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DMCI XF105
Service Manual
144 pgs1.89 Mb0
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DAF DMCI XF105 Service Manual

DMCI
XF105System and component information
©200528 DAF Trucks N.V., Eindhoven, The Netherlands.
In the interest of continuing product development, DAF reserves the right to change specifications or products at any time without prior notice.
No part of this publication may be reproduced and/or published by printing, by photocopying, on microfilm or in any way whatsoever without the prior consent in writing of DAF Trucks N.V.
©
200528 DW332094
XF105 series
STRUCTURE
Structure
TECHNICAL DATA
0
DMCI ENGINE MANAGEMENT SYSTEM
1
©
200528

TECHNICAL DATA

XF105 series
Contents
CONTENTS
Page Date
1. DMCI ENGINE MANAGEMENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200528
1.1 Power supply and earth of DMCI electronic unit . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200528
1.2 DMCI electronic unit CAN connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200528
1.3 Status signals DMCI electronic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . 200528
1.4 Accelerator pedal sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . 200528
1.5 Coolant temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 . . . . . 200528
1.6 2
1.7 Inlet air boost pressure and temperature sensor. . . . . . . . . . . . . . . . . . . . 1-10 . . . . 200528
1.8 Fuel pressure and temperature sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 . . . . 200528
1.9 Engine oil pressure and temperature sensor. . . . . . . . . . . . . . . . . . . . . . . 1-16 . . . . 200528
1.10 Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 . . . . 200528
1.11 Camshaft sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21 . . . . 200528
1.12 Engine oil level sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23 . . . . 200528
1.13 Switches (manual gearbox) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25 . . . . 200528
1.14 Switches (AS Tronic) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 . . . . 200528
1.15 Extra bulkhead lead-through functions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 . . . . 200528
1.16 Red warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28 . . . . 200528
1.17 Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 . . . . 200528
1.18 Glow components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 . . . . 200528
1.19 Waste gate valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31 . . . . 200528
1.20 Exhaust brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33 . . . . 200528
1.21 DEB solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34 . . . . 200528
1.22 Pump unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36 . . . . 200528
1.23 Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38 . . . . 200528
1.24 Electronically controlled fan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40 . . . . 200528
nd
coolant temperature sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 . . . . . 200528
0
©
200528 1
0
TECHNICAL DATA
Contents XF105 series
2
©
200528
TECHNICAL DATA
XF105 series
DMCI engine management system

1. DMCI ENGINE MANAGEMENT SYSTEM

1.1 POWER SUPPLY AND EARTH OF DMCI ELECTRONIC UNIT

A
41
45
49
53
57
60 62
C
B
0
21
25
29
33
37
1 4591317
i400726
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat = battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F Additional information available in Technical Data at "X" mark
AB C D E F
B44 Power supply after ignition (G426) Ubat V DC Ignition on
B57 Earth < 0.5 VDC Voltage loss measurement with
as many consumers as possible switched on.
B58 Earth < 0.5 VDC Voltage loss measurement with
as many consumers as possible switched on.
B59 Earth < 0.5 VDC Voltage loss measurement with
as many consumers as possible switched on.
B60 Power supply before ignition (G126) Ubat VDC
B61 Power supply before ignition (G126) Ubat VDC
B62 Power supply before ignition (G126) Ubat VDC
©
200528 1-1
0
TECHNICAL DATA
DMCI engine management system XF105 series

1.2 DMCI ELECTRONIC UNIT CAN CONNECTIONS

A
C
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat = battery voltage)
D Measuring unit
B
21
25
29
33
37
41
45
49
53
57
60 62
1 4591317
i400726
E Explanatory notes (if applicable)
F Additional information available in Technical Data at "X" mark
AB C D E F
B27 V-CAN1-H According to ISO 11898
B35 V-CAN1-L According to ISO 11898
B42 V-CAN1 through connection According to ISO 11898
B45 V-CAN2-H According to ISO 11898 X
B46 V-CAN1 terminating resistance
According to ISO 11898 X
through connection
B50 V-CAN1 through connection According to ISO 11898 X
B53 V-CAN2-L According to ISO 11898 X
B54 V-CAN1 terminating resistance
According to ISO 11898
through connection
V-CAN1 terminating resistance ≥120  V-CAN2 terminating resistance ≥120 
(1) Check the resistance by measuring at connection points B46 and B50 of the electronic unit. (2) Check the resistance by measuring at connection points B45 and B53 of the electronic unit.
1-2
(1)
(2)
©
200528
TECHNICAL DATA
XF105 series

