Maintenance manual

65CF

English
Printed in the Netherlands DW032737
 E DAF Trucks N.V., Eindhoven, The
Netherlands
In the interest of continuing product
development, DAF reserves the right to change
specifications or products at any time without
prior notice.
No part of this publication may be reproduced
and/or published by printing, photocopying, on
microfilm or in any manner whatsoever without
the prior written consent of DAF Trucks N.V.

ǹ 0111 DW03273703
dkjwqhesa
 CONTENTS
65CF series

TECHNICAL DATA
0
1
THREADED CONNECTIONS
2
COOLANT, OIL AND LUBRICANTS
3
MAINTENANCE SCHEDULE
4
EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
5

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fk
 TECHNICAL DATA
65CF series Contents

CONTENTS
Page Date
0
1. NS-ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0111
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0111
1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ...... 0111
1.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ...... 0111
2. GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0111
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0111
2.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0111
2.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 0111
3. REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0111
3.1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0111
3.2 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0111
4. BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0111
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0111
5. STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0111
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0111
5.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0111
6. FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 ...... 0111
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 ...... 0111
6.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 ...... 0111
6.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 ...... 0111

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 TECHNICAL DATA
Contents 65CF series

2 ǹ 0111
 TECHNICAL DATA
65CF series NS-engine

1. NS-ENGINE
1.1 GENERAL
0
Valve clearance
Valve clearance (cold/warm):
inlet 0.45 mm
exhaust 0.45 mm

V-belt tension
Belt tension “12.5-mm” V-belts in Newtons (N)
Multiple V-belt Single V-belt
raw edge1 raw edge1
New V-belt 2
Setting tension 1200 600
Test tension ≥800 ≥400
Run-in V-belt3
Minimum tension 500 250
Adjusting tension 700 350

1. Raw-edge V-belts can be recognised by

looking at their edges and at the inside of
the V-belt. Except for the upper part of the
belt side, no textile fabric is present in the
rubber (polished sides).
Version: either a toothed or a non-toothed
belt.
2. After fitting the new V-belt, set the
pre-tension to the “setting tension” and after
a trial run check whether the pre-tension
complies with the “test tension”.
If the tension reading is lower than the “test M2121

tension” specified in the table, set the V-belt

to the minimum “test tension”.
3. If the V-belt tension is lower than the
“minimum tension”, set the belt to the
“adjusting tension”.

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 TECHNICAL DATA
NS-engine 65CF series

1.2 TIGHTENING TORQUES

0 Lubrication system
Oil drain plug 50 Nm
Oil filter 50 Nm

Valve cover
Tighten valve cover attachment bolts to stop

1.3 FILLING CAPACITIES

Engine
Oil sump (incl. engine-oil filter) approx. 14 litres
Cooling system approx. 26 litres

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 TECHNICAL DATA
65CF series Gearbox

2. GEARBOX
2.1 GENERAL
0
Allison gearbox
The oil level when cold must be on the “Cold full”
mark.
Dip-stick readings:

FULL
HOT
- “Cold add” = top up cold oil level
- “Cold full” = cold oil level full
- “Hot add” = top up hot oil level
- “Hot full” = hot oil level full

HOT
ADD
COLD
FULL
COLD
ADD
W 3 03 099

2.2 TIGHTENING TORQUES

ZF S6-36/2 / 6S-850 gearboxes

Drain plug 60 Nm
Level check/filler plug 60 Nm

ZF 9S-75 gearboxes
Drain plug 50 Nm
Level check/filler plug 50 Nm

Allison gearbox
Oil filter caps attachment bolts 55 Nm
Drain plugs 30 Nm

Steyr splitter box

Drain plug 50 Nm
Level check/filler plug 60 Nm

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 TECHNICAL DATA
Gearbox 65CF series

2.3 FILLING CAPACITIES

0 ZF gearboxes

ZF S6-36/2 / ZF 6S-850
Filling capacity approx. 7.5 litres
ZF 9S-75
Filling capacity approx. 9.5 litres

Allison MD3060P gearbox

Fill quantity 2″-oil sump approx. 18 litres
Fill quantity 4″-oil sump approx. 20 litres

The above fillings are approximate fillings,

without external pipes and cooler.

Steyr splitter box

Filling capacity approx. 6.4 litres

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 TECHNICAL DATA
65CF series Rear axle

3. REAR AXLE
3.1 TIGHTENING TORQUES
0
Filler and drain plugs/hub plugs (Torx wrench) 85 Nm
M24 hexagon U-bolt nut, property class 8 (leaf
spring) 600 Nm*
M24 hexagon U-bolt nut, property class 10
(air spring) 770 Nm*

* Tighten the two U-bolt nuts evenly and

alternately.

3.2 FILLING CAPACITIES

Differential gear Minimum caster Maximum caster

1132-axle
Filling capacity approx. 15.0 litres approx. 17.5 litres

Wheel hub
1132-axle
Capacity per wheel hub approx. 0.8 litres

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 TECHNICAL DATA
Rear axle 65CF series

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 TECHNICAL DATA
65CF series Brakes

4. BRAKES
4.1 GENERAL
0
Maximum brake-expander travel (Haldex) 35 - 40 mm
Reverse torque adjusting bolt > 18 Nm

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 TECHNICAL DATA
Brakes 65CF series

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 TECHNICAL DATA
65CF series Steering gear

5. STEERING GEAR
5.1 GENERAL
0
Maximum steering-ball joint axial clearance 1.5 mm

5.2 TIGHTENING TORQUES

Universal joint clamping bolt for steering box

input shaft 30 Nm + 60_ angular displacement*

* Always replace clamping bolt and nut

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 TECHNICAL DATA
Steering gear 65CF series

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 TECHNICAL DATA
65CF series Front axle

6. FRONT AXLE
6.1 GENERAL
0
Wheel-bearing play 0.025 - 0.25 mm
Hub cap sealant Silicone sealant

6.2 TIGHTENING TORQUES

Wheel-hub lock nut 210  30 Nm

Wheel nut (steel/aluminium)
( / ) 700 Nm
Tighten after
f 100 km
Wheel nut (wheel
( bolts replaced)
p ) Retighten
g 700 Nm after 100 km and also
after
f 500 km
M22 hexagon U-bolt nut, property class 8 480* Nm

* Tighten the two U-bolt nuts evenly and

alternately.

6.3 FILLING CAPACITIES

Differential gear
2235(V) axle
Caster 0_ 3_
Filling capacity 13.6 15.1 litres

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 TECHNICAL DATA
Front axle 65CF series

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 THREADED CONNECTIONS
65CF series Contents

CONTENTS
Page Date
1. THREADED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0111
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0111

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 THREADED CONNECTIONS
Contents 65CF series

2 ǹ 0111
 THREADED CONNECTIONS
65CF 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
using dipped nuts and bolts is that friction during
tightening is reduced, so that the specified
2
pre-tension can be accurately obtained. The
tightening torque can be reduced while the
pre-tension force remains the same.
To achieve a small spread in the pre-tension
force, the dipped threaded connection must be
tightened accurately. Therefore, always use a
reliable and accurate torque wrench.

NOTE:
Have torque wrenches regularly inspected and
calibrated.
To achieve the correct pre-tension when
re-using threaded connections, it is important to
clean the threaded parts thoroughly. After
cleaning, apply one drop of lubricant to the first
turn of the screw thread and one drop to the
abutting surface of the nut or bolt. Only use
engine oil as a lubricant for re-used bolts and
nuts. Lubricants other than engine oil or
factory-applied grease must not be used in any
circumstances because of the difference in
frictional coefficient.
If a locking compound was specified, no oil
should be applied to the thread.

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 THREADED CONNECTIONS
Threaded connections 65CF series

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
tighten/retorque in accordance with the
standard for dipped bolts;
- in the case of special connections,

2
apply the lubricant before fitting, and
tighten/retorque in accordance with the
values specified in the instructions.
The instructions for using a lubricant also apply
to new bolts supplied from the warehouse. Dry
threaded connections are not permitted because
of their highly variable friction coefficients.
Please consult the workshop
manual for the specified tightening
torque.

