DAF XF95 User manual

Maintenance manual
XF95

©200423 DW23211003
©200423 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.

STRUCTURE
©200423
0
1
2
3
4
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ΞΦ95 series
Structure TECHNICAL DATA
THREADED CONNECTIONS
FLUID, OIL AND LUBRICANTS
MAINTENANCE SCHEDULE
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

©200423 1
Contents
TECHNICAL DATA
ΞΦ95 series
0
0 Technica l data
CONTENTS
Page Date
1. ENGINE, COOLING SYSTEM AND FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423
1.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200423
1.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200423
2. STEERING GEAR AND BRAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200423
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200423
2.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200423
3. DRIVE AND CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200423
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200423
3.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200423
3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . 200423

TECHNICAL DATA
2©200423
Contents
0
ΞΦ95 series

©200423 1-1
Engine, cooling system and fuel system
TECHNICAL DATA
ΞΦ95 series
0
1. ENGINE, COOLING SYSTEM AND FUEL SYSTEM
1.1 GENERAL
XE engine
V-belt tension
(1) Raw-edge V-belts can be recognised by the absence of
textile fabric in the rubber, with the exception of the top of
the belt edge, on the edges and the insides of the belt
(polished belt edges). Version: either a toothed or a non-
toothed belt.
(2) After fitting the new V-belt, set the pre-tension to the
"setting tension" and after a trial run check whether the
pre-tension complies with the "test tension". If the test
tension reading is lower than the value specified in the
table, set the V-belt to the minimum "test tension".
(3) If the V-belt tension is lower than the "minimum tension",
set the belt to the "adjusting tension".
Valve clearance
Valve clearance (cold/hot)
Inlet 0.50 mm
Exhaust 0.50 mm
DEB
DEB setting 1.40 mm
V-belt tension, "AVX" raw edge (1)(N)
Application example: air-conditioning compressor drive
New V-belt (2)
Setting tension 600
Test tension 400
Run-in V-belt (3)
Minimum tension 250
Adjusting tension 350
V-belt tension, "XPB" raw edge (1)(N)
Application example: steering pump drive on FAX vehicle
New V-belt (2)
Setting tension 1250
Test tension 950
Run-in V-belt (3)
Minimum tension 750
Adjusting tension 950
M2121

TECHNICAL DATA
1-2 ©200423
Engine, cooling system and fuel system
0
ΞΦ95 series
1.2 TIGHTENING TORQUES
The tightening torques specified in this paragraph
are different from the standard tightening torques
cited in the overview of the standard tightening
torques. The other threaded connections not
specified must therefore be tightened to the
torque cited in the overview of standard
tightening torques.
When attachment bolts and nuts are replaced, it
is important - unless stated otherwise - that these
bolts and nuts are of exactly the same length and
property class as those removed.
XE engine
1.3 FILLING CAPACITIES
XE engine
Lubrication system
Oil drain plug 60 Nm
Oil filter screw cap 40 Nm
Centrifugal filter central bolt 20 Nm
Fuel system
Fuel filter screw cap 25 Nm
Cylinder head cover
Cylinder head cover attachment bolts 25 Nm
DEB
DEB attachment bolts 110 Nm
DEB set screw nut 25 Nm
V-belt tensioner
Central bolt, tensioning gear 110 Nm
Lubrication system
Total capacity (including oil cooler and oil filter) approx. 34 litres
Capacity of oil sump, maximum level approx. 30 litres
Capacity of oil sump, minimum level approx. 22 litres
Cooling system
Cooling system approx. 47 litres
With integrated retarder approx. 57 litres

©200423 2-1
Steering gear and brake system
TECHNICAL DATA
ΞΦ95 series
0
2. STEERING GEAR AND BRAKE SYSTEM
2.1 GENERAL
Steering gear
Braking system
Maximum steering ball joint axial clearance 1.5 mm
Brake travel of automatic brake adjuster (Haldex) 35 - 40 mm
Brake travel of automatic brake adjuster
(FTP axle) 25 - 35 mm
Reverse torque of adjusting bolt > 18 Nm

