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Explanatory notes for checking and testing

LF45IV

LF55IV

CF65IV

CF75 IV

CF85 IV

XF105

Explanatory notes for checking and testing LF 45IV LF 55IV CF 65IV CF 75 IV CF
Explanatory notes for checking and testing LF 45IV LF 55IV CF 65IV CF 75 IV CF

© 201219

©201219 DAF Trucks N.V., Eindhoven, The Netherlands.

In the interest of continuing product development, DAF reserves the right to change specifications or products at any time without prior notice.

No part of this publication may be reproduced and/or published by printing, by photocopying, on microfilm or in any way whatsoever without the prior consent in writing of DAF Trucks N.V.

by photocopying, on microfilm or in any way whatsoever without the prior consent in writing of

V58

STRUCTURE

     series

Structure

GENERAL

ABS-E

ABS-E2

ADAPTIVE CRUISE CONTROL

AIRBAG

AIRBAG-2

AIRTOP 2000 (ACH-W2)

AIRTOP 2000 ST (ACH-W3)

AIRTRONIC (ACH-EA)

AS TRONIC AND AS TRONIC MID

AS TRONIC LITE

BODY BUILDER MODULE (BBM)

CDS-3

DAF TELEMATICS SYSTEM (DTS)

DMCI

EAS

© 201219

AND AS TRONIC MID AS TRONIC LITE BODY BUILDER MODULE (BBM) CDS-3 DAF TELEMATICS SYSTEM (DTS)

0

EAS-2

STRUCTURE

     series

© 201219

  series © 201219 EBS-2 ECAS-3 ECAS-4 0 ECS-DC4 AND EAS ECS-DC5 AND EAS EMAS

EBS-2

ECAS-3

ECAS-4

0

ECS-DC4 AND EAS

ECS-DC5 AND EAS

EMAS

HYDRONIC 10 (ACH-EW)

VIC-2 AND VIC-2 LITE

VIC-3 AND VIC-3 LITE

ZF INTARDER EST-52

GENERAL

     series CONTENTS

General

Contents

 

Page

 

Date

1. VEHICLE CONFIGURATION MANAGER (VCM)

 

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1.1

Vehicle Configuration Manager (VCM)

 

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CAN

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GENERAL

0

Contents

     series

GENERAL

     series

1. VEHICLE CONFIGURATION MANAGER (VCM)

1.1 VEHICLE CONFIGURATION MANAGER (VCM)

Vehicle Configuration Manager (VCM)

NOTE: Make sure that the DAVIE is updated with the latest Parts Rapido Subset before performing the VCM test. updated with the latest Parts Rapido Subset before performing the VCM test.

The Vehicle Configuration Manager can be used to easily retrieve information about the truck software and installation version. The Vehicle Configuration Manager can be read out using DAVIE XD(c). The Vehicle Configuration Manager can be used to:

- quickly acquire an overview of all installation and software variants, with the number of the vehicle's relevant component group;

- quickly acquire an overview of the systems where the information in the Parts Rapido Subset and the information programmed in the vehicle itself differ.

NOTE: If a difference is found by the VCM: compare the information (software version and installation variants) on the identity card (Parts Rapido) VCM: compare the information (software version and installation variants) on the identity card (Parts Rapido) with the information that is programmed in the relevant ECU.

0

GENERAL

Vehicle Configuration Manager (VCM)

0

     series

GENERAL

     series

2. CAN

2.1

CAN

The CAN check is a simple tool used to check whether the CAN messages of the various electronic systems are in order. The CAN messages check can be carried out with DAVIE XD(c).

The following CAN tests are possible:

- Messages test

- Connector status test

Messages test This test is not possible for the following systems:

- Immobiliser

- Alarm system

- DIP-4

- FMS

With the messages test, it is possible to check receipt of a particular CAN message (heartbeat signal). An electronic unit transmits a particular CAN message and the VIC must receive this message within a specified time. For each electronic unit, this message can be checked on the CAN network to ascertain whether the dispatched message has been received correctly. The number of CAN networks depends on the vehicle configuration.

