DAF CF65, CF75, CF85 Service manual

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5

CONTENTS

CF65/75/85 Series ≥0E621376

 

 

 

TECHNICAL DATA

 

DIAGNOSTICS

 

COMPONENTS

 

WIRING REPAIR

 

BATTERIES

CONNECTION OF ACCESSORIES

READING DIAGRAMS

LOCATION OF COMPONENTS

LOCATION OF CONNECTORS

ELECTRICAL SYSTEM

CHANGES IN THE ELECTRICAL SYSTEM

ELECTRICAL SYSTEM: OPTIONS AND SPECIAL APPLICATIONS

0

1

2

3

4

5

6

7

8

9

10

11

12

200520

 

 

 

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5

TECHNICAL DATA

CF65/75/85 series ≥0E621376

Contents

 

CONTENTS

Page Date 0

1. COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200404 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200404 1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . 200404

200404

 

 

 

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TECHNICAL DATA

5

Contents

CF65/75/85 series ≥0E621376

0

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5

 

 

 

 

 

 

TECHNICAL DATA

CF65/75/85 series ≥0E621376

 

 

 

 

Components

 

1. COMPONENTS

 

 

 

 

 

 

 

 

1.1 GENERAL

 

 

 

 

 

 

 

0

 

 

 

 

 

 

 

 

Bulbs

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Headlight (main beam)

 

 

halogen

70 W

Headlight (dipped beam)

 

 

halogen

70 W

Parking light

 

 

 

 

spherical bulb

5 W

Rear light

 

 

 

 

spherical bulb

2 x 5 W

Rear fog lamp

 

 

 

 

spherical bulb

21 W

Reversing light

 

 

 

 

spherical bulb

21 W

Stop light

 

 

 

 

spherical bulb

21 W

Direction indicator lamp

 

 

spherical bulb

21 W

Marker light

 

 

 

 

spherical bulb

5 W

Side marker light

 

 

special type

3 W

Combilamp:

fog lamp

 

 

halogen

70 W

 

spotlight

 

 

halogen

70 W

Interior lighting

 

 

 

 

spherical bulb

10 and 21 W

Bunk light

 

 

 

 

spherical bulb

10 W

Stepwell lighting

 

 

spherical bulb

5 W

Marker light

 

 

 

 

spherical bulb

5 W

Work lamp:

white

 

 

halogen lamp

70 W

 

yellow

 

 

spherical bulb

35 W

 

 

 

 

 

 

 

 

 

 

 

 

 

Max. current and wire diameter (mm2)

 

 

 

 

Wire diameter

 

< 2 m

2 - 4 m

 

4 - 8 m

 

> 8 m

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

9

5

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1.5

 

 

22.5

13.5

 

7.5

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

2.5

 

 

37.5

22.5

 

12.5

 

10

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

60

36

 

20

 

16

 

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

90

54

 

30

 

24

 

 

 

 

 

 

 

 

 

 

 

 

 

10

 

 

150

90

 

50

 

40

 

 

 

 

 

 

 

 

 

 

 

 

 

16

 

 

240

144

 

80

 

64

 

 

 

 

 

 

 

 

 

 

 

 

 

25

 

 

375

225

 

125

 

100

 

 

 

 

 

 

 

 

 

 

 

 

 

35

 

 

525

315

 

175

 

140

 

 

 

 

 

 

 

 

 

 

 

 

 

50

 

 

750

450

 

250

 

200

 

 

 

 

 

 

 

 

 

 

 

 

 

70

 

 

1050

630

 

350

 

280

 

 

 

 

 

 

 

 

 

 

 

 

 

95

 

 

1425

855

 

475

 

380

 

 

 

 

 

 

 

 

 

 

 

 

 

120

 

 

1800

1080

 

600

 

480

 

 

 

 

 

 

 

 

 

 

 

 

 

200404

 

 

 

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TECHNICAL DATA

 

 

 

5

 

Components

 

CF65/75/85 series ≥0E621376

 

Alternator

 

 

 

 

0

NCB1

 

 

 

 

Max. current

 

80 A

 

 

 

 

 

 

 

Rated voltage

 

28 V

 

 

 

NCB2

 

