manual esquema electr. daf xf

7/21/2019 Manual Esquema Electr. Daf Xf

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XF95series

STRUCTURE

TECHNICAL DATA

DIAGNOSTICS

COMPONENTS

REPAIRING WIRING

BATTERIES

CONNECTION OF ACCESSORIES

READING OF DIAGRAMS

LOCATION OF COMPONENTS

LOCATION OF CONNECTORS

ELECTRICAL SYSTEM

CHANGES IN THE ELECTRICAL SYSTEM

ELECTRICAL SYSTEM: OPTIONS AND SPECIAL APPLICATIONS

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TECHNICAL DATA

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CONTENTS

Page Date

1. COMPONENTS 1-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 General 1-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Tightening torques 1-3 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents XF95series

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XF95series Components

TECHNICAL DATA

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1. COMPONENTS

1.1 GENERAL

Bulbs

Headlight (main beam) halogen 70 W

Headlight (dipped beam) halogen 70 W

Parking light spherical lamp 5 W

Rear light spherical lamp 2 x 5 W

Rear fog lamp spherical lamp 21 W

Reversing light spherical lamp 21 W

Stop light spherical lamp 21 W

Direction indicator lamp spherical lamp 21 W

Marker light spherical lamp 5 W

Side marker light special type 3 W

Combilamp: fog lamp halogen 70 W

spotlight halogen 70 W

Interior lighting spherical lamp 10 and 21 W

Bunk light spherical lamp 10 W

Stepwell lighting spherical lamp 5 W

Marker light spherical lamp 5 W

Work lamp: white halogen lamp 70 W

yellow spherical lamp 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 14050 750 450 250 200

70 1050 630 350 280

95 1425 855 475 380

120 1800 1080 600 480

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Components XF95series

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Alternator

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 points3 and 5: 10 A

Maximum cut-out current

breaking connection betweenpoints 3 and 4: 5 A

+1

+3

2

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E500146

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5

2 4 1

E500147

Mini relay

Maximum cut-in currentmaking connection between points30 and 87: 20 A

Maximum cut-out current

breaking connection betweenpoints 30 and 87a: 10 A

86

85

87a 87

30

8586

87

87a

30

E500169

Handheld transmitter CDS

Battery type (2x) CR1620, 3 V

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XF95series Components

TECHNICAL DATA

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1.2 TIGHTENING TORQUES

Tightening torques

Drive pulley 80 Nm 5 NmB+ connection 15 Nm

Chassis earth connection 65 Nm

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Components XF95series

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XF95series Contents

DIAGNOSTICS

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CONTENTS

Page Date

1. BATTERIES 1-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Fault-finding table 1-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Service life 1-4 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. ALTERNATOR 2-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Fault-finding table 2-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. FAULT FINDING 3-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Short circuits 3-2 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Open circuit 3-3 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 Earthing problems 3-4 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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XF95series Batteries

DIAGNOSTICS

1-1

1. BATTERIES

1.1 FAULT-FINDING TABLE

SYMPTOM: NEW BATTERY HEATS UP CONSIDERABLY DURING FILLING

Possible cause Remedy

Inadequate formation because of storage inunsuitable or damp conditions over a long period

Allow to coolCharge fullyCheck the relative density

SYMPTOM: BATTERY ACID LEAKING FROM THE PLUG HOLES


Battery overfilled Siphon off some of the fluid

Overcharging Check the charger and repair if necessary

SYMPTOM: ELECTROLYTE LEVEL TOO LOW


Leaking battery Replace the battery

Excessive gas development due to chargingcurrent being set too high

Check/repair the charger

SYMPTOM: RELATIVE DENSITY TOO LOW (1.290)


Topped up with acid instead of distilled water Siphon off some of the fluid and top up with

distilled waterIf necessary, repeat this after mixing (charging)

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Batteries XF95series

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SYMPTOM: STARTING TROUBLEPOOR STARTING TEST RESULT

POWER FAILS UNDER LOAD


- Discharged battery Charge the battery

- Worn battery (plates corroded and wornaway)

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


- Terminals not securely fitted, or poor contact Have the battery poles repaired, fit the terminalsproperly and replace the terminals if necessary

SYMPTOM: 1 OR 2 CELLS BUBBLE EXCESSIVELY UNDER HIGH LOAD(STARTING OR STARTING TEST)


- Defective cells Replace the battery

- Leaking cell partition Replace the battery

SYMPTOM: BATTERY DISCHARGES VERY FAST (DOES NOT RETAIN POWER)


- Insufficient charging Check the charging. Is the charging time (drivingtime) sufficient?

- Short circuit in charging circuit Check the charging circuit

- Major self-discharging, for example due tocontamination

Clean the battery

- Battery sulphated (on examining the plates,they are found to be hard and, in some

cases, whitened)

Replace the battery

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XF95series Batteries

DIAGNOSTICS

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SYMPTOM: SHORT BATTERY LIFE


- Wrong type of battery chosen (for example inthe case of tail lifts)

Install Super Heavy Duty or semi-traction battery

- Often too deeply discharged Intermediate charging with rectifier

- No recharging after deep discharge (whitedeposits)

Always charge the battery after deep discharge

SYMPTOM: BATTERY HOT DURING OPERATION WITH EXCESSIVE WATER CONSUMPTION


- Overcharging or charging voltage too high Check the charger (voltage regulator)

SYMPTOM: BATTERY HAS EXPLODED


- Fire or sparks during or just after charging Ensure good ventilation and exercise duecaution 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 OTHERPOLARITY-SENSITIVE EQUIPMENT NOT WORKING)


- Reversed battery polarity or incorrectcharging

Discharge the battery, and charge in the correctdirectionIf necessary, replace the battery

SYMPTOM: BATTERY IS INACTIVE (NO VOLTAGE)


- Internal open circuit Replace the battery

- Battery very deeply discharged Charge the battery and test it; replace ifnecessary

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Fault finding XF95series

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3.1 SHORT CIRCUITS

A short circuit is caused by a positive wire

shorting to earth somewhere. In most cases thiswill cause a fuse to blow.To remedy this failure, use a test lamp ofapproximately 70 W. First check the diagram tosee which consumers are connected to the fusein question, and then switch them all off.Remove the fuse and connect the test lamp inits place. Now switch each of the consumers onand off one by one. If the lamp comes on verybrightly when a consumer is switched on, thefault is almost certainly in the wiring of thatconsumer. Now check the diagram to see viawhich 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 thefuse and this wiring connection.

If, however, the lamp goes out, the fault issomewhere further on in the wiring.Now reconnect the connectors and disconnectthe next wiring connection. If the lamp is stillbright, the failure is between these two wiringconnections.However, if the lamp goes out again, thefault-finding procedure must be continued.The faulty wiring section can be found in thisway.

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Fault finding XF95series

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3.3 EARTHING PROBLEMS

Earthing problems are mainly caused by

corrosion between the contact surfaces ofelectrical connections.Earthing problems can only be detected using amultimeter (preferably digital). A digital tester ispreferable because usually only a few volts willbe measured and an analogue meter isgenerally not precise enough for this purpose.To find out whether a specific earthing point hasa good earth connection, use a voltmeter tomeasure the voltage between the negativebattery pole and this earthing point.Switch on as many consumers as possible.If there is a correct earth connection, no voltageshould be found.

