DAF CF65, CF75, CF85 Service manual

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Page 1

ΧΦ65/75/85 series

STRUCTURE

Structure

TECHNICAL DATA

DIAGNOSTICS

CHASSIS

SHOCK ABSORBERS

STABILISERS AND TORQUE RODS

LEAF SUSPENSION

REAR AXLE ALIGNMENT

FAG

200448 DW23241902

Page 2

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TECHNICAL DATA

ΧΦ65/75/85 series

0 Technical data

CONTENTS

Page Date

1. CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

2. STABILISERS, TORQUE RODS AND LEAF SUSPENSION. . . . . . . . . . . . . . . 2-1 . . . . . 200448

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200448

2.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200448

3. REAR AXLE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200448

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200448

4. FAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200448

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200448

Contents

200448 1

Page 4

TECHNICAL DATA

Contents

ΧΦ65/75/85 series

200448

Page 5

TECHNICAL DATA

ΧΦ65/75/85 series

1. CHASSIS

1.1 GENERAL

Chassis materials

Type Chassis type Material

FT Side member thickness 6 mm KF 600

Side member thickness 7 mm KF 500

FTG n/a KF 500

FTP n/a KF 600

FTS Side member height 260 mm KF 500

Side member height 310 mm KF 375

FTT RHD version: side member height 260 mm, side member

thickness 7 mm KF 500

Other versions KF 375

FA n/a KF 375

Chassis

(1)

FAC n/a KF 375

FAD Side member height 310 mm, side member thickness 6 mm KF 600

Other versions KF 375

FAG n/a KF 375

FAL n/a KF 375

FAN n/a KF 375

FAR n/a KF 375

FAS n/a KF 375

FAT RHD version: side member height 260 mm, side member

thickness 7 mm KF 500

Side member height 310 mm, side member thickness 6 mm KF 600

Other versions KF 375

FAX n/a KF 375

(1) KF 500 and KF 600 are "High Tensile Strength" types of steel.

(1)

200448 1-1

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TECHNICAL DATA

Chassis

ΧΦ65/75/85 series

1-2

200448

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TECHNICAL DATA

ΧΦ65/75/85 series

Stabilisers, torque rods and leaf suspension

2. STABILISERS, TORQUE RODS AND LEAF SUSPENSION

2.1 GENERAL

Minimum dimensions of wearing plates

If one of the dimensions of the wearing plates, on which the spring assembly rests, is smaller than indicated by the dotted line in the opposite drawing, the wearing plates must be replaced.

Alignment plate/tandem axle spring clearance

If applicable, the clearance between the alignment plate and the tandem axle is: 1.5 - 2.5 mm.

2.2 TIGHTENING TORQUES

W9 00 013

The tightening torques stated in this section are different from the standard tightening torques stated in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.

When attachment bolts and nuts are replaced, it is important that - unless stated otherwise - these bolts and nuts are of exactly the same length and property class as those removed.

200448 2-1

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TECHNICAL DATA

Stabilisers, torque rods and leaf suspension

Front axle, leaf-sprung

ΧΦ65/75/85 series

F F

A Attachment bolt M24 for spring assembly,

property class 10.9 880 Nm

B U-bolt nut

- if flange nut M20, with yellow washer 450 ≥ 40 Nm

- if yellow zinc-plated hexagonal nut M20, property class 10, with black washer 400 ≥ 40 Nm

C Self-locking nut M16 for shock absorber 65 Nm D Attachment bolt/nut M16 for stabiliser rod

shackle, property class 10.9/10 260 ≥ 20 Nm

E Attachment bolt/nut M12 for stabiliser rod

bearing bush cover, property class 10.9/10 110 ≥ 8 Nm

F Attachment bolt/nut M14 for spring

bracket, property class 10.9/10 170 ≥ 15 Nm

(1) Evenly tighten the two U-bolt nuts alternately. (2) Only applies in case of tandem axle/trailing axle

B C

C9 00 477

(1)

(2)

2-2

200448

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TECHNICAL DATA

ΧΦ65/75/85 series

Front axle, air-sprung

A AJ B C I

Stabilisers, torque rods and leaf suspension

FH DG E E

C9 00 479

A Attachment bolt M16 for torque rod,

property class 10.9 260 ≥ 20 Nm

B U-bolt nut

- if flange nut M22 700 ≥ 50 Nm

- if yellow zinc-plated hexagonal nut M22, property class 10, with black washer 530 ≥ 40 Nm

C Attachment bolt M16 for bellows, property

class 8.8 195 Nm

D Attachment nut M10 for bellows, property

class 10 46 Nm

E Attachment bolt/nut M16 for spring

bracket, property class 10.9/10 260 ≥ 20 Nm

F Attachment bolt/nut M14 for spring

bracket, property class 10.9/10 170 ≥ 15 Nm G Self-locking nut M16 for shock absorber 65 Nm H Attachment bolt/nut M12 for bellows

support, property class 10.9/10 110 ≥ 8 Nm I Attachment bolt M10 for pin attachment of

spring assembly, property class 10.9 60 ≥ 4 Nm J Attachment bolt M12 for torque rod

support, property class 10.9 110 ≥ 8 Nm

(1) Evenly tighten the two U-bolt nuts alternately. (2) Bellows must first be tightened on the chassis side.

(1)

(2)

200448 2-3

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TECHNICAL DATA

Stabilisers, torque rods and leaf suspension

Leading rear axle, vehicle in FTG, FAG version

A B

ΧΦ65/75/85 series

GH A

A Attachment bolt/nut M16 for torque rod

(support), property class 10.9/10 260 ≥ 20 Nm B Self-locking nut M16 for shock absorber 65 Nm C Attachment nut M10 for bellows, property

class 10 46 Nm D Attachment bolt M16 for bellows, property

class 10.9 195 Nm E U-bolt nut

- if flange nut M22 700 ≥ 50 Nm

- if yellow zinc-plated hexagonal nut M22, property class 10, with black washer 530 ≥ 40 Nm

F Attachment bolt M8 for lifting bellows,

property class 10.9 20 Nm

G Attachment bolt/nut for stabiliser bar

bracket

- if M14, property class 10.9/10 170 ≥ 15 Nm

- if M16, property class 10.9/10 260 ≥ 20 Nm

H Attachment bolts M8 for locking plate,

property class 10.9 30 Nm

(1) Bellows must first be tightened on the chassis side. (2) Evenly tighten the two U-bolt nuts alternately.

BA A

C9 00 486

(1)

(2)

2-4

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TECHNICAL DATA

ΧΦ65/75/85 series

Leading rear axle, vehicle in FTP version

Stabilisers, torque rods and leaf suspension

B I DC

A Attachment bolt M20 for shock absorber,

property class 8.8 250 ≥ 25 Nm B Attachment nut M12 for bellows 30 Nm C U-bolt nut M20, property class 10.9 553 Nm D Attachment nut M10 for bellows 30 Nm E Attachment bolt M16 for leaf spring,

property class 10.9 100 Nm F Attachment bolt/nut M20 for leaf spring,

property class 10.9/10 553 Nm G Attachment bolt/nut M24 for leaf spring 830 Nm H Attachment bolt/nut M16 for spring

bracket, property class 10.9 310 Nm I Attachment bolt/nut M10 for bellows

support, property class 10.9/10 60 ≥ 4 Nm

(1) Evenly tighten the two U-bolt nuts alternately.

DEFEAG BH

C9 00 481

(1)

200448 2-5

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TECHNICAL DATA

Stabilisers, torque rods and leaf suspension

Double front axle

CF F C

A Attachment bolt M24 for spring assembly,

property class 10.9 880 Nm B U-bolt nut

- if flange nut M20, with yellow washer 450 ≥ 40 Nm

- if yellow zinc-plated hexagonal nut M20, property class 10, with black washer 400 ≥ 40 Nm

C Self-locking nut M16 65 Nm D Ball end nut

- if self-locking nut 285 Nm

- if castle nut 285 Nm

E Attachment bolt/nut M12 for stabiliser rod

bearing bush cover, property class 10.9/10 110 ≥ 8 Nm

F Attachment bolt/nut M16 for stabiliser rod

shackle, property class 10.9/10 260 ≥ 20 Nm

BEF EFA B C A DD AC

ΧΦ65/75/85 series

C900465

(1)

(2)

(3)

(1) Evenly tighten the two U-bolt nuts alternately. (2) Fit new self-locking nut. (3) Tighten until the split pin fits (max. 60).

It is not allowed to fit a self-locking nut to the ball end with split pin hole.

2-6

200448

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TECHNICAL DATA

ΧΦ65/75/85 series

Rear axle, leaf suspension

Stabilisers, torque rods and leaf suspension

DA A

C D F

A Attachment bolt/nut M16 for spring

bracket, property class 10.9/10 260 ≥ 20 Nm

B Attachment bolt M24 for spring assembly,

property class 10.9 880 Nm

C U-bolt nut

- if flange nut M24, with black washer 750 ≥ 50 Nm

- if yellow zinc-plated hexagonal nut M24, property class 10, with black washer 615 ≥ 50 Nm

D Self-locking nut M16 for shock absorber 65 Nm E Catch bolt M12, property class 10.9 68 ≥ 12 Nm F Attachment bolt/nut M14 for stabiliser rod

bracket, property class 10.9/10 170 ≥ 15 Nm

C9 00 478

(1)

(1) Evenly tighten the two U-bolt nuts alternately.

