Maintenance Manual CF85

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Maintenance manualCF85https://www.truck-manuals.net/

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

200423 DAF Trucks N.V., Eindhoven,The Netherlands.In the interest of continuing product development,DAF reserves the right to change specificationsor products at any time without prior notice.No part of this publication may be reproducedand/or published by printing, by photocopying, onmicrofilm or in any way whatsoever without theprior consent in writing of DAF Trucks N.V. 200423https://www.truck-manuals.net/DW13278604

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

STRUCTUREΧΦ85 seriesTECHNICAL DATAStructure01 200423THREADED CONNECTIONS2FLUIDS, OIL AND LUBRICANTS3MAINTENANCE SCHEDULE4EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES5https://www.truck-manuals.net/

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

TECHNICAL DATAΧΦ85 seriesContentsCONTENTS0 Technical dataPage1.XE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 2004232.1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 2004232.2 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 2004233.REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 2004233.1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 2004233.2 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 2004234.BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 2004234.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 2004235.STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 2004235.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 2004235.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 2004236.FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 2004236.1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 2004237.LEADING REAR AXLE 09N044 (FTP-TYPE VEHICLES) . . . . . . . . . . . . . . . . . 7-1 . . . . . 2004237.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 2004237.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 . . . . . 200423 200423https://www.truck-manuals.net/1-1 . . . . .1-1 . . . . .1-2 . . . . .1-2 . . . . .Date20042320042320042320042310

TECHNICAL DATAΧΦ85 seriesContents02 https://www.truck-manuals.net/200423

TECHNICAL DATAΧΦ85 seriesXE engine1. XE ENGINE01.1 GENERALXE engineValve clearanceValve clearance (cold/hot)InletExhaust0.50 mm0.50 mmDEBDEB setting1.40 mmV-belt tensionV-belt tension, "AVX" raw edge (1)(N)Application example: air-conditioning compressor driveNew V-belt (2)Setting tension600Test tension 400Run-in V-belt (3)Minimum tension250Adjusting tension350V-belt tension, "XPB" raw edge (1)(N)Application example: steering pump drive on FAX vehicleNew V-belt (2)Setting tension1250Test tension 950Run-inV-belt (3)Minimum tension750Adjusting tension950(1) Raw-edge V-belts can be recognised by the absence oftextile fabric in the rubber, with the exception of the top ofthe 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 thepre-tension complies with the "test tension". If the testtension reading is lower than the value specified in thetable, 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".M2121 200423https://www.truck-manuals.net/1-1

TECHNICAL DATAΧΦ85 seriesXE engine01.2 TIGHTENING TORQUESThe tightening torques specified in this paragraphare different from the standard tightening torquescited in the overview of the standard tighteningtorques. The other threaded connections notspecified must therefore be tightened to thetorque cited in the overview of standardtightening torques.When attachment bolts and nuts are replaced, itis important - unless stated otherwise - that thesebolts and nuts are of exactly the same length andproperty class as those removed.XE engineLubrication systemOil drain plugOil filter screw capCentrifugal filter central bolt60 Nm40 Nm20 NmFuel systemFuel filter screw cap25 NmCylinder head coverCylinder head cover attachment bolts25 NmDEBDEB attachment boltsDEB set screw nut110 Nm25 NmV-belt tensionerCentral bolt, tensioning gear110 Nm1.3 FILLING CAPACITIESXE engineLubrication systemTotal capacity (including oil cooler and oil filter)Capacity of oil sump, maximum levelCapacity of oil sump, minimum levelapprox. 34 litresapprox. 30 litresapprox. 22 litresCooling systemCooling systemWith integrated retarderapprox. 47 litresapprox. 57 litres1-2 https://www.truck-manuals.net/200423

TECHNICAL DATAΧΦ85 seriesGearbox2. GEARBOX02.1 TIGHTENING TORQUESThe tightening torques specified in this paragraphare different from the standard tightening torquescited in the overview of the standard tighteningtorques. The other threaded connections notspecified must therefore be tightened to thetorque cited in the overview of standardtightening torques.When attachment bolts and nuts are replaced, itis important - unless stated otherwise - that thesebolts and nuts are of exactly the same length andproperty class as those removed.ZF 8S -151/181 and 16S-151/181/221gearboxesLevel check/filler plug (A)60 NmM24 drain plug (B)60 NmM38 drain plug (B)120 NmDrain plug (C/D)60 NmABCDM3023ZF 8S-151/181 and 16S-151/181/221 withintegrated retarderDrain plug (D)60 NmBDCV300186 200423https://www.truck-manuals.net/2-1

