Руководство по ремонту daf xf95

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  Maintenance manual 95XF…
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  E 200424 DAF Trucks N.V., Eindhoven, the Netherlands In the interest of continuing product development, DAF reserves the right to change specification or equipment at any time without notice. No part of this publication may be reproduced and/or published by printing, photocopying, microfilming or by any other means without the manufacturer’s prior permission in writing.
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  STRUCTURE 95XF series TECHNICAL DATA THREADED CONNECTIONS FLUIDS, OIL AND LUBRICANTS MAINTENANCE SCHEDULE EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES  200424…
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  TECHNICAL DATA 95XF series Contents CONTENTS Page Date XF/XE ENGINE …………
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  TECHNICAL DATA 95XF series Contents  200424…

• Page 9: Technical Data

  TECHNICAL DATA 95XF series XF/XE engine 1. XF/XE ENGINE 1.1 GENERAL Valve clearance Valve clearance (cold/warm): inlet 0.45 mm exhaust 0.45 mm DEB setting 1.40 mm V-belt tension Belt tension “12.5–mm” V-belts in Newtons (N) Multiple V-belt Single V-belt raw-edge…

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  TECHNICAL DATA 95XF series XF/XE engine 1.2 TIGHTENING TORQUES Lubrication system Oil drain plug 60 Nm Oil filter 45 Nm Central bolt for centrifugal oil filter 20 Nm Valve cover Valve cover attachment bolts 25 Nm DEB attachment bolts 110 Nm…
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  TECHNICAL DATA 95XF series VF engine 2. VF ENGINE 2.1 GENERAL Valve clearance (cold) Inlet valve 0.35 mm Exhaust valve 0.70 mm Unit injector Setting value for unit injector (cold) 0.50 — 0.75 mm C-brake Setting value for C-brake (cold) 0.58 mm…
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  TECHNICAL DATA 95XF series VF engine 2.2 TIGHTENING TORQUES Lubrication system Oil drain plug 135 Nm Oil filter 55 Nm Valve cover Valve cover attachment bolts 12 Nm Lock nut for valve clearance adjusting bolt 55 Nm Unit injector Lock nut for unit injector adjusting bolt…
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  TECHNICAL DATA 95XF series Gearbox 3. GEARBOX 3.1 TIGHTENING TORQUES Gearbox ZF 8S-151/181 and 16S-151/181/221 Level check/filler plug (A) 60 Nm Drain plug (B) 60 Nm Drain plug (C/D) 60 Nm M3023 ZF 8S-151/181 and 16S-151/181/221 with integrated retarder Drain plug (D)
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  TECHNICAL DATA 95XF series Gearbox 3.2 FILLING CAPACITIES ZF 16S-181 Filling capacity approx. 13 litres ZF 16S-221 Filling capacity approx. 13 litres ZF 16S-181/221 with integrated retarder Filling capacity approx. 12 litres  200424…

• Page 15: Rear Axle

  TECHNICAL DATA 95XF series Rear axle 4. REAR AXLE 4.1 GENERAL Wheel bearing play, 1347 axle 0.025 — 0.25 mm 4.2 TIGHTENING TORQUES Filler and drain plugs/hub plugs (Torx wrench) 85 Nm M24 hexagon U-bolt nut, property class 8 600 Nm*…

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  TECHNICAL DATA 95XF series Rear axle  200424…
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  TECHNICAL DATA 95XF series Retarder 5. RETARDER 5.1 TIGHTENING TORQUES VOITH retarder 133-2 Retarder drain plug 150 Nm Butterfly valve drain plug 65 Nm Retarder dipstick 80 Nm Retarder level check plug 80 Nm Retarder filler plug M18 x 1.5 50 Nm M24 x 1.5…
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  TECHNICAL DATA 95XF series Retarder  200424…
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  TECHNICAL DATA 95XF series Brakes 6. BRAKES 6.1 GENERAL Automatic brake adjuster stroke (09N044 axle, 25 — 35 mm FTP-type vehicles) Automatic brake adjuster stroke (other axles) 35 — 40 mm Reverse torque of adjusting bolt 18 Nm  200424…
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  TECHNICAL DATA 95XF series Brakes  200424…

• Page 21: Steering Gear

  TECHNICAL DATA 95XF series Steering gear 7. STEERING GEAR 7.1 GENERAL Maximum steering ball joint axial clearance 1.5 mm 7.2 TIGHTENING TORQUES Retention bolt/nut for universal joint steering box input shaft 30 Nm + 60_ angular displacement* Always replace bolt and nut…

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  TECHNICAL DATA 95XF series Steering gear  200424…

• Page 23: Front Axle

  TECHNICAL DATA 95XF series Front axle 8. FRONT AXLE 8.1 GENERAL Wheel bearing play 0.025 — 0.25 mm 8.2 TIGHTENING TORQUES Wheel hub lock nut 30 Nm Hub cap bolt 9 Nm Wheel nut (steel/aluminium) 700 Nm Tighten after 100 km…

