DAF CF65, CF75, CF85 Service manual

3

CF65/75/85 series

PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT)

STRUCTURE

TECHNICAL DATA

0

DIAGNOSTICS

1

MECHANICAL GEARBOX CONTROL

2

3

GEARBOX - PNEUMATIC SECTION

4

ZF 6S-850 GEARBOX

5

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

6

7

8

9

10

11

12

ᓻ 200337

PTO

13

AS TRONIC GEARBOX

14

3

TECHNICAL DATA

CF65/75/85 Serie Contents

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.................................................. ....

0

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 AUTOMA TIC 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 1 1-1 200337......................................................... ...

1 1.1 General 11-1 200337......................................................... ...

1 1.2 Tightening torques 1 1-1 200337................................................ ...

ᓻ 200337

6-1

0

3TECHNICAL DATA

Contents CF65/75/85 Serie

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.................................................. ...

6-2

ᓻ 200337

3

CF65/75/85 series Mechanical gearbox control

TECHNICAL DATA

1. MECHANICAL GEARBOX CONTROL

1.1 GENERAL

0

- 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.

ᓻ 200337

V300382

1-1

0

TECHNICAL DATA

3

Mechanical gearbox control CF65/75/85 series

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.

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.

Bonding the gear lever into the ball

De-greaser DAF No. 1322827
Glue DAF No. 1340646

V300383

A

V300833

Bonding the ball joint to the control rod

De-greaser DAF No. 1322827
Glue DAF No. 1340646

1-2

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3

TECHNICAL DATA

CF65/75/85 series Mechanical gearbox control

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

Attachment nuts (3), gear
lever unit

Attachment bolt, selector shaft
lever to gearbox selector
housing

40 Nm

27 Nm

40 Nm

0

312

V300275

ᓻ 200337

1-3

0

TECHNICAL DATA

Mechanical gearbox control CF65/75/85 series

3

1-4

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series Pneumatically assisted gearbox control (Servoshift)

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.

0

Air pipe banjo bolt (1) 38 Nm
Attachment bolts:
Servoshift unit (2) 23 Nm

2

1

V300328

ᓻ 200337

2-1

0

TECHNICAL DATA

Pneumatically assisted gearbox control (Servoshift) CF65/75/85 series

3

2-2

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series Pneumatic section of gearbox

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)
Total clutch pedal
travel (D)

NEUTRAL POSITION VALVE

Situation with separate air distribution block:
2 x 3/2-way valve
Servicepressure 6.5to10bar
Pipe connection M14 x 1.5

123  2mm

154  2mm

0

A

Situation with integrated air distribution
block:
3/2-way valve

Servicepressure 6.5to10bar
Pipe connection Not applicable

1

B

C

D

V300315

ᓻ 200337

3-1

TECHNICAL DATA

3

Pneumatic section of gearbox CF65/75/85 series

GEAR LEVER SELECTOR VALVE

0

Range-change gear

Connection point

1 Supply Black

3 Bleed Red

21 Range-change gear

command (A)

Colour

White

B

A

21

1

PNEUMATIC SYMBOL

3

13

III

Range

21

V300488

V300267

3-2

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series Pneumatic section of gearbox

GEAR LEVER SELECTOR VALVE

Range-change gear and splitter

Connection point

1 Supply Black

3 Bleed Red

21 Range-change gear

command (A)

22 Splitter command (B) Yellow

Colour

White

0

B

A

21

1

22

PNEUMATIC SYMBOL

Range-change gear and splitter

Position

GP Range-change gear

GV Splitter

Function

3

22 21

H

L

GV GP

1

V300489

H

L

V300161

ᓻ 200337

3-3

TECHNICAL DATA

3

Pneumatic section of gearbox CF65/75/85 series

3.2 TIGHTENING TORQUES

0

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

3-4

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3

TECHNICAL DATA

CF65/75/85 series ZF 6S-850 gearbox

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

Output shaft bearing axial play

Output shaft bearing axial play 0.00 - 0.10 mm

3

6
8

0

1

2
4

5
7

9

10

V300049

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

ᓻ 200337

4-1

TECHNICAL DATA

3

ZF 6S-850 gearbox CF65/75/85 series

4.2 TIGHTENING TORQUES

0

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)

ZF 6S-850 7.5 7.5

First filling, e.g. during repair

(litres)

4-2

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series ZF 8/9/16S-109 gearbox

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

Output shaft bearing axial play

Output shaft bearing axial play 0.00 - 0.10 mm

3

6
8

0

1

2
4

5
7

9

10

V300049

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

ᓻ 200337

5-1

TECHNICAL DATA

3

ZF 8/9/16S-109 gearbox CF65/75/85 series

5.2 TIGHTENING TORQUES

0

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

5-2

ᓻ 200337

3

CF65/75/85 series ZF 8/9/16S-109 gearbox

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

TECHNICAL DATA

A

B

2

B

M3017

0

1

V300372

1

M3052

ᓻ 200337

5-3

TECHNICAL DATA

3

ZF 8/9/16S-109 gearbox CF65/75/85 series

5.3 FILLING CAPACITIES

0

Filling amounts, ZF gearboxes without
intarder

Gearbox type

ZF 8/16S-109 9 9.5

ZF 9/S-109 8 8.5

Filling amounts, ZF gearboxes with
integrated intarder

Gearbox type

ZF 8/16S-109 12.5 22

ZF 9S-109 12 21

Filling amounts at oil change

Filling amounts at oil change

(litres)

(litres)

First filling, e.g. during repair

(litres)

First filling, e.g. during repair

(litres)

5-4

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series ZF 8/16S-151/181 and 16S-221 gearboxes

6. ZF 8/16S-151/181 AND 16S-221 GEARBOXES

6.1 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

Output shaft bearing axial play

Output shaft bearing axial play 0.00 - 0.10 mm

3

6
8

0

1

2
4

5
7

9

10

V300049

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

Retaining element

Standard spring force 168 N
Heavy-duty spring force 191 N

ᓻ 200337

6-1

TECHNICAL DATA

3

ZF 8/16S-151/181 and 16S-221 gearboxes CF65/75/85 series

6.2 TIGHTENING TORQUES

0

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

M12 x 70 drive flange - 8.8 60 Nm
M12 x 60 drive flange - 10.9 120 Nm
M12 x 70 drive flange - 10.9 120 Nm
M12 x 165 drive flange - 10.9 120 Nm

Gearbox front cover

Attachment bolts 46 Nm

Bearing cover

Output shaft bearing cover 49 Nm
Control bearing cover 23 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

6-2

ᓻ 200337

3

CF65/75/85 series ZF 8/16S-151/181 and 16S-221 gearboxes

TECHNICAL DATA

Plugs

Gearbox with integrated intarder
Drainplug(B) M24 60Nm
Drain plug (B) M38 120 Nm
Drain plug (D) 60 Nm
Level check/filler plug (4) 60 Nm
Filler plug (5) 60 Nm
Oil filter attachment bolt (1) 23 Nm

D

B

0

C

V300186

4

5

1

V300260

M3052

ᓻ 200337

6-3

TECHNICAL DATA

3

ZF 8/16S-151/181 and 16S-221 gearboxes CF65/75/85 series

6.3 FILLING CAPACITIES

0

Filling amounts, ZF gearboxes without
intarder

Gearbox type

ZF 8/16S-151 11 11

ZF 8/16S-181 13 13

ZF 16S-221 13 13

Filling amounts, ZF gearboxes with
integrated intarder

Gearbox type

ZF 8/16S-151 11 18.5

ZF 8/16S-181 12 21.5

ZF 16S-221 12 21.5

Filling amounts at oil change

Filling amounts at oil change

(litres)

(litres)

First filling, e.g. during repair

(litres)

First filling, e.g. during repair

(litres)

6-4

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series Eaton FS/6309A gearbox

7. EATON FS/6309A GEARBOX

7.1 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.

Eaton gearbox type-plate

1. Type of gearbox

2. Specification no. Eaton

3. DAF article Eaton code

4. Series no. Eaton

5. Production date code

The Eaton specification number is unique for
each customer and gives detailed information on
the development level of the gearbox.
The number must be quoted whenever
replacement parts are ordered.

