DAF CF65, CF75, CF85 Service manual

3

STRUCTURE

CF65/75/85 series

TECHNICAL DATA

DIAGNOSTICS

MECHANICAL GEARBOX CONTROL

PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT)

GEARBOX - PNEUMATIC SECTION

ZF 6S-850 GEARBOX

ZF 8/9/16S-109 GEARBOX

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

EATON FS/6309A GEARBOX

AUTOMATIC GEARBOXES

CLUTCH

PROP SHAFTS

ZF INTARDER

PTO

AS TRONIC GEARBOX

0

1

2

3

4

5

6

7

8

9

10

11

12

13

14

200337 https://www.truck-manuals.net/

https://www.truck-manuals.net/

3	TECHNICAL DATA
CF65/75/85 Serie	Contents

CONTENTS

Page Date	0

1. MECHANICAL GEARBOX CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200337 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200337 1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . 200337

2. PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) . . . . . . . 2-1 . . . . 200337 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200337 2.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200337

3. PNEUMATIC SECTION OF GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 200337 3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 200337 3.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . 200337

4. ZF 6S-850 GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . 200337 4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . 200337 4.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . 200337 4.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . 200337

5. ZF 8/9/16S-109 GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . 200337 5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . 200337 5.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . 200337 5.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 . . . . 200337

6. ZF 8/16S-151/181 AND 16S-221 GEARBOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . 200337 6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . 200337 6.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . 200337 6.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 . . . . 200337

7. EATON FS/6309A GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . 200337 7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . 200337 7.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 . . . . 200337 7.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 . . . . 200337

8. ALLISON AUTOMATIC GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . 200337 8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . 200337 8.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 . . . . 200337 8.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 . . . . 200337

9. CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . 200337 9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . 200337 9.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 . . . . 200337 9.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 . . . . 200337

10. PROP SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . 200337 10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 . . . 200337 10.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 . . . 200337 10.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 . . . 200337

11. ZF INTARDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . 200337 11.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . 200337 11.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . 200337

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TECHNICAL DATA		3
Contents	CF65/75/85 Serie
	Page	Date

12. PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 . . . 200337 0 12.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 . . . 200337 12.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2 . . . 200337 12.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4 . . . 200337

13. AS TRONIC GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 . . . 200337 13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 . . . 200337 13.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2 . . . 200337 13.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 . . . 200337

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3		TECHNICAL DATA
CF65/75/85 series		Mechanical gearbox control
1.	MECHANICAL GEARBOX CONTROL
1.1	GENERAL			0

V300382

-Within the entire CF65/75/85 vehicle series many gearbox variations as well as the accompanying controls are possible, both mechanical and pneumatic.

-A gearbox with a splitter and range-change switch will be equipped with several pneumatic valves.

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	TECHNICAL DATA	3
	Mechanical gearbox control	CF65/75/85 series
	ADJUSTING THE LINKAGE MECHANISM
0	Vehicle series CF65/75/85 LHD/RHD with
	ZF 6S-850, 8/9/16S-109, 8/16S-151/181/221
	and Eaton FS/6309A gearboxes.
	Angle A: 90_
	Note:	A
	After the gear lever has been manually

positioned at an angle of 90_, the linkage mechanism should be fitted together with the selector shaft lever.

V300383

Vehicle series CF65 / RHD with gearbox type

ZF 6S-850

If the selector shaft lever has two attachment holes, the attachment hole (A) in the selector shaft lever should be used to attach the shaft lever properly to the control rod.

	A
	V300833
Bonding the gear lever into the ball
De-greaser	DAF No. 1322827
Glue	DAF No. 1340646
Bonding the ball joint to the control rod
De-greaser	DAF No. 1322827
Glue	DAF No. 1340646

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3		TECHNICAL DATA
CF65/75/85 series		Mechanical gearbox control
1.2 TIGHTENING TORQUES
The tightening torques stated in this section are		0
different from the standard tightening torques
included in the overview of standard tightening
torques.
Any other threaded connections that are
not specified must therefore be tightened to the
torque stated in the overview of
standard tightening torques.
When attachment bolts and nuts are to be
replaced, it is important that they are of exactly
the same length and property class as the ones
removed unless stated otherwise.
Control rod
Fastening bolt (1) of control rod
on gear lever unit	40 Nm
Attachment nuts (3), gear
lever unit	27 Nm
Attachment bolt, selector shaft
lever to gearbox selector
housing	40 Nm

3

1

2

V300275

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TECHNICAL DATA	3
Mechanical gearbox control	CF65/75/85 series

0

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3	TECHNICAL DATA
CF65/75/85 series	Pneumatically assisted gearbox control (Servoshift)
2. PNEUMATICALLY ASSISTED GEARBOX CONTROL
(SERVOSHIFT)			0
2.1 GENERAL
Servoshift unit
Service pressure	max. 10 bar

2.2 TIGHTENING TORQUES

The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques.