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  TECHNICAL DATA 95XF series Front axle  200424…
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  TECHNICAL DATA 95XF series Trailing axle 9. TRAILING AXLE 9.1 GENERAL Wheel bearing play 0.025 — 0.25 mm Hub cap sealant Silicone sealant 9.2 TIGHTENING TORQUES Wheel hub lock nut, 09N220 axle 560 Nm Wheel hub lock nut, 09N075 axle…
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  TECHNICAL DATA 95XF series Trailing axle  200424…
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  TECHNICAL DATA 95XF series Leading rear axle 09N044 (FTP-type vehicles) 10.LEADING REAR AXLE 09N044 (FTP-TYPE VEHICLES) 10.1 GENERAL Wheel bearing play 0 mm 10.2 TIGHTENING TORQUES The tightening torques stated in this paragraph are different from the standard tightening torques stated in the overview of standard tightening torques.
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  TECHNICAL DATA 95XF series Leading rear axle 09N044 (FTP-type vehicles)  200424 10-2…
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  THREADED CONNECTIONS 95XF series Contents CONTENTS Page Date THREADED CONNECTIONS ……….
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  THREADED CONNECTIONS 95XF series Contents  200424…
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  THREADED CONNECTIONS 95XF series Threaded connections 1. THREADED CONNECTIONS 1.1 GENERAL The vehicle components are provided with threaded connections, which have been treated with lubricant (dipped threaded connection). Factory-galvanised bolts and nuts are wax-dipped. Black annealed and phosphatised bolts and nuts are oil-dipped. The advantage of…
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  THREADED CONNECTIONS 95XF series Threaded connections The following applies to all threaded connections (for both new and used vehicles): in the case of standard connections, apply the lubricant before fitting, and retighten in accordance with the standard for dipped bolts;…
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  COOLANT, OIL AND LUBRICANTS 95XF series Contents CONTENTS Page Date SPECIFICATIONS ……….. . .
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  COOLANT, OIL AND LUBRICANTS 95XF series Contents  200424…
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  1.1 GENERAL IN ORDER TO SATISFY THE WARRANTY CONDITIONS AND GUARANTEE THE LIFESPAN, SAFETY AND RELIABILITY OF DAF PRODUCTS, IT IS OF THE UTMOST IMPORTANCE THAT THE CORRECT FLUIDS, OIL AND LUBRICANTS, COOLANT AND FUEL ARE USED, AND THAT THE REQUIRED REPLACEMENT INTERVALS ARE OBSERVED.
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  COOLANT, OIL AND LUBRICANTS 95XF series Specifications Avoid contact with: — Lubricants — Coolant — Fuel — Clutch fluid In the event of contact with the skin: remove with paper or a cloth, wash with soap and water. If irritation persists, consult a doctor.

• Page 37: Table Of Contents

  MAINTENANCE SCHEDULE 95XF series Contents CONTENTS Page Date MAINTENANCE INTERVALS ……….

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  MAINTENANCE SCHEDULE 95XF series Contents  200424…
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  MAINTENANCE SCHEDULE 95XF series Maintenance intervals 1. MAINTENANCE INTERVALS 1.1 MAINTENANCE SCHEDULE The service intervals stated in the maintenance schedule are based on use of the oils and fuels specified by DAF. Maintenance Intermediate X service Y service schedule inspection…

• Page 40: Explanatory Notes On The Maintenance Schedule

  MAINTENANCE SCHEDULE 95XF series Maintenance intervals 1.2 EXPLANATORY NOTES ON THE MAINTENANCE SCHEDULE MAINTENANCE GROUP CLASSIFICATION Depending upon the use to which the vehicle is put, the vehicle is placed in maintenance group I, II or III. Maintenance group I Operation on building sites, in quarries, etc.

• Page 41: Maintenance Schedule

  MAINTENANCE SCHEDULE 95XF series Maintenance intervals INTERMEDIATE INSPECTION Intermediate This is the intermediate inspection symbol. inspection Intermediate inspections are based on several visual inspections. When an extended changing interval is applicable to the engine oil (X-service) an intermediate inspection should be carried out.

• Page 42: Maintenance Intervals Under Special Operating Conditions

  1 PTO hour of XF engine = 20 km 1 PTO hour of XE engine = 40 km 1.4 MAINTENANCE INTERVALS UNDER SPECIAL OPERATING CONDITIONS Contact a DAF dealer/main branch or importer for vehicles used in very specific or heavy conditions.

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  MAINTENANCE SCHEDULE 95XF series Maintenance activities 2. MAINTENANCE 2.1 OVERVIEW OF MAINTENANCE ACTIVITIES FOR THE FIRST SERVICE INSPECTION Change engine oil Change oil filter Change gearbox oil/transfer gearbox oil Change retarder oil (Voith retarder) Change differential oil Change hub oil…

• Page 44: Overview Of Annual Maintenance Activities

  MAINTENANCE SCHEDULE 95XF series Maintenance activities 2.2 OVERVIEW OF ANNUAL MAINTENANCE ACTIVITIES ANNUAL MAINTENANCE ACTIVITIES (Y-SERVICE) ”Correct if necessary after inspection” CAB AND ELECTRICAL SYSTEM Check pedal rubbers Check headlight setting Check fluid level of cab tilting pump Check cab fastening…

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  MAINTENANCE SCHEDULE 95XF series Maintenance activities Note: Every 2 years with coolant according to DAF specification 74001. Every 4 years with coolant according to DAF specification 74002. For changing interval, see maintenance schedule in maintenance manual. For changing interval, see maintenance schedule in maintenance manual.

• Page 46: Overview Of Mileage-Dependent Maintenance Activities

  MAINTENANCE SCHEDULE 95XF series Maintenance activities 2.3 OVERVIEW OF MILEAGE-DEPENDENT MAINTENANCE ACTIVITIES MILEAGE-DEPENDENT MAINTENANCE ACTIVITIES (X-SERVICE) ”Correct if necessary after inspection” CAB AND ELECTRICAL SYSTEM Clean/renew heater ventilation filter Replaced Clean battery terminals Check/top up battery fluid level ENGINE, COOLING SYSTEM AND FUEL SYSTEM…
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  MAINTENANCE SCHEDULE 95XF series Maintenance activities Note: For changing interval, see maintenance schedule in maintenance manual. For changing interval, see maintenance schedule in maintenance manual. When changing the gearbox oil on a gearbox with intarder or an automatic gearbox, the gearbox oil filter must also be replaced.

• Page 48: Overview Of Intermediate Inspection Activities

  MAINTENANCE SCHEDULE 95XF series Maintenance activities 2.4 OVERVIEW OF INTERMEDIATE INSPECTION ACTIVITIES INTERMEDIATE INSPECTION ACTIVITIES ”Correct if necessary after inspection” In case of 100,000 km service intervals, an intermediate inspection should take place between the X-service intervals. CAB AND ELECTRICAL SYSTEM…

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Contents CONTENTS Page Date SAFETY INSTRUCTIONS ……….
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Contents Page Date Drive and chassis 3.30 Checking the clutch fluid level ……..
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Contents Page Date DRAINING AND FILLING ……….
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Contents  200424…

• Page 53: Safety Instructions

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Safety instructions 1. SAFETY INSTRUCTIONS Comply with all the warnings and safety precautions given in this maintenance manual. First read the instructions and warnings on the labels and stickers which are affixed to various components on the vehicle and follow them.

