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ZF 8/9/16S-109 GEARBOX

Removal and installation, gearbox

CF

65/75/85

series

4-2

Installing the entire gearbox

1.

Before positioning the gearbox, one gear
should be engaged in order to allow the
input shaft to slide into the clutch plate
during installation. Also grease the input
shaft sparingly with the specified grease.
See “Technical data”.

2.

Fit the exhaust pipe between the engine
brake and the silencer (depending on the
vehicle type).

3.

Fit the selector rod and torque rod.

4.

Fit the air pipes.

5.

Fit the gearbox connectors and the
tachometer connection.

6.

Fit the clutch servo.

7.

Fit the prop shaft flange to the gearbox.
Tighten the attachment bolts to the
specified torque. See “Technical data”.

8.

Connect the negative terminal of the
battery.

9.

Check the oil level after installing the
gearbox.

10. Inspect the shift control. See “Inspection

and adjustment”.

11. If a gearbox of a different type is mounted,

or a gearbox with a different reduction, this
should be reported. If the correct data are
present, they can be input into the VIC
using DAVIE XD.

ᓻ

0111

6

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

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Summary of Contents for CF65

Page 1: ...ISTED GEARBOX CONTROL SERVOSHIFT GEARBOX PNEUMATIC SECTION ZF 6S 850 GEARBOX ZF 8 9 16S 109 GEARBOX ZF 8 16S 151 181 AND 16S 221 GEARBOXES EATON FS 6309A GEARBOX AUTOMATIC GEARBOXES CLUTCH PROP SHAFTS...

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

Page 3: ...337 5 3 Filling capacities 5 4 200337 6 ZF 8 16S 151 181 AND 16S 221 GEARBOXES 6 1 200337 6 1 General 6 1 200337 6 2 Tightening torques 6 2 200337 6 3 Filling capacities 6 4 200337 7 EATON FS 6309A GE...

Page 4: ...00337 12 1 General 12 1 200337 12 2 Tightening torques 12 2 200337 12 3 Filling capacities 12 4 200337 13 AS TRONIC GEARBOX 13 1 200337 13 1 General 13 1 200337 13 2 Tightening torques 13 2 200337 13...

Page 5: ...1 GENERAL V300382 Within the entire CF65 75 85 vehicle series many gearbox variations as well as the accompanying controls are possible both mechanical and pneumatic A gearbox with a splitter and ran...

Page 6: ...sm should be fitted together with the selector shaft lever V300383 A Vehicle series CF65 RHD with gearbox type ZF 6S 850 If the selector shaft lever has two attachment holes the attachment hole A in t...

Page 7: ...d must therefore be tightened to the torque stated in the overview of standard tightening torques When attachment bolts and nuts are to be replaced it is important that they are of exactly the same le...

Page 8: ...3 TECHNICAL DATA Mechanical gearbox control CF65 75 85 series 1 4 0 200337 https www truck manuals net...

Page 9: ...ening torques included in the overview of standard tightening torques Any other threaded connections that are not specified must therefore be tightened to the torque stated in the overview of standard...

Page 10: ...3 TECHNICAL DATA Pneumatically assisted gearbox control Servoshift CF65 75 85 series 2 2 200337 0 https www truck manuals net...

Page 11: ...nd range change protection frequencies programmed into the electronic unit are related to the drive configuration GV VALVE GV valve begins to open C 123 2 mm Total clutch pedal travel D 154 2 mm NEUTR...

Page 12: ...5 75 85 series 3 2 GEAR LEVER SELECTOR VALVE Range change gear Connection point Colour 1 Supply Black 3 Bleed Red 21 Range change gear command A White V300488 21 1 B A 3 PNEUMATIC SYMBOL I II V300267...

Page 13: ...nd splitter Connection point Colour 1 Supply Black 3 Bleed Red 21 Range change gear command A White 22 Splitter command B Yellow V300489 21 1 22 B A 3 PNEUMATIC SYMBOL Range change gear and splitter P...

Page 14: ...ghtening torques Any other threaded connections that are not specified must therefore be tightened to the torque stated in the overview of standard tightening torques When attachment bolts and nuts ar...

Page 15: ...2 Series no ZF 3 Parts list ZF 4 Specification no 5 Pulse generator ratio 6 Gearbox ratio 7 Engine speed using PTO 8 PTO speed 9 Gearbox oil capacity 10 Oil specification V300049 1 2 4 5 3 8 6 7 10 9...

Page 16: ...same length and property class as the ones removed unless stated otherwise Gearbox to engine M8 attachment bolts 10 9 30 Nm M10 attachment bolts 10 9 60 Nm M12 attachment bolts 10 9 110 Nm Drive flan...

Page 17: ...io 6 Gearbox ratio 7 Engine speed using PTO 8 PTO speed 9 Gearbox oil capacity 10 Oil specification V300049 1 2 4 5 3 8 6 7 10 9 Output shaft bearing axial play Output shaft bearing axial play 0 00 0...

Page 18: ...class as the ones removed unless stated otherwise Gearbox to engine M8 attachment bolts 10 9 30 Nm M10 attachment bolts 10 9 60 Nm M12 attachment bolts 10 9 110 Nm Drive flange Retaining plate attach...

Page 19: ...CAL DATA 5 3 Plugs Gearbox with integrated intarder Drain plug B M24 60 Nm Drain plug B M38 120 Nm Drain plug C 60 Nm Level check filler plug A 60 Nm Oil filter attachment bolt 1 23 Nm M3017 B B A V30...

Page 20: ...ox type Filling amounts at oil change litres First filling e g during repair litres ZF 8 16S 109 9 9 5 ZF 9 S 109 8 8 5 Filling amounts ZF gearboxes with integrated intarder Gearbox type Filling amoun...

Page 21: ...Parts list ZF 4 Specification no 5 Pulse generator ratio 6 Gearbox ratio 7 Engine speed using PTO 8 PTO speed 9 Gearbox oil capacity 10 Oil specification V300049 1 2 4 5 3 8 6 7 10 9 Output shaft bear...

Page 22: ...ed unless stated otherwise Gearbox to engine M8 attachment bolts 10 9 30 Nm M10 attachment bolts 10 9 60 Nm M12 attachment bolts 10 9 110 Nm Drive flange M12 x 70 drive flange 8 8 60 Nm M12 x 60 drive...

Page 23: ...DATA 6 3 Plugs Gearbox with integrated intarder Drain plug B M24 60 Nm Drain plug B M38 120 Nm Drain plug D 60 Nm Level check filler plug 4 60 Nm Filler plug 5 60 Nm Oil filter attachment bolt 1 23 N...

Page 24: ...g amounts at oil change litres First filling e g during repair litres ZF 8 16S 151 11 11 ZF 8 16S 181 13 13 ZF 16S 221 13 13 Filling amounts ZF gearboxes with integrated intarder Gearbox type Filling...

Page 25: ...stomer and gives detailed information on the development level of the gearbox The number must be quoted whenever replacement parts are ordered Input shaft play adjusting rings Colour coding 3 70 mm Re...

Page 26: ...Drive flange M39 drive flange nut 650 Nm 1 Drive flange oil seal housing attachment bolts 60 Nm Gearbox front cover Attachment bolts 37 Nm Selector shaft housing Selector shaft housing attachment bol...

Page 27: ...FS 6309A gearbox TECHNICAL DATA 7 3 Plugs Drain plug 50 Nm Level check filler plug 50 Nm 1 Use new nut 2 Loctite 243 7 3 FILLING CAPACITIES Gearbox capacity Type Contents FS 6309A 8 5 litres 200337 h...

Page 28: ...3 TECHNICAL DATA Eaton FS 6309A gearbox CF65 75 85 series 7 4 200337 0 https www truck manuals net...

Page 29: ...diagnostic system that saves any faults in the memory of the ECU Electronic Control Unit The faults can be read at a later date The system is operated and the faults are read via the selector keypad T...

Page 30: ...they are of exactly the same length and property class as the ones removed unless stated otherwise Gearbox bleeder 14 Nm M14 x 2 0 drive flange attachment bolt 75 Nm Gearbox rear mounting bracket 100...

Page 31: ...t second filling MD 3060P 4 oil sump 27 litres 20 litres MD 3066P 4 oil sump 27 litres 20 litres MD 3560P 4 oil sump 27 litres 20 litres The oil level when cold must be on the Cold full mark Dip stick...

Page 32: ...3 TECHNICAL DATA Allison automatic gearbox CF65 75 85 series 8 4 0 200337 https www truck manuals net...

Page 33: ...Automatically adjusting clutch release assembly and wear indicator PE MF 395 MF 395 with extended service life MFZ 430 MFZ 430 with extended service life Automatically adjusting clutch release assembl...

Page 34: ...I 4 KZI 4 KZI 4 KZI 4 PE 395 WGTZ 395 WGTZ 430 GTZ 430 GTZ 3 5 3 5 1 75 1 75 2 2 KZI 4 KZI 4 KZIZ 5 KZIZ 5 XE 430 GTZ 430 GTZ 3 5 2 2 KZIZ 5 KZIZ 5 Note All clutch plates are single dry plate versions...

Page 35: ...ICAL DATA 9 3 Clutch pedal Clutch pedal proximity sensor A 1 0 1 mm Clutch pedal free travel B approx 2 4 mm GV valve begins to open C 123 2 mm Total clutch pedal travel D 154 2 mm V300315 C D B 1 A 2...

Page 36: ...L DATA Clutch CF65 75 85 series 9 4 Main cylinder Maximum piston stroke 34 mm Pressure pin setting E approx 0 2 0 8 mm Mounting seals Silicone grease V300411 1 E 2 3 4 5 6 7 0 200337 https www truck m...

Page 37: ...d unless stated otherwise Main cylinder Pressure pin attachment nut 55 Nm Bleeder 8 Nm Steel pipe coupling 40 Nm Clutch release assembly ZF gearboxes Attachment bolts clutch release assembly to flywhe...

Page 38: ...lts clutch lever to gearbox 79 Nm AS TRONIC clutch unit Clutch unit attachment nut 23 Nm Clutch unit stud 10 Nm Bleed screw clutch unit 22 Nm Compressed air connection 50 Nm 9 3 FILLING CAPACITIES Clu...

Page 39: ...missible axial play of universal joints 0 3 mm CF65 Balancing speed 85 x 5 mm retracted length 1750 mm max n 3000 n min Length of idler shaft 1950 mm CF75 Balancing speed 120 x 3 mm retracted length 2...

Page 40: ...tions that are not specified must therefore be tightened to the torque stated in the overview of standard tightening torques When attachment bolts and nuts are to be replaced it is important that they...

Page 41: ...rop shafts are maintenance free although vehicles that are used in heavy conditions are fitted as standard with lubricating nipples on the universal joints Clean grease must emerge visibly from all fo...

Page 42: ...3 TECHNICAL DATA Prop shafts CF65 75 85 series 10 4 0 200337 https www truck manuals net...

Page 43: ...torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques Any other threaded connections that are not specified must the...

Page 44: ...olts rear gearbox cover 50 Nm Heat exchanger Studs in heat exchanger 18 Nm 1 Attachment nuts 62 Nm 1 Oil connection flange attachment bolt 23 Nm 1 Heat exchanger attachment surfaces Loctite 574 Hydrau...

Page 45: ...eel housing The ZF Eaton PTOs can be recognised by the position at the rear of the gearbox DAF ENGINE PTO Axial play Drive gears between crankshaft and PTO 0 15 0 30 mm PTO housing prop shaft bearings...

Page 46: ...olt in flywheel housing 110 Nm Sealing plate at rear of flywheel housing 30 Nm Output shaft flange bolt 110 Nm Gear shift lever 30 Nm PTO operating cylinder cover 30 Nm Operating cylinder housing expa...

Page 47: ...23 Nm Bolts for fastening attachment to gearbox 79 Nm 1 Secure with Loctite 243 EATON GEARBOX PTO Attachment Z81 Drive flange attachment bolt 100 5 Nm Install attachment studs with a liquid gasket 28...

Page 48: ...0 2 NL 1C 0 2 NH 4B 0 5 NL 4B 0 5 NH 4C 0 5 NL 4C 0 5 N221 10B 1 0 N221 10C 1 0 N221 10 IT 1 0 N221 10 C IT 1 0 N221 10 B PL 1 0 N221 10 C PL 1 0 N AS 10 B 1 0 N AS 10 B IT 1 0 N AS 10 C 1 0 N AS 10...

Page 49: ...stated on the identity card of the relevant vehicle ZF gearbox type plate 1 Type of gearbox 2 Series no ZF 3 Parts list ZF 4 Specification no 5 Pulse generator ratio 6 Gearbox ratio 7 Engine speed usi...

Page 50: ...re to be replaced it is important that they are of exactly the same length and property class as the ones removed unless stated otherwise Gearbox to engine M8 attachment bolts 10 9 30 Nm M10 attachmen...

Page 51: ...3 3 Plugs AS Tronic Drain plug B C 60 Nm Level check filler plug A 60 Nm B A C G000243 AS Tronic with intarder Drain plug B C 60 Nm Level check filler plug A 60 Nm A B C G000250 Oil filter attachment...

