Daf 96xf Series Workshop Manual

Full download: http://manualplace.com/download/daf-96xf-series-workshop-manual/

5 CONTENTS
95XF series

TECHNICAL DATA
0
DIAGNOSIS
1
COMPONENTS
2
3
BATTERIES
4
MASTER SWITCHES
5
CONNECTING ACCESSORIES
6
READING DIAGRAMS
7
LOCATION OF COMPONENTS
8
LOCATION OF CONNECTORS
9
ELECTRICAL INSTALLATION
10
MODIFICATIONS TO THE ELECTRICAL INSTALLATION
11
ELECTRICAL SYSTEM: OPTIONS AND SPECIAL APPLICATIONS
12

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5 TECHNICAL DATA
95XF series Contents

CONTENTS
Page Date
0
1. COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9811
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9811

ǹ 9811 1
TECHNICAL DATA 5
Contents 95XF series

2 ǹ 9811
5 TECHNICAL DATA
95XF series Components

1. COMPONENTS
1.1 GENERAL
0
Bulbs
Headlights 75/70 W
Parking light 5W
Tail light 10 W
Rear fog light 21 W
Back--up light 21 W
Stop light 21 W
Direction indicator 21 W
Side light 3W
Instrument panel lighting 2W
Tachograph 2W
Cab lighting 21 W
Bunk reading lamp 10 W
Warning lamps on instrument panel 1.2 W
Stepwell lighting 5W
Marker light 5W

REVOLUTION SENSOR
Air gap between tooth and sensor 0.3 - 0.7 mm

Max. current and wire cross sectional area (mm2)

Wire diameter <2m 2-4m 4-8m >8m
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 95XF series

Microrelay

0 Maximum making current

between points 3 and 5: 10A +1 2
Maximum breaking current
between points 3 and 4: 5A 5
+3
4
E500146

5
2 4 1

E500147

Minirelay
Maximum making current 86 87a 87
between points 30 and 87: 20A
Maximum breaking current
between points 30 and 87a: 10A

85 30

87
87a
86 85
30
E500169

1-2 ǹ 9811
5 DIAGNOSIS
95XF series Contents

CONTENTS
Page Date
1. BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9711
1.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9711
2. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Short circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
2-2
......
......
9711
9711
1
2.2 Open circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 9711
2.3 Earthing problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 9711

ǹ 9711 1
DIAGNOSIS 5
Contents 95XF series

2 ǹ 9711
5 DIAGNOSIS
95XF series Batteries

1. BATTERIES
1.1 FAULT-FINDING TABLE

FAULT: NEW BATTERY GETS QUITE HOT DURING CHARGING

Possible cause Remedy 1
Inadequate formation because of bad Allow battery to cool down
conservation or long-term (moist) storage Charge properly
Check density

FAULT: ELECTROLYTE LEVEL TOO LOW

Possible cause Remedy
Leaking battery box Replace battery
Excessive gas production caused by Check/repair charger
overcharging

FAULT: BATTERY ACID SPILLS FROM THE PLUG HOLES

Possible cause Remedy
Battery level exceeds capacity Siphon off liquid
Overcharging Check charger and repair, if necessary

FAULT: DENSITY IS TOO LOW (<1,240)

BAD STARTING
Possible cause Remedy
Power user left on Charge battery
Insufficient charge Check/repair charger
Short circuit in the charging circuit Check charging circuit

FAULT: DENSITY IS TOO HIGH (<1,290)

Possible cause Remedy
Topped up with acid instead of distilled water Siphon off liquid and top up with distilled water
If necessary, repeat after mixing (charging)

ǹ 9711 1-1
DIAGNOSIS 5
Batteries 95XF series

FAULT: BAD STARTING

BAD STARTING TEST
POWER FAILS UNDER LOAD
Possible cause Remedy

1 -
-
Discharged battery
Worn battery (corroded plates)
Charge battery
Replace battery
- Defective battery (“dead cell”) Replace battery
- Battery too small Install battery with a larger capacity
- Sulphated battery (plates are hard) Replace battery

FAULT: BURNT-IN BATTERY TERMINALS

Possible cause Remedy
- Wire clamps not securely fitted or bad Have battery terminals repaired, securely fit wire
contact clamps, and replace clamps, if necessary

