DAF CF65 User manual

Maintenance manual
CF65/CF65 (II)
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©200518 DW13280404
©200518 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.
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STRUCTURE
©200518
0
1
2
3
4
5
ΧΦ65/65 (II) series
Structure TECHNICAL DATA
THREADED CONNECTIONS
FLUIDS, OIL AND LUBRICANTS
MAINTENANCE SCHEDULE
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
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©200518 1
Contents
TECHNICAL DATA
ΧΦ65/65 (II) series
0
0 Technica l data
CONTENTS
Page Date
1. ENGINE, COOLING SYSTEM AND FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200518
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200518
1.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200518
1.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200518
2. STEERING GEAR AND BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200518
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200518
2.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200518
3. DRIVE AND CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200518
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200518
3.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200518
3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200518
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TECHNICAL DATA
2©200518
Contents
0
ΧΦ65/65 (II) series
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©200518 1-1
Engine, cooling system and fuel system
TECHNICAL DATA
ΧΦ65/65 (II) series
0
1. ENGINE, COOLING SYSTEM AND FUEL SYSTEM
1.1 GENERAL
1.2 TIGHTENING TORQUES
The tightening torques stated in this section are
different from the standard tightening torques
stated in the overview of the standard tightening
torques. The other threaded connections which
are not stated must therefore be tightened to the
torque stated in the overview of standard
tightening torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Valve clearance
Inspection dimension, cold valve clearance
Inlet 0.15 - 0.40 mm
Exhaust 0.40 - 0.75 mm
Setting dimension, cold valve clearance
Inlet 0.25 mm
Exhaust 0.50 mm
Lubrication system
Oil drain plug 60 Nm
Valve cover
Valve cover attachment bolts 10 Nm
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TECHNICAL DATA
1-2 ©200518
Engine, cooling system and fuel system
0
ΧΦ65/65 (II) series
1.3 FILLING CAPACITIES
Lubrication system
CF 65 cooling system
CF65 (II) cooling system
Total capacity (including oil cooler and oil filter) approx. 19.5 litres
Sump capacity, maximum level approx. 17.5 litres
Sump capacity, minimum level approx. 15.4 litres
Cooling system approx. 26 litres
With Allison gearbox approx. 40 litres
Cooling system approx. 23 litres
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©200518 2-1
Steering gear and brake system
TECHNICAL DATA
ΧΦ65/65 (II) series
0
2. STEERING GEAR AND BRAKE SYSTEM
2.1 GENERAL
2.2 TIGHTENING TORQUES
The tightening torques stated in this section are
different from the standard tightening torques
stated in the overview of the standard tightening
torques. The other threaded connections not
specified must therefore be tightened to the
torque stated in the overview of standard
tightening torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
(1) Fit new original attachment bolt and self-locking nut.
Maximum steering ball joint axial clearance 1.5 mm
Bolt, steering column universal joint 56 Nm (1)
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TECHNICAL DATA
2-2 ©200518
Steering gear and brake system
0
ΧΦ65/65 (II) series
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©200518 3-1
Drive and chassis
TECHNICAL DATA
ΧΦ65/65 (II) series
0
3. DRIVE AND CHASSIS
3.1 GENERAL
Allison gearbox
The Allison MD3060 automatic gearbox is
electronically controlled. The oil level can be read
out via the selector keypad. This keypad is
located next to the driver's seat. The oil level can
also be checked using the dipstick.
Dipstick readings:
The oil level when cold must be on the "Cold full"
mark.
R
D
MODE
N
V300392
HOT
FULL
COLD
FULL
HOT
ADD
COLD
ADD
W 3 03 099
"Cold add" add when cold
"Cold full" full when cold
"Hot add" add when hot
"Hot full" full when hot
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TECHNICAL DATA
3-2 ©200518
Drive and chassis
0
ΧΦ65/65 (II) series
3.2 TIGHTENING TORQUES
The tightening torques stated in this section are
different from the standard tightening torques
stated in the overview of the standard tightening
torques. The other threaded connections not
specified must therefore be tightened to the
torque stated in the overview of standard
tightening torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
ZF 6S-850 gearbox
Eaton 6309 A gearbox
B
M3038
A
Level check/filler plug (A) 50 Nm
Drain plug (B) 50 Nm
1
2
3
4
V3 00 376
Level check/filler plug (1) 35 Nm
Drain plug/oil strainer (4) 44 Nm
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©200518 3-3
Drive and chassis
TECHNICAL DATA
ΧΦ65/65 (II) series
0
Allison gearbox
CF65 front axle
(1) Evenly tighten the two U-bolt nuts alternately.
