DAF CF65, CF75, CF85 Service manual

1

STRUCTURE

ΧΦ65/75/85 series

TECHNICAL DATA

DIAGNOSTICS

INTERNAL CAB COMPONENTS

CAB HEATING

EXTERNAL CAB COMPONENTS

CAB SUSPENSION

CAB TILTING MECHANISM

SEATS

ACCESSORIES

PREWAX TREATMENT

0

1

2

3

4

5

6

7

8

9

10

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1	TECHNICAL DATA
ΧΦ65/75/85 series		Contents
CONTENTS
	Page	Date		0

1. INTERNAL AND EXTERNAL CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200346 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200346 1.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 . . . . 200346

2. CAB SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346 2.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200346

3. CAB TILTING MECHANISM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346 3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346 3.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200346 3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200346

4. SEATS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346 4.1 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200346

5. ACCESSORIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200346

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200346

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TECHNICAL DATA	1
Contents	ΧΦ65/75/85 series

0

2

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1	TECHNICAL DATA
ΧΦ65/75/85 series	Internal and external cab components

	1. INTERNAL AND EXTERNAL CAB COMPONENTS
		0
	1.1 GENERAL

1

2

3

K1 01 008

Legend

1.Day cab

2.Sleeper cab

3.High sleeper cab

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TECHNICAL DATA

1

Internal and external cab components

ΧΦ65/75/85 series

Main dimensions and weights

0

B2

L(slaap)

B1

L(dag)

H SH
K	K1 01 010
K1

Cab dimensions in mm:	Day cab (D)	Sleeper cab (SL)	High sleeper cab (SH)
length (L)	1760	2190	2190
width (B1)	2300	2300	2300
width (B2)	2490	2490	2490
max. height (H)	1730	1703
height (SH)			2400
tilting (K)	1290 (1)	1290 (1)
tilting (K1)			1690 (1)
Cab weights
day cab (D)	820 (2)
sleeper cab (SL)	965 (2)
high sleeper cab (SH)	1085 (2)

(1)Dimensions (K) and (K1) measured from the front of the bumper

(2)Cab weights for fully equipped cabs, including windscreen washer reservoir but excluding suspension

1-2

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1				TECHNICAL DATA
ΧΦ65/75/85 series				Internal and external cab components
Permissible cab weights, day and sleeper cab					0
Item	Description	Max. load		A
A	Roof loading above	150	kg
B	Roof console	15	kg	B
C	Bunk	100	kg
D	Under bunk storage box	50	kg	C

D

25 kg

(2x)

K1 00 997

Permissible cab weights, high sleeper:

A

Item	Description	Max. load
A	Roof loading above	40	kg
B	Roof console	20	kg
C	Below roof console	15	kg
D	Upper bunk	100	kg
E	Upper bunk (folded away)	50	kg
F	Bunk	100	kg
G	Under bunk storage box	50	kg
H	Tool storage	2 x 25 kg

Cab side members

Welding on cab side members is NOT permitted.

When repairing the cab side member, you must use sheet-metal trimming panels.

These must be fitted by spot welding.

E D

B

C

F

G

H

K1 00 998

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TECHNICAL DATA	1
Internal and external cab components	ΧΦ65/75/85 series
Recommended dimensions

0

A		,
		A
				N
	B	O
		,
		B
		I	A’	P’
				P
		J	A

I

B

I

B

J

O

J

P	P’	O O

N

K1 01 645

Recommended dimension between measuring points on the same side.

A - B	818 mm
I - I	2070 mm
J - J	2185 mm
O - O	2247 mm

Recommended dimension between measuring points on opposite sides.

