DAF CF65, CF75, CF85 Service manual

5

CONTENTS

CF65/75/85 series

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

200332 https://www.truck-manuals.net/

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5	TECHNICAL DATA
CF65/75/85 series	Contents

CONTENTS

Page Date	0

1. COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200315 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200315 1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . 200315

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TECHNICAL DATA	5
Contents	CF65/75/85 series

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5							TECHNICAL DATA
CF65/75/85 series								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

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	TECHNICAL DATA				5
	Components				CF65/75/85 series
	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		+1		2
	points 3 and 5:	10 A			5
	Maximum cut out current
			+3		4
	breaking connection between
	points 3 and 4:	5 A			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

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5		TECHNICAL DATA
CF65/75/85 series		Components
1.2 TIGHTENING TORQUES
Tightening torques				0
Drive pulley	80	Nm 5 Nm
B+ connection	15	Nm
Chassis earth connection	65	Nm

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TECHNICAL DATA	5
Components	CF65/75/85 series

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5			DIAGNOSTICS
CF65/75/85 series				Contents
CONTENTS
			Page	Date
1.	BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 1-1 . .	. . 200315
	1.1	Fault-finding table	1-1	200315
	1.2	Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1-4 . .	. . 200315		1
2.	ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . 2-1 . .	. . 200315
	2.1	Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2-1 . .	. . 200315

3. FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 200315 3.1 Short circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . 200315 3.2 Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . 200315 3.3 Earthing problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . 200315

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DIAGNOSTICS	5
Contents	CF65/75/85 series

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5	DIAGNOSTICS
CF65/75/85 series	Batteries
1. BATTERIES
1.1 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: RELATIVE DENSITY TOO HIGH (>1.290)
Possible cause	Remedy
Topped up with acid instead of distilled water	Siphon off some of the fluid and top up with
	distilled water
	If necessary, repeat this after mixing (charging)

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		DIAGNOSTICS	5
		Batteries	CF65/75/85 series
		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 away)	Replace the battery
		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 POLES
		Possible cause	Remedy
		Terminals not securely fitted, or poor contact	Have the battery poles repaired, fit the terminals
			properly and replace the terminals 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, they	Replace the battery
		are found to be hard and, in some cases,
		whitened)

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5	DIAGNOSTICS
CF65/75/85 series	Batteries
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)
				1
Often too deeply discharged	Intermediate charging with rectifier
No recharging after deep discharge	Always charge the battery after deep discharge
(white deposits)
SYMPTOM: BATTERY HOT DURING OPERATION WITH EXCESSIVE WATER CONSUMPTION
Possible cause	Remedy
Overloading, or charging voltage too high	Check the charger (voltage regulator)
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 charging	Discharge the battery and charge in the correct
	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
1.2 SERVICE LIFE

The service life of a battery is significantly shortened if it is used ‘cyclically’.

This means that the batteries are used a lot without their being charged.

1 For example when using a tail lift, cab heater, microwave oven and a 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 12.5 V. 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	Alternator
2. ALTERNATOR
2.1 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 still present, check connection 15 on
	the alternator
Voltage difference between ‘B+’ and ‘S’	Check all contacts between alternator and
connections is greater than 2.5 V	batteries (contact resistances). Internal battery
	resistance too high.
Voltage too low <16 V	Check alternator drive. Check wiring on contact
	resistances
	Check regulated voltage
Open circuit in voltage regulator	Replace voltage regulator
SYMPTOM: ALTERNATOR VOLTAGE HIGH (RED)
Possible cause	Remedy
Voltage too high >31 V	Measure voltage
Internal defect	Replace regulator/alternator

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DIAGNOSTICS	5
Alternator	CF65/75/85 series

1

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5	DIAGNOSTICS
CF65/75/85 series	Fault finding
3. 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
measure voltages, currents and resistances			1
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
		3.1 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.
1		To remedy this failure, use a test lamp of
		approximately 70 W. 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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5	DIAGNOSTICS
CF65/75/85 series	Fault finding
3.2 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 starts burning, the earth connection of the component is interrupted. If the test lamp does notlight 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

1

W 5 03 016

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DIAGNOSTICS	5
Fault finding	CF65/75/85 series
3.3 EARTHING PROBLEMS

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

Earthing problems can only be detected using a 1 multimeter (preferably digital). A digital tester is preferable because usually only a few volts will

be measured and an analogue meter is generally not precise enough for this purpose. To find out whether a specific earthing point has a good earth connection, use a voltmeter to measure the voltage between the negative battery pole and this earthing point.

Switch on as many consumers as possible.

If there is a correct earth connection, no voltage should be found.

In practice, however, a loss of approx. 0.5 volts will often be measured.

If the reading is higher, the earth connection must be checked carefully.

In this way, the earth connections of all consumers can be checked and measured.

W 5 03 014

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5			COMPONENTS
CF65/75/85 series				Contents
CONTENTS
			Page	Date
1.	GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . 1-1 . .	. . . . 0202
	1.1	Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . 1-1 . .	. . . . 0202
	1.2	Scopemeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . 1-2 . .	. . . . 0202
	1.3	Signal measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . 1-3 . .	. . . . 0202
2.	DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . 2-1 . .	. . . . 0202
	2.1	Inductive sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 2-1 . .	. . . . 0202		2
	2.2	Vehicle speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 2-2 . .	. . . . 0202
	2.3	Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 2-4 . .	. . . . 0202
	2.4	Fluid level sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 2-6 . .	. . . . 0202
	2.5	Pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 2-7 . .	. . . . 0202
	2.6	Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 2-8 . .	. . . . 0202
	2.7	Proximity sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 2-10 .	. . . . 0202
	2.8	Steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 2-11 .	. . . . 0202
3.	DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 3-1 . .	. . . . 0202
	3.1	Diagnostics in electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 3-1 . .	. . . . 0202

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COMPONENTS	5
Contents	CF65/75/85 series

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5	COMPONENTS
CF65/75/85 series	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

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		COMPONENTS		5
		General		CF65/75/85 series
		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.
2		Practical examples of complex signals are:
		-	PWM signals
		-	signal deformation
		-	CAN-bus-signals

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5	COMPONENTS
CF65/75/85 series	General
1.3 SIGNAL MEASUREMENTS

Sine-wave signal (AC voltage)

This signal changes polarity regularly in relation to the “0” line.

