DAF CF85 Maintenance Manual
DAF CF85 Maintenance Manual
DAF CF85 Maintenance Manual
CF85
https://www.truck-manuals.net/
https://www.truck-manuals.net/
©200423 DAF Trucks N.V., Eindhoven,
The Netherlands.
©
200423 DW13278604
https://www.truck-manuals.net/
https://www.truck-manuals.net/
STRUCTURE
ΧΦ85 series
TECHNICAL DATA
Structure
0
1
THREADED CONNECTIONS
2
FLUIDS, OIL AND LUBRICANTS
3
MAINTENANCE SCHEDULE
4
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
5
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200423
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TECHNICAL DATA
ΧΦ85 series Contents
CONTENTS
0 Technical data
Page Date 0
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
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TECHNICAL DATA
Contents ΧΦ85 series
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TECHNICAL DATA
ΧΦ85 series XE engine
1. XE ENGINE
1.1 GENERAL 0
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 (1)(N)
Application example: air-conditioning compressor drive
New V-belt (2)
Setting tension 600
Test tension 400
Run-in V-belt (3)
Minimum tension 250
Adjusting tension 350
M2121
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TECHNICAL DATA
XE engine ΧΦ85 series
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
DEB
DEB attachment bolts 110 Nm
DEB set screw nut 25 Nm
V-belt tensioner
Central bolt, tensioning gear 110 Nm
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
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TECHNICAL DATA
ΧΦ85 series Gearbox
2. GEARBOX
2.1 TIGHTENING TORQUES 0
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.
A
B C D
M3023
V300186
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TECHNICAL DATA
Gearbox ΧΦ85 series
0
Oil filter attachment bolt (1) 23 Nm
1 M3052
ZF AS Tronic
Level check/filler plug (A) 60 Nm
Drain plug (B/C) 60 Nm
A C
B
G000243
B C
G000250
1 M3052
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TECHNICAL DATA
ΧΦ85 series Gearbox
ZF gearboxes
0
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 AS Tronic gearboxes
ZF 12 AS 1930/2330
Filling capacity approx. 11 litres
ZF 12 AS 2540
Filling capacity approx. 12 litres
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TECHNICAL DATA
Gearbox ΧΦ85 series
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TECHNICAL DATA
ΧΦ85 series Rear axle
3. REAR AXLE
3.1 TIGHTENING TORQUES 0
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.
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TECHNICAL DATA
Rear axle ΧΦ85 series
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TECHNICAL DATA
ΧΦ85 series Brakes
4. BRAKES
4.1 GENERAL 0
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
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TECHNICAL DATA
Brakes ΧΦ85 series
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TECHNICAL DATA
ΧΦ85 series Steering gear
5. STEERING GEAR
5.1 GENERAL 0
Maximum steering ball joint axial clearance 1.5 mm
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TECHNICAL DATA
Steering gear ΧΦ85 series
S7 00 906
Note:
S7 00 907
- The two plugs are interchangeable.
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TECHNICAL DATA
ΧΦ85 series Front axle
6. FRONT AXLE
6.1 TIGHTENING TORQUES 0
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.
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TECHNICAL DATA
Front axle ΧΦ85 series
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TECHNICAL DATA
ΧΦ85 series Leading rear axle 09N044 (FTP-type vehicles)
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TECHNICAL DATA
Leading rear axle 09N044 (FTP-type vehicles) ΧΦ85 series
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THREADED CONNECTIONS
ΧΦ85 series Contents
CONTENTS
2 Threaded connections
Page Date
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THREADED CONNECTIONS
Contents ΧΦ85 series
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THREADED CONNECTIONS
ΧΦ85 series Threaded connections
1. THREADED CONNECTIONS
1.1 GENERAL
Note:
Have torque wrenches regularly inspected and
calibrated.
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THREADED CONNECTIONS
Threaded connections ΧΦ85 series
2
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.
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FLUIDS, OIL AND LUBRICANTS
ΧΦ85 series Contents
CONTENTS
3 Fluids, oil and lubricants
Page Date
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FLUIDS, OIL AND LUBRICANTS
Contents ΧΦ85 series
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FLUIDS, OIL AND LUBRICANTS
ΧΦ85 series Specifications
1. SPECIFICATIONS
1.1 GENERAL
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FLUIDS, OIL AND LUBRICANTS
Specifications ΧΦ85 series
3
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.
Note:
Refer to the "Fluids and lubricants" specification
manual for the prescribed fluid, oil and lubricant
specifications.