 

 

 

 

Max. current

 

100 A

 

 

 

Rated voltage

 

28 V

 

 

 

Micro relay

 

 

 

 

 

Maximum cut in current

 

 

 

 

 

making connection between

10 A

+1

 

2

 

points 3 and 5:

 

 

5

 

Maximum cut out current

 

 

 

 

 

+3

 

4

 

breaking connection between

 

 

 

 

 

 

 

5 A

 

 

 

 

points 3 and 4:

 

 

E500146

 

 

 

 

 

3

 

 

 

 

5

 

 

 

 

2

4

1

 

 

 

 

 

E500147

 

Mini relay

 

 

 

 

 

Maximum cut in current

 

86

 

87a 87

 

making connection between

 

 

 

 

 

 

 

 

points 30 and 87:

20 A

 

 

 

 

Maximum cut out current

 

 

 

 

 

breaking connection between

 

 

 

 

 

points 30 and 87a:

10 A

85

 

30

 

 

 

 

 

87

86

87a

85

 

30

E500169

Handheld transmitter CDS

 

Battery type (2x)

CR1620, 3 V

1-2

 

 

200404

 

 

 

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5

 

TECHNICAL DATA

CF65/75/85 series ≥0E621376

 

Components

 

1.2 TIGHTENING TORQUES

 

 

 

 

 

 

 

 

Tightening torques

 

 

 

0

 

 

 

 

Drive pulley

80

Nm 5 Nm

 

 

B+ connection

15

Nm

Chassis earth connection

65

Nm

200404

 

 

 

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TECHNICAL DATA

5

Components

CF65/75/85 series ≥0E621376

0

1-4

 

 

200404

 

 

 

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5

 

 

DIAGNOSTICS

 

CF65/75/85 Series ≥0E621376

 

Contents

 

 

CONTENTS

 

 

 

 

 

 

 

Page

Date

 

1.

FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1-1 . .

. . 200520

 

 

 

1.1

Short circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 1-2 . .

. . 200520

 

 

 

 

1

 

1.2

Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 1-3 . .

. . 200520

 

 

1.3

Earthing problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 1-4 . .

. . 200520

 

2.

BATTERIES

2-1

200520

 

 

 

 

 

2.1

Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 2-1 . .

. . 200520

 

 

 

2.2

Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 2-4 . .

. . 200520

 

 

3.

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 3-1 . .

. . 200520

 

 

 

3.1

Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 3-1 . .

. . 200520

 

 

4.

XENON LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 4-1 . .

. . 200520

 

 

 

4.1

Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 4-1 . .

. . 200520

 

 

200520

 

 

 

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DIAGNOSTICS

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Contents

CF65/75/85 Series ≥0E621376

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2

 

 

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5

DIAGNOSTICS

CF65/75/85 Series ≥0E621376

Fault finding

 

 

1. FAULT FINDING

 

 

 

The following test equipment and tools can be

 

 

 

used to trace faults.

 

 

 

1. The best instrument for this is a digital

 

 

 

multimeter. This instrument can be used to

 

 

 

 

 

1

measure voltages, currents and resistances

 

 

avoiding reading errors, and it can be used

 

to trace virtually any faults.

 

 

 

 

 

 

2. Many, but not all, faults are easily traced by

 

 

 

means of warning lamps. Failures caused

 

 

 

by poor earthing cannot normally be

 

 

 

detected by a warning lamp or buzzer.

 

 

 

The most frequently occurring faults are:

a.short circuit

b.open circuits

c.earthing problems (poor earthing due to corrosion).

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DIAGNOSTICS

5

Fault finding

CF65/75/85 Series ≥0E621376

1.1 SHORT CIRCUITS

 

A short circuit is caused by a positive wire shorting to earth somewhere. In most cases this will cause a fuse to blow.

1To remedy this failure, use a test lamp of approximately 70W. First check the diagram to see which consumers are connected to the fuse in question, and then switch them all off. Remove the fuse and connect the test lamp in its place. Now switch each of the consumers on and off one by one. If the lamp comes on very brightly when a consumer is switched on, the

fault is almost certainly in the wiring of that

 

consumer. Now check the diagram to see via

 

which connectors the consumer is connected.