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Safety instructions To avoid the risk of fire, the engine and its surroundings should be kept free of inflammable fluids. If an engine encapsulation is present, the encapsulation panels must be thoroughly…

• Page 55: Technical Information

  DAF reserves the right to make changes without prior notice. Note: Important changes relating to technical…

• Page 56: Warning Symbol

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series General 2.3 WARNING SYMBOL When text is accompanied by the warning symbol shown here, the information provided is essential for the health and personal safety of the mechanic. This warning symbol is also shown if circumstances threaten the safety of the vehicle or could lead to damage to the vehicle.

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  All DAF parts and components have been carefully attuned to each other, a decisive factor in ensuring the original DAF quality. It is only logical, therefore, that the original DAF quality can best be maintained if original DAF parts and components are used when replacing parts or components.

• Page 58: Maintenance Guidelines

  Particular attention should be paid to components directly related to driving safety. Consult the DAF workshop instructions when welding at and/or drilling in the chassis. Welding to and/or drilling in wrong spots of the chassis will cause the material to weaken.

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series General Always make sure that when welding at the vehicle the alternator wiring and the positive and negative battery leads are disconnected. Position the earth clamp as close as possible to the weld location. The earth…
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series General  200424…
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 CHECKING THE PEDAL RUBBERS Check that the pedal rubbers are still securely mounted on the pedal. Check that the pedal rubbers are not worn out and there is still sufficient tread.

• Page 62: Checking The Battery Fluid Level

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.2 CHECKING THE BATTERY FLUID LEVEL Avoid sparks and open flames in the vicinity of batteries. Battery acid is an aggressive fluid. In the event of contact with the skin: rinse the skin with plenty of water for a sustained period.

• Page 63: Inspection And Adjustment, Headlight Setting

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.4 INSPECTION AND ADJUSTMENT, HEADLIGHT SETTING Checking the headlight setting Note: In view of the required precision we advise you to use the correct optical and electronic adjustment equipment, and always follow the manufacturer’s instructions and advice.

• Page 64: Checking The Fluid Level Of The Cab Tilting Pump

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.5 CHECKING THE FLUID LEVEL OF THE CAB TILTING PUMP The fluid level must be checked when the cab is tilted back. The cock (2) should be in the “lowering”…

• Page 65: Inspection And Adjustment, Valve Clearance

  Place the fuel pump in the stop position. Lock the fuel pump in this position. Use the special tool (DAF no. 1310477) to turn the crankshaft clockwise, as seen from the timing gear end (this is the engine’s normal direction of rotation), until the valves of cylinder 1 overlap.

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  See “Technical data” for the correct valve clearance. M200540 By always cranking the camshaft by 1/3 of a stroke using the special tool (DAF no. 1310477), the valves can be adjusted according to the injection sequence 1-5-3-6-2-4. Valve overlap of Set valves…

• Page 67: Inspection And Adjustment, Deb Clearance

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.8 INSPECTION AND ADJUSTMENT, DEB CLEARANCE XF/XE engine Remove the valve covers. Tighten the DEB attachment bolts to the specified torque. See “Technical data”. Crank the engine in the direction of rotation…

• Page 68: Inspection/Adjustment: Valve Clearance/Unit Injectors

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.9 INSPECTION AND ADJUSTMENT, VALVE CLEARANCE AND UNIT INJECTORS VF engine Note: The valve clearances and unit injectors must be adjusted when the engine is cold 60_C). Each cylinder has three rockers:…

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Disconnect the battery earth lead. Remove the valve covers. See “Removal and installation”. If the vehicle is equipped with a C-brake, the C-brake must be removed first, see chapter “Removal and installation”.
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Rotate the drive pulley (in the direction of rotation of the crankshaft) using the attachment nut on the pulley, until the “A” marking is in line with the marking on the timing cover.
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  Inspection and adjustment Adjusting the valve clearance Slacken the lock nut of the adjusting bolt. Using a feeler gauge and special tool (DAF no. 1240043), adjust the specified valve clearance, see “Technical data”. Tighten the adjusting bolt using special tool (DAF no.
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Adjusting the unit-injector Slacken the lock nut of the adjusting bolt. Turn the adjusting bolt three to four times clockwise and anti-clockwise. This will force the fuel beneath the injector plunger out, thus moving the injector plunger downwards.

• Page 73: Inspection And Adjustment, C-Brake Play

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.10 INSPECTION AND ADJUSTMENT, C-BRAKE PLAY VF engine Note: The C-brake must be adjusted when the engine is cold ( <60°C). Use a dial gauge for C-brake adjustments. Each cylinder has three rockers:…

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment The C-brakes of the specified cylinders can be set using the table below and the marks on the drive pulley and on the timing cover. Marks on drive pulley:…
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  The setting value is also shown on the shield (1) fitted on the C-brake housing. 10. Tighten the lock nut to the specified tightening torque. See “Technical data”. Use special tool (DAF no. 1240042). M2152 11. Repeat this adjustment procedure for the remaining cylinders. Consult the following table to this end.

• Page 76: Inspection And Adjustment, V-Belt Tension

  3.11 INSPECTION AND ADJUSTMENT, V-BELT TENSION XF/XE engine Checking the V-belt tension Check the V-belt tension using special tool (DAF no. 1240442) for the single V-belts and using special tool (DAF no. 1240443) for the multiple V-belts or poly V-belts. M2079 Set the gauge to zero by depressing the measuring arm (1).

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Take the reading as indicated by the position of the measuring arm in relation to the scale. Compare this reading with the recommended pre-tension figure. See “Technical data”. M2062 …
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Adjusting the V-belt tension of the air conditioning compressor drive Loosen the upper attachment bolt (1) on the compressor. Loosen the lower attachment bolt (2) on the compressor. Loosen the attachment bolt from the threaded spindle which is attached to the coolant pump.
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  Inspection and adjustment VF ENGINE Checking the V-belt tension Check the V-belt tension using special tool (DAF no. 1240442) for the single V-belts and using special tool (DAF no. 1240443) for the multiple V-belts or poly V-belts. M2079 Set the gauge to zero by depressing the measuring arm (1).
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Adjusting the V-belt tension of the air conditioning compressor drive Slacken the attachment bolt (1) in the clamping block (2) and slacken the attachment bolt of the threaded spindle on the cylinder block.