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MAINTENANCE SCHEDULE
ΧΦ85 series Contents
CONTENTS
4 Maintenance schedule
Page Date
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MAINTENANCE SCHEDULE
Contents ΧΦ85 series
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MAINTENANCE SCHEDULE
ΧΦ85 series Maintenance intervals
1. MAINTENANCE INTERVALS
1.1 MAINTENANCE SCHEDULE
CF85 +
+
4
1 year 1 year
30.000 km max. 100.000 km max. 100.000 km
1 year 1 year
50.000 km max. 100.000 km max. 100.000 km
1 year 1 year
75.000 km max. 150.000 km max. 200.000 km
(2)
G000234
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MAINTENANCE SCHEDULE
Maintenance intervals ΧΦ85 series
4 Maintenance group II
Urban and regional transport
- Distribution traffic in urban areas
- Traffic between adjacent villages/cities
Maintenance group III
(Inter)national traffic
- 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.
G0 00 230
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MAINTENANCE SCHEDULE
ΧΦ85 series Maintenance intervals
Intermediate inspection
This is the intermediate inspection symbol.
Intermediate inspections are based on several
visual inspections. Intermediate
inspection
When an extended changing interval is
applicable to the engine oil (X-service), an
intermediate inspection should be carried out.
G000088
X-service
This is the symbol for an X-service.
An X-service is a mileage-dependent
maintenance check which consists of changing X service
the engine oil plus a number of visual inspections.
Note:
+
4
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.
G000086
Y-service
This is the symbol for a Y-service.
A Y-service is an annual maintenance check
consisting of several maintenance activities plus Y service
changing of the gearbox and rear axle oil.
1x per YEAR
Note:
If the prescribed oil specification (see
specification manual "Fluids and lubricants") has
been met, an extended changing interval may be +
applied.
(1)
G000087
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MAINTENANCE SCHEDULE
Maintenance intervals ΧΦ85 series
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
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.
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MAINTENANCE SCHEDULE
ΧΦ85 series Maintenance activities
2. MAINTENANCE ACTIVITIES
2.1 OVERVIEW OF MAINTENANCE ACTIVITIES FOR THE FIRST SERVICE
INSPECTION
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MAINTENANCE SCHEDULE
Maintenance activities ΧΦ85 series
4
O Check air inlet dust trapping valve
O Check/adjust valve clearance (4) Done O Yes O No
O Replace coolant filter
O Check coolant freezing point
O Change coolant (1) Changed O Yes O No
STEERING GEAR AND BRAKE SYSTEM
O Replace steering gear filter element (6) Replaced O Yes O No
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 (2) Changed O Yes O No
O Change the hub oil (2) Changed O Yes O No
O Change grease of leading rear axle hubs of FTP-type
vehicles (5) Done O Yes O No
O Check operation of differential lock
O Check drive shaft play
O Change the gearbox oil (3) Changed O Yes O No
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.
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MAINTENANCE SCHEDULE
ΧΦ85 series Maintenance activities
4
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 (1)
O Check oil-lubricated wheel hubs for leaks (1)
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 (2)
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.
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MAINTENANCE SCHEDULE
Maintenance activities ΧΦ85 series
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Contents
CONTENTS
5 Explanatory notes on the maintenance activities
Page Date
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Contents ΧΦ85 series
Page Date
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
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Contents
Page Date
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Contents ΧΦ85 series
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Safety instructions
1. SAFETY INSTRUCTIONS
1.1 SAFETY INSTRUCTIONS
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Safety instructions ΧΦ85 series
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series General
2. GENERAL
2.1 INTRODUCTION
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
General ΧΦ85 series
Note:
Important changes relating to technical
information that is not contained in this manual
will be made available in TI sheets (Technical
Information Sheet).
M0015
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series General
2.4 ENVIRONMENT
5
carried out in an environmentally aware
manner.
2.5 PARTS
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
General ΧΦ85 series
5 -
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.
- 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.
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
5
air, rest and consult a doctor.
M5011
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
M201062
K1 01 660
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
V300384
5
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.
Note:
For the difference between minimum and
maximum engine oil level, see "Technical
data".
D
V300389
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
Note:
"Overlap" is the moment at which the inlet
valve starts opening and the exhaust valve M201185
finishes closing.
M200539
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
5
5. Then tighten set screw (B) to the specified
torque, see main group "Technical data".
and installation".
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
5
Then remove the belt tension gauge
carefully. Take care not to let the measuring
arm move.
M2062
2 M2041
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
5
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.