In practice, however, a loss of approx. 0.5 voltswill often be measured.If the reading is higher, the earth connectionmust be checked carefully.In this way, the earth connections of allconsumers can be checked and measured.

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XF95series Contents

COMPONENTS

1

CONTENTS

Page Date

1. GENERAL 1-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Multimeter 1-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Scopemeter 1-2 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 Signal measurements 1-3 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. DESCRIPTION OF COMPONENTS 2-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Inductive sensor 2-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Vehicle speed sensor 2-2 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 Temperature sensors 2-4 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 Fluid level sensors 2-6 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5 Pressure sensors 2-7 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6 Alternator 2-8 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7 Proximity sensors 2-10 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.8 Stalk switch 2-10 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. DIAGNOSTICS 3-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Diagnostics in electrical systems 3-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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XF95series General

COMPONENTS

1-3

1.3 SIGNAL MEASUREMENTS

Sine-wave signal (AC voltage)

The signal regularly changes polarity withrespect to the0line

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

+

-

0

VoltageIf the number of sines per second increases, not

just the frequency increases but also thevoltage.

+

-

t

1 2 3

0

Measuring a sine wave signalThe sine wave signal can be measured in thefollowing ways using a multimeter:- With the multimeter in the frequency (Hz)

position.In this way, the number of complete sinesper second is measured.

- Multimeter in the AC voltage position.In this way, the average value of thesupplied voltage is measured.

Sine wave signals in the vehicle- Wheel speed sensor output signal.- Engine speed sensor output signal.

+

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General XF95series

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XF95series Description of components

COMPONENTS

2-1

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 speedThe engine speed is recorded via the crankshaftposition sensor. The crankshaft position sensoroutput signal is a sine wave signal with afrequency corresponding to the number of holesin the pulse disc and the crankshaft rotationfrequency.

In the electronic unit, the signal is converted intoa message, which is sent via the CAN network.The DIP reads this message from the CANnetwork and activates the rev counter.

i400442

1

2

3

Engine speed sensor operating principleThe inductive sensor consists of a permanentmagnet (1), a core (2) and a coil (3).When the inductive sensor is situated betweentwo teeth, the lines of force of the magnetic fieldwill run directly from the north pole to the southpole via the housing.

The moment a tooth approaches the inductive

sensor, the lines of force of the magnetic fieldwill run from the north pole to the south pole viathe housing, the teeth of the toothed wheel andthe core.As more lines of force are now running throughthe core, a more powerful magnetic field isobtained.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 dependson the speed of rotation of the toothed wheeland the air gap between sensor (core) andtooth.

N

S

1

2

3

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Description of components XF95series

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2.2 VEHICLE SPEED SENSOR

The vehicle speed sensor has two connections

for output signals. The real-time speed signal,triggered by a Hall IC, is sent via the firstconnection,Via the other connection, a data signal(bi-directional signal) is sent, which involves anexchange of data between the MTCO and thespeed sensor. The MTCO requests data fromthe sensor.The sensor sends the coded data to the MTCOin sequence, and the MTCO checks theaccuracy 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

In the MTCO, the coded speed signal iscompared with the real-time speed signal.

The MTCO sends commands and data to thesensor at 10-second intervals.

Speed data for the CAN system is sent viaMTCO outputs A4 and A8.

Speed data for the UPEC system and ECASsystem are sent for UPEC via output B7 and for

ECAS and EMAS via output B6; these are dutycycle signals.

1 2 M

- +

4.

3.

2.

1.

-

+

E501055

Duty cycle speed signalThe speed signal sent via the vehicle speedsensor to the MTCO is processed by the MTCOand sent as a message via the CAN network.The speed signal is also converted into a dutycycle signal. This signal is used by electronicunits that do not receive/read the vehicle speedsignal message via the CAN network.The diagram alongside shows the linearcharacteristic of the duty cycle (%) in relation tothe vehicle speed (V).

This graph applies to all vehicle models.

44

22

50 100

V(km/h)

%

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COMPONENTS

2-3

InspectionThe duty cycle signal (square wave voltage) canbe checked with a multimeter that is set to theDC voltage or duty cycle range or with a

scopemeter.

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COMPONENTS

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InspectionThe temperature sensors can be checked usinga multimeter that is set to the resistance range.

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2.4 FLUID LEVEL SENSORS

The vehicle has a number of fluid level sensors,

such as:- fluid level sensor for the cooling system- engine oil level sensor

Coolant level sensorThe coolant level sensor consists of twomicroswitches (reed switches), connected inparallel with two resistors.These microswitches are influenced by amagnetic field positioned outside the sensor.If the coolant level drops, the microswitches willbe closed by a float fitted with a fixed magnet.The alarm switch detects that the coolant level istoo low and short-circuits the resistor connected

in parallel.The daily inspection switch detects that thecoolant needs to be topped up and short-circuitsthe resistor connected in parallel.The VIC uses the resistance value to detect thestatus of the microswitches.As a result the instrument display is activated bythe VIC.

Note:The VIC will only send a message to theinstrument display during the startup phase ifthe daily inspection switch is closed during thestartup phase.

E501602

1

2

E501434

Engine oil level sensorThe operation of the engine oil level sensor isbased on a resistance measurement.When the contact is activated, a current is sentthrough the sensor from the VIC control unit fora specific period of time.Applying this current briefly in this way ensuresthat the sensor is properly warmed up.When the level is being measured theresistance value is influenced by the quantity ofoil in the sump.

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COMPONENTS

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Connection 15When the contact has been turned on, power issupplied to the alternator via connection 15(1010). The controller uses this power to

activate pre-excitation (self-energising). If thereis an open circuit in this connection, thealternator will not produce any power until itreaches a speed of about 5000 rpm. Thiscorresponds to an engine speed of approx.1500 rpm. The alternator will energise itselfwhen it reaches this speed.

Sens connectionThe sens connection can be used tocompensate for voltage losses in B+. There arevoltage differences between the alternator andthe battery. Voltage regulation can be improvedif these voltage variations can be controlled. Thesens connection is connected to terminal 30 onthe starter motor.

L connectionThe L connection is connected to the VICelectronic unit.This connection is used to activate a faultmessage in the master display via the VIC, ifnecessary.

L voltage high: no faultL voltage low: fault

The following faults can be detected via the Lconnection:- Voltage too low (< 16 V)- Open circuit in connection 15 (1010)- Open circuit inSconnection- Open circuit inLconnection

These faults are indicated by the yellowAlternator faultwarning.

Too high a voltage (red warning) can berecognised by too high a voltage (>31 V) on theVIC electronic unit.

E501129

L 15 S

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2-10

2.7 PROXIMITY SENSORS

The vehicle has a number of proximity sensors,

such as:- sensor under the clutch pedal for engine

management- cab lock sensor- mechanical rear axle lifting gear

Inductive proximity sensorsAn alternating electromagnetic field is generatedby a pulsating current in a coil (oscillation).If a metal object is introduced into theelectromagnetic field, eddy currents will occur inthat metal object.These eddy currents willdampthe magnetic

field in the coil, so that the current taken up inthe coil will change.This change results in an output voltage.