• Page 81: Checking The Antifreeze Content In The Cooling System

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.12 CHECKING THE ANTIFREEZE CONTENT IN THE COOLING SYSTEM When the coolant is hot, there is an overpressure in the cooling system. Carefully remove the filler cap to release the overpressure.

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.13 CHECKING THE RACOR FILTER ELEMENT FOR WATER SEPARATION If necessary, open drain plug (8) and pump the water out using the feed pump (1). Close the drain plug (8).

• Page 83: Bleeding The Fuel System

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.15 BLEEDING THE FUEL SYSTEM Bleeding the fuel system with Racor filter While bleeding the fuel system, fuel will escape. Collect this fuel, bearing in mind the risk of fire.

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Bleeding the XF engine fuel system While bleeding the fuel system, fuel will escape. Collect this fuel, bearing in mind the risk of fire. Open the bleed screw (1) on the filter housing.
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.16 CHECKING THE GLOW COILS Note: To avoid engine damage it is important that the glow coils be checked periodically. Check the glow coils for the following points: windings that have worn thin due to abrasion (A);…

• Page 86: Checking The Radiator And Intercooler For Fouling

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.17 CHECKING THE RADIATOR AND INTERCOOLER FOR FOULING Visually inspect the radiator and intercooler for fouling. If required, clean the radiator and intercooler, see “Cleaning”. 3.18 CHECKING THE STEERING OIL LEVEL…

• Page 87: Checking The Steering Gear Pipes And Connections

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.19 CHECKING THE STEERING GEAR PIPES AND CONNECTIONS Condition of the pipes Check all pipes for tightness and wear. When one or more supply pipes is subject to negative pressure, it is especially likely that porous pipes will give rise to faults (air in the system).

• Page 88: Checking The Steering Ball Joints

  S700430 Checking the axial steering ball joint play Check the axial steering ball joint play using the special tool (DAF no. 1329426). First jack up the axle until the wheels come off the ground and put the axle on stands.

• Page 89: Checking The Brake Components/Brake System For Leaks

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Measure the play “A” between the thrust sleeve and the bracket using a feeler gauge. Compare the measured play with the maximum allowable steering ball joint play. See “Technical data”.

• Page 90: Checking The Brake Lining Thickness

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.22 CHECKING THE BRAKE LINING THICKNESS Checking the brake lining thickness (FTP axle excepted) Pressurise the air brake system (pressure switch should cut out) and make sure that the vehicle’s parking brake is not activated.
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.23 CHECKING THE BRAKE CYLINDER FASTENING Check that the brake cylinders do not move during operation of the service brake.  200424 3-31…

• Page 92: Checking The Automatic Brake Adjuster

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.24 CHECKING THE AUTOMATIC BRAKE ADJUSTER Checking the brake adjuster travel Measure the basic setting L1. Measure the position when the brakes are applied, L2 (minimum brake system pressure 6 bar).

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.25 INSPECTION AND ADJUSTMENT, LOAD-DEPENDENT CONTROL VALVE, LEAF SUSPENSION Explanatory notes on instruction plate 1261660 The instruction plate contains details of the axle TYPE — TIPO : FA loads and output pressures; these correspond to AUTOM.
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Depress the brake pedal until pressure gauge (1) reads 6 bar and read off the braking pressure of the rear axle on pressure gauge (2). Compare this value with the data in the table attached to the door pillar.

• Page 95: Air Suspension

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.26 INSPECTION AND ADJUSTMENT, LOAD-DEPENDENT CONTROL VALVE, AIR SUSPENSION Explanatory notes on instruction plate 1263639 The information contained on the instruction TYPE — TIPO : FA plate relates to the axle loads, the output AUTOM.

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Set the simulated bellows pressure at its highest value, as indicated on the instruction plate. Depress the brake pedal until pressure gauge (4) indicates a pressure of 6 bar.

• Page 97: Checking The Electropneumatic Valves Of Abs/Asr

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.27 CHECKING THE ELECTROPNEUMATIC VALVES OF ABS/ASR Ensure there is an adequate air supply. Connect a pressure gauge to the brake cylinder of the wheels to be tested. Fully depress the brake pedal. The pressure…

• Page 98: Checking The Compressor Line

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.28 CHECKING THE COMPRESSOR LINE Remain at a safe distance from rotating and/or moving components. Note: When measuring excessive values, the inside of the air dryer housing and the silencer on the exhaust should first be cleaned.

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Run the engine at idling speed. 10. Blow off the brake system until the cut-in pressure of the pressure regulator is reached and switch off the engine. The indicator on the pressure gauge should not drop rapidly.
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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.29 CHECKING THE ATTACHMENT OF THE UNIVERSAL JOINT OF THE STEERING BOX INPUT SHAFT Checking the attachment of the universal joint of the steering box input shaft Check the universal joint for noticeable play.

• Page 101: Checking The Clutch Fluid Level

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.30 CHECKING THE CLUTCH FLUID LEVEL Hydraulic fluid is toxic and can have a damaging effect on your health. It is therefore important to avoid inhalation and direct contact.

• Page 102: Checking The Hgs Fluid Level

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.31 CHECKING THE HGS FLUID LEVEL Hydraulic fluid is toxic and can have a damaging effect on your health. It is therefore important to avoid inhalation and direct contact.

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.32 CHECKING THE OIL AND GREASE LUBRICATED HUBS FOR LEAKS If leaks occur in oiled wheel hubs, the wheel hub should be refilled to the correct level – once the leak has been repaired –…

• Page 104: Checking The Operation Of The Differential Lock

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.37 CHECKING THE OPERATION OF THE DIFFERENTIAL LOCK Jack up the rear axle and support it on stands. Bring the air system to operating pressure. Engage the differential lock. The warning lamp should now come on.

• Page 105: Checking The Pivots Of The Axle Suspension, Air Suspension

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.39 CHECKING THE PIVOTS OF THE AXLE SUSPENSION, AIR SUSPENSION Torque rod Check the attachment of the torque rod and torque rod supports. Check the pivots of the torque rod for wear and play.

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.40 CHECKIGN THE DRIVE SHAFT PLAY Check the universal joints and centre bearing for play and damage. M3032 Check the sliding clutch for axial and radial play. M3019 There must be no clearly noticeable play on universal joints, centre bearing or sliding clutch.