Page 52: ...nge litres First filling e g during repair litres ZF 12 AS 1930 TD 11 11 ZF 12 AS 2330 TO 11 11 ZF 12 AS 2540 TD 12 12 Filling amounts ZF gearboxes with integrated intarder Gearbox type Filling amount...

Page 53: ...Fault finding table 3 1 200337 4 MECHANICAL GEARBOX 4 1 200337 4 1 Fault finding table 4 1 200337 5 AUTOMATIC GEARBOX 5 1 200337 5 1 Reading deleting fault codes 5 1 200337 5 2 Table of fault codes 5...

Page 54: ...3 DIAGNOSTICS Contents CF65 75 85 series 2 1 200337 https www truck manuals net...

Page 55: ...Mechanical problem in gearbox See Mechanical gearbox fault finding table Clutch does not release properly Check clutch operating unit SYMPTOM GEARS CANNOT BE ENGAGED Possible cause Remedy Gearbox cont...

Page 56: ...3 DIAGNOSTICS Mechanical gearbox control CF65 75 85 series 1 2 1 200337 https www truck manuals net...

Page 57: ...rative Inspect air pipes Servoshift unit leaking air internally Check air seals in unit Mechanical problem See Mechanical gearbox control and Mechanical gearbox fault finding tables SYMPTOM GEARBOX JU...

Page 58: ...3 DIAGNOSTICS Pneumatically assisted gearbox control Servoshift CF65 75 85 series 2 2 200337 1 https www truck manuals net...

Page 59: ...Incorrectly programmed VIC Report the incorrect or altered configuration SYMPTOM HIGH OR LOW RANGE ENGAGING IS SLOW Possible cause Remedy Air pressure too low Check air supply of circuit 4 Pipes block...

Page 60: ...tch type Wrong bore hole plugged in splitter cylinder Plug correct bore hole Splitter cylinder not working Check cylinder and replace if necessary SYMPTOM SPLITTER CYLINDER OPERATES IN REVERSE MODE Po...

Page 61: ...l from CTE Leaking or blocked air pipes Replace the air pipes No air from neutral position valve in neutral position Check neutral position valve and replace if necessary Defective low range switch E5...

Page 62: ...3 DIAGNOSTICS Pneumatic section of gearbox CF65 75 85 series 3 4 1 200337 https www truck manuals net...

Page 63: ...ning element fitted too deep Check repair retaining elements Problem in mechanical gearbox control See Mechanical gearbox control fault finding table Range change gear does not work properly See Pneum...

Page 64: ...R STUCK IN GATE 3 4 Possible cause Remedy Oil leak in gate protection piston Replace O ring SYMPTOM SINGLE H BECOMES DOUBLE H Possible cause Remedy Locking plate in control cover not positioned correc...

Page 65: ...tive fault in the gearbox No message during reading means that the fault is inactive The ECU can save five active inactive fault codes in its memory and show them on the display Fault codes consist of...

Page 66: ...ault need their causes tracing and remedying as quickly as possible After the fault codes have been deleted the ignition must be switched off and re started otherwise it will not be possible to drive...

Page 67: ...uptions or short circuits between wires or earth in wiring harness to accelerator pedal sensor Replace the accelerator pedal sensor if necessary If all points are in order contact your Allison dealer...

Page 68: ...Check whether the correct dip stick has been installed 4 Check the oil level 5 If necessary correct the oil level 6 If the oil level is in order check whether the engine system has overheated causing...

Page 69: ...irmly attached is clean and undamaged b ECU connector is connected is firmly attached is clean and undamaged c No interruptions or short circuits between wires or earth in wiring harness If all points...

Page 70: ...o interruptions or short circuits between wires or earth in wiring harness Replace wiring harness if necessary If all points are in order contact your Allison dealer Short circuit in the electromagnet...

Page 71: ...are connected The connectors are undamaged and clean b No interruptions or short circuits between wires or earth in sensor wiring c Let the engine idle in neutral while the vehicle is on the brake Che...

Page 72: ...rt circuits between wires or earth in sensor wiring c Let the engine idle in neutral while the vehicle is on the brake Check the following points 1 Specified dip stick 2 Oil level d Check that there i...

Page 73: ...2 Oil level d Check that there is no interruption or short circuit between the wiring or earth connection in the coupling 3 pressure switch wiring e Check the following points 1 Main connector is prop...

Page 74: ...3 DIAGNOSTICS Automatic gearbox CF65 75 85 series 5 10 1 200337 https www truck manuals net...

Page 75: ...rectly fitted Fit the release bearing correctly Fork hinge points or fork itself worn Check hinge points and fork replace if necessary Defective clutch servo Repair and or replace clutch servo Gearbox...

Page 76: ...iston seal in clutch servo Repair or replace clutch servo Note A drop of oil in the vent opening is a normal situation and is not a reason to repair replace the clutch servo SYMPTOM CLUTCH PLATE SLIPS...

Page 77: ...ngers of clutch release assembly broken Replace clutch release assembly Wrong clutch release assembly has been fitted Fit correct clutch release assembly Clutch fork is broken Replace fork Clutch rele...

Page 78: ...3 DIAGNOSTICS Clutch CF65 75 85 series 6 4 1 200337 https www truck manuals net...

Page 79: ...d by e g excessive caster Check universal joint angle Play in universal joints Replace universal joint Play in centre bearing Replace centre bearing Play in sliding joint Replace prop shaft Forks not...

Page 80: ...3 DIAGNOSTICS Prop shafts CF65 75 85 series 7 2 1 200337 https www truck manuals net...

Page 81: ...el too low Check oil level Intarder is not filled with the specified oil Change the oil Pump pressure too low Check system Control pressure too low Check system Intarder pressure too low Check system...

Page 82: ...IL LEAK Possible cause Remedy Oil level too high Check oil level Oil leak between gearbox housing and intarder Replace gasket Oil leak in pump Replace O ring Oil leak in proportional valve Replace O r...

Page 83: ...disrupted Check the following air connections Non return valve at output 26 of the air supply unit Pressure relief valve on transverse support in front of left front wheel Both connections and valve o...

Page 84: ...arbox input shaft clutch valves in clutch unit mechanically locked in open or closed position Check whether clutch is released during self test Remove inspection cover from clutch and check whether cl...

Page 85: ...tion and adjustment of gearbox control LHD RHD 2 1 0111 3 REMOVAL AND INSTALLATION 3 1 0111 3 1 Removal and installation entire gear lever unit 3 1 0111 3 2 Removal and installation gear lever gaiter...

Page 86: ...3 MECHANICAL GEARBOX CONTROL Contents CF65 75 85 series 2 2 0111 https www truck manuals net...

Page 87: ...er is moved backwards the control rod moves forwards When the gear lever is moved left the control rod moves right When the gear lever is moved right the control rod moves left Operating mechanism RHD...

Page 88: ...OVERVIEW DRAWING GEAR LEVER UNIT 1 Switch 2 Gaiter 3 Gear lever 4 Retaining plate 5 Inner gaiter 6 Attachment tape 7 Pressure spring 8 Circlip 9 Gear lever ball 10 Bearing housing 11 Spacer sleeve 4 2...

Page 89: ...75 85 series General MECHANICAL GEARBOX CONTROL 1 3 1 3 OVERVIEW DRAWING GEAR LEVER 1 Switch 2 Gear lever 3 Bearing housing 4 Gear lever ball 5 Circlip V300394 5 2 3 4 1 0111 2 https www truck manual...

Page 90: ...3 MECHANICAL GEARBOX CONTROL General CF65 75 85 series 1 4 2 0111 https www truck manuals net...

Page 91: ...GEARBOX CONTROL LHD RHD Inspection gearbox control LHD RHD 1 Push the control against the spring pressure to check whether it can move freely in neutral The control should spring back independently in...

Page 92: ...shaft and fit the attachment bolt tightening it to the specified torque See Technical data Note The torque rod 1 of the gearbox control is equipped with fixed non adjustable ball joints If the torque...

Page 93: ...s Removal entire gear lever unit 1 Make sure there are no loose items in the cab Tilt the cab 2 After marking them remove the air pipes that run from the switch to the various valves 3 Remove the clam...

Page 94: ...tening torque See Technical data Note When fitting the set of air pipes make sure that these are away from any moving parts 2 Fit the air pipes that run from the switch to the various valves 3 Fit the...

Page 95: ...hem remove the air pipes that run from the switch to the various valves 3 Slide the gaiter over the threaded bush and then loosen it from the connection piece between the gear lever and the selector v...

Page 96: ...ng the gaiter lips away from the locking plate 7 Then remove the Seeger ring that has become visible from the bearing cover It is now possible to remove the entire gear lever from the bearing cover 8...

Page 97: ...se must be pulled through the slots in the locking plate 5 Feed the air pipes through the gear lever and fit the switch with the valve to the gear lever Tighten the threaded bush and slide the gaiter...

Page 98: ...t 2 Loosen the gaiter from the locking plate by lifting the gaiter and pulling the gaiter lips away from the locking plate 3 Then remove the Seeger ring that has become visible from the bearing cover...

Page 99: ...e the dust cover from the locking plate Installation gear lever unit inner dust cover 1 Fit the inner dust cover Note When fitting the inner dust cover ensure that it is fitted properly to the locking...

Page 100: ...the bearing cover and fit the snap ring 4 Secure the gaiter by means of the lips These must be pulled through the slots in the locking plate 5 Fit the selector rod 6 Connect the air pipes Ensure that...

Page 101: ...gear lever and the selector valve 4 Remove the gear lever control rod and secure it so that no damage can be caused to the air pipes 5 Remove the switch with the selector valve and air pipes from the...

Page 102: ...hat the pipe is not pushed out Turn the gear lever once or twice to achieve a good bond 4 Place the gear lever and ball to one side in a vertical position and leave the assembly to harden for 10 minut...

Page 103: ...king them remove the air pipes that run from the switch to the various valves 3 Remove the lock nut 4 from the torque rod ball joint and remove the torque rod from the control rod 4 Remove the castle...

Page 104: ...d and tighten the ball joint lock nut 4 to the specified tightening torque 4 Check that the gearbox is in neutral 5 Position the gear lever exactly in position A See Technical data 6 Fit the control r...

Page 105: ...no account be used again Removing the control rod ball joint 1 Remove the control rod See Removal and installation 2 Using evenly distributed force remove the ball joint from the control rod Installin...

Page 106: ...3 MECHANICAL GEARBOX CONTROL Removal and installation CF65 75 85 series 3 14 2 0111 https www truck manuals net...

Page 107: ...escription pneumatically assisted gearbox control Servoshift 1 1 200337 2 DESCRIPTION OF COMPONENTS 2 1 200337 2 1 Servoshift unit operation 2 1 200337 2 2 Function of the emergency selector 2 7 20033...

Page 108: ...3 PNEUMATICALLY ASSISTED GEARBOX CONTROL SERVOSHIFT Contents CF65 75 85 series 2 3 200337 https www truck manuals net...

Page 109: ...he selector mechanism refer to Mechanical gearbox control The Servoshift unit is an important feature of the pneumatically assisted gearbox control The Servoshift unit can be ventilated in two ways 1...

Page 110: ...eft or to the right Engaging gears To engage the gears move the gear lever forwards or backwards Switching begins mechanically with the operation of the selector valve in the Servoshift unit This valv...

Page 111: ...rating piston 3 Venting valve 4 Selector valve for operating piston 1st 3rd 5th 7th gear 5 Valve seat 1st 3rd 5th 7th gear 6 Valve 1st 3rd 5th 7th gear 7 Valve 2st 4rd 6th 8th gear 8 Valve seat 2nd 4t...

Page 112: ...T Description of components CF65 75 85 series 2 2 SERVOSHIFT SELECTOR SHAFT HOUSING Situation with separate air distribution block V300345 27 29 28 26 23 24 25 42 40 35 39 33 34 37 41 43 36 47 46 38 4...

Page 113: ...et 26 Sealing plug 27 Sealing plug 28 Locking plate 29 Locking plate 30 Circlip 31 Attachment pin 32 Circlip 33 Needle bush 34 Pin 35 Pin 36 Needle bush 37 Selector valve lever 38 Pin 39 Hollow shaft...

Page 114: ...now selected When the gears are activated and the gear lever is no longer operated the selector valve is pressed back into the neutral position by the spring and the piston is bled on both sides V3003...

Page 115: ...bled when this happens When the cylinder reaches the end position it switches off the air supply Supply pressure will only be applied to the cylinder if the gear lever is in operation When the gear le...

Page 116: ...3 7 N 3 2 1 1 V300332 When the cylinder is in the 2nd 6th or 4th 8th position and the gear lever is again released the selector valve will again spring back to the middle position while the cylinder...

Page 117: ...ould fail In such case a small amount of play between the selector shaft 3 and the attachment pin 4 will have to be bypassed before the selector finger 1 is operated The hollow shaft 2 will be operate...