 

Now disconnect the first wiring connection (as

 

seen from the fuse).

 

If the lamp is still bright, the fault is between the

 

fuse and this wiring connection.

W 5 03 013

If, however, the lamp goes out, the fault is somewhere further on in the wiring.

Now reconnect the connectors and disconnect the next wiring connection. If the lamp is still bright, the failure is between these two wiring connections.

However, if the lamp goes out again, the fault-finding procedure must be continued. The faulty wiring section can be found in this way.

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DIAGNOSTICS

CF65/75/85 Series ≥0E621376

Fault finding

 

1.2 OPEN CIRCUIT

 

 

Suppose a consumer is not functioning. The fault may be in the consumer itself, or there may be an open circuit in the wiring.

First switch on the consumer. Then check the consumer for voltage using a test lamp. If no voltage is found, first check whether the fuse is still intact.

If there is voltage at the fuse, check the wiring from the fuse to the consumer. This means every wiring connection must be checked. Stop at the first wiring connection that has no voltage. The open circuit will be between this connection and the previous one.

However, if there was a voltage at the consumer, there may still be an open circuit in the negative (earth) wiring. Check this using a test lamp.

Ensure that the relevant circuit is switched on. Connect one end of the test lamp to earth and the other end to the earth connection of the component to be checked.

If the test lamp lights up, the earth connection of the component is interrupted. If the test lamp does not light up, the earth connection will in many cases be in good condition.

If both the positive and negative connections are in good order, the consumer in question must be replaced.

W 5 03 015

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W 5 03 016

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DIAGNOSTICS

5

Fault finding

CF65/75/85 Series ≥0E621376

1.3 EARTHING PROBLEMS

 

Earthing problems are mainly caused by corrosion between the contact surfaces of electrical connections.

1A poor earth connection of the main earth circuit (2) between cab and chassis may result in a current through the steering shaft (1).

1

2

E502316

To check this main earth connection, two complementary tests must be carried out.

-A current measurement using a current probe.

-A voltage loss measurement using a multimeter.

A current probe, which is a special tool (DAF no. 1453183), must be used for a current measurement; this measures the current through the steering shaft (1).

The current measurements have to be carried out while the cab is in the driving position.

1-4

 

 

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DAF CF65, CF75, CF85 Service manual

5

DIAGNOSTICS

CF65/75/85 Series ≥0E621376

Fault finding

 

INSPECTION 1, MEASURING THE SYSTEM

CURRENT

1.Open the grille.

2.

Switch on vehicle ignition and as many

 

 

 

consumers as possible, e.g.:

1

 

 

-

dipped beam

1

 

- heater fan in position 4

 

 

-

spotlights, etc.

 

3.

Use the current probe to check whether the

 

 

 

power consumption through the battery

 

 

 

cable at the battery is between 20 A and 40

 

 

 

A. Switch on extra consumers if this is not

 

 

 

the case until the power consumption is

 

 

 

between 20 A and 40 A.

 

 

4.

Then measure the system current through

 

 

 

the steering shaft (1) using the probe. Make

 

 

 

sure that the current probe is placed in the

 

 

right position (direction of current) and its jaws are closed around the steering shaft.

5.Depending on the measured current value, the following actions need to be carried out:

E502267

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DIAGNOSTICS

5

 

 

 

Fault finding

CF65/75/85 Series ≥0E621376

 

 

 

 

 

 

 

 

 

Measured

Measures to be taken

 

 

 

 

current value

 

 

 

 

 

 

 

 

 

 

 

< 2.0 A

- The main earth connections are in good order, end of inspection 1. Continue

 

 

 

 

 

with inspection 2.

 

 

1

 

≥ 2.0 A and

- Inspect - and if necessary repair - all main earth connections from the cab to

 

 

 

< 5.0 A

the negative battery terminal between the following points:

 

 

 

 

 

- battery earth and cab earth

 

 

 

 

 

 

 

 

 

 

- cab earth and flywheel housing earth

 

 

 

 

 

- flywheel housing earth and chassis earth

 

 

 

 

 

- chassis earth and battery earth

 

 

 

 

 

Note:

 

 

 

 

 

A voltage loss measurement must be carried out to identify which earthing point

 

 

 

 

 

is in poor condition. This measurement is described later on in this procedure.