InspectionPlacing a metal object in front of the sensor(inductive sensor) makes it possible to check theoutput voltage using a multimeter set to thedirect voltage range.

W 5 01 014

E500551

2.8 STALK SWITCH

The stalk switches in the XF vehicle series havebeen re-designed.Both the design and the functionality havechanged.The advantages of the new switches are:

- Switches are short-circuit proof- Longer service life thanks to use of reed

switches

- The intarder function has been integratedinto the right-hand switch, so there are nowtwo switches on the steering column

- All cruise-control and speed-controlfunctions have been integrated into theright-hand stalk switch

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Diagnostics XF95series

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XF95series General

REPAIRING WIRING

1-1

1. GENERAL

The increasing application of electronics invehicles means a much broader range of

connectors, contacts and wiring is being used.Be sure to pay special attention to this duringrepairs, so as to avoid unnecessary faults.

1.1 CONNECTOR

A connector is a removable connection betweentwo or more electrical wires or components. Thefemale contacts are on one side and the malecontacts on the other side. This way they can beconnected and disconnected.The connector should protect the contacts

against unwanted electrical connections andexternal influences. It also ensures the properconnection of the applicable contacts.

1.2 CONTACT

A connector has one or more contacts. Thesecontacts are available in various sizes andmodels.However, they all have the same design:

The mating part (1) enables the electricalconnection between the contacts.The contact press part (2) is the electricalconnection between the stripped part of the wireand the contact.The relief part (or pull relief) (3) relieves thecontact press part from mechanical wear. Theinsulation relief is placed over the insulatingsheath and/or the SCAT.

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General XF95series

1-2

With contacts, three dimensions are important:the diameter (1) of the wire to be connected, thesize of the contact press part (2), which is linkedto the wire diameter, and the size of the mating

part (3).

E501504

2

1

1.3 CONTACT KITS

Contact kit AContact kit A (DAF no. 0694960) is available forthe contacts, except SCAT contacts andmicro-timer contacts.

There is a sticker on the inside of the kit tofacilitate selection of the contact, contactcrimping tool and ejector tool.

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XF95series General

REPAIRING WIRING

1-3

At the top is the DAF no. of the contact shown.Roman numerals I and II, shown below theillustrations, refer to the contact crimping tool tobe used.

The numeral or letter added to Roman numeral Ior II indicates the hole in the contact crimpingtool in which the contact is to be placed.Roman numerals III to VII refer to the type ofejector tool to be used for removing the contactfrom the connector.The information at the bottom refers to the coresection suitable for the contact.

W 5 03 018

Contact kit B

Additional contact crimping and ejector tools arerequired for SCAT contacts and for micro-timercontacts. Contact kit B (DAF no. 1240065) isavailable for this purpose.There is a sticker on the inside of the kit tofacilitate selection of the contact, contactcrimping tool and ejector tool (to be used in thesame way as for contact kit A).

Note:The proper ejector and the proper contactcrimping tool for each contact can also be foundthroughParts Rapido.

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General XF95series

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XF95series Removal and installation

REPAIRING WIRING

2-1

2. REMOVAL AND INSTALLATION

2.1 REMOVAL AND INSTALLATION, CONNECTORS

Unlocking the connector connectionsThe connectors can often be locked with oneanother or with a component. They can bedivided into:

A. Active locking.This means that the lock must be activated.Often a lock must be pressed with this type.

B. Passive locking.Opens when the parts are pulled apart witha certain force.

E501480

A

B

Two connectors in one housingThese connectors consist of two separateconnectors. To remove the contacts first removethe connectors from the connector housing.Push the locking lip aside before removal.

The connector can then be slid out of theconnector housing.

Examples:- Connector for VIC electronic unit

E501484

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Removal and installation XF95series

2-2

2.2 REMOVAL AND INSTALLATION, CONTACTS

Contact lock

There are various types of contact locks. A fewexamples are given below. When a lock isapplied, individually for each contact, this iscalled a primary lock. An extra general lock forseveral contacts in a connector is a secondarylock.

Primary contact lockTo keep an individual contact in the connector inplace, a contact is often furnished with one ormore locking bolts. This is a primary lock. Theselocking bolts should never be damaged, with aview to pressing and ejecting the contacts.

E501481

Secondary contact lockThis type of lock is normally used on 2 and3-row connectors.For connectors (1) with a locking lip (2) first

remove the lip before removing the contacts.This is a secondary lock. The locking lip is onthe side of the connector and can usually berecognised from a colour that is different fromthe colour of the connector.The lip is removed entirely. Now the contactscan be removed using the proper ejector tool byunlocking the primary lock.

Examples:- Cab connectors- Electronic unit connectors

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REPAIRING WIRING

2-3

The contacts may also be locked secondarily bythe lower part of the connector. After tilting thislower part, the contacts can be removed byunlocking the primary lock using the proper

ejector tool.This type of lock is used only on 2-rowconnectors.

Examples:- MTCO connector

E501497

A different type of secondary lock is formed by

two sliding parts of the connector.The upper half (on the wire insert side) and thelower half form the extra contact lock.

To unlock this secondary contact lock the upperhalf of the connector must be pushed awayslightly in the direction of the arrows on theconnector housing.The contacts can then be removed from theconnector using the proper ejector tool.

After any installation of wires with contacts, theconnector must be pressed into the lock again. Ifthis is not done it will not fit into the counterpart.

Application examples:- Connector, CDS electronic unit- Connector, ECAS-2/3 electronic unit- Connector for UPEC electronic unit

Ejecting contactsFor repair or extension of the wiring a contactmay have to be replaced or added. Usingspecial ejector tools a contact can be removedfrom the connector without being damaged.For the proper ejector tools, seeParts Rapido.

E500475

15

8

14

7

13

6

12

5

11

4

10

3

9

2 115

8

14

7

13

6

12

5

11

4

10

3

9

2 1

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2-6

Note:The larger contacts are locked with four lockingbolts. The smaller contacts are locked with twolocking bolts.

Always unlock the locks when adding contacts!

Fitting the Bosch 89-pin connectorWhen refitting the protective cover, ensure thatthe siphon and slide are both in the unlockedposition.If they are not, the connector, when fitted, willnot be locked correctly on the electronic unit. Asa result, the contact between the connector andthe electronic unit may be bad.

Application examples:- Connector, ECS-DC3 electronic unit

E501498

3

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REPAIRING WIRING

2-7

Removing 39-pin connector contacts1. Loosen union G.

2. Push pressure ring H and seal K back

slightly over the wiring.

3. Then eject the contacts from connectorhousing F using a special ejector tool fromcontact kit A or B.

Fitting 39-pin connector contacts1. Fit union G, pressure ring H over the wiring.

2. Fit the new contacts to the wires using thecorrect tool.

3. Insert the wires and contacts throughseal K.

4. Press the contacts to their definitivepositions in connector housing F.

5. Press seal K against connector housing F.

6. Position pressure ring H so that the tworidges on the side of connector housing Ffall into the pressure ring recesses.

7. Tighten union G by hand.

Note:- Pressure ring H has contact numbers (their

purpose is to enable the contacts to be

positioned correctly). These contactnumbers must be in the same position asthe contact numbers on the connectorhousing.