TECHNICAL DATAΧΦ85 seriesGearbox0Oil filter attachment bolt (1)23 Nm1ZF AS TronicLevel check/filler plug (A)Drain plug (B/C)M305260 Nm60 NmACBG000243ZF AS Tronic with integrated retarderLevel check/filler plug (A)60 NmDrain plug (B/C)60 NmAB CG000250Oil filter attachment bolt (1)23 Nm12-2M3052 https://www.truck-manuals.net/200423

TECHNICAL DATAΧΦ85 seriesGearbox2.2 FILLING CAPACITIES0ZF gearboxesZF 8S/16S-151Filling capacityapprox. 11 litresZF 8S/16S-181Filling capacityapprox. 13 litresZF 16S-221Filling capacityapprox. 13 litresZF 16S-151 with integrated retarderFilling capacityapprox. 11 litresZF 16S-181 with integrated retarderFilling capacityapprox. 12 litresZF 16S-221 with integrated retarderFilling capacityapprox. 12 litresZF AS Tronic gearboxesZF 12 AS 1930/2330Filling capacityapprox. 11 litresZF 12 AS 2540Filling capacityapprox. 12 litresZF 12 AS 1931/2331 with integrated retarderFilling capacityapprox. 12 litresZF 12 AS 2541 with integrated retarderFilling capacityapprox. 13 litres 200423https://www.truck-manuals.net/2-3

TECHNICAL DATAΧΦ85 seriesGearbox02-4 https://www.truck-manuals.net/200423

TECHNICAL DATAΧΦ85 seriesRear axle3. REAR AXLE03.1 TIGHTENING TORQUESThe tightening torques stated in this paragraphare different from the standard tightening torquesstated in the overview of the standard tighteningtorques. The other threaded connections notspecified must therefore be tightened to thetorque stated in the overview of standardtightening torques.When attachment bolts and nuts are replaced, itis important that - unless stated otherwise - thesebolts and nuts are of exactly the same length andproperty class as those removed.Filler and drain plugs/hub plugs (Torx wrench)85 NmM24 U-bolt nut, property class 8If flanged nutIf yellow zinc plated hexagonal nut740 Nm 55 Nm (1)615 Nm 50 Nm (1)(1) Evenly tighten the two U-bolt nuts alternately.M24 U-bolt nut, property class 10If flanged nutIf yellow zinc plated hexagonal nut880 Nm 60 Nm (1)615 Nm 50 Nm (1)(1) Evenly tighten the two U-bolt nuts alternately.M22 U-bolt nut, property class 10(leading rear axle)If flanged nutIf yellow zinc plated hexagonal nut700 Nm 50 Nm (1)530 Nm 40 Nm (1)(1) Evenly tighten the two U-bolt nuts alternately. 200423https://www.truck-manuals.net/3-1

TECHNICAL DATAΧΦ85 seriesRear axle03.2 FILLING CAPACITIESDifferential1339 axle1347 axle1354 axle1355(T) axle (1st axle)1355(T) axle (2nd axle)1132(T) axle (1st axle)1132(T) axle (2nd axle)Filling quantity withminimum casterapprox. 18.0 litresapprox. 21.5 litresapprox. 16.5 litresapprox. 13.0 litresapprox. 11.5 litresapprox. 17.0 litresapprox. 15.0 litresWheel hub1354 axle1355(T) axle1132(T) axleFilling capacity per hubapprox. 2 litresapprox. 2 litresapprox. 0.8 litres3-2Filling quantity withmaximum casterapprox. 20.0 litresapprox. 23.5 litresapprox. 16.5 litresapprox. 18.0 litresapprox. 13.0 litresapprox. 25.5 litresapprox. 17.5 litres https://www.truck-manuals.net/200423

TECHNICAL DATAΧΦ85 seriesBrakes4. BRAKES04.1 GENERALBrake travel of automatic brake adjuster (Haldex)Brake travel of automatic brake adjuster(FTP axle)Reverse torque of adjusting bolt 20042335 - 40 mm25 - 35 mm 18 Nmhttps://www.truck-manuals.net/4-1

TECHNICAL DATAΧΦ85 seriesBrakes04-2 https://www.truck-manuals.net/200423

TECHNICAL DATAΧΦ85 seriesSteering gear5. STEERING GEAR05.1 GENERALMaximum steering ball joint axial clearance 2004231.5 mmhttps://www.truck-manuals.net/5-1

TECHNICAL DATAΧΦ85 seriesSteering gear05.2 TIGHTENING TORQUESSteering gearThe tightening torques stated in this paragraphare different from the standard tightening torquesstated in the overview of the standard tighteningtorques. The other threaded connections notspecified must therefore be tightened to thetorque stated in the overview of standardtightening torques.When attachment bolts and nuts are replaced, itis important that - unless stated otherwise - thesebolts and nuts are of exactly the same length andproperty class as those removed.Filter plug without flange (A),fluid flow control valve blockof EMAS systemA125 Nm 5 NmS7 00 906Filter plug with flange (B),fluid flow control valve blockof EMAS systemB270 Nm 20 NmNote:The two plugs are interchangeable.Attachment bolt, steering column universal jointS7 00 90754 Nm 4 Nm (1)(1) Fit new original attachment bolt and nut.5-2 https://www.truck-manuals.net/200423

