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This workshop service repair manual PDF download for the CF65, CF75 & CF85 Series DAF Trucks has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.
APPLICABLE MODELS :
FT-FA - 4x2
FTP - 6x2
FTG-FAG - 6x2
FAN - 6x2
FAS-FAR-FTS - 6x2
FTT-FAT - 6x4
FAC-FAL - 8x2
FAX - 8x2
FAD - 8x4
TABLE OF CONTENTS :
Workshop-Manual
Group 0 - Techincal Data
Group 1 - Cab
Group 2 - CE, PE, XE Engine
Group 3 - Gearbox
Group 4 - Fuel System
Group 5 - Electrical System (from Chassis 0E621376)
Group 5 - Electrical System (to Chassis 0E621376)
Group 6 - Braking System
Group 7 - Steering
Group 8 - Rear Axle
Group 9 - Suspension
Maintenance Manual CF65
0 Technical data
2 Threaded connections
3 Fluids, oil and lubricants
4 Maintenance schedule
5 Explanatory notes on the maintenance activities
Maintenance Manual CF75
0 Technical data
2 Threaded connections
3 Fluids, oil and lubricants
4 Maintenance schedule
5 Explanatory notes on the maintenance activities
Maintenance Manual CF85
0 Technical data
2 Threaded connections
3 Fluids, oil and lubricants
4 Maintenance schedule
5 Explanatory notes on the maintenance activities
Davie Diagnostics Manual
1 EBS
2 UPEC
3 AS Tronic
4 VIC
5 EMAS
6 Hydronic 10 (ACH-EW)
7 CDS-3
8 ECAS-2
9 Airtronic (ACH-EA)
10 ABS-D and ABS/ASR-E
11 D3LC (ACH-EA)
12 EBS-2
13 ECAS-3
14 AGS
15 ZF intarder EST42
16 ALS-S
17 ECS-DC3
18 Immobiliser
19 CDM
Special Tools
0. TOOLS, GENERAL
1. CAB
2. ENGINE
3. GEARBOX
4. FUEL SYSTEM
5. ELECTRICAL COMPONENTS
6. BRAKES
7. STEERING AND AXLES
8. DIFFERENTIAL GEAR
9. CHASSIS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : -
Total Pages : 5125
This OEM service manual/ repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
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DAF.CF65-CF75-CF85-Series
Workshop-Manual
Group 0 - Techincal Data
Group 1 - Cab
Group 2 - CE, PE, XE Engine
Group 3 - Gearbox
Group 4 - Fuel System
Group 5 - Electrical System (from Chassis 0E621376)
Group 5 - Electrical System (to Chassis 0E621376)
Group 6 - Braking System
Group 7 - Steering
Group 8 - Rear Axle
Group 9 - Suspension
Maintenance Manual CF65
0 Technical data
1. Engine, cooling system and fuel system
1.1 General
1.2 Tightening torques
1.3 Filling capacities
2. Steering gear and brake system
2.1 General
2.2 Tightening torques
3. Drive and chassis
3.1 General
3.2 Tightening torques
3.3 Filling capacities
2 Threaded connections
1. Threaded connections
1.1 General
3 Fluids, oil and lubricants
1. Specifications
1.1 General
4 Maintenance schedule
1. Maintenance intervals
1.1 Maintenance schedule
1.2 Explanatory notes on the maintenance schedule
1.3 Effect of diesel fuel and PTO hours on maintenance intervals
1.4 Maintenance in special operating conditions
1.5 First service inspection
2. Maintenance activities
2.1 Overview of maintenance activities for the first service inspection
2.2 Overview of annual maintenance activities
2.3 Overview of mileage-dependent maintenance activities
5 Explanatory notes on the maintenance activities
1. Safety instructions
1.1 Safety instructions
2. General
2.1 Introduction
2.2 Technical information
2.3 Warning symbol
2.4 Environment
2.5 Parts
2.6 Maintenance guidelines
3. Inspection and adjustment
3.1 Checking pedal rubbers
3.2 Checking the battery fluid level
3.3 Checking the battery terminals
3.4 Checking the fluid level of the cab tilting pump
3.5 Check cab fastening
3.6 Bleeding the fuel system
3.7 Checking the engine oil level
3.8 Inspection and adjustment, CE engine valve clearance
3.9 Checking the poly V-belt
3.10 Checking the coolant freezing point
3.11 Checking for fuel leaks
3.12 Checking the components and hose connections for leaks
3.13 Checking the exhaust system
3.14 Checking the radiator and intercooler for fouling
3.15 Checking the air inlet dust trapping valve
3.16 Checking fastening of universal joint to steering box input shaft
3.17 Checking the steering ball joint sleeve for damage
3.18 Checking the steering ball joints
3.19 Checking the steering oil level
3.20 Checking the steering gear lines and connections
3.21 Inspecting the compressor line