Connector status test VIC allows the connection of a number of CAN connectors to be checked. A 24 V signal is applied to the wire with the CAN connectors. If one of the connectors has a poor connection or

no connection at all, the VIC does not receive 24

V at a particular input. This leads to a fault

message.

If the CAN network contains a counter connector

with a terminating resistor, this connector will also

have a check wire. This means that a wire runs through this connector, which is fed by the vehicle battery voltage. If this counter connector with a terminating resistor is not connected, this also leads to a fault message.

CAN

0

GENERAL

0

CAN

     series

ABS-E

     series CONTENTS

ABS-E

Contents

 

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Date

1. GENERAL

 

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2. INSPECTION OF WHEEL SPEED SENSORS

 

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3. INSPECTION OF

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Inspection of

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ABS-E

0

Contents

     series

ABS-E

     series

1. GENERAL

1.1

GENERAL

If DAVIE is being used to communicate with the ABS(/ASR) electronic unit, the following points need to be taken into account:

If ABS valve failures occur while driving, the fault lamp will go out after switching the vehicle ignition off and on if the fault is no longer active. If faults occur with the wheel speed sensors while driving, switch the vehicle ignition off and on; the fault lamp should then remain on if the fault is no longer present. The fault lamp will not go out until the vehicle has reached a speed of at least 7 km/h.

If DAVIE XD has been used to erase faults from the memory of the electronic unit, the fault lamp will go out when the vehicle has reached a speed of at least 7 km/h.

In some "direct test" functions, it is possible to drive the vehicle while communications are taking place between DAVIE XD and the ABS(/ASR) unit. With the remaining 'direct test' functions, communications between DAVIE XD and the electronic unit will be interrupted.

If a new ABS(/ASR) electronic unit is fitted, the unit will 'recognise' whether the vehicle has an ASR system when the vehicle ignition is switched on. If such an electronic unit is subsequently fitted in a vehicle that does not have an ASR system, the unit will always output ASR error messages. Whenever an ABS(/ASR) electronic unit is replaced, it is therefore important to reset the unit using DAVIE/XD.

General

0

ABS-E

0

General

     series

ABS-E

     series

2. INSPECTION OF WHEEL SPEED SENSORS

2.1 INSPECTION OF WHEEL SPEED SENSORS

Inspection of wheel speed sensors

1. Connect DAVIE.

2. Select the 'wheel speed sensor' function in the ABS/EBS application.

3. Check the minimum (Vmin) and maximum (Vmax) peak voltage of all wheel speed sensors at a speed of 5 km/h. Compare the Vmin readings with the values in the 'Technical data' chapter in the relevant system manual.

4. Check that the Vmax/Vmin ratio does not exceed the permissible ratio; see the 'Technical data' chapter in the relevant system manual.

5. In the event of nonconforming readings, check the following:

- the sensor ring for damage/soiling

- the wheel speed sensor being stuck in the housing. If it can be moved within the housing, press it against the sensor ring.

- wheel-bearing play

- tyre size

- wiring in wheel speed sensor

- resistance value of wheel speed sensor

0

ABS-E

Inspection of wheel speed sensors

0

     series

ABS-E

     series

3. INSPECTION OF ABS VALVES

3.1 INSPECTION OF ABS VALVES

1. Connect DAVIE.

2. Select the 'ABS valves' function in the ABS application.

3. Connect a pressure gauge to the brake chamber of the ABS valve to be inspected.

4. Ensure there is sufficient air pressure.

5. Upon selection of the ABS valve test, DAVIE will start an automatic actuation process in accordance with the example shown.

