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3STRUCTURECF65/75/85 seriesᓻ 200337TECHNICAL DATA0DIAGNOSTICS1MECHANICAL GEARBOX CONTROL2PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT)3GEARBOX - PNEUMATIC SECTION4ZF 6S-850 GEARBOX5ZF 8/9/16S-109 GEARBOX6ZF 8/16S-151/181 AND 16S-221 GEARBOXES7EATON FS/6309A GEARBOX8AUTOMATIC OP SHAFTS11ZF INTARDER12PTO13AS TRONIC GEARBOX14

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

3TECHNICAL DATACF65/75/85 SerieContentsCONTENTSPageDate1.MECHANICAL GEARBOX CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 2003371.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 2003371.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . 2003372.PNEUMATICALLY ASSISTED GEARBOX CONTROL (SERVOSHIFT) . . . . . . . 2-1 . . . . 2003372.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 2003372.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 2003373.PNEUMATIC SECTION OF GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 2003373.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 2003373.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . 2003374.ZF 6S-850 GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14-14-24-2.2003372003372003372003375.ZF 8/9/16S-109 GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15-15-25-4.2003372003372003372003376.ZF 8/16S-151/181 AND 16S-221 GEARBOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16-16-26-4.2003372003372003372003377.EATON FS/6309A GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17-17-27-3.2003372003372003372003378.ALLISON AUTOMATIC GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-18-18-28-3.2003372003372003372003379.CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-19-19-59-6.20033720033720033720033710-1 . . .10-1 . . .10-2 . . .10-3 . . .20033720033720033720033710. PROP SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11. ZF INTARDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . 20033711.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . 20033711.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 . . . 200337ᓻ 200337https://www.truck-manuals.net/6-10

3TECHNICAL DATAContentsCF65/75/85 SeriePage012. PTO12.112.212.3Date.General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1 . . .12-1 . . .12-2 . . .12-4 . . .20033720033720033720033713. AS TRONIC GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1 . . .13-1 . . .13-2 . . .13-4 . . als.net/ᓻ 200337

3TECHNICAL DATACF65/75/85 seriesMechanical gearbox control1. MECHANICAL GEARBOX CONTROL01.1 GENERALV300382--Within the entire CF65/75/85 vehicle seriesmany gearbox variations as well as theaccompanying controls are possible, bothmechanical and pneumatic.A gearbox with a splitter and range-changeswitch will be equipped with severalpneumatic valves.ᓻ 200337https://www.truck-manuals.net/1-1

3TECHNICAL DATACF65/75/85 seriesMechanical gearbox controlADJUSTING THE LINKAGE MECHANISM0Vehicle series CF65/75/85 LHD/RHD withZF 6S-850, 8/9/16S-109, 8/16S-151/181/221and Eaton FS/6309A gearboxes.Angle A: 90Note:After the gear lever has been manuallypositioned at an angle of 90 , the linkagemechanism should be fitted together with theselector shaft lever.AV300383Vehicle series CF65 / RHD with gearbox typeZF 6S-850If the selector shaft lever has two attachmentholes, the attachment hole (A) in the selectorshaft lever should be used to attach the shaftlever properly to the control rod.AV300833Bonding the gear lever into the ballDe-greaserGlueDAF No. 1322827DAF No. 1340646Bonding the ball joint to the control rodDe-greaserGlueDAF No. 1322827DAF No. 13406461-2https://www.truck-manuals.net/ᓻ 200337

3TECHNICAL DATACF65/75/85 seriesMechanical gearbox control1.2 TIGHTENING TORQUES0The tightening torques stated in this section aredifferent from the standard tightening torquesincluded in the overview of standard tighteningtorques.Any other threaded connections that arenot specified must therefore be tightened to thetorque stated in the overview ofstandard tightening torques.When attachment bolts and nuts are to bereplaced, it is important that they are of exactlythe same length and property class as the onesremoved unless stated otherwise.Control rodFastening bolt (1) of control rodon gear lever unit40 NmAttachment nuts (3), gearlever unit27 NmAttachment bolt, selector shaftlever to gearbox selectorhousing40 Nm312V300275ᓻ 200337https://www.truck-manuals.net/1-3

3TECHNICAL DATAMechanical gearbox controlCF65/75/85 series01-4https://www.truck-manuals.net/ᓻ 200337

