DAF XF95 Maintenance Manual
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DAF XF95 Maintenance Manual

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Summary of Contents for DAF XF95

  • Page 1 Maintenance manual XF95...
  • Page 3 No part of this publication may be reproduced and/or published by printing, by photocopying, on microfilm or in any way whatsoever without the prior consent in writing of DAF Trucks N.V. © 200423 DW23211003...
  • Page 5 STRUCTURE ΞΦ95 series TECHNICAL DATA Structure THREADED CONNECTIONS FLUID, OIL AND LUBRICANTS MAINTENANCE SCHEDULE EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES © 200423...
  • Page 7 TECHNICAL DATA ΞΦ95 series Contents CONTENTS 0 Technical data Page Date ENGINE, COOLING SYSTEM AND FUEL SYSTEM ..... 1-1 ..200423 General .
  • Page 8 TECHNICAL DATA ΞΦ95 series Contents © 200423...
  • Page 9 TECHNICAL DATA ΞΦ95 series Engine, cooling system and fuel system 1. ENGINE, COOLING SYSTEM AND FUEL SYSTEM 1.1 GENERAL XE engine Valve clearance Valve clearance (cold/hot) Inlet 0.50 mm Exhaust 0.50 mm DEB setting 1.40 mm V-belt tension V-belt tension, "AVX" raw edge Application example: air-conditioning compressor drive New V-belt Setting tension...
  • Page 10 TECHNICAL DATA ΞΦ95 series Engine, cooling system and fuel system 1.2 TIGHTENING TORQUES The tightening torques specified in this paragraph are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
  • Page 11 TECHNICAL DATA ΞΦ95 series Steering gear and brake system 2. STEERING GEAR AND BRAKE SYSTEM 2.1 GENERAL Steering gear Maximum steering ball joint axial clearance 1.5 mm Braking system Brake travel of automatic brake adjuster (Haldex) 35 - 40 mm Brake travel of automatic brake adjuster (FTP axle) 25 - 35 mm...
  • Page 12 TECHNICAL DATA ΞΦ95 series Steering gear and brake system 2.2 TIGHTENING TORQUES Steering gear The tightening torques stated in this paragraph are different from the standard tightening torques stated in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.
  • Page 13 TECHNICAL DATA ΞΦ95 series Drive and chassis 3. DRIVE AND CHASSIS 3.1 GENERAL Wheel bearing play, 09N044 leading rear axle 0 mm © 200423...
  • Page 14 TECHNICAL DATA ΞΦ95 series Drive and chassis 3.2 TIGHTENING TORQUES The tightening torques stated in this paragraph are different from the standard tightening torques stated in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque stated in the overview of standard tightening torques.
  • Page 15 TECHNICAL DATA ΞΦ95 series Drive and chassis M24 drain plug (B) 60 Nm M38 drain plug (B) 120 Nm Drain plug (C/D) 60 Nm V300186 Oil filter attachment bolt (1) 23 Nm M3052 ZF AS Tronic Level check/filler plug (A) 60 Nm Drain plug (B/C) 60 Nm...
  • Page 16 TECHNICAL DATA ΞΦ95 series Drive and chassis Oil filter attachment bolt (1) 23 Nm M3052 Front axle(s) U-bolt nut: If flange nut M20, property class 10, with 450 Nm ≥ 40 Nm yellow washer If yellow zinc-plated hexagonal nut M20, 400 Nm ≥...
  • Page 17 TECHNICAL DATA ΞΦ95 series Drive and chassis Rear axle(s) U-bolt nut: If flange nut M24, property class 10, with 750 Nm ≥ 50 Nm yellow washer If yellow zinc-plated hexagonal nut M24, 615 Nm ≥ 50 Nm property class 10, with black washer If high hexagonal nut M24, property class 10, 770 Nm ≥...
  • Page 18 TECHNICAL DATA ΞΦ95 series Drive and chassis 3.3 FILLING CAPACITIES Gearbox ZF 16S-151 Filling capacity approx. 11 litres ZF 16S-181 Filling capacity approx. 13 litres ZF 16S-221 Filling capacity approx. 13 litres ZF 16S-151 with integrated retarder Filling capacity approx. 11 litres ZF 16S-181 with integrated retarder Filling capacity approx.
  • Page 19 THREADED CONNECTIONS ΞΦ95 series Contents CONTENTS 2 Threaded connections Page Date THREADED CONNECTIONS ........1-1 ..200423 General .
  • Page 20 THREADED CONNECTIONS ΞΦ95 series Contents © 200423...
  • Page 21 THREADED CONNECTIONS ΞΦ95 series Threaded connections 1. THREADED CONNECTIONS 1.1 GENERAL The components may have threaded connections that have been treated with lubricant (dipped threaded connection). Galvanised bolts and nuts are wax dipped in the factory. Black annealed and phosphatised bolts and nuts are oil dipped. The advantage of using dipped nuts and bolts is that friction during tightening is reduced, so that the specified pre-tension force can be accurately...
  • Page 22 THREADED CONNECTIONS ΞΦ95 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 (re)tighten in accordance with the standard for dipped bolts; in the case of special connections, apply the lubricant before fitting, and (re)tighten in accordance with the values specified in the...
  • Page 23 FLUID, OIL AND LUBRICANTS ΞΦ95 series Contents CONTENTS 3 Fluid, oil and lubricants Page Date SPECIFICATIONS..........1-1 ..200423 General .
  • Page 24 FLUID, OIL AND LUBRICANTS ΞΦ95 series Contents © 200423...
  • Page 25 Ask your lubricant and fuel supplier(s) whether the products supplied comply with DAF specifications. DAF is not liable for damage or problems in the following instances: use of oil of a lower grade than specified. use of oil of a different viscosity than specified.
  • Page 26 FLUID, OIL AND LUBRICANTS ΞΦ95 series Specifications Avoid contact with: Lubricants Coolant Fuel Clutch fluid In the event of contact with the skin: remove the liquid with paper or a cloth, wash with soap and water. If irritation persists, consult a doctor. In the event of contact with the eyes: remove with a cloth and rinse with water.