 

 

 

 

 

- The current value through the steering shaft must be less than 2.0 A after

 

 

 

 

 

repair. Otherwise one or more earth connections are not yet in good order and

 

 

 

 

the main earth connections must be inspected again and if necessary

 

 

 

 

 

repaired.

 

 

 

 

 

- If the current value is < 2.0 A, the main earth connections are in good order:

 

 

 

 

end of inspection 1. Continue with inspection 2.

 

 

 

 

≥ 5.0 A

- Inspect - and if necessary repair - all main earth connections from the cab to

 

 

 

 

 

the negative battery terminal between the following points:

 

 

 

 

 

- battery earth and cab earth

 

 

 

 

 

- cab earth and flywheel housing earth

 

 

 

 

 

- flywheel housing earth and chassis earth

 

 

 

 

 

- chassis earth and battery earth

 

 

 

 

 

Note:

 

 

 

 

 

A voltage loss measurement must be carried out to identify which earthing point

 

 

 

 

 

is in poor condition. This measurement is described later on in this procedure.

 

 

 

 

 

- The current value through the steering shaft must be less than 2.0 A after

 

 

 

 

 

repair. Otherwise one or more main earth connections are not yet in good

 

 

 

 

 

order and the earth connections must be inspected again and if necessary

 

 

 

 

 

repaired.

 

 

 

 

 

- If the current value is < 2.0 A, the earth connections are in good order.

 

 

 

 

 

Note:

 

 

 

 

 

A high current through the steering shaft can affect the mechanical condition of

 

 

 

 

 

the steering shaft bearing.

 

 

 

 

 

 

 

 

1-6

 

 

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5

 

DIAGNOSTICS

CF65/75/85 Series ≥0E621376

Fault finding

 

 

INSPECTION 2, MEASURING THE STARTING

 

 

 

 

CURRENT

 

 

 

 

 

Measure the starting current through the

 

 

 

 

steering shaft while starting, using the current

 

 

 

 

probe.

 

 

 

 

 

This measurement must be carried out with the

 

 

 

 

 

 

 

1

probe’s “Max Hold” function. Make sure that the

 

 

 

current probe is placed in the right position

 

(direction of current) and its jaws are closed

 

 

 

 

 

 

 

 

around the steering shaft.

 

 

 

 

 

 

 

 

 

 

Measured

Measures to be taken

 

 

 

 

current value

 

 

 

 

 

 

 

 

 

< 5.0 A

- Main earth connections are in good condition; end of inspection 2: vehicle

 

 

 

 

is OK.

 

 

 

 

≥ 5.0 A

- Inspect - and if necessary repair - all main earth connections from the cab

 

 

 

 

to the negative battery terminal between the following points:

 

 

 

- battery earth and cab earth

 

 

 

 

 

- cab earth and flywheel housing earth

 

 

 

 

 

- flywheel housing earth and chassis earth

 

 

 

 

 

- chassis earth and battery earth

 

 

 

 

 

Note:

 

 

 

 

 

A voltage loss measurement must be carried out to identify which earthing

 

 

 

point is in poor condition. This measurement is described later on in this

 

 

 

procedure.

 

 

 

 

 

- The starting current value through the steering shaft must be less than 5.0

 

 

 

A after repair. Otherwise one or more main earth connections are not yet in

 

 

 

good order and the main earth connections must be inspected again and if

 

 

 

necessary repaired.

 

 

 

 

 

- If the current value is < 5.0 A, the earth connections are in good order;

 

 

 

end of inspection 2: vehicle is OK.

 

 

 

 

 

 

 

 

 

 

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DIAGNOSTICS

5

Fault finding

CF65/75/85 Series ≥0E621376

MEASURING VOLTAGE LOSS

 

1

4

3

2

1

E502269

1 negative battery terminal

2flywheel housing

3chassis

4bulkhead lead-through connector

To find out whether a specific earthing point has a good earth connection, measure the voltage loss between the negative battery terminal and this earthing point.

The figure shown is an example; the actual course of the earth connection may differ somewhat depending on vehicle type and production date.