200448 2-7

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TECHNICAL DATA

Stabilisers, torque rods and leaf suspension

Rear axle, air-sprung

A H H

ΧΦ65/75/85 series

AEE F G

DCB B

C9 00 480

A Attachment nut M10 for bellows, property

class 10 46 Nm

B Attachment bolt M16 for bellows, property

class 8.8 195 Nm

C Attachment bolt M20 for shock absorber,

property class 10.9 520 ≥ 40 Nm

D U-bolt nut

- if black high hexagonal nut M24 with black washer 770 ≥ 60 Nm

- if yellow zinc-plated hexagonal nut M24, property class 10, with black washer 615 ≥ 50 Nm

E Clamping flange bolt M18 for triangular

link, property class 12.9 460 ≥ 40 Nm

F Attachment bolt M14, for triangular link

ball, property class 10.9 135 Nm

G Attachment bolt/nut M16 for stabiliser

shackle support, property class 10.9/10 260 ≥ 20 Nm

H Attachment bolt/nut M10 for bellows

support, property class 10.9/10 60 ≥ 4 Nm

(1) Bellows must first be tightened on the chassis side. (2) The high hexagonal nut can be recognised by the nut height, which is 1.5 x thread . Evenly tighten the two U-bolt nuts

alternately.

(3) The yellow zinc-plated hexagonal nut can be recognised by the nut height, which is 1 x thread . Evenly tighten the two U-bolt

nuts alternately.

(1)

(2)

(3)

2-8

200448

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TECHNICAL DATA

ΧΦ65/75/85 series

Trailing axle, leaf suspension

A U-bolt nut

- if flange nut M24 750 ≥ 50 Nm

- if yellow zinc-plated hexagonal nut M24, property class 10, with black washer 615 ≥ 50 Nm

B Self-locking nut M16 65 Nm C Shock absorber attachment nut 260 ≥ 20 Nm D Attachment bolt/nut M16 for spring

bracket, property class 10.9/10 260 ≥ 20 Nm

E Attachment bolt/nut M14 for stabiliser rod

bracket, property class 10.9/10 170 ≥ 15 Nm

F Attachment bolt M10 for pin attachment of

spring assembly, property class 10.9 60 ≥ 4 Nm

G Attachment bolt/nut M12 for spring

shackle, property class 10.9/10 110 ≥ 8 Nm

A B

Stabilisers, torque rods and leaf suspension

E G

(1)

C9 00 483

(1) Evenly tighten the two U-bolt nuts alternately.

200448 2-9

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TECHNICAL DATA

Stabilisers, torque rods and leaf suspension

Trailing axle, air-sprung, 6 bellows version

A BI H A

E F E

A Attachment nut M10 for bellows, property

class 10 46 Nm

B Clamping flange bolt M18 for triangular

link, property class 12.9 460 ≥ 40 Nm

C Attachment bolt M14, for triangular link

ball, property class 10.9 135 Nm

D U-bolt nut

- if black high hexagonal nut M24 with black washer 770 ≥ 60 Nm

- if yellow zinc-plated hexagonal nut M24, property class 10, with black washer 615 ≥ 50 Nm

E Attachment bolt M16 for bellows, property

class 8.8 195 Nm

F Attachment bolt M20 for shock absorber,

property class 10.9 520 ≥ 40 Nm

G Attachment bolt/nut M16 for stabiliser

shackle support, property class 10.9/10 260 ≥ 20 Nm

H Attachment bolt/nut M10 for bellows

support, property class 10.9/10 60 ≥ 4 Nm

I Attachment bolt/nut M16 for stabiliser

shackle support, property class 10.9/10 260 ≥ 20 Nm

(1)

(2)

(3)

ΧΦ65/75/85 series

B G

C900463

(1) Bellows must first be tightened on the chassis side. (2) The high hexagonal nut can be recognised by the nut height, which is 1.5 x thread . Evenly tighten the two U-bolt nuts

alternately.

(3) The yellow zinc-plated hexagonal nut can be recognised by the nut height, which is 1 x thread . Evenly tighten the two U-bolt

nuts alternately.

2-10

200448

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TECHNICAL DATA

ΧΦ65/75/85 series

Trailing axle, air-sprung, 8 bellows version

A B C BCG H GA

D DDF FD D

A Attachment nut M10 for bellows, property

class 10 46 Nm

B Clamping flange bolt M18 for triangular

link, property class 12.9 460 ≥ 40 Nm

C Attachment bolt M14, for triangular link

ball, property class 10.9 135 Nm

D Attachment bolt M16 for bellows, property

class 8.8 195 Nm

E U-bolt nut

- if black high hexagonal nut M24 with black washer 770 ≥ 60 Nm

- if yellow zinc-plated hexagonal nut M24, property class 10, with black washer 615 ≥ 50 Nm

F Attachment bolt M20 for shock absorber,

property class 10.9 520 ≥ 40 Nm

G Attachment bolt/nut M16 for stabiliser

shackle support, property class 10.9/10 260 ≥ 20 Nm

H Attachment bolt/nut M10 for bellows

support, property class 10.9/10 60 ≥ 4 Nm

HHH

E E

Stabilisers, torque rods and leaf suspension

A AA

(1)

(2)

(3)

C9 00 482

(1) Bellows must first be tightened on the chassis side. (2) The high hexagonal nut can be recognised by the nut height, which is 1.5 x thread . Evenly tighten the two U-bolt nuts

alternately.

(3) The yellow zinc-plated hexagonal nut can be recognised by the nut height, which is 1 x thread . Evenly tighten the two U-bolt

nuts alternately.

200448 2-11

Page 18

TECHNICAL DATA

Stabilisers, torque rods and leaf suspension

Tandem axle, leaf-sprung, trapezoidal leaf spring version

A C

ΧΦ65/75/85 series

C B

ABC CG

A Attachment bolt/nut M16 for arresting

cable 150 ≥ 20 Nm

B Attachment bolt M14, for triangular link

ball, property class 10.9 135 Nm

C Clamping flange bolt M18 for triangular

link, property class 12.9 460 ≥ 40 Nm

D U-bolt nut

- if flange nut M20 450 ≥ 40 Nm

- if yellow zinc-plated hexagonal nut M20, property class 10, with black washer 400 ≥ 40 Nm

E Attachment bolt M14, for bearing bush

plate, property class 10.9 170 ≥ 15 Nm

F Tie rod nut

if flange nut M22 650 ≥ 50 Nm if yellow zinc-plated hexagonal nut M22, property class 10, with black washer 480 ≥ 40 Nm

G Attachment bolt/nut M12 for alignment

plate, property class 10.9/10 110 ≥ 8 Nm

C9 00 485

(1)

(2)

(1)

2-12

200448

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TECHNICAL DATA

ΧΦ65/75/85 series

H Tighten the bolts according to the standard

tightening torque, in the order shown.

(1) Evenly tighten the two U-bolt/tie rod nuts alternately. (2) Fasten with Loctite 243.

Stabilisers, torque rods and leaf suspension

4 1 5

7 2 3 6

C9 00 144

200448 2-13

Page 20

TECHNICAL DATA

Stabilisers, torque rods and leaf suspension

Tandem axle, leaf-sprung, parabolic leaf spring version

A B AB

ΧΦ65/75/85 series

C CDFI E

A Clamping flange bolt M18 for triangular

link, property class 12.9 460 ≥ 40 Nm

B Attachment bolt M14, for triangular link

ball, property class 10.9 135 Nm C Self-locking nut M16 for shock absorber 65 Nm D U-bolt nut

- if flanged nut 450 ≥ 40 Nm

- if yellow zinc-plated hexagonal nut M20, property class 10, with black washer 400 ≥ 40 Nm

E Attachment bolt M14, for bearing bush

plate, property class 10.9 170 ≥ 15 Nm

F Tie rod nut

- if flanged nut 650 ≥ 50 Nm

- if yellow zinc-plated hexagonal nut M22, property class 10, with black washer 480 ≥ 40 Nm

G Attachment bolt M16 for pivot pin flange,

property class 10.9 260 ≥ 20 Nm

H Attachment bolt/nut M14 for stabiliser rod

bracket, property class 10.9/10 170 ≥ 15 Nm

C9 00 484

(1)

(2)

(1)

2-14

200448

Page 21

TECHNICAL DATA

ΧΦ65/75/85 series

I Tighten the bolts according to the standard

tightening torque, in the order shown.

(1) Evenly tighten the two U-bolt/tie rod nuts alternately. (2) Fasten with Loctite 243.

Stabilisers, torque rods and leaf suspension

4 1 5

7 2 3 6

C9 00 144

200448 2-15

Page 22

TECHNICAL DATA

Stabilisers, torque rods and leaf suspension

Tandem axle, air-sprung, Meritor version

A B

C A A C B A

D E F B BG

A Attachment bolt/nut M16 for torque rod,

property class 10.9/10 260 ≥ 60 Nm

B Tighten shock absorber attachment nut

until the rubber sleeve and the steel ring have the same diameter.

C Attachment bolt/nut M22 for yoke, property

class 10.9/10 750 Nm D Attachment bolt for bellows 1/2" UNC 34 ≥ 7 Nm E Attachment bolt/nut M16 for torque rod,

property class 10.9/10 260 ≥ 60 Nm F Attachment bolt/nut M10 for torque rod,

property class 10.9/10 60 ≥ 4 Nm G Attachment nut M20 for torque rod,

property class 10.9 520 ≥ 40 Nm

ΧΦ65/75/85 series

FE DG

C9 00 404

2-16

200448

Page 23

TECHNICAL DATA

ΧΦ65/75/85 series

3. REAR AXLE ALIGNMENT

3.1 GENERAL

Rear axle misalignment standard

The angle achieved by the driven rear axle relative to the vehicle centreline is calculated from the angle achieved by both wheels of this axle relative to the vehicle centreline. See "Rear axle alignment".