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 COOLANT, OIL AND LUBRICANTS
65CF series Contents

CONTENTS
Page Date
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0111
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0111

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 COOLANT, OIL AND LUBRICANTS
Contents 65CF series

2 ǹ 0111
 COOLANT, OIL AND LUBRICANTS
65CF series Specifications

1. SPECIFICATIONS
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.
Additives to lubricants, engine coolant and fuel
- of whatever type - must not be used except in 3
those circumstances prescribed by DAF.
Always follow the safety instructions below as
well as the instructions that are supplied with the
product.
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 cases
amongst other things:
1. If oil is used of a quality which
is inferior to the specified
quality.
2. If oil has been used of a
different viscosity than
specified.
3. If the replacement interval is
exceeded.
4. If fuel, lubricants or coolants
have been used which do not
meet the requirements
specified by DAF.

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 COOLANT, OIL AND LUBRICANTS
Specifications 65CF series

Avoid contact with:

- Lubricants
- Coolant
- Fuel
In the event of contact with the
skin: Remove with paper or a cloth,
wash with water and soap. If
irritation persists, consult a doctor.
In the event of contact with the
eyes: remove with a cloth and rinse
with water. If irritation persists,
consult a doctor.
If swallowed: DO NOT induce
vomiting. Rinse mouth, drink two
3 glasses of water and consult a
doctor.
In the event of inhalation: Get some
fresh air and rest.

Note:
Refer to the “Fluids and lubricants” specification
manual for the prescribed fluid, oil and
lubrication specifications.

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 MAINTENANCE SCHEDULE
65CF series Contents

CONTENTS
Page Date
1. MAINTENANCE INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0111
1.1 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0111
1.2 Explanatory notes on the maintenance schedule . . . . . . . . . . . . . . . . . . . . . . 1-2 ...... 0111
1.3 Influence of diesel fuel and pto hours on maintenance intervals . . . . . . . . . 1-4 ...... 0111
1.4 Maintenance intervals in heavy conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 ...... 0111
1.5 First service interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 ...... 0111
2. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0111
2.1 Overview of maintenance activities for the first service interval . . . . . . . . . . 2-1 ...... 0111
2.2 Overview of annual maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 0111
2.3 Overview of mileage-dependent maintenance activities . . . . . . . . . . . . . . . . 2-4 ...... 0111

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 MAINTENANCE SCHEDULE
Contents 65CF series

2 ǹ 0111
 MAINTENANCE SCHEDULE
65CF 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
1x per YEAR
45
55 +
65CF +
75CF
85CF
95XF (1) 4
1 year 1 year
15.000 km max.100.000 km max.100.000 km

1 year 1 year
30.000 km max.100.000 km max.100.000 km

1 year 1 year
M max.100.000 km max.200.000 km
50.000 km

(2) (3)

2 year 2 year
S 50.000 km 100.000 km max.300.000 km max.300.000 km

(4) (4) (5) (6)

G000085

1. 1 year/max. 40,000 km for automatic “Explanatory notes on the maintenance

gearboxes. schedule” in the maintenance manual.
2. For 65CF, 40,000 km. 5. Only applicable for ZF gearboxes.
For 45/55 series, 30,000 km. 6. 2 year/max. 200,000 km if the 1347 axle is
3. 1 year/max. 100,000 km if the 1347 axle is not used.
not used.
4. Applicable to extended changing intervals
(100,000 km), if permitted, see

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 MAINTENANCE SCHEDULE
Maintenance intervals 65CF series

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.
- Operation on unmetalled roads
- Traffic in dusty conditions
- Sanitation-department vehicles
- Distribution transport with an annual
mileage up to 30,000 km.
Maintenance group II
Urban and regional transport
- Distribution traffic in cities
4 - Traffic between adjacent villages/cities
Maintenance group III
(Inter)national traffic
- Long-distance/very long-distance traffic
STANDARD CHANGING INTERVAL
This is the symbol for the standard changing
interval. See “Fluids and lubricants”
specifications manual for prescribed oil
specification. M
G000089

EXTENDED CHANGING INTERVAL

This is the extended changing interval symbol.
If the prescribed oil specification and any
additional conditions (see specification manual S
“Fluids and lubricants”) has to be complied with,
an extended changing interval may be applied. G000077

Note:
An extended engine oil changing interval is
applicable for the NS-engine

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 MAINTENANCE SCHEDULE
65CF series Maintenance intervals

INTERMEDIATE INSPECTION Intermediate

This is the intermediate inspection symbol.
Intermediate inspections are based on several inspection
visual inspections.
When an extended changing interval is
applicable to the engine oil (X-service) an
G000088
intermediate inspection should be carried out.
X-SERVICE
This is the symbol for an X-service. X service
An X-service is a maintenance check depending
upon the distance covered which consists of
changing the engine oil plus a number of visual
inspections. +
Note:
An X-service should be carried out at least once
every year.

4
G000086

Y-SERVICE
This is the symbol for a Y-service. Y service
A Y-service is an annual maintenance check
which consists of several maintenance activities 1x per YEAR
plus changing of the gearbox and rear axle oil.

(1)
G000087

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 MAINTENANCE SCHEDULE
Maintenance intervals 65CF series

1.3 INFLUENCE OF DIESEL FUEL AND PTO HOURS ON MAINTENANCE

INTERVALS

Diesel fuels
Sulphur content Engine oil change interval
> 0.2% Halve interval to max. of 25,000 km

PTO hours
PTO hours should be converted into km
according to the following formula:
1 PTO hour = 20 km.

1.4 MAINTENANCE INTERVALS IN HEAVY CONDITIONS

4 Contact the importer for vehicles used in very

specific or heavy conditions.
If required, he will adapt the service intervals
and the accompanying activities.

1.5 FIRST SERVICE INTERVAL

The first service inspection should be carried out

between the first 7,500 and 10,000 km or at
most 8 weeks after delivery of the vehicle,
whichever comes first.
Note:
- For the splitter box, the oil must be changed
between the first 2,000 and 3,000 km.

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 MAINTENANCE SCHEDULE
65CF series Maintenance

2. MAINTENANCE
2.1 OVERVIEW OF MAINTENANCE ACTIVITIES FOR THE FIRST SERVICE
INTERVAL

O Change engine oil

O Changing the oil filter
O Changing the differential oil/torque divider
oil
O Changing the differential oil
O Changing the hub oil
O Check components and hose connections
for leaks
O Checking the setting of the load-sensing
valve, leaf suspension
O Check leaf-spring U-bolt attachment

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 MAINTENANCE SCHEDULE
Maintenance 65CF series

2.2 OVERVIEW OF ANNUAL MAINTENANCE ACTIVITIES

ANNUAL MAINTENANCE ACTIVITIES (Y-SERVICE)

“correct if necessary after inspection”

CAB AND ELECTRICAL SYSTEM

O Inspection, pedal rubbers
O Inspection of the headlight setting
O Check fluid level of cab tilting pump
O Inspection, cab fastening

ENGINE, COOLING SYSTEM AND FUEL SYSTEM

O Replace the air filter element
O Check valve clearance - See Note 6

4 O Check anti-freeze concentration of coolant

O Change coolant - See Note 1 Changed O Yes O No
O Check glow plugs - See Note 7

STEERING MECHANISM AND BRAKE SYSTEM

O Replace steering gear filter element - See Note 1 Replaced O Yes O No
O Inspection, steering-ball joints
O Replace the air-dryer filter element
O Inspection, compressor pipe
O Check the brake-cylinder fastening
O Inspection, automatic slack adjuster
O Check the load-sensing valve setting, leaf suspension
O Inspection, electro-pneumatic valves of the ABS/ASC
O Check universal joint for steering box input shaft
O Push front axle wheel speed sensors up against pole
ring

DRIVE AND CHASSIS

O Change differential-oil - See Note 2 Changed O Yes O No
O Change hub oil - See Note 2 Changed O Yes O No
O Inspection, operation of differential-gear lock
O Inspection, drive-shaft play
O Change gearbox oil - See Note 3 Changed O Yes O No
O Change torque divider oil - See Note 5 Changed O Yes O No
O Replace the grease of grease lubricated hubs - See
Note 4 Replaced O Yes O No
O Inspection, trailer coupling
O Check the superstructure attachment