• Page 107: Checking The Air Suspension Bellows

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.41 CHECKING THE AIR SUSPENSION BELLOWS Raise the chassis to its highest position using the remote control. Clean the air bellows using a cleaning rag or a soap solution, if required.

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  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.43 CHECKING THE FIFTH WHEEL Check the attachment of the fifth wheel. Check the play of the closing gear of the fifth wheel. Note: For maximum play values, consult the manufacturer’s instructions or the legal…

• Page 109: Checking The Trailer Coupling

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.44 CHECKING THE TRAILER COUPLING Check the upward play of the arched pin. Check the radial play of the arched pin. M9002 Check the vertical and horizontal play of the coupling jaw.
• Page 110
  Select the split pin hole where the hub nut needs to be turned back least. Fit the hub cap. Tighten the hub cap to the specified torque using the special tool (DAF no. 1329498). See “Technical data”. Adjust the brakes.

• Page 111: Inspection And Adjustment, Wheel Bearing Play

  FRONT AXLE/TRAILING AXLE 09N075/LEADING REAR AXLE Checking the wheel bearing play To make sure that the inspection of the wheel bearing play is reliable, use the special tool (DAF no. 0535595). The special tool consists of: extensions central nut dial gauge holder…

• Page 112
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Fit the central nut (2) to the axle journal using the socket wrench (6). If the length of screw thread protruding from the lock nut is not enough to fit the central nut (2) to the axle journal, remove the lock nut from the axle journal.
• Page 113
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Place a torque wrench on the hexagon 40Nm head of the spindle (4). Press the hub firmly onto the axle journal by screwing the spindle in, until a tightening torque of 40 Nm is reached.
• Page 114
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Adjusting the wheel bearing play Use a socket wrench (A), special tool (DAF no. 0535832), to remove the lock nut from the axle journal. Remove the lock plate and the circlip from the axle journal.
• Page 115
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment The specified wheel-bearing play is achieved by turning the adjusting nut (1) counter-clockwise between 45° and 60° (distance A — B in the drawing) using the adjusting spanner (A). The precise angle should be such that the circlip (2) can be fitted.
• Page 116
  Fit the hub cap. Tighten the hub cap to the specified torque using the special tool (DAF no. 1329498). See “Technical data”. Adjust the brakes. S7 00 635…
• Page 117
  Fit the hub cap. Tighten the hub cap to the specified torque using the special tool (DAF no. 1329498). See “Technical data”. 10. Adjust the brakes.
• Page 118
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment Fit the central nut (2) to the axle journal using the socket wrench (6). Place the dial gauge in the dial gauge holder (3) so that the stylus abuts the hub.
• Page 119
  Mark these two nuts and tighten them after 100 km. Adjusting the wheel bearing play Use a special tool (DAF no. 0535648) to remove the lock nut from the axle journal. Remove the lock plate and the circlip from the axle journal.

• Page 120: Checking The Wheel Hub And Wheel Bearings

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Inspection and adjustment 3.47 CHECKING THE WHEEL HUB AND WHEEL BEARINGS Inspect the bearings for damage at the following points: the roller bearing race, the bearing cage, the raceways of the inner and outer race.

• Page 121: Removal And Installation

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, INTERIOR FILTER ELEMENT Removing the interior filter element Open the grille. Remove the attachment bolts (1) at the bottom of the filter.

• Page 122: Removal And Installation, Oil Filter

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.2 REMOVAL AND INSTALLATION, OIL FILTER To prevent skin injury, avoid unnecessary contact with the drained oil. XF/XE engine Removing the oil filter Place a tray beneath the filter.

• Page 123
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation VF engine Removing the oil filter Place a tray beneath the filter. Remove the filter by turning it counter-clockwise using special tool (DAF no. 1240115). Note: The oil filter is a disposable filter, and may not be cleaned and reused.

• Page 124: Removal And Installation, Centrifugal Oil Filter Rotor

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.3 REMOVAL AND INSTALLATION, CENTRIFUGAL OIL FILTER ROTOR To prevent skin injury, avoid unnecessary contact with the drained oil. Removing the centrifugal oil filter rotor Clean the housing (3).

• Page 125: Removal And Installation, Air Filter Element

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.4 REMOVAL AND INSTALLATION, AIR FILTER ELEMENT Removing the air filter element Loosen the retaining clamps (1) on the air filter cover (2). Remove the air filter cover. Remove the air filter element (3).

• Page 126: Removal And Installation, Fuel Filter

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.5 REMOVAL AND INSTALLATION, FUEL FILTER When removing the fuel filter, a quantity of fuel will escape. Collect the fuel to avoid the risk of fire. XF/XE engine Removing the fuel filter Place a tray beneath the filter.

• Page 127
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation VF engine Removing the fuel filters Place a tray beneath the filters to capture any escaping fuel. Remove the filters by turning them counter-clockwise. Note: The fuel filter is a disposable filter, and must not be cleaned and reused.

• Page 128: Removal And Installation, Racor-Filter Element

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.6 REMOVAL AND INSTALLATION, RACOR-FILTER ELEMENT When removing the Racor filter element, fuel will escape. Collect the fuel to avoid the risk of fire. Removing the Racor filter element…

• Page 129: Removal And Installation, Fuel Coarse Filter

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.7 REMOVAL AND INSTALLATION, FUEL COARSE FILTER A quantity of fuel will escape when the fuel coarse filter is removed. Collect the fuel to avoid the risk of fire.

• Page 130: Removal And Installation, Coolant Filter

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.8 REMOVAL AND INSTALLATION, COOLANT FILTER When the coolant is hot, there is an overpressure in the cooling system. Carefully remove the filler cap to release the overpressure. Coolant is a toxic fluid. Contact with the skin should therefore be avoided.
• Page 131
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation VF engine Removing the coolant filter ”ON” Place a tray beneath the coolant filter to collect any escaping coolant. Remove the filler cap from the expansion tank. Switch the shut-off valve to the “OFF”…

• Page 132: Removal And Installation, V-Belt

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.9 REMOVAL AND INSTALLATION, V-BELT XF/XE engine Adjusting the V-belt tension of the water pump and alternator drive Slacken the alternator bracket attachment bolts (1) and (2). Loosen the attachment bolt (3) of the threaded spindle that is fixed to the water pump.