Driven axle relative to the vehicle centreline:

- max. 4 mm/m (angle A in drawing).

This value also applies to the individual tandem axles and the driven axle of the trailing axle suspension.

Non-parallelism of the rear tandem axle relative to the front tandem axle:

- max. 2 mm/m (angle B in drawing).

Rear axle alignment

C9 00 123

C9 00 124

200448 3-1

Page 24

TECHNICAL DATA

Rear axle alignment

Non-parallelism of the trailing axle relative to the driven axle:

- max. 2 mm/m (angle C in drawing).

Non-parallelism of the unsteered leading rear axle (FTP) relative to the driven axle:

- max. 2 mm/m (angle D in drawing).

ΧΦ65/75/85 series

C9 00 235

C9 00 519

3-2

200448

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TECHNICAL DATA

ΧΦ65/75/85 series

4. FAG

4.1 GENERAL

Valve adjustment

Pressure-limiting valve 7.0 bar Pressure-relief valve 0.5 bar

Control values/adjustment of height-control valve, axle load ratio 6.0/10.0 and fitted with leaf spring suspension (DAF no. 1368293)

Lever length 60 mm

Joint axle load of leading rear axle/

drive shaft (N)

30,000 0.4

40,000 0.7

50,000 1.1

60,000 1.5

FAG

Bellows pressure (bar)

70,000 1.9

80,000 2.2

90,000 2.6

100,000 3.0

110,000 3.4

120,000 3.7

130,000 4.1

140,000 4.5

150,000 4.9

160,000 5.2

170,000 5.6

180,000 6.0

190,000 6.4

200,000 6.7

200448 4-1

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TECHNICAL DATA

FAG

Control values/adjustment of height-control valve, axle load ratio 6.0/10.0 and fitted with leaf spring suspension (DAF no. 1386990)

Lever length 70 mm

Joint axle load of leading rear axle/

drive shaft (N)

30,000 0.4

40,000 0.7

50,000 1.1

60,000 1.5

70,000 1.9

80,000 2.2

90,000 2.6

100,000 3.0

110,000 3.4

ΧΦ65/75/85 series

Bellows pressure (bar)

120,000 3.7

130,000 4.1

140,000 4.5

150,000 4.9

160,000 5.2

170,000 5.6

180,000 6.0

190,000 6.4

200,000 6.7

4-2

200448

Page 27

TECHNICAL DATA

ΧΦ65/75/85 series

Control values/adjustment of height-control valve, axle load ratio 7.1/11.5 and fitted with leaf spring suspension (DAF no. 1368293)

Lever length 60 mm

Joint axle load of leading rear axle/

drive shaft (N)

30,000 0.4

40,000 0.8

50,000 1.1

60,000 1.5

70,000 1.9

80,000 2.3

90,000 2.7

100,000 3.1

110,000 3.4

FAG

Bellows pressure (bar)

120,000 3.8

130,000 4.2

140,000 4.6

150,000 5.0

160,000 5.3

170,000 5.7

180,000 6.1

190,000 6.5

200,000 6.9

200448 4-3

Page 28

TECHNICAL DATA

FAG

Control values/adjustment of height-control valve, axle load ratio 7.1/11.5 and fitted with leaf spring suspension (DAF no. 1386990)

Lever length 70 mm

Joint axle load of leading rear axle/

drive shaft (N)

30,000 0.4

40,000 0.8

50,000 1.1

60,000 1.5

70,000 1.9

80,000 2.3

90,000 2.7

100,000 3.1

110,000 3.4

ΧΦ65/75/85 series

Bellows pressure (bar)

120,000 3.8

130,000 4.2

140,000 4.6

150,000 5.0

160,000 5.3

170,000 5.7

180,000 6.1

190,000 6.5

200,000 6.9

4-4

200448

Page 29

TECHNICAL DATA

ΧΦ65/75/85 series

Control values/adjustment of height-control valve, axle load ratio 7.5/11.5 and fitted with leaf spring suspension (DAF no. 1368293)

Lever length 60 mm

Joint axle load of leading rear axle/

drive shaft (N)

30,000 0.4

40,000 0.8

50,000 1.2

60,000 1.6

70,000 2.0

80,000 2.4

90,000 2.8

100,000 3.2

110,000 3.6

FAG

Bellows pressure (bar)

120,000 4.0

130,000 4.4

140,000 4.8

150,000 5.2

160,000 5.5

170,000 5.9

180,000 6.3

190,000 6.7

200,000 7.0

200448 4-5

Page 30

TECHNICAL DATA

FAG

Control values/adjustment of height-control valve, axle load ratio 7.5/11.5 and fitted with leaf spring suspension (DAF no. 1368293)

Lever length 70 mm

Joint axle load of leading rear axle/

drive shaft (N)

30,000 0.3

40,000 0.7

50,000 1.1

60,000 1.4

70,000 1.8

80,000 2.4

90,000 2.5

100,000 2.9

110,000 3.3

ΧΦ65/75/85 series

Bellows pressure (bar)

120,000 3.6

130,000 4.0

140,000 4.4

150,000 4.7

160,000 5.1

170,000 5.5

180,000 5.8

190,000 6.2

200,000 6.6

4-6

200448

Page 31

TECHNICAL DATA

ΧΦ65/75/85 series

Control values/adjustment of height-control valve, axle load ratio 7.5/11.5 and fitted with leaf spring suspension (DAF no. 1386990)

Lever length 70 mm

Joint axle load of leading rear axle/

drive shaft (N)

30,000 0.4

40,000 0.8

50,000 1.2

60,000 1.6

70,000 2.0

80,000 2.4

90,000 2.8

100,000 3.2

110,000 3.6

FAG

Bellows pressure (bar)

120,000 4.0

130,000 4.4

140,000 4.8

150,000 5.2

160,000 5.5

170,000 5.9

180,000 6.3

190,000 6.7

200,000 7.0

200448 4-7

Page 32

TECHNICAL DATA

FAG

Control values/adjustment of height-control valve, axle load ratio 7.5/11.5 and fitted with leaf spring suspension (DAF no. 1386990)

Lever length 80 mm

Joint axle load of leading rear axle/

drive shaft (N)

30,000 0.3

40,000 0.7

50,000 1.1

60,000 1.4

70,000 1.8

80,000 2.2

90,000 2.5

100,000 2.9

110,000 3.3

ΧΦ65/75/85 series

Bellows pressure (bar)

120,000 3.6

130,000 4.0

140,000 4.4

150,000 4.7

160,000 5.1

170,000 5.5

180,000 5.8

190,000 6.2

200,000 6.6

205,000 6.7

4-8

200448

Page 33

DIAGNOSTICS

ΧΦ65/75/85 series

1 Diagnostics

CONTENTS

Page Date

1. SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

1.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

2. LEAF SUSPENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200448

2.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200448

3. REAR AXLE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200448

3.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200448

Contents

200448 1

Page 34

DIAGNOSTICS

Contents

ΧΦ65/75/85 series

200448

Page 35

DIAGNOSTICS

ΧΦ65/75/85 series

Shock absorbers

1. SHOCK ABSORBERS

1.1 FAULT-FINDING TABLE

SYMPTOM: SHOCK ABSORBER PRODUCES NOISE (CHATTERING, BUMPING ETC.)

Possible cause Remedy

Shock absorber is loose. Secure shock absorber.

Attachment rubbers too soft. Fit new rubbers.

Shock absorber comes into contact with other components.

Shock absorber cover is loose. Secure shock absorber cover or replace shock

SYMPTOM: SHOCK ABSORBER DOES NOT FUNCTION

Possible cause Remedy

Internal shock absorber defect. Replace shock absorber.

Shock absorber loses oil. Replace shock absorber.

Remove components or fasten them.

absorber.

SYMPTOM: SHOCK ABSORBER LEAKAGE

Possible cause Remedy

Defective piston rod sealing. Note: a thin, greasy layer is normal.

SYMPTOM: SHOCK ABSORBER TOO HARD

Possible cause Remedy

Incorrect shock absorber type fitted. Fit correct shock absorber type.

Internal shock absorber defect. Check shock absorber using a test bench and

SYMPTOM: SHOCK ABSORBER TOO SOFT

Possible cause Remedy

Incorrect shock absorber type fitted. Fit correct shock absorber type.

Internal shock absorber wear. Check shock absorber using a test bench and

Shock absorber loses oil. Replace shock absorber.

Vehicle overloaded. Adjust vehicle loading.

Replace shock absorber.

replace, if required.

200448 1-1

Page 36

DIAGNOSTICS

Shock absorbers

SYMPTOM: POOR DRIVING CHARACTERISTICS/FLAT WEAR SPOTS ON THE TYRES

Possible cause Remedy

Incorrect damping. Check shock absorbers using a test bench and

replace, if required.

Vehicle overloaded. Adjust vehicle loading.

SYMPTOM: SHOCK ABSORBER HITS END STOP

Possible cause Remedy

Defective stop rubber. Replace stop rubber.

Insufficient damping. See under Shock absorber too soft.

Vehicle overloaded. Adjust vehicle loading.