Any other threaded connections that are

not specified must therefore be tightened to the torque stated in the overview of

standard tightening torques.

When attachment bolts and nuts are to be replaced, it is important that they are of exactly the same length and property class as the ones removed unless stated otherwise.

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

38 Nm

23 Nm

2

1

V300328

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TECHNICAL DATA	3
Pneumatically assisted gearbox control (Servoshift)	CF65/75/85 series

0

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3	TECHNICAL DATA
CF65/75/85 series	Pneumatic section of gearbox
3. PNEUMATIC SECTION OF GEARBOX
3.1 GENERAL			0

If the vehicle is modified and the configuration changed, the electronic unit may have to be programmed.

Note:

If the vehicle’s drive configuration is changed, this must always be stated. The gate protection and range-change protection frequencies programmed into the electronic unit are related to the drive configuration.

	GV VALVE
	GV valve begins to
	open (C)	123 2 mm
	Total clutch pedal
	travel (D)	154 2 mm
	NEUTRAL POSITION VALVE
	Situation with separate air distribution block:
	2 x 3/2-way valve		A
	Service pressure	6.5 to 10 bar
	Pipe connection	M14 x 1.5
	Situation with integrated air distribution
	block:
	3/2-way valve		1
	Service pressure	6.5 to 10 bar
	Pipe connection	Not applicable

B

C

D

V300315

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	TECHNICAL DATA		3
	Pneumatic section of gearbox		CF65/75/85 series
	GEAR LEVER SELECTOR VALVE
0	Range-change gear
		Connection point	Colour
	1	Supply	Black
	3	Bleed	Red
	21	Range-change gear	White
		command (A)	B

A

21

1

		3
		V300488
PNEUMATIC SYMBOL	1	3
	I	I I
		Range
		21
		V300267

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3		TECHNICAL DATA
CF65/75/85 series		Pneumatic section of gearbox
GEAR LEVER SELECTOR VALVE
Range-change gear and splitter		0
	Connection point	Colour
1	Supply	Black
3	Bleed	Red
21	Range-change gear	White
	command (A)	B
22	Splitter command (B)	Yellow

A

21

1

22

3

V300489

PNEUMATIC SYMBOL

Range-change gear and splitter

Position	Function
GP	Range-change gear
GV	Splitter

22

H

L

GV

21

H

L

GP

1

V300161

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		TECHNICAL DATA		3
		Pneumatic section of gearbox		CF65/75/85 series
		3.2 TIGHTENING TORQUES
0		The tightening torques stated in this section are
		different from the standard tightening torques
		included in the overview of standard tightening
		torques.
		Any other threaded connections that are
		not specified must therefore be tightened to the
		torque stated in the overview of
		standard tightening torques.
		When attachment bolts and nuts are to be
		replaced, it is important that they are of exactly
		the same length and property class as the ones
		removed unless stated otherwise.
		Gear button on gear lever
		Gear button lock nut	70 Nm

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3		TECHNICAL DATA
CF65/75/85 series		ZF 6S-850 gearbox
4.	ZF 6S-850 GEARBOX
4.1	GENERAL			0

Gearbox type

Each gearbox has a type-plate attached to it, indicating the type of gearbox. This data is also stated on the identity card of the relevant vehicle.

ZF gearbox type-plate

1.Type of gearbox

2.	Series no. (ZF)	1
3.	Parts list (ZF)

4.Specification no.

5.	Pulse generator ratio	3																		2
6.	Gearbox ratio																			4
7.	Engine speed using PTO	6
																				5
8.	PTO speed
9.	Gearbox oil capacity	8																		7
10.	Oil specification
		9										10
																		V300049
Output shaft bearing axial play
Output shaft bearing axial play		0.00 - 0.10 mm
Bearing axial play, main and input shafts
Bearing axial play, main and input shafts		0.00 - 0.10 mm
Auxiliary shaft bearing axial play
Auxiliary shaft bearing axial play		0.00 - 0.10 mm

