DAF CF85 Series - User Manual

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Service Manual352 pages

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Summary

STRUCTURE

TECHNICAL DATA

DIAGNOSTICS

1. MECHANICAL GEARBOX CONTROL

1.1 FAULT-FINDING TABLE

Table listing symptoms, possible causes, and remedies for mechanical gearbox control issues.

1.2 TIGHTENING TORQUES

2. PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT)

2.1 FAULT-FINDING TABLE

Table detailing symptoms, possible causes, and remedies for Servoshift gearbox control issues.

2.2 TIGHTENING TORQUES

3. PNEUMATIC SECTION OF GEARBOX

3.1 FAULT-FINDING TABLE

Table listing symptoms, possible causes, and remedies for pneumatic section issues like range engagement.

3.2 TIGHTENING TORQUES

4. ZF 6 S-850 GEARBOX

4.2 TIGHTENING TORQUES

4.3 FILLING CAPACITIES

5. ZF 8;9;16 S-109 GEARBOX

5.2 TIGHTENING TORQUES

5.3 FILLING CAPACITIES

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

6.2 TIGHTENING TORQUES

6.3 FILLING CAPACITIES

7. EATON FS;6309 A GEARBOX

7.2 TIGHTENING TORQUES

7.3 FILLING CAPACITIES

8. ALLISON AUTOMATIC GEARBOX

8.2 TIGHTENING TORQUES

8.3 FILLING CAPACITIES

9. CLUTCH

9.2 TIGHTENING TORQUES

9.3 FILLING CAPACITIES

10. PROP SHAFTS

10.2 TIGHTENING TORQUES

10.3 FILLING CAPACITIES

11. ZF INTARDER

11.2 TIGHTENING TORQUES

11.3 INSPECTION, GEARBOX;INTARDER OIL LEVEL

12.2 TIGHTENING TORQUES

12.3 FILLING CAPACITIES

13. AS TRONIC GEARBOX

13.2 TIGHTENING TORQUES

13.3 FILLING CAPACITIES

3.2 INSPECTION, DOWNSIHFT PROTECTION VALVE

4. MECHANICAL GEARBOX

4.1 FAULT-FINDING TABLE

Table of symptoms, possible causes, and remedies for general mechanical gearbox problems like engaging gears.

5. AUTOMATIC GEARBOX

5.1 READING;DELETING FAULT CODES

Instructions on how to read and delete fault codes from the automatic gearbox ECU.

5.2 TABLE OF FAULT CODES

6. CLUTCH

6.1 FAULT-FINDING TABLE

Table listing clutch symptoms, possible causes, and remedies for issues like pedal return or sticking.

6.2 BLEEDING THE CLUTCH SYSTEM

7. PROP SHAFTS

7.1 FAULT-FINDING TABLE

Table of symptoms, possible causes, and remedies for prop shaft vibrations and imbalances.

8. ZF INTARDER

8.1 FAULT-FINDING TABLE

Table listing symptoms, possible causes, and remedies for ZF Intarder issues like braking moment.

9. AS TRONIC

9.1 FAULT-FINDING TABLE

Table listing symptoms, possible causes, and remedies for AS Tronic gearbox issues, particularly air supply pressure.

2. INSPECTION AND ADJUSTMENT

2.1 INSPECTION AND ADJUSTMENT OF GEARBOX CONTROL LHD;RHD

Procedures for inspecting and adjusting the gearbox control for LHD and RHD vehicles.

2.1 INSPECTION, GEARBOX OIL LEVEL

Procedure for inspecting the gearbox oil level on an Eaton FS/6309A gearbox.

2.1 INSPECTION, PROP SHAFT

3. REMOVAL AND INSTALLATION

3.1 REMOVAL AND INSTALLATION, ENTIRE GEAR LEVER UNIT

3.1 REMOVAL AND INSTALLATION, SERVOSHIFT UNIT

3.1 REMOVAL AND INSTALLATION, PROP SHAFT;AUXILIARY SHAFT ASSEMBLY

PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT)