ΧΦ65/75/85 series

1-2

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DIAGNOSTICS

ΧΦ65/75/85 series

2. LEAF SUSPENSION

2.1 FAULT-FINDING TABLE

SYMPTOM: LOOSE U-BOLTS

Possible cause Remedy

Use of a U-bolt or nut of an incorrect property class.

The tightening torque used for the U-bolt nut was too low.

Reuse of a U-bolt with corroded or damaged thread.

No or inadequate cleaning of the thread (which includes removal of paint) before reuse of the U-bolt.

No oil or faulty application of oil on the thread and the bearing surface of the nut.

The nut has been tightened using a tool rotating too fast. There is a risk of the nut being welded to the thread.

Leaf suspension

Use U-bolts and nuts of the correct property class.

Tighten the U-bolt to the specified torque.

Fit new U-bolt.

Thoroughly clean the thread when reusing it.

Apply the oil as prescribed.

Tighten the nut slowly.

Coating (i.e. paint) on the contact faces of the connection.

Inadequate retorquing of the U-bolt nut or no retorquing.

SYMPTOM: BROKEN SPRING

Possible cause Remedy

Regular overloading. Adjust vehicle loading.

Driving too fast over bad roads. Adjust speed when the road is bad.

Notching effect due to welding or grinding activities.

Spring damaged due to impact of a steel hammer. Never hit the springs using a steel hammer or

Incorrect repair of a spring leaf which has broken before.

Spring has been heated. Replace spring assembly. Springs should never be

Clean the contact faces before assembly.

Tighten the U-bolt nut as specified.

Cover spring assembly when welding or grinding.

some other hard tool.

When replacing a broken spring leaf, always replace the leaf on top and under the broken leaf; better yet, replace the entire spring assembly.

heated.

200448 2-1

Page 38

DIAGNOSTICS

Leaf suspension

SYMPTOM: SPLAYING OF THE SPRING ASSEMBLY (BROKEN SPRING SHACKLES)

Possible cause Remedy

Incorrect pre-tension of the U-bolts. See symptom: Loose U-bolts.

SYMPTOM: SPRING HITS END STOP

Possible cause Remedy

Vehicle overloaded. Adjust vehicle loading.

Sagged spring assembly. Check spring opening of both spring assemblies.

Replace spring assemblies.

Broken spring. See symptom: Broken spring.

SYMPTOM: SHIFTING OR BREAKING OF CENTRE BOLT

Possible cause Remedy

Incorrect pre-tension of the U-bolts. See symptom: Loose U-bolts.

ΧΦ65/75/85 series

SYMPTOM: BUMPING OR CHATTERING OF THE SPRING

Possible cause Remedy

Shackle pin bearing play at air-sprung front axle. Replace shackle pin/bearing bush.

Loose U-bolts. See symptom: Loose U-bolts.

Loose shackle pin locking at air-sprung front axle. Secure the shackle pin locking.

Spring bracket is loose. Secure the spring bracket.

Spring comes into contact with other components during spring action.

Check freedom of movement of spring.

2-2

200448

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DIAGNOSTICS

ΧΦ65/75/85 series

Rear axle alignment

3. REAR AXLE ALIGNMENT

3.1 FAULT-FINDING TABLE

SYMPTOM: AXLE MISALIGNMENT

Possible cause Remedy

Axle suspension clearance. Check the axle suspension. Replace the worn

parts.

Loose U-bolts. Check the tightening torques of the U-bolts.

Tighten the nuts to the specified tightening torques.

Shifted centre bolt. Check the centre bolt. Check the tightening

torques of the U-bolts.

Loose or shifted front spring bracket. Check the spring brackets. Fit the spring bracket

as specified.

Incorrect spring bracket fitted. Fit the spring bracket as specified.

Sagged spring assembly or spring assembly with broken spring leaves.

Check opening of both spring assemblies. Replace spring assemblies.

Difference in length between the spring assemblies.

Misalignment of the vehicle due to wrongly adjusted or defective height adjustment.

Bent torque rod (air suspension and tandem axle). Check the torque rods. Replace if necessary.

Incorrectly fitted torque rods (air suspension and tandem axle).

Difference in length between the torque rods at the vehicle's left and right sides (air suspension and tandem axle).

Bent axle housing. Check the straightness of the axle housing. If

Bent leaf-sprung trailing axle yoke. Replace the trailing axle yoke.

Misalignment of the vehicle because the superstructure is heavier on one side.

Inadequate alignment of axle suspension. Check the alignment. Adjust the axle alignment.

Bent chassis. Measure the chassis.

Chassis side members have shifted in relation to one another.

Measure the centre-to-centre distance between shackle pin or spring eye bolt and centre bolt. Adjust the alignment or replace the spring assemblies.

Check/replace sensor. Recalibrate.

Check the torque rods. Fit the torque rods correctly.

Measure the length of the torque rods. Adjust the difference in length.

possible, adjust by changing the axle alignment.

Measure the wheel pressure. Distribute the weight more evenly.

Straighten the chassis, if possible.

Measure the chassis. Straighten the chassis, if possible. Align the axle.

200448 3-1

Page 40

DIAGNOSTICS

Rear axle alignment

ΧΦ65/75/85 series

3-2

200448

Page 41

CHASSIS

ΧΦ65/75/85 series

2 Chassis

CONTENTS

Page Date

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

1.1 Repairs to the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

1.2 Drilling in the chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . 200448

1.3 Replacing rivets by bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 . . . . . 200448

Contents

200448 1

Page 42

CHASSIS

Contents

ΧΦ65/75/85 series

200448

Page 43

CHASSIS

ΧΦ65/75/85 series

1. GENERAL

1.1 REPAIRS TO THE CHASSIS

- Any welding, aligning, drilling and wheelbase

alteration activities that are not described in this workshop manual or in any of the latest releases of DAF's Chassis Guidelines must be authorised by DAF.

- Following chassis repair, the cause of the

chassis damage should be rectified.

Welding

- Chassis welding may only be carried out by

welders holding a valid EN 287-1 certificate.

- For welding operations on the steel grade KF

375 chassis, the welding electrode must meet one of the following standards:

ISO 2560: E 515 B 24(H) DIN 1913 (January 1976): E 5155 B 10 EN 499

General

- Slag inclusions and other contamination in

the welds are totally unacceptable.

Note:

Welding on a chassis constructed of high-tensile strength steel grades KF 420, KF 500 and KF 600 is strongly advised against. If, however, you do wish to weld a high-tensile strength steel chassis, contact must always first be sought with DAF. The welding electrode must meet the standard:

DIN 8529: EY 5066 1.5 NiNoB

200448 1-1

Page 44

CHASSIS

General

To repair cracks in the chassis, proceed as follows, taking account of the guidelines given above:

1. Remove all parts restricting a clear working

area.

2. Thoroughly clean the crack so that the

course of the crack is clearly visible.

3. Drill a small hole at the end of the crack. This

will prevent the crack from continuing.

ΧΦ65/75/85 series

W9 01 001

4. Thoroughly grind out the crack on both sides.

5. Take the necessary precautions to prevent

damage to electronic components. Place the earth clamp as close as possible to the weld and avoid bridges.

6. Lay a bead on one side of the ground-out

crack.

7. Gouge or grind off the material at the back of

the bead (see the arrow) so that the new weld material is clearly visible.

8. Finish-weld the X-seam in the usual manner.

9. Fill in the drilled hole.

10. Grind down the new weld so that it is flush.

Take care not to grind the chassis flange in the process.

11. The beginning and end of a weld should not

curve inwards (see the arrow).

W9 01 002

W9 01 003

1-2

W9 01 004

200448

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CHASSIS

ΧΦ65/75/85 series

12. Round off the chassis flange at the edge of

the weld.

Straightening

Do not forget your own safety during straightening operations. When

}

The straightening of a chassis demands a high degree of craftsmanship as in every case of damage, an individual assessment must be made to establish whether or not straightening would be a sensible measure. Deformations found after accidents will mainly be of the following 6 types:

- chassis is bent sideways

- chassis has a double sideways bend ("S-

- chassis sags

- chassis bulges upwards

- chassis is twisted

- chassis is out of square.

working with presses, take care that parts cannot fly out.

bend")

R=1

General

100mm

W9 01 005

In many cases, the damage will be a combination of two or more of these basic deformations. In general, the deformations should be dealt with in the sequence shown above, although some combinations can be dealt with in one straightening operation. When deciding whether or not to straighten a chassis, you must consider not only the degree of chassis bending but also the angle of a bend. If there is a sharp angular bend or fold in the chassis, the material in that area is likely to be severely deformed. If such a chassis were to be realigned to its original form, there would be a high risk of overstretching the already weakened material and causing a crack to develop.

"Cold" straightening

The general rule for cold straightening of a chassis is that the degree to which the chassis should be forced back beyond the straight line is equal to the degree to which the chassis is bent. For example, if a chassis is bent by 10, the chassis should be forced back by an additional 10 beyond the straight line. This means that in total the chassis is forced back 20. Cold straightening is done with forces ranging from 40 to 100 tonnes. Therefore, work as safely as possible. Particularly when working with auxiliary tools and aids, you are advised - from a safety point of view

- to attach them correctly.

200448 1-3

Page 46

CHASSIS

General

"Warm" straightening

DAF chassis should not be warm straightened. Heating can cause grains in the material which will adversely affect the material properties.

General

For every straightening operation, all stresses in the stiffer parts of the chassis, for example in the tandem axle attachment cross member, should be relieved. If this is not done, these stresses will later cause new distortions or cracks in the chassis.