  • Page 27: Table Of Contents

    MAINTENANCE SCHEDULE ΞΦ95 series Contents CONTENTS 4 Maintenance schedule Page Date MAINTENANCE INTERVALS ........1-1 ..200423 Maintenance schedule.
  • Page 28 MAINTENANCE SCHEDULE ΞΦ95 series Contents © 200423...

  • Page 29: Maintenance Schedule

    MAINTENANCE SCHEDULE ΞΦ95 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 X service Intermediate Y service inspection schedule...

  • Page 30: Explanatory Notes On The Maintenance Schedule

    MAINTENANCE SCHEDULE ΞΦ95 series Maintenance intervals 1.2 EXPLANATORY NOTES ON THE MAINTENANCE SCHEDULE Maintenance group classification Depending on 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 31 MAINTENANCE SCHEDULE ΞΦ95 series Maintenance intervals Intermediate inspection This is the intermediate inspection symbol. Intermediate inspections are based on several Intermediate visual inspections. inspection When an extended changing interval is applicable to the engine oil (X-service), an intermediate inspection should be carried out. G000088 X-service This is the symbol for an X-service.

  • Page 32: Effect Of Diesel Fuel And Pto Hours On Maintenance Intervals

    1 PTO hour = 40 km 1.4 MAINTENANCE IN SPECIAL OPERATING CONDITIONS Contact a DAF dealer/main branch or importer for vehicles used in very specific or heavy conditions. The service intervals can be modified, if...

  • Page 33: Maintenance Activities

    MAINTENANCE SCHEDULE ΞΦ95 series Maintenance activities 2. MAINTENANCE ACTIVITIES 2.1 OVERVIEW OF MAINTENANCE ACTIVITIES FOR THE FIRST SERVICE INSPECTION Change the engine oil Replace oil filter Change the differential oil Changing the hub oil Check components and hose connections for leaks Check/set the load-dependent control valve, leaf suspension Adjust the clutch wear indicator circlip Replace oil filter in fluid flow control valve block of EMAS system...
  • Page 34 OTHER ACTIVITIES O Check whether there are any field actions that need to be performed on the vehicle. (1) Every 2 years with coolant according to DAF specification 74001. Every 4 years with coolant according to DAF specification 74002. (2) For changing interval see maintenance schedule in maintenance manual.
  • Page 35 MAINTENANCE SCHEDULE ΞΦ95 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 O Check/clean battery terminals O Check/top up battery fluid level ENGINE, COOLING SYSTEM AND FUEL SYSTEM O Change the engine oil O Replace oil filter O Replace rotor of centrifugal oil filter...