FAULT: EXCESSIVE BUBBLING IN 1 OR 2 CELLS DURING HIGH LOADS

(STARTING OR STARTING TEST)
Possible cause Remedy
- Defective cells Replace battery
- Leaking partition Replace battery

FAULT: BATTERY DISCHARGES QUICKLY (CANNOT CONTAIN ITS CHARGE)

Possible cause Remedy
- Insufficient charge Check charge, is charging time (driving time)
sufficient?
- Short circuit in the charging circuit Check charging circuit
- Major self-discharging, e.g. because of Clean battery
contamination
- Battery sulphated (on inspection, plates Replace battery
prove hard and possibly have white
appearance)

1-2 ǹ 9711
5 DIAGNOSIS
95XF series Batteries

FAULT: SHORT BATTERY LIFE

Possible cause Remedy
- Wrong type of battery (e.g. in case of Install Super Heavy Duty or semi-traction battery
tailboards)
- Too many deep discharges Intermediate additional charging with battery
charger
1
- No recharging after deep discharge (white Always recharge battery after deep discharge
deposition)

FAULT: BATTERY GETS HOT DURING OPERATION AND USES A LOT OF WATER
Possible cause Remedy
- Overcharging or charging voltage too high Check charger (voltage regulator)

FAULT: BATTERY HAS EXPLODED

Possible cause Remedy
- Fire or spark during or immediately after Ensure proper ventilation and be careful with fire
charging and sparks
- Short-circuiting tools Be careful where you put tools
- Internal fault (loose connection) Replace battery

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

POLARITY-SENSITIVE EQUIPMENT DO NOT WORK)
Possible cause Remedy
- Reversed battery polarity or incorrect Discharge battery and recharge in the proper
charging direction
Replace battery, if necessary

FAULT: BATTERY IS INACTIVE (NO VOLTAGE)

Possible cause Remedy
- Internal open circuit Replace battery
- Battery extremely deeply discharged Charge and test battery, replace if necessary

ǹ 9711 1-3
DIAGNOSIS 5
Batteries 95XF series

1-4 ǹ 9711
5 DIAGNOSIS
95XF series Troubleshooting

2. TROUBLESHOOTING
The following test equipment and tools can be
used to localise faults.
1. The best instrument for this purpose is a
digital multimeter. This instrument enables
voltages, currents and resistances to be
measured without reading errors, and it can
trace virtually all faults.
1
2. Many but not all faults can be traced in a
simple way by using warning lamps.
However, faults which are caused by a poor
earth connection can in general not be
traced via a warning lamp or a buzzer.
The most frequently occurring faults are:
a. short circuit
b. open circuit
c. earthing problems (poor earth connection
caused by corrosion).

ǹ 9711 2-1
DIAGNOSIS 5
Troubleshooting 95XF series

2.1 SHORT CIRCUITS

A short circuit is caused by a positive wire

shorting somewhere to earth. In most cases this
will cause a fuse to blow.

1
70W is then used to trace this fault. First check
the diagram to see which consumers are
protected by the fuse and then switch them all
off.
Remove the fuse and replace it with a test lamp.
Then, one by one, switch the consumers on and
off. If the test lamp starts burning very brightly
when a consumer is switched on, it is almost
certain that the fault is in the wiring of that
particular consumer. Check the diagram to see
which connector is used to connect this
consumer. Remove the first wiring connection
(looking from the fuse).
If the test lamp continues to burn brightly, the
fault is between the fuse and this wiring W 5 03 013
connection.
However, if the test lamp stops burning, the fault
is somewhere further on in the wiring.
Restore the wiring connection and disconnect
the next one. If the test lamp continues to burn
brightly, the fault is between these two wiring
connections.
However, if the lamp stops burning again, the
fault tracing procedure must be continued.
In this way the faulty section of the wiring can
be found.

2-2 ǹ 9711
5 DIAGNOSIS
95XF series Troubleshooting

2.2 OPEN CIRCUITS

Suppose a consumer is not functioning. The

fault may then be in the consumer itself, or the
wiring may be interrupted.

