DAF CF85 Maintenance Manual

Download

Page 1

Maintenance manual CF85

Page 2

Page 3

In the interest of continuing product development, DAF reserves the right to change specifications or products at any time without prior notice.

No part of this publication may be reproduced and/or published by printing, by photocopying, on microfilm or in any way whatsoever without the prior consent in writing of DAF Trucks N.V.

200423 DW13278604

Page 4

Page 5

ΧΦ85 series

STRUCTURE

Structure

TECHNICAL DATA

THREADED CONNECTIONS

FLUIDS, OIL AND LUBRICANTS

MAINTENANCE SCHEDULE

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

200423

Page 6

Page 7

TECHNICAL DATA

ΧΦ85 series

0 Technical data

CONTENTS

Page Date

1. XE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423

1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200423

1.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200423

2. GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200423

2.1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200423

2.2 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200423

3. REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200423

3.1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200423

3.2 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200423

4. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200423

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200423

5. STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200423

5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200423

5.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200423

Contents

6. FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200423

6.1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200423

7. LEADING REAR AXLE 09N044 (FTP-TYPE VEHICLES) . . . . . . . . . . . . . . . . . 7-1 . . . . . 200423

7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200423

7.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 . . . . . 200423

200423 1

Page 8

TECHNICAL DATA

Contents

ΧΦ85 series

200423

Page 9

TECHNICAL DATA

ΧΦ85 series

1. XE ENGINE

1.1 GENERAL

XE engine

Valve clearance

Valve clearance (cold/hot) Inlet 0.50 mm Exhaust 0.50 mm

DEB

DEB setting 1.40 mm

V-belt tension

V-belt tension, "AVX" raw edge

Application example: air-conditioning compressor drive

New V-belt

Setting tension 600

Test tension  400

Run-in V-belt

(2)

(3)

(1)

XE engine

(N)

Minimum tension 250

Adjusting tension 350

V-belt tension, "XPB" raw edge

Application example: steering pump drive on FAX vehicle

New V-belt

(2)

Setting tension 1250

Test tension  950

Run-in V-belt

(3)

Minimum tension 750

Adjusting tension 950

(1) Raw-edge V-belts can be recognised by the absence of

textile fabric in the rubber, with the exception of the top of the belt edge, on the edges and the insides of the belt (polished belt edges). Version: either a toothed or a nontoothed belt.

(2) After fitting the new V-belt, set the pre-tension to the

"setting tension" and after a trial run check whether the pre-tension complies with the "test tension". If the test tension reading is lower than the value specified in the table, set the V-belt to the minimum "test tension".

(3) If the V-belt tension is lower than the "minimum tension",

set the belt to the "adjusting tension".

(1)

(N)

M2121

200423 1-1

Page 10

TECHNICAL DATA

XE engine

1.2 TIGHTENING TORQUES

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

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

XE engine

Lubrication system

Oil drain plug 60 Nm Oil filter screw cap 40 Nm Centrifugal filter central bolt 20 Nm

Fuel system

Fuel filter screw cap 25 Nm

ΧΦ85 series

Cylinder head cover

Cylinder head cover attachment bolts 25 Nm

DEB

DEB attachment bolts 110 Nm DEB set screw nut 25 Nm

V-belt tensioner

Central bolt, tensioning gear 110 Nm

1.3 FILLING CAPACITIES

XE engine

Lubrication system

Total capacity (including oil cooler and oil filter) approx. 34 litres Capacity of oil sump, maximum level approx. 30 litres Capacity of oil sump, minimum level approx. 22 litres

Cooling system

Cooling system approx. 47 litres With integrated retarder approx. 57 litres

1-2

200423

Page 11

TECHNICAL DATA

ΧΦ85 series

2. GEARBOX

2.1 TIGHTENING TORQUES

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

ZF 8S -151/181 and 16S-151/181/221 gearboxes

Level check/filler plug (A) 60 Nm M24 drain plug (B) 60 Nm M38 drain plug (B) 120 Nm Drain plug (C/D) 60 Nm

Gearbox

ZF 8S-151/181 and 16S-151/181/221 with integrated retarder

Drain plug (D) 60 Nm

M3023

V300186

200423 2-1

Page 12

TECHNICAL DATA

Gearbox

Oil filter attachment bolt (1) 23 Nm

ZF AS Tronic

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

ΧΦ85 series

M3052

ZF AS Tronic with integrated retarder

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

Oil filter attachment bolt (1) 23 Nm

G000243

G000250

2-2

M3052

200423

Page 13

TECHNICAL DATA

ΧΦ85 series

2.2 FILLING CAPACITIES

ZF gearboxes

ZF 8S/16S-151

Filling capacity approx. 11 litres

ZF 8S/16S-181

Filling capacity approx. 13 litres

ZF 16S-221

Filling capacity approx. 13 litres

ZF 16S-151 with integrated retarder

Filling capacity approx. 11 litres

ZF 16S-181 with integrated retarder

Filling capacity approx. 12 litres

ZF 16S-221 with integrated retarder

Filling capacity approx. 12 litres

Gearbox

ZF AS Tronic gearboxes

ZF 12 AS 1930/2330

Filling capacity approx. 11 litres

ZF 12 AS 2540

Filling capacity approx. 12 litres

ZF 12 AS 1931/2331 with integrated retarder

Filling capacity approx. 12 litres

ZF 12 AS 2541 with integrated retarder

Filling capacity approx. 13 litres

200423 2-3

Page 14

TECHNICAL DATA

Gearbox

ΧΦ85 series

2-4

200423

Page 15

TECHNICAL DATA

ΧΦ85 series

3. REAR AXLE

3.1 TIGHTENING TORQUES

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

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

Filler and drain plugs/hub plugs (Torx wrench) 85 Nm

M24 U-bolt nut, property class 8

If flanged nut 740 Nm ≥ 55 Nm If yellow zinc plated hexagonal nut 615 Nm ≥ 50 Nm

Rear axle

(1)

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

M24 U-bolt nut, property class 10

If flanged nut 880 Nm ≥ 60 Nm If yellow zinc plated hexagonal nut 615 Nm ≥ 50 Nm

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

M22 U-bolt nut, property class 10 (leading rear axle)

If flanged nut 700 Nm ≥ 50 Nm If yellow zinc plated hexagonal nut 530 Nm ≥ 40 Nm

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

(1)

200423 3-1

Page 16

TECHNICAL DATA

Rear axle

ΧΦ85 series

3.2 FILLING CAPACITIES

Differential Filling quantity with

minimum caster

1339 axle approx. 18.0 litres approx. 20.0 litres 1347 axle approx. 21.5 litres approx. 23.5 litres 1354 axle approx. 16.5 litres approx. 16.5 litres 1355(T) axle (1 1355(T) axle (2 1132(T) axle (1 1132(T) axle (2

Wheel hub Filling capacity per hub

1354 axle approx. 2 litres 1355(T) axle approx. 2 litres 1132(T) axle approx. 0.8 litres

axle) approx. 13.0 litres approx. 18.0 litres

axle) approx. 11.5 litres approx. 13.0 litres

axle) approx. 17.0 litres approx. 25.5 litres

axle) approx. 15.0 litres approx. 17.5 litres

Filling quantity with maximum caster

3-2

200423

Page 17

TECHNICAL DATA

ΧΦ85 series

4. BRAKES

4.1 GENERAL

Brake travel of automatic brake adjuster (Haldex) 35 - 40 mm Brake travel of automatic brake adjuster

(FTP axle) 25 - 35 mm Reverse torque of adjusting bolt > 18 Nm

Brakes

200423 4-1

Page 18

TECHNICAL DATA

Brakes

ΧΦ85 series

4-2

200423

Page 19

TECHNICAL DATA

ΧΦ85 series

5. STEERING GEAR

5.1 GENERAL

Maximum steering ball joint axial clearance 1.5 mm

Steering gear

200423 5-1

Page 20

TECHNICAL DATA

Steering gear

5.2 TIGHTENING TORQUES

Steering gear

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.

Filter plug without flange (A), fluid flow control valve block of EMAS system 125 Nm ≥ 5 Nm

ΧΦ85 series

S7 00 906

Filter plug with flange (B), fluid flow control valve block of EMAS system 270 Nm ≥ 20 Nm

Note:

- The two plugs are interchangeable.

Attachment bolt, steering column universal joint 54 Nm + 4 Nm

(1) Fit new original attachment bolt and nut.

S7 00 907

(1)

5-2

200423

Page 21

TECHNICAL DATA

ΧΦ85 series

6. FRONT AXLE

6.1 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.

U-bolt nut M20, property class 10

If flanged nut 450 Nm ≥ 40 Nm If yellow zinc plated hexagonal nut 400 Nm ≥ 40 Nm

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

Front axle

(1)

M22 U-bolt nut, property class 10 (leading rear axle)

If flanged nut 700 Nm ≥ 50 Nm If yellow zinc plated hexagonal nut 530 Nm ≥ 40 Nm

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

(1)

200423 6-1

Page 22

TECHNICAL DATA

Front axle

ΧΦ85 series

6-2

200423

Page 23

TECHNICAL DATA

ΧΦ85 series

Leading rear axle 09N044 (FTP-type vehicles)

7. LEADING REAR AXLE 09N044 (FTP-TYPE VEHICLES)

7.1 GENERAL

Wheel bearing play, 09N044 leading rear axle 0 mm

200423 7-1

Page 24

TECHNICAL DATA

Leading rear axle 09N044 (FTP-type vehicles)

7.2 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.

Hub nut 100 Nm Hub cap 500 Nm U-bolt nut M20, property class 10 553 Nm

(1) Turn back until split pin can be fitted. (2) Evenly tighten the two U-bolt nuts alternately.