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		TECHNICAL DATA	3
		ZF 6S-850 gearbox	CF65/75/85 series
		4.2 TIGHTENING TORQUES
0		The tightening torques stated in this section are
		different from the standard tightening torques
		included in the overview of standard tightening
		torques.
		Any other threaded connections that are
		not specified must therefore be tightened to the
		torque stated in the overview of
		standard tightening torques.
		When attachment bolts and nuts are to be
		replaced, it is important that they are of exactly
		the same length and property class as the ones
		removed unless stated otherwise.
		Gearbox to engine
		M8 attachment bolts - 10.9	30 Nm
		M10 attachment bolts - 10.9	60 Nm
		M12 attachment bolts - 10.9	110 Nm
		Drive flange
		Drive flange attachment bolt
		- 120 mm flange diameter	140 Nm
		- 150 mm flange diameter	140 Nm
		Gearbox front cover
		Attachment bolts	23 Nm
		Selector shaft housing
		Attachment bolts	23 Nm
		Shifting arm lock nut	46 Nm
		Air connection banjo bolt	23 Nm
		Bleeder	10 Nm
		Plugs
		Drain plug	50 Nm
		Level check/filler plug	50 Nm

4.3 FILLING CAPACITIES

Gearbox type	Filling capacities at oil change	First filling, e.g. during repair
	(litres)	(litres)
ZF 6S-850	7.5	7.5

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3		TECHNICAL DATA
CF65/75/85 series		ZF 8/9/16S-109 gearbox
5.	ZF 8/9/16S-109 GEARBOX
5.1	GENERAL			0

Gearbox type

Each gearbox has a type-plate attached to it, indicating the type of gearbox. This data is also stated on the identity card of the relevant vehicle.

ZF gearbox type-plate

1.Type of gearbox

2.	Series no. (ZF)	1
3.	Parts list (ZF)

4.Specification no.

5.

Pulse generator ratio

3

2

6.

Gearbox ratio

4

7.

Engine speed using PTO

6

5

8.

PTO speed

9.

Gearbox oil capacity

8

7

10.

Oil specification

9

10

V300049

Output shaft bearing axial play

Output shaft bearing axial play

0.00 - 0.10 mm

Bearing axial pre-load, main and

input shafts

Bearing axial pre-load, main and input shafts

8/9S-109

0.18 - 0.30 mm

16S-109

0.18 - 0.30 mm

Bearing axial pre-load, auxiliary shaft

Bearing axial pre-load, auxiliary shaft

8/9S-109

0.18 - 0.30 mm

16S-109

0.18 - 0.30 mm

Retaining element

Standard spring force

168 N

Heavy-duty spring force

191 N

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		TECHNICAL DATA	3
		ZF 8/9/16S-109 gearbox	CF65/75/85 series
		5.2 TIGHTENING TORQUES
0		The tightening torques stated in this section are
		different from the standard tightening torques
		included in the overview of standard tightening
		torques.
		Any other threaded connections that are
		not specified must therefore be tightened to the
		torque stated in the overview of
		standard tightening torques.
		When attachment bolts and nuts are to be
		replaced, it is important that they are of exactly
		the same length and property class as the ones
		removed unless stated otherwise.
		Gearbox to engine
		M8 attachment bolts - 10.9	30 Nm
		M10 attachment bolts - 10.9	60 Nm
		M12 attachment bolts - 10.9	110 Nm
		Drive flange
		Retaining plate attachment bolts	60 Nm
		Gearbox front cover
		Attachment bolts	25 Nm
		Bearing cover
		Output shaft bearing cover	25 Nm
		Control bearing cover	25 Nm
		Air connection banjo bolt	38 Nm
		Shift control high/low
		Shifting fork high/low bolts	180 Nm
		Gear engaging cylinder piston lock nut	180 Nm
		Gear engaging cylinder attachment bolts	50 Nm
		Air connection banjo bolt	38 Nm
		Rear gearbox cover attachment bolts	50 Nm
		Plugs
		M24 drain plug	60 Nm
		M38 drain plug	120 Nm
		Level check/filler plug	60 Nm

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3			TECHNICAL DATA
CF65/75/85 series		ZF 8/9/16S-109 gearbox
Plugs
Gearbox with integrated intarder			0
Drain plug (B)	M24	60 Nm
Drain plug (B)	M38	120 Nm
Drain plug (C)		60 Nm
Level check/filler plug (A).		60 Nm
Oil filter attachment bolt (1)		23 Nm
		B	A
			B
			M3017

2

1

V300372

1

M3052

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		TECHNICAL DATA		3
		ZF 8/9/16S-109 gearbox		CF65/75/85 series
		5.3 FILLING CAPACITIES
0		Filling amounts, ZF gearboxes without
		intarder
		Gearbox type	Filling amounts at oil change	First filling, e.g. during repair
			(litres)	(litres)
		ZF 8/16S-109	9	9.5
		ZF 9/S-109	8	8.5
		Filling amounts, ZF gearboxes with
		integrated intarder
		Gearbox type	Filling amounts at oil change	First filling, e.g. during repair
			(litres)	(litres)
		ZF 8/16S-109	12.5	22
		ZF 9S-109	12	21

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

6. ZF 8/16S-151/181 AND 16S-221 GEARBOXES
6.1 GENERAL	0
Gearbox type
Each gearbox has a type-plate attached to it,
indicating the type of gearbox. This data is also
stated on the identity card of the relevant
vehicle.