  • Page 36: Overview Of Intermediate Inspection Activities

    MAINTENANCE SCHEDULE ΞΦ95 series Maintenance activities 2.4 OVERVIEW OF INTERMEDIATE INSPECTION ACTIVITIES INTERMEDIATE INSPECTION ACTIVITIES "Correct if necessary after inspection" In the case of an extended engine oil changing interval, an intermediate inspection must take place be- tween the X-service inspections. CAB AND ELECTRICAL SYSTEM O Check/clean battery terminals ENGINE, COOLING SYSTEM AND FUEL SYSTEM...
  • Page 37 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Contents CONTENTS 5 Explanatory notes on the maintenance activities Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200423 Safety instructions .

  • Page 38: Page Date

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Contents Page Date 3.38 Checking the clutch fluid level ........3-36 ..200423 3.39 Inspection and adjustment, clutch wear indicator .
  • Page 39 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Contents Page Date LUBRICATION ..........7-1 ..200423 Lubricating according to Y service lubrication schedule .
  • Page 40 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Contents © 200423...

  • Page 41: Safety Instructions

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 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 that are affixed to various components on the vehicle and follow them.
  • Page 42 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Safety instructions To avoid a fire hazard, the engine, the exhaust system and their surroundings must be kept free of flammable fluids and material such as dead leaves and dirt. Where there is an engine encapsulation, if necessary, the encapsulation panels must be thoroughly cleaned after each inspection interval because of the risk of fire if the inside of the...

  • Page 43: General

    It also contains safety instructions, which must be strictly adhered to. Activities not described in this manual, e.g. replacing components, overhaul, fault-finding, etc., are described in the DAF workshop instructions. This maintenance manual assumes that the mechanic is sufficiently experienced and has had...

  • Page 44: Technical Information

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

  • Page 45: Environment

    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 be maintained best if original DAF parts and components are used when replacing parts or components.

  • Page 46: Maintenance Guidelines

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series General 2.6 MAINTENANCE GUIDELINES When carrying out maintenance activities on the vehicle, it is important that the work is performed under the cleanest possible conditions. Filler caps, lubricating points, filler and drain plugs should be cleaned before and after maintenance activities.

  • Page 47: Inspection And Adjustment

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 CHECKING 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 48: Checking The Battery Fluid Level

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 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 49: Checking The Fluid Level Of The Cab Tilting Pump

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.4 CHECKING THE FLUID LEVEL OF THE CAB TILTING PUMP The fluid level must be checked when the cab is in the driving position. The cock (2) should be in the "tilting back" position (anti-clockwise).
  • Page 50 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.6 INSPECTION, ENGINE OIL LEVEL Ensure that the vehicle is standing on a flat and level surface. Wait at least 5 minutes before checking the engine oil level of a hot engine. Pull the dipstick (2) out of the holder.

  • Page 51: Inspection And Adjustment, Valve Clearance

    3.7 INSPECTION AND ADJUSTMENT, VALVE CLEARANCE Remove the valve covers, see "Removal and installation". Use the special tool (DAF no. 1310477) to turn the crankshaft clockwise, as seen from the timing gear end (this corresponds with the engine's direction of rotation), until the valves of cylinder 1 are in the overlap position.
  • Page 52 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment By cranking the crankshaft 1/3 stroke each time, using special tool (DAF no. 1310477, ) the valves can be adjusted according to the injection sequence 1-5-3-6-2-4. Valves in overlap...