1.3 STATUS SIGNALS DMCI ELECTRONIC UNIT

A
C
B
DMCI engine management system
21
25
29
33
37
41
45
49
53
57
60 62
1 4591317
0
i400726
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat = battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F Additional information available in Technical Data at "X" mark
AB C D E F
B51 Input signal, service brake (G469) Ubat V DC Brake pedal not operated
0 V DC Brake pedal operated
©
200528 1-3
0
TECHNICAL DATA
DMCI engine management system XF105 series

1.4 ACCELERATOR PEDAL SENSOR

A
C
B
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat = battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F Additional information available in Technical Data at "X" mark
29
33
37
41
45
49
53
57
60 62
1 45913172125
i400726
AB CDE F
B33 Input signal accelerator pedal
sensor (F672)
0.325 -
0.500
0.675 -
V DC Idling, accelerator pedal not operated
(0%)
V DC Switching point idling switch (circa 10%) X
X
0.875
3.000 -
V DC Full load (circa 85%) X
3.400
3.550 -
V DC Kickdown (circa 100%) X
4.265
B34 Power supply, accelerator
5V DC
pedal sensor (F672)
B37 Earth, accelerator pedal
0V DC
sensor (F672)
B38 Accelerator pedal sensor
0V DC
earth, idling switch (F672)
B41 Accelerator pedal sensor input
signal, idling switch (F672)
1-4
5 V DC Accelerator pedal not operated X
0 V DC Accelerator pedal operated circa 10% X
©
200528
TECHNICAL DATA
XF105 series
Potentiometer resistance value (B - C)
Potentiometer output resistance value (A - B)
Potentiometer output resistance value (A - C) Resistance value across idling switch (open position) Resistance value across idling switch (closed position)
(1) Accelerator pedal not operated (2) Accelerator pedal operated
(1)
(1)
(1)
(2)
1000 ≥ 40%
1500 ≥ 40%
2500 ≥ 40%
1000 ≥ 40%
DMCI engine management system
A B
C D
E F
0
A. Potentiometer signal B. Mass C. Potentiometer supply voltage D. Idling switch earth E. Not in use F. Idling switch signal
I400438
©
200528 1-5
0
TECHNICAL DATA
DMCI engine management system XF105 series

1.5 COOLANT TEMPERATURE SENSOR

A
C
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat = battery voltage)
D Measuring unit
B
21
25
29
33
37
41
45
49
53
57
60 62
1 4591317
i400726
E Explanatory notes (if applicable)
F Additional information available in Technical Data at "X" mark
AB C D E F
C25 Input signal, coolant temperature
(F566)
C26 Earth, coolant temperature sensor
5 V DC Open voltage, with detached
connector
0V DC
X
(F566)
1-6
©
200528
TECHNICAL DATA
XF105 series
Coolant temperature sensor
Model NTC
Resistance in relation to measured temperature
Temperature (C) Resistance ()
Minimum Maximum
- 40 38313 52926
- 30 22307 30194
-20 13402 17718
-10 8244 10661
0 5227 6623
DMCI engine management system
0
i 400440
(1)
10 3390 4217
20 2262 2760
25 1870 2260
30 1553 1866
40 1080 1277
50 771 900
60 555 639
70 408 465
80 304 342
90 230 257
100 178 196
110 136 152
120 106 119
130 84 95
140 67 76
(1) Check the resistance by measuring on the connection points of the sensor.
©
200528 1-7
TECHNICAL DATA
DMCI engine management system XF105 series
0
1.6 2
nd
COOLANT TEMPERATURE SENSOR
A
C
B
21
25
29
33
37
41
45
49
53
57
60 62
1 4591317
i400726
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat = battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F Additional information available in Technical Data at "X" mark
AB C D E F
A37 Input signal, coolant temperature
(F743)
A38 Earth, coolant temperature sensor
5 V DC Open voltage, with detached
connector
0V DC
X
(F743)
1-8
©
200528
TECHNICAL DATA
XF105 series
Resistance in relation to measured temperature
Temperature (C) Resistance ()
Minimum Maximum
- 40 87134 98852
- 30 44876 50910
-20 24215 27471
-10 13703 15545
0 7914 8978
10 4752 5390
20 2948 3344
40 1224 1388
50 8167 927
60 558 632
70 390 442
80 278 311
DMCI engine management system
0
90 201 227
100 148 168
110 110 124
120 83 95
Coolant temperature sensor
Model NTC
i401003
©
200528 1-9
0
TECHNICAL DATA
DMCI engine management system XF105 series