ΧΦ85 series

(1)

(2)

7-2

200423

Page 25

THREADED CONNECTIONS

ΧΦ85 series

2 Threaded connections

CONTENTS

Page Date

1. THREADED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423

Contents

200423 1

Page 26

THREADED CONNECTIONS

Contents

ΧΦ85 series

200423

Page 27

THREADED CONNECTIONS

ΧΦ85 series

1. THREADED CONNECTIONS

1.1 GENERAL

The components may have threaded connections that have been treated with lubricant (dipped threaded connection). Galvanised bolts and nuts are wax dipped in the factory. Black annealed and phosphatised bolts and nuts are oil dipped. The advantage of using dipped nuts and bolts is that friction during tightening is reduced, so that the specified pre-tension force can be accurately obtained. The tightening torque can be reduced while the pre-tension force remains the same.

To achieve a small spread in the pre-tension force, the dipped threaded connection must be tightened accurately. Therefore, always use a reliable torque wrench that provides a high degree of accuracy.

Note:

Have torque wrenches regularly inspected and calibrated.

Threaded connections

Re-use of fasteners (bolt/nut/threaded end)

1. Clean the thread (take particular care to remove locking compound residues) and the clamping faces

2. Check the thread for damage. To do so, manually screw a new nut/bolt onto the thread to be checked. If the new nut/bolt cannot be fully handscrewed onto the entire thread of the fastener to be checked, the fastener is not allowed to be re-used.

3. Apply one drop of engine oil to the upper turn of the bolt (threaded end)/lower turn of the nut and one drop to the clamping faces (other lubricants are not allowed).

4. If a locking compound has been specified, oil should not be applied to the thread.

200423 1-1

Page 28

THREADED CONNECTIONS

Threaded connections

The following applies to all threaded connections (for both new and used vehicles):

- in the case of standard connections, apply the lubricant before fitting, and (re)tighten in accordance with the standard for dipped bolts;

- in the case of special connections, apply the lubricant before fitting, and (re)tighten in accordance with the values specified in the instructions.

The instructions for using lubricants also apply to new bolts from the warehouse. Dry threaded connections may not be used because of their highly variable friction coefficients.

Please consult the workshop manual for the specified tightening torque.

}

ΧΦ85 series

1-2

200423

Page 29

FLUIDS, OIL AND LUBRICANTS

ΧΦ85 series

3 Fluids, oil and lubricants

CONTENTS

Page Date

1. SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423

Contents

200423 1

Page 30

FLUIDS, OIL AND LUBRICANTS

Contents

ΧΦ85 series

200423

Page 31

FLUIDS, OIL AND LUBRICANTS

ΧΦ85 series

1. SPECIFICATIONS

1.1 GENERAL

IN ORDER TO SATISFY THE WARRANTY CONDITIONS AND GUARANTEE THE LIFESPAN, SAFETY AND RELIABILITY OF DAF PRODUCTS, IT IS OF THE UTMOST IMPORTANCE THAT THE CORRECT FLUIDS, OIL AND LUBRICANTS, COOLANT AND FUEL ARE USED AND THAT THE REQUIRED REPLACEMENT INTERVALS ARE OBSERVED.

Lubricant, engine coolant and fuel additives - of whatever type - must not be used except in those circumstances specified by DAF.

Always follow the safety instructions below and the instructions that are supplied with the product.

Ask your lubricant and fuel supplier(s) whether the products supplied comply with DAF specifications.

Specifications

DAF is not liable for damage or problems in the following instances:

1. use of oil of a lower grade than specified.

2. use of oil of a different viscosity than specified.

3. if the change interval is exceeded.

4. if fuel, lubricants or coolants have been used which do not meet the requirements specified by DAF.

200423 1-1

Page 32

FLUIDS, OIL AND LUBRICANTS

Specifications

Avoid contact with: Lubricants

}

Note:

Refer to the "Fluids and lubricants" specification manual for the prescribed fluid, oil and lubricant specifications.

Coolant Fuel Clutch fluid In the event of contact with the skin: remove the liquid with paper or a cloth, wash with soap and water. If irritation persists, consult a doctor. In the event of contact with the eyes: remove with a cloth and rinse with water. If irritation persists, consult a doctor. If swallowed: DO NOT induce vomiting. Rinse mouth, drink two glasses of water and consult a doctor. In the event of inhalation: get fresh air and rest.

ΧΦ85 series

1-2

200423

Page 33

MAINTENANCE SCHEDULE

ΧΦ85 series

4 Maintenance schedule

CONTENTS

Page Date

1. MAINTENANCE INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423

1.1 Maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423

1.2 Explanatory notes on the maintenance schedule . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200423

1.3 Effect of diesel fuel and PTO hours on maintenance intervals . . . . . . . . . 1-4 . . . . . 200423

1.4 Maintenance in special operating conditions . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . 200423

1.5 First service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . 200423

2. MAINTENANCE ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200423

2.1 Overview of maintenance activities for the first service inspection . . . . . . 2-1 . . . . . 200423

2.2 Overview of annual maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200423

2.3 Overview of mileage-dependent maintenance activities . . . . . . . . . . . . . . 2-3 . . . . . 200423

2.4 Overview of intermediate inspection activities . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200423

Contents

200423 1

Page 34

MAINTENANCE SCHEDULE

Contents

ΧΦ85 series

200423

Page 35

MAINTENANCE SCHEDULE

ΧΦ85 series

1. MAINTENANCE INTERVALS

1.1 MAINTENANCE SCHEDULE

The service intervals stated in the maintenance schedule are based on use of the oils and fuels specified by DAF.

Maintenance

schedule

CF85

Intermediate

inspection

X service

30.000 km

Maintenance intervals

Y service

1x per YEAR

1 year

max. 100.000 km

1 year

Ext.

(1) Extended changing intervals not permitted on

1354 and 1355(T) rear axles.

(2) 1 year/maximum 100,000 km for:

- 1132(T), 1354 and 1355(T) rear axles

(3) Extended changing intervals not permitted on 1354

and 1355(T) rear axles. 3 years/maximum 300,000 km for:

- 1132(T) rear axle

30.000 km

50.000 km

60.000 km

50.000 km

100.000 km

75.000 km

120.000 km

3 year

max. 180.000 km

1 year

max. 100.000 km

3 year

max. 300.000 km

1 year

max. 150.000 km

3 year

max. 450.000 km

2 year

max. 120.000 km

(1)

1 year

max. 100.000 km

3 year

max. 300.000 km

(1)

1 year

max. 200.000 km

(2)

3 year

max. 450.000 km

(3)

G000234

200423 1-1

Page 36

MAINTENANCE SCHEDULE

Maintenance intervals

1.2 EXPLANATORY NOTES ON THE MAINTENANCE SCHEDULE

Maintenance group classification

Depending on the use to which the vehicle is put, the vehicle is placed in maintenance group I, II or III.

Maintenance group I

Operation on building sites, in quarries, etc.

- Operation on unmetalled roads

- Traffic in dusty conditions

- Sanitation department vehicles

- Distribution transport with an annual mileage up to 30,000 km.

Maintenance group II

Urban and regional transport

- Distribution traffic in urban areas

- Traffic between adjacent villages/cities

Maintenance group III

(Inter)national traffic

ΧΦ85 series

- Long-distance/very long-distance traffic

Standard changing interval

This is the standard changing interval symbol.

See the "Fluids and lubricants" specifications manual for the prescribed oil specification.

Extended changing interval

This is the extended changing interval symbol.

If the prescribed oil specification and any additional conditions (see specification manual "Fluids and lubricants") are complied with, an extended changing interval may be applied.

Note:

An extended changing interval for engine oil may be subject to additional conditions. The additional conditions are included in the "Fluids and lubricants" specification manual.

G0 00 230

Ext.

G0 00 229

1-2

200423

Page 37

MAINTENANCE SCHEDULE

ΧΦ85 series

Intermediate inspection

This is the intermediate inspection symbol.

Intermediate inspections are based on several visual inspections.

When an extended changing interval is applicable to the engine oil (X-service), an intermediate inspection should be carried out.

X-service

This is the symbol for an X-service.

An X-service is a mileage-dependent maintenance check which consists of changing the engine oil plus a number of visual inspections.

Note:

If the prescribed oil specification and additional conditions (see specification manual "Fluids and lubricants") are met, an extended changing interval (X-service) may be applied. An X service should be carried out at least once every year.

Maintenance intervals

Intermediate inspection

G000088

X service

Y-service

This is the symbol for a Y-service.

A Y-service is an annual maintenance check consisting of several maintenance activities plus changing of the gearbox and rear axle oil.

Note:

If the prescribed oil specification (see specification manual "Fluids and lubricants") has been met, an extended changing interval may be applied.

G000086

Y service

1x per YEAR

(1)

G000087

200423 1-3

Page 38

MAINTENANCE SCHEDULE

Maintenance intervals

ΧΦ85 series

1.3 EFFECT OF DIESEL FUEL AND PTO HOURS ON MAINTENANCE INTERVALS

Diesel fuels

Sulphur content Engine oil change interval

> 0,2% Halve interval to max. of 25,000 km

PTO hours

PTO hours should be converted into mileage according to the following formula:

1 PTO hour = 40 km

1.4 MAINTENANCE IN SPECIAL OPERATING CONDITIONS

Contact a DAF dealer/main branch or importer for vehicles used in very specific or heavy conditions. The service intervals can be modified, if necessary, in consultation with the dealer/main branch or importer to fit the appropriate operating conditions.

1.5 FIRST SERVICE INSPECTION

The first service inspection should be carried out between the first 7,500 and 10,000 km or at most 8 weeks after delivery of the vehicle, whichever comes first.