3.22 Checking the brake components and brake system for leaks
3.23 Checking the brake cylinder fastening
3.24 Checking the brake shoe thickness and brake disc
3.25 Inspection and adjustment, load-dependent control valve, air suspension
3.26 Inspection and adjustment, load-dependent control valve, leaf suspension
3.27 Checking the differential for leaks
3.28 Checking the operation of the differential lock
3.29 Checking the drive shaft play
3.30 Checking the trailer coupling
3.31 Check the superstructure attachment
3.32 Check the clutch fluid level
3.33 Inspection and adjustment, clutch wear indicator
3.34 Checking the gearbox for leaks
3.35 Checking the automatic gearbox oil level
3.36 Checking the greased wheel hubs for leaks
3.37 Checking the shock absorbers for attachment and leaks
3.38 Checking the condition and attachments of spring leaves, spring clamps and U-bolts
3.39 Checking the hinge points and axle suspension fastening (air suspension)
3.40 Checking the air suspension bellows
3.41 Checking the operation of the automatic lubrication system
4. Removal and installation
4.1 Removal and installation, interior filter element
4.2 Removal and installation, air filter element
4.3 Removal and installation, lubricating oil filter
4.4 Removal and installation, fuel fine filter
4.5 Removal and installation, fuel prefilter/water separator filter element
4.6 Removal and installation, valve cover
4.7 Removal and installation, steering gear filter element
4.8 Removal and installation, air dryer filter element
4.9 Removal and installation, automatic gearbox oil filters
5. Draining and filling
5.1 Topping up battery fluid
5.2 Draining and filling, engine oil
5.3 Draining and filling coolant
5.4 Draining and filling, differential
5.5 Draining and filling the gearbox
5.6 Filling grease supply of the automatic lubrication system
6. Cleaning
6.1 Cleaning the battery poles
6.2 Cleaning radiator and intercooler
6.3 Cleaning the vehicle
6.4 Cleaning gearbox vent(s)
6.5 Cleaning rear axle vent
7. Lubrication
7.1 Lubricate according to X service lubrication schedule
Maintenance Manual CF75
0 Technical data
1. PE engine
1.1 General
1.2 Tightening torques
1.3 Filling capacities
2. Gearbox
2.1 General
2.2 Tightening torques
2.3 Filling capacities
3. Rear axle
3.1 Tightening torques
3.2 Filling capacities
4. Brakes
4.1 General
5. Steering gear
5.1 General
5.2 Tightening torques
6. Front axle
6.1 Tightening torques
2 Threaded connections
1. Threaded connections
1.1 General
3 Fluids, oil and lubricants
1. Specifications
1.1 General
4 Maintenance schedule
1. Maintenance intervals
1.1 Maintenance schedule
1.2 Explanatory notes on the maintenance schedule
1.3 Effect of diesel fuel and PTO hours on maintenance intervals
1.4 Maintenance in special operating conditions
1.5 First service inspection
2. Maintenance activities
2.1 Overview of maintenance activities for the first service inspection
2.2 Overview of annual maintenance activities
2.3 Overview of mileage-dependent maintenance activities
2.4 Overview of intermediate inspection activities
5 Explanatory notes on the maintenance activities
1. Safety instructions
1.1 Safety instructions
2. General
2.1 Introduction
2.2 Technical information
2.3 Warning symbol
2.4 Environment
2.5 Parts
2.6 Maintenance guidelines
3. Inspection and adjustment
3.1 Checking pedal rubbers
3.2 Checking the battery fluid level
3.3 Checking the battery terminals
3.4 Checking the fluid level of the cab tilting pump
3.5 Checking the cab fastening
3.6 Inspection, engine oil level
3.7 Inspection and adjustment, valve clearance
3.8 Checking the poly-V-belt
3.9 Inspection and adjustment, V-belt tension
3.10 Checking the coolant freezing point
3.11 Checking for fuel leaks
3.12 Checking the components and hose connections for leaks
3.13 Checking the exhaust system
3.14 Checking the radiator and intercooler for fouling
3.15 Checking the air inlet dust trapping valve
3.16 Checking the universal joint attachment on steering box input shaft
3.17 Checking the steering ball joint sleeve for damage
3.18 Checking the steering ball joints
3.19 Checking the steering oil level