6. Depress the brake pedal fully during the automatic test.

7. Check that the pressure profile in the brake chamber approximates the line in the figure.

NOTE: When the pressure increases again after it had reached the minimum ('0'), it may be possible that it does not increase to half the maximum pressure, as shown in the figure. This pressure may differ per vehicle as a result of the difference in length and diameter of the air lines.

of the difference in length and diameter of the air lines. 8. In the event of

8. In the event of nonconforming readings, check the following:

- unobstructed routing of the air lines; the lines must not be kinked

- leakage of connections and/or lines

- soiling of the ABS valve vent

- the electrical connection of the ABS valve

Inspection of ABS valves

of the ABS valve vent - the electrical connection of the ABS valve Inspection of ABS

R600625

0

ABS-E

Inspection of ABS valves

0

     series

ABS-E2

     series CONTENTS

ABS-E2

Contents

 

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1. GENERAL

 

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2. INSPECTION OF WHEEL SPEED SENSORS

 

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2.1

Inspection of wheel speed sensors

 

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3. INSPECTION OF

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Inspection of

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ABS-E2

0

Contents

     series

ABS-E2

     series

1. GENERAL

1.1

GENERAL

If DAVIE is being used to communicate with the ABS(/ASR) electronic unit, the following points need to be taken into account:

If ABS valve failures occur while driving, the fault lamp will go out after switching the vehicle ignition off and on if the fault is no longer active. If faults occur with the wheel speed sensors while driving, switch the vehicle ignition off and on; the fault lamp should then remain on if the fault is no longer present. The fault lamp will not go out until the vehicle has reached a speed of at least 7 km/h.

If DAVIE XD has been used to erase faults from the memory of the electronic unit, the fault lamp will go out when the vehicle has reached a speed of at least 7 km/h.

In some "direct test" functions, it is possible to drive the vehicle while communications are taking place between DAVIE XD and the ABS(/ASR) unit. With the remaining 'direct test' functions, communications between DAVIE XD and the electronic unit will be interrupted.

If a new ABS(/ASR) electronic unit is fitted, the unit will 'recognise' whether the vehicle has an ASR system when the vehicle ignition is switched on. If such an electronic unit is subsequently fitted in a vehicle that does not have an ASR system, the unit will always output ASR error messages. Whenever an ABS(/ASR) electronic unit is replaced, it is therefore important to reset the unit using DAVIE/XD.

General

0

ABS-E2

0

General

     series

ABS-E2

     series

2. INSPECTION OF WHEEL SPEED SENSORS

2.1 INSPECTION OF WHEEL SPEED SENSORS

Inspection of wheel speed sensors

1. Connect DAVIE.

2. Select the 'wheel speed sensor' function in the ABS/EBS application.

3. Check the minimum (Vmin) and maximum (Vmax) peak voltage of all wheel speed sensors at a speed of 5 km/h. Compare the Vmin readings with the values in the 'Technical data' chapter in the relevant system manual.

4. Check that the Vmax/Vmin ratio does not exceed the permissible ratio; see the 'Technical data' chapter in the relevant system manual.

5. In the event of nonconforming readings, check the following:

- the sensor ring for damage/soiling

- the wheel speed sensor being stuck in the housing. If it can be moved within the housing, press it against the sensor ring.

- wheel-bearing play

- tyre size

- wiring in wheel speed sensor

- resistance value of wheel speed sensor

0

ABS-E2

Inspection of wheel speed sensors

0

     series

ABS-E2

     series

3. INSPECTION OF ABS VALVES

3.1 INSPECTION OF ABS VALVES

1. Connect DAVIE.

2. Select the 'ABS valves' function in the ABS application.

3. Connect a pressure gauge to the brake chamber of the ABS valve to be inspected.

4. Ensure there is sufficient air pressure.

5. Upon selection of the ABS valve test, DAVIE will start an automatic actuation process in accordance with the example shown.

6. Depress the brake pedal fully during the automatic test.

7. Check that the pressure profile in the brake chamber approximates the line in the figure.

NOTE: When the pressure increases again after it had reached the minimum ('0'), it may be possible that it does not increase to half the maximum pressure, as shown in the figure. This pressure may differ per vehicle as a result of the difference in length and diameter of the air lines.

of the difference in length and diameter of the air lines. 8. In the event of

8. In the event of nonconforming readings, check the following:

- unobstructed routing of the air lines; the lines must not be kinked

- leakage of connections and/or lines

- soiling of the ABS valve vent

- the electrical connection of the ABS valve

Inspection of ABS valves

of the ABS valve vent - the electrical connection of the ABS valve Inspection of ABS

R600625

0

ABS-E2

Inspection of ABS valves

0

     series

ADAPTIVE CRUISE CONTROL

     series CONTENTS

Adaptive Cruise Control

Contents

 

Page

 

Date

1.