TECHNICAL DATAΧΦ85 seriesFront axle6. FRONT AXLE06.1 TIGHTENING TORQUESThe tightening torques stated in this paragraphare different from the standard tightening torquesstated in the overview of the standard tighteningtorques. The other threaded connections notspecified must therefore be tightened to thetorque stated in the overview of standardtightening torques.When attachment bolts and nuts are replaced, itis important that - unless stated otherwise - thesebolts and nuts are of exactly the same length andproperty class as those removed.U-bolt nut M20, property class 10If flanged nutIf yellow zinc plated hexagonal nut450 Nm 40 Nm (1)400 Nm 40 Nm (1)(1) Evenly tighten the two U-bolt nuts alternately.M22 U-bolt nut, property class 10(leading rear axle)If flanged nutIf yellow zinc plated hexagonal nut700 Nm 50 Nm (1)530 Nm 40 Nm (1)(1) Evenly tighten the two U-bolt nuts alternately. 200423https://www.truck-manuals.net/6-1

TECHNICAL DATAΧΦ85 seriesFront axle06-2 https://www.truck-manuals.net/200423

TECHNICAL DATAΧΦ85 seriesLeading rear axle 09N044 (FTP-type vehicles)7. LEADING REAR AXLE 09N044 (FTP-TYPE VEHICLES)07.1 GENERALWheel bearing play, 09N044 leading rear axle 2004230 mmhttps://www.truck-manuals.net/7-1

TECHNICAL DATALeading rear axle 09N044 (FTP-type vehicles)0ΧΦ85 series7.2 TIGHTENING TORQUESThe tightening torques stated in this paragraphare different from the standard tightening torquesstated in the overview of the standard tighteningtorques. The other threaded connections notspecified must therefore be tightened to thetorque stated in the overview of standardtightening torques.When attachment bolts and nuts are replaced, itis important that - unless stated otherwise - thesebolts and nuts are of exactly the same length andproperty class as those removed.Hub nutHub capU-bolt nut M20, property class 10100 Nm (1)500 Nm553 Nm (2)(1) Turn back until split pin can be fitted.(2) Evenly tighten the two U-bolt nuts alternately.7-2 https://www.truck-manuals.net/200423

THREADED CONNECTIONSΧΦ85 seriesContentsCONTENTS2 Threaded connectionsPage1.DateTHREADED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 2004231.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 2004232 200423https://www.truck-manuals.net/1

THREADED CONNECTIONSΧΦ85 seriesContents22 https://www.truck-manuals.net/200423

THREADED CONNECTIONSΧΦ85 seriesThreaded connections1. THREADED CONNECTIONS1.1 GENERALThe components may have threaded connectionsthat have been treated with lubricant (dippedthreaded connection). Galvanised bolts and nutsare wax dipped in the factory. Black annealedand phosphatised bolts and nuts are oil dipped.The advantage of using dipped nuts and bolts isthat friction during tightening is reduced, so thatthe specified pre-tension force can be accuratelyobtained. The tightening torque can be reducedwhile the pre-tension force remains the same.2To achieve a small spread in the pre-tensionforce, the dipped threaded connection must betightened accurately.Therefore, always use a reliable torque wrenchthat provides a high degree of accuracy.Note:Have torque wrenches regularly inspected andcalibrated.Re-use of fasteners (bolt/nut/threaded end)1. Clean the thread (take particular care toremove locking compound residues) and theclamping faces2.Check the thread for damage.To do so, manually screw a new nut/bolt ontothe thread to be checked.If the new nut/bolt cannot be fully handscrewed onto the entire thread of thefastener to be checked, the fastener is notallowed to be re-used.3.Apply one drop of engine oil to the upper turnof the bolt (threaded end)/lower turn of thenut and one drop to the clamping faces(other lubricants are not allowed).4.If a locking compound has been specified, oilshould not be applied to the thread. 200423https://www.truck-manuals.net/1-1

THREADED CONNECTIONSΧΦ85 seriesThreaded connections2The following applies to all threadedconnections (for both new and usedvehicles):in the case of standard connections, applythe lubricant before fitting, and (re)tighten inaccordance with the standard for dippedbolts;in the case of special connections, apply thelubricant before fitting, and (re)tighten inaccordance with the values specified in theinstructions.The instructions for using lubricants also apply tonew bolts from the warehouse. Dry threadedconnections may not be used because of theirhighly variable friction coefficients.}1-2Please consult the workshop manualfor the specified tightening torque. https://www.truck-manuals.net/200423