The consumers that were switched when the current was measured should now be switched on as well, i.e. the power consumption should be between 20 A and 40 A.

If the earth connection is good, the voltage loss should be less than 0.5 V.

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5

DIAGNOSTICS

 

CF65/75/85 Series ≥0E621376

Batteries

 

 

2. BATTERIES

 

 

 

2.1 FAULT-FINDING TABLE

 

 

 

 

 

 

 

SYMPTOM: NEW BATTERY HEATS UP CONSIDERABLY DURING FILLING

 

 

 

1

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

 

Inadequate formation because of storage in

Allow to cool

 

 

 

 

unsuitable or damp conditions over a long period

Charge fully

 

 

 

Check the relative density

 

 

 

 

 

 

 

 

SYMPTOM: BATTERY ACID LEAKING FROM THE PLUG HOLES

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Battery overfilled

Siphon off some of the fluid

 

 

 

 

 

 

Overcharging

Check the charger and repair if necessary

 

 

 

 

 

 

 

 

SYMPTOM: ELECTROLYTE LEVEL TOO LOW

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Leaking battery

Replace the battery

 

 

Excessive gas development due to charging

Check/repair the charger

 

 

current being set too high

 

 

 

 

 

SYMPTOM: RELATIVE DENSITY TOO LOW (<1.240)

 

 

STARTING TROUBLE

 

 

Possible cause

Remedy

 

 

 

 

 

 

Power consumer left on by mistake

Charge the battery

 

 

Insufficient charging

Check/repair the charger

 

 

Short circuit in the charging circuit

Check the charging circuit

 

 

 

 

 

 

 

 

SYMPTOM: DENSITY IS TOO HIGH (>1.290)

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Topped up with acid instead of distilled water

Siphon off the fluid and fill with distilled water

 

 

 

If necessary, repeat this after mixing (charging)

 

 

 

 

 

 

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DIAGNOSTICS

5

 

 

 

Batteries

CF65/75/85 Series ≥0E621376

 

 

 

 

 

 

 

 

 

 

SYMPTOM: STARTING TROUBLE

 

 

 

 

POOR STARTING TEST RESULT

 

 

 

 

POWER FAILS UNDER LOAD

 

 

 

 

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

 

1

 

-

Discharged battery

Charge the battery

 

 

 

 

 

 

- Worn battery (plates corroded and worn

Replace the battery

 

 

 

 

away)

 

 

 

 

- Defective battery (“dead cell”)

Replace the battery

 

 

 

-

Battery too small

Replace with battery of a higher capacity

 

 

 

- Battery sulphated (plates have hardened)

Replace the battery

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SYMPTOM: BURNT-IN BATTERY TERMINALS

 

 

 

 

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

 

 

- Clamps not securely fitted, or poor contact

Have the battery terminals repaired, fit the

 

 

 

 

 

clamps properly or replace the clamps if

 

 

 

 

 

necessary

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SYMPTOM: 1 OR 2 CELLS BUBBLE EXCESSIVELY UNDER HIGH LOADS (STARTING OR

 

 

 

 

STARTING TEST)

 

 

 

 

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

 

 

 

-

Defective cells

Replace the battery

 

 

 

-

Leaking cell partition

Replace the battery

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SYMPTOM: BATTERY DISCHARGES VERY FAST (DOES NOT RETAIN POWER)

 

 

 

 

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

 

 

 

-

Insufficient charging

Check the charging. Is the charging time (driving

 

 

 

 

 

time) sufficient?

 

 

 

- Short circuit in charging circuit

Check the charging circuit

 

 

 

- Major self-discharging, for example due to

Clean the battery

 

 

 

 

contamination

 

 

 

 

- Battery sulphated (on examining the plates,

Replace the battery

 

 

 

 

they are found to be hard and, in some

 

 

 

 

 

cases, whitened)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SYMPTOM: SHORT BATTERY LIFE

 

 

 

 

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

 

 

- Wrong type of battery chosen (for example in

Install Super Heavy Duty or semi-traction battery

 

 

 

 

the case of tail lifts)

 

 

 

 

- Often too deeply discharged

Intermediate charging with rectifier

 