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 MAINTENANCE SCHEDULE
65CF series Maintenance

Note:
1. Every 2 years.
2. For changing interval see maintenance
schedule in maintenance manual.
3. 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
renewed.
4. Every two years if yearly mileage
>150,000 km.
Every three years if yearly mileage
≥150,000 km.
5. Change every year/maximum 60,000 km.
6. Check the valve clearance every 2 years
after the 2nd Y-service and adjust if
necessary. 1st - 2nd - 4th - 6th... year)
7. Once every 2 years at a maximum of
250,000 km. 4

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 MAINTENANCE SCHEDULE
Maintenance 65CF series

2.3 OVERVIEW OF MILEAGE-DEPENDENT MAINTENANCE ACTIVITIES

MILEAGE-DEPENDENT MAINTENANCE ACTIVITIES (X-SERVICE)

“correct if necessary after inspection”

CAB AND ELECTRICAL SYSTEM

O Cleaning/renewing heater ventilation filter Replaced O Yes O No
O Cleaning, battery poles
O Check/refill battery fluid level

ENGINE, COOLING SYSTEM AND FUEL SYSTEM

O Change the engine oil
O Change the oil filter
O Cleaning, air filter element

4 O Replacing the fuel filter

O Check for fuel leaks
O Check V-belt Replaced O Yes O No
O Check the components and hose connections for leaks
O Check the radiator and intercooler for fouling
O Check the air-inlet system hoses and seals
O Check the exhaust system

STEERING MECHANISM AND BRAKE SYSTEM

O Check the steering ball-joint sleeve for damage
O Inspection, steering oil level
O Inspection, steering-mechanism lines and connections
O Check the brake components and brake system for
leaks
O Inspection, brake-lining thickness

DRIVE AND CHASSIS

O Inspection, clutch fluid level
O Check differential for leaks - See Note: 1
O Check oiled and greased wheel hubs for leaks -
See Note 1
O Check gearbox for leaks - See Note: 2
O Check splitter box for leaks - See Note: 3
O Check the attachment of the shock absorbers and
whether they are leaking
O Inspect the attachment and condition of the spring
leaves, spring clamps and U-bolts
O Inspection, pivoting ends of the axle suspension, air
suspension
O Inspection, air-suspension bellows
O Check the grease supply of the automatic lubricating
system
O Check the operation of the automatic lubricating system
O Lubricate according to lubricating schedule

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 MAINTENANCE SCHEDULE
65CF series Maintenance

Note:
1. For changing interval see maintenance
schedule in maintenance manual.
2. 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
renewed.
3. Change every year/maximum 60,000 km.

ǹ 0111 2-5
 MAINTENANCE SCHEDULE
Maintenance 65CF series

2-6 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Contents

CONTENTS
Page Date
1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0111
2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0111
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0111
2.2 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ...... 0111
2.3 Warning symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 0111
2.4 Environmental warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 ...... 0111
2.5 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 ...... 0111
2.6 Maintenance guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ...... 0111
3. INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . . 0111
Cab and electrical system
3.1 Inspection, pedal rubbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0111
3.2 Inspection, battery-fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0111
3.3 Inspection, battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0111
3.4 Inspection and adjustment, headlight setting . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0111
3.5 inspection, cab tilting pump fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 ...... 0111
3.6 Inspection, cab fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ...... 0111

5
Engine, cooling system and fuel system
3.7 Inspection and adjustment valve clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . . 0111
3.8 Inspection and adjustment, V-belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . . 0111
3.9 Checking anti-freeze concentration, cooling system . . . . . . . . . . . . . . . . . . . 3-8 . . . . . . 0111
3.10 Checking for fuel leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 . . . . . . 0111
3.11 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . . 0111
3.12 Inspection, glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . . 0111
3.13 Inspection, exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0111
3.14 Inspecting the radiator and intercooler for fouling . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0111
Steering mechanism and brake system
3.15 Checking steering-oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . . 0111
3.16 Inspection, steering-mechanism lines and connections . . . . . . . . . . . . . . . . . 3-11 . . . . . 0111
3.17 Inspection, steering-ball joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . . 0111
3.18 Checking brake components/system for leaks . . . . . . . . . . . . . . . . . . . . . . . . 3-13 . . . . . 0111
3.19 Inspection, brake-lining thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 . . . . . 0111
3.20 Inspection, brake cylinder attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 . . . . . 0111
3.21 Inspection, automatic slack adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 . . . . . 0111
3.22 Inspection and adjustment, load sensing valve, leaf-spring . . . . . . . . . . . . . 3-15 . . . . . 0111
3.23 Inspection and adjustment, load sensing valve, air-suspension . . . . . . . . . . 3-17 . . . . . 0111
3.24 Inspection, electro-pneumatic valves of the ABS/ASC . . . . . . . . . . . . . . . . . 3-19 . . . . . 0111
3.25 Inspection, compressor line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 . . . . . 0111
3.26 Check universal joint for steering box input shaft . . . . . . . . . . . . . . . . . . . . . . 3-21 . . . . . 0111
Drive and chassis
3.27 Inspection, fluid level of the clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 . . . . . 0111
3.28 Checking oiled and greased wheel hubs for leaks . . . . . . . . . . . . . . . . . . . . . 3-23 . . . . . 0111
3.29 Checking differential for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 . . . . . 0111
3.30 Checking gearbox for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 . . . . . 0111
3.31 Checking splitter box for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 . . . . . 0111
3.32 Inspection, operation of differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 . . . . . 0111
3.33 Iinspection, pivoting ends of the axle suspension, air suspension . . . . . . . . 3-24 . . . . . 0111
3.34 Inspection, drive-shaft play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 . . . . . 0111
3.35 Inspecting air bellows of air suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 . . . . . 0111

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Contents

Page Date
3.36 Inspection, operation of the automatic lubricating system . . . . . . . . . . . . . . . 3-26 . . . . . 0111
3.37 Inspection, trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 . . . . . 0111
3.38 Checking shock absorbers for attachment and leaks . . . . . . . . . . . . . . . . . . . 3-28 . . . . . 0111
3.39 Inspection and adjustment, wheel bearing play . . . . . . . . . . . . . . . . . . . . . . . . 3-28 . . . . . 0111
3.40 Inspection, hub and wheel bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 . . . . . 0111
3.41 Inspecting the superstructure attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 . . . . . 0111
3.42 Checking the attachment and condition of the spring
leaves/spring clamps and u-bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 . . . . . 0111
4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0111
Cab and electrical system
4.1 Removal and installation, interior filter element . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0111
Engine, cooling system and fuel system
4.2 Removal and installation, oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ...... 0111
4.3 Removal and installation, air cleaner element . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 ...... 0111
4.4 Removal and installation, fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 ...... 0111
4.5 Removal and installation, V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 0111
4.6 Removal and installation, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 ...... 0111
Steering mechanism and brake system
4.7 Removal and installation, steering-mechanism filter element . . . . . . . . . . . . 4-6 . . . . . . 0111

5
4.8 Removal and installation, air-dryer filter element . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . . 0111
Drive and chassis
4.9 Removal and installation, gearbox oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 . . . . . . 0111
4.10 Removal and installation, wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 . . . . . . 0111
4.11 Removal and installation, hub oil seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . . 0111
4.12 Removal and installation, combined hub oil seal/wheel speed sensor ring . 4-16 . . . . . 0111
5. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0111
Cab and electrical system
5.1 Topping up battery fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0111
Engine, cooling system and fuel system
5.2 Draining and filling, engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . . 0111
5.3 Draining and filling/bleeding, cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . . 0111
Drive and chassis
5.4 Draining and filling, differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 ...... 0111
5.5 Draining and filling, wheel hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 ...... 0111
5.6 Draining and filling, gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 ...... 0111
5.7 Draining and filling, splitter box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ...... 0111
5.8 Filling the grease supply of the automatic lubricating system . . . . . . . . . . . . 5-9 ...... 0111
6. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0111
Cab and electrical system
6.1 Cleaning interior filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . . 0111
6.2 Cleaning, battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . . 0111
Engine, cooling system and fuel system
6.3 Cleaning, air filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 . . . . . . 0111
6.4 Cleaning, radiator and intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 . . . . . . 0111
Drive and chassis
6.5 Cleaning, vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 . . . . . . 0111
7. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 0111
7.1 Lubricate according to lubricating schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . . 0111