Note:

If the vehicle is equipped with a clutch wear indicator, ensure that the lock nut makes contact with the servo housing. If necessary, make sure that the lock nut makes contact with the housing.

The oil for the 1355 (T) axle must be renewed between the 2,000 and 3,000 km.

1-4

200423

Page 39

MAINTENANCE SCHEDULE

ΧΦ85 series

Maintenance activities

2. MAINTENANCE ACTIVITIES

2.1 OVERVIEW OF MAINTENANCE ACTIVITIES FOR THE FIRST SERVICE

INSPECTION

O Change the engine oil O Replace oil filter O Change the differential oil O Changing the hub oil O Check components and hose connections for leaks O Check/set the load-dependent control valve, leaf suspension O Adjust the clutch wear indicator circlip O Replace oil filter in fluid flow control valve block of EMAS system O Replace steering gear filter element, if vehicle is equipped with an EMAS system O Retighten hub nut of leading rear axle 09N044 (FTP-type vehicles)

200423 2-1

Page 40

MAINTENANCE SCHEDULE

Maintenance activities

2.2 OVERVIEW OF ANNUAL MAINTENANCE ACTIVITIES

ANNUAL MAINTENANCE ACTIVITIES = Y-SERVICE INTERVAL "Correct if necessary after inspection"

CAB AND ELECTRICAL SYSTEM

O Check pedal rubbers O Check whether the latest version of the ITS manual is kept in the cab O Replace interior filter element O Check fluid level of cab tilting pump O Check cab fastening

ENGINE, COOLING SYSTEM AND FUEL SYSTEM

O Replace air filter element O Check air inlet dust trapping valve O Check/adjust valve clearance O Replace coolant filter O Check coolant freezing point O Change coolant

(1)

STEERING GEAR AND BRAKE SYSTEM

O Replace steering gear filter element O Check steering ball joints O Replace air dryer filter element O Check compressor line O Check automatic slack adjuster O Check brake cylinder fastening O Check/adjust load-dependent control valve O Check fastening of universal joint to steering box input shaft

DRIVE AND CHASSIS

O Check fluid level of hydraulic trailing axle lifting device O Check pivot points of hydraulic trailing axle lifting device O Change the differential oil O Change the hub oil O Change grease of leading rear axle hubs of FTP-type

vehicles

(5)

(2)

O Check operation of differential lock O Check drive shaft play O Change the gearbox oil O Check fifth wheel O Check trailer coupling O Check superstructure attachment

OTHER ACTIVITIES

O Check whether there are any field actions that need to be performed on the vehicle.

(3)

(2)

(4)

(6)

Done O Yes O No

Changed O Yes O No

Replaced O Yes O No

Changed O Yes O No Changed O Yes O No

Done O Yes O No

Changed O Yes O No

ΧΦ85 series

(1) Every 2 years with coolant according to

DAF specification 74001. Every 4 years with coolant according to DAF specification 74002.

(2) For changing interval see maintenance schedule in

maintenance manual.

(3) For changing interval see maintenance schedule in

maintenance manual. When changing the gearbox oil on a gearbox with intarder, the gearbox oil filter must also be renewed.

(4) Check the valve clearance every 2 years after the 2

service and adjust if necessary (example: 1

... year). (5) Once every 3 years at a maximum of 500,000 km. (6) Every 2 years.

- 2nd - 4th -

2-2

200423

Page 41

MAINTENANCE SCHEDULE

ΧΦ85 series

Maintenance activities

2.3 OVERVIEW OF MILEAGE-DEPENDENT MAINTENANCE ACTIVITIES

MILEAGE-DEPENDENT MAINTENANCE ACTIVITIES (X-SERVICE)

"Correct if necessary after inspection"

CAB AND ELECTRICAL SYSTEM

O Check/clean battery terminals O Check/top up battery fluid level

ENGINE, COOLING SYSTEM AND FUEL SYSTEM

O Change the engine oil O Replace oil filter O Replace rotor of centrifugal oil filter O Remove fuel fine filter O Replace fuel prefilter/water separator filter element O Check for fuel leaks O Check poly V-belt Replaced O Yes O No O Check/adjust V-belt Replaced O Yes O No O Check components and hose connections for leaks O Check radiator and intercooler for fouling O Check exhaust system

STEERING GEAR AND BRAKE SYSTEM

O Check steering ball joint sleeve for damage O Check the steering oil level O Check steering gear lines and connections O Check brake components and brake system for leaks O Check brake lining thickness O Check brake pad thickness and brake disc

DRIVE AND CHASSIS

O Check the clutch fluid level O Check clutch wear indicator O Check central axle of tandem axle unit for leaks O Check differential for leaks O Check oil-lubricated wheel hubs for leaks O Check greased wheel hubs for leaks O Check wheel bearing play of leading rear axle 09N044 (FTP-type vehicles) O Check gearbox for leaks O Clean gearbox vent and rear axle vent on "offroad/semi-offroad" vehicles O Check shock absorbers for proper attachment and leaks O Check condition and attachments of spring leaves, spring clamps and U-bolts O Check hinge points and axle suspension fastening, air suspension O Check the air suspension bellows O Check operation of automatic lubrication system O Lubricate according to X-service lubrication schedule

OTHER ACTIVITIES

O Check whether there are any field actions that need to be performed on the vehicle.

(1)

(2)

(1) For changing interval see maintenance schedule in

maintenance manual.

(2) For changing interval see maintenance schedule in

maintenance manual. When changing the gearbox oil on a gearbox with intarder, the gearbox oil filter must also be renewed.

200423 2-3

Page 42

MAINTENANCE SCHEDULE

Maintenance activities

ΧΦ85 series

2.4 OVERVIEW OF INTERMEDIATE INSPECTION ACTIVITIES

INTERMEDIATE INSPECTION ACTIVITIES

"Correct if necessary after inspection"

In the case of an extended engine oil changing interval, an intermediate inspection must take place between the X-service inspections.

CAB AND ELECTRICAL SYSTEM

O Check/clean battery terminals

ENGINE, COOLING SYSTEM AND FUEL SYSTEM

O Check the engine oil level O Check for fuel leaks O Check poly V-belt Replaced O Yes O No O Check/adjust V-belt Replaced O Yes O No O Check components and hose connections for leaks O Check radiator and intercooler for fouling O Check exhaust system O Check fuel prefilter/water separator for moisture

STEERING GEAR AND BRAKE SYSTEM

DRIVE AND CHASSIS

O Check the clutch fluid level O Check clutch wear indicator O Check differential for leaks O Check oil-lubricated wheel hubs for leaks O Check greased wheel hubs for leaks O Check central axle of tandem axle unit for leaks O Check gearbox for leaks O Clean gearbox vent and rear axle vent on "offroad/semi-offroad" vehicles O Check shock absorbers for proper attachment and leaks O Check condition and attachments of spring leaves, spring clamps and U-bolts O Check hinge points and axle suspension fastening, air suspension O Check the air suspension bellows O Check operation of automatic lubrication system O Lubricate according to X-service lubrication schedule

OTHER ACTIVITIES

O Check whether there are any field actions that need to be performed on the vehicle.