It is obvious from the above points that straightening is a highly specialised job for which the specialist involved bears full responsibility. Always contact DAF when in doubt or for complicated "straightening operations".

ΧΦ65/75/85 series

1-4

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CHASSIS

ΧΦ65/75/85 series

1.2 DRILLING IN THE CHASSIS

Note:

There are several stress zones in a chassis. Working on the chassis without proper knowledge (and not according to DAF instructions) may cause irreversible damage to the chassis. The repair shop or bodybuilder would be held fully responsible for such work and for any superstructure fitted.

If holes must be drilled in the chassis frame, note the following points:

- Drilling holes within a distance of 70 mm

(distance A) from a bend in the chassis is not permitted.

- It is on no account permitted to drill holes in

the tapered ends at the rear of a tractor chassis.

- Drilling holes in the flanges of the chassis

side members is not permitted.

- The maximum diameter for drilled holes is

17 mm (dimension D in the drawing).

- The distance between the holes, and

between the holes and the side member flange, must be at least 3xD - with a minimum of 30 mm (dimension B in the drawing).

- The distance between the lower stud hole

and the chassis underside should at least be equal to distance C. Distance C is > 70 mm for a tractor chassis. Distance C is > 50 mm for all other chassis.

- Deburr (at an angle of 45) and paint the

drilled hole.

B B

General

C9 00 304

Wheelbase alteration

Any alteration to the wheelbase or changes to the rear overhang should be done in accordance with the latest DAF Trucks Bodybuilders' Guidelines.

Note:

When using the Bodybuilders' Guidelines, you are advised to first read the "General" section.

200448 1-5

C9 00 291

Page 48

CHASSIS

General

1.3 REPLACING RIVETS BY BOLTS

Note:

A rivet may either be replaced by a flange bolt M14 x 2, property class 8.8 (DIN 6921), or a flange bolt M16 x 2, property class 10.9.

Removing the rivet

1. Remove the rivet head. Make sure not to

damage the chassis during this procedure.

2. Use a 10-mm drill to drill a hole in the rivet.

Remove the rivet from the chassis.

Fitting flange bolt M14

1. Ream the rivet hole to fit 14 H7

(14 + .000 - 14 + .018 mm). Make sure not to damage any lines running behind the rivet hole. Deburr the edges.

2. Repair the chassis paintwork. The new

paintwork should be no thicker than 50 microns.

ΧΦ65/75/85 series

3. It is important that part of the bolt shank is not

threaded. Determine the length (L) of the non-threaded shank part using the formula below.

L = T1 + T3, in which T3 must be >

L = shank length without thread T1 = part to be clamped T2 = part to be clamped

4. Tighten the flange bolt to the standard

tightening torque for bolts, property class 8.8.

/2 T2.

C9 00 295

1-6

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CHASSIS

ΧΦ65/75/85 series

Fitting flange bolt M16

1. Drill the rivet hole out to  17 mm. Make sure

not to damage any lines running behind the rivet hole. Deburr the edges.

2. Repair the chassis paintwork. The

new paintwork should be no thicker than 50 microns.

3. Install a flange bolt M16 x 2, property

class 10.9, with a non-threaded shank (A) of 6 mm.

4. Tighten the flange bolt to the standard

tightening torque for bolts, property class 10.9.

General

C9 00 296

200448 1-7

Page 50

CHASSIS

General

ΧΦ65/75/85 series

1-8

200448

Page 51

SHOCK ABSORBERS

ΧΦ65/75/85 series

3 Shock absorbers

CONTENTS

Page Date

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

1.1 Operation of shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

2. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200448

2.1 Removal and installation, shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200448

Contents

200448 1

Page 52

SHOCK ABSORBERS

Contents

ΧΦ65/75/85 series

200448

Page 53

SHOCK ABSORBERS

ΧΦ65/75/85 series

1. GENERAL

1.1 OPERATION OF SHOCK ABSORBER

The function of the shock absorber is twofold:

- to control the movements of chassis and

superstructure in relation to the axle. Optimum comfort is achieved when the chassis and superstructure remain truly horizontal and are not subjected to any vertical accelerations when moving;

- to control the movements of the wheels on

the road. Optimum handling is achieved when all wheels remain in constant contact with the road surface.

The rate of the above-mentioned movements depends on the available spring travel. The available spring travel is the difference in height between an unloaded spring and a fully loaded spring. A well-functioning shock absorber with characteristics appropriate to the operating conditions will be the best possible compromise to fulfil the above-mentioned functions.

General

DAF only uses double-acting type shock absorbers. On vehicles with air suspension, hydraulic stroke limitation is used.

The shock absorber consists of:

- an operating cylinder, in which the actual

damping is done by a piston with piston rod of which the valve unit damps the rebound stroke;

- a bottom valve which, in combination with

the piston valve unit, damps the bump stroke.

- a reservoir tube which draws in oil surplus

(result of the volume taken up by the piston rod) via the bottom valve;

- a dust cover, attached to the piston rod.

200448 1-1

Page 54

SHOCK ABSORBERS

General

Double-acting shock absorbers

The operation of the shock absorber is as follows: The bump stroke moves the piston (1) down in relation to the operating cylinder (2). Subsequently, oil flows from the bottom chamber of the piston (1) through the piston holes and valves to the top chamber where the volume increases. The oil pressure is equal on either side of the piston (1).

To compensate for the volume taken up by piston rod (3), oil flows from under the piston (1), via the bottom valve (4), to the reservoir tube (5). The resistance met by the oil during this movement dampens the bump stroke of the shock absorber. The rebound stroke moves the piston (1) up in relation to the operating cylinder (2). Subsequently, pressure is exerted on the oil in the upper chamber of the piston (1) causing the oil to flow through the piston holes and valves to the bottom chamber under piston (1). The resistance met by the oil during this movement dampens the rebound stroke of the shock absorber. To compensate for the volume taken up by the piston rod (3) in the upper chamber, oil flows via bottom valve (4) from the reservoir tube (5) to the bottom chamber under the piston (1).

ΧΦ65/75/85 series

5 2

W9 02 001

1-2

200448

Page 55

SHOCK ABSORBERS

ΧΦ65/75/85 series

2. REMOVAL AND INSTALLATION

2.1 REMOVAL AND INSTALLATION, SHOCK ABSORBER

Removing shock absorber

1. Remove the attachment nuts and/or bolts.

2. Mark the exact positions and location of the

mounting rubbers.

3. Remove the shock absorber from under the

vehicle.

Installing shock absorber

1. Check the shock absorber mountings for

hairline cracks.

2. If the old rubbers are to be reused, check

them for hairline cracks and ageing. Install the rubbers in the original locations and positions.

3. When replacing the rubbers, use only the

specified types.

Removal and installation

4. When installing the shock absorbers on a

leaf-sprung trailing axle, bearing rings (1) have to be used with the treated (blackened) side facing away from the shock absorber rubbers (2).

5. Replace the self-locking nuts. Tighten the

attachment bolts to the specified torque. See "Technical data".

C9 00 164

200448 2-1

Page 56

SHOCK ABSORBERS

Removal and installation

ΧΦ65/75/85 series

2-2

200448

Page 57

STABILISERS AND TORQUE RODS

ΧΦ65/75/85 series

4 Stabilisers and torque r ods

CONTENTS

Page Date

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

1.1 Overview drawing, front axle stabiliser . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

1.2 Overview drawing, leaf-sprung rear axle stabiliser . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200448

1.3 Overview drawing, stabiliser of leaf-sprung trailing axle and parabolic

leaf-sprung tandem axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . 200448

1.4 Overview drawing, air-sprung rear axle stabiliser . . . . . . . . . . . . . . . . . . . 1-4 . . . . . 200448

1.5 Overview drawing, leading rear axle stabiliser . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . 200448

1.6 Description of axle load compensation device . . . . . . . . . . . . . . . . . . . . . 1-6 . . . . . 200448

2. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200448

2.1 Removal and installation, front axle stabiliser . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200448

2.2 Removal and installation, leaf-sprung rear axle stabiliser . . . . . . . . . . . . . 2-3 . . . . . 200448

2.3 Removal and installation, stabiliser of leaf-sprung trailing axle and

parabolic leaf-sprung tandem axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . 200448