- When an incorrectly positioned wire isremoved the seal will leak. If a new wire isnot inserted a sealing plug should be fitted.

E500477

G

H

K

F

3

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2-8

Removing contacts from 39-pin connectorcounterpart1. Loosen end union nut A and tapered

coupling nut B and push these as far as

possible back over the insulation pipe.

2. Push pressure ring H and seal K as far aspossible back over the wiring harness.

3. Push union E back over the wiring harness.

4. Carefully remove the sealing ring (2).

5. Carefully loosen the locking lugs (3) inconnector housing F.

6. Remove centring sleeve D from connectorhousing C.

7. Then eject the contacts from connectorhousing C using a special ejector tool fromcontact kit A or B.

Fitting contacts in 39-pin connectorcounterpart1. Push end union nut A and tapered coupling

nut B and as far as possible back over theinsulation pipe.

2. Fit the centring sleeve D in connectorhousing C so that all openings arepositioned opposite each another.

3. Check that all locking lugs (3) arepositioned in the lock openings (1).

4. Insert the wires without contacts throughpressure ring H and seal K.

5. Fit new contacts to the wires using thecorrect tool.

6. Feed the cable harness through taperedcoupling nut B.

7. Press seal K against connector housing C.

8. Position pressure ring H so that the tworidges on the side of connector housing Cfall into the pressure ring recesses.

9. Press the connector pins into their correctpositions in connector housing C.

10. Fit sealing ring (2) around centring sleeve Dand press it until the stop of connectorhousing C.

2

D

C

E

K

H

B

A

3

1

E500478

3

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2-10

2.3 FITTING CONTACTS TO ELECTRICAL WIRES

The increasing application of electronics in

vehicles means a much broader range ofconnectors, contacts and wiring is being used.The result of this is that more attention has to bepaid to making and repairing connections.The following criteria should be taken intoaccount:1. Wires with a reduced insulation thickness,

with retention of the mechanical properties,for use with core sections from 0.5 to2.5 mm2.

2. Wires with a normal insulation thickness, foruse with core sections from 4 to 120 mm2.

3. Wires for various temperature ranges:T1: from --40C to +70C(in cab and chassis) andT2: from --40C to +100C(in engine compartment and gearbox)

Note:In view of the mechanical strength required, theminimum permissible core section is 1 mm2,with the exception of cab wiring. At certainpoints this may be 0.5 mm2.

To ensure the reliability of systems andconnections, the following points should be

observed when repairs or extensions are madeto the wiring:

A. Always choose the following:- the correct type of contact- the correct wire diameter for the

contact used- the correct type of contact material

(tin-plated, silver-plated or gold-plated)

B. Use the right tool for the job. Wire ends arealways clamped to a contact. Specialcrimping tools have been developed for thispurpose.

Note:Connections will only be reliable if thesecrimping tools are used and the contact isfitted in the correct hole.

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REPAIRING WIRING

2-11

C. Strip the correct length of wire. Always usestripping pliers.The rule of thumb is:strip length = crimp-sleeve length + 1 mm.

Make sure that the core is not damagedduring stripping or problems may occur aftersome time.

Note:A good connection will only be obtained if pointsA, B and C are complied with. This implies thatboth the copper core and the insulation arefirmly clamped in place.

Crimping wire to a contactChoose the right crimping tool and place thecontact in the correct hole.

Note:The proper crimping tool for each contact can befound throughParts Rapido.

The contact may never be in a twisted, slantingor slid position (X) in the press clamp opening.

E501500

1. Place the wire in the contact.

2. The stripped wire part, the copperconductor must be in the contact presspart (1).The wire insulation must be in the reliefpart (2).

3. Check again whether the wire is in thecorrect position in the contact (1 and 2) andpress the contact press part (3 and 4)together.

4. Do not interrupt the contact pressing beforethe tool is completely compressed in theend position. Only then is full contactpressure reached and the tool may beopened.

E501502

3 4

1 2

3

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REPAIRING WIRING

2-13

Insulation connectionDifferent types of crimping are allowed:1. Normal crimping; the two sides of the relief

part fully engage the insulation.

2. Double crimping; two wires are clamped inone contact.

3. Overlap crimping; the two sides of the reliefpart engage one another slightly.

4. Double overlap crimping; two wires areclamped in one contact, the two sides of therelief part engaging one another slightly.

A. If the insulation connection is correct, thewire is clamped in the relief part with thecorrect pressure and the insulation is notbroken.

B. If the contact pressure is too high the

insulation could break, possibly causing ashort circuit.This may for instance be caused by:- using the wrong crimping tool- using an improper hole in the crimping

tool (too small)- a defect in the crimping tool delaying

the interruption of the contact pressing.

C. If the contact pressure is not sufficient theinsulation may not be clamped and the wiremay come loose. This will interrupt theelectrical connection but may also result ina short circuit.This may for instance be caused by:- using the wrong crimping tool- using an improper hole in the crimping

tool (too big)- interrupting the contact pressing

prematurely.

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2-16

2.4 FITTING A SCAT SEAL

SCATS are used in places where wires are

exposed to heavy conditions (environment orapplication of the vehicle), with the risk of waterentering the connector.

The SCAT seal, which is made of silicone,prevents corrosion inside the connector andkeeps the seal properties intact in the event oftemperature changes.

The SCAT seal is pressed around the wire withthe relief part of the contact.

The SCATS are available in various colours andsizes.

1. Select the right SCAT for the wire, contactand connector.

2. Slide the SCAT onto an unstripped wire (A).

3. Slide the SCAT far enough onto the wireand strip the wire to the proper length (B).

4. Slide the SCAT back to the tip of thestripped wire so that the copper just sticksout of the SCAT (C).

5. Place the contact in the proper manner (D)around the SCAT (2) and the stripped

wire (1).

6. Now crimp the contact around the SCATand the wire using the proper crimping tool.

E501503

2

1

A

B

C

D

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2-20

2.6 REMOVAL AND INSTALLATION, EARTH WIRE

When a failure occurs in an electrical system,

one of the first things to be checked is the earthconnection, with particular attention being paidto earth connections on the chassis.

Points for special attention when checkingearth connection on chassisIf an earth connection has been removed and isbeing re-installed, pay attention to the following:

- The bolt, nut, earth strip and washers mustbe cleaned (e.g. using a steel brush or sandpaper). If a component is corroded, it mustbe replaced by a new one.

- Clean all dirt and paint from the area around

the engine/chassis earth connection on bothsides of the chassis member so that thebare metal is visible.

- Clean all dirt and paint from the area aroundthe battery/chassis earth connection on theinside of the chassis member so that thebare metal is visible.

- On the earth strip side, the cleaned areamust be larger than the contact area of theearth strip.

- On the nut side, the cleaned area must belarger than the contact surface of the nut.

- After fitting the earth connection, aprotective zinc primer should be applied to

both sides of it and it should be painted.

