Need help with headlights; they didn't come on after 1 month in storage.

Lin · August 27, 2011, 10:35:51 PM

Several things to check, but I agree about the dimmer switch. They are known to corrode and fill with crude. I had mine out recently to clean the contacts.

luvrbus · August 28, 2011, 07:40:49 AM

Some of the dimmer switches on those buses are on the turn signal jumping on it may be a problem

good luck

hargreaves · August 28, 2011, 07:57:21 AM

Thanks Lin, I know some people think that living in the northwest, we are wet behind the ears. LOL!

luvrbus · August 28, 2011, 08:07:50 AM

Why would you remove a dimmer switch and not replace it they only cost 15 bucks for a new one

good luck

Busted Knuckle · August 28, 2011, 10:45:41 AM

Quote from: hargreaves on August 27, 2011, 09:56:25 PM
Try jumping on the dimmer switch a bunch of times. The contacts get corroded and the result is no headlights. good luck Gerry

OK so I jumped on the dimmer switch and now the turn signal lever is just hanging by a wire. What so I do now? (Oh and I got my leg stuck in the steering wheel too!

BK

Busted Knuckle · August 28, 2011, 10:59:43 AM

OH and Clifford if I remember correctly the Neo's are like a Setra and the headlights are the only 12V lights on the coach. The rest are 24V like an older MCI.

To the best of my memory that is why Sean did dual 12V LEDs to make it work on 24V system.

BK

OH and by the way Gerry & Lin. I agree that the dimmer switch can be a problem too! (regardless of whether it's on the steering column or floor!)

Mike make sure that the relays have the exact same part # before you try switching places with them. I usually just use a jumper rather than taking a chance on mixing up what relay went where!(take a piece of wire 3-4" long and put "blade" connectors on each end, & bend in a U shape)

It's easy to use a jumper to test. Take a volt meter and find which contact is "hot" with out the headlight switch on. That will be your power coming from the source. Put one end of the jumper in it, and the other in the one directly across from it. If you get lights you either have a bad relay or the relay is not getting power.
(with one relay warm, and two ambient it could be either. But my guess it the warm one is OK and the 2 ambients are not getting juice for what ever reason.)

BK

Lin · August 28, 2011, 11:20:38 AM

Clifford--You are absolutely right about changing the switch. However, the dimmer switch was sticking, so I removed it with the intention of getting one just like it. When I had it out, I saw the contacts were corroded. I cleaning it up, hit the mechanism with some WD40 and put it back until I got a new one. Unfortunately, it works fine now, so I have not been motivated to replace it.

luvrbus · August 28, 2011, 11:23:53 AM

That works Lin lot of the time a wire is broken on the switch causing the headlight not to come on

good luck

loosenut · August 28, 2011, 07:59:13 PM

Again thanks all.

Following the early advice I took the relays out, changed positions and hit them with a hammer. The lights still don't work. FWIW, the relays labeled headlight are 24 volt relays and the lights are 12v.

The dimmer is operated by the turn signal stalk. Tomorrow I will work over the dimmer switch like it was a slot machine and let you know if it changes.

Mike

Busted Knuckle · August 29, 2011, 09:40:36 AM

Quote from: loosenut on August 28, 2011, 07:59:13 PM
Again thanks all.

Following the early advice I took the relays out, changed positions and hit them with a hammer. The lights still don't work. FWIW, the relays labeled headlight are 24 volt relays and the lights are 12v.

The dimmer is operated by the turn signal stalk. Tomorrow I will work over the dimmer switch like it was a slot machine and let you know if it changes.

Mike

Mike yes those are 24V relays! The "signal" from the switch will be a low amp 24V, but the power for the headlights that the relay activates will be 12V (and higher amp!)

BK

Len Silva · August 29, 2011, 10:55:23 AM

Quote from: loosenut on August 28, 2011, 07:59:13 PM
Again thanks all.

Following the early advice I took the relays out, changed positions and hit them with a hammer. The lights still don't work. FWIW, the relays labeled headlight are 24 volt relays and the lights are 12v.

The dimmer is operated by the turn signal stalk. Tomorrow I will work over the dimmer switch like it was a slot machine and let you know if it changes.

Mike

You do understand that you need to use a special electrical hammer on those things, right? Regular hammers just won't work.

Busted Knuckle · August 29, 2011, 12:30:52 PM

LOL!

BK

loosenut · August 30, 2011, 09:43:55 AM

I traced the wiring from the small relays to a larger relay. The larger clicks and has voltage coming out so I'm calling it good.

I hit all 17 of the smaller relays with, my special electrical, hammer and knocked the cap off of one. Watching the operation of the now bald relay, it seems that a warm relay is a good relay.

I've two sizes of relays with the larger being 2"X2" all with the same part number and the smaller relays are smaller than an inch square and again they all have the same part number.
^_
The smaller ones have 5 pins roughly in this pattern _||
^_
The || pins are dark and the others are lighter in color.

BK, I managed not to hurt myself while jumping on the dimmer switch which is activated by the blinker stalk. The bright light signal illuminates on the dash properly. If I activate the switch fully the dash high beam indicator stays lit and if I move it marginally the indicator light flashes as expected. The actual head lights don't light.

I did this in the dark to give me better conditions to see if there was a quick flicker or a dim glow but there was nothing.

I'm going to the auto parts store to buy relays. I'll let you know if that helps.

Mike

PS

Quote from: Len Silva on August 29, 2011, 10:55:23 AM

You do understand that you need to use a special electrical hammer on those things, right? Regular hammers just won't work.

Oh and Len, my truck driver cousin gave me not only a special electrical hammer but also an official Detroit spark plug tool and told me to keep my eye out for a left handed monkey wrench when I bought the bus.

I thought he was pulling my leg particularly when he mentioned the monkey wrench. My grandfather used to send me to find his all the time. However Steve, the cousin, took the time to explain that I would need it on a Detroit and it is indeed a joke when mentioned in conjunction with a gas motor. I was glad he cleared that up. He also warned me to be careful as each tool is very powerful.