(2) The yellow zinc-plated hexagonal nut can be identified by
the nut height, which is 1 x thread . Evenly tighten the
two U-bolt nuts alternately.
CF65 (II) front axle
CF65 rear axle
(1) Evenly tighten the two U-bolt nuts alternately.
(2) The yellow zinc-plated hexagonal nut can be identified by
the nut height, which is 1 x thread . Evenly tighten the
two U-bolt nuts alternately.
(3) The high hexagonal nut can be identified by the nut
height, which is 1.5 x thread . Evenly tighten the two
U-bolt nuts alternately.
V300371
2
1
Drain plug (1) 28 Nm
Oil filter cover attachment
bolts (2) 55 Nm
U-bolt nut, if flange nut M20, with yellow washer 450 Nm (1)
U-bolt nut, if yellow zinc-plated hexagonal nut
M20, property class 10, with black washer 400 Nm (2)
U-bolt nut 537 Nm
U-bolt nut (leaf suspension), if flange nut M24,
with black washer 750 Nm (1)
U-bolt nut (leaf suspension), if yellow zinc-plated
hexagonal nut M20, property class 10, with black
washer 615 Nm (2)
U-bolt nut (air suspension), if black high hexago-
nal nut M24, property class 10, with black washer 770 Nm (3)
U-bolt nut (air suspension), if yellow zinc-plated
hexagonal nut M20, property class 10, with black
washer 615 Nm (2)
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TECHNICAL DATA
3-4 ©200518
Drive and chassis
0
ΧΦ65/65 (II) series
CF65 (II) rear axle
(1) Evenly tighten the two U-bolt nuts alternately.
Hubs and differentials
3.3 FILLING CAPACITIES
Gearboxes
Note:
The above filling capacities are approximate
capacities, excluding external pipes and cooler.
1132 axle differential
U-bolt nut, leaf suspension 700 Nm (1)
U-bolt nut, air suspension 615 Nm (1)
Filler and drain plugs/hub plugs (Torx) 85 Nm
ZF 6S-850 approx. 7.5 litres
Eaton 6309 A approx. 8.5 litres
Allison MD3060P with 4" sump approx. 20 litres
Minimum caster approx. 15 litres
Maximum caster approx. 17.5 litres
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©200518 1
Contents
THREADED CONNECTIONS
ΧΦ65/65 (II) series
2
2 Threaded connections
CONTENTS
Page Date
1. THREADED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200518
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200518
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THREADED CONNECTIONS
2©200518
Contents
2
ΧΦ65/65 (II) series
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©200518 1-1
Threaded connections
THREADED CONNECTIONS
ΧΦ65/65 (II) series
2
1. THREADED CONNECTIONS
1.1 GENERAL
The components may have threaded connections
that have been treated with lubricant (dipped
threaded connection). Galvanised bolts and nuts
are wax dipped in the factory. Black annealed
and phosphatised bolts and nuts are oil dipped.
The advantage of using dipped nuts and bolts is
that friction during tightening is reduced, so that
the specified pre-tension force can be accurately
obtained. The tightening torque can be reduced
while the pre-tension force remains the same.
To achieve a small spread in the pre-tension
force, the dipped threaded connection must be
tightened accurately.
Therefore, always use a reliable torque wrench
that provides a high degree of accuracy.
Note:
Have torque wrenches regularly inspected and
calibrated.
Re-use of fasteners (bolt/nut/threaded end)
1. Clean the thread (take particular care to
remove locking compound residues) and the
clamping faces
2. Check the thread for damage.
To do so, manually screw a new nut/bolt onto
the thread to be checked.
If the new nut/bolt cannot be fully hand-
screwed onto the entire thread of the
fastener to be checked, the fastener is not
allowed to be re-used.
3. Apply one drop of engine oil to the upper turn
of the bolt (threaded end)/lower turn of the
nut and one drop to the clamping faces
(other lubricants are not allowed).
4. If a locking compound has been specified, oil
should not be applied to the thread.
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THREADED CONNECTIONS
1-2 ©200518
Threaded connections
2
ΧΦ65/65 (II) series
The following applies to all threaded
connections (for both new and used
vehicles):
- in the case of standard connections, apply
the lubricant before fitting, and (re)tighten in
accordance with the standard for dipped
bolts;
- in the case of special connections, apply the
lubricant before fitting, and (re)tighten in
accordance with the values specified in the
instructions.
The instructions for using lubricants also apply to
new bolts from the warehouse. Dry threaded
connections may not be used because of their
highly variable friction coefficients.
Please consult the workshop manual
for the specified tightening torque.
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