  • Page 53: Inspection And Adjustment, Deb Play

    Tighten the DEB attachment bolts to the specified torque, see main group "Technical data". Using special tool (DAF no. 1310477), crank the engine in the direction of rotation until cylinder 1 has reached the top dead centre (TDC) and the valves of cylinder 6 are in overlap position.

  • Page 54: Inspection And Adjustment, V-Belt Tension

    Inspecting the V-belt tension Check the V-belt tension of the air conditioning compressor drive using the Krikit I, special tool (DAF no. 1240442). Check the V-belt tension of the FAX model steering pump drive using the Krikit II, special tool (DAF no. 1240443).
  • Page 55 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment Adjusting V-belt tension of FAX model steering pump Slacken the central bolt (1) of the tension roller. Turn the adjusting bolt (2) until the V-belt tension is correct, see "Technical data". Tighten the central bolt (1) to the specified tightening torque, see "Technical data".

  • Page 56: Checking The Coolant Freezing Point

    Check the anti-freeze content of the coolant. Fill the cooling system with anti-freeze, if this has not been done yet. Always use only coolants that meet DAF specifications. Consult the manufacturer’s instructions for the correct anti-freeze mixing ratio. Preferably, use 40% anti-freeze on an ethylene glycol base.

  • Page 57: Checking For Fuel Leaks

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.12 CHECKING FOR FUEL LEAKS Visually inspect all hose connections and fuel system components for leaks. 3.13 CHECKING THE COMPONENTS AND HOSE CONNECTIONS FOR LEAKS Check all hose connections and cooling system components for leaks.

  • Page 58: Checking The Air Inlet Dust Trapping Valve

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.16 CHECKING THE AIR INLET DUST TRAPPING VALVE Check the condition of the rubber valves. Steering gear and brake system 3.17 CHECKING FASTENING OF UNIVERSAL JOINT TO STEERING BOX INPUT SHAFT Check the universal joint for perceptible play.

  • Page 59: Checking The Steering Ball Joint Sleeve For Damage

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.18 CHECKING THE STEERING BALL JOINT SLEEVE FOR DAMAGE Inspection, dust cover Check that the seal of the steering ball joint dust cover is not damaged. Replace the steering ball joint if damaged. S7 00 795 ©...

  • Page 60: Checking The Steering Ball Joints

    3.19 CHECKING THE STEERING BALL JOINTS Checking axial steering ball joint play Check the axial steering-ball joint play using special tool (DAF no. 1329426) First jack up the axle until the wheels come off the ground and put the axle on stands.

  • Page 61: Checking The Steering Oil Level

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.20 CHECKING THE STEERING OIL LEVEL Check the steering oil level when the engine is not running. Clean the dipstick and its immediate surroundings to prevent any oil from entering the reservoir.

  • Page 62: Checking The Steering Gear Lines And Connections

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.21 CHECKING THE STEERING GEAR LINES AND CONNECTIONS Condition of the pipes Check all pipes for tightness and wear. Where supply pipes are subject to negative pressure, it is particularly likely that porous pipes will give rise to problems (air in the system).

  • Page 63: Inspecting The Compressor Line

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.22 INSPECTING THE COMPRESSOR LINE Remain at a safe distance from rotating and/or moving components. Note: If excessive values are measured, the inside of the air-dryer housing and the silencer on the vent should first be cleaned.
  • Page 64 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment The pressure gauge should indicate a pressure below 2 bar with the pressure regulator switched off. If the measured pressure exceeds the value indicated, the compressor line should be cleaned or replaced.

  • Page 65: Inspecting The Automatic Brake Adjuster

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.23 INSPECTING THE AUTOMATIC BRAKE ADJUSTER Brake drum Inspection, brake adjuster travel Measure the basic setting L1. Measure the position when the brakes are applied, L2 (minimum brake system pressure 6 bar).

  • Page 66: Checking The Brake Components And Brake System For Leaks

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.24 CHECKING THE BRAKE COMPONENTS AND BRAKE SYSTEM FOR LEAKS While operating the service brake, check whether any leaks occur in the brake system. If the brake system of a vehicle has been charged to the maximum pressure, it should generally be possible to drive the vehicle after a period of 16 hours of uninterrupted...