2-4

200423

Page 43

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

5 Explanatory notes on the maintenance activities

CONTENTS

Page Date

1. SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423

1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200423

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200423

2.2 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200423

2.3 Warning symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200423

2.4 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200423

2.5 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200423

2.6 Maintenance guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200423

3. INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200423

Cab and electrical system

3.1 Checking pedal rubbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200423

3.2 Checking the battery fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200423

3.3 Checking the battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200423

3.4 Checking the fluid level of the cab tilting pump . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200423

3.5 Checking the cab fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200423

Engine, cooling system and fuel system

3.6 Inspection, engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200423

3.7 Inspection and adjustment, valve clearance . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . 200423

3.8 Inspection and adjustment, DEB play . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . 200423

3.9 Checking the poly-V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . 200423

3.10 Inspection and adjustment, V-belt tension. . . . . . . . . . . . . . . . . . . . . . . . . 3-8 . . . . . 200423

3.11 Checking the coolant freezing point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . 200423

3.12 Checking for fuel leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . 200423

3.13 Checking the components and hose connections for leaks . . . . . . . . . . . 3-11 . . . . 200423

3.14 Checking the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . 200423

3.15 Checking the radiator and intercooler for fouling . . . . . . . . . . . . . . . . . . . . 3-11 . . . . 200423

3.16 Checking the air inlet dust trapping valve . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . 200423

Steering gear and brake system

3.17 Checking the universal joint attachment on steering box input shaft. . . . . 3-12 . . . . 200423

3.18 Checking the steering ball joint sleeve for damage . . . . . . . . . . . . . . . . . . 3-13 . . . . 200423

3.19 Checking the steering ball joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 . . . . 200423

3.20 Checking the steering oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 . . . . 200423

3.21 Checking the steering gear lines and connections . . . . . . . . . . . . . . . . . . 3-15 . . . . 200423

3.22 Inspecting the compressor line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 . . . . 200423

3.23 Checking the brake components and brake system for leaks . . . . . . . . . . 3-18 . . . . 200423

3.24 Inspecting the automatic brake adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 . . . . 200423

3.25 Checking the brake cylinder fastening. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 . . . . 200423

3.26 Inspection, brake lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 . . . . 200423

3.27 Checking the brake shoe thickness and brake disc . . . . . . . . . . . . . . . . . 3-22 . . . . 200423

Drive and chassis

3.28 Checking and adjusting load-sensing air-suspension control valve . . . . . 3-24 . . . . 200423

3.29 Checking and adjusting load-sensing leaf-spring control valve. . . . . . . . . 3-27 . . . . 200423

3.30 Inspection, fluid level of hydraulic trailing-axle device . . . . . . . . . . . . . . . . 3-30 . . . . 200423

3.31 Inspection, pivot points of the hydraulic trailing-axle device . . . . . . . . . . . 3-30 . . . . 200423

3.32 Checking the differential for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30 . . . . 200423

3.33 Checking the operation of the differential lock. . . . . . . . . . . . . . . . . . . . . . 3-31 . . . . 200423

3.34 Checking the drive shaft play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 . . . . 200423

3.35 Inspecting the fifth wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 . . . . 200423

3.36 Checking the trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 . . . . 200423

3.37 Check the superstructure attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 . . . . 200423

Contents

200423 1

Page 44

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Contents

3.38 Checking the clutch fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 . . . . 200423

3.39 Inspection and adjustment, clutch wear indicator . . . . . . . . . . . . . . . . . . . 3-37 . . . . 200423

3.40 Checking the gearbox for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 . . . . 200423

3.41 Checking the central axle of the tandem axle unit for leaks . . . . . . . . . . . 3-38 . . . . 200423

3.42 Inspection of oil lubricated wheel hubs for leaks . . . . . . . . . . . . . . . . . . . . 3-38 . . . . 200423

3.43 Checking the greased wheel hubs for leaks . . . . . . . . . . . . . . . . . . . . . . . 3-38 . . . . 200423

3.44 Retightening the hub nut of leading rear axle 09N044 (FTP-type vehicles) 3-39 . . . . 200423

3.45 Inspection and adjustment, wheel bearing play, 09N044 leading rear axle 3-40 . . . . 200423

3.46 Checking the shock absorbers for attachment and leaks . . . . . . . . . . . . . 3-42 . . . . 200423

3.47 Checking the condition and attachment of spring leaves, spring clamps

and U-bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42 . . . . 200423

3.48 Checking the hinge points and axle suspension fastening (air suspension) 3-42 . . . . 200423

3.49 Checking the air suspension bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 . . . . 200423

3.50 Checking the operation of the automatic lubrication system . . . . . . . . . . . 3-43 . . . . 200423

4. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200423

Cab and electrical system

4.1 Removal and installation, interior filter element . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200423

Engine, cooling system and fuel system

4.2 Removal and installation, air filter element . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200423

4.3 Removal and installation, coolant filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200423

4.4 Removal and installation, engine oil filter . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . 200423

4.5 Removal and installation, centrifugal filter rotor. . . . . . . . . . . . . . . . . . . . . 4-6 . . . . . 200423

4.6 Removal and installation, fuel filter element . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . 200423

4.7 Removal and installation, fuel prefilter/water separator filter element . . . . 4-9 . . . . . 200423

4.8 Removal and installation, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 . . . . 200423

Steering gear and brake system

4.9 Removal and installation, steering gear filter element. . . . . . . . . . . . . . . . 4-12 . . . . 200423

4.10 Removal and installation, oil filter in fluid flow control valve block of EMAS

system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . 200423

4.11 Removal and installation, air dryer filter element . . . . . . . . . . . . . . . . . . . . 4-15 . . . . 200423

Drive and chassis

4.12 Removal and installation, gearbox filter element . . . . . . . . . . . . . . . . . . . . 4-17 . . . . 200423

4.13 Removal and installation, wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . . 200423

ΧΦ85 series

Page Date

5. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200423

Cab and electrical system

5.1 Topping up battery fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200423

Engine, cooling system and fuel system

5.2 Draining and filling the engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200423

5.3 Draining and filling, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 . . . . . 200423

5.4 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 . . . . . 200423

Drive and chassis

5.5 Draining and filling, differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 . . . . . 200423

5.6 Draining and filling the wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 . . . . 200423

5.7 Draining and filling, gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 . . . . 200423

5.8 Filling grease supply of the automatic lubrication system . . . . . . . . . . . . . 5-16 . . . . 200423

6. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200423

6.1 Cleaning the battery poles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200423

6.2 Cleaning radiator and intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . 200423

6.3 Cleaning the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 . . . . . 200423

6.4 Cleaning gearbox vent(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 . . . . . 200423

6.5 Cleaning rear axle vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 . . . . . 200423

200423

Page 45

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Page Date

7. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200423

7.1 Lubricate according to X-service lubrication schedule. . . . . . . . . . . . . . . . 7-1 . . . . . 200423

Contents

200423 3

Page 46

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Contents

ΧΦ85 series

200423

Page 47

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

1. SAFETY INSTRUCTIONS

1.1 SAFETY INSTRUCTIONS

Comply with all the warnings and safety precautions given in this maintenance manual.

First read the instructions and warnings on the labels and stickers that are affixed to various components on the vehicle and follow them. They are provided for your safety and health, so do not ignore them.

Wear clean, fitted clothes and apply protective cream to unprotected parts of your body, if necessary.

Do not run the engine in an enclosed or unventilated area. In other words, make sure that the exhaust gases are effectively extracted.

Remain at a safe distance from rotating and/or moving components.

Never remove the filler cap from the cooling system when the engine is at operating temperature.

Safety instructions

Be careful when changing the oil. Hot oil may cause serious injuries. Various oils and lubricants used on the vehicle may constitute a health hazard. Avoid unnecessary contact with drained oil. Frequent contact damages the skin. This also applies to engine coolant, windscreen washer fluid, refrigerant in air conditioning systems, battery acid and diesel fuel. So avoid inhalation and direct contact.

When carrying out operations under the cab, make sure the cab is fully tilted.

200423 1-1

Page 48

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Safety instructions

To avoid a fire hazard, the engine, the exhaust system and their surroundings must be kept free of flammable fluids and material such as dead leaves and dirt.

Where there is an engine encapsulation, if necessary, the encapsulation panels must be thoroughly cleaned after each inspection interval because of the risk of fire if the inside of the panels is dirty.

Always disconnect the earth connection of the battery before working on the vehicle.

Always use stands to support the chassis or components when working under the vehicle. Always charge batteries in a properly ventilated area and avoid creating sparks and naked flames. Fast charging should only be used in an emergency. When fast-charging, the battery positive and negative leads (+ and -) must be disconnected.

ΧΦ85 series

1-2

200423

Page 49

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

2. GENERAL

2.1 INTRODUCTION

This maintenance manual describes all relevant maintenance activities. It also contains safety instructions, which must be strictly adhered to. Activities not described in this manual, e.g. replacing components, overhaul, fault-finding, etc., are described in the DAF workshop instructions.

This maintenance manual assumes that the mechanic is sufficiently experienced and has had the required instruction or training to carry out these maintenance activities in a safe and responsible manner.

The technical data and notes on the maintenance activities have been compiled with the utmost care.

General

200423 2-1

Page 50

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

General

2.2 TECHNICAL INFORMATION

The technical information in this maintenance manual, such as notes on maintenance activities and technical data required to carry out the maintenance activities in a safe manner, were upto-date at the time this manual went to press. DAF reserves the right to make changes without prior notice.

Note:

Important changes relating to technical information that is not contained in this manual will be made available in TI sheets (Technical Information Sheet).

2.3 WARNING SYMBOL

When text is accompanied by the warning symbol shown here, the information provided is essential for the health and safety of the mechanic. This warning symbol is also shown if there are circumstances in which there is a vehicle safety hazard or damage to the vehicle could arise.

ΧΦ85 series

M0015

2-2

200423

Page 51

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

2.4 ENVIRONMENT

By carrying out the maintenance activities in a professional manner, on time and at regular intervals, you will help to reduce the impact on the environment. This means, for example, noticing and remedying possible leakages in time and keeping the engine in an optimum condition (adjusting valves, replacing air filter element etc.), thus reducing the emission of harmful exhaust gasses. It should be noted that oils and fluids contain harmful substances that have a negative impact on the environment. That is why you should take care that drained oils and fluids and also discarded oil and fuel filters, are collected in separate receptacles or containers. In short: maintenance activities must be

carried out in an environmentally aware manner.

General

2.5 PARTS

All DAF parts and components have been carefully attuned to each other, a decisive factor in ensuring the original DAF quality. It is only logical, therefore, that the original DAF quality can be maintained best if original DAF parts and components are used when replacing parts or components. As far as maintenance activities are concerned, this includes components such as windscreenwiper blades, air-dryer elements, gaskets, V-belts and filters. For example, if "non-original DAF filters" are used, the engine will be insufficiently protected against fine microscopic airborne dust particles, almost imperceptible metal swarf in the oil and dirt in the fuel, resulting in:

- premature replacing of cylinders, pistons, bearings, valves, injector pump and other moving parts

- reduced engine performance

- increased fuel consumption

Therefore, always use original DAF parts and components.

G000183

200423 2-3

Page 52

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

General

2.6 MAINTENANCE GUIDELINES

- When carrying out maintenance activities on the vehicle, it is important that the work is performed under the cleanest possible conditions. Filler caps, lubricating points, filler and drain plugs should be cleaned before and after maintenance activities.

- When excessive leakage has been detected at oil seals and/or components, or in case of excessive drops in the oil level, a report should be made and the cause should be remedied.

- It is important to check the gearbox breathers, transfer box, rear axle and driven front axle regularly for fouling and blockages. If the breathers are blocked by dirt, overpressure may cause leaks.

- Depending on the circumstances in which the vehicle is used, e.g. on very bad roads or construction sites, important bolt connections such as the fifth wheel, spring suspension, U-bolts, trailer coupling, steering box attachment, superstructure attachments etc. should be inspected more often and, if necessary, be retightened.

ΧΦ85 series

- It is important that a visual inspection and test run are carried out following the maintenance activities. Particular attention should be paid to components directly related to driving safety.

- Once a service has been completed new information on the next service (mileage/ date) can be entered on the instrument panel display using DAVIE XD via the VIC.

