DAF CF65 User manual

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CF65/75/85 series
STRUCTURE
TECHNICAL DATA
DIAGNOSTICS
MECHANICAL GEARBOX CONTROL
PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT)
GEARBOX - PNEUMATIC SECTION
ZF 6S-850 GEARBOX
ZF 8/9/16S-109 GEARBOX
ZF 8/16S-151/181 AND 16S-221 GEARBOXES
EATON FS/6309A GEARBOX
AUTOMATIC GEARBOXES
CLUTCH
PROP SHAFTS
ZF INTARDER
PTO
AS TRONIC GEARBOX
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CF65/75/85 Serie Contents
TECHNICAL DATA
6-1
CONTENTS
Page Date
1. MECHANICAL GEARBOX CONTROL 1-1 200337.................................... ....
1.1 General 1-1 200337......................................................... ....
1.2 Tightening torques 1-3 200337................................................ ....
2. PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) 2-1 200337....... ....
2.1 General 2-1 200337......................................................... ....
2.2 Tightening torques 2-1 200337................................................ ....
3. PNEUMATIC SECTION OF GEARBOX 3-1 200337................................... ....
3.1 General 3-1 200337......................................................... ....
3.2 Tightening torques 3-4 200337................................................ ....
4. ZF 6S-850 GEARBOX 4-1 200337.................................................. ....
4.1 General 4-1 200337......................................................... ....
4.2 Tightening torques 4-2 200337................................................ ....
4.3 Filling capacities 4-2 200337.................................................. ....
5. ZF 8/9/16S-109 GEARBOX 5-1 200337.............................................. ....
5.1 General 5-1 200337......................................................... ....
5.2 Tightening torques 5-2 200337................................................ ....
5.3 Filling capacities 5-4 200337.................................................. ....
6. ZF 8/16S-151/181 AND 16S-221 GEARBOXES 6-1 200337............................ ....
6.1 General 6-1 200337......................................................... ....
6.2 Tightening torques 6-2 200337................................................ ....
6.3 Filling capacities 6-4 200337.................................................. ....
7. EATON FS/6309A GEARBOX 7-1 200337........................................... ....
7.1 General 7-1 200337......................................................... ....
7.2 Tightening torques 7-2 200337................................................ ....
7.3 Filling capacities 7-3 200337.................................................. ....
8. ALLISON AUTOMATIC GEARBOX 8-1 200337...................................... ....
8.1 General 8-1 200337......................................................... ....
8.2 Tightening torques 8-2 200337................................................ ....
8.3 Filling capacities 8-3 200337.................................................. ....
9. CLUTCH 9-1 200337.............................................................. ....
9.1 General 9-1 200337......................................................... ....
9.2 Tightening torques 9-5 200337................................................ ....
9.3 Filling capacities 9-6 200337.................................................. ....
10. PROP SHAFTS 10-1 200337........................................................ ...
10.1 General 10-1 200337......................................................... ...
10.2 Tightening torques 10-2 200337................................................ ...
10.3 Filling capacities 10-3 200337.................................................. ...
11. ZF INTARDER 11-1 200337......................................................... ...
11.1 General 11-1 200337......................................................... ...
11.2 Tightening torques 11-1 200337................................................ ...
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3TECHNICAL DATA
Contents CF65/75/85 Serie
6-2
Page Date
12. PTO 12-1 200337.................................................................. ...
12.1 General 12-1 200337......................................................... ...
12.2 Tightening torques 12-2 200337................................................ ...
12.3 Filling capacities 12-4 200337.................................................. ...
13. AS TRONIC GEARBOX 13-1 200337................................................ ...
13.1 General 13-1 200337......................................................... ...
13.2 Tightening torques 13-2 200337................................................ ...
13.3 Filling capacities 13-4 200337.................................................. ...
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CF65/75/85 series Mechanical gearbox control
TECHNICAL DATA
1-1
1. MECHANICAL GEARBOX CONTROL
1.1 GENERAL
V300382
- Within the entire CF65/75/85 vehicle series
many gearbox variations as well as the
accompanying controls are possible, both
mechanical and pneumatic.
- A gearbox with a splitter and range-change
switch will be equipped with several
pneumatic valves.
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TECHNICAL DATA
Mechanical gearbox control CF65/75/85 series
1-2
ADJUSTING THE LINKAGE MECHANISM
Vehicle series CF65/75/85 LHD/RHD with
ZF 6S-850, 8/9/16S-109, 8/16S-151/181/221
and Eaton FS/6309A gearboxes.
Angle A: 90_
Note:
After the gear lever has been manually
positioned at an angle of 90_, the linkage
mechanism should be fitted together with the
selector shaft lever.
V300383
A
Vehicle series CF65 / RHD with gearbox type
ZF 6S-850
If the selector shaft lever has two attachment
holes, the attachment hole (A) in the selector
shaft lever should be used to attach the shaft
lever properly to the control rod.
