Daf Xf95 Series Workshop Manual

Full download: http://manualplace.com/download/daf-xf95-series-workshop-manual/

5 CONTENTS
XF95 series ≥0E621373

TECHNICAL DATA
0
DIAGNOSTICS
1
COMPONENTS
2
WIRING REPAIR
3
BATTERIES
4
5
CONNECTION OF ACCESSORIES
6
READING DIAGRAMS
7
LOCATION OF COMPONENTS
8
LOCATION OF CONNECTORS
9
ELECTRICAL SYSTEM
10
CHANGES IN THE ELECTRICAL SYSTEM
11
ELECTRICAL SYSTEM: OPTIONS AND SPECIAL APPLICATIONS
12

 200520 DW23271604
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5 TECHNICAL DATA
XF95 series ≥0E621373 Contents

CONTENTS

1.
Page Date
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200429
0
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200429
1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . 200429

 200429 1
TECHNICAL DATA 5
Contents XF95 series ≥0E621373

2  200429
5 TECHNICAL DATA
XF95 series ≥0E621373 Components

1. COMPONENTS
1.1 GENERAL
0
Bulbs
Headlight (main beam) halogen 70 W
Headlight (dipped beam) halogen 70 W
Headlight (Xenon-dipped beam) HID-lamp 35 W D2S LL
(long life)
Parking light spherical bulb 5W
Rear light spherical bulb 2x5W
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 5W
Side marker light special type 3W
Combilamp: fog lamp halogen 70 W
spotlight halogen 70 W
Interior lighting spherical bulb 10 and 21 W
Bunk lamp spherical bulb 10 W
Stepwell lighting spherical bulb 5W
Marker light spherical bulb 5W
Work lamp: white halogen lamp 70 W
yellow spherical bulb 35 W

Max. current and wire diameter (mm2)

Wire diameter Up to 2 m 2-4m 4-8m From 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

 200429 1-1
TECHNICAL DATA 5
Components XF95 series ≥0E621373

Alternator
NCB1
0 Max. current
Rated voltage
80 A
28 V

NCB2
Max. current 100 A
Rated voltage 28 V

Micro relay
Maximum cut-in current +1 2
making connection between points
5
3 and 5: 10 A +3
Maximum cut-out current 4
breaking connection between E500146

points 3 and 4: 5A

5
2 4 1

E500147

Mini relay 86 87a 87

Maximum cut-in current
making connection between points
30 and 87: 20 A
Maximum cut-out current
breaking connection between 85 30
points 30 and 87a: 10 A

87
87a
86 85
30
E500169

Handheld transmitter CDS

Battery type (2x) CR1620, 3 V

1-2  200429
5 TECHNICAL DATA
XF95 series ≥0E621373 Components

1.2 TIGHTENING TORQUES

Tightening torques
Drive pulley 80 Nm  5 Nm
0
B+ connection 15 Nm
Chassis earth connection 65 Nm

 200429 1-3
TECHNICAL DATA 5
Components XF95 series ≥0E621373

1-4  200429
5 DIAGNOSTICS
XF95 series ≥0E621373 Contents

CONTENTS
Page Date
1. FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 .... 200520
1.1 Short circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 .... 200520
1.2 Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Earthing problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3
1-4
....
....
200520
200520 1
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 1
DIAGNOSTICS 5
Contents XF95 series ≥0E621373

2  200520
5 DIAGNOSTICS
XF95 series ≥0E621373 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
measure voltages, currents and resistances
avoiding reading errors, and it can be used
to trace virtually any faults.
1
2. Many, but not all, faults are easily traced by
means of warning lights. Failures caused by
poor earthing cannot normally be detected
by a warning light or buzzer.
The most frequently occurring faults are:
a. short circuit
b. open circuits
c. earthing problems (poor earthing due to
corrosion).

 200520 1-1
DIAGNOSTICS 5
Fault finding XF95 series ≥0E621373

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.
To remedy this failure, use a test lamp of
1 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.

1-2  200520
5 DIAGNOSTICS
XF95 series ≥0E621373 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
1
W 5 03 015
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. W 5 03 016

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.

 200520 1-3
DIAGNOSTICS 5
Fault finding XF95 series ≥0E621373

1.3 EARTHING PROBLEMS

Earthing problems are mainly caused by

corrosion between the contact surfaces of
electrical connections.
A poor earth connection of the main earth circuit
1 (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  200520
5 DIAGNOSTICS
XF95 series ≥0E621373 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.:
- dipped beam 1
-
-
heater fan in position 4
spotlights, etc. 1
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

 200520 1-5
DIAGNOSTICS 5
Fault finding XF95 series ≥0E621373

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  200520
5 DIAGNOSTICS
XF95 series ≥0E621373 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.

 200520 1-7
DIAGNOSTICS 5
Fault finding XF95 series ≥0E621373

MEASURING VOLTAGE LOSS

1
4

3
2

1
E502269

1 negative battery terminal

2 flywheel housing
3 chassis
4 bulkhead 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.

1-8  200520
5 DIAGNOSTICS
XF95 series ≥0E621373 Batteries

2. BATTERIES
2.1 FAULT-FINDING TABLE

SYMPTOM: NEW BATTERY HEATS UP CONSIDERABLY DURING FILLING

Possible cause Remedy 1
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 the fluid and fill with distilled water
If necessary, repeat this after mixing (charging)

 200520 2-1
Daf Xf95 Series Workshop Manual
Full download: http://manualplace.com/download/daf-xf95-series-workshop-manual/

DIAGNOSTICS 5
Batteries XF95 series ≥0E621373

SYMPTOM: STARTING TROUBLE

POOR STARTING TEST RESULT
POWER FAILS UNDER LOAD
Possible cause Remedy

1 -
-
Discharged battery
Worn battery (plates corroded and worn
Charge the battery
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 and 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)

2-2  200520
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