E501495

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XF95series Contents

BATTERIES

1

CONTENTS

Page Date

1. SAFETY INSTRUCTIONS 1-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Batteries 1-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Battery charging 1-2 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. CHARGING BATTERIES 2-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 General 2-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Methods of charging 2-3 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. STORAGE OF BATTERIES 3-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 General 3-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Storage up to four weeks 3-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 Storage for more than four weeks 3-2 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. INSPECTION OF BATTERIES 4-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Visual inspection 4-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Inspection of the charging condition 4-1 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Inspection using a battery tester 4-3 200303. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

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XF95series Safety instructions

BATTERIES

1-1

1. SAFETY INSTRUCTIONS

1.1 BATTERIES

- The sulphuric acid in the batteries is anaggressive and poisonous liquid. Whileworking on batteries, wear protectiveclothing, gloves and safety goggles.In case of contact with clothes, skin or eyes,rinse immediately with plenty of water.Consult a doctor in case of contact witheyes or skin.

- Always remove the earth lead beforeworking on batteries.When connecting battery leads, alwaysconnect the earth lead last.

- Always handle batteries carefully and holdthem upright.

- When topping up batteries, never allow theelectrolyte level to rise more than 10 mmabove the plates or to go higher than thelevel indicator.

- Never put down tools or other materials thatcould accidentally short circuit the batterypoles on the batteries or in the vicinity ofbatteries. Short-circuited battery poles maycause the battery to explode.

- Secure the batteries well after completingthe work, but not too tightly.

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XF95series Charging batteries

BATTERIES

2-1

2. CHARGING BATTERIES

2.1 GENERAL

- A battery may only be charged using DCcurrent. Connect the positive pole of thebattery to the positive terminal (+) of thecharger and the negative pole of the batteryto the negative terminal (--) of the charger.The cell sealing plugs may remain on thebattery during charging (except during fastcharging).During charging, the cell voltage will rise.This increase in voltage depends on thecharging current applied and thetemperature. During normal charging, thecell voltage will rise from about 2 volts/cell

to about 2.65 volts/cell. If a charging voltageof about 2.35 to 2.4 volts/cell (about14.2 volts in a 12V battery) is exceeded,this will start off active gas development.As a consequence of the rise in voltageduring charging, the charging current will,as a rule, fall gradually.Overcharging will reduce the service life ofa battery.

- If the charging of the battery is continuedafter it has been fully charged (even with alow current), this will lead to corrosion(corrosive attack) of the grids of the positive

battery plates. This type of wear leads topremature redundancy of the battery.Depending on the capacity of the charger,the normal charging time is between 8 and15 hours.If during charging the temperature of thebattery acid rises to more than 55C, thecharging should be stopped. Hightemperatures reduce the service life of thebattery.

4

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Charging batteries XF95series

2-4

Buffer charging- With this method, the consumer and the

charger are both connected to the battery.The charger delivers sufficient current to

ensure that the battery remains virtually fullycharged. The battery will deliver peakcurrents to the consumer.

- Buffer charging is best done at a constant(stabilised) voltage.

Trickle charging- A fully charged battery that is not used for

some time will start to discharge of its ownaccord. It may discharge at a rate of 0.1%to 1% per day. Trickle chargingcompensates for such discharges.

- The charging current for trickle chargingshould be around 0.1 A per 100 Ah.4

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XF95series Inspection of batteries

BATTERIES

4-3

4.3 INSPECTION USING A BATTERY TESTER

- The general condition of the battery can be

checked quickly using a battery tester. Forthis check, a load is applied to the batteryand then the discharge voltage at thebattery poles is measured. The load appliedto the battery must be at least 3 times thecapacity of the battery.

- The rule of thumb is that the test can becarried out when the battery is sufficientlycharged (relative density 1.25 -1.28 kg/dm).At normal temperatures (10-20C), thecharging voltage for a properly chargedbattery must be 10 volts after 10 seconds.

In the case of a partially discharged battery(relative density 1.25 kg/dm3), the readingshould be at least 9 volts.It is important that the voltage be measureddirectly at the battery poles.

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Inspection of batteries XF95series

4-4

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5CONNECTION OF ACCESSORIES

Contents XF95series

2 200323

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Connection of accessories XF95series

1-2

In the roof console on the drivers side of theXC cab there is a black 12-pin connector(connector no. 597) with two spare wires (spare12 and spare 2) that are connected to

connector 694.

E501558

597

The following signals are available there:

Pin pattern for wiring harness connectorno. 597:

Pin no. Wire no. Description

2 1154 Power supply before contact

4 2102 Left rear light signal

5 2103 Right rear light signal

6 2122 Main beam signal

7 2630 Instrument lighting

10 spare 1 Spare 111 spare 2 Spare 2

12 M Earth

NOTE: The power supplybeforecontact isfuse-protected via fuse E142.Fuse 25 A. The power supply to thecooler and connector 656 (if present)is also via fuse E142.

6

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XF95series Connection of accessories


1-3

A yellow 9-pin connector (connector 694) that isconnected to the two 1-pin connectors(XL/XH cab) or to connector no. 597 (XC cab) isfitted at the height of the top connector

attachment partition on the drivers side.

Pin pattern for wiring harness connectorno. 581:


1 spare 1 Spare 1

2 spare 2 Spare 2

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1-7

Pattern for dashboard lead-throughconnectors 0E608863:

Column A: Colour: Yellow

Rownumber

Function Numberof pins

1 - 2 EMAS 21

3 Not in use 6

4 Application connector,engine speed control

12

5 Fuel filter 6

6 Cab heater 12

7 Chassis wiring 6

8 Not in use 12

9 Not in use 2

10 Power supply beforecontact (1000)

1

E501435

1

A B C D

2

3

4

5

6

7

8

9

2

3

4

5

7

8

9

10

Column B: Colour: Grey

Rownumber

Function Numberof pins

1 - 2 AS Tronic gearbox 18

3 - 4 Engine wiring 21

5 - 6 ABS or EBS, rear axle 21

7 ECAS, front axleFAS/FAG/FTM/FAKECAS

6

8 ECAS, rear axle 12

9 ABS, drawn vehicle 2

10 Earth 1

E501436

1

A B C D

2

3

4

56

7

8

9

2

3

4

5

7

8

9

10

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1-9

1.4 CONNECTION OF ACCESSORIES VIA THE ACCESSORIES CONNECTOR

Fitted under the central PCB is a green 6-pin

accessories connector (connector no. 580),which is connected to the dashboard wiringharness.

E501552

580

The following signals are available there:

Pin pattern for wiring harness connector 580:


1 1154 Power supply before contact

2 1258 Power supply after contact

3 3412 Cab locking signal

4 3157 Engine running signal

5 M Earth

6 M Earth

NOTE: The power supplybeforecontact isfuse-protected via fuse E142. Thepower supplyaftercontact isfuse-protected via fuse E163. Both25 A. The power supply to thespotlights, rotating beam and cooler(among others) is also via fuse E142.

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1-10

Application connector 656 for superstructurefunctions (with 12 spare wires) is optional.A wiring harness is fitted from the connectorunder the PCB (connector no. 580) to the

connector lead-through (connector no. 656) andto the connector behind the cover of the radiopanel (connector no. 698) only if this option hasbeen selected.