AV300833
Bonding the gear lever into the ball
De-greaser DAF No. 1322827
Glue DAF No. 1340646
Bonding the ball joint to the control rod
De-greaser DAF No. 1322827
Glue DAF No. 1340646
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CF65/75/85 series Mechanical gearbox control
TECHNICAL DATA
1-3
1.2 TIGHTENING TORQUES
The tightening torques stated in this section are
different from the standard tightening torques
included in the overview of standard tightening
torques.
Any other threaded connections that are
not specified must therefore be tightened to the
torque stated in the overview of
standard tightening torques.
When attachment bolts and nuts are to be
replaced, it is important that they are of exactly
the same length and property class as the ones
removed unless stated otherwise.
Control rod
Fastening bolt (1) of control rod
on gear lever unit 40 Nm
Attachment nuts (3), gear
lever unit 27 Nm
Attachment bolt, selector shaft
lever to gearbox selector
housing 40 Nm
312 V300275
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TECHNICAL DATA
Mechanical gearbox control CF65/75/85 series
1-4
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CF65/75/85 series Pneumatically assisted gearbox control (Servoshift)
TECHNICAL DATA
2-1
2. PNEUMATICALLY ASSISTED GEARBOX CONTROL
(SERVOSHIFT)
2.1 GENERAL
Servoshift unit
Service pressure max. 10 bar
2.2 TIGHTENING TORQUES
The tightening torques stated in this section are
different from the standard tightening torques
included in the overview of standard tightening
torques.
Any other threaded connections that are
not specified must therefore be tightened to the
torque stated in the overview of
standard tightening torques.
When attachment bolts and nuts are to be
replaced, it is important that they are of exactly
the same length and property class as the ones
removed unless stated otherwise.
Air pipe banjo bolt (1) 38 Nm
Attachment bolts:
Servoshift unit (2) 23 Nm
V300328
2
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TECHNICAL DATA
Pneumatically assisted gearbox control (Servoshift) CF65/75/85 series
2-2 ᓻ200337
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CF65/75/85 series Pneumatic section of gearbox
TECHNICAL DATA
3-1
3. PNEUMATIC SECTION OF GEARBOX
3.1 GENERAL
If the vehicle is modified and the
configuration changed, the
electronic unit may have to be
programmed.
Note:
If the vehicle’s drive configuration is changed,
this must always be stated. The gate protection
and range-change protection frequencies
programmed into the electronic unit are related
to the drive configuration.
GV VALVE
GV valve begins to
open (C) 123 2mm
Total clutch pedal
travel (D) 154 2mm
NEUTRAL POSITION VALVE
Situation with separate air distribution block:
2 x 3/2-way valve
Servicepressure 6.5to10bar
Pipe connection M14 x 1.5
Situation with integrated air distribution
block:
3/2-way valve
Servicepressure 6.5to10bar
Pipe connection Not applicable
V300315
C
D
B
1
A
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TECHNICAL DATA
Pneumatic section of gearbox CF65/75/85 series
3-2
GEAR LEVER SELECTOR VALVE
Range-change gear
Connection point Colour
1 Supply Black
3 Bleed Red
21 Range-change gear
command (A)
White
V300488
21
1
B
A
3
PNEUMATIC SYMBOL
III
V300267
13
21 Range
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CF65/75/85 series Pneumatic section of gearbox
TECHNICAL DATA
3-3
GEAR LEVER SELECTOR VALVE
Range-change gear and splitter
Connection point Colour
1 Supply Black
3 Bleed Red
21 Range-change gear
command (A)
White
22 Splitter command (B) Yellow
V300489
21
1
22
B
A
3
PNEUMATIC SYMBOL
Range-change gear and splitter
Position Function
GP Range-change gear
GV Splitter
1
22 21
GV GP
H
L
H
L
V300161
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TECHNICAL DATA
Pneumatic section of gearbox CF65/75/85 series
3-4
3.2 TIGHTENING TORQUES
The tightening torques stated in this section are
different from the standard tightening torques
included in the overview of standard tightening
torques.
Any other threaded connections that are
not specified must therefore be tightened to the
torque stated in the overview of
standard tightening torques.
When attachment bolts and nuts are to be
replaced, it is important that they are of exactly
the same length and property class as the ones
removed unless stated otherwise.
Gear button on gear lever
Gear button lock nut 70 Nm
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CF65/75/85 series ZF 6S-850 gearbox
TECHNICAL DATA
4-1
4. ZF 6S-850 GEARBOX
4.1 GENERAL
Gearbox type
Each gearbox has a type-plate attached to it,
indicating the type of gearbox. This data is also
stated on the identity card of the relevant
vehicle.
ZF gearbox type-plate
1. Type of gearbox
2. Series no. (ZF)
3. Parts list (ZF)
4. Specification no.
5. Pulse generator ratio
6. Gearbox ratio
7. Engine speed using PTO
8. PTO speed
9. Gearbox oil capacity
10. Oil specification
V300049
1
2
4
5
3
8
67
10
9
Output shaft bearing axial play
Output shaft bearing axial play 0.00 - 0.10 mm
Bearing axial play, main and input shafts
Bearing axial play, main and input shafts 0.00 - 0.10 mm
Auxiliary shaft bearing axial play
Auxiliary shaft bearing axial play 0.00 - 0.10 mm
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TECHNICAL DATA
ZF 6S-850 gearbox CF65/75/85 series
4-2
4.2 TIGHTENING TORQUES
The tightening torques stated in this section are
different from the standard tightening torques
included in the overview of standard tightening
torques.