Page 118: ...3 PNEUMATICALLY ASSISTED GEARBOX CONTROL SERVOSHIFT Description of components CF65 75 85 series 2 8 3 200337 https www truck manuals net...

Page 119: ...anjo bolt is removed 2 Remove the banjo bolt from the air pipe 1 and plug the connection on the unit so that no dirt can enter Note While removing the Servoshift unit from the selector shaft housing a...

Page 120: ...unit using a new gasket 2 Tighten the attachment bolts 2 to the specified torque See Technical data 3 Fit the banjo bolt for the air pipe 1 with new sealing rings and tighten to the specified torque...

Page 121: ...2 3 Downshift protection valve 2 7 200337 2 4 High low range engaging cylinder 2 9 200337 2 5 Gear lever selector valve 2 10 200337 2 6 GV valve 2 12 200337 2 7 Splitter relay valve 2 13 200337 2 8 F...

Page 122: ...3 GEARBOX PNEUMATIC SECTION Contents CF65 75 85 series 2 4 200337 https www truck manuals net...

Page 123: ...PONENTS OF THE DOWNSHIFT PROTECTION FOR ZF EATON GEARBOXES ZF gearboxes ZF 8 9 16S 109 1 Neutral position valve At the side of the selector shaft housing on the gearbox V300140 2 Range change gear eng...

Page 124: ...of the gearbox Version CF75 production date 2003 21 1 Electropneumatic downshift protection valve 2 Pneumatic downshift protection valve V300879 2 1 Version CF75 production date 2003 21 V 300029 4 VIC...

Page 125: ...e gear lever B A D000096 ZF gearboxes ZF 8 16S 151 181 221 1 Neutral position valve At the side of the selector shaft housing on the gearbox With separate air distribution block V300140 With integrate...

Page 126: ...the gearbox V300141 3 Downshift protection valve At the left hand side of the gearbox Version CF75 85 production date 2003 21 1 Electropneumatic downshift protection valve 2 Pneumatic downshift prote...

Page 127: ...unit In the central box on the co driver s side 1 V300418 1 5 Gear lever range change switch Rocker switch B at the front of the gear lever B A D000096 Eaton FS 6309A gearbox 1 Neutral position valve...

Page 128: ...e gearbox 4 Range change gear engaging cylinder 4 At the side of the gearbox V300452 2 3 4 5 Reversing switch 6 At the side of the gearbox 6 Neutral switch 7 At the side of the gearbox 7 Speed sensor...

Page 129: ...x high range to the low range when the vehicle speed is too high Shifting down from the high to the low range when the vehicle speed is too high could cause serious damage to the clutch plate gearbox...

Page 130: ...range change switch 5 on the gear lever is shifted to the low range preference the GP air pressure valve will switch through to connection point 21 This air pressure is now applied to connection point...

Page 131: ...is now no longer possible to switch an air pressure to connection point 26 of the engaging cylinder 2 and hence to shift to the low range Note The air supply to the electropneumatic valve 6 is only a...

Page 132: ...the gear lever is shifted to the low range preference the GP air pressure valve will switch through to connection point 21 This air pressure is now applied to connection point 4 of the electropneumati...

Page 133: ...5 it is now no longer possible to switch an air pressure to connection point 26 of the engaging cylinder 2 and hence to shift to the low range Note The air supply to the electropneumatic valve 3 is o...

Page 134: ...OF GATE PROTECTION COMPONENTS 1 Neutral position valve At the side of the selector shaft housing on the gearbox V300140 2 Gate protection valve At the left hand or right hand side of the gearbox depe...

Page 135: ...tribution block at the rear of the selector shaft housing V300002 With integrated air distribution block at right angles to the selector shaft housing V300861 4 VIC electronic unit The electronic unit...

Page 136: ...3 GEARBOX PNEUMATIC SECTION General CF65 75 85 series 1 14 5 Low range switch Located at the rear of the gearbox V300005 4 200337 https www truck manuals net...

Page 137: ...block The gate protection only operates in the low range The low range is registered by the low range switch 2 It prevents shifting from third or fourth gear gate 3 4 to first or second gear gate 1 2...

Page 138: ...ronic gate protection valve 1 As a result gate 1 2 can no longer be engaged In the case of a gearbox with a separate air distribution block the locking cylinder is mounted at the back of the selector...

Page 139: ...17 1 5 PNEUMATIC DIAGRAM GEARBOX CONTROL Pneumatic diagram of 16 S Direct Drive Version CF75 85 production date 2003 21 N V 1 21 22 1 22 21 GV GP H L H L H L 4 1 21 22 V300420 1 5 4 3 6 26 H L 25 2 1...

Page 140: ...TIC SECTION General CF65 75 85 series 1 18 Version CF75 85 production date 2003 21 N V 1 21 22 1 22 21 GV GP H L H L 1 2 H L 4 1 21 22 26 H L 25 V300712 1 5 4 3 7 6 2 L H 1 41 H L 4 200337 https www t...

Page 141: ...PNEUMATIC SECTION 1 19 Pneumatic diagram of 16 S Overdrive Version CF75 85 production date 2003 21 N V 1 21 22 1 22 21 GV GP H L H L H L 4 1 21 22 V300421 1 5 4 3 6 26 H L 25 2 1 2 8 7 L H 1 41 H L 4...

Page 142: ...TIC SECTION General CF65 75 85 series 1 20 Version CF75 85 production date 2003 21 N V 1 21 22 1 22 21 GV GP H L H L L H 1 41 H L 1 2 H L 4 1 21 22 V300713 1 5 4 3 7 6 26 H L 25 2 4 200337 https www t...

Page 143: ...relay valve will be connected to the air supply via connection 2 of the GV valve 7 The splitter cylinder 8 is switched to the low L position If the GV switch 5 is then returned to the high H position...

Page 144: ...shift protection valve 3 If the GP switch 5 is moved to the low L position the range change gear engaging cylinder 2 is ventilated via connection 26 causing the range change gear engaging cylinder to...

Page 145: ...be bled via connection point 22 of the gear lever 5 As a result of the disappearance of the air pressure at connection 41 the splitter relay valve will move to the high H position When the clutch is...

Page 146: ...eed is lower than a certain value the electronic unit 4 will supply voltage to the downshift protection valve 3 This causes the electropneumatic valve to move to a different position The air supply of...

Page 147: ...General GEARBOX PNEUMATIC SECTION 1 25 Pneumatic diagram of 8 9 S Direct Drive Version CF75 production date 2003 21 N V 1 21 22 H L 4 1 21 22 V300491 1 4 3 5 26 H L 25 2 6 H L GP A 4 200337 https www...

Page 148: ...3 GEARBOX PNEUMATIC SECTION General CF65 75 85 series 1 26 Version CF75 production date 2003 21 N V 1 21 22 H L 4 1 21 22 V300880 1 4 3 26 H L 25 2 6 H L GP A 4 200337 https www truck manuals net...

Page 149: ...3 CF65 75 85 series General GEARBOX PNEUMATIC SECTION 1 27 Pneumatic diagram Eaton FS 6309A N V 1 1 21 GP H L H L 4 1 21 22 V300454 1 7 5 4 3 6 2 4 200337 https www truck manuals net...

Page 150: ...3 GEARBOX PNEUMATIC SECTION General CF65 75 85 series 1 28 4 200337 https www truck manuals net...

Page 151: ...lock at the side of the gearbox With an integrated air distribution block on the selector housing The integrated air distribution block has a single central connection for the air supply 10 from which...

Page 152: ...866 2 10 1 4 3 6 7 A 8 9 5 B Bottom view of integrated air distribution block Schematic representation of integrated air distribution block Connection points on integrated air distribution block 1 Con...

Page 153: ...V300868 1 3 4 6 8 5 7 9 10 2 1 Neutral position valve 2 Neutral position valve attachment pin 3 Air distribution block 4 Neutral switch 5 Neutral position valve attachment pin 6 Locking cylinder 7 Lo...

Page 154: ...Situation with separate air distribution block V300140 Pneumatic symbol Connection point Function 1 Supply 21 Cut in pressure range change switch 22 Plugged Position Function N Gearbox selector shaft...

Page 155: ...connection 21 and subsequently operate the range cylinder through the electropneumatic valve W 3 02 098 21 1 3 22 A B C Gearbox engaged When a gear has been engaged the selector shaft will push the th...

Page 156: ...ion with integrated air distribution block V300862 Pneumatic symbol Connection point Function 1 Supply 21 Cut in pressure range change switch Position Function N Gearbox selector shaft in neutral V Ge...

Page 157: ...2 7 2 3 DOWNSHIFT PROTECTION VALVE Version CF75 85 production date 2003 21 V300428 Pneumatic symbol Connection point Function 1 Supply 4 Control pressure 21 High range cut in pressure 22 Low range cut...

Page 158: ...vehicle speed exceeds a particular value the coil of the electropneumatic valve is interrupted Regardless of any pneumatic command from the gear lever range change switch to the connection point 4 it...

Page 159: ...ge gear high 26 Range change gear low Operation The engaging cylinder controlling the high low section of the gearbox receives its supply via the electropneumatic protection valve This protection valv...

Page 160: ...ents CF65 75 85 series 2 10 2 5 GEAR LEVER SELECTOR VALVE Splitter range switch A Range change gear B B A D000096 Pneumatic symbol Position Function GP Range change gear GV Splitter 1 22 21 GV GP H L...

Page 161: ...passes neutral Operation of the splitter switch Engaging half gears or splitting is done with the switch A on the side of the gear lever Tip the lower end of the switch for low split selection and th...

Page 162: ...ation of GV valve The GV Getriebevorschalt pre selector valve ensures that when the clutch pedal is depressed pressure is supplied to the splitter cylinder via the relay valve If the clutch pedal is n...

Page 163: ...e gearbox The valve is a 5 2 valve Depending on the type of gearbox direct input or overdrive two variants are possible V300169 Pneumatic symbol V300162 overdrive gearbox V300163 direct input gearbox...

Page 164: ...governor 1 on gearbox 2 3 4 1 5 V300558 Overview drawing filter governor Eaton FS 6309A 1 Filter governor housing 2 Filter element 3 Sealing ring 4 O ring 5 Cover 6 Plug 7 Output 8 Selector valve out...

Page 165: ...tor To connect DELSI to the speed sensor connector an adapter cable needs to be made The adapter cable must consist of the following wiring Pin 1 speed sensor power supply Pin 2 speed sensor earth Pin...

Page 166: ...vehicle ignition on 4 Use the range change switch B on the gear lever to select the lower range The range change gear should now switch to the lower range 5 Switch off the vehicle ignition The range...

Page 167: ...now switch to the lower range B A D000096 6 Use Delsi 2 to raise the simulated vehicle speed slowly to approximately 40 km h As the vehicle speed increases the range change gear should automatically...

Page 168: ...ch pedal until the gear can be engaged in regular fashion without rattling Note After the gear has been engaged or the rattling has stopped the splitter must switch to the pre selected mode high or lo...

Page 169: ...F and or Eaton gearbox GV valve 1 Note In order to perform the various adjustments to the clutch pedal the grille must first be opened Remove the stop 1 from the clutch housing 1 V300317 2 Fit an Alle...

Page 170: ...ed into the opening of the stop the adjusting screw 3 can be turned to correct the travel C See Technical data 4 Fit the stop V300316 3 5 Adjust the travel D by means of the adjusting screw 1 See Tech...

Page 171: ...3 7 3 4 INSPECTION FILTER GOVERNOR EATON FS 6309A Inspection filter governor Eaton FS 6309A 1 Remove plug 8 from the extra outlet and install a pressure gauge 2 Check the service pressure See Technica...

Page 172: ...3 GEARBOX PNEUMATIC SECTION Inspection and adjustment CF65 75 85 series 3 8 4 200337 https www truck manuals net...

Page 173: ...r the gear lever as high as possible 2 Loosen the union nut 1 on the selector valve 3 Raise the selector valve 5 slightly from the gear lever 3 far enough to enable the air pipes 4 to be disconnected...

Page 174: ...For the connection points in the selector valve see Technical data 2 Slide the coloured rings back over the connection points 3 Check whether the pneumatic system has an airtight connection and whethe...

Page 175: ...ater and a soap solution Then blow clean the filter with compressed air from the inside 1 Take the pressure off the air pressure system 2 Remove the plug 5 3 Remove and wash the filter 2 4 Clean the f...

Page 176: ...3 GEARBOX PNEUMATIC SECTION Cleaning CF65 75 85 series 5 2 200337 4 https www truck manuals net...

Page 177: ...earance 3 2 0111 3 3 Inspection and adjustment secondary shaft axial play 3 3 0111 4 REMOVAL AND INSTALLATION GEARBOX 4 1 0111 4 1 Removal and installation entire gearbox 4 1 0111 4 2 Removal and inst...

Page 178: ...3 ZF 6S 850 GEARBOX Contents CF65 75 85 series 2 5 0111 https www truck manuals net...