E501552

580

E501583

698

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1-16

1.6 DASHBOARD LEAD-THROUGH CONNECTOR FOR ENGINE SPEEDCONTROL APPLICATION CONNECTOR

Application connectors for engine speed controlare optional. (connector A068)

Dashboard lead-through connector 588 isconnected to a wiring harness outside the cabfor application connector A068.

E501032

588

1

A B C D

2

3

4

5

6

7

8

9

2

3

4

5

7

8

9

10

588

A068

E501031

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1-18

1.7 DASHBOARD LEAD-THROUGH CONNECTOR FOR CHASSIS WIRINGAPPLICATION CONNECTOR

Application connector: A070 This is only fitted onFA vehicles.

Dashboard lead-through connector 576 isconnected to a wiring harness outside the cabfor chassis wiring application connector A070.

E501034

576

1

A B C D

2

3

4

5

6

7

8

9

2

3

4

5

7

8

9

10

576

A070

E501033

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1-23

1.9 40 A CONNECTOR

This connector (A) is a 2-pin connector. The

supply voltage for this connector is branchedfrom the power supply before contact via fuseE168. This fuse is fitted as standard in a fuseholder on the edge of the central PCB.

A contact block can be connected to thisconnector, resulting in a central connection pointfor power supply and earth.

E500329

A

E500566

1334294

1.10 CONNECTOR FOR 12V CONNECTION IN ROOF CONSOLE

In the roof console is a white 2-pin connector(B026). This is intended for connecting a CB set.This connector has the following wires: 1108 andearth.

E501553

B026

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1-24

1.11 CONNECTOR FOR ALARM/IMMOBILISER LED IN ROOF CONSOLE

In the roof console is a white 2-pin connector

(A). This is for connecting an LED alarm.This LED alarm is fitted as standard if thevehicle doesnot have an alarm system. Thisconnector has the following wires: 1264 and3482.

E501556

A

1.12 CONNECTOR FOR COOLER

As standard, the wiring for the cooler has beenfitted in the bunk compartment ready for use.This connector consists of the following wires:1154 and M.

NOTE: The power supply before contact isfuse-protected via fuse E142 (25 A).The power supply for thesuperstructure functions dashboardlead-through connector (if present) is

also via these fuses.

E501557

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1-27

1.14 CONNECTORS FOR CONNECTING THE TELEPHONE

Telephone connection

There is space for a telephone connection onthe right side of the radio panel.A white 3-pin connector (A076) is fitted behindthe radio panel as standard.

E501555

A076


1 1108 Power supply before contact (12 V)

2 1353 Power supply before contact (12 V/25 mA)

3 M Earth

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XF95series General

READING OF DIAGRAMS

1-1

1. GENERAL

1.1 LIST OF ABBREVIATIONS

Abbreviation Explanation Translation/description

ABS/ASC-D Antilock Braking System/Anti-SlipControl - version D

Antilock Braking System/Anti-SlipControl, version D

ACH-E Additional Cab Heater -Eberspcher

Cab heater - Eberspcher

ACH-W Additional Cab Heater - Webasto Cab heater - Webasto

AGS Automatic Greasing System Automatic lubrication system

AIRCO Air conditioning Air conditioning

ALS-S Alarm system - Scorpion Alarm system - Scorpion

ASC Anti Slip Control Anti-slip control

CAN Controller Area Network Controller Area Network

CDB Central Distribution Board CF series central box

CDS Central door locking Central door locking

DAVIE XD DAF Vehicle InvestigationEquipment - version XD

DAF vehicle diagnosis tool - version XD

DEB DAF Engine Brake DAF engine brake

DIP-4 DAF Instrument Pack DAF instrument panel

DVB DoorVerBinding Through-connection

EBS Electronic Brake System Electronic brake system

ECAS-2 Electronically Controlled AirSuspension - version 2

Electronically Controlled Air Suspensionsystem - version 2

ECAS-3 Electronically Controlled AirSuspension system - version 3

Electronically Controlled Air Suspensionsystem - version 3

EMAS Electronically controlled multi-axlesteering

Electronically controlled trailing axlesteering

NMV Engine-dependent PTO Engine PTO

PTO Power Take Off Power take-off

MTCO Modular Tachograph Modular tachograph

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XF95series Marking of wiring

READING OF DIAGRAMS

2-1

2. MARKING OF WIRING

INTRODUCTIONThis standard sets out specifications for the

uniform use of markings on electrical wiring.

The marking system consists of a numericalsystem and a colour coding system, thusensuring a clear wiring layout and precludingfaulty connections and manufacturing errors.

The marking system does not apply to vehiclessubject to special conditions, such as militaryvehicles.

Numerical and colour codingEach numerical code consists of four digits, thefirst of which refers to the main group and to the

colour.Main groups

Power supplies (red)

1000 to 1099 Voltage generation

1100 to 1199 Power supplies beforecontact

1200 to 1499 Power supplies aftercontact

Lighting (yellow)

2000 to 2099 Indicator and alarm lighting

2100 to 2599 External vehicle lighting

2600 to 2999 Interior vehicle lighting

Warning and control functions (blue)

3000 to 3399 Engine functions

3400 to 3999 Vehicle functions

Consumers (black)

4000 to 4499 Start, stop, engine, glowingfunctions

4500 to 5499 Vehicle functions

5500 to 5999 Automatic gearboxes

Special applications (colour as desired)6000 to 6999

Earth connections (white)

Not marked

9000 to 9499 Test and signal earth

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5READING OF DIAGRAMS

Marking of wiring XF95series

2-2

I-CAN wiring (twisted)

3565 CAN-L (yellow)

3566 CAN-H (grey)

V-CAN wiring (twisted)

3700 CAN-L (yellow)

3701 CAN-H (blue)

Notes:- TheMwith serial number coding on earth

wiring is used for production-relatedreasons.

- In the case of straight splicing of the wiring(cascading), the numerical codes are shownon each separate wire followed by a serialletter.

Earth connectionsThe application of electronic systems has madeit necessary to divide the earth connections intogroups. There is a distinction to be madebetween two different types of earth connection:- switching earth- test and signal earthThe switching earth is the conventional type ofearth.The test and signal earth is used exclusively forelectronic systems.The wiring colour for both types of earth is white,but the test and signal earth wiring is markedwith numerical codes (from 9000 to 9500).

Never use the test and signal earthwhen fitting an electricalcomponent

If you do this, electronic components may notwork correctly.If an electronic component needs to beconnected, the earth for this system must beconnected to the central earth connection in thecab.The connection point is located in the dashboardconnector lead-through.

Abbreviations used in colour coding

Colour Ab-brevi-ation

Colour Ab-brevi-ation

red rd yellow gl

brown bn white wt

green gn grey gs

blue bw black zt

orange oe violet vi

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XF95series Reading of circuit diagrams

READING OF DIAGRAMS

3-3

7. If the wire numbers remain unchanged,these will not be repeated in the circuitdiagram.For example, in the example diagram wire

1101 is connected to connection point 87 ofrelay contact G107, but also to connectionpoint 2 of component C622.Wire 2100 (at location number 64) isconnected to connection point 30 of relayG154, but also to connection point 85 ofrelay G000, etc.