3TECHNICAL DATACF65/75/85 seriesPneumatically assisted gearbox control (Servoshift)2. PNEUMATICALLY ASSISTED GEARBOX CONTROL(SERVOSHIFT)02.1 GENERALServoshift unitService pressuremax. 10 bar2.2 TIGHTENING TORQUESThe tightening torques stated in this section aredifferent from the standard tightening torquesincluded in the overview of standard tighteningtorques.Any other threaded connections that arenot specified must therefore be tightened to thetorque stated in the overview ofstandard tightening torques.When attachment bolts and nuts are to bereplaced, it is important that they are of exactlythe same length and property class as the onesremoved unless stated otherwise.Air pipe banjo bolt (1)Attachment bolts:Servoshift unit (2)38 Nm23 Nm21V300328ᓻ 200337https://www.truck-manuals.net/2-1

3TECHNICAL DATAPneumatically assisted gearbox control (Servoshift)CF65/75/85 series02-2https://www.truck-manuals.net/ᓻ 200337

3TECHNICAL DATACF65/75/85 seriesPneumatic section of gearbox3. PNEUMATIC SECTION OF GEARBOX03.1 GENERALIf the vehicle is modified and theconfiguration changed, theelectronic unit may have to beprogrammed.Note:If the vehicle’s drive configuration is changed,this must always be stated. The gate protectionand range-change protection frequenciesprogrammed into the electronic unit are relatedto the drive configuration.GV VALVEGV valve begins toopen (C)Total clutch pedaltravel (D)123 2 mm154 2 mmNEUTRAL POSITION VALVESituation with separate air distribution block:2 x 3/2-way valveService pressure6.5 to 10 barPipe connectionM14 x 1.5Situation with integrated air distributionblock:3/2-way valveService pressure6.5 to 10 barPipe connectionNot applicableA1BCDV300315ᓻ 200337https://www.truck-manuals.net/3-1

3TECHNICAL DATACF65/75/85 seriesPneumatic section of gearboxGEAR LEVER SELECTOR VALVE0Range-change gearConnection pointColour1SupplyBlack3BleedRed21Range-change gearcommand (A)WhiteBA2113V300488PNEUMATIC als.net/ᓻ 200337

3TECHNICAL DATACF65/75/85 seriesPneumatic section of gearboxGEAR LEVER SELECTOR VALVE0Range-change gear and splitterConnection pointColour1SupplyBlack3BleedRed21Range-change gearcommand (A)White22Splitter command (B)YellowBA211223V300489PNEUMATIC SYMBOLRange-change gear and splitterPositionFunctionGPRange-change gearGVSplitter2221HHLLGVGP1V300161ᓻ 200337https://www.truck-manuals.net/3-3

3TECHNICAL DATAPneumatic section of gearboxCF65/75/85 series3.2 TIGHTENING TORQUES0The tightening torques stated in this section aredifferent from the standard tightening torquesincluded in the overview of standard tighteningtorques.Any other threaded connections that arenot specified must therefore be tightened to thetorque stated in the overview ofstandard tightening torques.When attachment bolts and nuts are to bereplaced, it is important that they are of exactlythe same length and property class as the onesremoved unless stated otherwise.Gear button on gear leverGear button lock nut3-470 Nmhttps://www.truck-manuals.net/ᓻ 200337

3TECHNICAL DATACF65/75/85 seriesZF 6S-850 gearbox4. ZF 6S-850 GEARBOX04.1 GENERALGearbox typeEach gearbox has a type-plate attached to it,indicating the type of gearbox. This data is alsostated on the identity card of the relevantvehicle.ZF gearbox type-plate1. Type of gearbox2. Series no. (ZF)3. Parts list (ZF)4. Specification no.5. Pulse generator ratio6. Gearbox ratio7. Engine speed using PTO8. PTO speed9. Gearbox oil capacity10. Oil specification12457368910V300049Output shaft bearing axial playOutput shaft bearing axial play0.00 - 0.10 mmBearing axial play, main and input shaftsBearing axial play, main and input shafts0.00 - 0.10 mmAuxiliary shaft bearing axial playAuxiliary shaft bearing axial play0.00 - 0.10 mmᓻ 200337https://www.truck-manuals.net/4-1