Page 179: ...ned ZF gearbox type plate 1 Type of gearbox 2 Serial no ZF 3 Parts list ZF 4 Specification no 5 Pulse generator ratio 6 Gearbox ratio 7 Engine speed using PTO 8 PTO speed 9 Gearbox oil capacity 10 Oil...

Page 180: ...3 ZF 6S 850 GEARBOX General CF65 75 85 series 1 2 0111 5 https www truck manuals net...

Page 181: ...thrust pieces 6 into a wedge shaped recess in the synchroniser sleeve 7 The gear wheels 1 and corresponding clutch bodies 2 move freely around the main shaft 8 If the synchroniser sleeve 7 is shifted...

Page 182: ...relevant gear is engaged A Not engaged B Synchronise C Engaged Double cone synchronisation As a result of the speed difference to be eliminated in the lower gears the synchronisation forces may be con...

Page 183: ...ined oil ZF 6S 850 gearbox 1 Position the vehicle on a level surface 2 Wait for some minutes for the oil to flow back 3 Remove the level check plug and check the oil level 4 The oil level must reach t...

Page 184: ...ance A 5 Install a new gasket in the gearbox housing Use a depth gauge to determine the height the ball bearing protrudes above the gearbox housing distance B 6 Calculate the play as follows See the t...

Page 185: ...so that the bearing gets set 2 Use a depth gauge to determine the distance between the outer bearing race and the gearbox housing A 3 Compare the measured value with the specified permissible value S...

Page 186: ...3 ZF 6S 850 GEARBOX Inspection and adjustment CF65 75 85 series 3 4 0111 5 https www truck manuals net...

Page 187: ...ing the torque rod bracket and the lever on the selector shaft 6 Remove the prop shaft and secure it so that it does not form a hindrance in further operations 7 Remove the exhaust pipe between the en...

Page 188: ...chment bolts around the gearbox 4 Install the clutch servo and tighten the attachment bolts 5 Fit the exhaust pipe between the engine brake and the silencer 6 Fit the drive flange 7 Fit the shift cont...

Page 189: ...nge in position 4 Remove the attachment bolt and washer 5 Remove the drive flange from the shaft using special tool DAF No 0484978 Installing the drive flange 1 Heat the drive flange to a temperature...

Page 190: ...oil seal 1 Around the oil seal clean the gearbox housing without letting dirt into the gearbox 2 Voorzie keerringen met een staalmantel aan de buitenzijde spaarzaam van vloeibare pakking Voorzie keerr...

Page 191: ...over Installing the gearbox front cover oil seal 1 Apply small amount of sealant to the oil seals fitted with a steel sleeve on the outside Apply a rubber coating to the oil seals exterior and apply g...

Page 192: ...ector shaft housing attachment bolts and remove the complete selector shaft housing from the gearbox Seal the gearbox opening so that no dirt can enter 3 Remove the locking pin and control stop from t...

Page 193: ...Apply grease to the oil seal lips 2 Fit special tool DAF No 0694817 a guide sleeve over the selector shaft and fit the selector fingers and the gear lever lock into the selector housing Fit the selec...

Page 194: ...DAF No 0694818 Press the bearing bush on the spring side 2 mm under the edge Installing the selector shaft oil seal 1 Sparingly apply a liquid gasket to the oil seal and fit it in the bearing housing...

Page 195: ...l surface 2 Drain the gearbox at operating temperature using plug B Filling gearbox 1 Clean the drain plug and fit it tightening to the specified torque See Technical data 2 Top up oil through the lev...

Page 196: ...3 ZF 6S 850 GEARBOX Draining and filling CF65 75 85 series 5 2 0111 5 https www truck manuals net...

Page 197: ...axial clearance 3 4 0111 3 4 Inspection and adjustment selector shaft housing on gearbox 3 5 0111 4 REMOVAL AND INSTALLATION GEARBOX 4 1 0111 4 1 Removal and installation entire gearbox 4 1 0111 4 2...

Page 198: ...3 ZF 8 9 16S 109 GEARBOX Contents CF65 75 85 series 2 6 0111 https www truck manuals net...

Page 199: ...x This data can also be found on the identity card for the vehicle concerned ZF gearbox type plate 1 Type of gearbox 2 Serial no ZF 3 Parts list ZF 4 Specification no 5 Pulse generator ratio 6 Gearbox...

Page 200: ...ward gears and one reverse gear C Auxiliary gearbox or range gearbox two gears 1 Input shaft 2 Lubricating oil pump 3 Main shaft 4 Selector shafts with shifting forks 5 Planetary gears for range group...

Page 201: ...xiliary gear This is a gearbox mounted onto the rear of the main gearbox consisting of one planetary gear wheel set Using this set of gears all gears of the main gearbox can be used once with the auxi...

Page 202: ...is used giving 4 x 2 8 or with the crawler gear as well 9 forward gears The diagram shows the power distribution across the individual gear pairs for each gear Direct input shaft version of the ZF 16S...

Page 203: ...thrust pieces 6 into a wedge shaped recess in the synchroniser sleeve 7 The gear wheels 1 and corresponding clutch bodies 2 move freely around the main shaft 8 If the synchroniser sleeve 7 is shifted...

Page 204: ...e main shaft 8 The bevelled sides of the teeth on the synchromesh ring 3 and the synchroniser sleeve 7 cause the synchromesh ring 3 to be turned back slightly after synchronisation This releases the l...

Page 205: ...ronisation a synchroniser with a double cone is used This synchroniser consists of an outer and an inner ring synchromesh rings connected to the main shaft of the gearbox by means of the selector slee...

Page 206: ...3 ZF 8 9 16S 109 GEARBOX Component description CF65 75 85 series 2 4 6 0111 https www truck manuals net...

Page 207: ...rim of the level check filler opening A 5 After checking the oil level tighten the level check plug to the specified torque See Technical data ZF 8S 9S 109 with integrated retarder 1 Place the vehicl...

Page 208: ...e cover off the input shaft 3 Use a depth gauge to determine the depth of the recess in the gearbox front cover Make a note of this measurement 4 Install a new gasket in the gearbox housing Using a de...

Page 209: ...by means of another adjusting ring 7 Install a new gasket and the adjusting ring into the gearbox front cover and fit it to the gearbox 8 Install the attachment bolts and tighten them to the specifie...

Page 210: ...cover 3 Use a depth gauge to determine the depth of the bearing cover recess distance A 4 Use a depth gauge to determine the height the ball bearing protrudes above the gearbox housing distance B 5 Ca...

Page 211: ...hift the selector housing forwards or backwards as such that this transfer is identical in both gears direction A A 3 Then repeat point 2 for the 7th and 8th gears 4 If 1st or 2nd gear cannot be engag...

Page 212: ...3 ZF 8 9 16S 109 GEARBOX Inspection and adjustment CF65 75 85 series 3 6 6 0111 https www truck manuals net...

Page 213: ...sconnect the tachometer connection from the gearbox 6 Disconnect the gearbox wiring harness connector 7 Remove the various air pipes Pipes that are not recognisable must be marked 8 Disconnect the sel...

Page 214: ...Fit the selector rod and torque rod 4 Fit the air pipes 5 Fit the gearbox connectors and the tachometer connection 6 Fit the clutch servo 7 Fit the prop shaft flange to the gearbox Tighten the attach...

Page 215: ...ing the drive flange 1 Lightly oil the oil seal in the bearing cover 2 Heat the drive flange to 70_C Slide the flange as far as possible onto the output shaft With the locking plate and two standard b...

Page 216: ...he washer 1 and the drive flange See Technical data 6 Install the locking plate with the bolts and tighten them to the specified torque See Technical data Note Bolts that will be re used must be clean...

Page 217: ...c driver Installing the output shaft oil seal 1 Fit the oil seal in the bearing cover using special tool DAF Nos 1240491 and 1240483 Apply small amount of liquid gasket to the oil seals fitted with a...

Page 218: ...gearbox front cover Installing the gearbox front cover oil seal 1 Pull the oil seal into the gearbox front cover using the special tool DAF No 0535423 Apply small amount of liquid gasket to the oil s...

Page 219: ...aper 5 Drive the oil seal out and inspect the bearing bush Installing the selector shaft oil seal 1 Sparingly apply a liquid gasket to the oil seal and fit it in the bearing housing using special tool...

Page 220: ...3 ZF 8 9 16S 109 GEARBOX Removal and installation gearbox CF65 75 85 series 4 8 0111 6 https www truck manuals net...

Page 221: ...ce 2 Drain the gearbox at operating temperature 3 Remove the level check filler plug A and drain plugs B and drain the oil Filling gearbox 1 Clean the drain plugs B and tighten them to the specified t...

Page 222: ...Clean the drain plugs and tighten them to the specified tightening torque See Technical data 2 Top up oil through level check filler opening A until the oil reaches the rim of the filler opening A 3 F...

Page 223: ...ft bearing axial play 3 4 200337 3 4 Inspection and adjustment selector shaft housing on gearbox 3 5 200337 4 REMOVAL AND INSTALLATION OF GEARBOX 4 1 200337 4 1 Removal and installation gearbox assemb...

Page 224: ...3 ZF 8 16S 151 181 AND 16S 221 GEARBOXES Contents CF65 75 85 series 2 7 200337 https www truck manuals net...

Page 225: ...of gearbox This data is also stated on the identity card of the relevant vehicle ZF gearbox type plate 1 Type of gearbox 2 Series no ZF 3 Parts list ZF 4 Specification no 5 Pulse generator ratio 6 Ge...

Page 226: ...rd gears and one reverse gear C Rear mounted range box or range group two gears 1 Input shaft 2 Lubricating oil pump 3 Main shaft 4 Selector shafts with shifting forks 5 Planetary gears for range grou...

Page 227: ...x This is a range box mounted against the rear of the main box consisting of a planetary gear wheel set Using this set of gears all gears of the main box can be used once with the rear mounted range b...

Page 228: ...rear mounted range box creating 4x2 8 or if the crawler gear is counted 9 forward gears The diagram shows the power distribution across the individual gear pairs for each gear Direct input shaft vers...

Page 229: ...5 push the thrust pieces 6 into a wedge shaped recess in the selector sleeve 7 The gear wheels 1 and corresponding selector rings 2 move freely around the main shaft 8 If the selector sleeve 7 is shif...

Page 230: ...ed of the main shaft 8 The bevelled sides of the teeth on the synchromesh ring 3 and the selector sleeve 7 cause the synchromesh ring 3 to be turned back slightly after synchronisation This releases t...

Page 231: ...e synchronisation a synchroniser with a double cone is used This synchroniser consists of an outer and an inner ring synchromesh rings connected to the main shaft of the gearbox by means of the select...

Page 232: ...3 ZF 8 16S 151 181 AND 16S 221 GEARBOXES Description of components CF65 75 85 series 2 4 7 200337 https www truck manuals net...

Page 233: ...l ZF 8S 16S 151 181 and 16S 221 gearboxes 1 Position the vehicle on a level surface 2 Wait for some minutes to allow the oil to flow back Note The oil level must reach the rim of the level check fille...

Page 234: ...rface Apply the brakes without activating the retarder 2 Wait for some minutes to allow the oil to flow back Note The oil level must reach the rim of the level check filler opening A 3 Remove the leve...

Page 235: ...he recess in the gearbox front cover distance B B V300240 3 Install a new gasket in the gearbox housing Use a depth gauge to determine the height the ball bearing protrudes above the gearbox housing d...

Page 236: ...e to determine the depth of the bearing cover recess distance A A V300227 3 Use a depth gauge to determine the height the ball bearing protrudes above the gearbox housing distance B 4 Calculate the ax...

Page 237: ...ing slightly 2 Shift the selector housing forwards or backwards until this transfer is identical in both gears direction A A 3 Now repeat point 2 for 7th and 8th gears 4 If 1st or 2nd gear cannot be e...

Page 238: ...3 ZF 8 16S 151 181 AND 16S 221 GEARBOXES Inspection and adjustment CF65 75 85 series 3 6 7 200337 https www truck manuals net...

Page 239: ...ipes from the central air distribution block at the side of the gearbox or in the case of an integrated air distribution block on the selector shaft housing the central air supply at the side of the i...

Page 240: ...r can no longer be moved by hand 5 Install the clutch servo and tighten the attachment bolts 6 If the exhaust pipe was removed reinstall it 7 Connect the connectors of the gearbox wiring harness 8 Fit...

Page 241: ...and the engine 5 Disconnect the electrical connectors and remove the air pipes from the retarder 6 Remove the gearbox assembly with retarder Installing the gearbox with integrated retarder 1 Fit the...

Page 242: ...p shaft flange to the shaft The same distance must be observed when the prop shaft flange is reinstalled Remove the prop shaft flange and O ring using a commercially available puller Fitting prop shaf...

Page 243: ...e prop shaft flange is removed during overhaul the bolts must always be locked afterwards with a locking plate 6 Note Bolts that will be re used must be cleaned and lightly oiled Tighten the attachmen...

Page 244: ...seal and turn the special tool DAF No 0484899 into the oil seal Then pull the oil seal out of the bearing cover using the special tool DAF No 0694928 Installing the output shaft oil seal 1 Apply a sma...

