- The basic descriptions of the warning lights and the actions required when the lights are illuminated have been reviewed. Helping the customer know the meaning of the warning lights associated with the engine, the DPF and DEF, will insure proper operation of the vehicle and maintain a positive relationship between the customer and the dealer.
- DAF CF65 CF75 CF85 Series Truck ServiceRepair Workshop Manual DOWNLOADINSTANT DOWNLOADOriginal Factory DAF CF65 CF75 CF85 Series Truck Service RepairManual is a Complete Informational Book. This Service Manual haseasy-to-read text sections with top quality diagrams and instructions.Trust DAF CF65 CF75 CF85 Series Truck Service Repair Manualwill.
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5
LF45/55 series
Alternator
A caution advises you of conditions that could result in dam-age to your vehicle or property. Study this manual carefully. Do not operate your vehicle until you are completely familiar with the contents of this manual. Always retain this manual in your vehicle for reference. If you sell the vehicle, make sure the manual goes with it.
DIAGNOSTICS
2-1
2. ALTERNATOR
2.1 FAULT-FINDING TABLE
Warning Lights Traffic Control
SYMPTOM: ALTERNATOR NOT PRODUCING POWER WHEN IDLING
Possible cause
Remedy
Open circuit in connection 15 on alternator
Repair connection 15
Connection 15 on alternator short-circuited to
earth
Repair connection 15
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
“S” connections is greater than 2.5 V
Check all contacts between alternator and B+
(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
1
200440
The Video Course teaches you everything about modern cars.
The ignition warning light, sometimes known as the no-charge light, is oneof the most important lights on your dashboard. It warns you when the car'sgenerator is not charging the battery.
In general, if the charging system is working normally, the warning lightshould glow when the ignition is switched on and then extinguish when theengine is started. But the light does behave in slightly different waysdepending on the type of generator fitted to your car.
If your car is equipped with a dynamo it is normal for the light to flickerat idling speeds as this type of generator produces little or no current at lowengine speeds. The light should extinguish when the engine speed is raised.
If your car is fitted with an alternator the warning light should not comeon when the engine is idling, provided the idle setting is correct, because analternator produces current even at low speeds.
There are three basic problems that an ignition warning light can develop.First, the warning light bulb may fail to illuminate when the ignition isswitched on and the engine has not yet been started. (This is usually thesimplest to fix.) Second, the warning light may fail to go out when you raisethe engine speed. Third, the light may behave normally at low revs but thencome on at high engine speed.
If the warning light fails to illuminate when the ignition is turned on,there are two possible causes.
One is that the warning light bulb may simply have blown. This could be dueto old age. The other possibility is a fault in the charging circuit - if thegenerator is overcharging it may cause the bulb to blow. You can make a simplecheck to find out which is at fault.
To make this check you will need to find the warning light wire in theengine bay where it connects to the charging system. But first you need to knowexactly which type of charging system you have so that you can identify thecorrect wire.
Cars fitted with a dynamo have the warning light wire connected to a remotevoltage regulator, often mounted on the bulkhead or inner wing. Look on theregulator cover for the terminal marked either WL or IND - this is the wire youwant.
If your car has an alternator, the warning light wire connection depends onwhether the alternator is fitted with an internal or an external voltageregulator.
If the alternator is fitted with an internal regulator, the wire you wantconnects directly to a terminal on the back of the unit marked WL or IND. Ifthe alternator has an external regulator, the warning light wire attaches to itin the same way as a dynamo. Again the terminal will be marked WL or IND.
Some cars, however, have an alternator which uses a separate relay for thewarning light circuit. In this case you should disconnect the wire from thisrelay.
Remove the warning light wire and touch it to earth. Turn the ignition on and observe the warning light. If it illuminates suspect a charging fault. If not suspect a blown bulb or faulty wiring.
For a dynamo, the warning light wire always runs from the light to a separate voltage regulator. On an alternator the wire may run to an internal regulator, to an external regulator or to a separate relay.
Many alternators are fitted with a multi-connector plug which fixes straight into the rear casing of the unit.The warning light wire is usually the smallest of the wires in the multi-plug. To remove the wire from the multi-plug, first disconnect the plug from the alternator, then remove the clip at the rear of the plug holding the wires in.The wire can now be pulled out and touched to earth to test the circuit.Fitting a new bulb
To change the warning light bulb you will need to gain access to the rear of the dash.