7

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XF95series Reading of circuit diagrams

READING OF DIAGRAMS

3-5

E501578

29 30 31 32

33 34 35 36

37 38 39 40

41 42 43 44

45 46 47 48

49 50 51 52

53 54

M M

R

L

X1

X1

Y1

Y1

L

1

4 2

30B

DL31

DO

M

P

G3

2

1

U

M

7

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Reading of circuit diagrams XF95series

3-6

Symbolnumber

Description

1 Loudspeaker

2 Electropneumatic or hydraulic valve, 1 driving coil

3 Electropneumatic or hydraulic valve, 2 non-compound relay valves

4 Electropneumatic or hydraulic valve, 3 non-compound relay valves

5 Diode

6 Bipolar diode

7 LED

8 LED with series resistor

9 4-position switch, key-operated

10 3-position switch with fixed central position, manually operated, spring return

11 Dual 3-position switch with fixed central position, manually operated, spring return

12 Potentiometer with series resistor

13 Potentiometer without series resistor

14 Dual switch; one 2-position switch, manually operated, changeover contact, one2-position switch, manually operated, contact normally open

15 Dual switch; one 2-position switch, spring return, contact normally open, one 3-positionswitch, fixed central contact, spring return, changeover contact

16 2-position switch with fixed 0-position, spring return, contact normally open

17 Through-connection

18 Relay with changeover contact

19 Relay with changeover contact

20 Switch, pressure-controlled, dual break, contact normally closed

21 Switch, pressure-controlled, dual break, contact normally open

22 Switch, temperature-controlled, single break, contact normally closed

23 Switch, mechanically operated, dual break, contact normally closed

24 Switch, mechanically operated, dual break, contact normally open

25 Pressure - voltage converter

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XF95series Reading of section diagrams

READING OF DIAGRAMS

4-1

4. READING OF SECTION DIAGRAMS

EXPLANATION OF THE POSITION NUMBERS IN THE SECTION DIAGRAMS

In the section diagram only information that isfunctional in the section diagram described isshown in detail.

1. The wiring is shown in the same colours asthe wiring in the vehicle.

2. The wire numbers are as they are printedon the wiring in the vehicle.Suffixes to wire numbers, such as A, B, Cetc., have been omitted.

3. Basic code of a component. For componentdescriptions, see the legend to the diagram.For more information, see the relevantsection diagram.

4. Number of the wire connection point or thePCB track on the component.

5. The basic code of the connector and theconnection point on this connector.

6. The symbols indicate which system orcomponent is being referred to (in mostcases, the symbol is also shown on the lensof the warning lamp or switch).

7. PCB tracks.

8. The central box and instrument panel PCBsare grey.

9. Removable components are shown inwhite.

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Reading of section diagrams XF95series

4-2

10. Reference to the component andconnection point and to the section (sectiondiagram) which gives further informationabout this component.

G17885

7

G178 = Basic code of thecomponent

85 = Connection point on thecomponent

7 = Reference to sectiondiagram 7

11. ATTENTION!The situation on the vehiclemay be different, because of differentspecifications. Always consult the legend tothe diagram.

12. The housing of this component is connectedto earth. The line shown is therefore not awire.

13. Search bar numbers.

14. Section diagram number as well as sectionnumber.

15. Relation to the circuit diagram.7

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5

XF95series Contents


1

CONTENTS

Page Date

1. GENERAL LOCATION OF COMPONENTS 1-1 200323. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Introduction 1-1 200323. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Location of components in relation to circuit diagram: 1426261/07-11 1-2 200323. . . . . . . . .

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5LOCATION OF COMPONENTS

Contents XF95series

2

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5

XF95series General location of components


1-3

1 2 3 4

B245 PTO control valve Gearbox, co-drivers side 12

B378 Heating element for fuel filter/waterseparator

Behind the cab, drivers side 7

B403 ECAS resistor for increasedmanoeuvring level, lowering

In ECAS cable harness, central box 11

B404 ECAS resistor for increasedmanoeuvring level, lifting

In ECAS cable harness, central box 11

C622 Switch, lighting Dashboard, panel on drivers side 5

C716 Switch, rotating beams Roof console, drivers side 5

C725 Work lamp switch Dashboard, instrument panel 5

C727 Front/rear fog lamp switch Dashboard, instrument panel 5

C731 Interior roof console lighting switch,co-drivers side F249 XC

Dashboard, central console 5

C733 Interior roof console lighting switch,drivers side F249 XC


C735 Interior nightlight switch Dashboard, central console 5

C736 Roof hatch switch Dashboard, central console 5

C737 ABS/ASC-D traction switch Dashboard, central console 5

C739 Mechanical lifting-gear switch Dashboard, radio panel 5

C740 ECAS switch, normal driving level Dashboard, radio panel 5

C741 ECAS switch, axle lifting Dashboard, radio panel 5

C742 Traction assistance switch Dashboard, radio panel 5

C748 Cross-axle differential lockoperation switch

Dashboard, radio panel 5

C749 Longitudinal controlled slipdifferential control switch


C750 PTO control switch Dashboard, instrument panel 5

C751 PTO control switch Dashboard, instrument panel 5

8

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General location of components XF95series

1-4

1 2 3 4

C760 Air conditioning switch Dashboard, radio panel 5

C763 Instrument lighting dimmingpotentiometer

Dashboard, instrument panel 5

C764 Potentiometer, headlampheight adjustment


C765 Switch, warning lamps (withLED search lighting)


C773 Rear fog lamp switch Dashboard, instrument panel 5

C774 Central door locking switch Dashboard, central console 5

C778 Cab heater switch Dashboard, central console 5

C802 Switch, recirculation valve Dashboard, radio panel 5

C813 Spotlight switch, roof Roof console, drivers side 5

C835 Switch for turning off interiordetection


C836 Switch for turning offsuperstructure/drawn vehicle loadspace detection


C844 Switch for Eberspcher cab heaterwith timer unit


C853 Cab main switch Dashboard, central console 5

C854 Chassis main switch In chassis side member housing,drivers side

7

C859 Interior lighting roof console switch,drivers side

In rear wall, drivers side 11

C881 Switch, ECAS lifting Dashboard, radio panel 5

C883 FAG traction assistance switch Dashboard, radio panel 5

C890 Switch for turning off integration ofthird brake


C895 ECAS limited height switch,speed-dependent


C897 Interior lighting, SH cab, co-driversside In rear wall, drivers side 11

8

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5



1-5

1 2 3 4

D094 Warning light (orange), PTO (2nd) Dashboard, instrument panel 5

D503 Electronic unit, mechanical liftinggear

In distributor box, inside of chassison co-drivers side, front of drivenaxle

10

D529 Electronic unit, ECAS remotecontrol

Left of seat console, driver s side 5

D609 Light switch diode On PCB print track, central box 1

D610 Diode, main beam/dipped beam On PCB print track, central box 1

D611 Diode, damping valve for loweringmechanical lifting gear


10

D612 Diode, damping valve for liftingmechanical lifting gear In distributor box, inside of chassison co-drivers side, front of drivenaxle