2 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Safety precautions

1. SAFETY PRECAUTIONS
Comply with all the warnings and safety
precautions given in this workshop manual.
First read the instructions and warnings on the
labels and stickers which are affixed to various
components on the vehicle and follow them.
They are provided for your safety and health, so
do not ignore them.
Wear clean, fitted clothes and apply protective
cream to unprotected parts of your body, if
necessary.
Do not run the engine in an enclosed or
unventilated area. In other words, make sure
that the exhaust gases are effectively extracted.
Remain at a safe distance from rotating and/or
moving components.
Do not remove the filler cap of the cooling
system when the engine is at operating
temperature. 5
Be careful when changing the oil. Hot oil can
cause serious injuries.
Avoid unnecessary contact with drained oil.
Frequent contact damages the skin.
Various sorts of oil and other lubricants used on
the vehicle may constitute a health hazard.
This also applies to engine coolant, windscreen
washer fluid, refrigerant in air-conditioning
systems, battery acid and diesel fuel.
So avoid inhaling and direct contact.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Safety precautions 65CF series

When carrying out operations under the cab,

make sure the cab is fully tilted and locked.
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
cleaned after each inspection interval in view of
the risk of fire if the inside of the panels should
be dirty.
Always disconnect the earth lead of the battery
before working on the vehicle.
Always use stands to support the chassis or
components when working under the vehicle.
Always charge batteries in a properly ventilated
area and avoid sparking and naked flames.
Fast-charging should only be resorted to in an
emergency. When fast-charging, the battery
positive and negative leads (+ and −) must be
5 disconnected.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series General

2. GENERAL
2.1 INTRODUCTION

This maintenance manual describes all relevant

maintenance activities. It also contains safety
precautions which must be strictly observed.
Activities not described in this manual, e.g.
revision, fault finding etc. are described in the
DAF workshop instructions.
This maintenance manual assumes that the
mechanic is sufficiently experienced and will
have had sufficient instruction or training to carry
out the maintenance activities in a responsible
and safe manner.
The technical data and notes on the
maintenance activities have been compiled with
the utmost care.

2.2 TECHNICAL INFORMATION

5
The technical information in this maintenance
manual, such as notes on maintenance activities
and technical data required to carry out the
maintenance activities in a responsible manner,
were up-to-date at the time this manual went to
press.
DAF reserves the right to make changes without
prior notice.
Note:
Important changes relating to technical
information which is not contained in this
maintenance manual will be published in a TI
(Technical Information Sheet).

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
General 65CF series

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.

M0015

2.4 ENVIRONMENTAL WARNINGS

By carrying out the maintenance activities in a

5
professional manner, on time and at regular
intervals, you will help to reduce the impact on
the environment.
This means, for example, noticing and
remedying possible leakages on time and
keeping the engine in an optimum condition
(adjusting valves, replacing air filter element
etc.), thus reducing the emission of harmful
exhaust gasses.
It should be noted that oils and fluids contain
harmful substances which have a negative
impact on the environment.
That is why you should take care that drained
oils and fluids, also discarded oil and fuel filters,
are collected in separate receptacles or
containers.
In short: maintenance activities must be
carried out in an environmentally conscious
manner.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series General

2.5 PARTS

All DAF parts and components have been

carefully matched 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.
As far as maintenance activities are concerned,
you should think of windscreen-wiper blades,
air-dryer elements, gaskets, V-belts and filters.
If, for example, “non-original DAF filters” are
used, the engine will be insufficiently protected
against microscopically small airborne dust G000067
particles, almost imperceptible metal swarf in the
oil and contaminated fuel, resulting in:
- premature replacing of cylinders, pistons,
bearings, valves, injector pump and other
moving parts
- reduced engine performance

5
- increased fuel consumption.
Therefore, always use original DAF parts and
components.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
General 65CF series

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.
- When excessive leakage has been detected
at oil seals and/or components, or in case of
excessive oil-level decreases, a report
should be made and the cause should be
remedied.
- It is important to check the exhaust ports of
the gearbox, transfer case, rear axle and
driven front axle regularly for fouling and
blocking.
If the exhaust ports are blocked by dirt,
overpressure could cause leakage.
5 - Depending on the circumstances in which
the vehicle is used, e.g. on very bad roads
or at construction sites, important bolt
connections such as the coupling disk,
spring suspension, U-bolts, trailer coupling,
steering box attachment, superstructure
attachments etc. should be inspected more
often and, if required, be retorqued.
- It is important that, following the
maintenance activities, a visual inspection
and test run are carried out.
Particular attention should be paid to
components directly related to driving
safety.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

3. INSPECTION AND ADJUSTMENT

3.1 INSPECTION, PEDAL RUBBERS

1. Check that the pedal rubbers are still

securely mounted on the pedal.
2. Check that the pedal rubbers are not worn
out and there is still sufficient tread.

3.2 INSPECTION, BATTERY-FLUID LEVEL

Avoid sparks and open flames in

the vicinity of batteries. Battery acid
is a corrosive fluid.

In the event of contact with the

skin: Rinse the skin with plenty of
water for a sustained period. If
redness or pain persists, consult a
doctor. Remove any clothing
affected and rinse with water. 5
In the event of contact with the
eyes: Rinse with plenty of water for
at least 15 minutes and see a
doctor.
If any is swallowed: do NOT induce
vomiting. Rinse the mouth, drink
two glasses of water and see a
doctor.
In the event of inhalation: get some
fresh air, rest and consult a doctor.

1. Check the electrolyte level. The electrolyte

level must be approx. 10 mm above the
plates or up to the level indicator if present.
2. If required, top up the batteries, see
“Draining and filling”.

M5011

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.3 INSPECTION, BATTERY TERMINALS

1. Visually check the battery terminals for

corrosion. Clean the battery terminals if
necessary, see chapter “Cleaning”.

2. Check attachment of battery clamps.

3.4 INSPECTION AND ADJUSTMENT, HEADLIGHT SETTING

Inspection of 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.
If the correct equipment is not available, the

5
setting of the headlights (dipped beam) can be
checked as follows:
- the dipped beam should have a downward
slant of 1%, which means that, when it is
projected on a board or wall at a distance of
10 metres, the light/dark division should be
10 cm below the centre height of the
headlamp.
1. When checking the headlight setting
(dipped beam) the vehicle must carry no
load and the tyres should have the
prescribed tyre pressure.
2. Ensure that the vehicle is standing on a flat
and horizontal surface.
3. Make sure that when checking the headlight
setting, the rotary knob for the headlight
adjustment, if available, is in the “O”
position.
1 1

2
2
3

D000235

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

Adjusting the headlight setting

Adjust the headlights using two adjusting bolts
which can be reached through the openings in 2
the headlight rim.
Adjusting bolt (1) changes the vertical
adjustment of the beam and adjusting bolt (2)
the horizontal adjustment.

M5010

3.5 INSPECTION, CAB TILTING PUMP FLUID LEVEL

1. The fluid level must be checked when the

cab is in the driving position.
2. The cock (2) should be in the ‘lowering’
position (counter-clockwise).
5
3. Loosen filler plug (1) 3 to 4 turns and wait
until the overpressure, if any, has left the
1
reservoir. Now the filler plug can be
removed.
4. Start pumping with a maximum of five pump
strokes, making sure that the pump lever is
in the lower position when finished.
5. Then check the fluid level. This level should
be no more than 2 cm under the filling
opening.
2
Top up if necessary. M1018

6. Fit the filler plug and hand-tighten it.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.6 INSPECTION, CAB FASTENING

1. Check if all attachment bolts are present.

2. Visually inspect the attachment of the cab to
the tilting mechanism.
3. Visually inspect the seals and condition of
the tilting mechanism.