 

 

- No recharging after deep discharge

Always charge the battery after deep discharge

 

 

 

 

(white deposits)

 

 

 

 

 

 

 

 

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DIAGNOSTICS

CF65/75/85 Series ≥0E621376

Batteries

 

 

 

 

 

 

 

 

SYMPTOM: BATTERY HOT DURING OPERATION WITH EXCESSIVE WATER CONSUMPTION

 

 

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

 

-

Overcharging or

Check the charger (voltage regulator)

 

 

- charging voltage too high

 

 

 

 

 

1

 

 

 

 

 

 

 

 

SYMPTOM: BATTERY HAS EXPLODED

 

 

 

 

 

 

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

- Fire or sparks during or just after charging

Ensure good ventilation and exercise due

 

 

 

 

caution as regards fire and sparks

 

 

-

Short-circuiting by tools

Be careful where tools are put down

 

 

- Internal defect (loose connection)

Replace the battery

 

 

 

 

 

 

 

 

 

 

 

SYMPTOM: DEFECTIVE ALTERNATOR AND/OR DIODES (RADIO AND OTHER

 

 

 

POLARITY-SENSITIVE EQUIPMENT NOT WORKING)

 

 

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

- Reversed battery polarity or incorrect

Discharge the battery and charge in the correct

 

 

 

charging

direction

 

 

 

 

If necessary, replace the battery

 

 

 

 

 

 

 

 

 

 

 

SYMPTOM: BATTERY IS INACTIVE (NO VOLTAGE)

 

 

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

 

-

Internal open circuit

Replace the battery

 

 

- Battery very deeply discharged

Charge the battery and test it; replace if

 

 

 

 

necessary

 

 

 

 

 

 

 

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DIAGNOSTICS

5

Batteries

CF65/75/85 Series ≥0E621376

2.2 SERVICE LIFE

 

The service life of a battery is significantly shortened if it used “cyclically”.

This means that the batteries are used a lot

1without being charged.

For example when using a tail lift, cab heater, microwave oven or cooler box.

This is why batteries in commercial vehicles and vehicles used for international transport often fail prematurely (within 1.5 years).

The battery must be charged whenever the voltage measured across the battery falls below 12.5V. If the battery is not charged, the “sulphating process” will begin.

This is a chemical reaction in the battery that produces lead sulphate. Lead sulphate adheres to the battery plates and can cause short-circuiting between the plates, reducing the capacity of the battery.

However, most lead sulphate breaks down when the battery is recharged.

If a battery is used (discharged) while it is not being charged by the alternator, short-circuiting between the battery plates will occur sooner. This reduces the capacity and consequently the service life of the battery.

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5

DIAGNOSTICS

 

CF65/75/85 Series ≥0E621376

Alternator

 

 

3. ALTERNATOR

 

 

 

3.1 FAULT-FINDING TABLE

 

 

 

 

 

 

 

SYMPTOM: ALTERNATOR NOT PRODUCING POWER WHEN IDLING

 

 

 

1

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

 

Open circuit in connection 15 on alternator

Repair connection 15

 

 

 

 

Connection 15 on alternator short-circuited to

Repair connection 15

 

 

earth

 

 

 

Internal defect

Replace regulator

 

 

 

 

 

 

 

 

SYMPTOM: ALTERNATOR WARNING (YELLOW)

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Open circuit in “S” connection

Measure the regulated alternator voltage with as

 

 

 

many consumers as possible switched on and

 

 

 

with the engine turning above idling speed

 

 

Open circuit in “L” connection

Check/repair wiring

 

 

Open circuit in connection 15

Increase the engine speed to approx. 1500 rpm.

 

 

 

If voltage is now present, check connection 15

 

 

 

on the alternator

 

 

Voltage difference between “B+” and

Check all contacts between alternator and

 

 

“S” connections is greater than 2.5V

batteries (contact resistors).