TECHNICAL DATA
2-2 ©200423
Steering gear and brake system
0
ΞΦ95 series
2.2 TIGHTENING TORQUES
Steering gear
The tightening torques stated in this paragraph
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.
Note:
- The two plugs are interchangeable.
(1) Fit new original attachment bolt and nut.
A
S7 00 906
Filter plug without flange (A),
fluid flow control valve block
of EMAS system 125 Nm ≥5 Nm
B
S7 00 907
Filter plug with flange (B),
fluid flow control valve block
of EMAS system 270 Nm ≥20 Nm
Attachment bolt, steering column universal joint 54 Nm + 4 Nm (1)

©200423 3-1
Drive and chassis
TECHNICAL DATA
ΞΦ95 series
0
3. DRIVE AND CHASSIS
3.1 GENERAL
Wheel bearing play, 09N044 leading rear axle 0 mm

TECHNICAL DATA
3-2 ©200423
Drive and chassis
0
ΞΦ95 series
3.2 TIGHTENING TORQUES
The tightening torques stated in this paragraph
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.
Gearbox
ZF 16S-151/181/221
ZF 16S-151/181/221 with integrated retarder
M3023
D
A
BC
Level check/filler plug (A) 60 Nm
M24 drain plug (B) 60 Nm
M38 drain plug (B) 120 Nm
Drain plug (C/D) 60 Nm
M3051
A
Level check/filler plug (A) 60 Nm

©200423 3-3
Drive and chassis
TECHNICAL DATA
ΞΦ95 series
0
ZF AS Tronic
ZF AS Tronic with integrated retarder
B
C
V300186
D
M24 drain plug (B) 60 Nm
M38 drain plug (B) 120 Nm
Drain plug (C/D) 60 Nm
M3052
1
Oil filter attachment bolt (1) 23 Nm
B
AC
G000243
Level check/filler plug (A) 60 Nm
Drain plug (B/C) 60 Nm
A
BC
G000250
Level check/filler plug (A) 60 Nm
Drain plug (B/C) 60 Nm

TECHNICAL DATA
3-4 ©200423
Drive and chassis
0
ΞΦ95 series
Front axle(s)
U-bolt nut:
(1) Evenly tighten the two U-bolt nuts alternately.
(2) The yellow zinc-plated hexagonal nut can be recognised
by the nut height, which is 1 X thread . Evenly tighten the
two nuts, alternately.
Leading rear axle
U-bolt nut:
(1) Evenly tighten the two U-bolt nuts alternately.
(2) The yellow zinc-plated hexagonal nut can be recognised
by the nut height, which is 1 X thread . Evenly tighten the
two nuts, alternately.
Leading rear axle 09N044 (FTP-type vehicles)
U-bolt nut:
(1) Evenly tighten the two U-bolt nuts alternately.
(2) Turn back until the split pin can be fitted.
M3052
1
Oil filter attachment bolt (1) 23 Nm
If flange nut M20, property class 10, with
yellow washer 450 Nm ≥40 Nm (1)
If yellow zinc-plated hexagonal nut M20,
property class 10, with black washer 400 Nm ≥40 Nm (2)
If flange nut M22, property class 10, with
yellow washer 700 Nm ≥50 Nm (1)
If yellow zinc-plated hexagonal nut M22,
property class 10, with black washer 530 Nm ≥40 Nm (2)
If flange nut M22, property class 10, with
yellow washer 700 Nm ≥50 Nm (1)
If yellow zinc-plated hexagonal nut M22,
property class 10, with black washer 530 Nm ≥40 Nm (2)
U-bolt nut M20, property class 10 553 Nm (1)
Hub nut 100 Nm (2)
Hub cap 500 Nm