FLUIDS, OIL AND LUBRICANTSΧΦ85 seriesContentsCONTENTS3 Fluids, oil and lubricantsPage1.DateSPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 2004231.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 2004233 200423https://www.truck-manuals.net/1

FLUIDS, OIL AND LUBRICANTSΧΦ85 seriesContents32 https://www.truck-manuals.net/200423

FLUIDS, OIL AND LUBRICANTSΧΦ85 seriesSpecifications1. SPECIFICATIONS1.1 GENERALIN ORDER TO SATISFY THE WARRANTYCONDITIONS AND GUARANTEE THELIFESPAN, SAFETY AND RELIABILITY OFDAF PRODUCTS, IT IS OF THE UTMOSTIMPORTANCE THAT THE CORRECT FLUIDS,OIL AND LUBRICANTS, COOLANT AND FUELARE USED AND THAT THE REQUIREDREPLACEMENT INTERVALS AREOBSERVED.3Lubricant, engine coolant and fuel additives - ofwhatever type - must not be used except in thosecircumstances specified by DAF.Always follow the safety instructions below andthe instructions that are supplied with the product.Ask your lubricant and fuel supplier(s) whetherthe products supplied comply with DAFspecifications.DAF is not liable for damage or problems inthe following instances:1.2.3.4. use of oil of a lower grade than specified.use of oil of a different viscosity thanspecified.if the change interval is exceeded.if fuel, lubricants or coolants have beenused which do not meet the requirementsspecified by DAF.200423https://www.truck-manuals.net/1-1

FLUIDS, OIL AND LUBRICANTSΧΦ85 seriesSpecifications}3Avoid contact with:LubricantsCoolantFuelClutch fluidIn the event of contact with the skin:remove the liquid with paper or acloth, wash with soap and water. Ifirritation persists, consult a doctor.In the event of contact with the eyes:remove with a cloth and rinse withwater. If irritation persists, consult adoctor.If swallowed: DO NOT inducevomiting. Rinse mouth, drink twoglasses of water and consult adoctor.In the event of inhalation: get freshair and rest.Note:Refer to the "Fluids and lubricants" specificationmanual for the prescribed fluid, oil and lubricantspecifications.1-2 https://www.truck-manuals.net/200423

MAINTENANCE SCHEDULEΧΦ85 seriesContentsCONTENTS4 Maintenance schedulePageDate1.MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Explanatory notes on the maintenance schedule . . . . . . . . . . . . . . . . . . .1.3 Effect of diesel fuel and PTO hours on maintenance intervals . . . . . . . . .1.4 Maintenance in special operating conditions . . . . . . . . . . . . . . . . . . . . . . .1.5 First service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 . . . . .1-1 . . . . .1-2 . . . . .1-4 . . . . .1-4 . . . . .1-4 . . . . .2004232004232004232004232004232004232.MAINTENANCE ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Overview of maintenance activities for the first service inspection . . . . . .2.2 Overview of annual maintenance activities . . . . . . . . . . . . . . . . . . . . . . . .2.3 Overview of mileage-dependent maintenance activities . . . . . . . . . . . . . .2.4 Overview of intermediate inspection activities . . . . . . . . . . . . . . . . . . . . . .2-1 . . . . .2-1 . . . . .2-2 . . . . .2-3 . . . . .2-4 . . . . .200423200423200423200423200423 200423https://www.truck-manuals.net/14

MAINTENANCE SCHEDULEΧΦ85 seriesContents42 https://www.truck-manuals.net/200423

MAINTENANCE SCHEDULEΧΦ85 seriesMaintenance intervals1. MAINTENANCE INTERVALS1.1 MAINTENANCE SCHEDULEThe service intervals stated in themaintenance schedule are based on use ofthe oils and fuels specified by DAF.MaintenancescheduleIntermediateinspectionX serviceY service1x per YEAR CF85 30.000 kmExt.30.000 km60.000 km50.000 km3 year2 yearmax. 180.000 km max. 120.000 km(1)1 year1 yearmax. 100.000 km max. 100.000 km3 year3 yearmax. 300.000 k

Gearbox TECHNICAL DATA ΧΦ85 series 2.2 FILLING CAPACITIES 0 ZF gearboxes ZF 8S/16S-151 ZF 8S/16S-181 ZF 16S-221 ZF 16S-151 with integrated retarder ZF 16S-181 with integrated retarder ZF 16S-221 with integrated retarder ZF AS Tronic gearboxes ZF 12 AS 1930/2330 ZF 12 AS 2540 ZF 12 AS 1931/2331 with integrated retarder ZF 12 AS 2541 with .

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