3TECHNICAL DATACF65/75/85 seriesZF 6S-850 gearbox4.2 TIGHTENING TORQUES0The tightening torques stated in this section aredifferent from the standard tightening torquesincluded in the overview of standard tighteningtorques.Any other threaded connections that arenot specified must therefore be tightened to thetorque stated in the overview ofstandard tightening torques.When attachment bolts and nuts are to bereplaced, it is important that they are of exactlythe same length and property class as the onesremoved unless stated otherwise.Gearbox to engineM8 attachment bolts - 10.9M10 attachment bolts - 10.9M12 attachment bolts - 10.930 Nm60 Nm110 NmDrive flangeDrive flange attachment bolt- 120 mm flange diameter- 150 mm flange diameter140 Nm140 NmGearbox front coverAttachment bolts23 NmSelector shaft housingAttachment boltsShifting arm lock nutAir connection banjo boltBleeder23 Nm46 Nm23 Nm10 NmPlugsDrain plugLevel check/filler plug50 Nm50 Nm4.3 FILLING CAPACITIES4-2Gearbox typeFilling capacities at oil change(litres)First filling, e.g. during repair(litres)ZF 6S-8507.57.5https://www.truck-manuals.net/ᓻ 200337

3TECHNICAL DATACF65/75/85 seriesZF 8/9/16S-109 gearbox5. ZF 8/9/16S-109 GEARBOX05.1 GENERALGearbox typeEach gearbox has a type-plate attached to it,indicating the type of gearbox. This data is alsostated on the identity card of the relevantvehicle.ZF gearbox type-plate1. Type of gearbox2. Series no. (ZF)3. Parts list (ZF)4. Specification no.5. Pulse generator ratio6. Gearbox ratio7. Engine speed using PTO8. PTO speed9. Gearbox oil capacity10. Oil specification12457368910V300049Output shaft bearing axial playOutput shaft bearing axial play0.00 - 0.10 mmBearing axial pre-load, main andinput shaftsBearing axial pre-load, main and input shafts8/9S-10916S-1090.18 - 0.30 mm0.18 - 0.30 mmBearing axial pre-load, auxiliary shaftBearing axial pre-load, auxiliary shaft8/9S-10916S-1090.18 - 0.30 mm0.18 - 0.30 mmRetaining elementStandard spring forceHeavy-duty spring force168 N191 Nᓻ 200337https://www.truck-manuals.net/5-1

3TECHNICAL DATACF65/75/85 seriesZF 8/9/16S-109 gearbox5.2 TIGHTENING TORQUES0The tightening torques stated in this section aredifferent from the standard tightening torquesincluded in the overview of standard tighteningtorques.Any other threaded connections that arenot specified must therefore be tightened to thetorque stated in the overview ofstandard tightening torques.When attachment bolts and nuts are to bereplaced, it is important that they are of exactlythe same length and property class as the onesremoved unless stated otherwise.Gearbox to engineM8 attachment bolts - 10.9M10 attachment bolts - 10.9M12 attachment bolts - 10.930 Nm60 Nm110 NmDrive flangeRetaining plate attachment bolts60 NmGearbox front coverAttachment bolts25 NmBearing coverOutput shaft bearing coverControl bearing coverAir connection banjo bolt25 Nm25 Nm38 NmShift control high/lowShifting fork high/low boltsGear engaging cylinder piston lock nutGear engaging cylinder attachment boltsAir connection banjo boltRear gearbox cover attachment bolts180 Nm180 Nm50 Nm38 Nm50 NmPlugsM24 drain plugM38 drain plugLevel check/filler plug60 Nm120 Nm60 Nm5-2https://www.truck-manuals.net/ᓻ 200337

3TECHNICAL DATACF65/75/85 seriesZF 8/9/16S-109 gearboxPlugsGearbox with integrated intarderDrain plug (B)M24Drain plug (B)M38Drain plug (C)Level check/filler plug (A).Oil filter attachment bolt (1)060 Nm120 Nm60 Nm60 Nm23 NmABBM301721V3003721ᓻ 200337https://www.truck-manuals.net/M30525-3

3TECHNICAL DATACF65/75/85 seriesZF 8/9/16S-109 gearbox5.3 FILLING CAPACITIES0Filling amounts, ZF gearboxes withoutintarderGearbox typeFilling amounts at oil change(litres)First filling, e.g. during repair(litres)ZF 8/16S-10999.5ZF 9/S-10988.5Gearbox typeFilling amounts at oil change(litres)First filling, e.g. during repair(litres)ZF 8/16S-10912.522ZF 9S-1091221Filling amounts, ZF gearboxes withintegrated intarder5-4https://www.truck-manuals.net/ᓻ 200337