HORIZONTAL ALIGNMENT .

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201219

0

ADAPTIVE CRUISE CONTROL

0

Contents

     series

ADAPTIVE CRUISE CONTROL

     series

1. HORIZONTAL ALIGNMENT

1.1 HORIZONTAL ALIGNMENT

If the alignment of the Adaptive Cruise Control

(ACC) radar is not within the tolerances, the ACC system does not work properly.

A test is available in the DAVIE application of

Adaptive Cruise Control (ACC): Horizontal alignment. In this test, DAVIE reads the horizontal alignment angle from the ECU ACC (D351). This angle is a value estimated by the ECU.

Horizontal alignment

0

Angle (°)

Action

between -0.1° and +0.1°

Alignment is OK

-0.3°

Check alignment of the ACC

+0.3°

Check alignment of the ACC

between -0.1° and -0.3°

If the driver complains that the ACC is not function- ing correctly, check alignment of the ACC

between +0.1° and +0.3°

If the driver complains that the ACC is not function- ing correctly, check alignment of the ACC

The horizontal alignment angle in the ECU ACC (D351) is not a dynamic value, which means that

if the ACC is realigned this value is not

immediately changed.

It can take several hours of driving with the ACC

engaged before this value is changed.

ADAPTIVE CRUISE CONTROL

Horizontal alignment

0

     series

AIRBAG

     series CONTENTS

Airbag

Contents

 

Page

 

Date

1.

INSPECTION OF IGNITION CIRCUITS

 

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1.1

Inspection of ignition circuits

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AIRBAG

0

Contents

     series

AIRBAG

     series

1. INSPECTION OF IGNITION CIRCUITS

1.1 INSPECTION OF IGNITION CIRCUITS

Inspection of ignition circuits

OF IGNITION CIRCUITS Inspection of ignition circuits NOTE: The ignition circuits of the airbag and seat

NOTE: The ignition circuits of the airbag and seat belt tensioner can be checked using DAVIE. When the ignition is switched on, the electronic unit stores fault codes if the ignition circuits are not working properly. These fault codes can be read with DAVIE. This is the only safe and approved way to check the ignition circuits.

If the electronic unit indicates that there is a fault in one or more ignition circuit(s) by means of a warning on the DIP and/or a fault code in the memory, its cause must be traced. The following procedures must be used for this purpose.

Fault in airbag module ignition circuit

1. Turn off contact and remove the key. Store the key in a safe place.

2. Switch off the main switch.

3. Disconnect the battery terminal clamp from the negative pole and insulate the clamp to prevent it accidentally touching the battery terminal.

4. Wait at least 30 seconds.

5. Disconnect the airbag module from the connector (2).

6. Remove the airbag module.

7. Attach the dummy plug, special tool (DAF no. 1406344) (1) to the connector (2) of the ignition wiring.

8. Connect the battery clamps to the battery terminal.

9. Switch the main switch on.

10. Insert the ignition key, switch the ignition on and wait 10 seconds.

11. Check the airbag warning on the DIP. Additionally, use DAVIE to check what fault codes are stored. If there is still a fault code on the airbag module ignition circuit, this indicates that the fault is or was in the wiring, and/or the clock spring, connectors and/or the electronic unit. Establish what caused the fault(s) by measuring the resistance.

2 1
2
1

K101586

0

AIRBAG

Inspection of ignition circuits

If the fault code does not recur, this indicates 0 that the fault is or was in the airbag module.