	Short cab	Long cab
A' - N	1367 mm	1797 mm
B' - P	1660 mm (1)	2110 mm (2)
B' - P'

(1)Measurement area between the brackets

(2)Measurement area under the bracket

1-4

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1	TECHNICAL DATA
ΧΦ65/75/85 series	Internal and external cab components

0

,

F

G
		K	,
,			F
F	F
H			,
			G
F			K
			F

H

K

	G
	K1 00 928
Recommended dimension between measuring points on the same side.
F - F'	1524 mm
F' - H	1419 mm
G - K	1662 mm
F' - G	708 mm
Recommended dimension between measuring points on opposite sides.
G' - G	2030 mm
G - F	2612 mm
G - K	2649 mm

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TECHNICAL DATA	1
Internal and external cab components	ΧΦ65/75/85 series

0

X

X

	Z	Z
	T
	L
		S
		R(D)
		R(S)
		Z
	R
X - X	1175 mm
Z - Z	1080 mm
	R(D) (short cab)	R(S) (long cab)
L - R	1176 mm	1606 mm
S - R	621 mm	1051 mm
T - R	1604 mm	2034 mm

X

K1 01 012

1-6

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1

TECHNICAL DATA

ΧΦ65/75/85 series

Internal and external cab components

Windscreens

0

Setting times for windscreen adhesive

Product name

Vehicle mobile

Cab can be

Vehicle usable

DAF number

in workshop

tilted after:

after:

after:

Sikaflex 255 FC

6 hours

8 hours

12 hours

1271129

2 hours

4 hours

6 hours

1241020

Sika Tack Ultrafast

Sika Tack plus booster

1 hour

1 hour

2 hours

1357925

A relative humidity of less than 50% delays

setting, as does a temperature lower than 20 C.

Products applied for bonded windscreens

Product

Properties

Applications

DAF

name

number

Sikaflex 255

Application time 20 min.

Adhesive (cold process) for

1271129

FC

bonding windscreens

Sika Tack

Application time 10 min.

Adhesive (warm process) for

1241020

Ultrafast

bonding windscreens

Sika Tack plus

Application time 5 min.

Adhesive (warm process) for

1357925

booster

bonding windscreens

Sika Aktivator

Minimum drying time 5 min.

Cleaning and activating the glass

1312362

and the frame.

Sika remover

Removal of adhesive which has

1241019

208

not yet set. Do not use on

surfaces to be bonded.

High sleeper cab

Products for gluing high sleeper cab

Product

Properties

Applications

DAF

name

number

Scotch brite

Abrasive

1387923

very fine A

(red)

Sika Cleaner

Minimum drying time 5 min.

Cleaning surface of raised roof

1240548

Sika Primer

Minimum drying time 15 min.

Application to raised roof

1240547

209

Maximum drying time 24 hours

Sika Activator

Minimum drying time 5 min.

Cleaning and activating the cab

1312362

roof edge to be glued

Sikaflex 252

Application time within 10 min.

Gluing raised roof on cab

1286578

(white)

Setting time 2 days

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		TECHNICAL DATA			1
		Internal and external cab components			ΧΦ65/75/85 series
		Windscreen wiper motor
0
		Fitting new rods		Fina Ceran grease
		Motor speed 1		35 rpm
		Motor speed 2		50 rpm
		Heater fan
		Fan setting		series resistors
		1		R1 + R2 + R3
		2		R2 + R3
		3		R3
		4		no series resistors
		Resistor rating:
		R1		4.2 ≥ 0.15
		R2		1.4 ≥ 0.15
		R3		2.2 ≥ 0.15
		Heater control
		Heater valve		black
		Defroster valve LHD		red
		Defroster valve RHD		blue
		Foot valve LHD		green
		Foot valve RHD		brown
		Doors
			Products for gluing anti-whistle weatherstrip
		Product	Properties	Applications		DAF
		name				number
		Scotch brite		Abrasive		1387923
		very fine A
		(red)
		Sika Cleaner	Minimum drying time 5 min.	Cleaning door edge		1240548
		Loctite 401	Dries within a few	Securing anti-whistle		0632192
		(superfast	}seconds	weatherstrip to door edge
		adhesive)
			Setting time 12 hours
		Adjustment dimensions:
		Entire perimeter (except the lower edge)		8 mm clearance
		Bottom		11 mm clearance
		Frame depth		0.5 mm within the cab to 1.5 mm outside the cab

1-8

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1	TECHNICAL DATA
ΧΦ65/75/85 series	Internal and external cab components
Adjustment dimensions of door lock rods

0

507

410

92

89

K1 01 023

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TECHNICAL DATA	1
Internal and external cab components	ΧΦ65/75/85 series

