DAF 95XF Maintenance Manual
Maintenance manual
95XF
E 200424 DAF Trucks N.V., Eindhoven,
the Netherlands
In the interest of continuing product
development, DAF reserves the right to change
specification or equipment at any time without
notice.
No part of this publication may be reproduced
and/or published by printing, photocopying,
microfilming or by any other means without the
manufacturer’s prior permission in writing.
200424
DW03247106
95XF series
STRUCTURE
TECHNICAL DATA
0
1
THREADED CONNECTIONS
2
FLUIDS, OIL AND LUBRICANTS
3
MAINTENANCE SCHEDULE
4
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
5
200424
TECHNICAL DATA
95XF series Contents
CONTENTS
Page Date
1. XF/XE ENGINE 1-1 200424........................................................ ....
1.1 General 1-1 200424......................................................... ....
1.2 Tightening torques 1-2 200424................................................ ....
1.3 Filling capacities 1-2 200424.................................................. ....
2. VF ENGINE 2-1 200424........................................................... ....
2.1 General 2-1 200424......................................................... ....
2.2 Tightening torques 2-2 200424................................................ ....
2.3 Filling capacities 2-2 200424.................................................. ....
3. GEARBOX 3-1 200424............................................................ ....
3.1 Tightening torques 3-1 200424................................................ ....
3.2 Filling capacities 3-2 200424.................................................. ....
4. REAR AXLE 4-1 200424........................................................... ....
4.1 General 4-1 200424......................................................... ....
4.2 Tightening torques 4-1 200424................................................ ....
4.3 Filling capacities 4-1 200424.................................................. ....
5. RETARDER 5-1 200424........................................................... ....
5.1 Tightening torques 5-1 200424................................................ ....
5.2 Filling capacities 5-1 200424.................................................. ....
6. BRAKES 6-1 200424.............................................................. ....
6.1 General 6-1 200424......................................................... ....
7. STEERING GEAR 7-1 200424...................................................... ....
7.1 General 7-1 200424......................................................... ....
7.2 Tightening torques 7-1 200424................................................ ....
0
8. FRONT AXLE 8-1 200424......................................................... ....
8.1 General 8-1 200424......................................................... ....
8.2 Tightening torques 8-1 200424................................................ ....
9. TRAILING AXLE 9-1 200424....................................................... ....
9.1 General 9-1 200424......................................................... ....
9.2 Tightening torques 9-1 200424................................................ ....
10. LEADING REAR AXLE 09N044 (FTP-TYPE VEHICLES) 10-1 200424.................... ...
10.1 General 10-1 200424......................................................... ...
10.2 Tightening torques 10-1 200424................................................ ...
200424
1
0
TECHNICAL DATA
Contents 95XF series
2
200424
TECHNICAL DATA
95XF series XF/XE engine
1. XF/XE ENGINE
1.1 GENERAL
Valve clearance
Valve clearance (cold/warm):
inlet 0.45 mm
exhaust 0.45 mm
DEB
DEB setting 1.40 mm
V-belt tension
Belt tension “12.5–mm” V-belts in Newtons (N)
Multiple V-belt Single V-belt
raw-edge
New V-belt
2
Setting tension 1200 600
Test tension ≥800 ≥400
Worn-in V-belt
3
Minimum tension 500 250
Adjusting tension 700 350
1
raw-edge
0
1
(1)
Raw-edge V-belts can be recognised by looking at
their edges and at the inside of the V-belt. Except for
the upper part of the belt side, no textile fabric is
present in the rubber (polished sides).
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 inspect whether
the pre-tension complies with the ”test tension”.
If the tension reading is lower than the ”test tension”
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”.
