DAF 95XF Maintenance Manual Download

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Removal and installation

series

4-6

4.5 REMOVAL AND INSTALLATION, FUEL FILTER

When removing the fuel filter, a
quantity of fuel will escape. Collect
the fuel to avoid the risk of fire.

XF/XE engine

Removing the fuel filter

Place a tray beneath the filter.

Remove the filter by turning it
counter-clockwise.

Note:

The fuel filter is a disposable filter, and must
not be cleaned and reused.

Installing the fuel filter

not

fill the new fuel filter with diesel fuel.

Lightly lubricate the sealing ring with engine
oil, not with diesel fuel.

Fit the filter until the sealing ring abuts, and
manually rotate a

turn further.

Note:

Do not use any tools when tightening.

Bleed the fuel system, if necessary. See
“Inspection and adjustment”.

Start the engine and check for leaks. If
necessary, tighten the filter.

i 400192



200424

Summary of Contents for 95XF

Page 1: ...Maintenance manual 95XF...

Page 2: ......

Page 3: ...product development DAF reserves the right to change specification or equipment at any time without notice No part of this publication may be reproduced and or published by printing photocopying micro...

Page 4: ......

Page 5: ...0 95XF series STRUCTURE TECHNICAL DATA THREADED CONNECTIONS FLUIDS OIL AND LUBRICANTS MAINTENANCE SCHEDULE EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 200424 1 2 3 4 5...

Page 6: ......

Page 7: ...4 4 1 General 4 1 200424 4 2 Tightening torques 4 1 200424 4 3 Filling capacities 4 1 200424 5 RETARDER 5 1 200424 5 1 Tightening torques 5 1 200424 5 2 Filling capacities 5 1 200424 6 BRAKES 6 1 2004...

Page 8: ...TECHNICAL DATA Contents 95XF series 2 200424 0...

Page 9: ...lts can be recognised by looking at their edges and at the inside of the V belt Except for the upper part of the belt side no textile fabric is present in the rubber polished sides Version either a to...

Page 10: ...ilter 45 Nm Central bolt for centrifugal oil filter 20 Nm Valve cover Valve cover attachment bolts 25 Nm DEB DEB attachment bolts 110 Nm DEB set screw nut 25 Nm 1 3 FILLING CAPACITIES Oil sump incl en...

Page 11: ...ing value for C brake cold 0 58 mm V belt tension Belt tension for poly V belts in Newtons N 6 rib version 10 rib version New poly V belt 700 1100 Run in poly V belt1 300 600 450 900 1 A run in poly V...

Page 12: ...bolt 65 Nm Unit injector attachment bolt 40 Nm C brake Lock nut for C brake adjusting bolt 24 Nm C brake housing attachment bolts 102 Nm Rocker housing Rocker housing attachment bolts 1 to 6 Rocker h...

Page 13: ...S Gearbox ZF 8S 151 181 and 16S 151 181 221 Level check filler plug A 60 Nm Drain plug B 60 Nm Drain plug C D 60 Nm M3023 D A B C ZF 8S 151 181 and 16S 151 181 221 with integrated retarder Drain plug...

Page 14: ...arbox 95XF series 3 2 3 2 FILLING CAPACITIES ZF 16S 181 Filling capacity approx 13 litres ZF 16S 221 Filling capacity approx 13 litres ZF 16S 181 221 with integrated retarder Filling capacity approx 1...

Page 15: ...y tighten the two U bolt nuts alternately 4 3 FILLING CAPACITIES Differential 1347 axle Minimum caster Maximum caster Filling capacity approx 21 5 litres approx 23 5 litres 1354 axle Filling capacity...

Page 16: ...TECHNICAL DATA Rear axle 95XF series 4 2 0 200424...

Page 17: ...H retarder 133 2 Retarder drain plug 150 Nm Butterfly valve drain plug 65 Nm Retarder dipstick 80 Nm Retarder level check plug 80 Nm Retarder filler plug M18 x 1 5 50 Nm M24 x 1 5 80 Nm Coolant drain...

Page 18: ...TECHNICAL DATA Retarder 95XF series 5 2 200424 0...

Page 19: ...rakes TECHNICAL DATA 6 1 6 BRAKES 6 1 GENERAL Automatic brake adjuster stroke 09N044 axle FTP type vehicles 25 35 mm Automatic brake adjuster stroke other axles 35 40 mm Reverse torque of adjusting bo...

Page 20: ...TECHNICAL DATA Brakes 95XF series 6 2 200424 0...

Page 21: ...ATA 7 1 7 STEERING GEAR 7 1 GENERAL Maximum steering ball joint axial clearance 1 5 mm 7 2 TIGHTENING TORQUES Retention bolt nut for universal joint steering box input shaft 30 Nm 60_ angular displace...