-50
-60
-70
-80
0 10 20 30 40 50 60 70 80 90 100 % Ethyleenglycol
100 90 80 70 60 50 40 30 20 10 0 H 2O
M2016
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
S7 00 639
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
S7 00 592
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
5
locking screw (5). It should be possible to
move the pressure sleeve (6) freely. 7
Note:
Fit the correct pressure sleeve (6).
The pressure sleeve (6) must abut the outer
edge of the steering ball joint (7).
6
6. Loosen thrust bolt (2) until the pressure A
sleeve (6) with the flange abuts the bracket 5
(A = 0 mm). 4
7. Fit the special tool over the steering ball joint 3
(7) and turn the threaded spindle (9) by hand
until the special tool is tight around the
steering ball joint (7). 1
2
8. Tighten thrust bolt (2) until its head abuts
S700426
bracket (1).
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
Note:
When the steering oil is at operating S7 00 676
temperature, the level may be above the top
mark on the dipstick.
5
3.21 CHECKING THE STEERING GEAR LINES AND CONNECTIONS
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.
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
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.
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
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).
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
3.23 CHECKING THE BRAKE COMPONENTS AND BRAKE SYSTEM FOR LEAKS
Note:
Always connect auxiliary consumers and
accessories to circuit 4.
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
Brake drum
5
in respect of the fixed bracket.
©
200423 3-19
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
©
3-20 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
Note:
If in doubt about the amount of brake lining
wear, release the brakes and remove the
dust cover.
M6012
5
M6002
Note:
If in doubt about the amount of brake lining
wear, release the brakes and remove the
dust cover. R6 00 677
©
200423 3-21
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
1
4
A
6
R600481
©
3-22 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
A
R600730
©
200423 3-23
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
VALVOLA VUOTO-CARICO
VALVULA VACIO-CARGA
p43
If the vehicle is fitted with a relay valve in the front
VALVE CHARGE-VIDE
EMPTY-LOAD VALVE
LAST-LEER VENTIEL
MEEREGELVENTIEL
axle brake circuit, the box beneath the valve
1 = 1 : 1.5
p1
p2
W475 721 003 0
illustration will be blank. Throughout the column,
p4
5 If the vehicle is equipped with a control valve
instead of the relay valve mentioned, the box will
p43
contain a pressure ratio, e.g."i = 1 : 1.5". The
PRESSION COUSSIN
"delivery pressure p2" of axle "1" then indicates
PRESION FUELLES
variable readings.
bar
BALG DRUCK
BALG DRUK
0.2
0.5
1.3
1.8
2.3
4.2
4.9
5.6
2
These values can be used to check the brake
pressure values of the front axle and to carry out
1
the inspection/adjustment below at the same
AUSGESTEUERTER DRUCK
UITGESTUURDE DRUK p2
PRESSION DELIVREE
PRESION DE SALIDA
PRESSIONE USCITA
cylinders.
bar
±0.4 ±0.2
2.0
2.1
2.8
3.5
4.3
7.3
8.3
8.3
2
5.7
5.8
6.0
6.3
6.6
7.7
8.1
8.1
1
G
x104 N
CARICO ASSE
AXLE LOAD
CARGA EJE
10.0
11.5
13.0
ACHSLAST
1.8
2.5
4.0
5.0
6.0
2
ASLAST
R600472
©
3-24 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
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.
R600478
©
200423 3-25
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
Note:
©
3-26 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
L = 140 mm
illustration will be blank. Throughout the column,
VALVOLA VUOTO-CARICO
a = 15 ±2
VALVULA VACIO-CARGA
G=11.0
a value of 8.1 bar has been filled in for "delivery
VALVE CHARGE-VIDE
EMPTY-LOAD VALVE
LAST-LEER VENTIEL
MEEREGELVENTIEL
pressure p2" under axle "1".
i = 1 : 1.5
W475 721 004 0
L
p1
p2
1396041
instead of the relay valve mentioned, the box will
contain a pressure ratio, e.g."i = 1 : 1.5". The
5
p4
"delivery pressure p2" of axle "1" then indicates
p3
variable readings.
PRESSION COUSSIN
These values can be used to check the brake
PRESION FUELLES
pressure values of the front axle and to carry out
bar
BALG DRUCK
BALG DRUK
PRESSION DELIVREE
PRESION DE SALIDA
PRESSIONE USCITA
bar
±0.4 ±0.2
1.8
1.8
2.2
3.1
6.4
7.6
8.2
8.2
2
5.7
5.7
5.8
6.1
7.4
7.8
8.0
8.0
1
G
x104 N
CARICO ASSE
AXLE LOAD
CARGA EJE
10.0
11.5
13.0
ACHSLAST
1.8
2.0
3.0
4.0
8.0
2
ASLAST
R600479
©
200423 3-27
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
©
3-28 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
Note:
The small socket head screw in the centre of the
valve must not be adjusted.