M2121
200424
1-1
TECHNICAL DATA
XF/XE engine 95XF series
1.2 TIGHTENING TORQUES
0
Lubrication system
Oil drain plug 60 Nm
Oil filter 45 Nm
Central bolt for centrifugal oil filter 20 Nm
Valve cover
Valve cover attachment bolts 25 Nm
DEB
DEB attachment bolts 110 Nm
DEB set screw nut 25 Nm
1.3 FILLING CAPACITIES
Oil sump (incl. engine oil filter) approx. 29 litres
Cooling system with integrated ZF retarder approx. 50 litres + 10 litres
1-2
200424
TECHNICAL DATA
95XF series VF engine
2. VF ENGINE
2.1 GENERAL
Valve clearance
(cold)
Inlet valve 0.35 mm
Exhaust valve 0.70 mm
Unit injector
Setting value for unit injector (cold) 0.50 - 0.75 mm
C-brake
Setting value for C-brake (cold) 0.58 mm
V-belt tension
Belt tension for poly V-belts in Newtons (N)
6-rib version 10-rib version
New poly V-belt 700 1100
Run-in poly V-belt
(1)
A run-in poly V-belt is a belt which has been used for
10 minutes or longer.
If the belt tension of a run-in poly V-belt is below the
minimum permitted tension, it should be adjusted to
the maximum permitted tension.
1
300 - 600 450 - 900
0
200424
2-1
TECHNICAL DATA
(
)
VF engine 95XF series
2.2 TIGHTENING TORQUES
0
Lubrication system
Oil drain plug 135 Nm
Oil filter 55 Nm
Valve cover
Valve cover attachment bolts 12 Nm
Lock nut for valve clearance adjusting bolt 55 Nm
Unit injector
Lock nut for unit injector adjusting bolt 65 Nm
Unit injector attachment bolt 40 Nm
C-brake
Lock nut for C-brake adjusting bolt 24 Nm
C-brake housing attachment bolts 102 Nm
Rocker housing
4 25
4 25
Rocker housing attachment
bolts (1 to 6)
Rocker housing attachment
bolts (7-8)
115 Nm
45 Nm
4 25
7 8
7 8
7 8
Rocker shaft
Rocker shaft attachment bolts 156 Nm
2.3 FILLING CAPACITIES
Oil sump (incl. engine oil filter) approx. 42 litres
Cooling system approx. 37 litres
316
316
316
M2144
M2144
M2144
2-2
200424
TECHNICAL DATA
95XF series Gearbox
3. GEARBOX
3.1 TIGHTENING TORQUES
Gearbox
ZF 8S-151/181 and 16S-151/181/221
Level check/filler plug (A) 60 Nm
Drain plug (B) 60 Nm
Drain plug (C/D) 60 Nm
ZF 8S-151/181 and 16S-151/181/221
with integrated retarder
Drain plug (D) 60 Nm
Oil filter attachment bolt (1) 23 Nm
D
B
A
C
0
D
M3023
B
1
C
V300186
M3052
200424
3-1
TECHNICAL DATA
Gearbox 95XF series
3.2 FILLING CAPACITIES
0
ZF 16S-181
Filling capacity approx. 13 litres
ZF 16S-221
Filling capacity approx. 13 litres
ZF 16S-181/221 with integrated retarder
Filling capacity approx. 12 litres
3-2
200424
TECHNICAL DATA
95XF series Rear axle
4. REAR AXLE
4.1 GENERAL
Wheel bearing play, 1347 axle 0.025 - 0.25 mm
4.2 TIGHTENING TORQUES
Filler and drain plugs/hub plugs (Torx wrench) 85 Nm
M24 hexagon U-bolt nut, property class 8 600 Nm*
M24 hexagon U-bolt nut, property class 10 770 Nm*
M22 hexagon U-bolt nut (tandem axle),
property class 10
* Evenly tighten the two U-bolt nuts
alternately.