Frequency

The frequency is shown in Hertz (Hz).

The number of complete sines per second is the frequency of the signal (3 Hz in the diagram).

Voltage

If the number of sines per second increases, not just the frequency increases but also the voltage.

Measuring a sine wave signal

The sine wave signal can be measured in the following ways using a multimeter:

-Multimeter in the frequency position (Hz). This measures the number of complete sines per second.

-Multimeter in the AC voltage position. This measures the average value of the supplied voltage.

+
0
-		2
+	t
0
- 1	2	3

+

0

Sine wave signals in the vehicle	-
	W 5 01 002

-Wheel speed sensor output signal.

-Engine speed sensor output signal.

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COMPONENTS	5
General					CF65/75/85 series
Square wave signals		t1
Square wave signals are signals with only two
voltage levels, both of which have the same	+
duration in principle (t1 is equal to t2).

0

t2

2

If there is a difference between the duration for the two levels (t1 is not equal to t2), the signal is also called a ”pulse train“.

Duty cycle

The duty cycle is the ratio between the two voltage levels, expressed as a percentage.

A

x 100%

B

The voltage level ratio of a “pulse train” may change (for example, when the vehicle speed increases).

If the number of pulses per unit of time increases, the duty cycle reading will rise.

Voltage

An increase in the number of pulses per unit of time will not only lead to a higher duty cycle ratio but also to a higher mean voltage.

t1

+

0

t2

A

+

0

B

A

+

0

B	W 5 01 001

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5	COMPONENTS
CF65/75/85 series	General
Measuring a square wave signal
The square wave signal can be measured in the
following ways using a multimeter:
- Multimeter in the duty cycle position (%).
This measures the voltage level ratio.
- Multimeter in the DC voltage position.
This measures the average value of the
supplied voltage.
Square wave signals in the vehicle
			2
- Speed sensor output signal
- Vehicle speed signal to electronic units

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COMPONENTS	5
General	CF65/75/85 series

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5	COMPONENTS
CF65/75/85 series	Description of components
2. DESCRIPTION OF COMPONENTS
2.1 INDUCTIVE SENSOR

The vehicle has a number of inductive sensors, such as:

-wheel speed sensor

-engine speed sensor

-camshaft sensor

Recording engine speed

The engine speed is recorded via the crankshaft position sensor. The crankshaft position sensor output signal is a sine wave signal with a frequency corresponding to the number of holes in the pulse disc and the crankshaft rotation frequency.

The signal is converted in the electronic unit into a message that is sent via the CAN network. The VIC sends this message to the DIP, which then activates the rev counter.

Engine speed sensor operating principles

The inductive sensor consists of a permanent magnet (1), a core (2) and a coil (3).

When the inductive sensor is situated between two teeth, the lines of force of the magnetic field will run directly from the north pole to the south pole via the housing.

The moment a tooth approaches the inductive sensor, the lines of force of the magnetic field will run from the north pole to the south pole via the housing, the teeth of the toothed wheel and the core.

As more lines of force are now running through the core, a more powerful magnetic field is obtained.

As a result of this change in the magnetic field, an AC voltage is generated in the coil.

The value of the AC voltage generated depends on the speed of +rotation of the toothed wheel and the air gap between sensor (core) and tooth.

1
2	2
3
	i400442

1

N

2

S

3

W 5 01 005

	0202				2-1
		https://www.truck-manuals.net/

COMPONENTS	5
Description of components	CF65/75/85 series
2.2 VEHICLE SPEED SENSOR

	The vehicle speed sensor has two connections
	for output signals. The “real-time” speed signal,
	generated by a Hall IC, is sent via the first
	connection,
	A data signal (bi-directional signal) is sent via
	the other connection, data being exchanged		1.	+
	between the MTCO and the speed sensor.		2.	-
2	The MTCO requests data from the sensor.		3.
	The sensor sends the coded data to the MTCO
	in sequence, and the MTCO checks the		4.
	accuracy of this data.
	The coded signal consists of the following data:
	- Serial number of the sensor
	- “Master key” (the same as that of the
		MTCO)
	-	Coded speed signal
				1

- +

2 M

The MTCO compares the coded speed signal to
the “real-time” speed signal.
The MTCO sends commands and data to the				E501055
sensor at 10 second intervals.
Speed data for the CAN-system is sent via
MTCO-outputs A6 and A7.
Speed data for the UPEC-system and
ECAS-system is sent for UPEC via output B7
and for ECAS via output B6; these are
duty-cycle signals.
Duty cycle speed signal	%
The speed signal sent via the vehicle speed	44
sensor to the MTCO is processed by the MTCO
and sent as a message via the CAN network.
The speed signal is also converted into a duty
cycle signal. This signal is used by electronic
units that do not receive/read the vehicle speed	22
signal message via the CAN network.
This diagram shows the linear characteristic of
the duty cycle (%) in relation to the vehicle
speed (V).
This graph applies to all vehicle models.
	50			100
				V(km/h)
				E501057

	2-2				0202
		https://www.truck-manuals.net/