  • Page 67: Inspection, Brake Lining Thickness

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.26 INSPECTION, BRAKE LINING THICKNESS Inspecting the brake lining thickness (FTP axle excepted) Pressurise the air brake system (pressure regulator should cut out) and make sure that the vehicle's parking brake is not engaged. Check the brake lining thickness through the openings in the dust cover.

  • Page 68: Checking The Brake Shoe Thickness And Brake Disc

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.27 CHECKING THE BRAKE SHOE THICKNESS AND BRAKE DISC Version: Knorr SB 7000 Check whether guide bush (4) protrudes from guide sleeve (6) (C). If the guide bush (4) is level with the guide sleeve (6) (see detail A) the brake shoe and brake disc thicknesses should be checked.
  • Page 69 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment Version: Knorr SN 7000 Check the transition between the ribbed part of the rubber cover and the smooth part (A). If the smooth part is rolled inwards, the brake shoe and brake disc thicknesses must be checked.

  • Page 70: Checking And Adjusting Load-Sensing Air-Suspension Control Valve

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.28 CHECKING AND ADJUSTING LOAD-SENSING AIR-SUSPENSION CONTROL VALVE Explanatory notes on instruction plate This plate is mounted on the rear door pillar on the left-hand side of the vehicle. The information 1425289 on the instruction plate relates to the axle loads, TYPE - TIPO : FA...
  • Page 71 "delivery pressure p2" to the rear axle. If the measured value is not correct, depressurise connection (43) and, using a special tool (DAF no. 1329464), turn the adjusting nut (s): braking pressure too high: unscrew the adjusting nut braking pressure too low: screw in the adjusting nut.
  • Page 72 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 11. Set the simulated bellows pressure to its second highest value, as indicated on the instruction plate. 12. Depress the brake pedal until pressure gauge (4) indicates a pressure of 8 bar. 13.

  • Page 73: Checking And Adjusting Load-Sensing Leaf-Spring Control Valve

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.29 CHECKING AND ADJUSTING LOAD-SENSING LEAF-SPRING CONTROL VALVE Explanatory notes on instruction plate This plate is mounted on the rear door pillar on the left-hand side of the vehicle. The data on axle 1425287 loads and delivery pressures are listed on the TYPE - TIPO : FA...
  • Page 74 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment Checking and adjusting load-sensing leaf- spring control valve Measure the weight plus load of the rear axle(s). Check the attachment of the control lever and its ease of operation. Check whether the correct valve and the correct springs have been fitted (for information, see the instruction plate).
  • Page 75 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 10. Correct, if necessary, the brake pressure by moving the rubber sleeve (1) in relation to the vertical connecting rod. On no account change the length L of the (horizontal) control lever.

  • Page 76: Inspection, Fluid Level Of Hydraulic Trailing-Axle Device

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.30 INSPECTION, FLUID LEVEL OF HYDRAULIC TRAILING-AXLE DEVICE Make sure that the trailing axle wheels are fully lowered and on the ground. Check the fluid level. The liquid level must be between the "min."...

  • Page 77: Checking The Operation Of The Differential Lock

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.33 CHECKING THE OPERATION OF THE DIFFERENTIAL LOCK Jack up the rear axle and support the axle on stands. Bring the air system to operating pressure. Engage the differential lock. The warning indicator should now be active.

  • Page 78: Checking The Drive Shaft Play

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.34 CHECKING THE DRIVE SHAFT PLAY Check the universal joints and suspension bearing for play and damage. M3032 Check the sliding joint for axial and radial play. M3019 There must be no clearly perceptible play on the universal joints, suspension bearing and the sliding joint.

  • Page 79: Inspecting The Fifth Wheel

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.35 INSPECTING 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 requirements.