2.4 Removal and installation, air-sprung rear axle stabiliser . . . . . . . . . . . . . . 2-7 . . . . . 200448

2.5 Removal and installation, leading rear axle stabiliser . . . . . . . . . . . . . . . . 2-9 . . . . . 200448

2.6 Removal and installation, silentblock with rubber casing. . . . . . . . . . . . . . 2-11 . . . . 200448

2.7 Removal and installation, silentblock with steel casing . . . . . . . . . . . . . . . 2-13 . . . . 200448

2.8 Removal and installation, triangular link and air-sprung rear axle torque

rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 . . . . 200448

2.9 Removal and installation, triangular link and tandem axle torque rods . . . 2-16 . . . . 200448

2.10 Removal and installation, leading rear axle torque rods . . . . . . . . . . . . . . 2-18 . . . . 200448

2.11 Removal and installation, axle load compensation device rod . . . . . . . . . 2-20 . . . . 200448

Contents

3. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200448

3.1 Disassembly and assembly, silentblock of triangular link . . . . . . . . . . . . . 3-1 . . . . . 200448

3.2 Disassembly and assembly, ball joint of triangular link . . . . . . . . . . . . . . . 3-3 . . . . . 200448

3.3 Disassembly and assembly, mounting rubbers . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . 200448

200448 1

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STABILISERS AND TORQUE RODS

Contents

ΧΦ65/75/85 series

200448

Page 59

STABILISERS AND TORQUE RODS

ΧΦ65/75/85 series

1. GENERAL

1.1 OVERVIEW DRAWING, FRONT AXLE STABILISER

General

1. Flange bolt

2. Shackle

3. Silentblock

4. Bracket

5. Flange nut

6. Stabiliser bar

7. Flange bolt

8. Silentblock

9. Flange nut

10. Flange bolt

11. Bracket

12. Bearing bush

13. Bearing bush cover

14. Flange nut

C9 00 292

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STABILISERS AND TORQUE RODS

General

ΧΦ65/75/85 series

1.2 OVERVIEW DRAWING, LEAF-SPRUNG REAR AXLE STABILISER

2 1

1. Circlip

2. Bracket

3. Axle

4. Bearing bush

5. Bracket

6. Ring

7. Circlip

8. Flange bolt

9. Bearing bush

10. Stabiliser bar

11. Bracket

12. Attachment bolt

13. Attachment nut

14. Silentblock

15. Ring

16. Attachment nut

C9 00 425

1-2

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STABILISERS AND TORQUE RODS

ΧΦ65/75/85 series

General

1.3 OVERVIEW DRAWING, STABILISER OF LEAF-SPRUNG TRAILING AXLE AND PARABOLIC LEAF-SPRUNG TANDEM AXLE

2 1

1. Circlip

2. Bracket

3. Axle

4. Bearing bush

5. Bracket

6. Washer

7. Circlip

8. Flange bolt

9. Bearing bush

10. Stabiliser bar

11. Bracket

12. Attachment bolt

13. Attachment nut

14. Silentblock

15. Ring

16. Attachment nut

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General

ΧΦ65/75/85 series

1.4 OVERVIEW DRAWING, AIR-SPRUNG REAR AXLE STABILISER

16 17

7 9

1. Bracket

2. Attachment bolt

3. Ring

4. Ring

5. Attachment nut

6. Silentblock

7. Shackle

8. Attachment bolt

9. Ring

10. Ring

11. Attachment nut

12. Silentblock

13. Stabiliser bar

14. Bearing bush

15. Bearing bush cover

16. Ring

17. Attachment bolt

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1.5 OVERVIEW DRAWING, LEADING REAR AXLE STABILISER

General

1. Stabiliser bar

2. Bracket

3. Attachment bolt

4. Bearing bush

5. Locking plate

6. Attachment bolt

7. Bearing bush

8. Bracket

9. Attachment nut

10. Attachment bolt

11. Ring

12. Silentblock

13. Ring

14. Attachment nut

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General

1.6 DESCRIPTION OF AXLE LOAD COMPENSATION DEVICE

21 3 4 5

Vehicles equipped with a double front axle are fitted with an axle load compensation device. The axle load compensation device ensures that the vehicle weight is distributed evenly over both front axles. Via the shackle (2), rod (3) and shackle (5) force is transferred from the front spring assembly (1) to the rear spring assembly (4) and vice versa.

ΧΦ65/75/85 series

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Removal and installation

2. REMOVAL AND INSTALLATION

2.1 REMOVAL AND INSTALLATION, FRONT AXLE STABILISER

Removing front axle stabiliser

1. Remove the bearing bush covers (13).

2. Remove the attachment bolts (7).

3. Remove the stabiliser bar (6) from under the

vehicle.

4. Remove the bearing bushes (12) from the

stabiliser bar (6).

5. Remove the attachment bolts (1) and the

shackles (2).

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Removal and installation

Installing front axle stabiliser

1. Check the condition of the silentblocks (3)

and (8) and the bearing bushes (12).

2. Fit the shackles (2).

3. Turn the bearing bush (12) so that the edges

come to rest in the support (11) and the bearing bush cover (13).

4. Fit the bearing bush covers (13).

5. Install the stabiliser bar (6) in the

shackles (2).

6. Fit the attachment bolts (7) with the heads

facing towards the chassis.

7. Tighten the attachment bolts (1), (7) and (10)

to the specified torque, see "Technical data".

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Removal and installation

2.2 REMOVAL AND INSTALLATION, LEAF-SPRUNG REAR AXLE STABILISER

2 1

Removing leaf-sprung rear axle stabiliser

1. Remove the brackets (5) and (11).

2. Remove the attachment bolts (12).

3. Remove the stabiliser bar (10) from under

the vehicle.

4. Remove the bearing bushes (9) from the

stabiliser bar (10).

5. Remove the circlip (7) with the washer (6)

and remove the bearing bush (4) from the axle (3).

Installing leaf-sprung rear axle stabiliser

1. Check the condition of the silentblock (14)

and the bearing bushes (4) and (9).

2. Fit the bearing bushes (4), using new

circlips (7).

3. Fit the bearing bushes (9) to the stabiliser

bar (10).

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Removal and installation

4. Turn the bearing bushes (4) and (9) into the

indicated position.

5. Fit the brackets (5) and (11). Fit the

attachment bolts (8) with the heads facing towards the front of the vehicle and tighten the bolts (8) to the specified torque, see "Technical data".

6. Fit the attachment bolts (12) with the heads

facing towards the chassis.

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Removal and installation

2.3 REMOVAL AND INSTALLATION, STABILISER OF LEAF-SPRUNG TRAILING AXLE AND PARABOLIC LEAF-SPRUNG TANDEM AXLE

2 1

Removing stabiliser of leaf-sprung trailing axle and parabolic leaf-sprung tandem axle

1. Remove the brackets (5) and (11).

2. Remove the attachment bolts (12).

3. Remove the stabiliser bar (10) from under

the vehicle.

4. Remove the bearing bushes (9) from the

stabiliser bar (10).

5. Remove the circlip (7) with the washer (6)

and remove the bearing bush (4) from the axle (3).

Installing stabiliser of leaf-sprung trailing axle and parabolic leaf-sprung tandem axle

1. Check the condition of the silentblock (14)

and the bearing bushes (4) and (9).

C9 00 426

2. Fit the bearing bushes (4), using new

circlips (7).

3. Fit the bearing bushes (9) to the stabiliser

bar (10).

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Removal and installation

4. Turn the bearing bushes (4) and (9) into the

indicated position.

5. Fit the brackets (5) and (11). Fit the

attachment bolts (8) with the heads facing towards the rear of the vehicle and tighten the bolts (8) to the specified torque, see "Technical data".

6. Fit the attachment bolts (12) with the heads

facing towards the chassis.

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Removal and installation

2.4 REMOVAL AND INSTALLATION, AIR-SPRUNG REAR AXLE STABILISER

16 17

7 9

Removing air-sprung rear axle stabiliser

1. Remove the bearing bush covers (15).

2. Remove the attachment bolts (8).

3. Remove the stabiliser bar (13) from under

the vehicle.

4. Remove the bearing bushes (14) from the

stabiliser bar (13).

5. Remove the attachment bolts (2) and

remove the shackle (7) from the bracket (1).

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Removal and installation

Installing air-sprung rear axle stabiliser

1. Check the condition of the bearing bush (14)

and the silentblocks (6) and (12).

2. Fit the shackle (7).

3. Turn the bearing bushes (14) such that the

opening is located at the contact surface of the bearing cover.

4. Fit the bearing bush covers (15). Evenly

tighten the attachment bolts (17).

5. Fit the attachment bolts (8) with the heads

facing towards the chassis.

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Removal and installation

2.5 REMOVAL AND INSTALLATION, LEADING REAR AXLE STABILISER

Removing leading rear axle stabiliser

1. Remove the brackets (2) and (8).

2. Remove the attachment bolts (10).

3. Remove the stabiliser bar (1) from under the

vehicle.

4. Remove the bearing bushes (7) from the

stabiliser bar (1).

5. Remove the locking plate (5) and remove the

bearing bush (4) from the axle.

Installing leading rear axle stabiliser

1. Check the condition of the silentblock (12)

and the bearing bushes (4) and (7).

2. Fit bearing bush (4), using the locking

plate (5). Tighten the attachment bolts (6) to the specified torque. See "Technical data".

3. Fit the bearing bushes (7) to the stabiliser

bar (1).

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Removal and installation

4. Turn the bearing bushes (4) and (7) into the

indicated position.

5. Fit the brackets (2) and (8). Fit the

attachment bolts (3) with the heads facing towards the rear of the vehicle and tighten the bolts (3) to the specified torque, see "Technical data".

6. Fit the attachment bolts (10) with the heads

facing towards the chassis.

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Removal and installation

2.6 REMOVAL AND INSTALLATION, SILENTBLOCK WITH RUBBER CASING

Note:

- The silentblocks for the stabiliser bar and the

stabiliser bar shackle are identical to one another.

- The silentblocks have to be fitted using

special tool (DAF no. 1310476). It is not possible to install the silentblocks undamaged, without using this puller.

- The stabiliser bar does not have to be

removed when replacing the silentblocks on the stabiliser bar.

Removing silentblock with rubber casing

1. Force the silentblock (1) - using the

puller (A), special tool (DAF no. 1310476) from the stabiliser bar (2) or the stabiliser bar shackle (2). Before fitting the puller, apply a lubricant to the contact surface of the puller or the silentblock, for example tyre grease or a soap solution.