M1030

3.7 INSPECTION AND ADJUSTMENT VALVE CLEARANCE

5 1. Remove the valve cover, see “Removal and

installation”.
2. Place the fuel pump in the stop position.
Lock the fuel pump in this position.
3. Crank 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 are in overlap
position. The pistons of cylinders 1 and 6
are now at top dead centre.
Note:
“Overlap” is the moment at which the inlet valve
starts opening and the exhaust valve finishes
closing.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

4. Check/correct the valve clearance of

cylinder 6. The correct valve clearance is
adjusted by loosening the lock nut (4) and
turning the adjusting screw (5) in the correct 5
direction. See “Technical Data” for the
correct valve clearance. 4
5. By cranking the camshaft always 1/3 stroke,
the valves can be adjusted according to the
injection sequence 1-5-3-6-2-4.

Cylinder with valves Set valves

in overlap position of cylinder
1 6 M2118

5 2
3 4
6 1
2 5
4 3
5
6. Fit the valve cover. See “Removal and
installation”.

ǹ 0111 3-5
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.8 INSPECTION AND ADJUSTMENT, V-BELT TENSION

Check V-belt tension OP

A BTLIB
EEUL
TI
N.2
1. Check the V-belt tension with the special 00

tool (DAF no. 1240442). for the single V-belt LBS

.50
600

model and with special tool 100

150
(DAF no. 1240443) for the multiple V-belt
model or poly-V-belt model.
OPBT
A
LIBEE
U
LTII
N.5
00

LBS
.100 150
0
200

300

M2079

2. Set the gauge to zero by depressing the

measuring arm (1). 1
5

M2061

3. Place the belt-tension gauge on the V-belt,

halfway between the two pulleys.

M2055

3-6 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

4. Slowly depress the V-belt by means of the

belt-tension gauge until a click is heard.
Carefully remove the gauge. Make sure that
the measuring arm is not moved.
5. Take the reading as indicated by the
position of the measuring arm in relation to
the scale. Compare this pressure reading
with the recommended pre-tension. See
“Technical Data”.

M2062

Check V-belt tension

1. Slacken the attachment bolts (1) of the
brackets.
2. Shift the alternator until the correct V-belt
tension is achieved, see main group
“Technical Data”. 1
1
3. Tighten the attachment bolts (1) of the
brackets.
5

1 M2063

ǹ 0111 3-7
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.9 CHECKING ANTI-FREEZE CONCENTRATION, COOLING SYSTEM

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 noxious fluid. Contact

with the skin should therefore be
avoided.

In order to avoid damaging the

cylinder block, do not top up a
warm engine with cold coolant.

1. Check the coolant anti-freeze content. Fill o

C 0
the cooling system with anti-freeze, if this -10
has not been done yet. Always use only
-20
those coolants or anti-freeze agents which
meet DAF specifications. -30

-40

5
2. Consult the manufacturer’s instructions for
-50
the correct anti-freeze mixing ratio.
Preferably, use 40% anti-freeze, on an -60
ethylene glycol base. At this percentage, -70
not only good frost protection, but also good
-80
corrosion protection is guaranteed. 0 10 20 30 40 50 60 70 80 90 100 % Ethyleenglycol
100 90 80 70 60 50 40 30 20 10 0 H 2O

M2016

3.10 CHECKING FOR FUEL LEAKS

1. Visually inspect all hose connections and

fuel system components for leaks.

3-8 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

3.11 BLEEDING THE FUEL SYSTEM

1. Open the bleed screw (3) on the filter

housing. 4 3
2. Using the primer pump (4), pump fuel
through the system until fuel without air
bubbles flows through the bleed screw.
3. Close the bleed screw (3).

M4031

3.12 INSPECTION, GLOW PLUGS

Note:
To avoid engine damage it is important that the
C 5
glow plugs should be checked periodically.
1. Check the glow plugs for the following
points:
- windings that have worn thin due to
abrasion (A). A B
- filament end broken or worn thin due to
continuous knocking of a loose
insulator (B).
- broken plug windings (C).
2. Replace all glow plugs if one or more of the
above-mentioned situations occurs.

y
;;
yy
;
;;
yy
;
y
A

M200818

ǹ 0111 3-9
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.13 INSPECTION, EXHAUST SYSTEM

1. Visually inspect the exhaust system for

leaks.
2. Check the exhaust suspension points.

3.14 INSPECTING THE RADIATOR AND INTERCOOLER FOR FOULING

1. Visually inspect the radiator and intercooler

for fouling If required, clean the radiator and
intercooler, see chapter “Cleaning”.

3.15 CHECKING STEERING-OIL LEVEL

1. Clean the dip stick and its immediate

surroundings.
2. Check the fluid level in the reservoir using
1
5 the dip stick (1).
3. The fluid level should reach the upper
dipstick mark (maximum) when the engine
is running. When the engine is not running,
the fluid level should be approx. 2 cm
higher.

S700173

3-10 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

3.16 INSPECTION, STEERING-MECHANISM LINES AND CONNECTIONS

1. Condition of the lines

- Check all parts for corrosion and wear.
When (a) supply line(s) is/are subject to
underpressure, it is especially likely
that porous lines will give rise to faults
(air in the system).
- If in doubt, always replace the line.
2. Pipe connections
- Check every line connection for leaks.
3. Line course
- Lines must not be twisted during
assembly.
To check for twisting, inspect the hose
for a mark (sometimes in the form of
text).
- Lines should not touch other parts (this
is in view of chafing).
- Lines should not bend sharply; this
applies especially to the flexible supply
line and return line. 5
- Lines should not be pinched off by
other components.

3.17 INSPECTION, STEERING-BALL JOINTS

Inspection, locking devices and dust cover

1. Check whether the locking devices are
present and undamaged.
2. Check the dust cover of the steering-ball
joint, to see whether its gasket is not
damaged. Replace the steering ball joint if
damage is detected.

S700430

ǹ 0111 3-11
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

Inspection, axial steering ball joint play

1. Check the axial steering-ball joint play using 9
special tool (DAF no. 1329426).
2. First jack up the axle until the wheels come
off the ground, and put the axle on stands.
3. Make sure that the castle nut split pin at the
nut does not come into contact with the
ends of the threaded end.
8
4. Screw the thrust washer (8) on to the
threaded spindle.
5. Fit the spring retainer (3), spring (4) and
pressure sleeve (6) into bracket (1).
Fit the locking screw (5). It should be 7
possible to move the pressure sleeve (6)
freely.
Note:
Fit the correct pressure sleeve (6). The
pressure sleeve (6) must abut the rim of the

5 steering ball joint (7). 6

A
6. Loosen thrust bolt (2) until the flange of the 5
pressure sleeve (6) abuts the bracket 4
(A = 0 mm). 3
7. Apply the special tool to the steering ball
joint (7) and turn the threaded spindle (9) by
hand until the special tool is tight around the 1
2
steering ball joint (7).
S700426
8. Tighten thrust bolt (2) until its head abuts
bracket (1).
9. Measure play “A” between the pressure
sleeve and the bracket using a feeler
gauge.
Compare the reading with the maximum
allowable steering ball joint play. See
“Technical Data”.
If necessary, replace the steering ball joint.

3-12 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

3.18 CHECKING BRAKE COMPONENTS/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 standstill,
without having to first charge the brake system
to sufficient operating pressure.
This comes down to a maximum pressure drop
of approx. 0.4 bar per hour at a normal system
pressure.
Note:
Auxiliary consumers and accessories must
always be connected to circuit 4.

3.19 INSPECTION, BRAKE-LINING THICKNESS

1. Pressurise the compressed air-braking

system (pressure switch should cut out) and
5
make sure that the vehicle’s parking brake
is not activated.
2. Check the brake-lining thickness through
the openings in the dust cover.

M6012

3. Replace the brake lining if it is worn down to

the wear-indicator mark on the brake lining.
Note:
When in doubt about the brake-lining wear,
release the brakes and remove the dust
cover.

M6002

ǹ 0111 3-13
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.20 INSPECTION, BRAKE CYLINDER ATTACHMENT

1. Check that the brake cylinders do not move

during operation of the service brake.

