DAF CF65, CF75, CF85 Series . Manual - part 682

CF65/75/85 series

Removal and installation

REPAIRING WIRING

2-17

It is very important to carry out contact crimping
in the correct way to prevent electrical faults. For
cold fusion a contact crimping tool is required.
This tool creates a cold fusion between wire and
buffer connector.

E501491

Fitting the contact crimp connector
1.

Select the right buffer connector for the
wires to be connected.

Note:
If three wires of the same diameter have to be
connected after all, choose a buffer connector
that is the same diameter as two of the wires.
The single wire on the other side must be
stripped to double length and folded double.
The same applies when a wire is used on one
side that is twice the diameter of the other.

Strip the wire to a length of 4 to 5 mm.

Note:
The stripped wire end may not be twisted.

E501490

Choose the proper contact crimping tool on
the basis of the buffer connector and wire
diameter, and check the holes to be used.

Place the buffer connector in the hole of the
tool and clamp it gently so the buffer
connector will remain in the hole.

Slide the stripped wire ends into the side of
the buffer connector that is engaged by the
contact crimping tool.

Note:
The wire insulation may not be slid into the
contact part of the buffer connector.

E501492

200315

REPAIRING WIRING

Removal and installation

CF65/75/85 series

2-18

Compress the contact crimping tool: Do not
interrupt the contact crimping before the tool
is completely compressed to the end
position. Only then is full contact crimping
completed and the tool can be opened.

Repeat this for the other ends of the buffer
connector.

Check the contact crimping for damage and
pull the wires to ensure they are properly
fixed.

Note:
Improper contact crimping means a bad
connection, which may cause failures.

Avoid breathing in the vapours
produced when heating the
crimping insulation.

Heat the crimping insulation to fix it properly
to the wire insulation. Ensure that the
insulation does not get burnt. If the
insulation gets burnt it will become brittle
and easily break or crack.

E501493

200315

CF65/75/85 series

Removal and installation

REPAIRING WIRING

2-19

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 earth
connection, with particular attention being paid
to earth connections on the chassis.

Points for special attention when checking
earth connection on chassis
If an earth connection has been removed and is
being re-installed, pay attention to the following:

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

Clean all dirt and paint from the area around
the engine/chassis earth connection on both
sides of the chassis member so that the
bare metal is visible.

Clean all dirt and paint from the area around
the battery/chassis earth connection on the
inside of the chassis member so that the
bare metal is visible.

On the earth strip side, the cleaned area
must be larger than the contact area of the
earth strip.

On the nut side, the cleaned area must be
larger than the contact surface of the nut.

After fitting the earth connection, a
protective zinc primer should be applied to
both sides of it and it should be painted.

E501495

200315

REPAIRING WIRING

Removal and installation

CF65/75/85 series

2-20

2.7 REPAIRING CAN NETWORK WIRING

When repairing or replacing the CAN wiring, the
original twisted lengths and diameters of the
wiring must be taken into consideration. A 10%
tolerance in the twisted length of the wiring is
permitted. Winding density 40-50 turns/m.

When repairing the wiring, the winding density
must be maintained, with the provision that it is
permissible for the wiring at the point of repair to
have no twists over a maximum length of 60
mm. When the wiring is being repaired, it must
be secured in a wire tie at the end and in the
middle.

Replacing CAN wire
1.

Measure the length of the original wire
when untwisted.

Measure the diameter of the original wire.
Always take a wire of the same diameter or,
if this is not available, of the next size.

Preferably choose a wire of the same colour
as the original wire.

Follow the routing of the original wire and
install the wire in the original way.

Max. 60mm

E500977

200315

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