Any other threaded connections that are
not specified must therefore be tightened to the
torque stated in the overview of
standard tightening torques.
When attachment bolts and nuts are to be
replaced, it is important that they are of exactly
the same length and property class as the ones
removed unless stated otherwise.
Gearbox to engine
M8 attachment bolts - 10.9 30 Nm
M10 attachment bolts - 10.9 60 Nm
M12 attachment bolts - 10.9 110 Nm
Drive flange
Drive flange attachment bolt
- 120 mm flange diameter 140 Nm
- 150 mm flange diameter 140 Nm
Gearbox front cover
Attachment bolts 23 Nm
Selector shaft housing
Attachment bolts 23 Nm
Shifting arm lock nut 46 Nm
Air connection banjo bolt 23 Nm
Bleeder 10 Nm
Plugs
Drainplug 50Nm
Level check/filler plug 50 Nm
4.3 FILLING CAPACITIES
Gearbox type Filling capacities at oil change
(litres)
First filling, e.g. during repair
(litres)
ZF 6S-850 7.5 7.5
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CF65/75/85 series ZF 8/9/16S-109 gearbox
TECHNICAL DATA
5-1
5. ZF 8/9/16S-109 GEARBOX
5.1 GENERAL
Gearbox type
Each gearbox has a type-plate attached to it,
indicating the type of gearbox. This data is also
stated on the identity card of the relevant
vehicle.
ZF gearbox type-plate
1. Type of gearbox
2. Series no. (ZF)
3. Parts list (ZF)
4. Specification no.
5. Pulse generator ratio
6. Gearbox ratio
7. Engine speed using PTO
8. PTO speed
9. Gearbox oil capacity
10. Oil specification
V300049
1
2
4
5
3
8
67
10
9
Output shaft bearing axial play
Output shaft bearing axial play 0.00 - 0.10 mm
Bearing axial pre-load, main and
input shafts
Bearing axial pre-load, main and input shafts
8/9S-109 0.18 - 0.30 mm
16S-109 0.18 - 0.30 mm
Bearing axial pre-load, auxiliary shaft
Bearing axial pre-load, auxiliary shaft
8/9S-109 0.18 - 0.30 mm
16S-109 0.18 - 0.30 mm
Retaining element
Standard spring force 168 N
Heavy-duty spring force 191 N
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TECHNICAL DATA
ZF 8/9/16S-109 gearbox CF65/75/85 series
5-2
5.2 TIGHTENING TORQUES
The tightening torques stated in this section are
different from the standard tightening torques
included in the overview of standard tightening
torques.
Any other threaded connections that are
not specified must therefore be tightened to the
torque stated in the overview of
standard tightening torques.
When attachment bolts and nuts are to be
replaced, it is important that they are of exactly
the same length and property class as the ones
removed unless stated otherwise.
Gearbox to engine
M8 attachment bolts - 10.9 30 Nm
M10 attachment bolts - 10.9 60 Nm
M12 attachment bolts - 10.9 110 Nm
Drive flange
Retaining plate attachment bolts 60 Nm
Gearbox front cover
Attachment bolts 25 Nm
Bearing cover
Output shaft bearing cover 25 Nm
Control bearing cover 25 Nm
Air connection banjo bolt 38 Nm
Shift control high/low
Shifting fork high/low bolts 180 Nm
Gear engaging cylinder piston lock nut 180 Nm
Gear engaging cylinder attachment bolts 50 Nm
Air connection banjo bolt 38 Nm
Rear gearbox cover attachment bolts 50 Nm
Plugs
M24 drain plug 60 Nm
M38 drain plug 120 Nm
Level check/filler plug 60 Nm
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CF65/75/85 series ZF 8/9/16S-109 gearbox
TECHNICAL DATA
5-3
Plugs
Gearbox with integrated intarder
Drainplug(B) M24 60Nm
Drain plug (B) M38 120 Nm
Drain plug (C) 60 Nm
Level check/filler plug (A). 60 Nm
Oil filter attachment bolt (1) 23 Nm
M3017
B
BA
V300372
1
2
M3052
1
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TECHNICAL DATA
ZF 8/9/16S-109 gearbox CF65/75/85 series
5-4
5.3 FILLING CAPACITIES
Filling amounts, ZF gearboxes without
intarder
Gearbox type Filling amounts at oil change
(litres)
First filling, e.g. during repair
(litres)
ZF 8/16S-109 9 9.5
ZF 9/S-109 8 8.5
Filling amounts, ZF gearboxes with
integrated intarder
Gearbox type Filling amounts at oil change
(litres)
First filling, e.g. during repair
(litres)
ZF 8/16S-109 12.5 22
ZF 9S-109 12 21
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