Input shaft play adjusting rings: Colour coding:

3.70 mm Red, green, white

3.75 mm Yellow, green, blue

3.80 mm Blue, green, white

3.85 mm Red, green, yellow

3.90 mm Green, green, white

3.95 mm Red, green, red

0

Secondary shaft pre-load

New bearings 0.075 - 0.125 mm
Original bearings 0.000 - 0.050 mm

Sealant

Sealing compound for seal contact surfaces of
drive flange oil seal housing

Input shaft Lithium-based grease, class NLGI 3

Filter/governor

Governed pressure 5.3 - 5.7 bar

Loctite 518

ᓻ 200337

7-1

TECHNICAL DATA

3

Eaton FS/6309A gearbox CF65/75/85 series

7.2 TIGHTENING TORQUES

0

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.

Drive flange

M39 drive flange nut 650 Nm
Drive flange oil seal housing attachment bolts 60 Nm

Gearbox front cover

Attachment bolts 37 Nm

Selector shaft housing

Selector shaft housing attachment bolts 37 Nm
Retaining cover attachment bolts 22 Nm
M8 shifting arm lock nut 25 Nm
M8 shifting arm lock nut 25 Nm
End cover attachment bolts 22 Nm

(1)

(2)

Bleed valve

Attachment bolts 19 Nm

Bearing cover

Output shaft bearing cover 25 Nm
Air connection banjo bolt 38 Nm

Filter/governor

M6 attachment bolts 13 Nm
Cover 25 Nm

Selector valve

M6 attachment bolts 22 Nm
M16 discharge valve attachment bolts 19 Nm
M8 cover plate attachment bolts 22 Nm

Range-change cylinder

M8 cover plate attachment bolts 17 Nm
M16 nut on piston 105 Nm

7-2

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series Eaton FS/6309A gearbox

Plugs

Drainplug 50Nm
Level check/filler plug 50 Nm

(1) Use new nut
(2) Loctite 243

7.3 FILLING CAPACITIES

Gearbox capacity

Type

FS/6309A 8.5 litres

Contents

0

ᓻ 200337

7-3

0

TECHNICAL DATA

Eaton FS/6309A gearbox CF65/75/85 series

3

7-4

ᓻ 200337

3

CF65/75/85 series Allison automatic gearbox

TECHNICAL DATA

8. ALLISON AUTOMATIC GEARBOX

8.1 GENERAL

Allison transmission, used in the CF65/75, is
electronically controlled and has its own
diagnostic system that saves any faults in the
memory of the ECU (Electronic Control Unit).
The faults can be read at a later date. The
system is operated and the faults are read via
the selector keypad. The “Selector keypad” fitted
with a display is located next to the driver’s seat
and replaces the gear lever with manual
stick-shift gearboxes.

R

N

D

0

MODE

V300392

ᓻ 200337

8-1

TECHNICAL DATA

3

Allison automatic gearbox CF65/75/85 series

8.2 TIGHTENING TORQUES

0

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 bleeder 14 Nm

M14 x 2.0 drive flange attachment bolt 75 Nm

Gearbox rear mounting bracket 100 Nm
PTO bracket 55 Nm

Gearbox with flywheel housing adapter, M10 x

1.5

Flex plates to flex plate adapter

CF65 68 Nm
CF75 34 Nm

Flex plate adapter to torque converter 34 Nm

55 Nm

Hydraulic pipes to oil cooler 60 Nm

Gearbox main connector 2.5 Nm

Attachment bolts for oil filter caps 55 Nm
Oil drain plugs 28 Nm

Coolant pipe attachment 55 Nm

Molycote for the top bearing of the torque
converter on installation

BR2S or BR2 Plus

8-2

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series Allison automatic gearbox

8.3 FILLING CAPACITIES

Allison automatic gearbox oil capacities

Type of gearbox

Capacity at first filling Capacity at second filling

MD 3060P 4″ oil sump 27 litres 20 litres

MD 3066P 4″ oil sump 27 litres 20 litres

MD 3560P 4″ oil sump 27 litres 20 litres

The oil level when cold must be on the “Cold
full” mark.

Dip-stick readings:

- “Cold add” = add when cold

- “Cold full” = full when cold

- “Hot add” = add when hot

- “Hot full” = full when hot

HOT

FULL

HOT

ADD

FULL

COLD

0

ADD

COLD

W 3 03 099

ᓻ 200337

8-3

0

TECHNICAL DATA

Allison automatic gearbox CF65/75/85 series

3

8-4

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series Clutch

9. CLUTCH

9.1 GENERAL

CLUTCH RELEASE ASSEMBLIES

Clutch release assembly

Engine type

Clutch release assembly type Note

0

V300390

CE MF 395

MF 395 with extended service life

PE MF 395

MF 395 with extended service life
MFZ 430
MFZ 430 with extended service life

XE MFZ 430

MFZ 430 with extended service life

Automatically adjusting clutch release
assembly and wear indicator

Automatically adjusting clutch release
assembly

Automatically adjusting clutch release
assembly and wear indicator

Automatically adjusting clutch release
assembly and wear indicator

ᓻ 200337

9-1

0

TECHNICAL DATA

3

Clutch CF65/75/85 series

CLUTCH PLATE

V300391

Clutch plate

Engine type

Clutch plate Lining thickness

(mm)

Splines Thrust bearing

CE 395 WGTZ

395 WGTZ
395 WGTZ
395 WGTZ

PE 395 WGTZ

395 WGTZ
430 GTZ
430 GTZ

XE 430 GTZ

430 GTZ

Note:

All clutch plates are single dry plate versions
and have a lining of the Valeo-Raybestos B9605
asbestos-free type.
The AS Tronic gearbox is fitted with a clutch
plate with the following type of lining: Valeo F202
asbestos-free.

3
3
5
5

3
5
3
5

3
5

1.5″

1.75″

1.5″

1.75″

1.75″

1.75″
2″
2″

2″
2″

KZI-4
KZI-4
KZI-4
KZI-4

KZI-4
KZI-4
KZIZ-5
KZIZ-5

KZIZ-5
KZIZ-5

9-2

ᓻ 200337

3

CF65/75/85 series Clutch

Clutch pedal

Clutch pedal proximity
sensor (A)
Clutch pedal free
travel (B)
GV valve begins to
open (C)
Total clutch pedal
travel (D)

1-0+1mm

approx. 2-4mm

123  2mm

154  2mm

TECHNICAL DATA

A

1

0

C

B

D

V300315

ᓻ 200337

9-3

0

TECHNICAL DATA

Clutch CF65/75/85 series

Main cylinder

Maximum piston stroke 34 mm
Pressure pin setting (E) approx. 0.2 - 0.8 mm
Mounting seals Silicone grease

3

1

2

3

4

E

5

7

6

V300411

9-4

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series Clutch

9.2 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.

Main cylinder

Pressure pin attachment nut 55 Nm
Bleeder 8 Nm
Steel pipe coupling 40 Nm

Clutch release assembly
ZF gearboxes

Attachment bolts, clutch release assembly to
flywheel
Attachment bolt, automatically adjusting clutch
release assembly stop plate

54 Nm

39 Nm

0

(1)

(1) Loctite 648

ZF 6S-850

Attachment bolts, clutch release assembly to
flywheel
Attachment bolts, clutch lever to gearbox 27 Nm

8/9/16S-109

M16 round bolt, clutch lever to clutch housing 90 Nm

8/16S-151/181/221

M8 attachment bolts, clutch lever to gearbox 30 Nm

EATON FS/6309A gearbox

Attachment bolts, clutch release assembly to
flywheel
Attachment bolts, clutch lever to gearbox 27 Nm

54 Nm

54 Nm

ᓻ 200337

9-5

TECHNICAL DATA

Clutch CF65/75/85 series

AS TRONIC gearbox

M12 attachment bolts, clutch lever to gearbox 79 Nm

3

0

AS TRONIC clutch unit

Clutch unit attachment nut 23 Nm
Clutch unit stud 10 Nm
Bleed screw, clutch unit 22 Nm
Compressed air connection 50 Nm

9.3 FILLING CAPACITIES

Clutch operating unit

First filling  0.4 litres

9-6

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series Prop shafts

10. PROP SHAFTS

10.1 GENERAL

For the CF 65/75/85 vehicle series, DAF has
one manufacturer of prop shafts, Klein.
Klein shafts can be identified by their highly
bevelled flanges.