12. Turn the ignition off.

13. Switch off the main switch.

14. Disconnect the battery terminal clamps from the battery terminals.

15. Remove the dummy plug, special tool (DAF no. 1406344) from the contact unit.

16. Fit the airbag module.

17. Connect the battery clamps to the battery terminal.

18. Switch the main switch on.

19. Turn the ignition on and check the airbag warning on the instrument panel. The warning should be displayed for 5 - 10 seconds and then disappear immediately. If it remains displayed, use DAVIE to locate and remedy the fault.

Fault in seat belt tensioner ignition circuit

1. Turn the ignition off. Remove the ignition key and store in a safe place.

2. Switch off the main switch.

3. Disconnect the battery terminal clamp from the negative pole and insulate the clamp to prevent it touching the battery terminal by accident later on.

4. Wait at least 30 seconds.

5. Disconnect the seat belt tensioner connector.

     series

AIRBAG

     series

6. Attach the dummy plug, special tool (DAF no. 1406344) (1) to the plug (2) of the wiring harness to the seat belt tensioner igniter.

7. Connect the battery clamps to the battery terminal.

8. Switch the main switch on.

9. Insert the ignition key, switch the ignition on and wait 10 seconds.

10. Check the airbag warning on the DIP. Additionally, use DAVIE to check what fault codes are stored. If there is still a fault code on the seat belt tensioner ignition circuit, this indicates that the fault is or was in the wiring, and/or the clock spring, connectors and/or the electronic unit. Establish what caused the fault(s) by measuring the resistance. If the fault code does not recur, this indicates that the fault is or was in the seat belt tensioner.

11. Turn the ignition off.

12. Switch off the main switch.

13. Disconnect the battery terminal clamps from the battery terminals.

14. Remove the dummy plug, special tool (DAF no. 1406344) from the wiring harness.

15. Fit the wiring harness connector to the seat belt tensioner igniter.

16. Connect the battery clamps to the battery terminal.

17. Switch the main switch on.

18. Turn the ignition on and check the airbag warning on the instrument panel. The warning should be displayed for 5 - 10 seconds and then disappear immediately. If it remains displayed, use DAVIE to locate and remedy the fault.

Inspection of ignition circuits

2 1
2
1

K101586

0

AIRBAG

Inspection of ignition circuits

0

     series

AIRBAG-2

     series CONTENTS

Airbag-2

Contents

 

Page

 

Date

1. NO COMMUNICATION POSSIBLE

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No communication

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2. INSPECTION OF IGNITION CIRCUITS

 

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Inspection of ignition circuits

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AIRBAG-2

0

Contents

     series

AIRBAG-2

     series

1. NO COMMUNICATION POSSIBLE

1.1 NO COMMUNICATION POSSIBLE

No communication possible between the airbag electronic unit and DAVIE.

No communication possible

0

Possible cause

Remedy

Problem with airbag electronic unit supply voltage

- Check the power supply

Problem with airbag electronic unit earth connec- tion

- Check the earth connection

Problem with airbag electronic unit CAN connection

- Check the CAN connection

Problem with DAVIE connection

- Check the connection between the vehicle and DAVIE

Internal fault in airbag electronic unit

- Replace airbag electronic unit

AIRBAG-2

No communication possible

0

     series

AIRBAG-2

     series

2. INSPECTION OF IGNITION CIRCUITS

2.1 INSPECTION OF IGNITION CIRCUITS

Inspection of ignition circuits

OF IGNITION CIRCUITS Inspection of ignition circuits NOTE: The ignition circuits of the airbag and seat

NOTE: The ignition circuits of the airbag and seat belt tensioner can be checked using DAVIE. When the ignition is switched on, the electronic unit stores fault codes if the ignition circuits are not working properly. These fault codes can be read with DAVIE. This is the only safe and approved way to check the ignition circuits.

If the electronic unit indicates that there is a fault in one or more ignition circuit(s) by means of a warning on the DIP and/or a fault code in the memory, its cause must be traced. The following procedures must be used for this purpose.