10

D613 Diode for pump relay damping,mechanical lifting gear


10

D622 Diode for mechanical lifting gear,lifting lock


10

D623 Diode for mechanical lifting gear,lowering lock


10

D709 Diode for interior lighting to preventfeedback to co-drivers switch

In roof console, drivers side 6

D710 Interior lighting diode to preventfeedback to drivers side switch


D715 Alarm system LED Under roof console, centre 2

D758 Diode to prevent feedback to VIC On PCB print track, central box 1

D759 Diode to prevent feedback to stoplights

On PCB print track, central box 1

D782 Diode to prevent door lockingfeedback, drivers side

On PCB print track, central box 1

D783 Interior lighting diode, drivers side On PCB print track, central box 1

D802 ECAS-2 (6x2) electronic unit On attachment plate, central box 1

8

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1-6

1 2 3 4

D814 UPEC electronic unit Against engine block, left side 3

D826 Electronic unit for VLG currentlimiter

Chassis side member, drivers side 12

D850 Electronic unit for ABS/ASC,D model

On attachment plate, central box 1

D851 Electronic unit, ECAS-3 (4x2) On attachment plate, central box 1

D880 Electronic unit for EBS On attachment plate, central box 1

D895 Electronic unit for (10A) converterwith power supply for radio memory

On attachment plate under PCB,central box

1

D900 VIC electronic unit On attachment plate under PCB,central box

1

D901 Electronic unit for Hydronic 10 cabheater

Rear of cab, central 7

D902 Electronic unit, ZF intarder withCAN


1

D904 Menu Control Switch, MCS Dashboard, radio panel 5

D905 Electronic unit for central doorlocking


D909 Electronic unit, ultrasonic alarmsystem

Under roof console, centre 2

D910 Electronic unit, battery charger On attachment plate, central box 2

D911 Electronic unit, alarm system(ALS-S)


1

D912 Electronic unit, immobiliser Against steering column nearignition/starter switch

2

D924 Electronic unit for main switch In chassis side member housing,drivers side

7

D929 Central PCB Central box, co-drivers side 1

D931 LED unit, immobiliser On attachment plate under PCB,central box

1

D932 EMAS electronic unit On attachment plate, central box 1

D954 AS Tronic gearbox modulator Gearbox, centre 8

8

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5



1-7

1 2 3 4

D955 AS Tronic gear lever unit On engine tunnel, drivers side 6

D969 CAN-data manager, CDM Central box, co-drivers side 1

E112 Fuse, glow warning lamp Above glow plug relay 3

E153 Fuse, main switch for timer/enginestop/main switch power supply

In chassis side member housing,drivers side

7

E279 Fuse, generator voltage regulation Above starter motor relay 9

E286 Main fuse On engine block bracket, left side 3

E330 Fuse,senswire main switch In chassis side member housing,drivers side

7

E507 Proximity switch for axle-loadprotection lifting gear (10 tons)

Next to distributor box, inside ofchassis on co-drivers side, front of

driven axle

10

E509 Operating switch, air conditioning,low pressure

In evaporator pipe, on outside ofcab, co-drivers side

9

E511 Stop light operating switch Behind radio panel 4

E524 Mechanical lifting-gear operatingswitch, oil pressure limit switch

On mechanical lifting device pump,between side members behinddriven axle

10

E564 Operating switch, engine brake On floor plate, drivers side 5

E566 Operating switch, EberspcherAirtronic cab heater thermostat


E570 Proximity switch, clutch PTO N10 Above clutch pedal 4

E575 Proximity switch, clutch To left of clutch pedal 4

E579 Operating switch, Eberspcher cabheater thermostat (water)


E580 Operating switch, Eberspcher cabheater timer (timer)


8

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1-8

1 2 3 4

E581 Operating switch/timer,Eberspcher cab heater, Airtronic


E584 Proximity switch for axle-loadprotection lifting gear (7.5 tons)

Next to distributor box, inside ofchassis on co-drivers side, front ofdriven axle

10

E590 AS Tronic selector switch On engine tunnel, drivers side 6

E592* Operating switch, reversing light (noPTO)

Gearbox, top 8

E592** Operating switch, reversing light(with N10 PTO)

Gearbox, top 8

E593* Neutral position switch for RHD Gearbox, top 8

E593** Neutral position switch for LHD Gearbox, top 8E595 Low-range switch Gearbox, drivers side 8

E599 Neutral position switch Gearbox, top 8

F000 Control switch for parking brake Behind radio panel 4

F050 Differential lock pressure controlswitch (1st and 2nd differentials)

In chassis side member, above rearaxle, drivers side

9

F087 Control switch, gearbox PTO Gearbox, drivers side 8

F097 Proximity switch for trailing axlemechanical lifting gear

Next to distributor box, inside ofchassis on co-drivers side, front ofdriven axle

10

F120 Gearbox switch, gates 3-4 Left side of gearbox 8

F533 Speed sensor (4-pin, 1st) Gearbox, drivers side 8

F603 Transmitter, ultrasonic Under roof console, centre 2

F604 Receiver, ultrasonic Under roof console, centre 2

F616 Cab locking sensor In cab lock, co-drivers side 12

F619 Cab locking sensor, alarm system In cab lock, drivers side 12

F651 Ambient temperature sensor Behind bumper, drivers side 7

8

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5



1-9

1 2 3 4

F652 Air pressure sensor On air supply unit 8

F656 Coolant level sensor Rear of expansion tank 9

F673 Sensor, engine oil level andtemperature

In engine oil sump, drivers side 7

F686 Alarm system sensor, radar Under headlining, centre 2

F705 Speed sensor Gearbox, drivers side 8

G014 Relay, glowing Against engine block, left side 3

G052 Relay, mechanical lifting-gear motor In distributor box, inside of chassison co-drivers side, front of drivenaxle

10

G066 Relay, mechanical lifting-gear

takeover

In distributor box, inside of chassis

on co-drivers side, front of drivenaxle

10

G257 Recirculation valve relay Right-hand side of heater unit 5

G258 Recirculation valve relay Right-hand side of heater unit 5

G267 Air conditioning relay Right-hand side of heater unit 5

G279 Air conditioning relay Right-hand side of heater unit 5

G367 Relay, main switch power supply In chassis side member housing,drivers side

7

G380 Relay, mechanical lifting axle

upwards

In distributor box, inside of chassis

on co-drivers side, front of drivenaxle

10

G381 Relay, mechanical lifting axle (7.5tons)


10

G535 CAN distributor block On attachment plate under PCB,central box

1

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2

E501755

E501571

E501575

D715F604

D909

F603

E501577

F686

E501574

A510

D910

E501576

D912

E501767

E579

E580

E501764

E566

E581

8

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5



3

E501584

E501168

E112

G014

E286

VD0084

D814

8

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4

E501635

E501571

E501553

B026

E501598

A007

E501593

F000E511

E501555

A076

E501068

E570

E575

8

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5



5

A043

D529

E501596

E501824

E501571

G258G279G267 G257

E501627

E501837

C760

C802

C749

C742

C748

C890

C883

C740

C741

C739

C895

C881

C763

C727

C773

C764

C725

C835

C836

D094

C750

C751

D904

C622

C765 C853 C735

C778

C844

C774

C731

C733

C736

C737

C716

C813

E501069

E564

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6

E501825

E501571

D905

D905

E501601

E501595

D955

manual esquema electr. daf xf

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