3.20 Checking the steering gear lines and connections
3.21 Inspecting the compressor line
3.22 Checking the brake components and brake system for leaks
3.23 Inspecting the automatic brake adjuster
3.24 Checking the brake cylinder fastening
3.25 Inspection, brake lining thickness
3.26 Checking the brake shoe thickness and brake disc
3.27 Checking and adjusting load-sensing air-suspension control valve
3.28 Checking and adjusting load-sensing leaf-spring control valve
3.29 Inspection, fluid level of hydraulic trailing-axle device
3.30 Inspection, pivot points of the hydraulic trailing-axle device
3.31 Checking the differential for leaks
3.32 Checking the operation of the differential lock
3.33 Checking the drive shaft play
3.34 Inspecting the fifth wheel
3.35 Checking the trailer coupling
3.36 Check the superstructure attachment
3.37 Checking the clutch fluid level
3.38 Inspection and adjustment, clutch wear indicator
3.39 Checking the gearbox for leaks
3.40 Checking the automatic gearbox oil level
3.41 Checking the central axle of the tandem axle unit for leaks
3.42 Inspection of oil lubricated wheel hubs for leaks
3.43 Checking the greased wheel hubs for leaks
3.44 Checking the shock absorbers for attachment and leaks
3.45 Checking the condition and attachment of spring leaves, spring clamps and U-bolts
3.46 Checking the hinge points and axle suspension fastening (air suspension)
3.47 Checking the air suspension bellows
3.48 Checking the operation of the automatic lubrication system
4. Removal and installation
4.1 Removal and installation, interior filter element
4.2 Removal and installation, air filter element
4.3 Removal and installation, coolant filter
4.4 Removal and installation, engine oil filter
4.5 Removal and installation, centrifugal filter rotor
4.6 Removal and installation, fuel filter element
4.7 Removal and installation, fuel prefilter/water separator filter element
4.8 Removal and installation, valve cover
4.9 Removal and installation, steering gear filter element
4.10 Removal and installation, oil filter in fluid flow control valve block of EMAS system
4.11 Removal and installation, air dryer filter element
4.12 Removal and installation, gearbox filter element
4.13 Removal and installation, automatic gearbox oil filters
5. Draining and filling
5.1 Topping up battery fluid
5.2 Draining and filling the engine oil
5.3 Draining and filling, cooling system
5.4 Bleeding the fuel system
5.5 Draining and filling, differential
5.6 Draining and filling the wheel hub
5.7 Draining and filling, gearbox
5.8 Filling grease supply of the automatic lubrication system
6. Cleaning
6.1 Cleaning the battery poles
6.2 Cleaning radiator and intercooler
6.3 Cleaning the vehicle
6.4 Cleaning gearbox vent(s)
6.5 Cleaning rear axle vent
7. Lubrication
7.1 Lubricate according to X-service lubrication schedule
Maintenance Manual CF85
0 Technical data
1. XE engine
1.1 General
1.2 Tightening torques
1.3 Filling capacities
2. Gearbox
2.1 Tightening torques
2.2 Filling capacities
3. Rear axle
3.1 Tightening torques
3.2 Filling capacities
4. Brakes
4.1 General
5. Steering gear
5.1 General
5.2 Tightening torques
6. Front axle
6.1 Tightening torques
7. Leading rear axle 09N044 (FTP-type vehicles)
7.1 General
7.2 Tightening torques
2 Threaded connections
1. Threaded connections
1.1 General
3 Fluids, oil and lubricants
1. Specifications
1.1 General
4 Maintenance schedule
1. Maintenance intervals
1.1 Maintenance schedule
1.2 Explanatory notes on the maintenance schedule
1.3 Effect of diesel fuel and PTO hours on maintenance intervals
1.4 Maintenance in special operating conditions
1.5 First service inspection
2. Maintenance activities
2.1 Overview of maintenance activities for the first service inspection
2.2 Overview of annual maintenance activities
2.3 Overview of mileage-dependent maintenance activities
2.4 Overview of intermediate inspection activities
5 Explanatory notes on the maintenance activities
1. Safety instructions
1.1 Safety instructions
2. General
2.1 Introduction
2.2 Technical information
2.3 Warning symbol
2.4 Environment
2.5 Parts
2.6 Maintenance guidelines