Adjustment dimensions of mirrors without

0	dead angle exterior mirror

D E

C

A

B

B AB

		K1 01 027
Size	Normal (mm)	Normal adjustment angle
A	114	45
B	326	36
C		9
D (main mirror)	1374
E	1406

1-10

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1	TECHNICAL DATA
ΧΦ65/75/85 series	Internal and external cab components
Adjustment dimensions of mirrors with dead
			0
angle exterior mirror

E F

A

B

C D

B C DA

		K1 01 333
Size	Normal (mm)	Normal adjustment angle
A	326	9
B	396	45
C	219	35
D	47	31
E (main mirror)	1379
F	1406

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TECHNICAL DATA	1
Internal and external cab components	ΧΦ65/75/85 series
Dimensions of compulsory field of vision

0

			D1
	A
	A2	D
A	A3					C3
B1	1						C4
B	B5
B2
		C			C1
	B4
B3
			C2
							K100237
Mirror		size 1	size 2	size 3	size 4		size 5
Pavement mirror [A]		1 m	1 m	1.25 m
Wide-angle exterior mirror [B]		2.5 m	15 m	12.5 m	25 m		3 m
Main exterior mirror, co-driver side [C]		30 m	3.5 m	0.75 m	4 m
Main exterior mirror, driver side [D]		10 m	2.5 m

1-12

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1		TECHNICAL DATA
ΧΦ65/75/85 series		Internal and external cab components
1.2 TIGHTENING TORQUES
				0
The tightening torques specified in this section
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 that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Windscreen wiper motor
Attachment on bulkhead	20	- 25 Nm
Motor shaft nut	40	- 50 Nm
Windscreen wiper arm nut	16	- 20 Nm
Roof hatch
Fixing bolts for roof hatch edging	10	Nm
Clutch pedal
Sealant for end of clutch pedal spindle	silicone sealant
Locking bolt	according to standard (1)
(1) Use Loctite 243 to secure
Engine brake switch
Sealant for bolts	silicone sealant
Steering column
Attachment bolt for steering shaft universal joint	54	Nm (1)
Attachments nuts at underside of steering column	23	Nm
Steering wheel attachment nut	65	Nm
(1) Always replace the attachment bolt and nut
Doors
Striker plate Torx screws	23	Nm
Exterior mirrors
Lower pivoting point of D-shaped support, M8 nut	32	Nm
Pavement mirror adjusting nut	7.0 - 8.1 Nm
Raised roof
Attachment bolts for raised roof frame	30	Nm

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TECHNICAL DATA	1
Internal and external cab components	ΧΦ65/75/85 series

0

1-14

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1	TECHNICAL DATA
ΧΦ65/75/85 series	Cab suspension
2. CAB SUSPENSION
			0
2.1 GENERAL

The F230 cab is mounted to the chassis at four points with adjustable coil spring/air suspension elements. These have integral shock absorbers.

Adjusting the coil spring elements:

Front	(size A) 318 ≥ 5 mm

A

K1 01 013

Rear	(size B) 272 ≥ 5 mm

The sizes given above are from the top centre to the support of the spring element (top).

The spring elements can be adjusted in 4 steps of 3 mm.

B

K1 01 014

Spring distance of the coil spring elements:
front	approx. 80 mm (+40/-40)
rear	approx. 60 mm (+30/-30)

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	TECHNICAL DATA		1
	Cab suspension		ΧΦ65/75/85 series
0	Adjusting the air suspension elements:
	Front	(size A) 318 ≥ 5 mm

A

K1 01 413

Rear	(size B) 272 ≥ 5 mm

The sizes given above are from the top centre to the support of the spring element (top).

B

K1 01 000

Spring distance of the air suspension
elements:
front	approx. 80 mm (+40/-40)
rear	approx. 60 mm (+30/-30)
The cab height can be adjusted at the front.

2-2

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1	TECHNICAL DATA
ΧΦ65/75/85 series	Cab suspension

2.2 TIGHTENING TORQUES

0

The tightening torques specified in this section 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 that - unless stated otherwise - these bolts and nuts are of exactly the same length and property class as those removed.