ZF gearbox type-plate

1.Type of gearbox

2.	Series no. (ZF)	1
3.	Parts list (ZF)

4.Specification no.

5.	Pulse generator ratio	3																		2
6.	Gearbox ratio																			4
7.	Engine speed using PTO	6
																				5
8.	PTO speed
9.	Gearbox oil capacity	8																		7
10.	Oil specification
		9										10
																		V300049
Output shaft bearing axial play
Output shaft bearing axial play		0.00 - 0.10 mm
Bearing axial play, main and input shafts
Bearing axial play, main and input shafts		0.00 - 0.10 mm
Auxiliary shaft bearing axial play
Auxiliary shaft bearing axial play		0.00 - 0.10 mm
Retaining element
Standard spring force		168 N
Heavy-duty spring force		191 N

	200337				6-1
		https://www.truck-manuals.net/

		TECHNICAL DATA	3
		ZF 8/16S-151/181 and 16S-221 gearboxes	CF65/75/85 series
		6.2 TIGHTENING TORQUES
0		The tightening torques stated in this section are
		different from the standard tightening torques
		included in the overview of standard tightening
		torques.
		Any other threaded connections that are
		not specified must therefore be tightened to the
		torque stated in the overview of
		standard tightening torques.
		When attachment bolts and nuts are to be
		replaced, it is important that they are of exactly
		the same length and property class as the ones
		removed unless stated otherwise.
		Gearbox to engine
		M8 attachment bolts - 10.9	30 Nm
		M10 attachment bolts - 10.9	60 Nm
		M12 attachment bolts - 10.9	110 Nm
		Drive flange
		M12 x 70 drive flange - 8.8	60 Nm
		M12 x 60 drive flange - 10.9	120 Nm
		M12 x 70 drive flange - 10.9	120 Nm
		M12 x 165 drive flange - 10.9	120 Nm
		Gearbox front cover
		Attachment bolts	46 Nm
		Bearing cover
		Output shaft bearing cover	49 Nm
		Control bearing cover	23 Nm
		Shift control high/low
		Shifting fork high/low bolts	180 Nm
		Gear engaging cylinder piston lock nut	180 Nm
		Gear engaging cylinder attachment bolts	50 Nm
		Air connection banjo bolt	38 Nm
		Rear gearbox cover attachment bolts	50 Nm
		Plugs
		M24 drain plug	60 Nm
		M38 drain plug	120 Nm
		Level check/filler plug	60 Nm

	6-2				200337
		https://www.truck-manuals.net/

3	TECHNICAL DATA

CF65/75/85 series

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

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

B

0

D

C

V300186

4 5

V300260

1

M3052

	200337				6-3
		https://www.truck-manuals.net/

		TECHNICAL DATA		3
		ZF 8/16S-151/181 and 16S-221 gearboxes		CF65/75/85 series
		6.3 FILLING CAPACITIES
0		Filling amounts, ZF gearboxes without
		intarder
		Gearbox type	Filling amounts at oil change	First filling, e.g. during repair
			(litres)	(litres)
		ZF 8/16S-151	11	11
		ZF 8/16S-181	13	13
		ZF 16S-221	13	13
		Filling amounts, ZF gearboxes with
		integrated intarder
		Gearbox type	Filling amounts at oil change	First filling, e.g. during repair
			(litres)	(litres)
		ZF 8/16S-151	11	18.5
		ZF 8/16S-181	12	21.5
		ZF 16S-221	12	21.5

	6-4				200337
		https://www.truck-manuals.net/

3		TECHNICAL DATA
CF65/75/85 series		Eaton FS/6309A gearbox
7.	EATON FS/6309A GEARBOX
7.1	GENERAL			0

Gearbox type

Each gearbox has a type-plate attached to it, indicating the type of gearbox. This data is also stated on the identity card of the relevant vehicle.