  • Page 80: Checking The Trailer Coupling

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.36 CHECKING THE TRAILER COUPLING Check the vertical 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 81: Check The Superstructure Attachment

    EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.37 CHECK THE SUPERSTRUCTURE ATTACHMENT Check that all attachment bolts are in place. Visually check the attachment of the superstructure for faults. See the DAF superstructure instructions. © 200423 3-35...
  • Page 82 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.38 CHECKING THE CLUTCH FLUID LEVEL Hydraulic fluid is toxic and can therefore have a damaging effect on your health. Hence avoid any direct or indirect physical contact. As hydraulic fluid is also a corrosive fluid, it may damage the paintwork of the vehicle.
  • Page 83 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.39 INSPECTION AND ADJUSTMENT, CLUTCH WEAR INDICATOR Checking the clutch wear indicator Visually check that the lock nut (12) makes contact with the housing. If the lock nut (12) no longer makes contact with the housing, the clutch plate is approximately 80% worn.
  • Page 84 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.40 CHECKING THE GEARBOX FOR LEAKS Visually check the gearbox for leaks. 3.41 CHECKING THE CENTRAL AXLE OF THE TANDEM AXLE UNIT FOR LEAKS Visually inspect the central axle for leaks. 3.42 INSPECTION OF OIL LUBRICATED WHEEL HUBS FOR LEAKS Check the wheel hubs for leaks.
  • Page 85 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. © 200423...
  • Page 86 S7 00 635 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. Adjusting the wheel bearing play Remove the hub cap (4) using special tool (DAF no.
  • Page 87 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. © 200423...
  • Page 88 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.46 CHECKING THE SHOCK ABSORBERS FOR ATTACHMENT AND LEAKS Visually inspect the attachment of the shock absorbers and for any leaks. 3.47 CHECKING THE CONDITION AND ATTACHMENT OF SPRING LEAVES, SPRING CLAMPS AND U-BOLTS Checking U-bolts Visually inspect the condition and...
  • Page 89 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment 3.49 CHECKING THE AIR SUSPENSION BELLOWS Raise the chassis to driving height using the remote control. Clean the air bellows using a cleaning cloth or a soap solution, if required. Check the air bellows for cracks and damage.
  • Page 90 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Inspection and adjustment © 3-44 200423...
  • Page 91 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, INTERIOR FILTER ELEMENT Removing interior filter Open the grille. Remove the attachment bolts (1) at the bottom of the filter (2). Remove the filter (2).
  • Page 92 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4.2 REMOVAL AND INSTALLATION, AIR FILTER ELEMENT Removing the air filter element Loosen the brackets (1) of the air filter cover (2). Remove the air filter cover (2). Remove the air filter element (3). Clean the inside of the air filter housing and the air filter cover.
  • Page 93 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation Check that the flexible sealing bellows (5) on the air intake is not damaged. Replace if necessary. G000248 © 200423...
  • Page 94 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4.3 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. Do not remove the filler cap when the engine is running.
  • Page 95 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4.4 REMOVAL AND INSTALLATION, OIL FILTER ELEMENT To prevent skin injury, avoid unnecessary contact with the drained lubricating oil. Discard the oil filter element. Removing the oil filter element Unscrew the cap (2) a few turns and drain the filter housing.
  • Page 96 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4.5 REMOVAL AND INSTALLATION, CENTRIFUGAL OIL FILTER ELEMENT To prevent skin injury, avoid unnecessary contact with the drained lubricating oil. Removing centrifugal oil filter element Remove the noise encapsulation on the right-hand side.
  • Page 97 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4.6 REMOVAL AND INSTALLATION, FUEL FILTER ELEMENT When removing the fuel filter, a quantity of fuel will escape. Collect the fuel to avoid the risk of fire. Removing the fuel filter element Remove the cover together with the fuel filter element from the filter housing.
  • Page 98 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation Fitting the fuel filter element Replace the cover O-ring. Fit the fuel filter element in the cover Fit the cover with fuel filter element. Tighten the filter cover to the specified torque. See "Technical data".
  • Page 99 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4.7 REMOVAL AND INSTALLATION, FUEL PREFILTER/WATER SEPARATOR FILTER ELEMENT When removing the fuel prefilter/ water separator, a quantity of fuel will escape. Collect the fuel to avoid the risk of fire. Removing the fuel prefilter/water separator filter element Drain the fuel from the filter element by...