• Page 133
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation Removing the V-belt of the air-conditioning compressor drive Loosen the lower attachment bolt (1) of the alternator. Loosen the upper attachment bolt (2) of the alternator. Loosen the attachment bolt (3) of the threaded spindle that is fixed to the water pump.
• Page 134
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation VF engine Removing the V-belt of the air-conditioning compressor drive Slacken the attachment bolt (1) in the clamping block (2) and slacken the attachment bolt of the threaded spindle on the cylinder block.
• Page 135
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation Removing the poly V-belt (10-rib) of fan and alternator drive Slacken the attachment bolt (1) in the clamping block (2) and slacken the attachment bolt of the threaded spindle on the cylinder block.

• Page 136: Removal And Installation, C-Brake

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.10 REMOVAL AND INSTALLATION, C-BRAKE Removing the C-brake Remove the C-brake connectors on the C-brake housing. Remove the C-brake housing attachment bolts. Installing the C-brake Clean and blow-dry the housing.

• Page 137: Removal And Installation, Valve Cover

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.11 REMOVAL AND INSTALLATION, VALVE COVER XF/XE engine When the engine or parts thereof are opened, it is possible for dirt to penetrate which can result in serious damage to the engine. So clean the engine thoroughly before opening any parts of it.

• Page 138
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation VF engine Removing the valve cover Clean the area around the valve cover. Remove the attachment bolts from the valve cover. Remove the valve cover and the gasket. Installing the valve cover Clean the sealing face of the valve cover.

• Page 139: Removal And Installation, Deb

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.12 REMOVAL AND INSTALLATION, DEB Make sure that the spring plate (5) under the main piston (4) is not damaged or deformed. If this spring plate is damaged or…

• Page 140: Removal And Installation, Steering Gear Filter Element

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.13 REMOVAL AND INSTALLATION, STEERING GEAR FILTER ELEMENT Clean the reservoir cover, so that absolutely no dirt can get into the reservoir. Remove the cover (3), turn filter holder (5) a…

• Page 141: Removal And Installation, Air Dryer Filter Element

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.14 REMOVAL AND INSTALLATION, AIR DRYER FILTER ELEMENT Removing the air dryer filter element Remove the compressor line (1); as a result, the inside of the air dryer will become pressureless.

• Page 142: Removal And Installation, Gearbox Oil Filter

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.15 REMOVAL AND INSTALLATION, GEARBOX OIL FILTER To prevent skin injury, avoid unnecessary contact with the drained oil. Gearbox 16S-181/221 with integrated retarder Removing the gearbox oil filter Remove the attachment bolt (1) of the oil filter.

• Page 143
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation Installing the gearbox oil filter Check the O-ring of the filter cover (2) for any damage. Replace the O-ring if necessary. Grease the O-ring. Grease the O-ring of the new filter (3) and place the filter on the filter cover.

• Page 144: Removal And Installation, Wheel Hub

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 4.16 REMOVAL AND INSTALLATION, WHEEL HUB FRONT AXLE/LEADING REAR AXLE/TRAILING AXLE 09N075 11 12 S7 00 401 Removing the wheel hub Jack up the axle until the wheels are clear from the floor and position suitable stands under the axle.

• Page 145
  95XF series Removal and installation Remove the adjusting nut (6) from the axle journal using adjusting spanner (A), special tool (DAF no. 0694783). Remove the outer wheel bearing (7) from the hub (8). Note: If the bearings are removed from both wheels, the bearings should be marked.
• Page 146
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 11 12 S7 00 401 Installing the wheel hub Check the wheel hub and the wheel bearings for wear and damage, see “Inspection and adjustment”. Fit a new wheel speed sensor ring (10) to the hub, if necessary.
• Page 147
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation 12. Slide the hub over the axle journal. Do not pry, as the oil seal (14) might be damaged in the process. 13. Fit the adjusting nut (6) to the axle journal.
• Page 148
  Adjust the wheel bearing play, see chapter “Inspection and adjustment”. Fit the split pin (2). Lower the leading rear axle. Fit the hub cap using special tool (DAF no. 1329894). Tighten the hub cap to the specified torque, see “Technical data”. Adjust the brakes.
• Page 149
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation TRAILING AXLE 09N220 A800267 Removing the wheel hub Remove the attachment bolts from the hub cap and remove the hub cap (4). Lift the trailing axle using the trailing axle load transfer device.
• Page 150
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation Note: If the bearings are removed from both wheels, the bearings should be marked. Each bearing should be re-installed in its original hub. Remove the hub with the wheel from the axle journal.
• Page 151
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation A800267 Installing the wheel hub Check the hub and the wheel bearings for wear and damage. See chapter “Inspection and adjustment”. Fit new wheel bearings into the hub, if necessary.
• Page 152
  14. Fit the lock nut (5) to the axle journal. Tighten the lock nut (5) to the specified tightening torque. See “Technical data”. Use special tool (DAF no. 0535648). 15. Secure lock nut (5) by tapping back the locking washer (6) against the side of the lock nut.
• Page 153
  Remove the hub from the axle journal. Drill two holes into the oil seal and screw the special tool (DAF no. 0484899) into the oil seal. Pull the oil seal from the wheel hub using the special tool (DAF no. 0694928).
• Page 154
  Check the seal chamber (4) in the hub (2) for damage. For the installation of the hub oil seal (4) use special tool (DAF no. 1240036). Assemble the special tool: turn the threaded ends (A) and (L) into the centring spindle (E).
• Page 155
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation Slide the appropriate centring flange (D) on the centring spindle (E). Fit the locking plate (C) and the nut (B) on the centring spindle (E). Align the centring flange (D) on the outer race of the outer wheel bearing and hand-tighten nut (B) (max.
• Page 156
  Remove the hub from the axle journal. Drill two holes into the oil seal and screw the special tool (DAF no. 0484899) into the oil seal. Pull the oil seal from the wheel hub using the special tool (DAF no. 0694928).
• Page 157
  Removing the hub seal/wheel speed sensor ring Remove the hub from the axle journal. Fit the special tool (3) (DAF no. 1329411) to the impact puller (2), special tool (DAF no. 0694928). Hook special tool (3) (DAF no. 1329411) behind the oil seal (1).
• Page 158
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Removal and installation Assemble the special tool: turn the threaded ends (A) and (L) into the centring spindle (E). Assemble the short stud (L) on the side where the pin is located in the centring spindle (E).

