DAF CF65 Maintenance Manual Download Page 87

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200518

4-3

Removal and installation

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΧΦ65/65

(II)

series

Fit the air filter element (3) in the air filter

housing.

Fit the air filter cover. Note the arrow (4) on

the air filter cover (2).

Fit all the clamping brackets (1).

Check that the flexible sealing bellows (5) on

the air intake is not damaged. Replace if

necessary.

i400949

ANT

Use only DAF g

enuin

e p

arts

i400443

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

Summary of Contents for CF65

Page 1: ...Maintenance manual CF65 CF65 II https www truck manuals net...

Page 2: ...https www truck manuals net...

Page 3: ...pment DAF reserves the right to change specifications or products at any time without prior notice No part of this publication may be reproduced and or published by printing by photocopying on microfi...

Page 4: ...https www truck manuals net...

Page 5: ...RE 200518 0 1 2 3 4 5 65 65 II series Structure TECHNICAL DATA THREADED CONNECTIONS FLUIDS OIL AND LUBRICANTS MAINTENANCE SCHEDULE EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES https www truck manua...

Page 6: ...https www truck manuals net...

Page 7: ...1 General 1 1 200518 1 2 Tightening torques 1 1 200518 1 3 Filling capacities 1 2 200518 2 STEERING GEAR AND BRAKE SYSTEM 2 1 200518 2 1 General 2 1 200518 2 2 Tightening torques 2 1 200518 3 DRIVE A...

Page 8: ...TECHNICAL DATA 2 200518 Contents 0 65 65 II series https www truck manuals net...

Page 9: ...ated 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 bolt...

Page 10: ...ooling system CF65 II cooling system Total capacity including oil cooler and oil filter approx 19 5 litres Sump capacity maximum level approx 17 5 litres Sump capacity minimum level approx 15 4 litres...

Page 11: ...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 importan...

Page 12: ...TECHNICAL DATA 2 2 200518 Steering gear and brake system 0 65 65 II series https www truck manuals net...

Page 13: ...be read out via the selector keypad This keypad is located next to the driver s seat The oil level can also be checked using the dipstick Dipstick readings The oil level when cold must be on the Cold...

Page 14: ...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 an...

Page 15: ...the nut height which is 1 5 x thread Evenly tighten the two U bolt nuts alternately V300371 2 1 Drain plug 1 28 Nm Oil filter cover attachment bolts 2 55 Nm U bolt nut if flange nut M20 with yellow w...

Page 16: ...apacities are approximate capacities excluding external pipes and cooler 1132 axle differential U bolt nut leaf suspension 700 Nm 1 U bolt nut air suspension 615 Nm 1 Filler and drain plugs hub plugs...

Page 17: ...200518 1 Contents THREADED CONNECTIONS 65 65 II series 2 2 Threaded connections CONTENTS Page Date 1 THREADED CONNECTIONS 1 1 200518 1 1 General 1 1 200518 https www truck manuals net...

Page 18: ...THREADED CONNECTIONS 2 200518 Contents 2 65 65 II series https www truck manuals net...

Page 19: ...connection must be tightened accurately Therefore always use a reliable torque wrench that provides a high degree of accuracy Note Have torque wrenches regularly inspected and calibrated Re use of fas...

Page 20: ...th the standard for dipped bolts in the case of special connections apply the lubricant before fitting and re tighten in accordance with the values specified in the instructions The instructions for u...

Page 21: ...200518 1 Contents FLUIDS OIL AND LUBRICANTS 65 65 II series 3 3 Fluids oil and lubricants CONTENTS Page Date 1 SPECIFICATIONS 1 1 200518 1 1 General 1 1 200518 https www truck manuals net...

Page 22: ...FLUIDS OIL AND LUBRICANTS 2 200518 Contents 3 65 65 II series https www truck manuals net...

Page 23: ...liable for damage or problems in the following instances 1 use of oil of a lower grade than specified 2 use of oil of a different viscosity than specified 3 if the change interval is exceeded 4 if fue...

Page 24: ...FLUIDS OIL AND LUBRICANTS 1 2 200518 Specifications 3 65 65 II series https www truck manuals net...

Page 25: ...ect of diesel fuel and PTO hours on maintenance intervals 1 4 200518 1 4 Maintenance in special operating conditions 1 4 200518 1 5 First service inspection 1 4 200518 2 MAINTENANCE ACTIVITIES 2 1 200...