  • Page 100 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4.8 REMOVAL AND INSTALLATION, VALVE COVER When the engine or parts thereof are opened, dirt may penetrate. This may cause serious damage to the engine. Therefore, the engine should be cleaned thoroughly before any parts are opened.
  • Page 101 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4.9 REMOVAL AND INSTALLATION, STEERING GEAR FILTER ELEMENT Version with plastic reservoir Removing the steering gear filter element Clean the reservoir cover, so that absolutely no dirt can get into the reservoir. Remove the cover (3).
  • Page 102 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation Version with steel reservoir Removing the steering gear filter element Clean the reservoir cover, so that absolutely no dirt can get into the reservoir. Remove the wingnut (1). Remove the steel ring (2) and the sealing ring (3).
  • Page 103 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4.10 REMOVAL AND INSTALLATION, OIL FILTER IN FLUID FLOW CONTROL VALVE BLOCK OF EMAS SYSTEM Drained steering oil must not be re- used. Make sure that during filling and bleeding the reservoir always remains filled with oil in order to prevent the pump from drawing in air...
  • Page 104 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4.11 REMOVAL AND INSTALLATION, AIR DRYER FILTER ELEMENT Note: To be certain that the air dryer is functioning properly, the air reservoirs should regularly be checked for condensation. If more than the normal amount of water is drained off repeatedly, the air dryer element must be replaced.
  • Page 105 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation Using a water-resistant felt pen, write on the sticker the latest date by which the dryer Artikelnummer element must be replaced (not later than 1 year after the date of fitting). Reference Teilenummer Drive and chassis...
  • Page 106 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation 4.12 REMOVAL AND INSTALLATION, GEARBOX FILTER ELEMENT To prevent skin injury, avoid unnecessary contact with the drained oil. ZF gearbox with integrated retarder Removing the gearbox filter element Remove the attachment bolt (1) of the oil filter.
  • Page 107 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Removal and installation Installing the gearbox filter element Check the O-ring of the filter cover (2) for damage. If necessary, replace the O-ring. Grease the O-ring. Grease the O-ring of the new filter (3) and place the filter on the filter cover.
  • Page 108 "Inspection and adjustment". Fit the split pin (2). Lower the leading rear axle. Fit the hub cover using special tool (DAF no. 1329498). Tighten the hub cover to the specified torque, see main group "Technical data". Adjust the brakes. ©...
  • Page 109 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 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 110 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Draining and filling 5.2 DRAINING AND FILLING THE ENGINE OIL To prevent skin injury, avoid unnecessary contact with the drained oil Draining the engine oil Ensure that the vehicle is standing on a flat and level surface.
  • Page 111 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Draining and filling 5.3 DRAINING, FILLING AND BLEEDING THE 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 112 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Draining and filling If the vehicle is equipped with a 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 maximum "hot"...
  • Page 113 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Draining and filling 5.4 BLEEDING THE FUEL SYSTEM While bleeding the fuel system, fuel will escape. Collect the fuel to avoid the risk of fire. Dirt in the fuel system can lead to significant damage to pump units and housing.
  • Page 114 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Draining and filling Bleeding by pressurising the fuel tank To prevent deformation of the fuel tank, the delivery pressure in the fuel tank must not exceed 0.4 bar. Remove the fuel tank cap and replace it by a cap with an adjustable air connection.
  • Page 115 Position the vehicle on a level surface. Remove the level check/filler plug (A) and drain plug (B). Drain the oil. Fit the plug using the special Torx wrench (DAF no. 1329493) and tighten the plug to the specified tightening torque. See "Technical data". Filling the differential...
  • Page 116 Remove the level check/filler plug (A) and drain plugs (B) and drain the oil. Fit the drain plugs (B) using the special Torx wrench (DAF no. 1329493) and tighten the plug to the specified tightening torque. See "Technical data". Filling the differential Fill the differential gear with the specified quantity of oil.
  • Page 117 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Draining and filling 5.6 DRAINING AND FILLING THE WHEEL HUB To prevent skin injury, avoid unnecessary contact with the drained oil. 1354 axle and 1355(T) axle Draining the wheel hub Position the vehicle on a level surface. Position the wheels in such a way that the oil drain/filler plug (A) is on the underside.