Page 245: ...ove the old gasket from the gearbox front cover and or from the gearbox housing V300441 Installing the gearbox front cover oil seal 1 Apply a thin layer of liquid gasket to the outer circumference of...

Page 246: ...Remove the locking bolt and if necessary the circlip from the selector shaft and remove the selector shaft lever together with the dust cover 3 Loosen the bolts of the oil seal cover and remove the c...

Page 247: ...35659 4 Apply a thin layer of grease to the inside of both oil seals 5 Install a new gasket and carefully slide the cover over the selector shaft and hand tighten the bolts Move the selector shaft fro...

Page 248: ...move the eight bolts that are used to attach the selector housing to the gearbox Remove the selector housing with the Servoshift unit from the gearbox V300409 3 4 2 1 5 Drill two holes into the seal a...

Page 249: ...ket on the gearbox and tighten the attachment bolts to the specified torque See Technical data 4 Fit the dust cap and the selector shaft lever on the selector shaft Ensure that the dust cap is placed...

Page 250: ...3 ZF 8 16S 151 181 AND 16S 221 GEARBOXES Removal and installation of gearbox CF65 75 85 series 4 12 7 200337 https www truck manuals net...

Page 251: ...el surface 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...

Page 252: ...ter M3051 A Filling the gearbox 1 Clean the drain plugs and tighten them to the specified torque See Technical data 2 Top up oil through level check filler opening A until the oil reaches the rim of t...

Page 253: ...ance 2 2 0111 3 REMOVAL AND INSTALLATION GEARBOX 3 1 0111 3 1 Removal and installation entire gearbox 3 1 0111 3 2 Removal and installation drive flange 3 3 0111 3 3 Removal and installation output sh...

Page 254: ...3 EATON FS 6309A GEARBOX Contents CF65 75 85 series 2 8 0111 https www truck manuals net...

Page 255: ...STEM DESCRIPTION The gearbox consists of a main gearbox with four synchronised forward gears a non synchronised crawler gear and one non synchronised reverse gear Between the main gearbox and the outp...

Page 256: ...3 EATON FS 6309A GEARBOX General CF65 75 85 series 1 2 0111 8 https www truck manuals net...

Page 257: ...drained oil 1 Position the vehicle on a level surface 2 Wait for some minutes for the oil to flow back 3 Remove the level check filler plug 1 and check the oil level 4 The oil level must reach the rim...

Page 258: ...ary adjust the axial play by means of a thicker or thinner adjusting ring 2 Adjustment input shaft bearing axial play 1 Remove the circlip 1 of the input shaft bearing 2 Remove the adjusting ring 2 3...

Page 259: ...Remove the clamping straps of the intermediate pipe and remove the same 6 Remove the end of the exhaust by removing the clamping strap and the attachment bolt of the rubber suspension point at the en...

Page 260: ...Fit the exhaust end pipe 7 Install the compressor pipe bracket 8 Install the electrical connectors to the gearbox 9 Fit the clutch cylinder and tighten the attachment bolts to the specified torque Se...

Page 261: ...he lock nut and ring 6 Remove the flange with a suitable puller Note In order to prevent the synchroniser for the high low transmission ratios from coming loose the output shaft must not slide out of...

Page 262: ...il seal 3 Clean the contact surfaces of the oil seal and the seal housing Installing the output shaft oil seal 1 Press the oil seal into its housing with special tool DAF No 1329358 2 Apply sealant to...

Page 263: ...of the gearbox front cover and the gearbox housing 4 Remove the oil seal from the gearbox front cover Installing the gearbox front cover oil seal 1 Fit the oil seal in the gearbox front cover using s...

Page 264: ...ove the nut 4 of the ball joint of the control rod on the selector shaft lever and the nut 5 of the torque rod Hang the control rod on the chassis 2 Remove the selector shaft lever locking bolt Then r...

Page 265: ...8 Remove the bleeder 20 9 Remove the end cover 14 and remove the circlip 13 10 Remove the spring holders 11 the springs 12 and the circlip 10 11 Turn the selector shaft housing over and drive the plu...

Page 266: ...11 13 7 V3 00 475 1 Fit a new oil seal ring and if necessary new bushes 4 and 9 using special tool DAF No 1329352 2 Place the selector finger 18 in the selector shaft housing 15 with the long groove...

Page 267: ...the retaining pin 7 and put a new gasket in the retaining cover 5 before fitting that as well Tighten the attachment bolts to the specified torque See Technical data 9 Fit the rubber sleeve 2 10 Insta...

Page 268: ...3 EATON FS 6309A GEARBOX Removal and installation gearbox CF65 75 85 series 3 10 0111 8 https www truck manuals net...

Page 269: ...heck filler plug 1 and drain the oil 3 Clean the oil strainer 4 in a suitable solvent and dry the oil strainer thoroughly Filling gearbox 1 Check and replace the O ring 3 and the sealing ring 2 if nec...

Page 270: ...3 EATON FS 6309A GEARBOX Draining and filling CF65 75 85 series 4 2 0111 8 https www truck manuals net...

Page 271: ...200337 3 INSPECTION AND ADJUSTMENT 3 1 200337 3 1 Inspection oil level 3 1 200337 4 REMOVAL AND INSTALLATION 4 1 200337 4 1 Removal and installation gearbox assembly 4 1 200337 4 2 Removal and install...

Page 272: ...3 AUTOMATIC GEARBOXES Contents CF65 75 85 series 2 9 200337 https www truck manuals net...

Page 273: ...r date The system is operated and the faults are read via the selector keypad The selector is equipped with a display and is located immediately next to the driver s seat The selector replaces the gea...

Page 274: ...the vehicle to a safe place as soon as possible and switch the ignition off It will no longer be possible to shift the gearbox to neutral The ECU will prevent this After approximately 30 seconds try...

Page 275: ...p has not gone out the engine must be turned off and the nearest DAF dealer contacted Use of the engine brake When the engine brake is operated in third or higher gear the ECU will change down to seco...

Page 276: ...3 AUTOMATIC GEARBOXES General CF65 75 85 series 1 4 9 200337 https www truck manuals net...

Page 277: ...No gears are activated in the N position The vehicle is not locked in this position and can thus roll Use the parking brake to lock the vehicle N appears on the display Automatic drive If the D posit...

Page 278: ...n unpaved terrain Economy program The LED lights up on the selector display This program will in general change gear at somewhat lower engine speeds This results in more economical fuel consumption Ch...

Page 279: ...Gearbox oil temperature too high OL 89 Output shaft is not stationary handbrake OL 95 Oil level indicator is defective The oil level reading function can be left by pressing D N or R Note the functio...

Page 280: ...3 AUTOMATIC GEARBOXES Description of components CF65 75 85 series 2 4 9 200337 https www truck manuals net...

Page 281: ...vice brake 5 Remove the dipstick when the engine is idling and wipe it clean with a lint free cloth Note To take the dipstick out of the holder the sealing cap must be held tightly and the dipstick tu...

Page 282: ...se 3 Put the dipstick back 4 Remove the dipstick and check the oil level 5 The oil level must be between the Hot add and the Hot full marks 6 Clean the dipstick with a lint free cloth and put it back...

Page 283: ...both arrow keys on the selector keypad simultaneously The display now indicates O and L Note O and L stand for Oil Level 4 If the oil level is correct O K will appear in the display When the oil level...

Page 284: ...3 AUTOMATIC GEARBOXES Inspection and adjustment CF65 75 85 series 3 4 9 200337 https www truck manuals net...

Page 285: ...ess Plug the openings 5 Remove the prop shaft 6 See what is best for gearboxes with PTO remove the PTO from the gearbox disconnect the hydraulic pipes from the pump or remove the prop shaft if fitted...

Page 286: ...d secure it so that it does not interfere with further operations W 3 03 061 2 Unscrew the attachment bolt 5 of the flange without removing it from the locking plate V300529 1 2 3 5 4 3 Remove the bol...

Page 287: ...l the oil seal from the gearbox housing using the special tool DAF No 0694928 Installing the output shaft oil seal 1 Apply a small amount of liquid gasket to the outside of oil seals fitted with a ste...

Page 288: ...ts are no longer locked with a locking plate but with self locking screw thread in the output shaft 5 Hold the prop shaft flange in place with the special tool DAF No 0484977 6 Tighten the attachment...

Page 289: ...ing the oil filters 1 Lightly lubricate the new O rings with clean gearbox oil and fit the various O rings on the filter covers Note Compare the new O rings with the old O rings to ensure that the cor...

Page 290: ...3 AUTOMATIC GEARBOXES Removal and installation CF65 75 85 series 4 6 9 200337 https www truck manuals net...

Page 291: ...more quickly and more completely 2 Place the vehicle on a level surface 3 Remove the drain plug 1 from the gearbox oil sump 4 Remove the oil filters 2 See Removal and installation Filling the gearbox...

Page 292: ...the Cold full mark Note To take the dipstick out of the holder the sealing cap must be held tightly and the dipstick turned anti clockwise 5 Use the selector keypad to check the oil level See Inspecti...

Page 293: ...utch wear indicator 3 12 200337 3 8 Thrust bearing 3 13 200337 4 INSPECTION AND ADJUSTMENT 4 1 200337 4 1 Inspection and adjustment clutch pedal 4 1 200337 4 2 Inspection clutch servo 4 3 200337 4 3 I...

Page 294: ...3 CLUTCH Contents CF65 75 85 series 2 10 200337 https www truck manuals net...

Page 295: ...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 spe...

Page 296: ...3 CLUTCH Safety instructions CF65 75 85 series 1 2 10 200337 https www truck manuals net...

Page 297: ...t be transferred by the clutch is determined by the maximum engine torque multiplied by the safety factor usually 1 3 To clamp the clutch plate a diaphragm spring is used in the clutch release assembl...

Page 298: ...3 CLUTCH General CF65 75 85 series 2 2 Push type clutch V 3 000 52 Fig 1 10 200337 https www truck manuals net...

Page 299: ...3 CF65 75 85 series General CLUTCH 2 3 Pull type clutch V300114 Fig 2 10 200337 https www truck manuals net...

Page 300: ...vibrations to be damped determines the version of the vibration damper design in the hub For the clutch plate to engage smoothly it is necessary that the lining material abuts the flywheel and clutch...

Page 301: ...coustic signal will sound when accelerating At the same time the accelerator pedal signal will be ignored so that acceleration is not possible To be able to drive away a lower gear than the 3rd must b...

Page 302: ...General CF65 75 85 series 2 6 2 3 OVERVIEW DRAWING MAIN CYLINDER 1 Thrust pin with eye 2 Thrust pin adjustment 3 Thrust pin 4 Piston 5 Valve 6 Spring V300410 3 4 5 6 2 1 10 200337 https www truck man...

Page 303: ...75 85 CLUTCH SERVO A A 8 3 2 7 1 6 10 5 11 4 9 V300412 Cross section A A 1 Servo piston 2 Air valve 3 Spring 4 Pressure pin 5 Air piston 6 Fluid piston 7 Pressure spring 8 Bleed bore 9 Bleed 10 Vent o...

Page 304: ...rod 6 Split seal 7 Piston 8 Piston seal 9 Conical spring 10 Circlip 11 Washer 12 Seal hydraulic part front 13 Seal hydraulic part rear 14 Split bearing 15 Booster housing 16 Bleed nipple 17 Vent open...

Page 305: ...1 Bleed screw 2 Electronic unit 3 Cable connection to modulator 4 Bleed 5 Compressed air connection 6 Position sensor 7 Fast clutching pneumatic valve 8 Fast declutching pneumatic valve 9 Slow declut...

Page 306: ...ch V300487 4 8 3 2 7 5 10 6 1 9 10 The automatically adjusting clutch release assembly comprises the following parts 1 Thrust plate 2 Stop plate 3 Stop plate attachment bolt 4 Clutch release assembly...

Page 307: ...ring 2 Lever assembly 3 Bracket 4 Bearing bush 5 Circlip 6 Shim 7 Lever bearing bush 8 Lever 9 Shaft V300439 3 9 5 4 3 1 8 2 6 4 6 7 AS Tronic 1 Bearing 2 Lever assembly 3 Attachment bolt 4 Bearing bu...

Page 308: ...CH General CF65 75 85 series 2 12 2 9 OVERVIEW DRAWING CLUTCH LEVER ATTACHMENT TO CLUTCH HOUSING V300440 2 3 4 1 1 Thrust bearing 2 Lever 3 Ball joint 4 Clutch housing 10 200337 https www truck manual...

Page 309: ...Any shortage of fluid underneath the piston 4 is refilled via a bore hole in the piston 6 and the valve 5 It is important that after depressing the clutch pedal the piston 4 returns fully to the orig...

Page 310: ...1 4 9 V300412 Cross section A A Declutching Depressing the clutch pedal results in a build up of hydraulic pressure This causes the servo piston 1 to push the air valve 2 from the valve seat against t...