Inspection

There must be no clearly noticeable play on
universal joints, centre bearing or sliding clutch.

Universal joint radial play 0.01 - 0.05 mm
Maximum permissible axial play of universal

joints

CF65

Balancing speed (∅ 85 x 5 mm)
retracted length ≤ 1750 mm max. n = 3000 n/
Length of idler shaft ≤ 1950 mm

CF75

Balancing speed (∅ 120 x 3 mm)
retracted length ≤ 2120 mm max. n = 3000 n/
Length of idler shaft ≤ 2340 mm

0.3 mm

0

min

min

CF85

Balancing speed (∅ 120 x 5 mm)
retracted length ≤ 2120 mm max. n = 3000 n/
Length of idler shaft ≤ 2340 mm

Balanceertoerental (∅ 140 x 5 mm)
retracted length ≤ 2320 mm max. n = 3000 n/
Length of idler shaft ≤ 2500 mm

Centre bearings

IfalubricatingnippleisfittedtotheCF65/75/85,
it must be lubricated.

min

min

ᓻ 200337

10-1

0

TECHNICAL DATA

3

Prop shafts CF65/75/85 series

Maximum permissible axial play of slide joint 0.25 mm

D

AB

10.2 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.

C

45

V300444

Attachment bolts, drive flanges
M12 - 10.9 110 Nm
M14 - 10.9 170 Nm

Centre bearing central nut
M24 x 1.5 250 Nm
M40 x 1.5 350 Nm
M55 x 1.5 380 Nm

Centre bearing attachment bolts 170 Nm

(1) Loctite 243

10-2

(1)

ᓻ 200337

3

CF65/75/85 series Prop shafts

10.3 FILLING CAPACITIES

TECHNICAL DATA

Note:

All prop shafts are maintenance-free, although
vehicles that are used in heavy conditions are
fitted as standard with lubricating nipples on the
universal joints.

Clean grease must emerge visibly from all four
needle sleeve seals of the spider during
greasing.

0

ᓻ 200337

10-3

0

TECHNICAL DATA

Prop shafts CF65/75/85 series

3

10-4

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series ZF intarder

11. ZF INTARDER

11.1 GENERAL

Axial play

Stator 0  0.05 mm
Output shaft bearing 0 - 0.1 mm
Oil pump external rotor 0.03 - 0.05 mm

Intarder drive sprocket

Heat in oven for a maximum of 15 minutes 130_ - 150_C

11.2 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.

0

ᓻ 200337

11-1

0

TECHNICAL DATA

3

ZF intarder CF65/75/85 series

Drive flange attachment bolts

Attachment bolts (8.8) 60 Nm
Attachment bolts (10.9) 120 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

Attachment bolts

rear gearbox cover 50 Nm

Heat exchanger

Studs in heat exchanger 18 Nm
Attachment nuts 62 Nm
Oil connection flange attachment bolt 23 Nm
Heat exchanger attachment surfaces Loctite 574

Hydraulic control unit

M10 attachment bolts 50 Nm

Sensors and transmitters

Temperature transmitter 40 Nm
Air supply valve 23 Nm
Proportional valve 23 Nm

Intarder attachment to gearbox

M10 attachment bolts 50 Nm

Oil pump

Attachment bolts 23 Nm

Oil filter

Attachment bolt 23 Nm

(1) Secure with Loctite 574

(1)

(1)

(1)

11-2

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series PTO

12. PTO

12.1 GENERAL

For the CF65/75/85 vehicle series, DAF has two
sorts of PTO:
the DAF engine PTO and the
ZF/Eaton gearbox PTOs.
The DAF engine PTO can be recognised by the
position of the PTO, i.e. on top of the flywheel
housing. The ZF/Eaton PTOs can be recognised
by the position at the rear of the gearbox.

DAF ENGINE PTO

Axial play
Drive gears between crankshaft and PTO 0.15 - 0.30 mm
PTO housing prop shaft bearings 0.02 - 0.1 mm

ZF GEARBOX PTO

Bearing axial play

Axial play on gearbox output shaft, in case of
attachment of N 211/10 PTO on gearbox
without intarder

Axial play in case of attachment of NL/1 PTO
on N211/10 PTO

0 - 0.1 mm

0 - 0.2 mm

0

ᓻ 200337

12-1

TECHNICAL DATA

3

PTO CF65/75/85 series

12.2 TIGHTENING TORQUES

0

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.

DAF ENGINE PTO

Main shaft lock nut 500 Nm
Gear attachment bolt in flywheel housing 110 Nm
Sealing plate at rear of flywheel housing 30 Nm
Output shaft flange bolt 110 Nm
Gear shift lever 30 Nm
PTO operating cylinder cover 30 Nm
Operating cylinder housing expansion plug Loctite 510
Attachment bolts, shift control on gearbox 30 Nm
PTO gearbox stud 68 Nm
Attachment nut, drive housing stud 68 Nm

(1)

(1)

(1)

Attachment, PTO housing to flywheel housing Loctite 510
Attachment bolt, PTO housing to flywheel

housing
Oil pipe banjo bolts 50 Nm

ZF GEARBOX PTO

Attachment NH/1-/4 and NL/1-/4

Install attachment studs with a liquid gasket 25 Nm
Nuts for fastening attachment to gearbox 86 Nm

Attachment NH/1-/4 and NL/1-/4 on
AS Tronic gearbox

Install attachment studs with a liquid gasket 18 Nm
Nuts for fastening attachment to gearbox 65 Nm

40 Nm

12-2

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series PTO

Attachment N221/10

Drive flange 120 Nm
Side cover attachment bolts 23 Nm
Bolts for fastening attachment to gearbox 79 Nm

Attachment N AS/10

Drive flange 120 Nm
Side cover attachment bolts 23 Nm
Bolts for fastening attachment to gearbox 79 Nm

(1) Secure with Loctite 243

EATON GEARBOX PTO

Attachment Z81

Drive flange attachment bolt 100  5Nm
Install attachment studs with a liquid gasket 28 Nm
Nuts for fastening attachment to gearbox 65 Nm

0

Attachment 2266

Drive flange attachment bolt 100  5Nm
Drive shaft cover attachment bolts 75  4Nm
Bolts for fastening attachment to gearbox 50  2.5 Nm

ᓻ 200337

12-3

TECHNICAL DATA

3

PTO CF65/75/85 series

12.3 FILLING CAPACITIES

0

Extra filling capacities, ZF gearbox PTOs

PTO TYPE

NH/1B 0.2

NL/1B 0.2

NH/1C 0.2

NL/1C 0.2

NH/4B 0.5

NL/4B 0.5

NH/4C 0.5

NL/4C 0.5

N221/10B 1.0

N221/10C 1.0

N221/10 IT 1.0

N221/10 C IT 1.0

N221/10 B PL 1.0

N221/10 C-PL 1.0

FILLING CAPACITY

(l)

N AS/10 B 1.0

N AS/10 B IT 1.0

N AS/10 C 1.0

N AS/10 C IT 1.0

N AS/10 B+C 1.0

N AS/10 B+C IT 1.0

Extra filling capacities, EATON gearbox PTO

PTO TYPE

2266 0.25

FILLING CAPACITY

(l)

12-4

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series AS TRONIC gearbox

13. AS TRONIC GEARBOX

13.1 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

Output shaft bearing axial play

Output shaft bearing axial play 0 - 0.1 mm

1
2

5
7
9

0

1
3

4
6

8

10

V300739

ᓻ 200337

13-1

TECHNICAL DATA

3

AS TRONIC gearbox CF65/75/85 series

13.2 TIGHTENING TORQUES

0

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

Attachment bolts 120 Nm

Gearbox front cover

Attachment bolts 23 Nm
Sealant Loctite 574

Bearing cover

Attachment bolts, output shaft bearing cover 46 Nm
Sealant, output shaft bearing cover Loctite 574