Page 22: ...TECHNICAL DATA Steering gear 95XF series 7 2 0 200424...

Page 23: ...NERAL Wheel bearing play 0 025 0 25 mm 8 2 TIGHTENING TORQUES Wheel hub lock nut 210 30 Nm Hub cap bolt 9 Nm Wheel nut steel aluminium 700 Nm Tighten after 100 km M22 hexagon U bolt nut property class...

Page 24: ...TECHNICAL DATA Front axle 95XF series 8 2 0 200424...

Page 25: ...ENERAL Wheel bearing play 0 025 0 25 mm Hub cap sealant Silicone sealant 9 2 TIGHTENING TORQUES Wheel hub lock nut 09N220 axle 560 Nm Wheel hub lock nut 09N075 axle 210 30 Nm Hub cap bolts 09N220 axle...

Page 26: ...TECHNICAL DATA Trailing axle 95XF series 9 2 200424 0...

Page 27: ...d tightening torques Any other threaded connections that are not specified must therefore be tightened to the tightening torque stated in the overview of standard tightening torques When attachment bo...

Page 28: ...TECHNICAL DATA Leading rear axle 09N044 FTP type vehicles 95XF series 10 2 0 200424...

Page 29: ...95XF series Contents THREADED CONNECTIONS 1 CONTENTS Page Date 1 THREADED CONNECTIONS 1 1 200424 1 1 General 1 1 200424 2 200424...

Page 30: ...THREADED CONNECTIONS Contents 95XF series 2 2 200424...

Page 31: ...in the pre tension force the dipped threaded connection must be tightened accurately Therefore always use a reliable and accurate torque wrench Note Have torque wrenches regularly inspected and calib...

Page 32: ...the standard for dipped bolts in the case of special connections apply the lubricant before fitting and retighten in accordance with the values specified in the instructions The instructions for using...

Page 33: ...95XF series Contents COOLANT OIL AND LUBRICANTS 1 CONTENTS Page Date 1 SPECIFICATIONS 1 1 200424 1 1 General 1 1 200424 3 200424...

Page 34: ...COOLANT OIL AND LUBRICANTS Contents 95XF series 2 3 200424...

Page 35: ...tever type must not be used except in those circumstances prescribed by DAF Always follow the safety instructions below as well as the instructions that are supplied with the product Ask your lubrican...

Page 36: ...ts consult a doctor In the event of contact with the eyes remove with a cloth and rinse with water If irritation persists consult a doctor If any is swallowed DO NOT induce vomiting Rinse mouth drink...

Page 37: ...tenance intervals 1 4 200424 1 4 Maintenance intervals under special operating conditions 1 4 200424 1 5 First service inspection 1 4 200424 2 MAINTENANCE 2 1 200424 2 1 Overview of maintenance activi...

Page 38: ...MAINTENANCE SCHEDULE Contents 95XF series 2 4 200424...

Page 39: ...r max 100 000 km 1 year max 100 000 km 1 year max 100 000 km 1 year max 200 000 km 2 year max 300 000 km 2 year max 300 000 km 15 000 km 30 000 km 50 000 km 50 000 km 100 000 km 1 2 3 4 6 4 5 1 1 year...

Page 40: ...transport Distribution transport in cities Traffic between adjacent villages cities Maintenance group III Inter national traffic Long distance very long distance transport STANDARD CHANGING INTERVAL...

Page 41: ...ediate inspection X SERVICE INTERVAL This is the symbol of the X service An X service is a maintenance check depending upon the distance covered which consists of changing the engine oil plus a number...

Page 42: ...TENANCE INTERVALS UNDER SPECIAL OPERATING CONDITIONS Contact a DAF dealer main branch or importer for vehicles used in very specific or heavy conditions The service intervals can be adapted if necessa...

Page 43: ...ne oil f Change oil filter f Change gearbox oil transfer gearbox oil f Change retarder oil Voith retarder f Change differential oil f Change hub oil f Check components and hose connections for leaks f...

Page 44: ...Yes f No f Check steering ball joints f Replace air dryer filter element f Check compressor line f Check brake cylinder fastening f Check automatic brake adjuster f Check adjust load dependent control...

Page 45: ...gearbox the gearbox oil filter must also be replaced 4 Every two years if yearly mileage 150 000 km Every three years if yearly mileage 150 000 km Every three years at a maximum of 500 000 km with FT...

Page 46: ...ll joint sleeve for damage f Check steering oil level f Check steering gear pipes and connections f Check brake components brake system for leaks f Check brake lining thickness DRIVE AND CHASSIS f Che...

Page 47: ...intenance schedule in maintenance manual When changing the gearbox oil on a gearbox with intarder or an automatic gearbox the gearbox oil filter must also be replaced 3 When using mineral oil Change o...