Page 311: ...us when the clutch pedal is not depressed any further The servo piston 1 again seals off against the valve seat closing the air supply and stopping the build up of pneumatic pressure Clutching When th...

Page 312: ...onents CF65 75 85 series 3 4 3 3 CF65 CLUTCH SERVO 3 2 7 1 10 8 9 A A 4 5 6 A V300352 A Cross section A A Declutching Depressing the clutch pedal results in a build up of hydraulic pressure 10 200337...

Page 313: ...quilibrium is achieved between the air pressure and hydraulic pressure status when the clutch pedal is not depressed any further The servo piston 1 again seals off against the valve seat closing the a...

Page 314: ...8 2 With AS Tronic gearboxes the clutch is operated fully automatically by the electropneumatic clutch unit 1 which in its turn is controlled by the electronics inside the gearbox modulator 5 The wiri...

Page 315: ...g valve Y17 for slow declutching Valve Y15 has the clutch engage slowly valve Y14 has it engage quickly The moment of engaging and the position and stroke of the operating piston are processed by the...

Page 316: ...material is bonded to the clutch plate A conventional clutch has a lining wear clearance of 3 mm as the lining material is riveted to the clutch plate The increase in lining wear clearance extends th...

Page 317: ...pressure of the diaphragm spring 7 6 1 2 3 A C 11 12 4 V300484 8 5 Compensation of rest position of diaphragm spring The adjustment takes place as follows as the clutch plate 12 wears the thrust plate...

Page 318: ...nsures that the diaphragm spring always returns to the same rest position V300486 5 E 10 10 Compensation occurs during the first 4 mm of clutch plate wear This is determined by the maximum adjustment...

Page 319: ...sembly comprises the following parts V300487 4 8 3 2 7 5 10 6 1 9 10 1 Thrust plate 2 Stop plate 3 Stop plate attachment bolt 4 Clutch release assembly cover 5 Stop spring 6 Adjusting ring 7 Slide pla...

Page 320: ...shows wear of 80 Among other things the position of the air piston 5 and consequently the pin 11 changes The circlip 12 on the pin 11 will no longer lie against the housing of the clutch servo The mo...

Page 321: ...coating can be recognised by the aluminium lining on the inner diameter V300288 The thrust bearing with plastic coating can be recognised by the spline shaped inner diameter When fitting the thrust b...

Page 322: ...3 CLUTCH Description of components CF65 75 85 series 3 14 10 200337 https www truck manuals net...

Page 323: ...ravel D of the clutch pedal see Technical data 2 Check the free travel B of the clutch pedal see Technical data The free travel B can be clearly felt by manually depressing the clutch pedal in from it...

Page 324: ...h pedal is set indirectly by loosening the lock nut 2 and then screwing the ball joint 1 into or out of the thrust pin 3 This sets the distance E between the thrust pin 3 and the piston 4 in the main...

Page 325: ...he 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 mineral oil Even one drop of min...

Page 326: ...d or replaced If in doubt as to whether the clutch servo situation is normal or whether there is a leak inspect the fluid level in the clutch reservoir 6 Depress the clutch pedal and check whether the...

Page 327: ...ept in a sealed container that 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...

Page 328: ...3 CLUTCH Inspection and adjustment CF65 75 85 series 4 6 10 200337 https www truck manuals net...

Page 329: ...c fluid which has been kept in a sealed container that meets the specifications Hydraulic fluid which has absorbed water from the ambient air may have an adverse effect on the operation of the clutch...

Page 330: ...pay attention to the following Make sure that the thrust pin fits into the cup shaped recess in the wear indicator 2 Tighten the attachment nuts evenly 3 After mounting clutch servos equipped with a...

Page 331: ...chment nuts 3 from the clutch unit 5 and remove the complete clutch unit including the wiring harness 5 Remove the thrust pin from the clutch lever Installing the clutch unit 1 Fit the thrust pin in t...

Page 332: ...on the gearbox front cover The grease will attack the plastic coating and shorten the service life of the thrust bearing The thrust bearing chamber has been greased for the full service life 1 Apply...

Page 333: ...etaining clip 3 have been fitted in the correct locations The diaphragm springs 4 have special recesses to accommodate the retaining clips 3 V300122 2 4 4 1 3 3 5 Fit the gearbox 6 Move the clutch lev...

Page 334: ...th a plastic coating no grease should be used on the gearbox front cover The grease will attack the plastic coating and shorten the service life of the thrust bearing 1 Apply a little grease to the pr...

Page 335: ...e gearbox 2 Remove the thrust bearing 3 Remove the attachment bolts from the clutch lever Installing the pull type clutch lever 1 Apply a little grease to the moving parts of the clutch lever 2 Instal...

Page 336: ...box 2 Remove the thrust bearing 3 Force the clutch lever 2 out of the ball joint 3 fitted in the clutch housing 4 Installing the push type clutch lever 1 Apply a little grease to the moving parts of t...

Page 337: ...shaft through the hub of the clutch plate in the flywheel pilot bearing V300124 4 Remove four attachment bolts distributed around the circumference from the clutch release assembly and replace them wi...

Page 338: ...ion the clutch plate against the flywheel 3 Install four studs in the flywheel distributed evenly around the circumference 4 Support the clutch release assembly and slide it onto the four studs 5 Fit...

Page 339: ...ing clutch release assembly clutch plate 1 Remove the gearbox 2 If necessary remove the thrust bearing 3 Insert a dummy input shaft through the hub of the clutch plate in the flywheel pilot bearing V3...

Page 340: ...nly remove the remaining attachment bolts from the clutch release assembly 7 Remove the clutch release assembly by sliding it off the four studs 8 Remove the clutch plate with the dummy input shaft In...

Page 341: ...e automatically adjusting assembly cannot be reset manually 4 Fit the clutch release assembly with the stop plate 2 loosened onto the flywheel 5 Fit the attachment bolts and tighten them crosswise and...

Page 342: ...ittle grease to the input shaft and check the movement of the clutch plate on the splines of the input shaft 2 Use a dummy input shaft to position the clutch plate against the flywheel 3 Install four...

Page 343: ...from the flywheel W 3 04 016 1 2 Fitting the pilot bearing 1 Check the flywheel bore for dirt and damage 2 Note The pilot bearing 1 has a grease and dust seal 2 on one side only When the pilot bearing...

Page 344: ...om the ambient air may have an adverse effect on the operation of the clutch system Avoid any contact with mineral oil Even one drop of mineral oil in the system will damage the seals Removing the mai...

Page 345: ...lts to the bracket and tighten them 5 Fit the dust cover in the thrust pin circlip 6 Fit the clutch pedal attachment bolt and the main cylinder 7 Fit the clutch spring onto the clutch pedal 8 Fit the...

Page 346: ...3 CLUTCH Removal and installation CF65 75 85 series 5 18 10 200337 https www truck manuals net...

Page 347: ...n kept in a sealed container that 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 cont...

Page 348: ...mbient air may have an adverse effect on the operation of the clutch system Avoid any contact with mineral oil Even one drop of mineral oil in the system will damage the seals Bleeding the clutch syst...

Page 349: ...eding the clutch system via the clutch servo 1 Note Sometimes it may be difficult to bleed the clutch system In such cases the clutch system can also be bled using a priming pump and the bleed nipple...

Page 350: ...unit must be bled before it is installed to prevent it from being installed under tension 1 Undo the bleed screw 2 of the clutch unit 1 2 Push the control rod 3 inwards and tighten the bleed screw whi...

Page 351: ...2 1 Inspection prop shaft 2 1 0111 3 REMOVAL AND INSTALLATION 3 1 0111 3 1 Removal and installation prop shaft auxiliary shaft assembly 3 1 0111 4 DISASSEMBLY AND ASSEMBLY 4 1 0111 4 1 Disassembly an...

Page 352: ...3 PROP SHAFTS Contents CF65 75 85 series 2 11 0111 https www truck manuals net...

Page 353: ...B D A F G G A Intermediate shaft B Centre bearing C Drive flange D Fork E Slide joint F Prop shaft G Balancing plates For the CF65 75 85 vehicle series DAF has one manufacturer of prop shafts Klein Kl...

Page 354: ...3 PROP SHAFTS General CF65 75 85 series 1 2 1 2 OVERVIEW DRAWING CENTRE BEARING 1 Sealing ring 2 Rubber block 3 Bearing 4 Dust cover 5 Flange W 3 06 023 1 2 3 1 4 5 0111 11 https www truck manuals net...

Page 355: ...JUSTMENT 2 1 INSPECTION PROP SHAFT 1 Check the universal joints and centre bearing for play and damage 2 Check the slide coupling for radial play 3 There must be no clearly noticeable play on universa...

Page 356: ...e prop shaft 5 Place the removed prop shaft on a flat working bench and support the shaft at positions A and B 6 Push the slide coupling around 45 mm outwards 7 Position the universal measuring tool o...

Page 357: ...s horizontally to avoid damage and subsequent imbalance Support the shaft in at least two places If possible hang the shaft in a hoist using two sturdy ropes Remove the attachment bolts from the flang...

Page 358: ...3 PROP SHAFTS Removal and installation CF65 75 85 series 3 2 0111 11 https www truck manuals net...

Page 359: ...he entire prop shaft and or intermediate shaft 2 If fitted remove the lubricating nipple and all Seeger rings from the spider to be replaced 3 Place the shaft on a bush underneath a press as shown and...

Page 360: ...om the shaft fork 7 Place the drive flange on a bush underneath a press and press the entire spider including bearings and drive flange down until the spider touches the fork of the drive flange 8 Rot...

Page 361: ...2 Press one bearing partly into the drive flange 3 Tilt the spider in the drive flange Note Maintenance free spiders do not have an assembly direction In the case of spiders fitted with lubricating ni...

Page 362: ...rop shaft 8 Slide the spider a little into the installed bearing and place everything onto a bush underneath a press The opposite bearing can now be pressed into the fork the spider serving as a guide...

Page 363: ...aft and the auxiliary shaft Also secure the prop shaft carefully to the chassis 3 Attach the special tool DAF no 0484977 to apply counter pressure against the flange and remove the central nut and the...

Page 364: ...85 series 4 6 6 Use a plastic hammer to tap the flange and the centre bearing from the auxiliary shaft If necessary use a puller 7 Remove the lock plate from the mounting bracket W 3 06 028 W 3 06 027...

Page 365: ...bracket 9 Press the flange from underneath and press the bearing out 10 Press the bearing with one sealing ring 1 out of the rubber block 11 If necessary remove the second sealing ring 1 Note In case...

Page 366: ...ing ring into the bush of the rubber block until it aligns with the outside of the bush 2 Press the bearing along the other side into the bush Then the other sealing ring can be pressed into the bush...

Page 367: ...e that the centre points are aligned to ensure that later all forks are in one line 6 Attach the centre bearing to the chassis by means of bolts but do not tighten the bolts 7 Tighten the central nut...

Page 368: ...3 PROP SHAFTS Disassembly and assembly CF65 75 85 series 4 10 11 0111 https www truck manuals net...

Page 369: ...avy conditions are fitted as standard with lubricating nipples in the prop shaft spiders The following applies to these vehicles Before lubricating clean the lubricating nipple with a cloth 2 Note The...

Page 370: ...3 PROP SHAFTS Lubrication CF65 75 85 series 5 2 11 0111 https www truck manuals net...

Page 371: ...Removal and installation intarder assembly 4 1 200337 4 2 Removal and installation air supply solenoid valve 4 3 200337 4 3 Removal and installation accumulator 4 4 200337 4 4 Removal and installation...

Page 372: ...3 ZF INTARDER Contents CF65 75 85 series 2 200337 12 https www truck manuals net...

Page 373: ...cause serious injuries Avoid unnecessary contact with drained oil Frequent contact damages the skin Various kinds of oil and other lubricants used on the vehicle may constitute a health hazard This al...

Page 374: ...3 ZF INTARDER Safety instructions CF65 75 85 series 1 2 200337 12 https www truck manuals net...

Page 375: ...0 7 A C V300074 1 Locking plate 2 Bolt 3 Plate 4 O ring 5 Prop shaft flange 6 Oil seal 7 Flange bolt 8 Output shaft shim 9 Drive sprocket 10 Stator shim 11 Gasket 12 Intarder housing A Intarder housin...

Page 376: ...ING HYDRAULIC CONTROL UNIT V300075 5 8 7 6 5 4 2 3 1 9 10 5 1 Attachment bolt 2 Attachment plate 3 Gasket 4 Attachment bolt 5 Plungers and springs 6 Drain plug 7 Control unit housing 8 Gasket 9 Propor...

Page 377: ...tional valve control plunger 2 Selector valve spring sealing plug 3 Accumulator 4 Heat exchanger 5 Oil pump gear wheels 6 Stator and rotor 7 Air supply solenoid valve 8 Proportional valve 9 Attachment...

Page 378: ...3 ZF INTARDER General CF65 75 85 series 2 4 12 200337 https www truck manuals net...

Page 379: ...D V300070 1 Measure and note down distance A B from sealing surface A with gasket to contact surface B 2 Measure and note down distance D from the ball bearing outer race to the gasket on the gearbox...

