Daf Lf45 Lf55 Electrical Wiring Diagram

Full download: http://manualplace.com/download/daf-lf45-lf55-electrical-wiring-diagram/

5 STRUCTURE
LF45/55 series

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

 200440 DW23259502
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ssss
5 TECHNICAL DATA
LF45/55 series Contents

CONTENTS

1.
Page Date
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200440
0
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200440
1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . 200440

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 TECHNICAL DATA 5
Contents LF45/55 series

2  200440
5 TECHNICAL DATA
LF45/55 series Components

1. COMPONENTS
1.1 GENERAL
0
BULBS
Dipped beam light 70 W
Main beam light 70 W
Parking light 5W
Rear light 10 W
Rear fog light 21 W
Reversing light 21 W
Stop light 21 W
Direction indicator lamp 21 W
Front fog light 70 W
Front spot lights 70 W
Interior lighting 10 - 21 W
Bunk lamp 21 W
Stepwell lighting 5W
Marker light 5W

Max. current and wire diameter (mm2)

Wire diameter Up to 2 m 2-4m 4-8m From 8 m
0.5 3 1.5 0.5
1 9 5 4
1.5 22.5 13.5 7.5 6
2.0 30 17 10 8
2.5 37.5 22.5 12.5 10
3.0 47 27 16 13
4 60 36 20 16
4.5 69 43 24 19
6 90 54 30 24
7.5 114 73 40 33
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 LF45/55 series

Alternator

0 NCB1
Max. current 80 A
Rated voltage 28 V

NCB2
Max. current 100 A
Rated voltage 28 V

Battery
Voltage 12 V
Max. capacity 128 Ah

Optional:
Voltage 12 V
Max. capacity 170 Ah

Mini relay (20 A) 2 4 5

Resistance value of coil approx. 250 Ω
Measured between points 1 and 2

1 3

5
4
1 2
3
E501287

Relay (50 A) 1 4
Resistance value of coil approx. 175 Ω
Measured between points 1 and 2

2 3

2 1
3
E501288

CDS hand-held transmitters

Battery type (2x) CR1620, 3 V

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5 TECHNICAL DATA
LF45/55 series Components

1.2 TIGHTENING TORQUES

Alternator
Drive pulley 80 Nm  5 Nm
0
B+ connection 15 Nm

Earth connection
Chassis 35  10 Nm

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 TECHNICAL DATA 5
Components LF45/55 series

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5 DIAGNOSTICS
LF45/55 series Contents

CONTENTS
Page Date
1. BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200440
1.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200440

2.
1.2 Service life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . 200440
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200440
1
2.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200440
3. FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 .... 200440
3.1 Short circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 .... 200440
3.2 Open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 .... 200440
3.3 Earthing problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 .... 200440

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 DIAGNOSTICS 5
Contents LF45/55 series

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5 DIAGNOSTICS
LF45/55 series Batteries

1. BATTERIES
1.1 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 OVERFLOWS, BATTERY ACID SPILLS FROM PLUG HOLES

Possible cause Remedy
Battery overfilled Siphon off some of the fluid
Overcharging Check charging voltage
Check/repair charging circuit

SYMPTOM: ACID LEVEL TOO LOW

Possible cause Remedy
Leaking battery Replace the battery
Excessive gas development due to charging Check charging voltage
current being set too high Check/repair charging circuit

SYMPTOM: RELATIVE DENSITY TOO LOW (<1.240)

STARTING TROUBLE
Possible cause Remedy
Power consumer left on by mistake Charge the battery
Insufficient charging Check alternator drive
Check/repair charging circuit

SYMPTOM: RELATIVE DENSITY TOO HIGH (>1.290)

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

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 DIAGNOSTICS 5
Batteries LF45/55 series

SYMPTOM: STARTING TROUBLE

POOR STARTING TEST RESULT
POWER FAILS UNDER LOAD
Possible cause Remedy

1 Discharged battery
Worn battery (plates corroded and worn away)
Charge the battery
Replace the battery
Defective battery (“dead cell”) Replace the battery
Battery sulphated (plates have hardened) Replace the battery

SYMPTOM: BURNT-IN BATTERY TERMINALS

Possible cause Remedy
Cable clamps not securely fitted or poor contact Have the battery terminals repaired, fit the cable
clamps properly and replace the cable clamps if
necessary

SYMPTOM: 1 OR 2 CELLS BUBBLE EXCESSIVELY UNDER HIGH LOAD

(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
LF45/55 series Batteries

SYMPTOM: SHORT BATTERY LIFE

Possible cause Remedy
Wrong type of battery chosen (for example if the Replace with battery of a higher capacity
vehicle has a tail lift) (170 Ah)
Often too deeply discharged Intermediate charging with rectifier 1
Not recharged after deep discharge Always charge the battery after deep discharge
(white deposits)
Alternator capacity too low Use alternator with higher capacity (100 A)

SYMPTOM: THE BATTERY HEATS UP DURING USE AND CONSUMES A LOT OF FLUID
Possible cause Remedy
Overloading, or charging voltage too high Check the charging circuit (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 circuit between the battery terminals Exercise caution when storing conductive
material (for example, tools)
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
Replace the battery and/or alternator if
necessary

SYMPTOM: BATTERY HAS 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 LF45/55 series

1.2 SERVICE LIFE

The service life of a battery is significantly

shortened if it used “cyclically”.
This means that the batteries are used a lot
without their being charged.
1 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 one 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
LF45/55 series Alternator

2. ALTERNATOR
2.1 FAULT-FINDING TABLE

SYMPTOM: ALTERNATOR NOT PRODUCING POWER WHEN IDLING

Possible cause Remedy 1
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 B+
“S” connections is greater than 2.5 V (contact resistors)
Internal battery resistance too high
Voltage too low < 16 V Check alternator drive.
Check wiring on contact resistors

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 LF45/55 series

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5 DIAGNOSTICS
LF45/55 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

1
multimeter. This instrument can be used to
measure voltages, currents and resistances
without reading errors and it can be used to
trace virtually any faults.
2. The “Multimeter” function of DAVIE XD can
be used to carry out all the measurements
that can be made with an ordinary, separate
multimeter.
3. 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 LF45/55 series

3.1 SHORT CIRCUITS

A short circuit is caused by a positive wire

shorting somewhere to earth. This can generate
a very high current. 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 W 5 03 013
fuse and this wiring connection.
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
LF45/55 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
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 comes on, 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.

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Daf Lf45 Lf55 Electrical Wiring Diagram
Full download: http://manualplace.com/download/daf-lf45-lf55-electrical-wiring-diagram/

DIAGNOSTICS 5
Fault finding LF45/55 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

3-4  200440
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