Fault in airbag module ignition circuit

1. Turn off contact and remove the key. Store the key in a safe place.

2. Switch off the main switch.

3. Disconnect the battery terminal clamp from the negative pole and insulate the clamp to prevent it accidentally touching the battery terminal.

4. Wait at least 30 seconds.

5. Disconnect the airbag module from the connector (2).

6. Remove the airbag module.

7. Attach the dummy plug, special tool (DAF no. 1406344) (1) to the connector (2) of the ignition wiring.

8. Connect the battery clamps to the battery terminal.

9. Switch the main switch on.

10. Insert the ignition key, switch the ignition on and wait 10 seconds.

11. Check the airbag warning on the DIP. Additionally, use DAVIE to check what fault codes are stored. If there is still a fault code on the airbag module ignition circuit, this indicates that the fault is or was in the wiring, and/or the clock spring, connectors and/or the electronic unit. Establish what caused the fault(s) by measuring the resistance.

2 1
2
1

K101586

0

AIRBAG-2

Inspection of ignition circuits

If the fault code does not recur, this indicates 0 that the fault is or was in the airbag module.

12. Turn the ignition off.

13. Switch off the main switch.

14. Disconnect the battery terminal clamps from the battery terminals.

15. Remove the dummy plug, special tool (DAF no. 1406344) from the contact unit.

16. Fit the airbag module.

17. Connect the battery clamps to the battery terminal.

18. Switch the main switch on.

19. Turn the ignition on and check the airbag warning on the instrument panel. The warning should be displayed for 5 - 10 seconds and then disappear immediately. If it remains displayed, use DAVIE to locate and remedy the fault.

Fault in seat belt tensioner ignition circuit

1. Turn the ignition off. Remove the ignition key and store in a safe place.

2. Switch off the main switch.

3. Disconnect the battery terminal clamp from the negative pole and insulate the clamp to prevent it touching the battery terminal by accident later on.

4. Wait at least 30 seconds.

5. Disconnect the seat belt tensioner connector.

     series

AIRBAG-2

     series

6. Attach the dummy plug, special tool (DAF no. 1406344) (1) to the plug (2) of the wiring harness to the seat belt tensioner igniter.

7. Connect the battery clamps to the battery terminal.

8. Switch the main switch on.

9. Insert the ignition key, switch the ignition on and wait 10 seconds.

10. Check the airbag warning on the DIP. Additionally, use DAVIE to check what fault codes are stored. If there is still a fault code on the seat belt tensioner ignition circuit, this indicates that the fault is or was in the wiring, and/or the clock spring, connectors and/or the electronic unit. Establish what caused the fault(s) by measuring the resistance. If the fault code does not recur, this indicates that the fault is or was in the seat belt tensioner.

11. Turn the ignition off.

12. Switch off the main switch.

13. Disconnect the battery terminal clamps from the battery terminals.

14. Remove the dummy plug, special tool (DAF no. 1406344) from the wiring harness.

15. Fit the wiring harness connector to the seat belt tensioner igniter.

16. Connect the battery clamps to the battery terminal.

17. Switch the main switch on.

18. Turn the ignition on and check the airbag warning on the instrument panel. The warning should be displayed for 5 - 10 seconds and then disappear immediately. If it remains displayed, use DAVIE to locate and remedy the fault.

Inspection of ignition circuits

2 1
2
1

K101586

0

AIRBAG-2

Inspection of ignition circuits

0

     series

AIRTOP 2000 (ACH-W2)

     series CONTENTS

Airtop 2000 (ACH-W2)

Contents

 

Page

 

Date

1.

GENERAL

 

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1.1

General

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AIRTOP 2000 (ACH-W2)

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Contents

     series

AIRTOP 2000 (ACH-W2)

     series

1. GENERAL

1.1

GENERAL

Communication between DAVIE XD and the cab heater can only be established if the cab heater is switched on.

General

0

AIRTOP 2000 (ACH-W2)

0

General

     series

AIRTOP 2000 ST (ACH-W3)

     series CONTENTS

Airtop 2000 ST (ACH-W3)

Contents

 

Page

 

Date

1.

GENERAL

 

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