Page 48: ...GEAR AND BRAKE SYSTEM f Check steering ball joint sleeve for damage f Check steering oil level f Check steering gear pipes and connections f Check brake components brake system for leaks f Check brake...

Page 49: ...justment V belt tension 3 16 200424 3 12 Checking the antifreeze content in the cooling system 3 21 200424 3 13 Checking the Racor filter element for water separation 3 22 200424 3 14 Checking the exh...

Page 50: ...0424 3 48 Checking the superstructure attachment 3 60 200424 3 49 Checking the attachment and condition of spring leaves spring clamps and U bolts 3 60 200424 4 REMOVAL AND INSTALLATION 4 1 200424 Cab...

Page 51: ...d filling gearbox 5 12 200424 5 7 Draining and filling retarder 5 14 200424 5 8 Filling the grease supply of the automatic lubrication system 5 15 200424 6 CLEANING 6 1 200424 Cab and electrical syste...

Page 52: ...EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES Contents 95XF series 4 5 200424...

Page 53: ...ted area In other words make sure that the exhaust gases are effectively extracted Remain at a safe distance from rotating and or moving components Never remove the filler cap from the cooling system...

Page 54: ...on interval in view of the risk of fire if the inside of the panels should be dirty Always disconnect the earth connection of the battery before working on the vehicle Always use stands to support the...

Page 55: ...carry out the maintenance activities in a responsible and safe manner The technical data and notes on the maintenance activities have been compiled with the utmost care 2 2 TECHNICAL INFORMATION The t...

Page 56: ...d at regular intervals you will help reduce the impact on the environment This means for example noticing and remedying possible leakages in time and keeping the engine in an optimum condition adjusti...

Page 57: ...as maintenance activities are concerned you should think of windscreen wiper blades air dryer elements gaskets V belts and filters If for example non original DAF filters are used the engine will be...

Page 58: ...riven front axle regularly for fouling and blocking If the breathers are blocked by dirt overpressure could cause leakage Depending on the circumstances in which the vehicle is used e g on very bad ro...

Page 59: ...and the positive and negative battery leads are disconnected Position the earth clamp as close as possible to the weld location The earth clamp must never be attached to a rotating component such as p...

Page 60: ...EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES General 95XF series 2 6 5 200424...

Page 61: ...ON THE MAINTENANCE ACTIVITIES 3 1 3 INSPECTION AND ADJUSTMENT 3 1 CHECKING THE PEDAL RUBBERS 1 Check that the pedal rubbers are still securely mounted on the pedal 2 Check that the pedal rubbers are n...

Page 62: ...h plenty of water for at least 15 minutes and see a doctor If swallowed do NOT induce vomiting Rinse the mouth drink two glasses of water and see a doctor In the event of inhalation get some fresh air...

Page 63: ...on a board or wall at a distance of 10 metres the light dark division should be 10 cm below the centre height of the headlamp 1 When checking the headlight setting dipped beam the vehicle must carry...

Page 64: ...servoir Now the filler plug can be removed 4 Start pumping with a maximum of five pump strokes making sure that the pump lever is in the lower position when finished 5 Then check the fluid level This...

Page 65: ...stop position Lock the fuel pump in this position 3 Use the special tool DAF no 1310477 to turn the crankshaft clockwise as seen from the timing gear end this is the engine s normal direction of rotat...

Page 66: ...echnical data for the correct valve clearance M200540 5 By always cranking the camshaft by 1 3 of a stroke using the special tool DAF no 1310477 the valves can be adjusted according to the injection s...

Page 67: ...ad centre TDC and the valves of cylinder 6 overlap 4 Use set screw B to set the DEB clearance A of cylinders 1 3 and 5 See Technical data Then tighten set screw B to the specified torque See Technical...

Page 68: ...alves and unit injectors use the marks made on the accessory drive pulley 1 for the air conditioning compressor and water pump The direction of rotation of the crankshaft is clockwise as seen from the...

Page 69: ...ke the C brake must be removed first see chapter Removal and installation 4 Tighten the rocker shaft attachment bolts to the specified torque See Technical data M2143 5 Tighten the rocker housing atta...

Page 70: ...e moved from side to side If necessary rotate the drive pulley through 360_ until the A marking is once again in line with the marking on the cylinder block 9 Now adjust the valve clearance and the un...

Page 71: ...special tool DAF no 1240043 adjust the specified valve clearance see Technical data 3 Tighten the adjusting bolt using special tool DAF no 1240043 before removing the feeler gauge The specified torque...

Page 72: ...er out thus moving the injector plunger downwards M2137 3 Then screw the adjusting bolt clockwise until there is clear considerable resistance Do not turn the adjusting bolt further in clockwise direc...