3.21 INSPECTION, AUTOMATIC SLACK ADJUSTER

Inspection, brake-adjuster travel

1. Measure the basic setting L1. L1

2. Measure the position when the brakes are

applied, L2 (minimum brake system
pressure 6 bar).
3. Calculate the slack adjuster travel L
L3 = L2 -- L1 (L3 = 35-40 mm).
L2

5 M6101

4. If the slack adjuster travel differs

considerably from the specified value, take
the following action:
- Check whether the control plate (1) is
locked, in respect of the fixed bracket.
If not, turn the control plate as far as
possible (until the internal stop is felt) in
the direction in which the slack adjuster
is moved during braking.
Fix the control plate in this position
using the attachment nut on the fixed
bracket.
- Check the internal slip using a torque
wrench. 1 M6005

Inspection, internal slip

1. Make certain that there is sufficient
pressure in the reservoirs (min. 6.5 bar).
2. Release the parking brake.
3. Turn the hexagonal adjustment screw
counter clockwise using a torque wrench.
4. If a tightening torque of 18 Nm is not
reached, but the worm shaft turns at a
lower torque, the slack adjuster should be
replaced.

3-14 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

3.22 INSPECTION AND ADJUSTMENT, LOAD SENSING VALVE, LEAF-SPRING

Explanatory notes on instruction plate 1261660

The instruction plate contains details of the axle TYPE - TIPO : FA
loads and output pressures, indicated in AUTOM. LASTAFHANKELIJKE REMKRACHTREGELING

accordance with the axle order beneath the AUTOM. LOAD SENSING DEVICE
AUTOM LASTABHANGIGE BREMSKRAFT REGELINR.
DISPOSITIF DE CORRECTION AUTOM DE FREINAGE
vehicle. REGOLATORE AUTOM. DELLA FORZA FRENANTE
REGULADOR AUTOM. DEL ESFUERZO DE FRENADA

So “1” is the front axle, etc.

VALVULA VIDA-CARGA
VALVOLA VUOTO-CARICO
VALVE CHARGE-VIDE
LAST-LEER VENTIEL
EMPTY-LOAD VALVE
MEEREGELVENTIEL

0093778

p4= 6.0 bar

p1= > 6.5 bar
KNR BR 4452
p4
To check the load-sensing control valve, the

p2

p1
i = 1 : 1.5
details on the instruction plate relating to the

L
“driven axle” are therefore vital.

α= 15

L= 195 MM
G= 11.5

2
1. Measure the rear axle load.

CARGA EJE
CARICO ASSE
CHARGE SOUS ESSIEU
ACHSLAST
AXLE LOAD
ASLAST
1
Note:

11.5
11.0
10.0
5.0
4.0
3.0
2.5
2.0
2

x 104N
Vehicles equipped with a trailing axle with
leaf spring should be adjusted with the

G
trailing axle lowered. When adjusting the

PRESION DE SALIDA
PRESSIONE USCITA
PRESSION DELIVREE
AUSGESTEUERTER DRUCK
DELIVERY PRESSURE
UITGESTUURDE DRUK p2
load sensing valve, take the weight of both

6.0
6.0
5.9
5.2
4.9
4.6
4.5
4.4

0.4
1
axles.

6.0
5.8
5.5
3.5
2.9
2.2
1.9
1.7

0.2
2

bar
2. Check the attachment of the control lever
and its ease of operation.
5

PRESION FUELLES
[Link] ARIA
PRESSION COUSSIN
BALG DRUCK
PRESSURE BELLOWS
BALGDRUK
3. Also check whether the correct valve and
the correct spring assembly have been

bar
fitted (See the instruction plate for
information).

p3
M6045

4. Check length L of the control lever (see

instruction plate). 1
5. Connect pressure gauge (1) to test
connection (1) of the load-sensing valve
and pressure gauge (2) to the test
connection on one of the spring-brake
cylinders (service-brake connection) of the
rear axle.
6. Reservoir pressure exceeding 6.5 bar.
2 L
7. Depress the brake pedal until pressure
gauge (1) reads 6 bar, and on pressure
gauge (2), read off the braking pressure of 3
the rear axle. M6106

ǹ 0111 3-15
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

8. Compare this value with the data on the

P2 (bar)
10
table, mounted on the door post. 9
9. The braking pressure can be corrected by 8
moving the rubber socket (2) in relation to
7

1
the vertical connecting rod; do not adjust

1:
length L of the control lever. 6

5
10. Also check whether the delivery pressure is
passed on practically unreduced under 4
maximum load. For this check remove ball 3
joint (3) and move the lever towards the
maximum load position. 2
1:8
1
0.5 0.1

0 1 2 3 4 5 6 7 8 9 10
0.3 0.2 P4 (bar)
W604027

10
P2 (bar)
9

5
P4=7,5 bar
7

1
0
-45 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 95
(¡) R 600108

3-16 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

3.23 INSPECTION AND ADJUSTMENT, LOAD SENSING 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. LASTAFHANKELIJKE REMKRACHTREGELING
AUTOM. LOAD SENSING DEVICE
pressures and bellows pressures, in accordance AUTOM LASTABHANGIGE BREMSKRAFT REGELINR.
DISPOSITIF DE CORRECTION AUTOM DE FREINAGE

with the order of axles beneath the vehicle. REGOLATORE AUTOM. DELLA FORZA FRENANTE
REGULADOR AUTOM. DEL ESFUERZO DE FRENADA

So “1” is the front axle, etc.

VALVULA VIDA-CARGA
VALVOLA VUOTO-CARICO
VALVE CHARGE-VIDE
LAST-LEER VENTIEL
EMPTY-LOAD VALVE
MEEREGELVENTIEL

L1 = 114.0 MM L2 = 4.0 MM

p4= 6.0 bar

p1= > 6.5 bar
W 475 711 071 0
L2
To check the load-sensing control valve, the

p1
i = 1: 1.5
details on the instruction plate relating to the
“driven axle” are therefore vital.

p4
L1
p3
L1 = Effective length of unloaded spring

CARGA EJE
CARICO ASSE
CHARGE SOUS ESSIEU
ACHSLAST
AXLE LOAD
ASLAST
between retainer sleeve and adjustable

1
plug. Spring length in mm.

13.0
12.0
11.5
10.0
4.0
3.0
2.5
2.0
2

x 104N
L2 = Screw length up to locknut in mm.

G
1. Check whether the correct valve is fitted

PRESION DE SALIDA
PRESSIONE USCITA
PRESSION DELIVREE
AUSGESTEUERTER DRUCK
DELIVERY PRESSURE
UITGESTUURDE DRUK p2
6.0
5.9
5.9
5.8
4.5
4.4
4.4
4.3

0.4
1
(see instruction plate).

5.9
5.5
5.3
4.6
2.0
1.6
1.5
1.4

0.2
2

bar
5

PRESION FUELLES
[Link] ARIA
PRESSION COUSSIN
BALG DRUCK
PRESSURE BELLOWS
BALGDRUK
1
5.6
5.1
4.8
4.1
1.2
0.7
0.5
0.3
2

bar

p3

M6046

2. Connect pressure gauge (4) to the test

4
connection of the load-sensing valve (input
pressure). 4
2
3. Connect pressure gauge (2) to the test
connection at the rear axle brake cylinder 2
(output pressure). 43 1
4. Connect pressure gauge (43) with a
pressure-reducer valve to the simulation
connection of the load-sensing valve
(simulated adjustable bellows pressure). 41 42
5. The reservoir pressure should exceed M6102

6.5 bar during the entire measurement

process.