Gearbox modulator

Attachment bolts 23 Nm
Bleeder 10 Nm

Clutch unit

Bleed screw 22 Nm
Compressed air connection 50 Nm

13-2

ᓻ 200337

3

TECHNICAL DATA

CF65/75/85 series AS TRONIC gearbox

Plugs

AS Tronic

Drain plug (B, C) 60 Nm
Level check/filler plug (A). 60 Nm

AC

0

AS Tronic with intarder

Drain plug (B, C) 60 Nm
Level check/filler plug (A). 60 Nm

Oil filter attachment bolt (1) 23 Nm

B

G000243

A

B

C

G000250

ᓻ 200337

1

M3052

13-3

TECHNICAL DATA

3

AS TRONIC gearbox CF65/75/85 series

13.3 FILLING CAPACITIES

0

Filling amounts, ZF gearboxes without
intarder

Gearbox type

ZF 12 AS 1930 TD 11 11

ZF 12 AS 2330 TO 11 11

ZF 12 AS 2540 TD 12 12

Filling amounts, ZF gearboxes with
integrated intarder

Gearbox type

ZF 12 AS 1931 TD 12 21

ZF 12 AS 2331 TO 12 21

ZF 12 AS 2541 TD 13 23

Filling amounts at oil change

Filling amounts at oil change

(litres)

(litres)

First filling, e.g. during repair

(litres)

First filling, e.g. during repair

(litres)

13-4

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Contents

CONTENTS

Page Date

1. MECHANICAL GEARBOX CONTROL 1-1 200337.................................... ....

1.1 Fault-finding table 1-1 200337................................................. ....

2. PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) 2-1 200337....... ....

2.1 Fault-finding table 2-1 200337................................................. ....

3. PNEUMATIC SECTION OF GEARBOX 3-1 200337................................... ....

3.1 Fault-finding table 3-1 200337................................................. ....

4. MECHANICAL GEARBOX 4-1 200337.............................................. ....

4.1 Fault-finding table 4-1 200337................................................. ....

5. AUTOMATIC GEARBOX 5-1 200337................................................ ....

5.1 Reading/deleting fault codes 5-1 200337....................................... ....

5.2 Table of fault codes 5-3 200337............................................... ....

6. CLUTCH 6-1 200337.............................................................. ....

6.1 Fault-finding table 6-1 200337................................................. ....

7. PROP SHAFTS 7-1 200337........................................................ ....

7.1 Fault-finding table 7-1 200337................................................. ....

8. ZF INTARDER 8-1 200337......................................................... ....

8.1 Fault-finding table 8-1 200337................................................. ....

9. AS TRONIC 9-1 200337........................................................... ....

9.1 Fault-finding table 9-1 200337................................................. ....

1

ᓻ 200337

1

1

3DIAGNOSTICS

Contents CF65/75/85 series

2

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Mechanical gearbox control

1. MECHANICAL GEARBOX CONTROL

1.1 FAULT-FINDING TABLE

SYMPTOM: GEAR LEVER VIBRATES

Possible cause Remedy

Excessive play at control hinge points Check/repair all points in the control

SYMPTOM: ENGAGING GEARS IS HEAVY

Possible cause Remedy

Gearbox control pivot and hinge points dry or
compressed

Mechanical problem in gearbox See “Mechanical gearbox” fault-finding table

Clutch does not release properly Check clutch operating unit

SYMPTOM: GEARS CANNOT BE ENGAGED

Possible cause Remedy

Gearbox control pivot and hinge points dry or
compressed

Mechanical problem in gearbox See “Mechanical gearbox” fault-finding table

SYMPTOM: GEARBOX JUMPS OUT OF GEAR

Possible cause Remedy

Check/repair all points in the control

Check/repair all points in the control

1

Incorrect adjustment of control Check/adjust all points in the control

Mechanical problem in gearbox See “Mechanical gearbox” fault-finding table

ᓻ 200337

1-1

1

DIAGNOSTICS

Mechanical gearbox control CF65/75/85 series

3

1-2

ᓻ 200337

3

CF65/75/85 series Pneumatically assisted gearbox control (Servoshift)

DIAGNOSTICS

2. PNEUMATICALLY ASSISTED GEARBOX CONTROL
(SERVOSHIFT)

2.1 FAULT-FINDING TABLE

SYMPTOM: ENGAGING GEARS IS HEAVY

Possible cause Remedy

Servoshift unit inoperative Inspect air pipes

Servoshift unit leaking air internally Check air seals in unit

Mechanical problem See “Mechanical gearbox control” and

“Mechanical gearbox” fault-finding tables

SYMPTOM: GEARBOX JUMPS OUT OF GEAR

Possible cause Remedy

Selector valve in Servoshift unit defective Replace Servoshift unit

Mechanical problem See “Mechanical gearbox control” and

“Mechanical gearbox” fault-finding tables

1

ᓻ 200337

2-1

1

DIAGNOSTICS

Pneumatically assisted gearbox control (Servoshift) CF65/75/85 series

3

2-2

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Pneumatic section of gearbox

3. PNEUMATIC SECTION OF GEARBOX

3.1 FAULT-FINDING TABLE

SYMPTOM: NOT POSSIBLE TO ENGAGE HIGH OR LOW RANGE

Possible cause Remedy

Air pressure too low Check air supply of circuit 4

Neutral position valve defective or incorrectly
connected

Defective downshift protection valve Replace valve

Defective high/low range engaging cylinder Check cylinder and replace if necessary

SYMPTOM: HIGH/LOW RANGE ENGAGING CYLINDER ENGAGES AT TOO HIGH A SPEED

Possible cause Remedy

Incorrectly programmed VIC Report the incorrect or altered configuration

SYMPTOM: HIGH OR LOW RANGE ENGAGING IS SLOW

Possible cause Remedy

Air pressure too low Check air supply of circuit 4

Pipes blocked Check pipes and clean if necessary

Defective neutral position valve Replace valve

SYMPTOM: THE HIGH/LOW GROUP ENGAGING WORKS IN REVERSE

Connect valve properly or replace

1

Possible cause Remedy

Air pipes on the high/low range engaging
cylinder are incorrectly connected

SYMPTOM: NOT POSSIBLE TO ENGAGE LOW RANGE

Possible cause Remedy

No power supply to the downshift protection
valve

Incorrect vehicle speed signal Check vehicle speed signal

Faulty VIC electronic unit Replace VIC if necessary

Connect engaging cylinder air pipes correctly

Check the wiring

ᓻ 200337

3-1

1

DIAGNOSTICS

3

Pneumatic section of gearbox CF65/75/85 series

SYMPTOM: SPLITTING NOT POSSIBLE

Possible cause Remedy

Air pressure too low Check pneumatic system

Defective or incorrectly set GV valve Check valve and adjust/replace as necessary

Wrong relay valve fitted for splitter Fit correct relay valve type

Broken or incorrectly connected air pipes Check air pipes and replace or connect properly,

if necessary

Wrong selector switch on gear lever Fit correct switch type

Wrong bore hole plugged in splitter cylinder Plug correct bore hole

Splitter cylinder not working Check cylinder and replace if necessary

SYMPTOM: SPLITTER CYLINDER OPERATES IN REVERSE MODE

Possible cause Remedy

Wrong splitter relay valve fitted Fit correct relay valve type

Wrong gear lever selector valve fitted Fit correct selector valve type

Air pipes connected incorrectly Check air connections and correct as necessary

SYMPTOM: SPLITTING IS SLOW

Possible cause Remedy

Air pressure too low Check pneumatic system

Blocked air pipes Check pipes

Defective or incorrectly set GV valve Check valve and adjust as necessary

3-2

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Pneumatic section of gearbox

SYMPTOM: GATE 1/2 NOT SAFEGUARDED

Possible cause Remedy

No power supply to the gate protection valve Check the wiring

Defective gate protection valve (B293) Replace the gate protection valve

VIC does not receive a speed signal or receives
an incorrect signal

Leaking or blocked air pipes Replace the air pipes

Check speed signal from CTE

1

No air from neutral position valve in neutral
position

Defective low-range switch (E561) Replace low-range switch

Faulty VIC electronic unit Replace electronic unit

SYMPTOM: GATES 1/2 AND 5/6 PERMANENTLY BLOCKED

Possible cause Remedy

Defective gearbox gate protection valve (B293) Replace the gearbox gate protection valve

Gate protection active in high and low range Check low-range switch

Check neutral position valve and replace if
necessary

ᓻ 200337

3-3

1

DIAGNOSTICS

Pneumatic section of gearbox CF65/75/85 series

3

3-4

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Mechanical gearbox

4. MECHANICAL GEARBOX

4.1 FAULT-FINDING TABLE

SYMPTOM: ENGAGING GEARS IS HEAVY

Possible cause Remedy

Gearbox oil level too low Topupoillevel

Oil with incorrect specification in the gearbox Fill gearbox with oil of correct specification