Page 73: ...or the exhaust valves 1 2 The rocker for the unit injector 2 3 The rocker for the inlet valves 3 M2146 1 2 3 3 2 1 For a correct setting of the C brake use the set marks shown on the accessory drive p...

Page 74: ...the crankshaft using the attachment nut on the pulley until the A marking is in line with the marking on the timing cover 4 Check that the inlet and exhaust valves of cylinder 5 are closed Note The v...

Page 75: ...chnical data Note The setting value is also shown on the shield 1 fitted on the C brake housing 10 Tighten the lock nut to the specified tightening torque See Technical data Use special tool DAF no 12...

Page 76: ...ecial tool DAF no 1240443 for the multiple V belts or poly V belts M2079 ABLEU ABLEU OPTIBELTI N 200 600 LBS 50 150 100 200 300 LBS 100 1500 N 500 OPTIBELTII 2 Set the gauge to zero by depressing the...

Page 77: ...PLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 3 17 5 Take the reading as indicated by the position of the measuring arm in relation to the scale Compare this reading with the recommended pre tension f...

Page 78: ...lock nuts 3 until the correct V belt tension is achieved See Technical data M2041 3 2 1 1 Adjusting the V belt tension of the water pump and alternator drive 1 Loosen the lock nut 4 of the threaded sp...

Page 79: ...100 200 300 LBS 100 1500 N 500 OPTIBELTII 2 Set the gauge to zero by depressing the measuring arm 1 1 M2061 3 Place the belt tension gauge on the V belt halfway between the two pulleys 4 Slowly depre...

Page 80: ...ieved See Technical data M2127 2 1 3 3 Adjusting the belt 10 rib tension of fan and alternator drive 1 Slacken the attachment bolt 1 in the clamping block 2 and slacken the attachment bolt of the thre...

Page 81: ...t top up a warm engine with cold coolant 1 Check the antifreeze content of the coolant Fill the cooling system with antifreeze if this has not been done yet Always use only those coolants or antifreez...

Page 82: ...G THE RACOR FILTER ELEMENT FOR WATER SEPARATION 1 If necessary open drain plug 8 and pump the water out using the feed pump 1 2 Close the drain plug 8 1 2 3 4 5 7 6 8 i400356 3 14 CHECKING THE EXHAUST...

Page 83: ...stem with Racor filter While bleeding the fuel system fuel will escape Collect this fuel bearing in mind the risk of fire 1 Open the bleed screw 2 on the filter housing 2 Using the hand pump 1 pump fu...

Page 84: ...until fuel without air bubbles flows through the bleed screw 3 Close the bleed screw 1 i 400172 1 2 Bleeding the XE engine fuel system While bleeding the fuel system fuel will escape Collect this fue...

Page 85: ...nt that the glow coils be checked periodically 1 Check the glow coils for the following points windings that have worn thin due to abrasion A coil end broken or worn thin due to continuous knocking of...

Page 86: ...radiator and intercooler see Cleaning 3 18 CHECKING THE STEERING OIL LEVEL 1 Clean the dipstick and its immediate surroundings so that no dirt can get into the reservoir 2 Check the fluid level in the...

Page 87: ...pes will give rise to faults air in the system If in doubt always replace the pipe 2 Pipe connections Check each pipe connection for leaks 3 Pipe routing Pipes must not be twisted during fitting A mar...

Page 88: ...nd put the axle on stands 3 Make sure that the castle nut split pin if present does not come into contact with the ends of the threaded end 4 Screw the thrust washer 8 onto the threaded spindle 5 Fit...

Page 89: ...AKE SYSTEM FOR LEAKS While operating the service brake check whether any leaks occur in the brake system If the brake system of a vehicle has been charged to the maximum pressure it should generally b...

Page 90: ...rn down to the wear indicator mark on the brake lining Note If in doubt about the amount of brake lining wear release the brakes and remove the dust cover M6012 M6002 Checking the brake lining thickne...

Page 91: ...nspection and adjustment EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 3 31 3 23 CHECKING THE BRAKE CYLINDER FASTENING 1 Check that the brake cylinders do not move during operation of the service br...

Page 92: ...on Check whether the control plate 1 is locked in respect of the fixed bracket If not turn the control plate as far as possible until the internal stop is felt in the direction in which the brake adju...

Page 93: ...tion plate 5 Connect pressure gauge 1 to the test connection 1 of the load dependent valve and pressure gauge 2 to the test connection on one of the spring brake cylinders service brake connection of...

Page 94: ...an be corrected by moving the rubber socket 2 in relation to the vertical connecting rod do not adjust the length L of the control lever 10 Also check that there is no significant reduction in output...

Page 95: ...essure gauge 43 with a reducer valve to the simulation connection of the load dependent valve simulated adjustable bellows pressure 5 Make sure that the reservoir pressure is higher than 6 5 bar throu...