Cab suspension front

A B

H

G

F

E

C

						D
						K1 01 077
A	M8 attachment bolt for tilt assist mechanism/					24 Nm (1)
	cab support
B	M14 cab support bolt					170 Nm
C	M18 locating bolt for cab stabiliser vibration					235 Nm (2)
	damper
D	M14 nut for underside of spring (coil spring
	and air suspension)					50 Nm
E	M14 rearmost bolt for cab stabiliser bearing
	support (left/right)					170 Nm
F	M14 foremost bolt for cab stabiliser bearing
	support (left and right)					170 Nm
G	M8 prestressed bolt for cab stabiliser bearing
	support					35 Nm
H	M14 attachment bolt for top of spring
	(coil spring and air suspension)					170 Nm

(1)Use Loctite 243 to secure

(2)Use Loctite 243 to secure and tighten with cab in fully tilted position.

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TECHNICAL DATA	1
Cab suspension	ΧΦ65/75/85 series
Rear cab suspension
0
	B
	A
	C
	D

E

F

G

			K1 01 078
A	M14 attachment bolt for top of spring
	(coil spring and air suspension)	170	Nm
B	M14 attachment bolt for horizontal damper	170	Nm
C	M14 attachment bolt for horizontal damper	170	Nm
D	M16 attachment bolts for chassis support	300	- 450 Nm
E	M12 attachment bolt for chassis	110	Nm
F	M14 attachment bolt for chassis	170	Nm
G	M14 attachment bolt for day cab spring
	element	170 Nm
	M14 attachment nut for sleeper cab
	spring element	50 Nm

2-4

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1	TECHNICAL DATA
ΧΦ65/75/85 series	Cab tilting mechanism
3. CAB TILTING MECHANISM
			0
3.1 GENERAL
Lifting cylinder
Nominal pressure	400 bar
Cab tilting pump
Nominal pressure	400 bar
Displacement	4 cm3
Pressure limiting valve	400 + 50 bar
Pressure relief valve, level check/filler plug	2.5 bar

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		TECHNICAL DATA	1
		Cab tilting mechanism	ΧΦ65/75/85 series
		3.2 TIGHTENING TORQUES
0
		The tightening torques specified in this section
		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 that - unless stated otherwise - these
		bolts and nuts are of exactly the same length and

property class as those removed.
Lifting cylinder
Lifting cylinder attachment bolt on cab	170 Nm
Lifting cylinder attachment bolt on chassis	60	Nm
Non-return valve seat	40	- 45 Nm

3.3 FILLING CAPACITIES

Cab tilting pump
Capacity of reservoir	480 cm3

3-2

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1	TECHNICAL DATA
ΧΦ65/75/85 series	Seats
4. SEATS
			0
4.1 TIGHTENING TORQUES
The tightening torques specified in this section
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 that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Seats
Seat attachment bolts M8	20 - 25 Nm
Attachment of seat belt mechanism 7/16", UNF-
2B	30 - 40 Nm

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TECHNICAL DATA	1
Seats	ΧΦ65/75/85 series

0

4-2

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1	TECHNICAL DATA

ΧΦ65/75/85 series

5. ACCESSORIES

5.1 GENERAL

The roof spoiler height of the 'aerodynamic' roof spoiler can be adjusted with the adjusting mechanism (B).

Accessories

0

P

B

K1 01 355

Roof spoiler setting range [mm]

	basic	aerodynamic
Day cab	525 - 775	760 - 1040
Sleeper Cab	525 - 775	760 - 1060
High sleeper cab	N/A	215 - 775

Note:

The size stated in the table represents the distance measured between the highest roof spoiler edge (P) and the cab roof plate local to the vehicle centreline.

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TECHNICAL DATA	1
Accessories	ΧΦ65/75/85 series

0

5-2

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1	DIAGNOSTICS
ΧΦ65/75/85 series		Contents
CONTENTS
	Page	Date
1. CAB HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1-1 . . .	. . 200346		1
1.1 Fault finding table, cab heating	1-1	200346

2. CAB SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346 2.1 Fault-finding table, cab suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200346 2.2 Fault-finding table, cab tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200346

3. SEATS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346 3.1 Fault-finding table, Isringhausen 6800 series . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200346

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DIAGNOSTICS	1
Contents	ΧΦ65/75/85 series

1

2

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