Problem in mechanical gearbox control See “Mechanical gearbox control” fault-finding

table

Clutch plate is not released See “Clutch” fault-finding table

SYMPTOM: GEARS CANNOT BE ENGAGED

Possible cause Remedy

Retaining element fitted too deep Check/repair retaining elements

Problem in mechanical gearbox control See “Mechanical gearbox control” fault-finding

table

Range-change gear does not work properly See “Pneumatic section of gearbox control”

fault-finding table

SYMPTOM: GEARBOX JUMPS OUT OF GEAR

Possible cause Remedy

Adjustment of selector shaft housing on gearbox Mount selector shaft housing on gearbox without

any play

1

Defective retaining element or wrong type of
retaining element fitted in selector shaft housing

Problem in mechanical gearbox control See “Mechanical gearbox control” fault-finding

Replace retaining element or fit other type of
retaining element

table

ᓻ 200337

4-1

DIAGNOSTICS

Mechanical gearbox CF65/75/85 series

SYMPTOM: GEAR LEVER STUCK IN GATE 3/4

Possible cause Remedy

Oil leak in gate protection piston Replace O-ring

3

1

SYMPTOM: SINGLE H BECOMES DOUBLE H

Possible cause Remedy

Locking plate in control cover not positioned
correctly

Check assembly of control cover

4-2

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Automatic gearbox

7

5. AUTOMATIC GEARBOX

5.1 READING/DELETING FAULT CODES

Fault code reading mode

To enter the fault code reading mode, briefly
press the two arrow keystwice simultaneously.
“D-1” appears on the display, followed by “--”.
This means that at that point there are no faults
(active faults) in the system. It also means that
no faults have been registered that were earlier
temporarily present and have now been cleared
(inactive faults) The fault code reading mode
can be left by pressing “D”, “N” or “R” or the
arrow keys.

If the red lamp lights up while reading a fault
code, this means that there is an active fault in
the gearbox.

R

MODE

1

No message during reading means that the fault
is inactive.
The ECU can save five active/inactive fault
codes in its memory and show them on the
display. Fault codes consist of two sets of two
figures (main codes and sub-codes). To read the
codes consecutively, the “MODE” button must
be pressed each time.

The letters and figures appear one at a time
after one other on the display.

Example: D1 25 - 22

D2 21-12
D3 24-12
D4 -

The hyphen after D4 means that there are no
further faults and that it is therefore not
necessary to look at level D5.

As the ECU can only contain the five most
important codes, the five most important codes
will be shown on D1 to D5. Only when one of the
faults has been remedied will the ECU be in a
position to show a less important fault.

N

D

V300392

ᓻ 200337

5-1

1

DIAGNOSTICS

3

Automatic gearbox CF65/75/85 series

Deleting fault codes

After faults have been remedied, the ECU
memory must be deleted. This is done as
follows.
Press the arrow keys twice simultaneously. This
is the fault code reading mode. Press the
“MODE” key and hold it down until the red lamp
flashes three times (the first flash will be after
approx. three seconds, the second after approx.
10 seconds). All codes, active or inactive, have
now been deleted. Codes which return following
deleting and can therefore no longer be deleted
are active. Both types of fault need their causes
tracing and remedying as quickly as possible.
After the fault codes have been deleted the
ignition must be switched off and re-started;
otherwise it will not be possible to drive. This
can be seen from the flashing of the gear lever
position.

R

N

MODE

Inactive faults are automatically deleted by the
ECU if the fault no longer occurs after the
contact has been switched off and on 25 times.

It is not possible to remedy all fault codes. Fault
codes that cannot be found in the “Table of Fault
Codes” can best be remedied by an
Allison dealer.
He has test and diagnostic apparatus at his
disposal that can be connected to a special
diagnostic plug in the central box (next to the
DAVIE connector).

D

V300392

5-2

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Automatic gearbox

5.2 TABLE OF FAULT CODES

Main code Sub-code RECOMMENDED PROCEDURES

Electronic control unit (ECU) supply

13 12 Low

23 High

Check the following points:
a. Earth and positive battery cables connected, firmly attached and

clean.
b. Batteries are charged.
c. Vehicle loading system fails to load or loads too little or too much.
d. VIM fuse (Vehicle Interface Module).
e. VIM connections are firmly attached, clean and undamaged.
f. The correct wiring is used.
g. ECU connections are firmly attached, clean and undamaged.
If all points are in order, contact your Allison dealer.

Accelerator pedal sensor

1

21 12

23

22 14

15
16

23 12

13
14
15
23
24

Check the following points:
a. Accelerator pedal sensor connector is connected.
b. No interruptions or short circuits between wires or earth in wiring

harness to accelerator pedal sensor.
Replace the accelerator pedal sensor if necessary.
If all points are in order, contact your Allison dealer.

Speed sensors

Check the following points:
a. Connectors are firmly attached, clean and undamaged.
b. The speed sensor attachment bolt is tightened to the specified

torque.
c. No interruptions or short circuits between wires or earth in wiring

harness to sensor.
If all points are in order, contact your Allison dealer.

Selector keypad

Check the following points:
a. ECU connections - connectors are connected and clamped.
b. Selector keypad is connected and the wire loop has been cut

through.
c. No interruptions or short circuits between wires or earth in wiring

harness to selector.
Replace the selector if necessary.
If all points are in order, contact your Allison dealer.

ᓻ 200337

5-3

1

DIAGNOSTICS

3

Automatic gearbox CF65/75/85 series

Main code Sub-code RECOMMENDED PROCEDURES

Temperature in the gearbox sump too low

24 12 Check the following points:

a. Temperature is lower than -6 ° C.

1) If this is the case, it is a normal response to the ambient
temperature.

2) If not, check whether the main gearbox is firmly connected and
that the connectors are undamaged.

If all points are in order, contact your Allison dealer.

Temperature in the gearbox sump too high

24 23 1. Run the engine at idling speed.

2. Ensure that the vehicle is entirely horizontal.

3. Check whether the correct dip stick has been installed.

4. Check the oil level.

5. If necessary, correct the oil level.

6. If the oil level is in order, check whether the engine system has
overheated, causing the gearbox to overheat.

7. Check that the ECU and gearbox connectors are correctly
connected, firmly attached and undamaged.

If all points are in order, contact your Allison dealer.

25 00

11
22
33
44
55
66
77

Output shaft speed sensor

Check the following points:
a. Connector is connected.
b. Sensor bolt is firmly attached.
c. ECU is firmly attached with no damaged connectors.
d. Oil level.
e. No interruptions or short circuits between wires or earth in wiring

harness to sensor.

If all points are in order, contact your Allison dealer.

5-4

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Automatic gearbox

Main code Sub-code RECOMMENDED PROCEDURES

Coupling 3 pressure switch open

32 00

33
55
77

33 12

23

34 12

13
14
15
16

1. Let the engine idle while the vehicle’s parking brake is applied.
Check the following points:
a. Specified dip stick.
b. Correct oil level.

2. Check the following points:
a. Gearbox main connector is connected, is firmly attached, is clean

and undamaged.

b. ECU connector is connected, is firmly attached, is clean and

undamaged.

c. No interruptions or short circuits between wires or earth in wiring

harness.

If all points are in order, contact your Allison dealer.

Sensor fault in gearbox oil sump

Check the following points:
a. Gearbox main connector is connected, is firmly attached, is clean

and undamaged.

b. ECU connector is connected, is firmly attached, is clean and

undamaged.

c. No interruptions or short circuits between wires or earth in wiring

harness.

If all points are in order, contact your Allison dealer.

EEPROM fault

1. Re-calibrate if possible.

2. If re-calibration is impossible, replace the ECU.

3. If ECU replacement is impossible, contact your Allison dealer.

1

35 00

16

EEPROM writing error as a result of loss of power supply

Check the following points:
a. ECU is firmly attached, clean and undamaged.
b. VIM (Vehicle Interface Module) is firmly attached, clean and

undamaged.

c. The vehicle manufacturer has used the specified wiring for power

supply and earth connection.

d. Battery positive pole.
e. Battery earth connection.
f. Specified connections for vehicle ignition.
If all points are in order, contact your Allison dealer.