Page 26: ...MAINTENANCE SCHEDULE 2 200518 Contents 4 65 65 II series https www truck manuals net...

Page 27: ...e maintenance schedule notes Extended changing interval not permitted for ZF 6S 850 gearbox Maintenance schedule 1x per YEAR G000378 2 X service Y service 40 000 km 40 000 km 40 000 km 1 year max 100...

Page 28: ...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 dis...

Page 29: ...If the prescribed oil specification see specification manual Fluids and lubricants is complied with an extended changing interval may be applied Automatic gearboxes are subject to different changing...

Page 30: ...in consultation with the dealer main branch or importer to fit the appropriate operating conditions 1 5 FIRST SERVICE INSPECTION The first service inspection should be carried out between the first 7...

Page 31: ...ENANCE SCHEDULE 65 65 II series 4 2 MAINTENANCE ACTIVITIES 2 1 OVERVIEW OF MAINTENANCE ACTIVITIES FOR THE FIRST SERVICE INSPECTION O Adjust clutch wear indicator mark O Change the oil filters on autom...

Page 32: ...int O Change coolant see Note 1 Changed O Yes O No O Change fuel fine filter STEERING GEAR AND BRAKE SYSTEM O Replace steering gear filter element see Note 5 Replaced O Yes O No O Check steering ball...

Page 33: ...e in maintenance manual 3 For the changing interval see maintenance schedule in maintenance manual When changing the gearbox oil in an automatic gearbox the gearbox oil filters must also be replaced 4...

Page 34: ...O Check steering oil level O Check steering gear lines and connections O Check brake components and brake system for leaks O Check brake shoe thickness and brake disc DRIVE AND CHASSIS O Check clutch...

Page 35: ...1 For the changing interval see maintenance schedule in maintenance manual 2 For the changing interval see maintenance schedule in maintenance manual When changing the gearbox oil in an automatic gea...

Page 36: ...MAINTENANCE SCHEDULE 2 6 200518 Maintenance activities 4 65 65 II series https www truck manuals net...

Page 37: ...200518 3 15 Checking the air inlet dust trapping valve 3 12 200518 Steering gear and brake system 3 16 Checking fastening of universal joint to steering box input shaft 3 13 200518 3 17 Checking the...

Page 38: ...6 200518 4 6 Removal and installation valve cover 4 8 200518 Steering gear and brake system 4 7 Removal and installation steering gear filter element 4 9 200518 4 8 Removal and installation air dryer...

Page 39: ...are effectively extracted Remain at a safe distance from rotating and or moving components Never remove the filler cap from the cooling system when the engine is at operating temperature Be careful wh...

Page 40: ...the inside of the panels is dirty Always disconnect the earth connection of the battery before working on the vehicle Always use stands to support the chassis or components when working under the vehi...

Page 41: ...truction or training to carry out these maintenance activities in a safe and responsible manner The technical data and notes on the maintenance activities have been compiled with the utmost care 2 2 T...

Page 42: ...egular intervals you will help to 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 adjusting...

Page 43: ...intenance activities are concerned this includes components such as windscreen wiper blades air dryer elements gaskets V belts and filters For example if non original DAF filters are used the engine w...

Page 44: ...driven front axle regularly for fouling and blockages If the breathers are blocked by dirt overpressure may cause leaks Depending on the circumstances in which the vehicle is used e g on very bad road...

Page 45: ...NCE ACTIVITIES 65 65 II series 5 3 INSPECTION AND ADJUSTMENT 3 1 CHECKING PEDAL RUBBERS 1 Check that the pedal rubbers are still securely mounted on the pedal 2 Check that the pedal rubbers are not wo...

Page 46: ...nty of water for at least 15 minutes and consult a doctor If swallowed do NOT induce vomiting Rinse the mouth drink two glasses of water and consult a doctor In the event of inhalation get fresh air r...

Page 47: ...reservoir Remove filler plug 1 4 Start pumping maximum 5 pump strokes Ensure that the pump lever is in the lowest position 5 Check the fluid level This level should be no more than 2 cm below the top...

Page 48: ...you continue pumping the fuel system may become internally damaged Note When the hand pump is used the fuel system will be automatically bled Air will be fed back to the tank through the return pipe...