5
2
R600781
©
200423 3-29
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
©
3-30 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
©
200423 3-31
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
M3032
5 play.
M3019
M3020
©
3-32 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
Note:
For maximum play values, consult the
manufacturer's instructions or the legal
requirements.
©
200423 3-33
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
M9002
5
coupling jaw.
M9001
Note:
For maximum play values, consult the
manufacturer’s instructions or the specified
legal requirements.
M9004
©
3-34 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
©
200423 3-35
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
5
operation of the clutch system.
Avoid any contact with mineral oil.
Even one drop of mineral oil in the
system will damage the seals.
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.
C
V300178
©
3-36 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
Note:
It is not permissible to remove the circlip, or
to move the circlip over the pin. This is to
prevent inaccurate indication.
servo.
Note:
5
It is not permissible to remove the circlip, or
to move the circlip over the pin. This is to
prevent inaccurate indication.
©
200423 3-37
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
3.41 CHECKING THE CENTRAL AXLE OF THE TANDEM AXLE UNIT FOR LEAKS
Note:
5 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".
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
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
4. Remove the split pin (3) from the hub nut (2).
©
200423 3-39
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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
5
reading falls outside the tolerance range, the
wheel bearing play should be re-adjusted.
S7 00 635
6. Fit the hub cap. Tighten the hub cap to the
specified torque using the special tool
(DAF no. 1329498), see "Technical data"'.
4. Remove the split pin (3) from the hub nut (2).
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.
©
3-40 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
©
200423 3-41
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
Checking U-bolts
1. Visually inspect the condition and
attachment of the U-bolts.
Torque rod
1. Check the attachment of the torque rod and
torque rod supports.
Stabiliser bar
1. Check the attachment of the stabiliser bar
and stabiliser bar support.
©
3-42 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Inspection and adjustment
position.
5
3.50 CHECKING THE OPERATION OF THE AUTOMATIC LUBRICATION SYSTEM
C900331
©
200423 3-43
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Inspection and adjustment ΧΦ85 series
©
3-44 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Removal and installation
5
Engine, cooling system and fuel system
K1 01 033
©
200423 4-1
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Removal and installation ΧΦ85 series
4
5 2 3
i400443
i400869
©
4-2 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Removal and installation
4
2 3
i400443
©
200423 4-3
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Removal and installation ΧΦ85 series
5
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.
©
4-4 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Removal and installation
5
Installing the engine oil filter
1. Replace the sealing ring in the cap (2)
1
2. Lightly lubricate the sealing ring with
engine oil.
M201049
©
200423 4-5
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Removal and installation ΧΦ85 series
5
3. Replace the sealing ring (5).
M200526
©
4-6 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Removal and installation
Note:
The fuel filter element is a disposable filter,
and may not be cleaned and reused.
Dispose of the filter as chemical waste.
i 400444
©
200423 4-7
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Removal and installation ΧΦ85 series
i 400445
©
4-8 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Removal and installation
Version: Racor
©
200423 4-9
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Removal and installation ΧΦ85 series
©
4-10 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Removal and installation
©
200423 4-11
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Removal and installation ΧΦ85 series
©
4-12 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Removal and installation
Note:
6
The filter element must be removed from the
reservoir with care so that no dirt remains in
the reservoir.
7 5
8
Installing the steering gear filter element
1. Fit a new filter element (8) into the
9
reservoir (9).
S7 00 720
©
200423 4-13
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Removal and installation ΧΦ85 series
5
and pressure is built up.
In the case of serious foaming, the
steering oil should be completely
drained.
©
4-14 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Removal and installation
Note:
To be certain that the air dryer is functioning
properly, the air reservoirs should regularly be
checked for condensation. If more than the
normal amount of water is drained off repeatedly,
the air dryer element must be replaced. Under
normal circumstances the element must be
replaced at least once per year.
R600525
©
200423 4-15
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Removal and installation ΧΦ85 series
5 R600523
©
4-16 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Removal and installation
5
1 M3052
M3053
2
M3054
©
200423 4-17
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Removal and installation ΧΦ85 series
©
4-18 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Removal and installation
10
9
8
7
5
5 6
4
1 2 3
S7 00 640
1. Remove the hub cover (1) using special tool
(DAF no. 1329498)
3. Remove the split pin (2) and the hub nut (3).
©
200423 4-19
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Removal and installation ΧΦ85 series
©
4-20 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Draining and filling
5
doctor.