ᓻ 200337

5-5

1

DIAGNOSTICS

3

Automatic gearbox CF65/75/85 series

Main code Sub-code RECOMMENDED PROCEDURES

Hardware/software not compatible

36 00 1. Replace ECU if possible.

2. Re-program ECU if possible.

3. If replacement or re-programming is not possible, contact your
Allison dealer.

Interruption or short circuit in electromagnetic valve circuit

41 12

13
14
15
16
20
22
23
24
25
26

Short circuit in the electromagnetic valve circuit to the battery

42 12

13
14
15
16
21
22
23
24
25
26

Check the following points:
a. Gearbox main connector is connected, is firmly attached, is clean

and undamaged.

b. ECU connector is connected, is firmly attached, is clean and

undamaged.

c. Visual inspection of the wiring harness: no damage, no chafed or too

taut wires, no screws through the wiring harness.

d. No interruptions or short circuits between wires or earth in wiring

harness.
Replace wiring harness if necessary.

If all points are in order, contact your Allison dealer.

Check the following points:
a. Gearbox main connector is connected, is firmly attached, is clean

and undamaged.

b. ECU connector is connected, is firmly attached, is clean and

undamaged.

c. Visual inspection of the wiring harness: no damage, no chafed or too

taut wires, no screws through the wiring harness.

d. No interruptions or short circuits between wires or earth in wiring

harness.

e. Replace wiring harness if necessary.
f. Incompetent repairs.
If all points are in order, contact your Allison dealer.

ECU circuits

43 21

5-6

25
26

1. Replace the ECU.

2. Contact your Allison dealer.

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Automatic gearbox

Main code Sub-code RECOMMENDED PROCEDURES

Transmission ratio test on the gear to be changed from (during shifting).

51 01

10
12
21
23
45
65

Coupling 3 pressure switch fails to register pressure drop during shifting

52 01

08
32
34
54
56
71
78
79
99

Check the following points:
a. Output shaft engine speed sensor and rev sensor are connected.

The connectors are undamaged and clean.

b. No interruptions or short circuits between wires or earth in sensor

wiring.

c. Let the engine idle in neutral while the vehicle is on the brake.

Check the following points:

1. Specified dip stick.

2. Oil level.

If all points are in order, contact your Allison dealer.

Check the following points:
a. Output shaft engine speed sensor and rev sensor are connected.

The connectors are undamaged and clean.

b. No interruptions or short circuits between wires or earth in sensor

wiring.

c. Let the engine idle in neutral while the vehicle is on the brake.

Check the following points:

1. Specified dip stick.

2. Oil level.

d. Check that there is no interruption or short circuit between wires or

earth connection in the main wiring harness to the gearbox.

If all points are in order, contact your Allison dealer.

Engine and turbine rev test when engaging neutral

1

53 08

18
28
29
38
39
48
49
58
59
68
69
78
99

Check the following points:
a. Output shaft engine speed sensor and rev sensor are connected.

The connectors are undamaged and clean.

b. No interruptions or short circuits between wires or earth in sensor

wiring.

c. Let the engine idle in neutral while the vehicle is on the brake.

Check the following points:

1. Specified dip stick.

2. Oil level.

If all points are in order, contact your Allison dealer.

ᓻ 200337

5-7

DIAGNOSTICS

3

Automatic gearbox CF65/75/85 series

Main code Sub-code RECOMMENDED PROCEDURES

Transmission ratio test immediately after changing gear

1

54 01,07

10,12
17,21
23,32
34,43
45,54
56,65
70,71
80,81
83,85
86,92
93,95
96,97

Pressure in coupling 3 immediately after changing gear.

55 17

87
97

Check the following points:
a. Output shaft engine speed sensor and rev sensor are connected.

The connectors are undamaged and clean.

b. No interruptions or short circuits between wires or earth in sensor

wiring.

c. Let the engine idle in neutral while the vehicle is on the brake.

Check the following points:

1. Specified dip stick.

2. Oil level.

If all points are in order, contact your Allison dealer.

Check the following points:
a. Output shaft engine speed sensor and rev sensor are connected.

The connectors are undamaged and clean.

b. No interruptions or short circuits between wires or earth in sensor

wiring.

c. Let the engine idle in neutral while the vehicle is on the brake.

Check the following points:

1. Specified dip stick.

2. Oil level.

d. Check that there is no interruption or short circuit between the wiring

or earth connection in the coupling 3 pressure switch wiring.

e. Check the following points:

1. Main connector is properly connected, is clean and undamaged.,

2. ECU connector is properly connected, is clean and undamaged.

3. Rev sensor is properly connected, is clean and undamaged.

If all points are in order, contact your Allison dealer.

56 00

11
22
33
44
55
66
77

Range test

Check the following points:
a. Output shaft engine speed sensor and rev sensor are connected.

The connectors are undamaged and clean.

b. No interruptions or short circuits between wires or earth in sensor

wiring.

c. Let the engine idle in neutral while the vehicle is on the brake.

Check the following points:

1. Specified dip stick.

2. Oil level.

If all points are in order, contact your Allison dealer.

5-8

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3

DIAGNOSTICS

CF65/75/85 series Automatic gearbox

Main code Sub-code RECOMMENDED PROCEDURES

Range test when using coupling C3

57 11

22
44
66
88
99

69 12,13

14,15
16,21
22,23
24,25
26,32
33,34
35,36

Check the following points:
a. Output shaft engine speed sensor and rev sensor are connected.

The connectors are undamaged and clean.

b. No interruptions or short circuits between wires or earth in sensor

wiring.

c. Let the engine idle in neutral while the vehicle is on the brake.

Check the following points:

1. Specified dip stick.

2. Oil level.

d. Check that there is no interruption or short circuit between the wiring

or earth connection in the coupling 3 pressure switch wiring.

e. Check the following points:

1. Main connector is properly connected, is clean and undamaged.

2. ECU connector is properly connected, is clean and undamaged.

3. Rev sensor is properly connected, is clean and undamaged.

If all points are in order, contact your Allison dealer.

Fault in ECU

1. Delete the fault codes and try to re-start the vehicle.

2. If the fault re-occurs, replace the ECU.

3. If the fault has not been cleared, contact your Allison dealer.

1

ᓻ 200337

5-9

1

DIAGNOSTICS

Automatic gearbox CF65/75/85 series

3

5-10

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Clutch

6. CLUTCH

6.1 FAULT-FINDING TABLE

SYMPTOM: CLUTCH PEDAL FAILS TO RETURN

Possible cause Remedy

Broken pedal return spring Replace spring

Worn clutch pedal bearing Check bearing and replace, if necessary

Dirt in hydraulic system Clean system and fill with fresh fluid

Incorrect fluid in hydraulic system Replace with fluid of correct specification

Air in hydraulic system Bleed the system

SYMPTOM: CLUTCH PEDAL STICKS WHEN PRESSED

Possible cause Remedy

Leak in hydraulic system Check system

Air in hydraulic system Bleed hydraulic system

Release bearing incorrectly fitted Fit the release bearing correctly

Fork hinge points or fork itself worn Check hinge points and fork; replace if

necessary

Defective clutch servo Repair and/or replace clutch servo

Gearbox front cover worn or broken Check, replace gearbox front cover

1

SYMPTOM: PEDAL FORCE TOO HIGH

Possible cause Remedy

No or insufficient pressure in circuit 4 of the
brake system

Kinked air pipe Check pipe and replace, if necessary

Kinked hydraulic pipe Check pipe and replace, if necessary

Worn clutch pedal bearing Check bearing and replace, if necessary

Defective clutch servo and/or main cylinder Repair or replace clutch servo and/or main

Check circuit 4 of the brake system

cylinder
Note: In the case of a swollen seal, clean the
system and re-fill with new fluid.

ᓻ 200337

6-1

DIAGNOSTICS

3

Clutch CF65/75/85 series

SYMPTOM: RESIDUAL PRESSURE IN CLUTCH SYSTEM

Possible cause Remedy

Bleed in reservoir cap closed off Check bleed in cap

1

Compensation bore in main cylinder closed off
by swollen seal or insufficient free thrust pin
travel.