Page 96: ...ng is within the tolerance limits 8 Set the simulated bellows pressure to its second lowest value as indicated on the instruction plate Depress the brake pedal until pressure gauge 4 indicates a press...

Page 97: ...y to the force exerted on the brake pedal Note Remember the influence of the ALR valve 4 No air should leak at the vent of the electropneumatic valves of the ABS system 5 Release the brake pedal 6 Con...

Page 98: ...he air dryer Then plug the opening at connection 23 4 Build up pressure in the brake system pressure switch should cut out 5 When the engine is not running remove the safety valve from the compressor...

Page 99: ...l the cut in pressure of the pressure regulator is reached and switch off the engine The indicator on the pressure gauge should not drop rapidly If necessary check the system for leaks Pay particular...

Page 100: ...y is detected the universal joint needs to be replaced 2 Check whether there is any noticeable play between the universal joint and the steering box input shaft If noticeable play is detected the spli...

Page 101: ...uid it may damage the paintwork of the vehicle Avoid any contact between hydraulic fluid and paintwork Always use new and clean hydraulic fluid which has been kept in a sealed container that meets the...

Page 102: ...d any contact between hydraulic fluid and paintwork Always use new and clean hydraulic fluid which has been kept in a sealed container that meets the specifications Hydraulic fluid which has absorbed...

Page 103: ...ry the grease should be replaced by grease of the correct specification once the leak has been repaired see specification manual Fluids and lubricants 3 33 CHECKING THE DIFFERENTIAL FOR LEAKS 1 Visual...

Page 104: ...should now come on 4 Check whether there is a rigid connection between the driven wheels 5 Disengage the differential lock The warning lamp should not light up and the rigid connection between the dr...

Page 105: ...ue rod supports 2 Check the pivots of the torque rod for wear and play Stabiliser bar 1 Check the attachment of the stabiliser bar and stabiliser bar support 2 Check the pivots of the stabiliser bar f...

Page 106: ...3 46 3 40 CHECKIGN THE DRIVE SHAFT PLAY 1 Check the universal joints and centre bearing for play and damage M3032 2 Check the sliding clutch for axial and radial play M3019 3 There must be no clearly...

Page 107: ...the webbing is visible the air bellows should be replaced 4 Check the air bellows bellows seating and air line connections for leaks Check that the air bellows when in their highest position and in dr...

Page 108: ...djustment 95XF series 3 48 3 43 CHECKING THE FIFTH WHEEL 1 Check the attachment of the fifth wheel 2 Check the play of the closing gear of the fifth wheel Note For maximum play values consult the manu...

Page 109: ...the arched pin 2 Check the radial play of the arched pin M9002 3 Check the vertical and horizontal play of the coupling jaw M9001 4 Check the diameter of the arched pin 5 Check the attachment of the...

Page 110: ...tightening torque see Technical data Turn the wheel at least 5 revolutions clockwise and then 5 revolutions anti clockwise while fixing the hub nut 6 Check that the wheel rotates smoothly 7 Turn back...

Page 111: ...use the special tool DAF no 0535595 The special tool consists of 1 extensions 2 central nut 3 dial gauge holder 4 threaded spindle 5 bridge 6 socket wrench 7 additional extension pieces 2 Remove the h...

Page 112: ...t has been removed tighten the central nut 2 to the tightening torque specified for the lock nut See Technical data S7 00 131 1 7 6 4 5 3 2 7 Place the dial gauge in the dial gauge holder 3 so that th...

Page 113: ...the spindle until a tightening torque of 15 Nm is reached Take the reading from the dial gauge and compare this value with the specified value see Technical data If the reading falls outside the toler...

Page 114: ...832 to remove the lock nut from the axle journal 2 Remove the lock plate and the circlip from the axle journal A S7 00 084 3 Use an adjusting spanner A special tool DAF no 0694783 to slacken the adjus...

Page 115: ...d 60 distance A B in the drawing using the adjusting spanner A The precise angle should be such that the circlip 2 can be fitted If necessary turn the circlip around changing the hole pattern 1 A S7 0...

Page 116: ...ance range the wheel bearing play should be re adjusted 6 Fit the hub cap Tighten the hub cap to the specified torque using the special tool DAF no 1329498 See Technical data 7 Adjust the brakes S7 00...

Page 117: ...ed torque using the special tool DAF no 1329498 See Technical data 10 Adjust the brakes TRAILING AXLE 09N220 Checking the wheel bearing play 1 To make sure that the inspection of the wheel bearing pla...

Page 118: ...xle journal by screwing the spindle in until a tightening torque of 40 Nm is reached A800149 10 Withdraw the hub by unscrewing the spindle until a tightening torque of 40 Nm is reached 11 Press the hu...

