DAF CF65, CF75, CF85 Series . Manual — part 492
5
CF65/75/85 Series ≥0E621376
Fault finding
DIAGNOSTICS
1-7
INSPECTION 2, MEASURING THE STARTING
CURRENT
Measure the starting current through the
steering shaft while starting, using the current
probe.
This measurement must be carried out with the
probe’s “Max Hold” function. Make sure that the
current probe is placed in the right position
(direction of current) and its jaws are closed
around the steering shaft.
Measured
current value
Measures to be taken
< 5.0 A
-
Main earth connections are in good condition; end of inspection 2: vehicle
is OK.
≥ 5.0 A
-
Inspect - and if necessary repair - all main earth connections from the cab
to the negative battery terminal between the following points:
-
battery earth and cab earth
-
cab earth and flywheel housing earth
-
flywheel housing earth and chassis earth
-
chassis earth and battery earth
y
Note:
A voltage loss measurement must be carried out to identify which earthing
point is in poor condition. This measurement is described later on in this
procedure.
-
The starting current value through the steering shaft must be less than 5.0
-
The starting current value through the steering shaft must be less than 5.0
A after repair. Otherwise one or more main earth connections are not yet in
good order and the main earth connections must be inspected again and if
necessary repaired.
-
If the current value is < 5.0 A, the earth connections are in good order;
end of inspection 2: vehicle is OK.
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DIAGNOSTICS
Fault finding
CF65/75/85 Series ≥0E621376
1-8
MEASURING VOLTAGE LOSS
E502269
4
1
3
2
1
negative battery terminal
2
flywheel housing
3
chassis
4
bulkhead lead-through connector
To find out whether a specific earthing point has
a good earth connection, measure the voltage
loss between the negative battery terminal and
this earthing point.
The figure shown is an example; the actual
course of the earth connection may differ
somewhat depending on vehicle type and
production date.
The consumers that were switched when the
current was measured should now be switched
on as well, i.e. the power consumption should be
between 20 A and 40 A.
If the earth connection is good, the voltage loss
should be less than 0.5 V.
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CF65/75/85 Series ≥0E621376
Batteries
DIAGNOSTICS
2-1
2. BATTERIES
2.1 FAULT-FINDING TABLE
SYMPTOM: NEW BATTERY HEATS UP CONSIDERABLY DURING FILLING
Possible cause
Remedy
Inadequate formation because of storage in
unsuitable or damp conditions over a long period
Allow to cool
Charge fully
Check the relative density
SYMPTOM: BATTERY ACID LEAKING FROM THE PLUG HOLES
Possible cause
Remedy
Battery overfilled
Siphon off some of the fluid
Overcharging
Check the charger and repair if necessary
SYMPTOM: ELECTROLYTE LEVEL TOO LOW
Possible cause
Remedy
Leaking battery
Replace the battery
Excessive gas development due to charging
current being set too high
Check/repair the charger
SYMPTOM: RELATIVE DENSITY TOO LOW (<1.240)
STARTING TROUBLE
Possible cause
Remedy
Power consumer left on by mistake
Charge the battery
Insufficient charging
Check/repair the charger
Short circuit in the charging circuit
Check the charging circuit
SYMPTOM: DENSITY IS TOO HIGH (>1.290)
Possible cause
Remedy
Topped up with acid instead of distilled water
Siphon off the fluid and fill with distilled water
If necessary, repeat this after mixing (charging)
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DIAGNOSTICS
Batteries
CF65/75/85 Series ≥0E621376
2-2
SYMPTOM: STARTING TROUBLE
POOR STARTING TEST RESULT
POWER FAILS UNDER LOAD
Possible cause
Remedy
-
Discharged battery
Charge the battery
-
Worn battery (plates corroded and worn
away)
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 TERMINALS
Possible cause
Remedy
-
Clamps not securely fitted, or poor contact
Have the battery terminals repaired, fit the
clamps properly or replace the clamps if
necessary
SYMPTOM: 1 OR 2 CELLS BUBBLE EXCESSIVELY UNDER HIGH LOADS (STARTING OR
STARTING TEST)
Possible cause
Remedy
-
Defective cells
Replace the battery
-
Leaking cell partition
Replace the battery
SYMPTOM: BATTERY DISCHARGES VERY FAST (DOES NOT RETAIN POWER)
Possible cause
Remedy
-
Insufficient charging
Check the charging. Is the charging time (driving
time) sufficient?
-
Short circuit in charging circuit
Check the charging circuit
-
Major self-discharging, for example due to
contamination
Clean the battery
-
Battery sulphated (on examining the plates,
they are found to be hard and, in some
cases, whitened)
Replace the battery
SYMPTOM: SHORT BATTERY LIFE
Possible cause
Remedy
-
Wrong type of battery chosen (for example in
the 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
(white deposits)
Always charge the battery after deep discharge
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200520
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