2. DESCRIPTION OF COMPONENTS

2.1 SERVOSHIFT UNIT OPERATION

2.1 INTEGRATED AIR DISTRIBUTION BLOCK

2.1 SYNCHRONISER

2.1 GEARBOX MODULATOR

2.2 FUNCTION OF THE EMERGENCY SELECTOR

GEARBOX - PNEUMATIC SECTION

1.1 LOCATION OF COMPONENTS OF THE DOWNSHIFT PROTECTION FOR ZF;EATON GEARBOXES

1.3 LOCATION OF GATE PROTECTION COMPONENTS

1.2 SYSTEM DESCRIPTION, DOWNSHIFT PROTECTION

1.4 SYSTEM DESCRIPTION, GATE PROTECTION

1.5 PNEUMATIC DIAGRAM, GEARBOX CONTROL

Pneumatic diagram of 8;9 S Direct Drive

2.2 NEUTRAL POSITION VALVE

2.3 DOWNSHIFT PROTECTION VALVE

2.4 HIGH;LOW RANGE ENGAGING CYLINDER

2.5 GEAR LEVER SELECTOR VALVE

2.6 GV VALVE

2.7 SPLITTER RELAY VALVE

3. INSPECTION AND ADJUSTMENT

3.1 SIMULATION OF THE SPEED SIGNAL

Procedure for simulating the speed signal using DELSI and an adapter cable.

3.1 INSPECTION, GEARBOX OIL LEVEL

Procedure for inspecting the gearbox oil level for ZF 8/9S-109 gearboxes.

3.1 INSPECTION OF GEARBOX OIL LEVEL

Procedure for inspecting the gearbox oil level for ZF 8/16S-151/181 and 16S-221 gearboxes.

3.1 INSPECTION AND ADJUSTMENT, OUTPUT SHAFT BEARING AXIAL PLAY

3.1 INSPECTION AND ADJUSTMENT, DAF ENGINE PTO PROP SHAFT AXIAL PLAY

3.1 INSPECTION AND ADJUSTMENT, GEARBOX OIL LEVEL

Procedure for inspecting the gearbox oil level for AS Tronic gearboxes.

3.3 INSPECTION AND ADJUSTMENT, ZF;EATON GEARBOX GV VALVE

4. REMOVAL AND INSTALLATION

4.1 REMOVAL AND INSTALLATION, GEAR LEVER SELECTOR VALVE

4.1 REMOVAL AND INSTALLATION, GEARBOX ASSEMBLY WITH OR WITHOUT INTEGRATED RETARDER

4.1 REMOVAL AND INSTALLATION, INTARDER ASSEMBLY

4.1 REMOVAL AND INSTALLATION, ENTIRE DAF ENGINE PTO ON FLYWHEEL HOUSING

ZF 6 S-850 GEARBOX

2. COMPONENT DESCRIPTION

3.2 INSPECTION AND ADJUSTMENT, INPUT SHAFT BEARING AXIAL CLEARANCE

3.3 INSPECTION AND ADJUSTMENT, SECONDARY SHAFT AXIAL PLAY

4. REMOVAL AND INSTALLATION, GEARBOX

4.1 REMOVAL AND INSTALLATION, ENTIRE GEARBOX

5. DRAINING AND FILLING

5.1 DRAINING AND FILLING, GEARBOX

Procedures for draining and filling the AS Tronic gearbox with oil.

ZF 8;9;16 S-109 GEARBOX

3.3 INSPECTION AND ADJUSTMENT, GEARBOX OUTPUT SHAFT BEARING AXIAL CLEARANCE

3.4 INSPECTION AND ADJUSTMENT, SELECTOR SHAFT HOUSING ON GEARBOX

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

3.2 INSPECTION AND ADJUSTMENT, INPUT SHAFT BEARING AXIAL PLAY

3.3 INSPECTION AND ADJUSTMENT, GEARBOX OUTPUT SHAFT BEARING AXIAL PLAY

4. REMOVAL AND INSTALLATION OF GEARBOX

EATON FS;6309 A GEARBOX

2.2 INSPECTION AND ADJUSTMENT, INPUT SHAFT BEARING AXIAL CLEARANCE

3. REMOVAL AND INSTALLATION, GEARBOX

3.1 REMOVAL AND INSTALLATION, ENTIRE GEARBOX

4. DRAINING AND FILLING

4.1 DRAINING AND FILLING, GEARBOX

Procedures for draining and filling the gearbox with oil.