 

 

 

Internal battery resistance too high

 

 

Voltage too low <16V

Check alternator drive. Check wiring on contact

 

 

 

resistors. Check regulated voltage

 

 

Open circuit in voltage regulator

Replace voltage regulator

 

 

 

 

 

 

 

 

SYMPTOM: ALTERNATOR VOLTAGE HIGH (RED)

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Voltage too high > 31V

Measure voltage

 

 

Internal defect

Replace regulator/alternator

 

 

 

 

 

 

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DIAGNOSTICS

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Alternator

CF65/75/85 Series ≥0E621376

1

3-2

 

 

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DIAGNOSTICS

 

CF65/75/85 Series ≥0E621376

Xenon lighting

 

 

4. XENON LIGHTING

 

 

 

4.1 FAULT-FINDING TABLE

 

 

 

 

 

 

 

SYMPTOM: XENON LIGHTING NOT WORKING ON ONE SIDE

 

 

 

1

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

 

Faulty dipped beam fuse

Check fuse

 

 

 

 

No power to the ballast unit on the faulty side

Check the power supply to the ballast unit

 

 

Faulty xenon bulb

Replace xenon bulb

 

 

Faulty ignition unit

Replace ignition unit

 

 

Faulty wiring between the ballast unit and the

Check the wiring

 

 

ignition unit

 

 

 

Faulty ballast unit

Replace ballast unit

 

 

Ignition unit connector not connected properly

Check connector

 

 

 

 

 

 

 

 

SYMPTOM: XENON LIGHTING NOT WORKING ON BOTH SIDES

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Faulty fuse

Check fuse

 

 

Faulty light switch (C622)

Check light switch

 

 

Faulty relay (G001)

Check relay

 

 

Faulty wiring

Check the wiring

 

 

 

 

 

 

 

 

SYMPTOM: COLOUR DIFFERENCE AFTER NEW BULB IS FITTED

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Bulb of a different make fitted

Bulbs of the same make should preferably be

 

 

 

fitted on both left and right

 

 

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DIAGNOSTICS

5

Xenon lighting

CF65/75/85 Series ≥0E621376

1

4-2

 

 

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COMPONENTS

 

CF65/75/85 series ≥0E621376

 

Contents

 

 

CONTENTS

 

 

 

 

 

 

 

Page

Date

 

1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1-1 . .

. . 200404

 

 

 

1.1

Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1-1 . .

. . 200404

 

 

 

1.2

Scopemeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1-2 . .

. . 200404

 

 

 

1.3

Signal measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 1-3 . .

. . 200404

 

 

2.

DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2-1 . .

. . 200404

 

 

 

2

 

2.1

Inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2-1 . .

. . 200404

 

 

2.2

Vehicle speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2-2 . .

. . 200404

 

 

2.3

Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2-4 . .

. . 200404

 

 

 

 

 

 

2.4

Fluid level sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2-6 . .

. . 200404

 

 

 

2.5

Pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2-7 . .

. . 200404

 

 

 

2.6

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2-8 . .

. . 200404

 

 

 

2.7

Proximity sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2-10 .

. . 200404

 

 

 

2.8

Steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . 2-11 .

. . 200404

 

 

3. DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 200404 3.1 Diagnostics in electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 200404

200404

 

 

 

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COMPONENTS

5

Contents

CF65/75/85 series ≥0E621376

2

2

 

 

200404

 

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5

COMPONENTS

CF65/75/85 series ≥0E621376

General

 

1. GENERAL

1.1 MULTIMETER

Various measurement options can be selected on the Fluke 87 multimeter.

Units of measurement

The multimeter should be set to the range for the unit of measurement required.

For example, voltage range, current range, or resistance range.

The units of measurement are indicated by symbols on the meter. The following symbols are used:

1.DC voltage

2.AC voltage

3.DC current

4.AC current

5.Resistance

6.Duty cycle

7.Frequency

2

1DCV - V

2ACV - V

3DCA - A

4ACA -A

5Ohm -

6%

7 Hz

W 5 01 004

200404

 

 

 

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COMPONENTS

5

General

CF65/75/85 series ≥0E621376

1.2 SCOPEMETER

 

Diagnostics in modern electronic systems is becoming steadily more complex.

Using a multimeter on its own is not always sufficient to diagnose a fault.

The scopemeter allows complex signals to be measured.

2Practical examples of complex signals are:

-PWM signals

-signal deformation

-CAN-bus-signals

1-2

 

 

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