Page 49: ...ACTIVITIES 65 65 II series 5 Fleetguard fuel prefilter water separator 1 Unscrew the button of the primer pump and pull it out 2 Use the primer pump until a clearly higher resistance is perceptible 3...

Page 50: ...the oil level Note It takes approx 20 minutes for all the oil to run into the sump when the engine is warm If the dipstick is checked immediately after switching the engine off or immediately after oi...

Page 51: ...tion 2 Use an open end spanner on the fan shaft to turn the crankshaft clockwise as seen from the vibration damper end this is the engine s normal direction of rotation until the mark A is between the...

Page 52: ...urn the crankshaft one rotation further so that the mark A is once again between the bolts B and the valves of cylinder 6 overlap 5 Check correct the valve clearance of the specified inlet and exhaust...

Page 53: ...ly V belt for damage and signs of serious wear 2 Check the pulleys for damage rust and grease deposits Clean or replace the belt pulleys if necessary Note Pay special attention to the plastic pulleys...

Page 54: ...iting Rinse mouth drink two glasses of water and consult a doctor 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...

Page 55: ...AND HOSE CONNECTIONS FOR LEAKS 1 Check all hose connections and cooling system components for leaks 2 Check the hose connections and inlet system components 3 13 CHECKING THE EXHAUST SYSTEM 1 Visually...

Page 56: ...NG THE RADIATOR AND INTERCOOLER FOR FOULING 1 Visually inspect the radiator and intercooler for fouling If necessary clean the radiator and intercooler see Cleaning 3 15 CHECKING THE AIR INLET DUST TR...

Page 57: ...any perceptible play between the spline connection of the universal joint and the steering box input shaft If perceptible play is detected the splines on the universal joint and those on the input sh...

Page 58: ...HE STEERING BALL JOINT SLEEVE FOR DAMAGE Inspection locking devices and dust cover 1 Check that the steering ball joint dust cover or seal is not damaged Replace the steering ball joint if damaged 2 I...

Page 59: ...o bracket 1 Fit the locking screw 5 It should be possible to move the pressure sleeve 6 freely Note Fit the correct pressure sleeve 6 The pressure sleeve 6 must abut the outer edge of the steering bal...

Page 60: ...not running 2 Clean the dipstick and its immediate surroundings to prevent any oil from entering the reservoir 3 Check the fluid level in the reservoir using the dipstick 4 The fluid level should be b...

Page 61: ...o problems air in the system If in doubt always replace the line 2 Pipe connections Check every pipe connection for leaks 3 Line route Pipes must not be twisted during assembly To facilitate checking...

Page 62: ...ple 5 Start the engine and run it at maximum engine speed 6 If the pressure regulator has switched off cut off pressure reached air dryer blown off the pressure gauge must show a pressure lower than 2...

Page 63: ...imum pressure it should generally be possible to drive the vehicle after a period of 16 hours of uninterrupted standstill without having to first charge the brake system to adequate operating pressure...

Page 64: ...24 CHECKING THE BRAKE SHOE THICKNESS AND BRAKE DISC Version Knorr SB 7000 1 Check whether guide bush 4 protrudes from guide sleeve 6 C If the guide bush 4 is level with the guide sleeve 6 see detail A...

Page 65: ...ACTIVITIES 65 65 II series 5 Version Knorr SN 7000 1 Check the transition between the ribbed part of the rubber cover and the smooth part A If the smooth part is rolled inwards the brake shoe and brak...

Page 66: ...These values can be used to check the brake pressure values of the front axle and to carry out the inspection adjustment below at the same time To do this connect a pressure gauge to the test connect...

Page 67: ...n and adjustment load dependent control valve air suspension 1 Check that the correct valve has been fitted see instruction plate 2 Connect pressure gauge 4 to the test connection close to connecting...

Page 68: ...ocedure described in point 6 until the measured brake pressure value is within the tolerance limits 11 Set the simulated bellows pressure to its second highest value as indicated on the instruction pl...

Page 69: ...s can be used to check the brake pressure values of the front axle and to carry out the inspection adjustment below at the same time To do this connect a pressure gauge to the test connection of one o...

Page 70: ...ylinders Inspection and adjustment load dependent control valve leaf suspension 1 Measure the weight plus load of the rear axle s 2 Check the attachment of the control lever and its ease of operation...