• Page 159: Draining And Filling

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Draining and filling 5. DRAINING AND FILLING 5.1 TOPPING UP BATTERY FLUID Avoid sparks and open flames in the vicinity of batteries. Battery acid is an aggressive fluid. In the event of contact with the skin: rinse the skin with plenty of water for a sustained period.

• Page 160: Draining And Filling, Engine Oil

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Draining and filling 5.2 DRAINING AND FILLING, ENGINE OIL To prevent skin injury, avoid unnecessary contact with the drained oil. XF/XE ENGINE Draining engine oil Position the vehicle on a level surface.

• Page 161: Draining And Filling/Bleeding, Cooling System

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Draining and filling 5.3 DRAINING AND FILLING/BLEEDING, COOLING SYSTEM In order to avoid damaging the cylinder block, do not top up a warm engine with cold coolant. Coolant is a toxic fluid and must be handled with care.

• Page 162
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Draining and filling Filling/bleeding the cooling system Turn the heater temperature control knob in the cab to the ”warmest” setting. Fill the cooling system with the specified coolant. Run the engine for several minutes.
• Page 163
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Draining and filling VF ENGINE Draining the cooling system Turn the heater control knob to the ”warmest” temperature setting. As a result, the heater valve will be fully opened. Remove the cooling system filler cap.
• Page 164
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Draining and filling If the vehicle is equipped with water/air cab heater Run the engine at idling speed. Switch on the cab heater, using the rocker switch on the dashboard. Turn the heater temperature control knob in the cab to the ”warmest”…

• Page 165: Draining And Filling, Differential

  Filling the differential Position the vehicle on a level surface. Fit the drain plug (B) using the special torx spanner (DAF no. 1329422) and tighten it to the specified torque. See ”Technical data”. Fill the differential with the specified quantity of oil.

• Page 166
  Filling the differential Position the vehicle on a level surface. Fit the drain plug (B) using the special torx spanner (DAF no. 1329422) and tighten it to the specified torque. See ”Technical data”. Fill the differential with the specified quantity of oil.
• Page 167
  Filling the differential, second axle Position the vehicle on a level surface. Fit the drain plug (B) using the special torx spanner (DAF no. 1329422) and tighten it to M8050 the specified torque. See ”Technical data”. Fill the differential with the specified quantity of oil.

• Page 168: Draining And Filling, Wheel Hub

  See ”Technical data”. Check the oil level after approximately 5 minutes. See ”Inspection and adjustment”. Fit the level check/filler plug (A) ) using the special Torx wrench (DAF no.1329422) and tighten the plug to the specified tightening torque. See ”Technical data”. M8009 …

• Page 169
  Check the oil level after approximately 5 minutes. See ”Inspection and adjustment”. Fit the level check plug (B) and the drain/filler plug (A) using the special torx wrench (DAF no. 1329422) and tighten the plug to the specified tightening torque. See ”Technical data”. A8 00 364 …

• Page 170: Draining And Filling, Gearbox

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Draining and filling 5.6 DRAINING AND FILLING, GEARBOX To prevent skin injury, avoid unnecessary contact with the drained oil. Gearbox ZF 16S-181/221 Draining the gearbox Position the vehicle on a level surface.

• Page 171
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Draining and filling Gearbox ZF 16S-181/221 with integrated retarder Draining the gearbox Before draining take a short test drive. Do not activate the intarder during the test drive. Position the vehicle on a level surface.

• Page 172: Draining And Filling, Retarder

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Draining and filling 5.7 DRAINING AND FILLING, RETARDER To prevent skin injury, avoid unnecessary contact with the drained oil. VOITH 133-2 Draining the retarder Drain off the oil when the retarder is at operating temperature.

• Page 173: Filling The Grease Supply Of The Automatic Lubrication System

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Draining and filling 5.8 FILLING THE GREASE SUPPLY OF THE AUTOMATIC LUBRICATION SYSTEM Remove the dust cover from the filler coupling (1). Connect the filler line to the filler coupling. Ensure that the filler line is completely filled with grease so that no air bubbles can get into the system.

• Page 174
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Draining and filling  200424 5-16…

• Page 175: Cleaning

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Cleaning 6. CLEANING 6.1 CLEANING THE INTERIOR FILTER ELEMENT Remove the filter (2), see chapter “Removal and installation”. The filter can be cleaned by tapping off the dirt which has accumulated at the front off the filter surface.

• Page 176: Cleaning The Battery Terminals

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Cleaning 6.2 CLEANING THE BATTERY TERMINALS Avoid sparks and open flames in the vicinity of batteries. Battery acid is an aggressive fluid. In the event of contact with the skin: rinse the skin with plenty of water for a sustained period.

• Page 177: Cleaning The Air Filter Element

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Cleaning 6.3 CLEANING THE AIR FILTER ELEMENT Inhalation of dust can seriously damage your health. Take the necessary precautions, such as wearing goggles or a facemask. Remove the air filter element. See “Removal and installation”.

• Page 178: Cleaning The Radiator And Intercooler

  Cleaning the radiator/intercooler element Note: With the aid of a simple tool, the radiator and the intercooler can be blow-cleaned. This tool can be made in your own workshop. It cannot be obtained from DAF. Key to drawing: 1150mm Solder up Solder Quick-release coupling for air hose Steel pipe, Ø…

• Page 179: Cleaning The Fuel Coarse Filter

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Cleaning Insert radiator cleaner (4) between intercooler (1) and radiator (2), from the bottom upwards, with the air holes facing the intercooler (1). Apply air pressure to the radiator cleaner (4) and continue blow-cleaning the intercooler (1) until no more dirt comes out.

• Page 180: Cleaning The Vehicle

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Cleaning 6.6 CLEANING THE VEHICLE Note: Before cleaning the vehicle, check the engine, axles, gearbox, etc. for evidence of leakage. Having cleaned the vehicle, it will no longer be possible to check for leaks during the maintenance activities.