3TECHNICAL DATACF65/75/85 seriesZF 8/16S-151/181 and 16S-221 gearboxes6. ZF 8/16S-151/181 AND 16S-221 GEARBOXES06.1 GENERALGearbox typeEach gearbox has a type-plate attached to it,indicating the type of gearbox. This data is alsostated on the identity card of the relevantvehicle.ZF gearbox type-plate1. Type of gearbox2. Series no. (ZF)3. Parts list (ZF)4. Specification no.5. Pulse generator ratio6. Gearbox ratio7. Engine speed using PTO8. PTO speed9. Gearbox oil capacity10. Oil specification12457368910V300049Output shaft bearing axial playOutput shaft bearing axial play0.00 - 0.10 mmBearing axial play, main and input shaftsBearing axial play, main and input shafts0.00 - 0.10 mmAuxiliary shaft bearing axial playAuxiliary shaft bearing axial play0.00 - 0.10 mmRetaining elementStandard spring forceHeavy-duty spring force168 N191 Nᓻ 200337https://www.truck-manuals.net/6-1

3TECHNICAL DATACF65/75/85 seriesZF 8/16S-151/181 and 16S-221 gearboxes6.2 TIGHTENING TORQUES0The tightening torques stated in this section aredifferent from the standard tightening torquesincluded in the overview of standard tighteningtorques.Any other threaded connections that arenot specified must therefore be tightened to thetorque stated in the overview ofstandard tightening torques.When attachment bolts and nuts are to bereplaced, it is important that they are of exactlythe same length and property class as the onesremoved unless stated otherwise.Gearbox to engineM8 attachment bolts - 10.9M10 attachment bolts - 10.9M12 attachment bolts - 10.930 Nm60 Nm110 NmDrive flangeM12 x 70 drive flange - 8.8M12 x 60 drive flange - 10.9M12 x 70 drive flange - 10.9M12 x 165 drive flange - 10.960 Nm120 Nm120 Nm120 NmGearbox front coverAttachment bolts46 NmBearing coverOutput shaft bearing coverControl bearing cover49 Nm23 NmShift control high/lowShifting fork high/low boltsGear engaging cylinder piston lock nutGear engaging cylinder attachment boltsAir connection banjo boltRear gearbox cover attachment bolts180 Nm180 Nm50 Nm38 Nm50 NmPlugsM24 drain plugM38 drain plugLevel check/filler plug60 Nm120 Nm60 Nm6-2https://www.truck-manuals.net/ᓻ 200337

3TECHNICAL DATACF65/75/85 seriesZF 8/16S-151/181 and 16S-221 gearboxesPlugsGearbox with integrated intarderDrain plug (B)M24Drain plug (B)M38Drain plug (D)Level check/filler plug (4)Filler plug (5)Oil filter attachment bolt (1)B60 Nm120 Nm60 Nm60 Nm60 Nm23 NmDCV30018645V3002601ᓻ 200337https://www.truck-manuals.net/M30526-30

3TECHNICAL DATACF65/75/85 seriesZF 8/16S-151/181 and 16S-221 gearboxes6.3 FILLING CAPACITIES0Filling amounts, ZF gearboxes withoutintarderGearbox typeFilling amounts at oil change(litres)First filling, e.g. during repair(litres)ZF 8/16S-1511111ZF 8/16S-1811313ZF 16S-2211313Gearbox typeFilling amounts at oil change(litres)First filling, e.g. during repair(litres)ZF 8/16S-1511118.5ZF 8/16S-1811221.5ZF 16S-2211221.5Filling amounts, ZF gearboxes withintegrated intarder6-4https://www.truck-manuals.net/ᓻ 200337

3TECHNICAL DATACF65/75/85 seriesEaton FS/6309A gearbox7. EATON FS/6309A GEARBOX07.1 G

TECHNICAL DATA 3 Mechanical gearbox control CF65/75/85 series 1-2 ADJUSTING THE LINKAGE MECHANISM Vehicle series CF65/75/85 LHD/RHD with ZF 6S-850, 8/9/16S-109, 8/16S-151/181/221

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