555 Nm*
4.3 FILLING CAPACITIES
Differential
1347 axle
Minimum caster Maximum caster
Filling capacity approx. 21.5 litres approx. 23.5 litres
0
1354 axle
Filling capacity approx. 16.5 litres
1355T axle
Minimum caster Maximum caster
1st axle capacity approx. 13.0 litres approx. 18.0 litres
2nd axle capacity approx. 11.5 litres approx. 13.0 litres
Wheel hub
1347 axle
Filling capacity per hub approx. 0.9 litres
1354 axle
Filling capacity per hub approx. 2 litres
1355T axle
Filling capacity per hub approx. 2 litres
200424
4-1
0
TECHNICAL DATA
Rear axle 95XF series
4-2
200424
TECHNICAL DATA
95XF series Retarder
5. RETARDER
5.1 TIGHTENING TORQUES
VOITH retarder 133-2
Retarder drain plug 150 Nm
Butterfly valve drain plug 65 Nm
Retarder dipstick 80 Nm
Retarder level check plug 80 Nm
Retarder filler plug M18 x 1.5 50 Nm
M24 x 1.5 80 Nm
Coolant drain plug 50 Nm
5.2 FILLING CAPACITIES
Voith 133-2
Filling capacity 8.2 litres
0
200424
5-1
0
TECHNICAL DATA
Retarder 95XF series
5-2
200424
TECHNICAL DATA
95XF series Brakes
6. BRAKES
6.1 GENERAL
Automatic brake adjuster stroke (09N044 axle,
FTP-type vehicles)
Automatic brake adjuster stroke (other axles) 35 - 40 mm
Reverse torque of adjusting bolt > 18 Nm
25 - 35 mm
0
200424
6-1
0
TECHNICAL DATA
Brakes 95XF series
6-2
200424
TECHNICAL DATA
95XF series Steering gear
7. STEERING GEAR
7.1 GENERAL
Maximum steering ball joint axial clearance 1.5 mm
7.2 TIGHTENING TORQUES
Retention bolt/nut for universal joint steering
box input shaft
* Always replace bolt and nut
30 Nm + 60_ angular displacement*
0
200424
7-1
0
TECHNICAL DATA
Steering gear 95XF series
7-2
200424
TECHNICAL DATA
95XF series Front axle
8. FRONT AXLE
8.1 GENERAL
Wheel bearing play 0.025 - 0.25 mm
8.2 TIGHTENING TORQUES
Wheel hub lock nut 210 30 Nm
Hub cap bolt 9 Nm
Wheel nut (steel/aluminium) 700 Nm
Tighten after 100 km
M22 hexagon U--bolt nut, property class 8 480 Nm*
* Evenly tighten the two U-bolt nuts
alternately.
0
200424
8-1
0
TECHNICAL DATA
Front axle 95XF series
8-2
200424
TECHNICAL DATA
95XF series Trailing axle
9. TRAILING AXLE
9.1 GENERAL
Wheel bearing play 0.025 - 0.25 mm
Hub cap sealant Silicone sealant
9.2 TIGHTENING TORQUES
Wheel hub lock nut, 09N220 axle 560 Nm
Wheel hub lock nut, 09N075 axle 210 30 Nm
Hub cap bolts, 09N220 axle 70 Nm
Wheel nut (steel/aluminium) 700 Nm
Tighten after 100 km
0
200424
9-1
0
TECHNICAL DATA
Trailing axle 95XF series
9-2
200424
TECHNICAL DATA
95XF series Leading rear axle 09N044 (FTP-type vehicles)
10.LEADING REAR AXLE 09N044 (FTP-TYPE VEHICLES)
10.1 GENERAL
Wheel bearing play 0 mm
10.2 TIGHTENING TORQUES
The tightening torques stated in this paragraph
are different from the standard tightening
torques stated in the overview of standard
tightening torques. Any other threaded
connections that are not specified must
therefore be tightened to the tightening 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.
Hub nut 100 Nm
Hub cap 500 Nm
U-bolt nut M20, property class 10 553 Nm
0
(1)
(2)
(1)
Turn back until split pin can be fitted.
(2)
Evenly tighten the two U-bolt nuts alternately.
10-1
0
TECHNICAL DATA
Leading rear axle 09N044 (FTP-type vehicles) 95XF series
10-2
200424
THREADED CONNECTIONS
95XF series Contents
CONTENTS
Page Date
1. THREADED CONNECTIONS 1-1 200424............................................ ....
1.1 General 1-1 200424......................................................... ....
2
200424
1
2
THREADED CONNECTIONS
Contents 95XF series
2
200424
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