1
First switch on the consumer and check for W 5 03 015

voltage with the test lamp. If no voltage is

present, first check whether the fuse is still
intact.
If there is voltage at the fuse, the wiring must be
checked again from the fuse to the consumer.
Every wiring connection must be checked.
If there is no voltage at one of these wiring
connections, the interruption is between this
connection and the connection checked
second-last.
If voltage was found at the consumer, there is
still the possibility of an interruption in the wiring
from the negative terminal of the consumer to
earth. This can be checked with a test lamp.
Make sure the circuit concerned is connected
up.
Connect one end of the test lamp to earth and
the other end to the negative (-) terminal 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 not come on, the earth
connection of the component will in most cases
be in good order.
If the positive and negative connections are both
W 5 03 016
in good order, the consumer is defective and
must be replaced.

ǹ 9711 2-3
DIAGNOSIS 5
Troubleshooting 95XF series

2.3 EARTHING PROBLEMS

Problems with the earth connections are mostly

caused by corrosion on the contact surfaces of
electrical connections.

1
Earthing problems can only be traced with a
(preferably digital) multimeter. Digital, because
this kind of problem usually involves only a few
volts and the readings of an analog meter are
not precise enough for this purpose.
To establish whether a certain earthing point has
a good earth connection, measure with a
voltmeter between the battery negative pole and
the earthing point in question.
Now 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. 0,5V will
often be measured.
If the reading is higher, the earth connection
must be checked carefully.
In this way the earth connections of all the
consumers can be checked and measured.

W 5 03 014

2-4 ǹ 9711
5 COMPONENTS
95XF series Contents

CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9811
1.1 Multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 9811
1.2 Measuring signals with the multimeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . . 9811
2. DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 9811
2.1 Engine speed and vehicle speed sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 9811

2
2.2 Temperature sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 9811
2.3 Fluid-level sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 9811
2.4 Pressure sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 ...... 9811
2.5 Proximity sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 ...... 9811
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 9811
3.1 Checking electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 9811
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 9811
4.1 Removing and installing contacts from connectors . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 9811
4.2 Installing contact units on electrical wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 ...... 9811
4.3 Removal and installation of contact units of 39-pin floor connector . . . . . . . 4-5 ...... 9811
4.4 Removal and installation of contact units of connectors
with single contact lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . . 9811
4.5 Removal and installation of contact units of connectors
with additional contact lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . . 9811

ǹ 9811 1
COMPONENTS 5
Contents 95XF series

2 ǹ 9811
5 COMPONENTS
95XF series General

1. GENERAL
1.1 MULTIMETER

Multimeters are available in two different

versions:
- analog meter
- digital meter
An analog meter has an indicating needle
(pointer) which can move over a graduated
scale. 2
A digital meter indicates the measured values
by means of digits in a read-out window.
Analog meter
Disadvantages:
- Difficult to read due to the various
graduated scales.
- Not capable of giving precision readings
(depending on the scale
arrangement/measuring range).
- If the meter is connected up incorrectly,
there is a real risk of electrical defects in the
meter.
- The indicating needle (pointer) is not
resistant to powerful mechanical vibrations.
- The meter must usually be used in a certain
position.
Advantages:
- Useful, for example, when measuring a
potentiometer with a minor interruption.
Digital meter
Disadvantages:
- Meter is slow. With a fluctuating voltage all
you can see are flashing digits.
Advantages:
- It indicates the correct value without the risk
of misinterpretation.
- Gives more accurate readings.
- It is protected against faulty connection.
- It is resistant to powerful mechanical
vibrations.
- It can be used in any position.

ǹ 9811 1-1
Daf 96xf Series Workshop Manual
Full download: http://manualplace.com/download/daf-96xf-series-workshop-manual/

COMPONENTS 5
General 95XF series

Key to the symbols on analog meters.

The following symbols may occur on an analog
meter:

1 2 3 4 5 6 7 8 9 10 11 12 13 14

2 1,5 0,5
45°

2
W 5 01 007

1. Moving-coil meter with permanent magnet.

2. Moving-coil meter with rectifier cell.
3. Electromagnetic or soft-iron meter.
4. With rectifier cell.
5. Suitable for direct current.
6. Suitable for alternating current.
7. Suitable for direct current and alternating
current.
8. Meter with zero adjustment.
9. Meter may only be used in the vertical
position.
10. Meter may only be used in the horizontal
position.
11. Test voltage is 2 kilovolts (without a digit it
is 0.5 kilovolt).
12. Meter may only be used at the angle
indicated.
13. Suitable for direct current, class 1.5
(inaccuracy 1.5% of full scale).
14. Suitable for direct current and alternating
current, classes 1 and 0.5 (see item 13 for
explanation).

1-2 ǹ 9811
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