On older cars this is usually quite easy as the bulb can often simply be pulled out of its holder by reaching around the back of the dash with your hand.
On newer cars the bulb is often located in the instrument cluster and connected to the wiring via a multi-plug connector and a printed circuit.
When fitting a bulb to the cluster unit, make sure it has a good contact with the metal strips in the printed circuit — it is quite easy to misalign them.
Disconnect the warning light wire and make sure the terminal connections areclean and that the wire fits tightly. If the terminals look dirty or corroded,clean them up using wetor-dry paper, reconnect the wire and test the lightagain.
If the light still fails to illuminate, disconnect the wire again, turn theignition on and earth it to the bodywork or engine block.
If the light now illuminates, the fault lies in the generator or the voltageregulator. If the light still fails to illuminate, you will find that thewarning bulb has blown or the wiring is faulty.
If the warning light fails to go out when the engine is revved, the faultmay again lie in the generator or in the warning light circuit.
A simple check you can make to find out where the fault lies is to start the engine and turn on as manyelectrical components as possible. Now rev the engine and look at theheadlights. If the lights noticeably brighten, the charging system is workingand the problem lies in the warning light circuit.
One possibility is that the warning light wire is being earthed somewherealong its length. Check this by turning on the ignition and disconnecting thewarning light wire. If the warning light stays on, the wire is earthingsomewhere. Inspect the wire for any chafing against the bodywork and repair itwith insulating tape. If the wire is completely severed or badly chafed it willneed replacing with a whole new section.
The warning light may be faulty because of problems with the voltage regulator unit.Check that the regulator plastic cover is not cracked — which may allow moisture into the unit—and that the regulator has not become corroded or damp where it mounts to the body.High resistance
Daf Warning Lights Manually
The third possible problem with a warning light is that it goes out asnormal when you rev the engine slightly but comes on again as the engine speedis further increased.
If the warning light simply glows dimly it usually indicates the problem isa high resistance somewhere in the warning light circuit.
Test this by switching on more and more electrical accessories once thelight has started to glow. If high resistance is the problem, the warning lightwill become brighter as you do so.
Carefully work your way through the entire charging system looking for looseor dirty wiring connections causing the high resistance. Disconnect the wiresand clean up the terminals if they are dirty. Don't forget to check whether thebattery lead connections and engine earthing strap are still good.
Remember also to check the generator to engine mounting bolts. These providean earth passage from the generator to the engine and body, but because oftheir exposed position in the engine bay they can become oily and provide onlya poor earth connection.
Warning Lights Ct
Check this connection by removing the mounting bolts. Clean away all tracesof oil and dirt then refit the mounting bolts, making sure they are tight.
Daf Warning Lights Manual Free
Disconnect the old wire from its terminals at either end. Strip back the insulation from the new wire and lay the bared ends in the connector terminals, then apply the solder.
Daf Warning Lights Manual Download
Once the solder has cooled refit the wire alongside the existing loom, taping it at regular intervals. Make sure it can't touch any hot or moving parts.
If the warning light comes on at full brightness at high engine speeds, thefault is more serious.
There are several possible causes. On a dynamo it may be damaged brushes, aworn commutator or possibly faulty internal windings.
With an alternator the problem may be caused by a faulty rectifier, which isusually situated inside the alternator unit. The unit will have to be removedfrom the engine in order to be stripped down so the faulty parts can bereplaced where possible.
Check with your dealer to find out what replacement parts of the alternatorare available - you may find it cheaper and more convenient to buy an exchangeunit.
If the warning light glows above idling speed, you should check the charging circuit wiring for any poor connections that are causing a high resistance.Disconnect the battery leads to avoid a short circuit. Then check the battery terminals, making sure they are clean.Carefully check the battery earth lead where it joins the bodywork and also the main earth strap from the engine to the bodywork.The generator earths via the engine and a poor connection here will affect its performance. If any of the leads are corroded you should replace them.Check the wiring connections to the back of the generator, then work your way along the wires to the regulator box or startersolenoid.Pull each wire from the voltage regulator in turn, or disconnect the wires to the solenoid, and clean up the terminals using wet-or-dry paper.Remember when replacing the generator wires that the connecting terminals need to be soldered on to ensure a good connection. To eliminate any chance of overheating, the replacement wire should be of the correct thickness.Look in a workshop manual or ask your dealer if you are not sure what size of wire you.need. If the faulty wire runs through a loom, it is easier to disconnect it at both ends and run the new wire alongside the loom, securing it with tape.