SYMPTOM: FLUID LEAK VIA VENT OPENING

Possible cause Remedy

Leak through piston seal in clutch servo Repair or replace clutch servo

SYMPTOM: CLUTCH PLATE SLIPS

Possible cause Remedy

Worn lining Replace lining

Oil on lining Replace lining and check engine and gearbox

Dirt on clutch plate and flywheel Clean plate and surrounding area

Burnt clutch plate Check entire clutch and replace, if necessary

Check free thrust pin travel or repair/replace
main cylinder
Note: In the case of a swollen seal, clean the
system and re-fill with new fluid.

Note: A drop of oil in the vent opening is a
normal situation and is not a reason to
repair/replace the clutch servo

sealing rings

Clamping force of clutch release assembly too
low or absent

Clutch release assembly is not released Check clutch release assembly

Check clutch release assembly and replace, if
necessary

6-2

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Clutch

SYMPTOM: CLUTCH RELEASE ASSEMBLY FAILS TO RELEASE

Possible cause Remedy

Fluid level in hydraulic system too low Topupfluid

Incorrect pedal setting Check setting and adjust if necessary

Air in hydraulic system Bleed hydraulic system

Leak in hydraulic system Check hydraulic system

Fingers of clutch release assembly broken Replace clutch release assembly

Wrong clutch release assembly has been fitted Fit correct clutch release assembly

Clutch fork is broken Replace fork

Clutch release assembly severely contaminated Clean entire clutch assembly

Defective clutch servo Check clutch servo and replace, if necessary

Thrust bearing incorrectly fitted Fit thrust bearing correctly

Clutch housing disconnected from gearbox Tighten the clutch housing bolts to the correct

torque

1

ᓻ 200337

6-3

1

DIAGNOSTICS

Clutch CF65/75/85 series

3

6-4

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series Prop shafts

7. PROP SHAFTS

7.1 FAULT-FINDING TABLE

SYMPTOM: VIBRATION IN DRIVE LINE AT LOW SPEED

Possible cause Remedy

Universal joint angle too large caused by e.g.
excessive caster

Play in universal joints Replace universal joint

Play in centre bearing Replace centre bearing

Play in sliding joint Replace prop shaft

Forks not in line Align forks

SYMPTOM: VIBRATION IN DRIVE LINE AT HIGH SPEED

Possible cause Remedy

Prop shaft imbalance Balance prop shafts or replace if necessary

Check universal joint angle

1

ᓻ 200337

7-1

1

DIAGNOSTICS

Prop shafts CF65/75/85 series

3

7-2

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series ZF intarder

8. ZF INTARDER

8.1 FAULT-FINDING TABLE

SYMPTOM: NO BRAKING MOMENT

Possible cause Remedy

Oil level too low Check oil level

Intarder is not filled with the specified oil Change the oil

No pump pressure Check system

No control pressure Check system

No intarder pressure Check system

SYMPTOM: INSUFFICIENT BRAKING MOMENT

Possible cause Remedy

Oil level too low Check oil level

Intarder is not filled with the specified oil Change the oil

Pump pressure too low Check system

Control pressure too low Check system

Intarder pressure too low Check system

Freewheeling turning torque system remains
fully or partly switched on

Check the free movement of the plungers in the
freewheeling turning torque system

1

SYMPTOM: CONSTANT BRAKING MOMENT WHEN INTARDER IS SWITCHED OFF

Possible cause Remedy

Oil level too high Check oil level

Control pressure is independent of the position
of the control lever

Check system

ᓻ 200337

8-1

1

DIAGNOSTICS

3

ZF intarder CF65/75/85 series

SYMPTOM: DELAYED RESPONSE

Possible cause Remedy

Air supply absent/too low Check air supply

Intarder air supply valve is not activated Check system

Intarder air supply valve does not empty
accumulator in spite of activation

Idle pressure too low Check system

SYMPTOM: DELAYED SWITCH-OFF

Possible cause Remedy

Check system

Slow decrease of intarder pressure after
switch-off

SYMPTOM: OIL LEAK

Possible cause Remedy

Oil level too high Check oil level

Oil leak between gearbox housing and intarder Replace gasket

Oil leak in pump Replace O-ring

Oil leak in proportional valve Replace O-ring

Oil leak in the accumulator Replace O-ring

Oil leak in the prop shaft flange Replace O-ring

SYMPTOM: AIR LEAKAGE

Possible cause Remedy

Air leak via intarder air supply valve Replace O-ring

SYMPTOM: COOLANT TEMPERATURE TOO HIGH

Possible cause Remedy

Check system

Coolant level too low Check coolant level

Temperature adjustment Check system

Intarder pressure present after intarder has been
switched off

Check system

8-2

ᓻ 200337

3

DIAGNOSTICS

CF65/75/85 series AS Tronic

9. AS TRONIC

9.1 FAULT-FINDING TABLE

UsingDAVIE,theairpressurecanbeexamined
after the pressure regulator. The air pressure
before the pressure regulator can be measured
using a pressure gauge on the screw valve of
the AS Tronic air reservoir.

SYMPTOM: AIR SUPPLY PRESSURE TOO LOW

Possible cause Remedy

1

Air supply pressure too low due to:

- Air leakage in air pipe from air supply unit to
modulator pressure regulator

- Pressure regulator factory setting disrupted

Defective or incorrectly functioning pressure
regulator on modulator

Check the following air connections:

- Non-return valve at output 26 of the air
supply unit

- Pressure relief valve on transverse support in
front of left front wheel

- Both connections and valve on air reservoir
of AS Tronic

- Air connection of T-piece on modulator
pressure regulator

- Sealing ring between pressure regulator and
modulator upper cover

- Pressure regulator set screw seal (underside
of pressure regulator under plastic cover)

- Air lead-through sealing ring between
modulator upper and lower covers

- Air connection on clutch unit

- Bleed screw, clutch unit

- Replace pressure regulator

ᓻ 200337

9-1

DIAGNOSTICS

3

AS Tronic CF65/75/85 series

SYMPTOM: AIR SUPPLY PRESSURE TOO HIGH

Possible cause Remedy

1

- Defective or incorrectly functioning pressure
regulator on modulator

- Pressure regulator factory setting disrupted

SYMPTOM: SYSTEM NOT AVAILABLE ONCE ENGINE STARTED

Possible cause Remedy

During the system self-test clutch conditions
cannot be stored due to:

- jammed clutch plate on gearbox input shaft

- clutch valves in clutch unit mechanically
locked in open or closed position

SYMPTOM: GEAR IS NOT ENGAGED WHEN OPERATING UNIT HAS BEEN SWITCHED ON VIA

SELECTOR SWITCH

Possible cause Remedy

Signal of selected driving position from selector
switch not received by gear lever unit

- Check pressure regulator set screw seal
(underside of pressure regulator under plastic
cover)

- Replace pressure regulator

Check whether clutch is released during self-test.

- Remove inspection cover from clutch and
check whether clutch operating unit changes
position during self-test

- If necessary replace the clutch unit

- If necessary remove the gearbox so as to
check the clutch parts

Check whether the wire from the relevant
selector switch driving position to the gear lever
unit is interrupted.

9-2

ᓻ 200337

3

MECHANICAL GEARBOX CONTROL

CF65/75/85 series Contents

CONTENTS

Page Date

1. GENERAL 1-1 0111............................................................ ......

1.1 Description of mechanical gearbox control 1-1 0111........................... ......

1.2 Overview drawing, gear lever unit 1-2 0111................................... ......

1.3 Overview drawing, gear lever 1-3 01 11....................................... ......

2. INSPECTION AND ADJUSTMENT 2- 1 0 111....................................... ......

2.1 Inspection and adjustment of gearbox control LHD/RHD 2-1 0111............... ......

3. REMOVAL AND INSTALLATION 3 - 1 0 111........................................ ......

3.1 Removal and installation, entire gear lever unit 3-1 01 11........................ ......

3.2 Removal and installation, gear lever gaiter 3-3 0111........................... ......

3.3 Removal and installation, gear lever unit inner dust cover 3-6 0111.............. ......

3.4 Removal and installation of gear lever ball 3-9 0111............................ ......

3.5 Removal and installation, control rod 3-11 0111................................ .....

3.6 Removal and installation, control rod ball joint 3-13 0111......................... .....

2

ᓻ 0111

1

2

MECHANICAL GEARBOX CONTROL

Contents CF65/75/85 series

3

2

ᓻ 0111

3

MECHANICAL GEARBOX CONTROL

CF65/75/85 series General

1. GENERAL

1.1 DESCRIPTION OF MECHANICAL GEARBOX CONTROL

Operating mechanism, LHD

When the gear lever is moved forwards, the
control rod moves backwards.