CLUTCH

1.1 SAFETY INSTRUCTIONS

2.2 SYSTEM DESCRIPTION OF CLUTCH PROTECTION

2.3 OVERVIEW DRAWING, MAIN CYLINDER

2.4 OVERVIEW DRAWING, CF75;85 CLUTCH SERVO

2.5 OVERVIEW DRAWING, CF65 CLUTCH SERVO

2.6 OVERVIEW DRAWING, AS TRONIC CLUTCH UNIT

2.7 OVERVIEW DRAWING, AUTOMATICALLY ADJUSTING CLUTCH RELEASE ASSEMBLY

3. DESCRIPTION OF COMPONENTS

3.1 MAIN CYLINDER

3.2 CF75;85 CLUTCH SERVO

3.3 CF65 CLUTCH SERVO

3.4 AS TRONIC CLUTCH UNIT

3.5 AUTOMATICALLY ADJUSTING CLUTCH RELEASE ASSEMBLY

Compensation of rest position of diaphragm spring

3.6 CF75;85 CLUTCH WEAR INDICATOR

3.7 CF65 CLUTCH WEAR INDICATOR

4. INSPECTION AND ADJUSTMENT

4.1 INSPECTION AND ADJUSTMENT, CLUTCH PEDAL

2. The free travel (B) of the clutch pedal is set indirectly...

4.2 INSPECTION, CLUTCH SERVO

4.3 INSPECTION, CLUTCH FLUID LEVEL

5. REMOVAL AND INSTALLATION

5.1 REMOVAL AND INSTALLATION, CLUTCH SERVO

5.2 REMOVAL AND INSTALLATION, AS TRONIC CLUTCH UNIT

5.7 REMOVAL AND INSTALLATION, CLUTCH RELEASE ASSEMBLY;CLUTCH PLATE

5.8 REMOVAL AND INSTALLATION, AUTOMATICALLY ADJUSTING CLUTCH RELEASE ASSEMBLY;CLUTCH PLATE

5.10 REMOVAL AND INSTALLATION, MAIN CYLINDER

6. DRAINING AND FILLING

6.1 DRAINING AND FILLING, CLUTCH SYSTEM

6.1 DRAINING AND FILLING, GEARBOX;INTARDER

6.3 BLEEDING AS TRONIC CLUTCH UNIT

PROP SHAFTS

4. DISASSEMBLY AND ASSEMBLY

4.1 DISASSEMBLY AND ASSEMBLY, UNIVERSAL JOINT

4.2 DISASSEMBLY AND ASSEMBLY, CENTRE BEARING

5. LUBRICATION

5.1 LUBRICATION, PROP SHAFT AND AUXILIARY SHAFT

ZF INTARDER

1. SAFETY INSTRUCTIONS

2.2 OVERVIEW DRAWING, HYDRAULIC CONTROL UNIT

2.3 LOCATION OF MAIN COMPONENTS

3.2 INSPECTION AND ADJUSTMENT, STATOR AXIAL PLAY

3.3 INSPECTION, GEARBOX;INTARDER OIL LEVEL

5. DISASSEMBLY AND ASSEMBLY

5.1 DISASSEMBLY AND ASSEMBLY, ACCUMULATOR

5.1 DISASSEMBLY AND ASSEMBLY, DAF ENGINE PTO

3. CF65;75;85 series

1. SAFETY INSTRUCTIONS

Safety instructions for working with Power Take-Off (PTO) units, especially regarding oil and engaged PTO.

3.2 INSPECTION AND ADJUSTMENT, AXIAL PLAY OF DRIVE SPROCKETS IN FLYWHEEL HOUSING OF DAF ENGINE PTO

3.3 INSPECTION AND ADJUSTMENT, AXIAL PLAY ON GEARBOX OUTPUT SHAFT WITHOUT INTARDER WITH N221;10 PTO

3.4 INSPECTION AND ADJUSTMENT, AXIAL PLAY OF NL;1 PTO ON N221;10 PTO

5.2 DISASSEMBLY AND ASSEMBLY, DAF ENGINE PTO HOUSING

AS TRONIC GEARBOX

2.2 OPERATING UNIT

2.3 TRANSMISSION BRAKE

3.2 INSPECTION AND ADJUSTMENT, GEARBOX OUTPUT SHAFT BEARING AXIAL PLAY

DAF CF85 Series Specifications

General

Brand	DAF
Model	CF85 Series
Category	Trucks
Language	English

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