2-4

200423

Page 53

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

3. INSPECTION AND ADJUSTMENT

3.1 CHECKING PEDAL RUBBERS

1. Check that the pedal rubbers are still securely mounted on the pedal.

2. Check that the pedal rubbers are not worn out and there is still sufficient tread.

Inspection and adjustment

200423 3-1

Page 54

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.2 CHECKING THE BATTERY FLUID LEVEL

Avoid sparks and open flames in the vicinity of batteries.

}

1. Check the electrolyte level. The electrolyte

Battery acid is an aggressive fluid. In the event of contact with the skin: rinse the skin with plenty of water for a sustained period. If redness or pain persists, consult a doctor. Remove any clothing affected and rinse with water. In the event of contact with the eyes: rinse with plenty of water for at least 15 minutes and consult a doctor. If swallowed: do NOT induce vomiting. Rinse the mouth, drink two glasses of water and consult a doctor. In the event of inhalation: get fresh air, rest and consult a doctor.

level must be approx. 10 mm above the plates or up to the level indicator if available.

ΧΦ85 series

2. If necessary, top up the batteries, see chapter "Draining and filling".

3.3 CHECKING THE BATTERY TERMINALS

1. Visually check the battery terminals for corrosion. Clean the battery terminals if necessary, see chapter on "Cleaning".

2. Check the attachment of the battery terminals.

M5011

3-2

200423

Page 55

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Inspection and adjustment

3.4 CHECKING THE FLUID LEVEL OF THE CAB TILTING PUMP

1. The fluid level must be checked when the cab is in the driving position.

2. The cock (2) should be in the "tilting back" position (anti-clockwise).

3. Unscrew the filler plug (1) 3 to 4 turns. Wait until the overpressure, if any, has left the reservoir. Remove filler plug (1).

4. Start pumping (maximum 5 pump strokes). Ensure that the pump lever is in the lowest position.

5. Check the fluid level. This level should be no more than 2 cm below the top of the filling opening. Top up if necessary.

6. Fit the filler plug (1) and hand tighten it.

3.5 CHECKING THE CAB FASTENING

1. Check that all attachment bolts are in place.

2. Visually inspect the attachment of the cab to the tilting mechanism.

3. Visually inspect the seals and condition of the tilting mechanism.

Engine, cooling system and fuel system

M201062

K1 01 660

200423 3-3

Page 56

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.6 INSPECTION, ENGINE OIL LEVEL

1. Ensure that the vehicle is standing on a flat and level surface.

2. Wait at least 5 minutes before checking the engine oil level of a hot engine.

3. Pull the dipstick (2) out of the holder.

4. Wipe the dipstick clean with a lint-free cloth.

5. Put the dipstick back into the holder.

6. Pull the dipstick out again and check the oil level.

7. If necessary, top up oil via the filler opening with the red cap (D) to the maximum oil level. Always use the specified oil. Do not top up above maximum level.

ΧΦ85 series

V300384

Note:

For the difference between minimum and maximum engine oil level, see "Technical data".

V300389

3-4

200423

Page 57

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Inspection and adjustment

3.7 INSPECTION AND ADJUSTMENT, VALVE CLEARANCE

1. Remove the valve covers, see "Removal and installation".

2. Use the special tool (DAF no. 1310477) to turn the crankshaft clockwise, as seen from the timing gear end (this corresponds with the engine's direction of rotation), until the valves of cylinder 1 are in the overlap position. The pistons of cylinders 1 and 6 are now at top dead centre.

Note:

"Overlap" is the moment at which the inlet valve starts opening and the exhaust valve finishes closing.

If the engine has a DEB, you must use a flat ring spanner to loosen the

}

3. Check/correct the valve clearance of cylinder

lock nut. This is necessary to avoid damaging the DEB spring plate.

6. Set the correct valve clearance by loosening the lock nut and turning the adjusting screw in the correct direction. See "Technical data" for the correct valve clearance.

M201185

M200539

200423 3-5

Page 58

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

4. By cranking the crankshaft 1/3 stroke each time, using special tool (DAF no. 1310477, ) the valves can be adjusted according to the injection sequence 1-5-3-6-2-4.

Valves in overlap

position of

cylinder

5. If the engine has been fitted with a DEB, the DEB play must be checked following the valve play adjustment.

6. Fit the valve covers, see "Removal and installation".

Adjusting valves

of cylinder

ΧΦ85 series

M200540

3-6

200423

Page 59

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

3.8 INSPECTION AND ADJUSTMENT, DEB PLAY

1. Remove the valve covers, see chapter "Removal and installation".

2. Tighten the DEB attachment bolts to the specified torque, see main group "Technical data".

3. Using special tool (DAF no. 1310477), crank the engine in the direction of rotation until cylinder 1 has reached the top dead centre (TDC) and the valves of cylinder 6 are in overlap position.

4. Use set screw (B) to set the DEB clearance (A) of cylinders 1, 3 and 5, see main group "Technical data".

5. Then tighten set screw (B) to the specified torque, see main group "Technical data".

6. Using special tool (DAF no. 1310477), crank the engine in the direction of rotation until cylinder 6 has reached the top dead centre (TDC) and the valves of cylinder 1 are in overlap position.

Inspection and adjustment

7. Use set screw (B) to set the DEB clearance (A) of cylinders 2, 4 and 6, see main group "Technical data". Then tighten set screw (B) to the specified torque, see main group "Technical data".

8. Fit the valve covers, see chapter "Removal and installation".

3.9 CHECKING THE POLY-V-BELT

1. Check the poly-V-belt for damage and signs of serious wear.

i 400166

200423 3-7

Page 60

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.10 INSPECTION AND ADJUSTMENT, V-BELT TENSION

Inspecting the V-belt tension

1. Check the V-belt tension of the air conditioning compressor drive using the Krikit I, special tool (DAF no. 1240442). Check the V-belt tension of the FAX model steering pump drive using the Krikit II, special tool (DAF no. 1240443).

2. Set the gauge to zero by depressing the measuring arm (1).

3. Place the belt tension gauge on the V-belt, halfway between the two pulleys.

4. Slowly depress the V-belt by means of the belt-tension gauge until a click is heard. Then remove the belt tension gauge carefully. Take care not to let the measuring arm move.

5. Take the reading as indicated by the position of the measuring arm in relation to the scale. Compare this reading with the recommended pre-tension, see "Technical data".

ΧΦ85 series

M2061

Adjust V-belt tension of air conditioning compressor drive

1. Slacken the upper attachment bolt (1) of the compressor.

2. Slacken the lower attachment bolt (2) of the compressor.

3. Loosen the attachment bolt from the threaded spindle which is attached to the coolant pump.

4. Shift the compressor using the lock nuts (3) until the correct V-belt tension is achieved, see "Technical data".

M2062

M2041

3-8

200423

Page 61

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Adjusting V-belt tension of FAX model steering pump

1. Slacken the central bolt (1) of the tension roller.

2. Turn the adjusting bolt (2) until the V-belt tension is correct, see "Technical data".

3. Tighten the central bolt (1) to the specified tightening torque, see "Technical data".

Inspection and adjustment

200423 3-9

Page 62

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.11 CHECKING THE COOLANT FREEZING POINT

When the coolant is hot, there is an overpressure in the cooling system.

}

Carefully remove the filler cap to release the overpressure. Do not remove the filler cap when the engine is running. Coolant is a toxic fluid. Contact with the skin should therefore be avoided. In the event of contact with the skin: remove with paper or a cloth, wash with soap and water. If irritation persists, consult a doctor. If swallowed: DO NOT induce vomiting. Rinse mouth, drink two glasses of water and consult a doctor. In the event of inhalation: get some fresh air and rest. In order to avoid damaging the cylinder block, do not top up a warm engine with coolant.

ΧΦ85 series

1. Check the anti-freeze content of the coolant. Fill the cooling system with anti-freeze, if this has not been done yet. Always use only coolants that meet DAF specifications.

2. Consult the manufacturer’s instructions for the correct anti-freeze mixing ratio. Preferably, use 40% anti-freeze on an ethylene glycol base. At this percentage, not only good frost protection, but also good corrosion protection is guaranteed.

-10

-20

-30

-40

-50

-60

-70

-80

10009010802070306040505040603070208010

Ethyleenglycol

100

M2016

3-10

200423

Page 63

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Inspection and adjustment

3.12 CHECKING FOR FUEL LEAKS

1. Visually inspect all hose connections and fuel system components for leaks.

3.13 CHECKING THE COMPONENTS AND HOSE CONNECTIONS FOR LEAKS

1. Check all hose connections and cooling system components for leaks.

2. Check the hose connections and inlet system components.

3.14 CHECKING THE EXHAUST SYSTEM

1. Visually inspect the exhaust system for leaks.

2. Check the exhaust suspension points.

3. Check that no heat transfer (due to accumulated dirt, for example) can take place to the exhaust system area, such as pipes, components etc.

3.15 CHECKING THE RADIATOR AND INTERCOOLER FOR FOULING

1. Visually inspect the radiator and intercooler for fouling If necessary, clean the radiator and intercooler, see "Cleaning".

200423 3-11

Page 64

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.16 CHECKING THE AIR INLET DUST TRAPPING VALVE

1. Check the condition of the rubber valves.

Steering gear and brake system

ΧΦ85 series

3.17 CHECKING THE UNIVERSAL JOINT ATTACHMENT ON STEERING BOX

INPUT SHAFT

1. Check the universal joint for perceptible play. If perceptible play is detected, the affected part must be replaced.

2. Check whether there is any perceptible play between the spline connection of the universal joint and the steering box input shaft. If perceptible play is detected, the splines on the universal joint and those on the input shaft must be checked for wear. If wear is detected, the affected part must be replaced.

3. If there is perceptible play but the parts are not worn, the attachment bolt and nut must be replaced. Tighten the attachment bolt and nut to the specified torque, see "Technical data".

