.5V/28.0V 8.0V - 28.0V 5.0W Direction Indicator 16 LEDs 13.5V/28.0V 8.0V - 28.0V 3.
Ch 6 page 49 ELECTRICAL SYSTEM Beacon light Figure 84 Voltage Action Current Consumption 12/24V Flash Rate (per min) Mounting Weight(kg) 10-30VdC Double Flash 0.6/0.3 A 80 DIN 0.50 Direction/Marking Lights Figure 85 Diameter (mm) 90 Consumption 12V 0.4W = approx. 0.
Ch 6 page 50 ELECTRICAL SYSTEM Work lights 4x Ultra Beam LED Gen. II Figure 86 Technical data: Operating voltage/Rated voltage 9 - 33 V Recommended angle of inclination Close-range: 12°, long: 5° Light source type 8 high-power LEDs Power consumption 56 W Light output 4.000 lm Color temperature 6.500° Kelvin Protection class IP 6K9K and IP 6K8 Type approval ECE-R10 Housing Aluminium die cast Light exit area 105 x 95 mm Weight 1.040 g / 1.
Ch 6 page 51 ELECTRICAL SYSTEM Marking light for mirrors Figure 88 HELLA LED clearance light with integrated side marker light in short rubber arm. Can be used on both left and right-side, for side mounting on vertical surfaces, clear lens, on side with interior amber cover lens, 2 white LEDs for position light, 1 red LED for clearance light and 2 amber LEDs for side marker light. 24V / 1.5W, current consumption = approx.0.05A.
Ch 6 page 52 ELECTRICAL SYSTEM Wiring routing Front frame UNDER CONSTRUCTION Figure 89 Position Item Position Item 1 Cable set 10 Module control 2 Cable set 11 Battery 3 Cable set 12 Cable 4 Cable set 13 Cable 5 Cable set for mirror arm 14 Battery cable 6 Cable set 15 Cable 7 Cable set 16 Cable set for mirror arm 8 Cable set 17 Marking light assembly 9 Cable set 18 Cable set SHOP MANUAL
Ch 6 page 53 ELECTRICAL SYSTEM Rear frame S6 1 Figure 90 Position Item 1 Cable set SHOP MANUAL
Ch 6 page 54 ELECTRICAL SYSTEM Cabin X Y Z \ ] ^ _ [ ` XW Figure 91 Position Item Position Item 1 Main cable set cabin 6 Fusebox 2 Cable set roof top 7 Relay 3 Cable set split 8 VCU3 4 Cable set front wall 9 Cable set cabine floor 5 DC - DC converter 10 Cable set steering SHOP MANUAL
Ch 6 page 55 ELECTRICAL SYSTEM Electrical diagrams Cabin SHOP MANUAL
Ch 6 page 56 ELECTRICAL SYSTEM Front and rear SHOP MANUAL
Ch 6 page 57 ELECTRICAL SYSTEM Power, engine and options SHOP MANUAL
Ch 6 page 58 ELECTRICAL SYSTEM HVAC unit VCU3 VCU3 PT1000 input ch 1 + - Y2,1 Y2,11 Bl 0.75 Bk 0.75 S2,25 S2,26 Bl 0.75 Bk 0.75 1 2 Vi 1.5 Bk 1.5 S2,16 S2,17 Vi 1.5 Bk 1.5 1 2 °C 160 Ambient (grill) 350 A/C Compressor clutch 24V GND F46 Y10,6 Y10,10 4-20mA input ch 15 + - F12 Y22,4 Y22,14 Or 0.75 Gr 0.75 B A P 73 A/C LP Sensor 4-20mA input ch 16 + - F12 Y22,5 Y22,15 Ye 0.75 Br 0.