©200423 3-5
Drive and chassis
TECHNICAL DATA
ΞΦ95 series
0
Rear axle(s)
U-bolt nut:
(1) Evenly tighten the two U-bolt nuts alternately.
(2) The yellow zinc-plated hexagonal nut can be recognised
by the nut height, which is 1 X thread . Evenly tighten the
two nuts, alternately.
(3) The high hexagonal nut can be recognised by the nut
height, which is 1.5 X thread . Evenly tighten the two
nuts, alternately.
Tandem axle
U-bolt nut:
(1) Evenly tighten the two U-bolt nuts alternately.
(2) The yellow zinc-plated hexagonal nut can be recognised
by the nut height, which is 1 X thread . Evenly tighten the
two nuts, alternately.
(3) The high hexagonal nut can be recognised by the nut
height, which is 1.5 X thread . Evenly tighten the two
nuts, alternately.
Pull rod nut:
(1) Evenly tighten the two U-bolt nuts alternately.
(2) The yellow zinc-plated hexagonal nut can be recognised
by the nut height, which is 1 X thread . Evenly tighten the
two nuts, alternately.
If flange nut M24, property class 10, with
yellow washer 750 Nm ≥50 Nm (1)
If yellow zinc-plated hexagonal nut M24,
property class 10, with black washer 615 Nm ≥50 Nm (2)
If high hexagonal nut M24, property class 10,
with black washer 770 Nm ≥60 Nm (3)
Filler and drain plugs/hub plugs (Torx wrench) 85 Nm
If flange nut M20, property class 10, with
yellow washer 450 Nm ≥40 Nm (1)
If yellow zinc-plated hexagonal nut M20,
property class 10, with black washer 400 Nm ≥40 Nm (2)
If yellow zinc-plated hexagonal nut M24,
property class 10, with black washer 615 Nm ≥50 Nm (2)
If high hexagonal nut M24, property class 10,
with black washer 770 Nm ≥60 Nm (3)
If flange nut M22, property class 10 650 Nm ≥50 Nm (1)
If yellow zinc-plated hexagonal nut M22,
property class 10, with black washer 480 Nm ≥40 Nm (2)
Filler and drain plugs/hub plugs (Torx wrench) 85 Nm

TECHNICAL DATA
3-6 ©200423
Drive and chassis
0
ΞΦ95 series
3.3 FILLING CAPACITIES
Gearbox
ZF 16S-151
ZF 16S-181
ZF 16S-221
ZF 16S-151 with integrated retarder
ZF 16S-181 with integrated retarder
ZF 16S-221 with integrated retarder
ZF AS Tronic gearboxes
ZF 12 AS 1930/2330
ZF 12 AS 2540/16 AS 2230/2630
ZF 12 AS 1931/2331 with integrated retarder
ZF 12 AS 2541/16 AS 2231/2631 with
integrated retarder
Rear axle
Filling capacity approx. 11 litres
Filling capacity approx. 13 litres
Filling capacity approx. 13 litres
Filling capacity approx. 11 litres
Filling capacity approx. 12 litres
Filling capacity approx. 12 litres
Filling capacity approx. 11 litres
Filling capacity approx. 12 litres
Filling capacity approx. 12 litres
Filling capacity approx. 13 litres
Differential Filling capacity
at minimum
caster
Filling capacity
at maximum
caster
1347 axle approx. 21.5 litres approx. 23.5 litres
1354 axle approx. 16.5 litres approx. 16.5 litres
1355(T) axle (1st axle) approx. 13.0 litres approx. 18.0 litres
1355(T) axle (2nd axle) approx. 11.5 litres approx. 13.0 litres
Wheel hub Filling capacity
per hub
1354 axle approx. 2 litres
1355(T) axle approx. 2 litres

©200423 1
Contents
THREADED CONNECTIONS
ΞΦ95 series
2
2 Threaded connections
CONTENTS
Page Date
1. THREADED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423

THREADED CONNECTIONS
2©200423
Contents
2
ΞΦ95 series