ǹ 0111 3-17
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

6. Set the simulated bellows pressure at its

highest value, as indicated on the
instruction plate. Depress the brake pedal
until gauge (4) indicates a pressure of 6 bar.
Read off pressure gauge (2) and check
whether this braking pressure matches the
pressure marked in the table on the 2
instruction plate. 1
If the measured value is incorrect, the value
of L2 should be altered.
Before attempting to change L2, first make
all connections pressureless.
- Braking pressure too high: shorten L2 L2
- Braking pressure too low: extend L2 41 42
L1
R600120
7. Repeat the procedure described in point 6
until the measured braking pressure is
within the tolerance limits.
8. Set the simulated bellows pressure at its 8 P41 =5.9 bar

P2 (bar)
P41
second highest value, as indicated on the 7
instruction plate. Depress the brake pedal
6

5
until gauge (4) indicates a pressure of 6 bar.
Read off pressure gauge (2) and check 5
whether this braking pressure matches the 4 P41 =2.3 bar
pressure marked in the table on the P42
instruction plate. 3
If the measured value is incorrect, the value 2 P41 =0.5 bar
of L1 should be altered. This is possible P42
1
without removing the spring. 0.5 0.1
Insert a Philips screwdriver of sufficient 0 1 2 3 4 5 6 7 8
length into the hollow adjusting screw.
P4 (bar)
Before attempting to change L1, first make
all connections pressureless. W604025

- Braking pressure too high: extend L1

- Braking pressure too low: shorten L1
9. If L1 has been changed, repeat the
procedure from point 6.

3-18 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

3.24 INSPECTION, ELECTRO-PNEUMATIC VALVES OF THE ABS/ASC

1. Ensure there is sufficient system pressure.

2. Connect a pressure gauge to the brake
cylinder of the wheels to be tested.
3. Fully depress the brake pedal. The pressure
in the brake cylinder will increase
proportionally to the force exerted on the
brake pedal.
Note:
Remember the influence of the
load-sensing valve.
4. No air leakage should occur at the exhaust
of the ABS systems electro-pneumatic
valves.
5. Release the brake pedal.
6. Connect DAVIE to the vehicle.
7. Fully depress the brake pedal.
5
8. Activate the electro-pneumatic valves of the
ABS system using DAVIE and check their
reaction using the pressure gauge.
9. Release the brake pedal.
10. Activate the electro-pneumatic valve of the
ABS system using DAVIE and check its
reaction using the pressure gauge.
11. Remove the pressure gauges and DAVIE.

ǹ 0111 3-19
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.25 INSPECTION, 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.
Then repeat the following checks.
1. Bring the engine to operating temperature.
2. Build up pressure in the brake system
(governor should cut out).
3. Remove the battery earth lead.
4. Remove the safety valve from the
compressor line and replace it with a test
nipple.

5 5. Connect a pressure gauge (measuring

range 0 - 16 bar) to the test nipple.
6. Connect the battery earth lead.
7. Start the engine and run it at maximum
speed.
10 15

8. If the governor is switched off, the 5 20

pressure gauge must show a pressure of 0

25

less than 2 bar; if the measured pressure is

higher than the indicated reading, the
compressor pipe will have to be replaced.
Note:
If the pressure measured is too high, there
is excessive carbon deposit in the
compressor pipe. The cause could be
poor condition of the compressor
(oil consumption).

3-20 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

9. Run the engine at idling speed.

10. Bleed the brake system until the cut-in
pressure of the pressure regulator is
reached, and switch off the engine. The
indictor on the pressure gauge should not
drop rapidly. If necessary, check the system
for leaks. During the inspection special
attention should be paid to the compressor
pipe and the compressor.
11. Remove the battery earth lead.
12. Remove the pressure gauge and re-fit the
safety valve.
13. Connect the battery earth lead.
14. Check safety valve connection for air leaks.

3.26 CHECK UNIVERSAL JOINT FOR STEERING BOX INPUT SHAFT

Check universal joint for steering box input

shaft
5
1. Check the universal joint for noticeable play.
If noticeable play is detected, the universal
joint should be replaced.
2. Check whether noticeable play can be
detected between the universal joint and the
steering box input shaft. If noticeable play is
detected, the universal joint splines and the
input shaft splines should be checked for
wear. If wear is detected, the worn part
should be replaced.
3. If the components are not worn but there is
discernible play, the nut and bolt should be
replaced. Tighten the nut and bolt to the
specified torque. See “Technical Data”.

S7 00 639

ǹ 0111 3-21
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.27 INSPECTION, FLUID LEVEL OF THE CLUTCH

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. Avoid any
contact between hydraulic fluid and
paintwork.

Always use new and clean hydraulic

fluid which has been kept in a C
sealed container and meets the
specifications.
Hydraulic fluid which has absorbed
water (from the ambient air) may
have an adverse effect on the
operation of the clutch system.

5
Avoid any contact with mineral oil.
Even one drop of mineral oil in the
B
system will damage the seals.

1. Check whether the fluid level is between the

(A) and (B) marks when the cab is in the
A
driving position.
2. Mark (C) applies to fully tilted cabs.

V300178

3-22 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

3.28 CHECKING OILED AND GREASED WHEEL HUBS FOR LEAKS

1. If leaks occur in the oil lubricated wheel

hubs, the wheel hub should be refilled to the
correct level once the leak has been
repaired, see “Draining and Filling”.
2. If there is leakage on the greased wheel
hubs, the bearing grease should be
checked. If necessary, the grease should be
replaced by grease with the prescribed
specification once the leak has been
repaired, see “Fluids and lubricants”
specification manual.

3.29 CHECKING DIFFERENTIAL FOR LEAKS

1. Visually inspect the differential for leaks.

3.30 CHECKING GEARBOX FOR LEAKS

5
1. Visually inspect the gearbox for leaks.

3.31 CHECKING SPLITTER BOX FOR LEAKS

1. Visually inspect the splitter box for leaks.

ǹ 0111 3-23
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.32 INSPECTION, OPERATION OF DIFFERENTIAL LOCK

1. Jack up the rear axle and support the axle

on stands.
2. Bring the air system to operating pressure.
3. Engage the differential-gear lock. The
warning lamp should now come on.
4. Check whether there is a “rigid” connection
between the driven wheels.
5. Disengage the differential-gear lock. The
warning lamp must not light up and the
“rigid” connection between the driven
wheels should be broken.
M8031

3.33 INSPECTION, PIVOTING ENDS OF THE AXLE SUSPENSION, AIR

SUSPENSION
5 Torque rod
1. Check the attachment of the torque rod and
torque-rod supports.
2. Check the pivoting ends of the torque rod
for wear and play.
Stabiliser
1. Check the attachment of the stabiliser and
stabiliser supports.
2. Check the pivoting ends of the torque rod
for wear and play.
Ball joints three-point fixation
1. Check the attachment of the ball joints and
three-point fixation support.
2. Check the ball-joint housing for surface
cracks.
3. Check the dust cover for damage.

3-24 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

3.34 INSPECTION, DRIVE-SHAFT PLAY

1. Check the universal joints and centre

bearing for play and damage.

M3032

2. Check the slide joint for axial and radial

play.

M3019

3. There must be no clearly noticeable play on

universal joints, centre bearing and slide
joint.

M3020

ǹ 0111 3-25
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.35 INSPECTING AIR BELLOWS OF AIR SUSPENSION

1. Raise the chassis in its highest position

using the remote control.
2. Clean the air bellows using a cleaning rag
or a soapy solution, if required.
3. Check the air bellows for cracks and
damage. If cracks or damage is found
through which the webbing is visible, the air
bellows should be replaced.
4. Check the air bellows, bellows seating and
air-line connections for leaks.
Check that the air bellows, when in their
highest position and in driving position, do
M9040
not rub against air lines etc.

3.36 INSPECTION, OPERATION OF THE AUTOMATIC LUBRICATING SYSTEM

5 1. Check the system for line fracture and

operation of the jets.
2. Check whether all lubricating points are
lubricated.
3. Check the lubricant level in the reservoir. If
required, top up the reservoir, see chapter
“Draining and filling”.

W 9 07 004

3-26 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

3.37 INSPECTION, TRAILER COUPLING

1. Check the upward play of the arched pin.

2. Check the radial play of the arched pin.

M9002

3. Check the vertical and horizontal play of the

coupling jaw.

M9001

4. Check the diameter of the arched pin.

5. Check the attachment of the trailer coupling
and the rear cross member.
Note:
For maximum play values, consult the
manufacturer’s instructions or the legal
requirements.

M9004

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.38 CHECKING SHOCK ABSORBERS FOR ATTACHMENT AND LEAKS

1. Visually inspect the attachment of the shock

absorbers and whether they are leaking.