3-12

S7 00 639

200423

Page 65

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Inspection and adjustment

3.18 CHECKING THE STEERING BALL JOINT SLEEVE FOR DAMAGE

Inspection, locking devices and dust cover

1. Check that the steering ball joint dust cover or seal is not damaged. Replace the steering ball joint if damaged.

2. If a castle nut is fitted, check that the locking devices are present and undamaged.

S7 00 592

200423 3-13

Page 66

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.19 CHECKING THE STEERING BALL JOINTS

Checking axial steering ball joint play

1. Check the axial steering-ball joint play using special tool (DAF no. 1329426)

2. First jack up the axle until the wheels come off the ground and put the axle on stands.

3. Make sure that the castle nut split pin (if fitted) at the nut does not come into contact with the head of the threaded end.

4. Screw the thrust washer (8) on to the threaded spindle.

5. Fit the spring retainer (3), spring (4) and pressure sleeve (6) into bracket (1). Fit the locking screw (5). It should be possible to move the pressure sleeve (6) freely.

Note:

Fit the correct pressure sleeve (6). The pressure sleeve (6) must abut the outer edge of the steering ball joint (7).

6. Loosen thrust bolt (2) until the pressure sleeve (6) with the flange abuts the bracket (A = 0 mm).

7. Fit the special tool over the steering ball joint (7) and turn the threaded spindle (9) by hand until the special tool is tight around the steering ball joint (7).

ΧΦ85 series

4 3

8. Tighten thrust bolt (2) until its head abuts bracket (1).

9. Measure play "A" between the pressure sleeve and the bracket using a feeler gauge. Compare the reading with the maximum permissible steering ball joint play, see "Technical data". If necessary, replace the steering ball joint.

S700426

3-14

200423

Page 67

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Inspection and adjustment

3.20 CHECKING THE STEERING OIL LEVEL

1. Check the steering oil level when the engine is not running.

2. Clean the dipstick and its immediate surroundings to prevent any oil from entering the reservoir.

3. Check the fluid level in the reservoir using the dipstick.

4. The fluid level should be between the marks when the steering oil is "cold".

Note:

When the steering oil is at operating temperature, the level may be above the top mark on the dipstick.

S7 00 676

3.21 CHECKING THE STEERING GEAR LINES AND CONNECTIONS

1. Condition of the pipes

- Check all pipes for tightness and wear.

Where supply pipes are subject to negative pressure, it is particularly likely that porous pipes will give rise to problems (air in the system).

- If in doubt, always replace the line.

2. Pipe connections

- Check every pipe connection for leaks.

3. Line route

- Pipes must not be twisted during

assembly. To facilitate checking this, a mark may have been provided on the hose (sometimes in the form of text).

- Pipes should not touch other parts (to

prevent chafing).

- The course pipes follow should not

include any sharp bends; this applies especially to the flexible suction and return pipes.

- Pipes should not be pinched off by other

components.

200423 3-15

Page 68

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.22 INSPECTING THE COMPRESSOR LINE

Remain at a safe distance from rotating and/or moving components.

}

Note:

If excessive values are measured, the inside of the air-dryer housing and the silencer on the vent should first be cleaned. Then repeat the inspection.

1. Bring the engine up to operating temperature.

2. Bleed the system to a pressure below the cut-in pressure of the pressure regulator.

3. Remove compressor control line (1) which is hooked up to connection point 23 of the air dryer. Then seal the opening at connection point 23.

ΧΦ85 series

4. Build up pressure in the brake system (pressure regulator must cut out).

5. When the engine is not running, remove the safety valve from the compressor line and replace it with a test nipple.

6. Connect a pressure gauge (measuring range 0-16 bar) to the test nipple.

7. Start the engine and run it at maximum speed.

R600521

3-16

200423

Page 69

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

8. The pressure gauge should indicate a pressure below 2 bar with the pressure regulator switched off. If the measured pressure exceeds the value indicated, the compressor line should be cleaned or replaced.

Note:

If the pressure measured is too high, there is excessive carbon deposit in the compressor line. This may be due to the poor condition of the compressor (oil consumption).

9. Run the engine at idling speed.

10. Bleed the brake system until the cut-in pressure of the pressure regulator has been reached and switch off the engine. The needle of the pressure gauge may not drop too quickly now. If necessary, check the system for air leakage. Pay particular attention to the compressor line and compressor.

11. Fit the safety valve.

Inspection and adjustment

R600249

12. Connect the compressor control line to connection point 23 of the air dryer.

200423 3-17

Page 70

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

ΧΦ85 series

3.23 CHECKING THE BRAKE COMPONENTS AND BRAKE SYSTEM FOR LEAKS

1. While operating the service brake, check whether any leaks occur in the brake system. If the brake system of a vehicle has been charged to the maximum pressure, it should generally be possible to drive the vehicle after a period of 16 hours of uninterrupted standstill, without having to first charge the brake system to adequate operating pressure. This implies a maximum pressure drop of approx. 0.4 bar per hour at normal system pressure.

Note:

Always connect auxiliary consumers and accessories to circuit 4.

3-18

200423

Page 71

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

3.24 INSPECTING THE AUTOMATIC BRAKE ADJUSTER

Brake drum

Inspection, brake adjuster travel

1. Measure the basic setting L1.

2. Measure the position when the brakes are applied, L2 (minimum brake system pressure 6 bar).

3. Calculate the brake stroke L3 = L2 - L1, see "Technical data". If the brake stroke differs from the specified value, take the following action:

4. Check whether the control plate (1) is locked in respect of the fixed bracket.

Inspection and adjustment

M6101

5. If not, turn the control plate as far as possible (until the internal stop is felt) in the direction in which the brake adjuster is moved during braking.

6. Fix the control plate in this position using the attachment nut on the fixed bracket.

7. Check the internal slip using a torque wrench.

Inspection, internal slip

1. Make certain that there is sufficient pressure in the reservoirs (6.5 bar minimum).

2. Release the parking brake.

3. Fit a torque wrench on the hexagonal adjusting bolt and turn this counterclockwise. For the permitted value, see "Technical data". If the specified reverse torque is not reached, but the worm shaft already turns at a lower value, the brake adjuster should be replaced.

M6005

200423 3-19

Page 72

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.25 CHECKING THE BRAKE CYLINDER FASTENING

1. Check that the brake cylinders do not move during operation of the service brake.

ΧΦ85 series

3-20

200423

Page 73

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

3.26 INSPECTION, BRAKE LINING THICKNESS

Inspecting the brake lining thickness (FTP axle excepted)

1. Pressurise the air brake system (pressure regulator should cut out) and make sure that the vehicle's parking brake is not engaged.

2. Check the brake lining thickness through the openings in the dust cover.

3. Replace the brake lining if it is worn down to the wear indicator mark on the lining.

Note:

If in doubt about the amount of brake lining wear, release the brakes and remove the dust cover.

Inspection and adjustment

M6012

Inspecting the brake lining thickness (FTP axle)

1. Pressurise the air brake system (pressure regulator should cut out) and make sure that the vehicle's parking brake is not engaged.

2. Check the brake lining thickness through the openings in the dust cover.

3. Replace the brake lining if it is worn down to the wear indicator mark on the lining.

Note:

If in doubt about the amount of brake lining wear, release the brakes and remove the dust cover.

M6002

R6 00 677

200423 3-21

Page 74

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.27 CHECKING THE BRAKE SHOE THICKNESS AND BRAKE DISC

Version: Knorr SB 7000

1. Check whether guide bush (4) protrudes from guide sleeve (6) (C). If the guide bush (4) is level with the guide sleeve (6) (see detail A) the brake shoe and brake disc thicknesses should be checked.

ΧΦ85 series

R600481

3-22

200423

Page 75

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Version: Knorr SN 7000

1. Check the transition between the ribbed part of the rubber cover and the smooth part (A). If the smooth part is rolled inwards, the brake shoe and brake disc thicknesses must be checked.

Drive and chassis

Inspection and adjustment

R600730

200423 3-23

Page 76

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.28 CHECKING AND ADJUSTING LOAD-SENSING AIR-SUSPENSION

CONTROL VALVE

Explanatory notes on instruction plate

This plate is mounted on the rear door pillar on the left-hand side of the vehicle. The information on the instruction plate relates to the axle loads, the delivery pressures and bellows pressures, following the sequence of the axles beneath the vehicle.

Therefore, "1" refers to the (first) front axle, "2" to the next following axle, etc.

If the vehicle is fitted with a relay valve in the front axle brake circuit, the box beneath the valve illustration will be blank. Throughout the column, a value of 8.1 bar has been filled in for "delivery pressure p2" under axle "1".

If the vehicle is equipped with a control valve instead of the relay valve mentioned, the box will contain a pressure ratio, e.g."i = 1 : 1.5". The "delivery pressure p2" of axle "1" then indicates variable readings.

These values can be used to check the brake pressure values of the front axle and to carry out the inspection/adjustment below at the same time. To do this, connect a pressure gauge to the test connection of one of the front axle brake cylinders.