A12A

Installing silentblock with rubber casing

1. Apply plenty of lubricant to the outer

circumference of the new silentblock (1) and the contact surface of the puller or the silentblock, for example tyre grease. Never apply any grease or oil product to the new silentblock.

2. Place the guide sleeve (B), which forms part

of the puller, on the stabiliser bar or the shackle.

3. Place the new silentblock (1) on guide

sleeve (B) and pull the silentblock (A) into the stabiliser bar (2) or the shackle (2) using puller (A), special tool (DAF no. 1310476).

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Removal and installation

4. Pull the silentblock into the eye until the

collar of the silentblock has been pulled fully through the eye. Remove the guide sleeve (B) and, if necessary, slightly force the silentblock backwards so that the collars of the silentblock protrude from both sides of the stabiliser bar or the shackle. See arrows in drawing.

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Removal and installation

2.7 REMOVAL AND INSTALLATION, SILENTBLOCK WITH STEEL CASING

Note:

- The silentblocks with steel casing should be

fitted using special tool (DAF no. 1310479). It is not possible to install the silentblocks undamaged, without using this puller.

- The stabiliser bar does not have to be

removed when replacing the silentblocks.

Removing silentblock with steel casing

1. Fit the thrust piece with the smallest

diameter (B in the drawing) on the puller (A), special tool (DAF no. 1310479).

2. Apply a lubricant to the thrust piece, for

example tyre grease, and fit the puller.

3. Using the puller, force the silentblock from

the stabiliser bar.

12ABA

C9 00 149

Installing silentblock with steel casing

1. Place the thrust piece with the largest

diameter (C in the drawing) on the puller (A).

2. Apply for example tyre grease to the thrust

piece, and place the puller (A) with the silentblock (1) on the stabiliser bar (2).

3. Force the silentblock into the stabiliser bar

using the puller. The thrust piece (C) must just touch the stabiliser bar.

4. Check whether the two sides of the

silentblock protrude equally out of the stabiliser bar.

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ΧΦ65/75/85 series

2.8 REMOVAL AND INSTALLATION, TRIANGULAR LINK AND AIR-SPRUNG REAR AXLE TORQUE RODS

Removing triangular link

1. Remove the attachment bolts (2).

2. Remove the attachment bolts (3) and

remove the torque rod (1). This can only be done by two persons working together.

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Installing triangular link

1. Before installation, check the rubber bushes

of the triangular link and the silentblock for hairline cracks and wear. Check to see if the contact surface of the triangular link flange (1) (see arrow) and the contact surface on the axle housing are free from grease and paint.

2. Install the triangular link (1) to the vehicle.

This can only be done by two persons working together. Fit the attachment bolts (2) and (3). Tighten the attachment bolts (2) evenly to the specified torque. See "Technical data".

Removing torque rod

1. Remove the attachment bolts (5) and (8) and

remove the torque rod (7).

Installing torque rod

1. Before installation, check the rubber bushes

of the torque rod (7) for hairline cracks and wear.

Removal and installation

2. Clean the contact surfaces if necessary.

These should be free from dirt and grease.

3. Fit the torque rod (7) between the torque rod

bracket (4) and the yoke (10).

4. Fit the attachment bolts (5) and (8) with the

heads facing towards the front of the vehicle. Secure the attachment bolts (5) and (8).

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2.9 REMOVAL AND INSTALLATION, TRIANGULAR LINK AND TANDEM AXLE TORQUE RODS

}

If the triangular link and torque rods are removed from an axle, the axle should be adequately supported to prevent it from tipping over.

ΧΦ65/75/85 series

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w9 03 011

Removing triangular link

1. Remove the attachment bolts (6).

2. Remove the attachment bolts (5) and

remove the triangular link (4). This can only be done by two persons working together.

Installing triangular link

1. Before installation, check the rubber bushes

of the triangular link for hairline cracks and wear. Check if the contact surface of the triangular link flange and the contact surface on the axle housing are free from grease and paint.

2. Install the triangular link (4). This will take two

persons working together. Fit the attachment bolts (5) and (6) and secure the bolts (5).

3. Tighten the attachment bolts (6) evenly to

the specified torque. See "Technical data".

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Removing torque rod

1. Remove the attachment bolts (1) and (2) and

remove the torque rod (3).

Installing torque rod

1. Before installation, check the rubber bushes

of the torque rod (3) for hairline cracks and wear.

2. Clean the contact surfaces if necessary.

These should be free from dirt and grease.

3. Install the torque rod (3) between the

brackets.

Note:

If torque rod bracket (7) has been removed, it must be reinstalled with the arrow (A) on the bracket pointing in the driving direction.

If there were any filler plates (B) previously between the torque rod bracket and the axle housing, they must be returned to the same position. The clearance between axle housing and bracket should not exceed 0.5 mm.

4. Secure the attachment bolts (1).

Removal and installation

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Removal and installation

ΧΦ65/75/85 series

2.10 REMOVAL AND INSTALLATION, LEADING REAR AXLE TORQUE RODS

1 2

3 4

3 2

6 7 8 6 7

Removing upper torque rod

1. Remove both attachment bolts (2) and

remove the torque rod (1).

Installing upper torque rod

1. Before installation, check the rubber bushes

of the torque rod (1) for hairline cracks and wear.

2. Clean the contact surfaces if necessary.

These should be free from dirt and grease.

3. Fit the torque rod (1) as shown.

4. Fit the attachment bolts (2) with the heads

facing towards the rear of the vehicle. Tighten the attachment bolts to the specified torque. See "Technical data".

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Removing lower torque rod

1. Remove both attachment bolts (6) and

remove the torque rod (8).

Installing lower torque rod

1. Before installation, check the rubber bushes

of the torque rod (8) for hairline cracks and wear.

2. Clean the contact surfaces if necessary.

These should be free from dirt and grease.

3. Fit the torque rod (8) as shown.

4. Fit the attachment bolts (6) with the heads

facing towards the front of the vehicle. Tighten the attachment bolts to the specified torque. See "Technical data".

Removal and installation

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Removal and installation

2.11 REMOVAL AND INSTALLATION, AXLE LOAD COMPENSATION DEVICE ROD

Removing axle load compensation device rod

1. Remove the ball end nuts on both sides of

the rod. Self-locking nuts must not be reused.

2. Remove the ball ends from the shackles

using a ball end puller (A).

ΧΦ65/75/85 series

Installing axle load compensation device rod

1. Check the balls of the rod for wear and

damage.

2. Check the ball end thread for damage before

fitting a new self-locking nut. To do so, handtighten a new non-self-locking nut on the ball end to be checked. If the new nut cannot be fully hand-screwed onto the entire thread, the ball end must be replaced.

Fitting a new self-locking nut to a ball end with a damaged thread may

}

3. Clean the tapered contact surfaces of both

4. Fit the rod.

lead to dangerous situations.

the balls and the shackles. The tapered surfaces should be absolutely free from dirt, grease and paint.

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It is not allowed to fit a self-locking nut to a ball end with split-pin hole.

}

5. In the case of self-locking nuts, use new self-

locking nuts. Tighten the ball end nuts to the specified torque. See "Technical data". In the case of a castle nut, if the ball end splitpin hole does not match the recesses in the castle nut, the castle nut should be tightened further.

6. In the case of castle nuts, secure them with

new split pins.

Removal and installation

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Removal and installation

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Disassembly and assembly

3. DISASSEMBLY AND ASSEMBLY

3.1 DISASSEMBLY AND ASSEMBLY, SILENTBLOCK OF TRIANGULAR LINK

Disassembling silentblock of triangular link

1. Loosen the attachment bolts (7) a few turns.

2. Remove the attachment bolt (1).

3. Screw an M24 x 1.5 bolt into the silent-

block (4). This will remove the triangular link (2) from the tapered attachment pin. If the triangular link (2) cannot be removed, the flange (5) must be removed from the axle housing and be forced from the triangular link (2) using a pressing tool.

4. Remove the attachment bolts (7). Remove

the triangular link from under the vehicle. This can only be done by two persons working together.

5. Remove the circlip (3).

123

6. Remove the silentblock (4) from the

triangular link (2) using a pressing tool. Make sure that the tool rests on the outer rim of the silentblock (4).

Assembling silentblock of triangular link

1. Clean the chamber in the triangular link (2).

2. Remove all rust and grease from the tapered

part of the flange (5).

3. Apply a thin layer of acid-free petroleum

jelly to the circumference of the new silentblocks (4).

4. Position the new silentblock (4) such that the

marking (see arrow) is positioned in between the torque rods as indicated.

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Disassembly and assembly

5. Force the silentblock (4) into the triangular

link (2). Make sure that the tool rests on the outer rim of the silentblock (4).

6. Fit the circlip (3) as indicated. Make sure that

the entire circlip (3) is positioned correctly in the groove.

7. Install the flange (5), if it was removed, on the

axle housing. Check to see if the contact surface of the flange (5) and the contact surface on the axle housing are free from grease and paint. Tighten the attachment bolts (6) to the specified torque. See "Technical data".

8. Install the triangular link (2) under the

vehicle. This will take two persons working together. Tighten the attachment bolts (7) by hand.

9. Fit the attachment bolt (1). Tighten the

attachment bolt (1) to the specified torque. See "Technical data".

123

ΧΦ65/75/85 series

C9 00 300

10. Secure the attachment bolts (7).

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Disassembly and assembly

3.2 DISASSEMBLY AND ASSEMBLY, BALL JOINT OF TRIANGULAR LINK

Disassembling ball joint of triangular link

1. Carefully grind away the tack welds on the

cover (1) and remove the cover and felt ring (2).