Page 380: ...ADJUSTMENT STATOR AXIAL PLAY A C A B D V300070 1 Measure and note down distance A C from sealing surface A with gasket to contact surface C Example Distance A C 1 10 mm Distance A C should be 0 0 05...

Page 381: ...L Inspection gearbox intarder oil level 1 Slow the vehicle down without using the intarder and place the vehicle on a level surface 2 Wait for some minutes for the gearbox oil to flow back 3 The oil l...

Page 382: ...3 ZF INTARDER Inspection and adjustment CF65 75 85 series 3 4 12 200337 https www truck manuals net...

Page 383: ...as necessary and collect in clean containers 4 Disconnect the water hoses from both sides of the heat exchanger 5 Remove the air pipe from the intarder solenoid valve 6 Remove all electrical wiring fr...

Page 384: ...olt end faces prop shaft 5 Install the output prop shaft flange without heating it 6 Install the O ring and the disk 7 Install the attachment bolts and tighten them to the specified torque See Technic...

Page 385: ...e electric wiring from the solenoid valve 3 Remove the attachment bolts from the solenoid valve and remove the solenoid valve 4 Remove the O ring Installation air supply solenoid valve 1 Fit a new O r...

Page 386: ...enoid valve 5 Remove the attachment bolt from the water pipe bracket and the attachment bolts on top of the accumulator bracket 6 Take out the bolts attaching the accumulator to the heat exchanger and...

Page 387: ...he solenoid valve 4 Remove all electrical wiring from the intarder 5 Remove the attachment nuts from the studs attaching the heat exchanger to the hydraulic control unit 6 Remove an attachment bolt fr...

Page 388: ...he control unit and tighten the attachment nuts to the specified torque See Technical data 5 Install the heat exchanger oil connection flange attachment bolt which is attached to the rear cover of the...

Page 389: ...and control unit Collect the oil and water Take measures to prevent the heat exchanger from falling down Removing the hydraulic control unit 1 Remove the heat exchanger 2 Remove the electrical wiring...

Page 390: ...t bench Installing the hydraulic control unit 1 Fix the gasket 8 in the gearbox with as many long studs as possible The studs also serve as guide pins to facilitate mounting of the control unit 2 Line...

Page 391: ...echnical data Check the pump housing for the presence of slots If necessary replace the entire oil pump Installing the oil pump 1 Fit a new O ring in the slot on the control unit 2 Install the outer r...

Page 392: ...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 the filter cover 2 Do not clean the filter The filter m...

Page 393: ...cessary 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 housing 3 Use a plastic mallet to...

Page 394: ...Remove the attachment bolts and remove the proportional valve 3 Remove the O ring Installing the proportional valve 1 Fit a new O ring on the proportional valve and lightly grease the O ring 2 Install...

Page 395: ...der drive 1 Remove the intarder 2 Remove the air connections from the high low shift control to the cylinder 2 3 Remove the attachment bolts 1 of the cylinder 2 and remove the cylinder 4 Remove the lo...

Page 396: ...sprocket and install the drive sprocket onto the intarder See Technical data 2 Install the gasket on the gearbox housing 3 Install the rear cover over the guide pins Pay attention to the shifting fork...

Page 397: ...Install the piston 9 on the selector shaft and tighten the lock nut 6 to the specified torque See Technical data 7 Install the cylinder 2 and tighten the attachment bolts to the specified torque See...

Page 398: ...3 ZF INTARDER Removal and installation CF65 75 85 series 4 16 200337 12 https www truck manuals net...

Page 399: ...r to the accumulator bracket and remove the bracket 2 Remove the O rings on the bottom of the sealing surfaces of the accumulator heat exchanger 3 Remove the O rings from the accumulator cylinder 4 Re...

Page 400: ...piston 3 Install the sleeve without the steel inner spring at the air side of the piston 4 Thoroughly cover the piston and cylinder with grease and install the piston in the cylinder 5 Fit the two O r...

Page 401: ...nd installation Filling gearbox oil change ZF 8 9 16S 109 1 Clean the drain plugs and tighten them to the specified torque See Technical data 2 Fill the oil through the level check filler opening 4 un...

Page 402: ...rim of the level check filler opening 4 3 After filling take a short test drive The intarder must be briefly fully activated at the beginning of the test drive 4 After the test drive check the oil lev...

Page 403: ...gearbox at operating temperature using plugs B C and D 4 Replace the oil filter See Removal and installation B C V300186 D ZF AS Tronic 1 Before draining take a short test drive Do not activate the i...

Page 404: ...the level check filler opening A 5 Tighten the level check filler plug to the specified torque See Technical data M3051 A ZF AS Tronic 1 Clean the drain plugs and tighten them to the specified torque...

Page 405: ...the rim of the level check filler opening A 5 Tighten the level check filler plug A to the specified torque See Technical data M3051 A ZF AS Tronic 1 Place the vehicle on a level surface 2 Top up oil...

Page 406: ...3 ZF INTARDER Draining and filling CF65 75 85 series 6 6 12 200337 https www truck manuals net...

Page 407: ...7 2 12 Overview drawing N221 10 PTO on gearbox without intarder 2 16 200337 2 13 Overview drawing N221 10 PTO on gearbox with intarder 2 16 200337 2 14 Overview drawing N AS 10 PTO 2 17 200337 2 15 Ov...

Page 408: ...ox with intarder 4 9 200337 4 9 Removal and installation NL 1 PTO on N221 10 PTO 4 10 200337 4 10 Removal and installation N AS 10 PTO 4 11 200337 4 11 Removal and installation PTO intermediate shaft...

Page 409: ...lect this oil Never park a vehicle with the PTO engaged In the case of air leakage the pressure in the air system may drop causing the PTO to switch off During the gradual build up of pressure in the...

Page 410: ...3 PTO Safety instructions CF65 75 85 series 1 2 200337 13 https www truck manuals net...

Page 411: ...3 CF65 75 85 series General PTO 2 1 2 GENERAL 2 1 DAF ENGINE PTO DRIVE SIDE CROSS SECTION V300295 13 200337 https www truck manuals net...

Page 412: ...3 PTO General CF65 75 85 series 2 2 2 2 DAF ENGINE PTO ENGINE SIDE CROSS SECTION V300296 13 200337 https www truck manuals net...

Page 413: ...3 CF65 75 85 series General PTO 2 3 2 3 OVERVIEW DRAWINGS DAF ENGINE PTO WITHOUT DRIVE FLANGE AND CONTROL V300297 13 200337 https www truck manuals net...

Page 414: ...3 PTO General CF65 75 85 series 2 4 2 4 OVERVIEW DRAWINGS DAF ENGINE PTO WITH DRIVE FLANGE AND WITHOUT CONTROL V300299 13 200337 https www truck manuals net...

Page 415: ...3 CF65 75 85 series General PTO 2 5 2 5 OVERVIEW DRAWINGS DAF ENGINE PTO WITH DRIVE FLANGE AND CONTROL V300298 13 200337 https www truck manuals net...

Page 416: ...3 PTO General CF65 75 85 series 2 6 2 6 OVERVIEW DRAWINGS DAF ENGINE PTO WITH THIRD GEAR WHEEL FOR OPPOSITE DRIVE FLANGE DIRECTION OF ROTATION V300300 13 200337 https www truck manuals net...

Page 417: ...3 CF65 75 85 series General PTO 2 7 2 7 OVERVIEW DRAWINGS PTO VERSIONS NL 1 AND NH 1 VERSIONS V300621 NL 4 AND NH 4 VERSIONS V300622 13 200337 https www truck manuals net...

Page 418: ...3 PTO General CF65 75 85 series 2 8 N221 10 VERSION FOR GEARBOX WITHOUT INTARDER V300213 13 200337 https www truck manuals net...

Page 419: ...3 CF65 75 85 series General PTO 2 9 N221 10 VERSION FOR GEARBOX WITH INTARDER V300214 13 200337 https www truck manuals net...

Page 420: ...3 PTO General CF65 75 85 series 2 10 N AS 10 VERSION V300876 13 200337 https www truck manuals net...

Page 421: ...3 CF65 75 85 series General PTO 2 11 Z81 VERSION FOR EATON GEARBOX V300624 2266 VERSION FOR EATON GEARBOX V300623 13 200337 https www truck manuals net...

Page 422: ...1 PTO B VERSION V300872 2 1 4 6 5 3 1 Studs 2 Gasket 3 NH 1 needle bearing width 16 mm NL 1 needle bearing width 12 mm 4 PTO housing 5 Lock washer and nut 6 PTO control switch depending on version thi...

Page 423: ...00873 2 4 1 5 6 7 8 9 10 3 1 11 1 Studs 2 Gasket 3 PTO housing 4 Gasket 5 Synchroniser sleeve 6 Spring 7 Piston 8 Centring ring 9 PTO housing cover 10 Lock washer and nut 11 PTO control switch dependi...

Page 424: ...N V300874 4 2 1 1 3 7 5 5 6 1 Studs 2 Gasket 3 NH 4 needle bearing width 16 mm NL 4 needle bearing width 12 mm 4 PTO housing 5 Lock washer and nut 6 Lock washer and nut 7 PTO control switch depending...

Page 425: ...11 1 Studs 2 Gasket 3 NH 4 needle bearing width 16 mm NL 4 needle bearing width 12 mm 4 PTO housing 5 Lock washer and nut 6 Gear 7 Gasket 8 Transport cover 9 Lock washer and nut 10 Lock washer and nu...

Page 426: ...ort attachment bolts 7 O ring 8 Centring ring 9 Gasket 10 Adjusting ring 1 10 9 2 3 4 5 7 8 6 V300221 2 13 OVERVIEW DRAWING N221 10 PTO ON GEARBOX WITH INTARDER 1 Side cover attachment bolts 2 Side co...

Page 427: ...attachment bolts 7 O ring 8 O ring 9 Centring ring 10 Gasket V300877 1 7 2 3 4 5 8 6 9 10 2 15 OVERVIEW DRAWING PTO INTERMEDIATE SHAFT FOR GEARBOX WITHOUT INTARDER 1 Auxiliary shaft 2 Taper roller bea...

Page 428: ...RAWING PTO INTERMEDIATE SHAFT FOR GEARBOX WITH INTARDER 1 Intermediate shaft 2 Ball bearing 3 Circlip 4 O ring 5 Intermediate housing 6 Long attachment bolt 7 Short attachment bolt 8 Gasket 6 7 8 2 4...

Page 429: ...4 5 3 V300629 7 8 2 10 11 12 13 9 6 1 Stud 2 Gasket 3 Adapter plate lubrication 4 PTO housing 5 Air connection 6 Synchroniser sleeve 7 Sleeve spring 8 Piston 9 Spacer ring 10 PTO housing cover 11 Lock...

Page 430: ...ERSION 1 2 2 4 3 5 7 8 11 12 9 10 6 2 V300630 1 Stud 2 Gasket 3 Adapter plate lubrication 4 PTO housing 5 Air connection 6 Synchroniser sleeve 7 Sleeve spring 8 Piston 9 Spacer ring 10 Shim 11 Transpo...

Page 431: ...13 14 18 15 16 17 9 1 PTO cover 2 Gasket 3 Drive sprocket 4 Spacer ring 5 Piston 6 Spring 7 Shim 8 PTO housing 9 Gasket 10 PTO cover 11 Lock washer and nut 12 Output shaft 13 Drive flange 14 Locking...

Page 432: ...10 6 5 4 3 2 1 7 8 13 16 14 15 11 1 PTO cover 2 Gasket 3 Drive sprocket 4 Spacer ring 5 Piston 6 Spring 7 Shim 8 PTO housing 9 Bolt 10 Output shaft 11 Gasket 12 Transport cover 13 Lock washer and nut...

Page 433: ...from the engine speed control application connector Depending on the programmed switching conditions the VIC applies voltage to the electropneumatic valve 1 Upon activation of the electropneumatic val...

Page 434: ...3 PTO General CF65 75 85 series 2 24 13 200337 https www truck manuals net...

Page 435: ...2 onto the engine PTO driving tool 1 special tool DAF No 1329341 V300633 1 2 3 4 5 6 7 3 Fit the driving tool with the flat sides firmly secured in a vice 4 Slide the PTO housing properly over the dr...

Page 436: ...6 7 8 Place the dial gauge holder onto the PTO housing and allow the stylus of the dial gauge to rest on the driving tool 9 Check the bearing play by moving the PTO housing up and down relative to the...

Page 437: ...sprockets 1 Press both outer bearing races 4 into the drive sprocket 1 V300637 1 4 2 On one side of the drive sprocket mount the inner bearing race 3 Place the drive sprocket on the inner race on a dr...

Page 438: ...her driving tool on the inner race and tighten it to a pressure of 1 5 tons V300305 6 Place a dial gauge on the drive sprocket and inspect the axial play See Technical data If the axial play is too gr...

Page 439: ...ousing Use a depth gauge to determine the depth of the bearing cover recess distance A A V300227 3 Use a depth gauge to determine the height the ball bearing protrudes above the gearbox housing distan...