  • Page 118 Fit the level check plug (B) and the drain/filler plug (A) using the special Torx wrench (DAF no. 1329493) and tighten the plug to the specified tightening torque. See "Technical data". A8 00 364 ©...
  • Page 119 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Draining and filling 5.7 DRAINING AND FILLING THE GEARBOX To prevent skin injury, avoid unnecessary contact with the drained oil. Version: ZF 16S-151/181/221 Draining the gearbox Position the vehicle on a level surface. Drain the gearbox at operating temperature.
  • Page 120 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Draining and filling Version: ZF 16S-151/181/221 with integrated retarder Draining the gearbox Before draining take a short test drive. Do not activate the retarder during the test drive. Position the vehicle on a level surface. Drain the gearbox at operating temperature.
  • Page 121 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Draining and filling Version: ZF AS Tronic Draining the gearbox Position the vehicle on a level surface. Drain the gearbox at operating temperature. Remove the drain plugs (B and C) and the level check/filler plug (A) and drain the oil.
  • Page 122 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Draining and filling Check the oil level after having taken the test drive. The oil level must reach the rim of the level check/filler opening (A). Fit the level check/filler plug (A), tightening it to the specified torque, see "Technical data".
  • Page 123 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Cleaning 6. CLEANING 6.1 CLEANING THE BATTERY POLES 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 124 With the aid of a simple tool, the radiator and the intercooler can be blow-cleaned. M2108 The tool (radiator cleaner) cannot be ordered from DAF. It should be manufactured by yourself according to the drawing. Unscrew the protective screen attachment bolts.
  • Page 125 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Cleaning Turn the radiator cleaner (4) over, turning the holes towards the radiator (2), and blow- clean the radiator (2). Fit the protective screen. M2110 © 200423...
  • Page 126 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Cleaning 6.3 CLEANING THE VEHICLE Before cleaning the vehicle, check the engine, axles, gearbox, etc. for of leaks. Having cleaned the vehicle, it will no longer be possible to check for leaks during the maintenance activities. Make sure that doors, windows and roof hatch are securely closed during cleaning.
  • Page 127 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Cleaning Make sure that during vehicle cleaning no water enters the air-intake system through the air intake of the flexible seals of the inlet. Do not aim the high-pressure cleaner jet at the gear lever unit.
  • Page 128 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Cleaning 6.4 CLEANING GEARBOX VENT(S) Cleaning gearbox vent(s) Clean the vent(s) and the surrounding area. Remove the vent(s) from the gearbox. Rinse the vent(s) in a cleaning fluid. Blow the vent(s) dry from the inside using compressed air.
  • Page 129 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Lubrication 7. LUBRICATION 7.1 LUBRICATING ACCORDING TO Y SERVICE LUBRICATION SCHEDULE Note: The lubricating points marked below with an (S) indicate that the lubricating point is positioned on both the left-hand and right-hand side of the vehicle.
  • Page 130 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Lubrication 7.2 LUBRICATE ACCORDING TO X-SERVICE LUBRICATION SCHEDULE Lubrication Check whether the lubricating points stated below are applicable. Note: Where the lubricating points below are marked with an (S), this indicates that the lubricating point is positioned on both the left and right of the vehicle.
  • Page 131 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Lubrication Lubricating the fifth wheel G000192 Lubricating the air-sprung front axle (S) G0 00 193 Lubricating the leaf-sprung trailing axle (S) G000191 © 200423...
  • Page 132 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Lubrication Lubricating the leaf-sprung tandem axle (S) G000187 Lubricating the trailer coupling G000188 © 200423...
  • Page 133 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Lubrication Lubricating the rear axle brake camshaft (S) (drum brake version) G000194 G0 00 267 © 200423...
  • Page 134 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΞΦ95 series Lubrication Lubricating the drive shaft universal joint Grease the universal joints of the drive shaft until the grease comes out of all 4 needle bushes. Note: If the grease does not come out of all 4 needle bushes, the joint may be turned to soften hardened grease.
  • Page 136 English Printed in the Netherlands DW23211003...

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