3. Inspection and adjustment
3.1 Checking pedal rubbers
3.2 Checking the battery fluid level
3.3 Checking the battery terminals
3.4 Checking the fluid level of the cab tilting pump
3.5 Checking the cab fastening
3.6 Inspection, engine oil level
3.7 Inspection and adjustment, valve clearance
3.8 Inspection and adjustment, DEB play
3.9 Checking the poly-V-belt
3.10 Inspection and adjustment, V-belt tension
3.11 Checking the coolant freezing point
3.12 Checking for fuel leaks
3.13 Checking the components and hose connections for leaks
3.14 Checking the exhaust system
3.15 Checking the radiator and intercooler for fouling
3.16 Checking the air inlet dust trapping valve
3.17 Checking the universal joint attachment on steering box input shaft
3.18 Checking the steering ball joint sleeve for damage
3.19 Checking the steering ball joints
3.20 Checking the steering oil level
3.21 Checking the steering gear lines and connections
3.22 Inspecting the compressor line
3.23 Checking the brake components and brake system for leaks
3.24 Inspecting the automatic brake adjuster
3.25 Checking the brake cylinder fastening
3.26 Inspection, brake lining thickness
3.27 Checking the brake shoe thickness and brake disc
3.28 Checking and adjusting load-sensing air-suspension control valve
3.29 Checking and adjusting load-sensing leaf-spring control valve
3.30 Inspection, fluid level of hydraulic trailing-axle device
3.31 Inspection, pivot points of the hydraulic trailing-axle device
3.32 Checking the differential for leaks
3.33 Checking the operation of the differential lock
3.34 Checking the drive shaft play
3.35 Inspecting the fifth wheel
3.36 Checking the trailer coupling
3.37 Check the superstructure attachment
3.38 Checking the clutch fluid level
3.39 Inspection and adjustment, clutch wear indicator
3.40 Checking the gearbox for leaks
3.41 Checking the central axle of the tandem axle unit for leaks
3.42 Inspection of oil lubricated wheel hubs for leaks
3.43 Checking the greased wheel hubs for leaks
3.44 Retightening the hub nut of leading rear axle 09N044 (FTP�type vehicles)
3.45 Inspection and adjustment, wheel bearing play, 09N044 leading rear axle
3.46 Checking the shock absorbers for attachment and leaks
3.47 Checking the condition and attachment of spring leaves, spring clamps and U-bolts
3.48 Checking the hinge points and axle suspension fastening (air suspension)
3.49 Checking the air suspension bellows
3.50 Checking the operation of the automatic lubrication system
4. Removal and installation
4.1 Removal and installation, interior filter element
4.2 Removal and installation, air filter element
4.3 Removal and installation, coolant filter
4.4 Removal and installation, engine oil filter
4.5 Removal and installation, centrifugal filter rotor
4.6 Removal and installation, fuel filter element
4.7 Removal and installation, fuel prefilter/water separator filter element
4.8 Removal and installation, valve cover
4.9 Removal and installation, steering gear filter element
4.10 Removal and installation, oil filter in fluid flow control valve block of EMAS system
4.11 Removal and installation, air dryer filter element
4.12 Removal and installation, gearbox filter element
4.13 Removal and installation, wheel hub
5. Draining and filling
5.1 Topping up battery fluid
5.2 Draining and filling the engine oil
5.3 Draining and filling, cooling system
5.4 Bleeding the fuel system
5.5 Draining and filling, differential
5.6 Draining and filling the wheel hub
5.7 Draining and filling, gearbox
5.8 Filling grease supply of the automatic lubrication system
6. Cleaning
6.1 Cleaning the battery poles
6.2 Cleaning radiator and intercooler
6.3 Cleaning the vehicle
6.4 Cleaning gearbox vent(s)
6.5 Cleaning rear axle vent
7. Lubrication
7.1 Lubricate according to X-service lubrication schedule
Davie Diagnostics Manual
1 EBS
1. EBS fault codes
1.1 Introduction
1.2 Explanatory notes to EBS fault codes
2. EBS customer parameters
2.1 Introduction
2.2 Explanatory notes to EBS customer parameters
3. System inspection with DAVIE XD
3.1 General
2 UPEC
1. UPEC fault codes
1.1 Introduction
1.2 Explanatory notes to UPEC fault codes