Page 71: ...rear axle 10 Correct if necessary the brake pressure by moving the rubber sleeve 1 in relation to the vertical connecting rod On no account change the length L of the horizontal control lever 11 Remov...

Page 72: ...DIFFERENTIAL LOCK 1 Jack up the rear axle and support the axle on stands 2 Bring the air system to operating pressure 3 Engage the differential lock The warning indicator should now be active 4 Check...

Page 73: ...CHECKING THE DRIVE SHAFT PLAY 1 Check the universal joints and suspension bearing for play and damage 2 Check the sliding joint for axial and radial play 3 There must be no clearly perceptible play o...

Page 74: ...ched pin 2 Check the radial play of the arched pin 3 Check the vertical and horizontal play of the coupling jaw 4 Check the diameter of the arched pin 5 Check the attachment of the trailer coupling an...

Page 75: ...MAINTENANCE ACTIVITIES 65 65 II series 5 3 31 CHECK THE SUPERSTRUCTURE ATTACHMENT 1 Check that all attachment bolts are in place 2 Visually check the attachment of the superstructure for faults See t...

Page 76: ...ealed container and meets the specifications Hydraulic fluid which has absorbed water from the ambient air may have an adverse effect on the operation of the clutch system Avoid any contact with miner...

Page 77: ...indicator of automatically adjusting clutch release assembly 1 Using a centre punch make a mark 1 on the wear indicator cover The mark 1 should be placed exactly opposite to the indicator 2 to show th...

Page 78: ...lease the service brake 5 Remove the dipstick when the engine is idling and wipe the dipstick clean with a lintfree cloth Note To take the dipstick out of the holder the sealing cap must be held tight...

Page 79: ...he dipstick is turned anti clockwise 3 Put the dipstick back 4 Remove the dipstick and check the oil level 5 The oil level should be between the Hot add and the Hot full marks 6 Clean the dipstick wit...

Page 80: ...s on the selector keypad simultaneously The display now shows the letters O and L Note O and Lstand for Oil Level 4 When the oil level is correct the letters O K appear on the display When the oil lev...

Page 81: ...s 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 T...

Page 82: ...ust not be slackened first and then tightened to the specified torque see Technical data 3 39 CHECKING THE HINGE POINTS AND AXLE SUSPENSION FASTENING AIR SUSPENSION Torque rod 1 Check the attachment o...

Page 83: ...air bellows using a cleaning cloth or a soap solution if required 3 Check the air bellows for cracks and damage If there are any cracks or damage through which the webbing is visible the air bellows s...

Page 84: ...THE OPERATION OF THE AUTOMATIC LUBRICATION SYSTEM 1 Check the system for line fractures and operation of the jets 2 Check whether all lubricating points are lubricated 3 Check the lubricant level in...

Page 85: ...INTERIOR FILTER ELEMENT Removing interior filter 1 Open the grille 2 Push the locknut on the filter casing to one side and remove the filter element Fitting interior filter 1 Fit the filter element 2...

Page 86: ...cover 2 3 Remove the air filter element 3 4 Clean the inside of the air filter housing and the air filter cover 5 When replacing the air filter element reset the air filter indicator if fitted by pre...

Page 87: ...t 3 in the air filter housing 2 Fit the air filter cover Note the arrow 4 on the air filter cover 2 3 Fit all the clamping brackets 1 4 Check that the flexible sealing bellows 5 on the air intake is n...

Page 88: ...dirty 3 Remove the filter element by turning it anti clockwise Collect the oil that comes out 4 Remove the O ring if it has not been removed already Installing the lubricating oil filter 1 Lightly oi...

Page 89: ...he fine filter with fuel until it has been fitted The fine filter is filled with fuel by the primer pump after it has been fitted This considerably reduces the risk of dirt getting into the fuel syste...

Page 90: ...d disconnect the water sensor 6 and the heating element 7 connectors 4 Remove the filter element 4 together with the bottom cover 5 and clean the O ring seal Installing the fuel prefilter water separa...

Page 91: ...hand whether the coupling piece for the filter attachment is securely attached 2 Lightly lubricate the sealing ring with engine oil 3 Fit the fuel prefilter water separator filter element 1 until the...