TYPE - TIPO : FA

AUTOM. LASTAFHANKELIJKE REMKRACHTREGELING AUTOM. LOAD SENSING DEVICE AUTOM. LASTABHAENGIGE BREMSKRAFT REGELEINR. DISPOSITIF DE CORRECTION AUTOM. DE FREINAGE REGOLATORE AUTOM. DELLA FORZA FRENANTE REGULADOR AUTOM. DEL ESFUERZO DE FRENANDA

W475 721 003 0

p1 = > 8.5 bar

p4 = 8.0 bar

BALG DRUK p43

PRESSURE BELLOWS

BALG DRUCK

PRESSION COUSSIN

p4 p43

PRESS. CUSCINI ARIA

PRESION FUELLES

bar

1425289

MEEREGELVENTIEL

EMPTY-LOAD VALVE

0.2

0.5

1.3

1.8

2.0

2.1

2.8

3.5

ΧΦ85 series

1 = 1 : 1.5

LAST-LEER VENTIEL

VALVE CHARGE-VIDE

VALVOLA VUOTO-CARICO

VALVULA VACIO-CARGA

2.3

4.2

4.9

5.6

4.3

7.3

8.3

UITGESTUURDE DRUK p2

DELIVERY PRESSURE

AUSGESTEUERTER DRUCK

PRESSION DELIVREE

ASLAST G

AXLE LOAD

ACHSLAST

CHARGE SOUS ESSIEU

±0.4 ±0.2

PRESSIONE USCITA

PRESION DE SALIDA

bar

x10

CARICO ASSE

CARGA EJE

5.7

1.8

5.8

2.5

6.0

4.0

6.3

5.0

6.6

6.0

7.7

8.1

10.0

11.5

R600472

8.1

13.0

3-24

200423

Page 77

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Checking and adjusting load-sensing airsuspension control valve

1. Check that the correct valve has been fitted (see instruction plate).

2. Connect pressure gauge (4) to the test connection close to connecting point  on the load-dependent control valve (input pressure).

3. Connect a pressure gauge (2) to the test connection on one of the brake cylinders (service brake connection) of the rear axle.

4. Connect a pressure gauge (43) with a pressure-reducing valve to the simulation connection near connections 41 and 42 of the load-sensing valve (= simulated adjustable bellows pressure).

5. Make sure that the reservoir pressure is higher than 8.5 bar throughout the testing process.

Inspection and adjustment

1/4

R600473

6. Set the simulated bellows pressure to its second lowest value, as indicated on the instruction plate.

7. Depress the brake pedal until pressure gauge (4) indicates a pressure of 8 bar.

8. Read the brake pressure of the rear axle on pressure gauge (2) and check that this brake pressure matches the one listed on the instruction plate in the table under "delivery pressure p2" to the rear axle.

9. If the measured value is not correct, depressurise connection (43) and, using a special tool (DAF no. 1329464), turn the adjusting nut (s):

- braking pressure too high: unscrew the

adjusting nut

- braking pressure too low: screw in the

adjusting nut.

Note:

When depressurising the simulation connection (pressure gauge 43), the air hose must remain connected to prevent the (actual) bellows pressure from accidentally activating the valve. The small socket head screw in the centre of the valve must not be adjusted.

10. Repeat the procedure described in point 6 until the measured braking pressure value is within the tolerance limits.

R600478

200423 3-25

Page 78

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

11. Set the simulated bellows pressure to its second highest value, as indicated on the instruction plate.

12. Depress the brake pedal until pressure gauge (4) indicates a pressure of 8 bar.

13. Read the pressure gauge (2) and check that this braking pressure matches the pressure indicated in the table on the instruction plate.

14. If the measured reading is not correct, depressurise connection (43) and turn the adjusting bolt (r) using a Torx screwdriver:

- braking pressure too high: screw in the

adjusting bolt

- braking pressure too low: unscrew the

adjusting bolt.

Note:

ΧΦ85 series

15. If the adjusting bolt (r) has been turned, repeat the procedure from point 6.

3-26

200423

Page 79

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Inspection and adjustment

3.29 CHECKING AND ADJUSTING LOAD-SENSING LEAF-SPRING

CONTROL VALVE

Explanatory notes on instruction plate

This plate is mounted on the rear door pillar on the left-hand side of the vehicle. The data on axle loads and delivery pressures are listed on the instruction plate in the sequence of the axles beneath the vehicle. Therefore, "1" refers to the (first) front axle, "2" to the next following axle, etc.

W475 721 004 0

BALG DRUK p3

TYPE - TIPO : FA

L = 140 mm

a = 15 ±2

p1 = > 8.5 bar

p4 = 8.0 bar

PRESSURE BELLOWS

BALG DRUCK

PRESSION COUSSIN

PRESS. CUSCINI ARIA

PRESION FUELLES

bar

G=11.0

1396041

1425287

MEEREGELVENTIEL

EMPTY-LOAD VALVE

LAST-LEER VENTIEL

VALVE CHARGE-VIDE

i = 1 : 1.5

VALVOLA VUOTO-CARICO

VALVULA VACIO-CARGA

UITGESTUURDE DRUK p2

DELIVERY PRESSURE

AUSGESTEUERTER DRUCK

PRESSION DELIVREE

ASLAST G

AXLE LOAD

ACHSLAST

CHARGE SOUS ESSIEU

±0.4 ±0.2

PRESSIONE USCITA

PRESION DE SALIDA

bar

x10

CARGA EJE

CARICO ASSE

1.8

5.7

1.8

5.7

2.0

2.2

5.8

3.0

3.1

6.1

4.0

6.4

7.4

8.0

7.6

8.2

7.8

8.0

10.0

11.5

R600479

8.2

8.0

13.0

200423 3-27

Page 80

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

Checking and adjusting load-sensing leafspring control valve

1. Measure the weight plus load of the rear axle(s).

2. Check the attachment of the control lever and its ease of operation.

3. Check whether the correct valve and the correct springs have been fitted (for information, see the instruction plate).

4. Check the length of the control lever (see "L" on the instruction plate).

5. Connect pressure gauge (4) to the test connection close to connecting point  on the load-dependent control valve (input pressure).

6. Connect pressure gauge (2) to the test connection on one of the brake cylinders (service brake connection) of the rear axle.

ΧΦ85 series

1/4

R600562

7. Make sure that the reservoir pressure is higher than 8.5 bar throughout the testing process.

8. Depress the brake pedal until gauge (4) indicates a reading of 8 bar.

9. Read the brake pressure of the rear axle from the pressure gauge (2) and check that this value matches the one listed on the instruction plate in the table under "delivery pressure p2" to the rear axle.

3-28

200423

Page 81

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

10. Correct, if necessary, the brake pressure by moving the rubber sleeve (1) in relation to the vertical connecting rod. On no account change the length L of the (horizontal) control lever.

11. Remove the rubber sleeve (2) and move the control lever towards maximum load. Check that the delivery pressure is now allowed through with little or no reduction.

Note:

The small socket head screw in the centre of the valve must not be adjusted.

Inspection and adjustment

R600781

200423 3-29

Page 82

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

ΧΦ85 series

3.30 INSPECTION, FLUID LEVEL OF HYDRAULIC TRAILING-AXLE DEVICE

1. Make sure that the trailing axle wheels are fully lowered and on the ground.

2. Check the fluid level. The liquid level must be between the "min." and "max." level mark. If necessary, top up.

3.31 INSPECTION, PIVOT POINTS OF THE HYDRAULIC TRAILING-AXLE DEVICE

1. Check the play on the pivot points when operating the hydraulic trailing axle.

3.32 CHECKING THE DIFFERENTIAL FOR LEAKS

1. Visually inspect the differential for leaks.

3-30

200423

Page 83

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Inspection and adjustment

3.33 CHECKING THE OPERATION OF THE DIFFERENTIAL LOCK

1. Jack up the rear axle and support the axle on stands.

2. Bring the air system to operating pressure.

3. Engage the differential lock. The warning indicator should now be active.

4. Check that there is a "rigid" connection between the driven wheels.

5. Disengage the differential lock. The warning light should now go out and the "rigid" connection between the driven wheels should be broken.

200423 3-31

Page 84

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.34 CHECKING THE DRIVE SHAFT PLAY

1. Check the universal joints and suspension bearing for play and damage.

2. Check the sliding joint for axial and radial play.

ΧΦ85 series

M3032

3. There must be no clearly perceptible play on the universal joints, suspension bearing and the sliding joint.

M3019

M3020

3-32

200423

Page 85

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

3.35 INSPECTING THE FIFTH WHEEL

1. Check the attachment of the fifth wheel.

2. Check the play of the closing gear of the fifth wheel.

Note:

For maximum play values, consult the manufacturer's instructions or the legal requirements.

3. In the case of fifth wheels with a plastic sliding plate (1), check for wear. The plastic sliding plate (1) must not lie flush with the top of the attachment bolts.

Inspection and adjustment

V300372

200423 3-33

Page 86

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.36 CHECKING THE TRAILER COUPLING

1. Check the vertical play of the arched pin.

2. Check the radial play of the arched pin.

3. Check the vertical and horizontal play of the coupling jaw.

ΧΦ85 series

M9002

4. Check the diameter of the arched pin.

5. Check the attachment of the trailer coupling and the rear cross member.

Note:

For maximum play values, consult the manufacturer’s instructions or the specified legal requirements.

M9001

M9004

3-34

200423

Page 87

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

3.37 CHECK THE SUPERSTRUCTURE ATTACHMENT

1. Check that all attachment bolts are in place.

2. Visually check the attachment of the superstructure for faults. See the DAF superstructure instructions.

Inspection and adjustment

200423 3-35

Page 88

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.38 CHECKING THE CLUTCH FLUID LEVEL

Hydraulic fluid is toxic and can therefore have a damaging effect on

}

your health. Hence avoid any direct or indirect physical contact. As hydraulic fluid is also a corrosive fluid, it may damage the paintwork of the vehicle. Avoid any contact between hydraulic fluid and paintwork. Always use new and clean hydraulic fluid which has been kept in a sealed container and meets the specifications. Hydraulic fluid which has absorbed water (from the ambient air) may have an adverse effect on the operation of the clutch system. Avoid any contact with mineral oil. Even one drop of mineral oil in the system will damage the seals.