When the gear lever is moved backwards, the
control rod moves forwards.

When the gear lever is moved left, the control
rod moves right.

When the gear lever is moved right, the control
rod moves left.

Operating mechanism, RHD

In the RHD version, the operating mechanism
remains mounted in place. An additional control
rod, passing over the engine to the right-hand
side of the vehicle, is added to the control
mechanism.

2

ᓻ 0111

1-1

2

MECHANICAL GEARBOX CONTROL

3

General CF65/75/85 series

1.2 OVERVIEW DRAWING, GEAR LEVER UNIT

1. Switch

2. Gaiter

3. Gear lever

4. Retaining plate

5. Inner gaiter

6. Attachment tape

7. Pressure spring

8. Circlip

9. Gear lever ball

10. Bearing housing
1 1. Spacer sleeve

1

2

3

4

6

5

7

8
9

10

1-2

11

V300393

ᓻ 0111

3

CF65/75/85 series General

1.3 OVERVIEW DRAWING, GEAR LEVER

1. Switch

2. Gear lever

3. Bearing housing

4. Gear lever ball

5. Circlip

MECHANICAL GEARBOX CONTROL

1

2

2

4

3

5

V300394

ᓻ 0111

1-3

2

MECHANICAL GEARBOX CONTROL

General CF65/75/85 series

3

1-4

ᓻ 0111

3

CF65/75/85 series Inspection and adjustment

MECHANICAL GEARBOX CONTROL

2. INSPECTION AND ADJUSTMENT

2.1 INSPECTION AND ADJUSTMENT OF GEARBOX CONTROL LHD/RHD

Inspection, gearbox control LHD/RHD

1. Push the control against the spring
pressure to check whether it can move
freely in neutral. The control should spring
back independently into the 3/4 gate.

2. Check that all gears can be engaged
without parts coming into contact with each
other.

2

ᓻ 0111

2-1

2

MECHANICAL GEARBOX CONTROL

3

Inspection and adjustment CF65/75/85 series

Adjustment, gearbox control LHD/RHD

1. Tilt the cab.

2. Remove the lever from the selector shaft.

3. Position the gear lever exactly in position A.
See “Technical data”.

4. Check that the gearbox is in neutral.

5. Fit the selector shaft lever (4) to the
selector shaft and fit the attachment bolt,
tightening it to the specified torque. See
“Technical data”.

Note:

The torque rod (1) of the gearbox control is
equipped with fixed (non-adjustable) ball
joints. If the torque rod (3) strut has been
fitted correctly and the gear lever is exactly
in position A, the shape of the control rod
(2) will dictate the correct position of the
lever (4) on the selector shaft.

A

1

2

4

3

V300404

6. Check that all gears can be engaged
without parts coming into contact with each
other.

2-2

ᓻ 0111

3

MECHANICAL GEARBOX CONTROL

CF65/75/85 series Removal and installation

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, ENTIRE GEAR LEVER UNIT

Note:

If the vehicle is equipped with a gearbox without
range-change switching or splitter box e.g. the
ZF 6S850, the gear lever unit can be removed
without it being necessary to consider the air
pipes.

Removal, entire gear lever unit

1. Make sure there are no loose items in the
cab. Tilt the cab.

2. After marking them, remove the air pipes
that run from the switch to the various
valves.

3. Remove the clamping bolt (1) and remove
the gear lever control rod (2) and secure it
so that it cannot cause any damage to the
air pipes.

4. Remove the attachment nuts (3) on the
bottom of the gear lever unit or those on the
manifold bracket and then remove the
entire gear lever unit including the set of air
pipes.

312

V300275

2

ᓻ 0111

W 3 02 049

3-1

2

MECHANICAL GEARBOX CONTROL

3

Removal and installation CF65/75/85 series

Installation, entire gear lever unit

1. Fit the entire gear lever unit including the
set of air pipes to the bottom of the shift unit
or on the manifold bracket and fit the
attachment nuts (3), tightening to the
specified tightening torque. See “Technical
data”.

Note:

When fitting the set of air pipes, make sure
that these are away from any moving parts.

2. Fit the air pipes that run from the switch to
the various valves.

3. Fit the gear lever control rod (2) to the gear
lever unit and fit the clamping bolt (1),
tightening to the specified tightening torque.
See “Technical data”.

4. Check that the pneumatic system is airtight.

5. Check that all switches, both mechanical
and pneumatic, function properly.

3-2

ᓻ 0111

3

MECHANICAL GEARBOX CONTROL

CF65/75/85 series Removal and installation

3.2 REMOVAL AND INSTALLATION, GEAR LEVER GAITER

Removing the gear lever gaiter

1. Make sure there are no loose items in the
cab. Tilt the cab.

2. After marking them, remove the air pipes
that run from the switch to the various
valves.

3. Slide the gaiter over the threaded bush and
then loosen it from the connection piece
between the gear lever and the selector
valve.

4. Remove the gear lever control rod and
secure it so that no damage can be caused
to the air pipes.

5. Remove the switch with the selector valve
and air pipes from the gear lever.

2

V300276

ᓻ 0111

V300277

3-3

2

MECHANICAL GEARBOX CONTROL

3

Removal and installation CF65/75/85 series

6. Loosen the gaiter from the locking plate by
lifting the gaiter and pulling the gaiter lips
away from the locking plate.

W 302059

7. Then remove the Seeger ring that has
become visible from the bearing cover. It is
now possible to remove the entire gear
lever from the bearing cover.

8. Use a press to remove the ball from the
gear lever. Heat the ball if necessary.

9. Remove the gaiter.

V300405

3-4

ᓻ 0111

3

MECHANICAL GEARBOX CONTROL

CF65/75/85 series Removal and installation

Installing the gear lever gaiter

1. Slide the gaiter over the gear lever.

2. Fit the ball.

3. Fit the entire gear lever to the shift unit and
lock it with the specific Seeger ring.

4. Secure the gaiter by means of the lips.
These must be pulled through the slots in
the locking plate.

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5. Feed the air pipes through the gear lever
and fit the switch with the valve to the gear
lever. Tighten the threaded bush and slide
the gaiter over the threaded bush.

6. Fit the selector rod.

7. Connect the air pipes. Ensure that the pipes
are clear of any moving parts.

8. Check that the pneumatic system is airtight.

9. Check that all switches, both mechanical
and pneumatic, function properly.

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MECHANICAL GEARBOX CONTROL

3

Removal and installation CF65/75/85 series

3.3 REMOVAL AND INSTALLATION, GEAR LEVER UNIT INNER DUST COVER

Removal, gear lever unit inner dust cover

1. Remove the entire gear lever unit from the
bracket.

2. Loosen the gaiter from the locking plate by
lifting the gaiter and pulling the gaiter lips
away from the locking plate.

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3. Then remove the Seeger ring that has
become visible from the bearing cover. It is
now possible to remove the entire gear
lever from the bearing cover.

4. Press the locking plate down and slide the
four attachment bands from the bearing
cover slots.

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MECHANICAL GEARBOX CONTROL

CF65/75/85 series Removal and installation

5. Remove the locking plate with the dust
cover and spring from the bearing cover.

6. Remove the dust cover from the locking
plate.

2

Installation, gear lever unit inner dust cover

1. Fit the inner dust cover.

Note:

When fitting the inner dust cover, ensure
that it is fitted properly to the locking plate
as can be seen in position A. Fitting as in
position B will lead to irritating engine noise
in the cab.

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A

B

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MECHANICAL GEARBOX CONTROL

3

Removal and installation CF65/75/85 series

2. Press the locking plate and spring down
and fit the four attachment bands in the
bearing cover slots.

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3. Fit the gear lever with the bearing to the
bearing cover and fit the snap ring.

4. Secure the gaiter by means of the lips.
These must be pulled through the slots in
the locking plate.

5. Fit the selector rod.

6. Connect the air pipes. Ensure that the pipes
are clear of any moving parts.

7. Check that the pneumatic system is airtight.

8. Check that all switches, both mechanical
and pneumatic, function properly.

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