163

2. Remove the circlip (3), the steel washer (4)

and the triangular shim (5).

3. Remove the attachment bolt (6).

4. Screw an M20 x 1.5 bolt into the ball (7). This

will drive the ball and the ball socket (8) out of the housing (14).

5. Remove the triangular shim (9).

6. Remove the clamping strip (10) from the

gaiter (11). The torque rod can now be separated from the pin.

7. Remove the spring (12) to replace the

gaiter (11).

13 12

W9 03 010

Note:

It is not necessary to take the ball out of the housing if only the gaiter (11) needs to be replaced. Remove the attachment bolt (6) and the clamping strip (10). By screwing an M20 x 1.5 bolt into ball (7), the torque rod is separated from the flange (13), and the gaiter can be replaced.

Assembling ball joint of triangular link

1. Before assembly, thoroughly clean all parts

to be reused.

2. Fit the gaiter (11) with the spring (12) onto

the flange (13). Repack the gaiter (space 15) with approx. 125 cm

3. Fit the triangular shim (9).

4. Grease the ball (7) and the ball socket (8)

and insert them into the housing (14).

of grease.

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Disassembly and assembly

5. Then fit the triangular shim (5), the steel

washer (4) and the circlip (3), in this order. Make sure that circlip (3) is correctly fitted in the groove of the housing.

6. Fit the ball (7) which is installed in the

housing onto the pin of the flange (13), using the attachment bolt (6). Tighten the attachment bolt (6) to the specified torque. See "Technical data".

7. Attach the gaiter (11) to the housing (14)

using the clamping strip (10).

8. Pack the space on top of the ball (space 16)

with approx. 35 cm

9. Carefully tap the cover (1) and the felt ring (2)

into place with a nylon mallet.

10. Secure the cover with tack welds (3).

Note:

When the flange (13) has been removed and repainted, the contact surface of the flange (see arrows in drawing) should be made free of paint before the flange is reinstalled.

of grease.

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Disassembly and assembly

3.3 DISASSEMBLY AND ASSEMBLY, MOUNTING RUBBERS

Disassembling mounting rubber

1. Remove the circlip (1) and, if fitted, the

shim (2).

2. Drive the pin and rubber bush unit (3) from

the torque rod housing (4).

Assembling mounting rubber

1. Apply a thin film of acid-free petroleum jelly

or tyre grease to the rubber.

2. Push the pin (3) into the housing (4). Make

sure that the bolt holes are parallel with the torque rod.

3. Fit the shim (2) (if removed earlier).

2 1

4. Fit the circlip (1) as indicated. Ensure that the

circlip (1) is correctly fitted into the groove of the housing.

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Disassembly and assembly

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LEAF SUSPENSION

ΧΦ65/75/85 series

5 Leaf suspension

CONTENTS

Page Date

1. SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200448

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200448

2.1 Description of leaf suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200448

2.2 Overview drawing, single-axle suspension with bolt attachment. . . . . . . . 2-4 . . . . . 200448

2.3 Overview drawing, single-axle suspension with pin attachment . . . . . . . . 2-5 . . . . . 200448

2.4 Overview drawing, tandem axle suspension . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . 200448

3. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200448

3.1 Removal and installation, single-axle spring assembly with bolt

attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200448

3.2 Removal and installation, spring assembly silentblock with bolt

attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200448

3.3 Removal and installation, single-axle spring assembly with pin

attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . 200448

3.4 Removal and installation, sealing rings of pin attachment. . . . . . . . . . . . . 3-8 . . . . . 200448

3.5 Removal and installation, shackle bush of pin attachment . . . . . . . . . . . . 3-9 . . . . . 200448

3.6 Removal and installation, bearing bush of pin attachment . . . . . . . . . . . . 3-10 . . . . 200448

3.7 Removal and installation, spring bracket. . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . 200448

3.8 Removal and installation, spring bracket silentblock . . . . . . . . . . . . . . . . . 3-12 . . . . 200448

3.9 Removal and installation, tandem axle spring assembly. . . . . . . . . . . . . . 3-15 . . . . 200448

3.10 Removal and installation, pivot pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17 . . . . 200448

3.11 Removal and installation, arresting cable and bump stop . . . . . . . . . . . . . 3-20 . . . . 200448

3.12 Removal and installation, wearing plates . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 . . . . 200448

3.13 Removal and installation, alignment plates . . . . . . . . . . . . . . . . . . . . . . . . 3-22 . . . . 200448

Contents

4. DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200448

4.1 Disassembly and assembly, spring assembly . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200448

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Contents

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1. SAFETY INSTRUCTIONS

1.1 SAFETY INSTRUCTIONS

Spring leaves

- Spring leaves should not be subjected to blasting. Blasting will cause indentations in the leaf spring which could initiate pitting corrosion.

- Corrosion should be prevented as this will considerably shorten the service life of the spring.

- Any type of damage should be prevented. Damage will considerably shorten the service life.

- Spring leaves should not be heated.

- Bear this in mind when welding on the vehicle. Take precautionary measures against weld and fire damage (notching effect).

- Never hit a parabolic spring leaf with a hammer. This could cause the leaf to break.

- Never replace a single broken leaf within a spring assembly, because this will substantially shorten the service life of the other spring leaves.

Safety instructions

Spring brackets

Spring brackets should be removed, if:

- there is doubt about the dimensional accuracy after having been subjected to a heavy load (e.g. a collision). The spring bracket should be magnaflux tested. If cracks are detected, the spring bracket should be replaced. If it is not possible to magnaflux test the spring bracket, the spring bracket should always be replaced.

- such a degree of wear has occurred that it must be replaced.

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Safety instructions

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1-2

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2. GENERAL

2.1 DESCRIPTION OF LEAF SUSPENSION

DAF uses two different types of leaf spring assemblies on its vehicles: parabolic and trapezoidal leaf spring assemblies. The trapezoidal leaf spring assemblies only come with the driven tandem axle.

The trapezoidal leaf spring assembly consists of a number of spring leaves of different lengths, fitted on top of each other.

The parabolic leaf spring assembly, which has fewer spring leaves than the trapezoidal leaf spring assembly, consists of several spring leaves of equal length whereby the thickness of each leaf follows a parabolic curve in relation to its length. Except at the centre clamping and at the spring leaf ends, the spring leaves of a parabolic leaf spring assembly should not come into contact. To that end spacer plates have been fitted between the spring leaves. As the leaves of a parabolic leaf spring assembly do not slide over each other, they are subjected to less friction than those of a trapezoidal leaf spring assembly. Consequently, they give a better ride under similar stiffness conditions.

General

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General

The spring leaves (3) of both types of assembly are held together by a centre bolt (1) and spring shackles (2). The head of the centre bolt (1) is used to centre the spring assembly. At the front, the spring assembly is connected to the spring bracket with a shackle pin. At the rear, the spring assembly is "attached" to the spring bracket with either a shackle or a slipper seat, depending on the type of vehicle. The spring assembly is clamped to the axle housing using U-bolts. A wedge and/or filler block may have been fitted between the spring assembly and the axle housing. The U-bolts clamp the spring leaves together and secure the spring assembly to the axle. The forces on the axle are therefore passed on to the spring brackets via the spring assembly.

The parabolic spring assemblies applied in the case of a rear axle suspension are fitted with a helper leaf (3). A centre bolt is used to attach the helper leaf (3) to the other spring leaves (2). At the ends of the helper leaf (2) rubber blocks (1) are installed which rest against the main spring assembly.

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C9 00 297

Except for the spring which comes with the airsprung front axle suspension, the parabolic spring assemblies are fitted with a maintenancefree suspension. To that end, a silentblock (4) is installed into the spring eyes. The silentblock is clamped in the spring bracket (1) using an attachment bolt (2) and sliding bush (3).

Apart from the spring function, the leaf spring assemblies also have the task of guiding the axle. This means that braking, driving and lateral forces are passed on to the chassis via the spring assembly and the front spring bracket.

3 4

C9 00 303

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During fierce braking on a rough road surface, the leaf spring and the spring bracket have to deal with the forces of the weight of the vehicle (which is increased by driving over holes) and with the braking forces at the same time. This results in a considerable total force exerted on the leaf spring and the spring bracket.

Spring opening

The spring opening (P in the drawing) indicates the deflection of the spring. The spring assembly is constructed to obtain the optimum spring opening for a laden vehicle. If possible, check the spring opening on both sides of an evenly laden vehicle. As a result of tolerances in the manufacturing process, it is possible that the spring openings differ from each other when the springs are unloaded, but are equal when the springs are loaded. When spring assemblies are new, the difference in spring opening is small. As a result of settling of the spring assembly, the difference in spring opening may increase. When the springs are loaded they become longer and the axle will move backwards. If the left and right spring openings of one axle differ too much, the result will be misalignment of both the vehicle and the axle.

General

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General

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2.2 OVERVIEW DRAWING, SINGLE-AXLE SUSPENSION WITH BOLT

ATTACHMENT

Note:

This drawing gives a general view and may differ from the actual situation on the vehicle.

1. Attachment bolt

2. Slide bush

3. Spring bracket

4. U-bolt

5. Upper spring seat

6. Shock absorber bracket

7. U-bolt nut

8. Spring assembly

9. Attachment nut

10. Shackle seat

11. Spring bracket

12. Sealing ring

13. Attachment bolt

C9 00 305

2-4

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