Eaton gearbox type-plate

1.Type of gearbox

2.Specification no. Eaton

3.DAF article Eaton code

4.Series no. Eaton

5.Production date code

The Eaton specification number is unique for each customer and gives detailed information on the development level of the gearbox.

The number must be quoted whenever replacement parts are ordered.

Input shaft play adjusting rings:

3.70 mm

3.75 mm

3.80 mm

3.85 mm

3.90 mm

3.95 mm

Secondary shaft pre-load

New bearings

Original bearings

Sealant

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

Input shaft

Filter/governor

Governed pressure

Colour coding:

Red, green, white

Yellow, green, blue

Blue, green, white

Red, green, yellow

Green, green, white

Red, green, red

0.075 - 0.125 mm

0.000 - 0.050 mm

Loctite 518

Lithium-based grease, class NLGI 3

5.3 - 5.7 bar

	200337				7-1
		https://www.truck-manuals.net/

		TECHNICAL DATA		3
		Eaton FS/6309A gearbox		CF65/75/85 series
		7.2 TIGHTENING TORQUES
0		The tightening torques stated in this section are
		different from the standard tightening torques
		included in the overview of standard tightening
		torques.
		Any other threaded connections that are
		not specified must therefore be tightened to the
		torque stated in the overview of
		standard tightening torques.
		When attachment bolts and nuts are to be
		replaced, it is important that they are of exactly
		the same length and property class as the ones
		removed unless stated otherwise.
		Drive flange
		M39 drive flange nut	650 Nm(1)
		Drive flange oil seal housing attachment bolts	60	Nm
		Gearbox front cover
		Attachment bolts	37	Nm
		Selector shaft housing
		Selector shaft housing attachment bolts	37	Nm(2)
		Retaining cover attachment bolts	22	Nm
		M8 shifting arm lock nut	25	Nm
		M8 shifting arm lock nut	25	Nm
		End cover attachment bolts	22	Nm
		Bleed valve
		Attachment bolts	19	Nm
		Bearing cover
		Output shaft bearing cover	25	Nm
		Air connection banjo bolt	38	Nm
		Filter/governor
		M6 attachment bolts	13	Nm
		Cover	25 Nm
		Selector valve
		M6 attachment bolts	22	Nm
		M16 discharge valve attachment bolts	19	Nm
		M8 cover plate attachment bolts	22	Nm
		Range-change cylinder
		M8 cover plate attachment bolts	17	Nm
		M16 nut on piston	105 Nm

	7-2				200337
		https://www.truck-manuals.net/

3		TECHNICAL DATA
CF65/75/85 series		Eaton FS/6309A gearbox
Plugs
Drain plug	50 Nm
				0
Level check/filler plug	50 Nm

(1)Use new nut

(2)Loctite 243

7.3 FILLING CAPACITIES

Gearbox capacity

Type	Contents
FS/6309A	8.5 litres

	200337				7-3
		https://www.truck-manuals.net/

TECHNICAL DATA	3
Eaton FS/6309A gearbox	CF65/75/85 series

0

	7-4				200337
		https://www.truck-manuals.net/

3		TECHNICAL DATA
CF65/75/85 series		Allison automatic gearbox
8.	ALLISON AUTOMATIC GEARBOX
8.1	GENERAL			0

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

R MODE

N

D

V300392

	200337				8-1
		https://www.truck-manuals.net/

		TECHNICAL DATA	3
		Allison automatic gearbox	CF65/75/85 series
		8.2 TIGHTENING TORQUES
0		The tightening torques stated in this section are
		different from the standard tightening torques
		included in the overview of standard tightening
		torques.
		Any other threaded connections that are
		not specified must therefore be tightened to the
		torque stated in the overview of
		standard tightening torques.
		When attachment bolts and nuts are to be
		replaced, it is important that they are of exactly
		the same length and property class as the ones
		removed unless stated otherwise.
		Gearbox bleeder	14 Nm
		M14 x 2.0 drive flange attachment bolt	75 Nm
		Gearbox rear mounting bracket	100 Nm
		PTO bracket	55 Nm
		Gearbox with flywheel housing adapter, M10 x
	1.5		55 Nm
		Flex plates to flex plate adapter
		CF65	68 Nm
		CF75	34 Nm
		Flex plate adapter to torque converter	34 Nm
	Hydraulic pipes to oil cooler		60 Nm
		Gearbox main connector	2.5 Nm
		Attachment bolts for oil filter caps	55 Nm
		Oil drain plugs	28 Nm
		Coolant pipe attachment	55 Nm
		Molycote for the top bearing of the torque
		converter on installation	BR2S or BR2 Plus

	8-2				200337
		https://www.truck-manuals.net/