Page 119: ...Loosen the hub nut one turn 4 Tighten the adjusting nut to a tightening torque of 100 Nm using a torque wrench while turning the hub 5 The specified wheel bearing play is achieved by turning the hub n...

Page 120: ...he axle journal should be inspected for damage the screw thread the bearing surfaces of the inner bearing races and the running surface of the seal 4 Check the sensor ring for damage If even the sligh...

Page 121: ...he grille 2 Remove the attachment bolts 1 at the bottom of the filter 3 Remove the filter 2 4 If required clean the filter see chapter Cleaning In case of excessive fouling or damage the filter should...

Page 122: ...strap wrench Note The oil filter is a disposable filter and may not be cleaned and reused M200370 Installing the oil filter 1 Fill the new oil filter before fitting using the specified oil grade 2 Lig...

Page 123: ...ilter and may not be cleaned and reused M200370 Installing the oil filter 1 Fill the new oil filter before fitting using the specified oil grade 2 Lightly lubricate the sealing ring with engine oil 3...

Page 124: ...ove the housing 3 together with the central bolt 4 and the rotor 2 4 Remove the rotor 2 from the central bolt 4 5 Replace the rotor 2 Installing the centrifugal oil filter rotor 1 Clean the housing 3...

Page 125: ...d clean the air filter see chapter Cleaning 7 When replacing the air filter element reset the air filter indicator if fitted by pressing the button on the upper side of the indicator Installing the ai...

Page 126: ...g it counter clockwise Note The fuel filter is a disposable filter and must not be cleaned and reused Installing the fuel filter 1 Do not fill the new fuel filter with diesel fuel 2 Lightly lubricate...

Page 127: ...filters by turning them counter clockwise Note The fuel filter is a disposable filter and must not be cleaned and reused Installing the fuel filters 1 Do not fill the new fuel filters with diesel fuel...

Page 128: ...ver 5 Remove the bottom cover and clean the O ring seal Installing the Racor filter element 1 Apply a film of engine oil to the O ring and the new sealing ring Fit the bottom cover 5 to the new filter...

Page 129: ...h the filter 2 Remove the cover by turning it counter clockwise 3 Remove the coarse filter 1 4 Check the seal 2 for damage Replace the seal if it is damaged Installing the fuel coarse filter 1 Apply a...

Page 130: ...the coolant filter to collect any escaping coolant 2 Remove the filler cap from the expansion tank 3 Turn the shut off valve 1 clockwise to the C position 4 Remove the coolant filter by turning it co...

Page 131: ...g it counter clockwise Installing the coolant filter 1 Clean the sealing face of the coolant filter 2 Apply a small amount of coolant to the seal of the coolant filter element 3 Fit the coolant filter...

Page 132: ...re in the guide ring see arrow in the illustration Hang the V belt over a fan blade Rotate the fan blade by blade hanging the V belt over them Repeat this for the entire fan after which the belt can b...

Page 133: ...hment bolt 1 of the compressor 6 Slacken the lower attachment bolt 2 of the compressor 7 Loosen the attachment bolt from the threaded spindle which is attached to the water pump 8 Turn the lock nut 3...

Page 134: ...chment bolt of the threaded spindle on the cylinder block 2 Slacken the attachment bolts on the compressor 3 Turn the lock nuts 3 so that the compressor is tilted towards the cylinder block Then remov...

Page 135: ...ng Installing the poly V belt 10 rib of fan and alternator drive 1 Inspect the pulleys for damage rust and grease deposits 2 Fit the new belt through the opening at the guide ring Adjust the belt tens...

Page 136: ...hment bolts Installing the C brake 1 Clean and blow dry the housing 2 Apply a film of oil to the sealing face of the C brake housing 3 Fit a new gasket 4 Fit the C brake using two studs as guide pins...

Page 137: ...the engine thoroughly before opening any parts of it Removing the valve cover 1 Clean the area around the valve cover 2 Remove the attachment bolts from the valve cover 3 Remove the valve cover and th...

Page 138: ...cover and the gasket Installing the valve cover 1 Clean the sealing face of the valve cover 2 Fit the valve cover using the valve cover gasket The valve cover gasket if not damaged may be reused do n...

Page 139: ...Removing the DEB 1 Remove the valve covers 2 Disconnect the electrical connection and remove the cable harness from its housing 3 Remove the DEB attachment bolts and the DEB assembly Installing the DE...

Page 140: ...containing the filter element 6 carefully from the reservoir so that no dirt from the filter element can get into the reservoir 3 Remove the filter element from the filter holder 4 Fit a new filter e...

Page 141: ...wrench 3 Clean the air dryer internally 4 Check the air dryer threaded connection 2 for damage and then lubricate it sparingly with grease 1 R600251 Installing the air dryer filter element 1 Lubricat...