Page 440: ...AY OF NL 1 PTO ON N221 10 PTO 1 Remove the cover 1 and shim 2 of the N221 10 PTO V300639 1 2 2 Use a depth gauge to measure the depth down to the outer bearing race distance A A V300230 3 Install a ne...

Page 441: ...centring edge to the gasket distance B Calculate the axial play The axial play equals distance A distance B 5 Compare the calculated value with the maximum allowable axial play See Technical data 6 I...

Page 442: ...3 PTO Inspection and adjustment CF65 75 85 series 3 8 13 200337 https www truck manuals net...

Page 443: ...g 5 Remove the entire PTO from the flywheel housing 6 Remove the PTO centring ring dowel pins from the flywheel housing Installing entire DAF engine PTO on flywheel housing 1 Fit the PTO centring ring...

Page 444: ...e the bolts attaching the flywheel housing to the engine block 9 Remove the flywheel housing 10 Remove the two drive sprockets from the flywheel housing Be aware of the mounting position of the sprock...

Page 445: ...e the drive flange which is mounted against the PTO flange 4 Remove the attachment nuts connecting the PTO to the gearbox and remove the PTO including needle bearing and gasket 5 If necessary remove t...

Page 446: ...nt nuts connecting the PTO to the gearbox and remove the PTO including selector sleeve and gasket 5 If necessary remove the intermediate shaft Installing NH 1 and NL 1 PTO C version 1 If necessary ins...

Page 447: ...ent nuts connecting the PTO to the gearbox and remove the PTO including needle bearing and gasket 5 If necessary remove the intermediate shaft Installing NH 4 and NL 4 PTO B version 1 If necessary ins...

Page 448: ...nt nuts connecting the PTO to the gearbox and remove the PTO including selector sleeve and gasket 5 If necessary remove the intermediate shaft Installing NH 4 and NL 4 PTO C version 1 If necessary ins...

Page 449: ...e gearbox drive shaft and hang the drive shaft on the side of the chassis 6 Remove the bolts and lock plate from the drive flange 7 Note Measure and make a note of the distance from the drive flange t...

Page 450: ...flange as far as possible onto the output shaft Use a locking plate and two standard bolts M12x75 to pull the drive flange further onto the shaft Check the position of the drive flange on the basis o...

Page 451: ...ve the bolts attaching the PTO to the rear cover of the gearbox and the two attachment bolts on the inside of the PTO Remove the entire PTO 6 Remove the gasket the O ring and centring ring from the re...

Page 452: ...ounted against the PTO flange 4 Remove the attachment bolts from the NL 1 PTO on the N221 10 PTO 5 Remove the PTO gasket and intermediate housing Installing NL 1 PTO on N221 10 PTO 1 Check and adjust...

Page 453: ...hassis 6 Hold the drive flange in place with the special tool DAF No 0484977 7 Remove the attachment bolts from the drive flange 8 Remove the bolts and the locking plate from the prop shaft flange 9 N...

Page 454: ...onto the output shaft Use a locking plate and two standard bolts M12x75 to pull the prop shaft flange further onto the shaft Check the position of the prop shaft flange on the basis of the above ment...

Page 455: ...bearing and circlip from the rear cover of the gearbox 5 Remove the circlip and the intermediate shaft bearing if necessary Installing intermediate shaft without intarder 1 Note The intermediate shaf...

Page 456: ...the intermediate shaft with bearing and circlip from the rear cover of the gearbox 6 Remove the circlip and the intermediate shaft bearing Installing intermediate shaft with intarder 1 Note The interm...

Page 457: ...nt nuts connecting the PTO to the gearbox and remove the PTO including adapter plate and gaskets 5 If necessary remove the intermediate shaft Installing Z81 PTO B version 1 If necessary install the in...

Page 458: ...nt nuts connecting the PTO to the gearbox and remove the PTO including adapter plate and gaskets 5 If necessary remove the intermediate shaft Installing Z81 PTO C version 1 If necessary install the in...

Page 459: ...ainst the PTO flange 4 Remove the attachment bolts connecting the PTO to the gearbox and remove the PTO including gasket 5 If necessary remove the intermediate shaft Installing 2266 PTO B version 1 If...

Page 460: ...ainst the PTO flange 4 Remove the attachment bolts connecting the PTO to the gearbox and remove the PTO including gasket 5 If necessary remove the intermediate shaft Installing 2266 PTO C version 1 If...

Page 461: ...procket out of the flywheel housing Note Before disassembling the drive sprockets note the mounting direction in the flywheel housing This is to ensure that the PTO housing fits when the gearwheels of...

Page 462: ...er a hand press and put the drive sprocket assembly in the lower part of the flywheel housing 5 Press the shaft through the flywheel housing into the drive sprocket until the shaft collar abuts the fl...

Page 463: ...he drive shaft 5 If fitted remove the pneumatic valve 6 If fitted remove the shift control 7 Remove the drive housing attachment nuts and the drive side cover with oil seal if fitted 8 If necessary re...

Page 464: ...haft 3 Fit the assembly consisting of inner races filler sleeve and shims made earlier with the aid of the driving tool onto the prop shaft take note of the position of the filler sleeve relative to t...

Page 465: ...d assembly PTO 5 5 5 Fit the prop shaft and the second inner bearing into the PTO housing V300645 6 Use a plastic or copper mallet to install the drive sprocket in the PTO housing V300646 V300647 13 2...

Page 466: ...earing and drive sprocket which are already in the PTO housing V300649 9 Place the mounting ring onto the prop shaft and clamp it firmly into a vice Now place the PTO housing with prop shaft onto the...

Page 467: ...TO housing round If necessary apply Loctite to the studs and tighten them to the specified torque See Technical data 13 Fit the gasket and the drive housing Make sure that the oil channel in the gaske...

Page 468: ...cover with the gasket and oil seal and tighten the attachment nuts to the specified torque See Technical data V300653 1 18 Apply sealant to the studs and tighten the attachment nuts to the specified t...

Page 469: ...a Version with prop shaft flange and shift control 1 Note Fit the gasket and drive housing over the studs against the PTO housing 2 Fit a needle bearing into the prop shaft 3 Fit the short drive shaft...

Page 470: ...elector housing 8 Fit the piston with O ring into the cylinder and mount the cylinder with a gasket on either side and the cover against the gearbox housing Tighten the attachment bolts to the specifi...

Page 471: ...ox output shaft bearing axial play 3 2 200337 4 REMOVAL AND INSTALLATION 4 1 200337 4 1 Removal and installation gearbox assembly with or without integrated retarder 4 1 200337 4 2 Removal and install...

Page 472: ...3 AS TRONIC GEARBOX Contents CF65 75 85 series 2 200337 14 https www truck manuals net...

Page 473: ...data is also stated on the identity card of the relevant vehicle ZF gearbox type plate 1 Type of gearbox 2 ZF serial number 3 Parts list ZF 4 Specification number 5 Pulse generator ratio 6 Gearbox ra...

Page 474: ...is no need for a clutch pedal Clutching and declutching are effected by means of an automatic single plate dry clutch 1 the clutch unit 2 and the modulator 3 An operating unit enables the driver to d...

Page 475: ...two gears 1 Input shaft 2 Transmission brake 3 Lubricating oil pump 4 Auxiliary shaft 5 Auxiliary shaft 6 Planetary gear wheel set for rear mounted range box 7 PTO connection point 8 Output shaft 9 PT...

Page 476: ...in the main box is thereby doubled The front mounted range box has been synchronised so as to restrict the number of times the transmission brake is activated B Main box The main box consists of thre...

Page 477: ...agrams show the power distribution across the individual gear pairs for each gear AS Tronic 12 gears By means of the splitter range the three gears in the main box are multiplied by two while using th...

Page 478: ...f the splitter range the four gears in the main box are multiplied by two while using the rear mounted range box multiplies this figure by two again This results in 2x4x2 16 forward gears V300664 1 2...

Page 479: ...N OF COMPONENTS 2 1 GEARBOX MODULATOR The gearbox modulator 2 is integrated in the gearbox housing 1 to save space and has all mechanical electrical and pneumatic connections that are necessary for co...

Page 480: ...tuated in the upper modulator cover The electronics serve to actuate and control the entire automated gear selector system gearbox clutch PTO depending on the driving conditions correct gear fully aut...

Page 481: ...tion of components AS TRONIC GEARBOX 2 3 The figures alongside show the situations with a 12AS or 16AS gearbox V300659 12 AS 3 2 5 1 4 GV GP 2 3 1 R V300658 16 AS 3 2 5 1 4 GV GP 3 4 2 1 R 14 200337 h...

Page 482: ...sition of the gear lever In this way the information relating to the correct gear is transmitted to the gearbox modulator via the internal electronics of the operating unit and the cab wiring 3 2 1 V3...

Page 483: ...n air duct in the gearbox housing and the air duct 1 in the cover The adjustable air pressure will cause the piston 4 to move the lamellae 5 6 against the clutch cover 7 The clutch cover 7 and the pre...

Page 484: ...3 AS TRONIC GEARBOX Description of components CF65 75 85 series 2 6 14 200337 https www truck manuals net...

Page 485: ...ck plug A and check the oil level 4 After checking the oil level tighten the level check plug A to the specified torque See Technical data B A C G000243 AS Tronic gearbox with integrated retarder 1 Pl...

Page 486: ...ine the depth of the bearing cover recess distance A A V300227 5 Use a depth gauge to determine the height the ball bearing protrudes above the gearbox housing distance B 6 Calculate the axial play Th...

Page 487: ...5 Remove the gearbox modulator connector at the right hand side 6 Remove the complete wiring harness conduit on the right hand side of the gearbox and hang it on the chassis 7 Remove the air pipe from...

Page 488: ...e thrust bearing into the clutch release assembly The clutch lever can no longer be moved by hand when the thrust bearing is fitted correctly in the clutch release assembly 4 Fit the clutch unit 5 If...

Page 489: ...ngine 6 Disconnect the electrical connectors and remove the air pipes from the retarder 7 Remove the gearbox including the retarder Installing the gearbox with integrated retarder 1 Fit the gearbox 2...

Page 490: ...y terminal 2 Remove the pressure regulator air pipe from the gearbox modulator 3 Remove the gearbox 4 Remove the attachment bolts 2 and the gearbox modulator 1 Note When removing the gearbox modulator...

Page 491: ...tral selector shaft 7 at a slant before moving it This means that the round bolt 9 points either to the left or to the right 2 Put the central selector shaft 7 in the neutral position using the specia...

Page 492: ...drawn out 4 Align the two outer control rods 3 and 5 and the central rod V300692 4 5 6 2 3 1 Note The alignment of the control rods can be checked with the aid of a simple tool This tool can be made...

Page 493: ...erly adjusted using the tool 1 if necessary V300696 4 2 1 3 6 Put the recess of the pad 6 on the selection cylinder exactly in the centre of the control rod 4 Note Ensure that the rubber seals 1 and 2...

Page 494: ...box modulator 1 with a new seal 3 see that the control rods fall into the recesses in the selector shafts 7 8 and 9 Tighten the bolts 2 to the specified torque See Technical data 9 Fit the gearbox 10...

Page 495: ...er 1 and the cap 2 from the selector switch button 2 Remove the attachment bolt from the gear lever knob and the knob from the selector switch Remove the gear lever knob and bottom plate and the knob...

Page 496: ...ove the cover 5 with the selector switch V300685 4 5 5 Disconnect connector 6 and remove the attachment bolts 7 from the gear lever unit lift the gear lever unit and remove the bolts 8 from the bottom...

Page 497: ...gear lever unit and fit connector 6 V300686 6 9 8 7 8 7 7 7 2 Connect connector 4 and fit the cover 5 with the selector switch Note Take care that the locking mechanism that is fitted to prevent the b...

Page 498: ...75 85 series 4 12 3 Install the gear lever knob and the bottom plate Fit the attachment bolt and position the cover 1 4 Fit the selector switch knob Fit the attachment bolt and the cap 2 V300683 1 2...

Page 499: ...ring using a commercially available puller Installing drive flange 1 Lightly oil the sealing ring in the bearing cover 2 Heat the drive flange to 70 C Slide it as far as possible onto the output shaf...

Page 500: ...the oil seal and turn the special tool DAF No 0484899 into the oil seal Then pull the oil seal out of the bearing cover using the special tool DAF No 0694928 Installing the output shaft oil seal 1 Ap...

Page 501: ...aling surfaces of the gearbox front cover and the gearbox housing Installing the gearbox front cover oil seal 1 Apply methylated spirit to the outer circumference of the oil seal and install the seal...

Page 502: ...3 AS TRONIC GEARBOX Removal and installation CF65 75 85 series 4 16 200337 14 https www truck manuals net...

Page 503: ...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 to the specified...

Page 504: ...illing the gearbox 1 Clean the drain plugs and tighten them to the specified torque See Technical data 2 Top up oil through level check filler opening A until the oil reaches the rim of the filler ope...

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