1.7 INLET AIR BOOST PRESSURE AND TEMPERATURE SENSOR

A
C
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat = battery voltage)
D Measuring unit
B
21
25
29
33
37
41
45
49
53
57
60 62
1 4591317
i400726
E Explanatory notes (if applicable)
F Additional information available in Technical Data at "X" mark
AB C D E F
A27 Earth air inlet boost pressure and
0V DC
temperature sensor (F649)
A28 Supply voltage air inlet boost
pressure and temperature sensor
5 V DC Open voltage, with detached
connector
(F649)
A30 Input signal air inlet boost pressure
(F649)
A34 Input signal air inlet temperature
(F649)
1-10
0.5 V DC Air inlet pressure 0 bar X
4.5 V DC Air inlet pressure 4 bar X
5 V DC Open voltage, with detached
connector
©
200528
X
TECHNICAL DATA
XF105 series
Colour of O-ring green Type of temperature sensor NTC Resistance value See table
DMCI engine management system
0
P
U
T
R
1. Mass
2. Temperature sensor output signal
3. Pressure sensor supply voltage
4. Pressure sensor output signal
i 400441
3
4
2
1
i400534
©
200528 1-11
TECHNICAL DATA
DMCI engine management system XF105 series
0
Resistance in relation to measured temperature
Temperature (C) Resistance ()
Minimum Maximum
- 40 38313 52926
- 30 22307 30194
-20 13402 17718
-10 8244 10661
0 5227 6623
10 3390 4217
20 2262 2760
25 1870 2260
30 1553 1866
40 1080 1277
50 771 900
60 555 639
70 408 465
80 304 342
(1)
90 230 257
100 178 196
110 136 152
120 106 119
130 84 95
140 67 76
(1) Check the resistance by measuring on connection points 1 and 2 of the sensor.
Type of pressure sensor piezoresistive Pressure sensor output signal See graph
U
(V)
5
4
3
2
1-12
1
P
1 2 34
(bar)
i400836
©
200528
TECHNICAL DATA
XF105 series
DMCI engine management system

1.8 FUEL PRESSURE AND TEMPERATURE SENSOR

A
C
B
0
21
25
29
33
37
41
45
49
53
57
60 62
1 4591317
i400726
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat = battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F Additional information available in Technical Data at "X" mark
AB C D E F
A41 Input signal fuel temperature (F713). 5 V DC Open voltage, with detached
X
connector
A42 Supply voltage fuel pressure and
temperature sensor (F713)
5 V DC Open voltage, with detached
connector
A45 Input signal fuel pressure (F713) 0.5 V DC Fuel pressure 0 bar X
4.5 V DC Fuel pressure 15 bar X
A46 Earth, fuel pressure and temperature
0V DC
sensor (F713)
©
200528 1-13
TECHNICAL DATA
DMCI engine management system XF105 series
0
Gasket Copper ring
P
2
1
U
3
T
R
4
i400791
1. Pressure sensor supply voltage
2. Pressure sensor output signal
3. Temperature sensor output signal
4. Mass
Type of temperature sensor NTC
13
42
i400792
1-14
©
200528
TECHNICAL DATA
XF105 series
Temperature sensor resistance value
Temperature (C) Resistance ()
- 30 24351 30653.2
- 20 13431 16594
- 10 7850 9095
0 4488 5372
10 2740 3236
20 1727 2010
30 1120 1291
40 746 850
50 510 574
60 355 396
70 253 279
80 185 198
DMCI engine management system
(1)
0
Minimum Maximum
90 134 145
100 100 107
110 75 81
120 57 62
130 44 48
(1) Check the resistance by measuring on connection points 3 and 4 of the sensor.
Type of pressure sensor piezo-capacitive
Voltage signal pressure sensor
U
(V)
5
4
3
2
1
5 10 15
©
200528 1-15
(bar)
P
i400835
0
TECHNICAL DATA
DMCI engine management system XF105 series