Page 142: ...ated retarder Removing the gearbox oil filter 1 Remove the attachment bolt 1 of the oil filter M3052 1 2 Pull the filter cover with the filter from the filter housing M3053 3 Remove the filter 3 from...

Page 143: ...age Replace the O ring if necessary Grease the O ring 2 Grease the O ring of the new filter 3 and place the filter on the filter cover Then insert the filter and the filter cover into the filter housi...

Page 144: ...the wheel hub 1 Jack up the axle until the wheels are clear from the floor and position suitable stands under the axle 2 Release the brake shoes 3 Remove the hub cap 2 4 Tap back the locking washer 4...

Page 145: ...both wheels the bearings should be marked Each bearing should be reinstalled in its original hub 9 Remove the hub with the wheel from the axle journal Avoid damaging the wheel speed sensor ring 10 10...

Page 146: ...h the specified wheel bearing grease Also apply a layer of grease to the wheel bearing circumference 6 Fit the wheel bearing 13 into the hub 9 7 Fill the inside circumference of the hub with wheel bea...

Page 147: ...3 to the specified tightening torque See Technical data Use a socket spanner A for this special tool DAF no 0535832 17 Secure lock nut 3 by tapping back the locking washer 4 against the side of the lo...

Page 148: ...split pin 2 and the hub nut 3 4 Remove the outer wheel bearing 4 5 Remove the hub 6 with the wheel Installing the wheel hub 1 Apply new grease to the hub 6 2 Install the hub with the wheel 3 Install t...

Page 149: ...remove the hub cap 4 2 Lift the trailing axle using the trailing axle load transfer device 3 Release the brakes 4 Tap back the locking washer 6 and remove the lock nut 5 using special tool DAF no 053...

Page 150: ...rings should be marked Each bearing should be re installed in its original hub 9 Remove the hub with the wheel from the axle journal 10 Remove the hub seal 14 11 Remove the inner wheel bearing 13 from...

Page 151: ...1 Check the hub and the wheel bearings for wear and damage See chapter Inspection and adjustment 2 Fit new wheel bearings into the hub if necessary 3 Blow dry the wheel bearings 10 and 13 using compr...

Page 152: ...t pry as the oil seal 14 might be damaged in the process 11 Fit the hub nut 9 to the axle journal 12 Adjust the specified wheel bearing play see chapter Inspection and adjustment and fit the circlip 7...

Page 153: ...HUB OIL SEAL FRONT AXLE LEADING REAR AXLE AND TRAILING AXLES 9N075 09N220 Removing the hub oil seal 1 Remove the hub from the axle journal 2 Drill two holes into the oil seal and screw the special to...

Page 154: ...use special tool DAF no 1240036 3 Assemble the special tool turn the threaded ends A and L into the centring spindle E Assemble the short stud L on the side where the pin is located in the centring sp...

Page 155: ...ithout the dummy sensor ring if the hub 2 does have a sensor ring 5 10 Position the seal 4 in front of the hub with the seal lip pointing to the outside of the hub Slide the draw in flange H over the...

Page 156: ...two holes into the oil seal and screw the special tool DAF no 0484899 into the oil seal Pull the oil seal from the wheel hub using the special tool DAF no 0694928 Installing the hub oil seal 1 Check t...

Page 157: ...l tool 3 DAF no 1329411 to the impact puller 2 special tool DAF no 0694928 Hook special tool 3 DAF no 1329411 behind the oil seal 1 Pull the seal 1 from the hub using impact puller 2 The removed seal...

Page 158: ...the centring spindle E 9 Fit the locking plate C and the nut B on the centring spindle E 10 Align the centring flange D on the outer race of the outer wheel bearing and hand tighten nut B max 20 Nm Th...

Page 159: ...ffected and rinse with water In the event of contact with the eyes rinse with plenty of water for at least 15 minutes and see a doctor If swallowed do NOT induce vomiting Rinse the mouth drink two gla...

Page 160: ...drain plug to the specified torque See Technical data Refilling engine oil 1 Fill the engine through oil filler pipe D with the specified engine oil quantity See Technical data D000268 D VF ENGINE Dr...

Page 161: ...em When removing the filler cap allow the overpressure to escape by first loosening the filler cap one turn XF XE ENGINE Draining the cooling system 1 Turn the heater control knob to the warmest tempe...

Page 162: ...ansion tank is not kinked or pinched off 5 Check the coolant level and top up with coolant if necessary If the vehicle is equipped with water air cab heater 1 Run the engine at idling speed 2 Switch o...

Page 163: ...via drain tap A at the radiator via drain plug B and at the heat exchanger via drain plug C 5 Flush the cooling system 6 Close drain taps A and C and install drain plug B Filling bleeding the cooling...