Page 92: ...t and the attachment of the plastic crankcase breather tube 3 Remove the valve cover attachment nuts 4 Remove the valve cover Installing the valve cover 1 Clean the sealing surface of the valve sleeve...

Page 93: ...nd filter element must be removed from the reservoir 1 with care so that no dirt remains in the reservoir 1 4 Remove the filter element 6 from the filter holder 5 Installing the steering gear filter e...

Page 94: ...oosening the compressor line 1 so that the interior of the air dryer is depressurised 2 Remove the filter element by turning it anti clockwise using a filter strap spanner 3 Dispose of the drying elem...

Page 95: ...ant felt pen write on the sticker the latest date by which the dryer element must be replaced not later than 1 year after the date of fitting Drive and chassis Artikelnummer Reference Teilenummer R f...

Page 96: ...left on the filter covers and the contact surfaces Fitting automatic gearbox oil filters 1 Lightly lubricate the new O rings with clean gearbox oil and fit the various O rings to the filter covers Not...

Page 97: ...er In the event of contact with the eyes rinse with plenty of water for at least 15 minutes and consult a doctor If swallowed do NOT induce vomiting Rinse the mouth drink two glasses of water and cons...

Page 98: ...n a flat and level surface 2 Drain the engine oil at operating temperature via the drain plug in the oil sump 3 Replace the drain plug sealing ring and tighten the drain plug to the specified torque s...

Page 99: ...cooling system filler cap 3 Collect the coolant To do this place a suitable container under the drain point 4 Drain the cooling system at the radiator via drain plug B 5 Flush the cooling system 6 Fit...

Page 100: ...ch on the dashboard 3 Turn the heater temperature control knob in the cab to the maximum hot setting 4 Switch on the heater fan 5 Set the rocker switch on the thermostat in the cab to position 1 Note...

Page 101: ...F no 1329493 Drain the oil 3 Fit the drain plug using the special Torx wrench DAF no 1329493 and tighten it to the specified torque see Technical data Filling the 1132 axle differential 1 Fill the dif...

Page 102: ...of the filler opening 3 After filling the gearbox tighten the level check plug to the specified torque see Technical data Eaton 6309A gearbox To prevent skin injury avoid unnecessary contact with the...

Page 103: ...ng the gearbox to operating temperature approx 71 C 93 C to allow the oil to drain more quickly and more fully 2 Place the vehicle on a level and horizontal surface 3 Remove the drain plug 1 from the...

Page 104: ...level reaches the Cold full mark Note To take the dipstick out of the holder the sealing cap must be held tightly while the dipstick is turned anti clockwise 5 Check the oil level using the selector k...

Page 105: ...mpletely 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 es...

Page 106: ...EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 5 10 200518 Draining and filling 5 65 65 II series https www truck manuals net...

Page 107: ...vomiting Rinse the mouth drink two glasses of water and consult a doctor In the event of inhalation get fresh air rest and consult a doctor 1 Disconnect the earth lead from the battery terminal 2 Disc...

Page 108: ...1 Remove the protective screen if applicable by removing the attachment bolts 2 Clean the protective screen if applicable with a hard brush and blow clean with compressed air 3 Insert radiator cleaner...

Page 109: ...ANCE ACTIVITIES 65 65 II series 5 5 Turn the radiator cleaner 4 over turning the holes towards the radiator 2 and blow clean the radiator 2 6 If applicable fit the protective screen using the attachme...

Page 110: ...ich may cause damage to the system Make sure that no water can enter the differential and gearbox via the vents Make sure that no water can enter via the reservoir vents of clutch brakes trailing axle...

Page 111: ...3 Rinse the vent s in a cleaning fluid 4 Blow the vent s dry from the inside using compressed air 5 Install the vent s on the gearbox 6 5 CLEANING REAR AXLE VENT Cleaning rear axle vent 1 Clean the v...

Page 112: ...EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 6 6 200518 Cleaning 5 65 65 II series https www truck manuals net...

Page 113: ...ting points marked below with an S indicate that the lubricating point is positioned on both the left and right hand side of the vehicle Lubricating stub axles S 1 To ensure that the grease can penetr...

Page 114: ...EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 7 2 200518 Lubrication 5 65 65 II series https www truck manuals net...

Page 115: ...https www truck manuals net...

Page 116: ...Printed in the Netherlands DW13280404 English https www truck manuals net...

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