2. UPEC customer parameters
2.1 Introduction
2.2 Explanatory notes to UPEC customer parameters
3. System inspection with DAVIE XD
3.1 General
3.2 Engine brake test
3.3 Speed variation control test
3 AS Tronic
1. AS Tronic fault codes
1.1 Introduction
1.2 Explanatory notes to AS Tronic fault codes
2. System inspection with DAVIE XD
2.1 General
2.2 'Transmission' menu
2.3 'Clutch actuator' menu
4 VIC
1. VIC fault codes
1.1 Introduction
1.2 Explanatory notes to VIC fault codes
2. VIC customer parameters
2.1 Introduction
2.2 Explanatory notes to VIC customer parameters, restricted version
2.3 Explanatory notes to VIC customer parameters, elaborate version
3. System inspection with DAVIE XD
3.1 General
5 EMAS
1. EMAS fault codes
1.1 Introduction
1.2 Explanatory notes to EMAS fault codes
2. System inspection with DAVIE XD
2.1 General
2.2 "Calibration" menu
6 Hydronic 10 (ACH-EW)
1. Hydronic 10 (ACH-EW) fault codes
1.1 Introduction
1.2 Explanatory notes to fault codes for Hydronic 10 (ACH-EW) with electronic unit D901
1.3 Explanatory notes to fault codes for Hydronic 10 (ACH-EW) with electronic unit D979
2. System inspection with DAVIE XD
2.1 General
7 CDS-3
1. CDS-3 fault codes
1.1 Introduction
1.2 Explanatory notes to CDS-3 fault codes
2. System inspection with DAVIE XD
2.1 General
2.2 Menu "Initialising new unit"
8 ECAS-2
1. ECAS-2 fault codes
1.1 Introduction
1.2 Explanatory notes to ECAS�2 fault codes
2. ECAS-2 customer parameters
2.1 Introduction
2.2 Explanatory notes to ECAS�2 customer parameters
3. System inspection with DAVIE XD
3.1 Calibrating the sensors
3.2 Checking height sensor
9 Airtronic (ACH-EA)
1. Airtronic (ACH-EA) fault codes
1.1 Introduction
1.2 Explanatory notes to Airtronic D2/D4 (ACH-EA) fault codes
2. System inspection with DAVIE XD
2.1 General
10 ABS-D and ABS/ASR-E
1. ABS-D and ABS/ASR-E fault codes
1.1 Introduction
1.2 Fault code overview
2. System inspection with DAVIE XD
2.1 General
11 D3LC (ACH-EA)
1. D3LC (ACH-EA) fault codes
1.1 Introduction
1.2 Explanatory notes to fault codes D3LC (ACH-EA)
2. System inspection with DAVIE XD
2.1 General
12 EBS-2
1. EBS-2 fault codes
1.1 Introduction
1.2 Explanatory notes to EBS-2 fault codes
2. EBS-2 customer parameters
2.1 Introduction
2.2 Explanatory notes to EBS-2 customer parameters
3. System inspection with DAVIE XD
3.1 General
3.2 VSC calibration
13 ECAS-3
1. ECAS-3 fault codes
1.1 Introduction
1.2 Explanatory notes to ECAS-3 fault codes
2. ECAS-3 customer parameters
2.1 Introduction
2.2 Explanatory notes to ECAS-3 customer parameters
3. System inspection with DAVIE XD
3.1 Calibrating the sensors
3.2 Inspection of height sensors
14 AGS
1. AGS fault codes
1.1 Introduction
1.2 Explanatory notes to AGS (diaphragm version) fault codes
1.3 Explanatory notes to AGS (bellows version) fault codes
2. AGS customer parameters
2.1 Introduction
2.2 Explanatory notes to AGS customer parameters
15 ZF intarder EST42
1. ZF intarder EST42 fault codes
1.1 Introduction
1.2 Explanatory notes to fault codes for ZF-intarder EST 42
2. System inspection with DAVIE XD
2.1 General
16 ALS-S
1. ALS-S fault codes
1.1 Introduction
2. Explanatory notes to ALS-S fault codes
2.1 Explanatory notes to ALS�S fault codes
3. System inspection with DAVIE XD
3.1 Inspection of radar sensor
17 ECS-DC3
1. ECS-DC3 fault codes
1.1 Introduction
1.2 Explanatory notes to ECS�DC3 fault codes
2. ECS-DC3 customer parameters
2.1 Introduction
2.2 Explanatory notes to ECS�DC3 customer parameters
3. System inspection with DAVIE XD
3.1 General
18 Immobiliser
1. Immobiliser fault codes
1.1 Introduction
1.2 Explanatory notes to immobiliser fault codes
19 CDM
1. CDM fault codes
1.1 Introduction
1.2 Explanatory notes to CDM fault codes
2. System inspection with DAVIE XD
2.1 General
Special Tools
Special tools
STRUCTURE
PREFACE
DIRECTIONS FOR USE
0. TOOLS, GENERAL
1. CAB
2. ENGINE
3. GEARBOX
4. FUEL SYSTEM
5. ELECTRICAL COMPONENTS
6. BRAKES
7. STEERING AND AXLES
8. DIFFERENTIAL GEAR
9. CHASSIS
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DAF CF65-CF75-CF85 Series Trucks Repair Service Workshop Manual.pdf
Source : Sitelux.com