• Page 181
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Cleaning Make sure that no water can enter via the reservoir vents of clutch, brakes, trailing axle, etc. The engine and engine compartment can be cleaned with a high-pressure cleaner. Make sure in this case not to spray directly onto seals, electrical components, such as the starting motor, alternator, etc.
• Page 182
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Cleaning  200424…

• Page 183: Lubrication

  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Lubrication 7. LUBRICATION 7.1 LUBRICATE ACCORDING TO LUBRICATION SCHEDULE Note: If the vehicle is equipped with a central lubrication system, all lubricating points are lubricated automatically with the exception of the propeller shaft.

• Page 184
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Lubrication 13 14 C9 00 345 S = SYMMETRIC Cab hinge pins Shackle pins, front axle Brake camshafts, front axle King pins, front axle Spring shackles, front axle Universal joint Centre bearing…
• Page 185
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Lubrication Lubricating the propeller shaft Lubricate the universal joints of the propeller shaft, until grease comes out. The maximum lubricating pressure should not exceed 15 bar. M9030 Lubrication of king pins To make sure that the grease can penetrate adequately, the king pins should be lubricated in unloaded condition.
• Page 186
  EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES 95XF series Lubrication Automatic brake adjusters and brake camshafts, FTP leading rear axle Lubricate the automatic brake adjusters and brake camshafts using the lubricating nipples. C9 00 346  200424…
• Page 188
  English Printed in the Netherlands DW03247106…

DAF XF95 owner’s, operators, service and maintenance manuals, error codes list, DTC, spare parts manuals & catalogues, wiring diagrams, schematics free download PDF

See also:

• DAF XF105 PDF Service Repair Manuals;
• DAF LF45, LF55 Series Workshop Manual;

DAF XF95 PDF manual

Tractor Truck DAF XF-95

DAF XF 95 is a family of Dutch heavy trucks. Despite worthy quality, special modernization under Russian operating conditions and the highest reliability, DAF products are inferior to the models of Mercedes and Iveco in terms of demand.

The most demanded in the line of the brand remains the truck DAF XF 95, which is produced for 30 years. It is this family that is considered the main one, and in Europe it successfully competes with “classmates”, and the only weak point of the car is a rather high cost. In 2007, the car was recognized as the best truck of the year.

General information

DAF XF 95 is a new family of trucks. However, the story of the series began in 1987. Then the Dutch brand introduced the debut truck 95. In appearance and technical characteristics, it differed little from the models of that time. For the DAF brand, the model became the flagship of the model line. The first 95 vehicle was positioned as a tractor intended for permanent traveling, designed for an annual mileage of more than 150,000 km.

The design of the debut truck also turned out to be quite classic. The model was completed with a large cockpit cabin with a “strip” radiator grille, a huge brand inscription in front and a bumper with standard headlights.

Despite the unpretentious appearance, the car was very successful and enjoyed stable demand in the world market. Thanks to high sales, the Dutch brand has firmly established itself on the European auto market.

Upgrade the tractor DAF decided only in 1997. Then the premiere of the improved variation of the truck took place. In order not to confuse generations, the developers added an additional marking to the title. Now the cabin was decorated with the inscription 95 XF, which meant “extra forte”. With a similar designation, the manufacturer decided to show the power and character of the truck. In the 1990s, the first Dutch cars appeared on the Russian car market. The technique had a high cost, which immediately limited its distribution. However, the machines did not disappoint the owners and in the end paid off fairly quickly.

Soon there were new versions of DAF 95 XF with incredibly roomy cabin Super Space Cab. The driver and passengers in it could move around without bending over. In the cabin were immediately 2 beds, connected by stairs. To one “sleeping bag” was attached a folding structure, made on the principle of carriages shelves.

The internal component was also refined. The greatest changes affected the motor scale. Initially, DAF 95 XF was offered with 12.7-liter engines with a capacity of 381-483 hp, but later in the line appeared 14-liter units with a capacity of up to 530 hp, corresponding to the “Euro-2”. The motor itself underwent a global modernization. It was adapted to new conditions (metric system of measures and 24 V instead of 12 V, used in American versions). But the finicky engines are preserved, which negatively affected the work of tractors in Russia. The engine on domestic fuel worked unstably.

In general, the successful design and high quality of the finish provided the novelty with an additional audience.

Specifications

The DAF XF 95 family includes several modifications of the chassis:

• with a total weight of 18,000 kg and a wheel formula of 4 by 2;
• with a total mass of 25,700 kg and a wheel formula of 6 by 2;
• with a total mass of 26,000 kg and a wheel formula of 6 by 2;
• with a total mass of 26500 kg and a wheel arrangement of 6 for 2 and 6 for 4;
• with a gross weight of 32,000 kg and a wheel formula of 8 by 4;
• with a total mass of 35,500 kg and a wheel formula of 8 by 2;

The base version was the model with the wheel formula 4 on 2 and the total weight of 18000 kg. Load on the front axle was 6000 kg, on the rear – 12000 kg.

The total mass of the train was 40,000 kg.

Dimensions of the base model:

• length – 7600 mm;
• width – 2400 mm;
• height – 2400 mm;
• wheelbase – 3600 mm.

The maximum tractor speed with a limiter is 95 km / h. The average fuel consumption is 32 liters per 100 kilometers, the main fuel tank accommodates 620 liters of fuel.

Engine

Tractors DAP XF 95 are equipped with 6-cylinder diesel engines with a working volume of 12.7 and 14 liters. The manufacturer of these engines is the well-known American company PACCAR (the plant is manufactured in Holland). On some modifications, Cummins motors were used. The units are equipped with the UPEC branded fuel injection system from DAF with injectors with electronically controlled individual pumps that increase efficiency and environmental friendliness. The power of the motors varies from 381 to 530 hp, the maximum torque – from 1750 to 2100 Nm. All units comply with the ecological class “Euro-3”.

The first modifications of the DAF XF 95 were “wet stoves” – liquid pre-start heaters. Later, there were self-contained pre-start heaters equipped with a heating function for the tank.

Руководство по эксплуатации, техобслуживанию и ремонту DAF 95XF

Дизельные двигатели: XF 280 M, XF 315 M, XF 355 M, XE, VF
Выпуск: с 1997 по 2002 год

Язык: Английский
Формат: PDF
Размер: 155 Мб

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