ΧΦ85 series

1. Check that the fluid level is between the (A) and (B) marks when the cab is in the driving position.

2. Mark (C) applies to fully tilted cabs.

3. Hand tighten the reservoir sealing cap.

Note:

There is an air bleed vent in the cap that may be closed if the cap is tightened with too great a force. If the air bleed vent is closed off, residual pressure will build up in the system.

3-36

V300178

200423

Page 89

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Inspection and adjustment

3.39 INSPECTION AND ADJUSTMENT, CLUTCH WEAR INDICATOR

Checking the clutch wear indicator

1. Visually check that the lock nut (12) makes contact with the housing. If the lock nut (12) no longer makes contact with the housing, the clutch plate is approximately 80% worn.

Note:

It is not permissible to remove the circlip, or to move the circlip over the pin. This is to prevent inaccurate indication.

Adjusting the clutch wear indicator

1. Press the circlip (12) against the clutch servo.

Note:

It is not permissible to remove the circlip, or to move the circlip over the pin. This is to prevent inaccurate indication.

5 11

V300355

200423 3-37

Page 90

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

ΧΦ85 series

3.40 CHECKING THE GEARBOX FOR LEAKS

1. Visually check the gearbox for leaks.

3.41 CHECKING THE CENTRAL AXLE OF THE TANDEM AXLE UNIT FOR LEAKS

1. Visually inspect the central axle for leaks.

3.42 INSPECTION OF OIL LUBRICATED WHEEL HUBS FOR LEAKS

1. Check the wheel hubs for leaks.

Note:

If leaks occur in the oil lubricated wheel hubs, the wheel hub should be refilled to the correct level - once the leak has been repaired, see chapter: "Draining and filling".

3.43 CHECKING THE GREASED WHEEL HUBS FOR LEAKS

1. Check the wheel hubs for leaks.

Note:

If there are serious grease marks on the brake disc side of the wheel hub, this could indicate excessive use of assembly grease on new or recently assembled wheel hubs. On wheel hubs that have not been assembled recently, serious grease marks could indicate a leak in the seal (1). This means that the entire hub unit must be replaced. Serious oil leakage on the driven rear axle hubs could indicate that the O-ring (2) is not sealing correctly. If there is an oil leak the hub unit should be dismantled to remedy the problem.

3-38

200423

Page 91

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Inspection and adjustment

3.44 RETIGHTENING THE HUB NUT OF LEADING REAR AXLE 09N044

(FTP-TYPE VEHICLES)

1. Remove the hub cap (4) using special tool (DAF no. 1329498).

2. Lift the leading rear axle.

3. Release the brakes.

4. Remove the split pin (3) from the hub nut (2).

5. Tighten the hub nut to the specified tightening torque, see "Technical data". Turn the wheel at least 5 revolutions in clockwise direction and then 5 revolutions in anticlockwise direction when fixing the hub nut.

6. Check that the wheel rotates smoothly.

7. Turn back the hub nut until the split pin can be fitted. Fit a new split pin.

Note:

There are 2 split pin holes in the axle journal. Select the split pin hole where the hub nut needs to be turned back least.

S7 00 657

8. Fit the hub cap. Tighten the hub cap to the specified torque using the special tool (DAF no. 1329498), see "Technical data".

9. Adjust the brakes.

200423 3-39

Page 92

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

ΧΦ85 series

3.45 INSPECTION AND ADJUSTMENT, WHEEL BEARING PLAY, 09N044

LEADING REAR AXLE

Checking the wheel bearing play

1. Remove the hub cap using special tool (DAF no. 1329498).

2. Lift the leading rear axle and support it properly.

3. Release the brakes.

4. Fit a dial gauge; let the stylus rest against the axle journal.

5. Push and pull on the wheel. Read the value off the gauge. Compare this reading to the specified value. See "Technical data". If the reading falls outside the tolerance range, the wheel bearing play should be re-adjusted.

6. Fit the hub cap. Tighten the hub cap to the specified torque using the special tool (DAF no. 1329498), see "Technical data"'.

S7 00 635

7. Adjust the brakes.

Adjusting the wheel bearing play

1. Remove the hub cap (4) using special tool (DAF no. 1329498).

2. Lift the leading rear axle.

3. Release the brakes.

4. Remove the split pin (3) from the hub nut (2).

5. Tighten the hub nut to the specified tightening torque, see "Technical data". Turn the wheel at least 5 revolutions in anticlockwise direction and then 5 revolutions in clockwise direction when fixing the hub nut.

6. Check that the wheel rotates smoothly.

7. Turn back the hub nut until the split pin can be fitted. Fit a new split pin.

Note:

There are 2 split pin holes in the axle journal. Select the split pin hole where the hub nut needs to be turned back the smallest distance.

S7 00 657

3-40

200423

Page 93

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

8. Check the wheel bearing play. Check the bearings for wear if the wheel bearing play remains too large after adjustment.

9. Fit the hub cap. Tighten the hub cap to the specified torque using the special tool (DAF no. 1329498), see "Technical data"'.

10. Adjust the brakes.

Inspection and adjustment

200423 3-41

Page 94

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

ΧΦ85 series

3.46 CHECKING THE SHOCK ABSORBERS FOR ATTACHMENT AND LEAKS

1. Visually inspect the attachment of the shock absorbers and for any leaks.

3.47 CHECKING THE CONDITION AND ATTACHMENT OF SPRING LEAVES,

SPRING CLAMPS AND U-BOLTS

Checking U-bolts

1. Visually inspect the condition and attachment of the U-bolts.

2. When retightening the U-bolt nuts, the attachment nut must not be slackened first and then tightened to a specific torque, see "Technical data".

3.48 CHECKING THE HINGE POINTS AND AXLE SUSPENSION FASTENING (AIR

SUSPENSION)

Torque rod

1. Check the attachment of the torque rod and torque rod supports.

2. Check the pivots of the torque rod for wear and play.

Stabiliser bar

1. Check the attachment of the stabiliser bar and stabiliser bar support.

2. Check the pivots of the stabiliser bar for wear and play.

Ball joints three-point fixation

1. Check the attachment of the ball joints and three-point fixation support.

2. Check the ball joint housing for surface cracks.

3. Check the dust cover for damage.

3-42

200423

Page 95

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Inspection and adjustment

3.49 CHECKING THE AIR SUSPENSION BELLOWS

1. Raise the chassis to driving height using the remote control.

2. Clean the air bellows using a cleaning cloth or a soap solution, if required.

3. Check the air bellows for cracks and damage. If there are any cracks or damage through which the webbing is visible, the air bellows should be replaced.

4. Check the air bellows, bellows seating and air line connections for leaks. Check that the air bellows are not chafing against air lines, etc. when in the driving position.

M9040

3.50 CHECKING THE OPERATION OF THE AUTOMATIC LUBRICATION SYSTEM

1. Check the system for line fractures and operation of the jets.

2. Check whether all lubricating points are lubricated.

3. Check the lubricant level in the reservoir. If necessary, top up the reservoir, see chapter "Draining and filling".

C900331

200423 3-43

Page 96

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

ΧΦ85 series

3-44

200423

Page 97

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Removal and installation

4. REMOVAL AND INSTALLATION

4.1 REMOVAL AND INSTALLATION, INTERIOR FILTER ELEMENT

Removing interior filter

1. Open the grille.

2. Push the locknut on the filter casing to one side and remove the filter element.

Fitting interior filter

1. Fit the filter element.

2. Push the filter element into the locknut on the filter casing.

3. Close the grille.

Engine, cooling system and fuel system

K1 01 033

200423 4-1

Page 98

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Removal and installation

4.2 REMOVAL AND INSTALLATION, AIR FILTER ELEMENT

Removing the air filter element

1. Loosen all the clamping brackets (1) of the air filter cover (2).

2. Remove the air filter cover (2).

3. Remove the air filter element (3).

4. Clean the inside of the air filter housing and the air filter cover.

5. When replacing the air filter element, reset the air filter indicator, if fitted, by pressing the button on the indicator.

ΧΦ85 series

i400443

4-2

i400869

200423

Page 99

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ85 series

Installing the air filter element

1. Fit the air filter element (3) in the air filter housing.

2. Fit the air filter cover. Note the arrow (4) on the air filter cover (2).

3. Fit all the clamping brackets (1).

4. Check that the flexible sealing bellows (5) on the air intake is not damaged. Replace if necessary.

Removal and installation

i400443

200423 4-3

Page 100

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Removal and installation

4.3 REMOVAL AND INSTALLATION, COOLANT FILTER

When the coolant is hot, there is an overpressure in the cooling system.

}

Carefully remove the filler cap to release the overpressure. Do not remove the filler cap when the engine is running. Coolant is a toxic fluid. Contact with the skin should therefore be avoided. In the event of contact with the skin: remove the liquid with paper or a cloth, wash with soap and water. If irritation persists, consult a doctor. If swallowed: DO NOT induce vomiting. Rinse mouth, drink two glasses of water and consult a doctor. In the event of inhalation: get fresh air and rest. In order to avoid damaging the cylinder block, do not top up a warm engine with coolant.

ΧΦ85 series

Removing the coolant filter

1. Place a tray beneath the coolant filter to collect any escaping coolant.

2. Remove the filler cap from the expansion tank.

3. Turn the shut-off valve (1) clockwise to the "C" position.

4. Remove the coolant filter by turning it counter-clockwise.

Installing the coolant filter

1. Clean the sealing face of the coolant filter.

2. Apply a small amount of coolant to the sealing ring of the coolant filter.

3. Fit the coolant filter so that the sealing ring makes contact. Then tighten the filter by hand ∂ to • of a turn.

4. Turn shut-off valve (1) anti-clockwise to the "O" position.

5. Fit the filler cap on the expansion tank.

M200372

6. Run the engine and check that the coolant filter seals correctly.

7. Check the coolant level.

4-4

200423