Page 164: ...e cab heater using the rocker switch on the dashboard 3 Turn the heater temperature control knob in the cab to the warmest setting 4 Switch on the heater fan 5 Set the rocker switch on the thermostat...

Page 165: ...the oil Filling the differential 1 Position the vehicle on a level surface 2 Fit the drain plug B using the special torx spanner DAF no 1329422 and tighten it to the specified torque See Technical dat...

Page 166: ...ferential 1 Position the vehicle on a level surface 2 Fit the drain plug B using the special torx spanner DAF no 1329422 and tighten it to the specified torque See Technical data 3 Fill the differenti...

Page 167: ...level check filler plug A using the special torx wrench DAF no 1329422 and tighten the plug to the specified tightening torque See Technical data Draining the differential second axle 1 Position the v...

Page 168: ...ide 3 Remove the level check filler plug A and drain the oil Filling the wheel hub 1 Position the vehicle on a level surface 2 Position the wheels so that the arrow on the hub cover is facing upwards...

Page 169: ...n the oil B A A8 00 363 Filling the wheel hub 1 Position the vehicle on a level surface 2 Position the wheels in such a way that the drain filler plug A is on the top side 3 Fill the hub with the spec...

Page 170: ...rface 2 Drain the gearbox at operating temperature 3 Remove drain plugs B C and D and the level check filler plug A and drain the oil Filling the gearbox 1 Clean drain plugs B C and D and tighten them...

Page 171: ...to the specified tightening torque See Technical data Filling the gearbox 1 Clean the drain plugs 1 and 2 and tighten them to the specified torque See Technical data V300261 3 1 2 2 Fill the oil thro...

Page 172: ...twice 5 Remove the retarder oil drain plug 3 and drain off the oil 6 Remove the butterfly valve drain plug 4 and drain the leak off oil 7 Fit the drain plugs 3 and 4 with new sealing rings and tighten...

Page 173: ...completely filled with grease so that no air bubbles can get into the system 3 Fill the reservoir to the specified maximum level Note When filling the reservoir the air above the follower piston will...

Page 174: ...EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES Draining and filling 95XF series 5 16 5 200424...

Page 175: ...THE INTERIOR FILTER ELEMENT 1 Remove the filter 2 see chapter Removal and installation 2 The filter can be cleaned by tapping off the dirt which has accumulated at the front off the filter surface In...

Page 176: ...h drink two glasses of water and see a doctor In the event of inhalation get some fresh air rest and consult a doctor 1 Disconnect the earth lead from the battery terminal 2 Disconnect the positive le...

Page 177: ...and installation 2 Check the air filter element for damage If the air filter element or its seals are damaged the air filter element must be replaced 3 Knock out the air filter element 4 Blow the air...

Page 178: ...ove the protective screen 4 Clean the protective screen with a hard brush and blow clean with compressed air Cleaning the radiator intercooler element Note With the aid of a simple tool the radiator a...

Page 179: ...r 4 and continue blow cleaning the intercooler 1 until no more dirt comes out 1 2 3 4 M2109 P 3 Turn the radiator cleaner over turning the holes towards the radiator 2 and blow clean the radiator 2 1...

Page 180: ...et of water so that the grease behind them is flushed away As a result the spider may get stuck so that the steering will jam A bleed screw is fitted to the power steering fluid reservoir of the steer...

Page 181: ...ncapsulation panels must be thoroughly cleaned after each inspection interval in view of the risk of fire if the inside of the panels should be dirty Do not direct the jet of water at electrical conne...

Page 182: ...EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES Cleaning 95XF series 6 8 5 200424...

Page 183: ...TENANCE ACTIVITIES 7 1 7 LUBRICATION 7 1 LUBRICATE ACCORDING TO LUBRICATION SCHEDULE Note If the vehicle is equipped with a central lubrication system all lubricating points are lubricated automatical...

Page 184: ...s front axle 6 Universal joint 7 Centre bearing 8 Fifth wheel 9 Shackle pins rear axle 10 Brake camshafts rear axle 11 Spring shackles rear axle 12 Drawn vehicle coupling 13 Pivoting points of trailer...

Page 185: ...ximum lubricating pressure should not exceed 15 bar M9030 Lubrication of king pins 1 To make sure that the grease can penetrate adequately the king pins should be lubricated in unloaded condition The...

Page 186: ...INTENANCE ACTIVITIES Lubrication 95XF series 7 4 Automatic brake adjusters and brake camshafts FTP leading rear axle 1 Lubricate the automatic brake adjusters and brake camshafts using the lubricating...

Page 187: ......

Page 188: ...English Printed in the Netherlands DW03247106...

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DAF 95XF, Maintenance Manual

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Summary of Contents for 95XF

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