1.9 ENGINE OIL PRESSURE AND TEMPERATURE SENSOR

A
C
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat = battery voltage)
D Measuring unit
B
21
25
29
33
37
41
45
49
53
57
60 62
1 4591317
i400726
E Explanatory notes (if applicable)
F Additional information available in Technical Data at "X" mark
AB C D E F
C29 Input signal engine oil temperature
(F744)
C30 Supply voltage engine oil pressure
and temperature sensor (F744)
C33 Input signal engine oil pressure
(F744)
C34 Earth, engine oil pressure and
5 V DC Open voltage, with detached
connector
5 V DC Open voltage, with detached
connector
0.5 V DC Engine oil pressure 0 bar X
4.5 V DC Engine oil pressure 15 bar X
0V DC
X
temperature sensor (F744)
1-16
©
200528
TECHNICAL DATA
XF105 series
Gasket Copper ring
DMCI engine management system
0
13
42
i400792
2
1. Pressure sensor supply voltage
2. Pressure sensor output signal
3. Temperature sensor output signal
4. Mass
Type of temperature sensor NTC
P
U
1
3
T
R
4
i400791
©
200528 1-17
TECHNICAL DATA
DMCI engine management system XF105 series
0
Resistance in relation to measured temperature
Temperature (C) Resistance ()
Minimum Maximum
- 30 24351 30653
- 20 13431 16594
- 10 7850 9095
0 4488 5372
10 2740 3236
20 1727 2010
30 1120 1295
40 746 850
50 510 574
60 355 396
70 253 279
80 185 198
90 134 145
100 100 107
(1)
110 75 81
120 57 62
130 44 48
(1) Check the resistance by measuring on connection points 3 and 4 of the sensor.
Type of pressure sensor piezo-capacitive
U
(V)
5
4
3
2
1
5 10 15
P
(bar)
i400835
1-18
©
200528
TECHNICAL DATA
XF105 series

1.10 CRANKSHAFT SENSOR

A
C
DMCI engine management system
21
25
29
33
37
41
45
49
53
57
60 62
1 4591317
B
0
i400726
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat = battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F Additional information available in Technical Data at "X" mark
AB CDE F
A49 Input signal, crankshaft sensor (F552) - Hz /
(VAC)
Frequency depends on engine speed
X
A50 Earth, crankshaft sensor (F552) 0 V DC
A60 Shield signal crankshaft sensor (F552) 0 V DC
Type Inductive Signal version sine-wave alternating voltage Total number of pulses per crankshaft revolution 54 Number of cylinder detection pulses per crankshaft revolution 3 Effective voltage when starting approx. 1.5 V Effective voltage when idling approx. 4.0 V Effective voltage at 1200 rpm approx. 7.0 V Resistance value 860 ≥ 10% at 20C
(1)
(1)
(1)
(2)
(1) Measurements taken with multimeter in "AC voltage" position (VAC). (2) Measured on connection points 1 and 2 of the sensor.
©
200528 1-19
TECHNICAL DATA
DMCI engine management system XF105 series
0
ab
1
2
1. Flywheel a. Area with two holes missing b. Segment with 18 holes c. Area with two holes missing
2. Crankshaft sensor signal
c
I400732
1-20
©
200528
TECHNICAL DATA
XF105 series

1.11 CAMSHAFT SENSOR

A
C
DMCI engine management system
21
25
29
33
37
41
45
49
53
57
60 62
1 4591317
B
0
i400726
A Electronic unit connection point
B Description of connection point
C Reading at connection point (Ubat = battery voltage)
D Measuring unit
E Explanatory notes (if applicable)
F Additional information available in Technical Data at "X" mark
AB CDE F
A53 Input signal camshaft sensor (F558) - Hz /
(VAC)
Frequency depends on the speed
X
A54 Earth, camshaft sensor (F558) 0 V DC
A61 Shield signal camshaft sensor (F558) 0 V DC
Type Inductive Signal version sine-wave alternating voltage Total number of pulses for every two crankshaft revolutions 7 Effective voltage when starting approx. 0.5 V Effective voltage when idling approx. 2.0 V Effective voltage at 1200 rpm approx. 4.0 V Resistance value 860 ≥ 10% at 20C
(1)
(1)
(1)
(2)
(1) Measurements taken with multimeter in "AC voltage" position (VAC). (2) Measured on connection points 1 and 2 of the sensor.
©
200528 1-21
TECHNICAL DATA
DMCI engine management system XF105 series
0
624s153
a
b
0
I400762
a. Pulse wheel b. Camshaft sensor signal
1-22
©
200528
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