In the event of inhalation: get fresh
air, rest and consult a doctor.
M5011
©
200423 5-1
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Draining and filling ΧΦ85 series
V300389
©
5-2 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Draining and filling
5
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.
©
200423 5-3
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Draining and filling ΧΦ85 series
Note:
Combustion will start after approximately
one minute.
©
5-4 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Draining and filling
Note:
The fuel system has to be bled if it has been
opened; this can be done in two ways.
i 400237
©
200423 5-5
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Draining and filling ΧΦ85 series
}
Bleeding by pressurising the fuel tank
To prevent deformation of the fuel
tank, the delivery pressure in the fuel
tank must not exceed 0.4 bar.
Note:
Use a cap (without a vent) that has a
connection for a pressure reducer valve. 2
1 3
0 4
i400600
5
2. Pressurise the tank to a maximum of 0.2 bar.
i 400237
©
5-6 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Draining and filling
©
200423 5-7
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Draining and filling ΧΦ85 series
©
5-8 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Draining and filling
©
200423 5-9
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Draining and filling ΧΦ85 series
4. Drain the oil and let the oil leak out of the A
hub.
5 M8010
©
5-10 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Draining and filling
4. Drain the oil and let the oil leak out of the
hub.
A8 00 363
A8 00 364
©
200423 5-11
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Draining and filling ΧΦ85 series
Version: ZF 8/16S-151/181/221
©
5-12 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Draining and filling
B
5
D
V300186
©
200423 5-13
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Draining and filling ΧΦ85 series
Version: ZF AS Tronic
B C
G000250
1 M3052
©
5-14 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Draining and filling
©
200423 5-15
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Draining and filling ΧΦ85 series
Note:
When filling the reservoir, the air above the
follower piston will escape. This air will flow
down through an opening in the piston line
and escape from the pump through the right-
angled coupling. Normally a small amount of
5
grease will escape from this coupling during
venting. C900331
©
5-16 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Cleaning
6. CLEANING
6.1 CLEANING THE BATTERY POLES
5
doctor.
In the event of inhalation: get fresh
air, rest and consult a doctor.
©
200423 6-1
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Cleaning ΧΦ85 series
1 Solder up 1
5mm
2 Solder
3 Quick-release coupling for air hose 32 5
4 Steel pipe, 10 mm 2
100mm
5 6 x 1.5 mm between holes, with a
centre-to-centre distance between the
holes of 7 mm, drilled on one side 4 4 5
1
5
Note:
With the aid of a simple tool, the radiator and the
intercooler can be blow-cleaned. M2108
P M2109
©
6-2 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Cleaning
P M2110
©
200423 6-3
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Cleaning ΧΦ85 series
©
6-4 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Cleaning
©
200423 6-5
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Cleaning ΧΦ85 series
©
6-6 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Lubrication
7. LUBRICATION
7.1 LUBRICATE ACCORDING TO X-SERVICE LUBRICATION SCHEDULE
Lubrication
Check whether the lubricating points stated
below are applicable.
Note:
Where the lubricating points below are marked
with an (S), this indicates that the lubricating point
is positioned on both the left and right of the
vehicle.
5
axle should therefore be completely jacked
up.
G000189
©
200423 7-1
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Lubrication ΧΦ85 series
G000192
Lubricating the air-sprung front axle (S)
G0 00 193
Lubricating the leaf-sprung trailing axle (S)
G000191
©
7-2 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Lubrication
G000187
Lubricating the trailer coupling
5
G000188
©
200423 7-3
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Lubrication ΧΦ85 series
G000194
G0 00 267
©
7-4 200423
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
ΧΦ85 series Lubrication
Note:
If the grease does not come out of all 4
needle bushes, the joint may be turned to
soften hardened grease.
If the grease does not come out of all 4
needle bushes after the prop shaft has been
repeatedly turned, the joint needs to be
replaced.
The maximum lubricating pressure should
not exceed 15 bar.
V300899
C9 00 346
©
200423 7-5
https://www.truck-manuals.net/
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
Lubrication ΧΦ85 series
©
7-6 200423
https://www.truck-manuals.net/
https://www.truck-manuals.net/
English
Printed in the Netherlands DW13278604
https://www.truck-manuals.net/