3.39 INSPECTION AND ADJUSTMENT, WHEEL BEARING PLAY

FRONT AXLE
Inspection, wheel bearing play
1. 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:
1. extensions 6
2. central nut
3. dial gauge holder
4. threaded spindle
5
5. bridge 2

5
6. socket wrench
7. additional extensions
2. Remove the hub cover. 4 3
1
3. Remove two opposite wheel nuts.
4. Fit the extensions (1) to the vacant wheel
7
studs. The extensions belonging to the set S7 00 131
should now be extended using the
extension pieces (7).
5. Place the dial gauge holder (3) on the
central nut (2).

S7 00 079

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65CF series Inspection and adjustment

6. Fit the central nut (2) to the axle end using

the socket wrench (6). If too little screw
thread protrudes from the lock nut to fit the
central nut (2) to the axle stub, the lock nut
should be removed from the axle stub.
If the lock nut is removed from the axle
stub, the central nut (2) should be tightened
to the tightening torque as specified for the
lock nut. See “Technical Data”.

S7 00 080

7. Place the dial gauge in the dial gauge

holder (3) so that the stylus abuts the hub.
Make sure that the stylus of the dial gauge
does not enter into a threaded hole of the
hub, because the stylus might break off

5
when the wheel is turned.

S7 00 081

8. Position the bridge (5) on the extensions (1)

so that the end of the spindle fits into the
recess of the central nut (2). Tighten the
bridge with the nuts.
9. Place a torque wrench on the hexagon 2
head of the spindle (4).
Press the hub firmly on to the axle stub by
screwing the spindle in, until a tightening
torque of 40 Nm is reached.

S7 00 082

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

10. Withdraw the wheel hub by unscrewing the

spindle, until a tightening torque of 40 Nm is 40Nm
reached.
11. Press the wheel hub on to the axle stub by (1)
screwing the spindle in, until a tightening
torque of 15 Nm is reached, and set the dial
gauge to “O”. 40Nm
12. Withdraw the wheel hub by unscrewing the
spindle, until a tightening torque of 15 Nm is (2)
reached. Take the reading from the dial
gauge and compare this value with the 15Nm
specified value. See “Technical Data”.
If the reading falls outside the tolerance
(3)
range, the wheel-bearing play should be
re-adjusted.
15Nm
13. Remove the special tool.
(4)
14. If the lock nut has been removed, the
locking plate should be replaced. Tighten A800150

5 the lock nut to the specified torque. See

“Technical Data”.
15. Apply some grease to the outside of the
bearing cage.
16. Apply silicone sealant to the hub cover.
17. Install the spring assembly.
18. Tighten the two wheel nuts to the specified
torque. See “Technical Data”.
Mark these two nuts and tighten them, after
100 km.

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65CF series Inspection and adjustment

Adjustment, wheel bearing play

1. Remove the locknut from the axle stub
using socket wrench (A), special tool
A
(DAF no. 0535832).
2. Remove the lock plate and the circlip from
the axle end.

S7 00 084

3. Loosen adjusting nut (1) one turn using

adjusting spanner (A), special tool
(DAF no.0694783).

5
1

A
S7 00 085

4. Place a torque wrench on the adjusting

spanner. Tighten the adjusting nut to a
tightening torque of 100 Nm, while turning
the wheel hub.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

5. 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 circlip (2) can be fitted.
If necessary, turn the circlip around,
changing the hole pattern. 1

A
S7 00 085

6. Fit the circlip (2) so that the circlip lip falls

into the key groove of the axle stub and the
dowel of the adjusting nut (1) falls into one
5 of the holes of the circlip (2).

S7 00 086

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Inspection and adjustment

3.40 INSPECTION, HUB AND WHEEL BEARINGS

1. Inspect the wheel bearings for damage at

the following points:
- the roller bearing race
- the bearing cage
- the raceways of the inner and outer
race.
If damage is found, the entire wheel bearing
(inner race/bearing cage and outer race)
should be replaced.
2. When the outer race of the bearing is loose
in the wheel hub or has turned in the wheel
hub, the wheel hub should be replaced.
3. The following points of the axle end should
be inspected for damage: the screw thread,
the bearing surfaces of the inner bearing
races and the running surface of the oil
seal.
4. Check the wheel speed sensor ring for
damage. If even the slightest damage is
5
found, it should be replaced.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Inspection and adjustment 65CF series

3.41 INSPECTING THE SUPERSTRUCTURE ATTACHMENT

1. Check if all attachment bolts are present.

2. Visually check the attachment of the
superstructure for faults.

3.42 CHECKING THE ATTACHMENT AND CONDITION OF THE SPRING

LEAVES/SPRING CLAMPS AND U-BOLTS

Inspect U-bolts
1. Visually inspect the condition and
attachment of the U-bolts.
2. When retightening the U-bolt nuts, the
attachment nut must not be slackened
first and then tightened to a specific torque,
see “Technical data”.

3-34 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Removal and installation

4. REMOVAL AND INSTALLATION

4.1 REMOVAL AND INSTALLATION, INTERIOR FILTER ELEMENT

Removal of interior filter element

1. Open the grille.
2. Undo the screws (1) so that the tab
fasteners turn down.
3. Remove the filter (2).
2
4. If required, clean the filter, see chapter
“Cleaning”.
In case of excessive fouling or damage, the
filter should be replaced.
1 1
Fitting interior filter element
1. Fit the filter (2) in the correct position.
The arrows on the filter indicate the air-flow
direction.
K100808
2. Fit the filter at the top first.
3. Secure the screws (1) so that the tab 5
fasteners secure the filter (2).

4.2 REMOVAL AND INSTALLATION, OIL FILTER

To prevent skin injury, avoid

unnecessary contact with the
drained oil.

Removal, oil filter

1. Place a tray beneath the filter.
2. Remove the filter by turning it
counter-clockwise using a strap wrench.
Note:
The oil filter is a disposable filter, and may
not be cleaned and reused.
Installation, oil filter
1. Fill the new oil filter before fitting using the M2115
specified oil grade.
2. Lightly lubricate the sealing ring with engine
oil.
3. Fit the filter so that the seal makes contact.
Then tighten the filter by hand 1/2 to 3/4 of a
turn.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Removal and installation 65CF series

4. Start the engine, and run it at idling speed

for a short time. Check whether the oil filter
is correctly sealed.
5. Then check the oil level.

4.3 REMOVAL AND INSTALLATION, AIR CLEANER ELEMENT

Removing the air filter element

1. Loosen the clamping brackets (1) on the air 1 2
filter cover.
2. Remove the air-filter cover and the air-filter
element (2).
3. Clean the inside of the air filter housing and
the air filter cover.
4. If required, clean the air filter, see chapter
“Cleaning”.

5
5. When replacing the air filter element, the air
i400353
filter indicator, if fitted, must be reset by
pressing the knob on the top of the
indicator.

M200729

4-2 ǹ 0111
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65CF series Removal and installation

Installing the air filter element

1. Smear the inside of the sealing ring (3) if
necessary sparingly with petroleum jelly and
install the air-filter in the air-filter housing.
2. Place the air-filter cover in the correct
position on the air-filter housing and fit the
clamping brackets (1).

3 i400354

3. Check whether the flexible sealing bellow

(4) on the air inlet is not damaged, and if
5
necessary renew.
Note:
The filter element can be cleaned once, 4
after which it must be renewed.

i400355

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Removal and installation 65CF series

4.4 REMOVAL AND INSTALLATION, FUEL FILTER

When removing the fuel filter, a

quantity of fuel will escape. Collect
the fuel and prevent fire.

Removal, fuel filter

1. Place a tray beneath the filter.
2. Remove the filter by turning it
counter-clockwise using a strap wrench.
Note:
The fuel filter is a disposable filter, and may
not be cleaned and reused.
Installation, fuel filter
1. Do not fill the new fuel filter with diesel fuel.
2. Lightly lubricate the sealing ring with engine
oil, not diesel fuel.

5
3. Fit the filter until the sealing ring abuts and M4030

then manually rotate a 1/2 to 3/4 turn further.

Note:
Do not use any tools when tightening.
4. Bleed the fuel system, if necessary. See
“Inspection and adjustment”.
5. Start the engine and check for leaks.
Retighten the filter by hand, if necessary.

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65CF series Removal and installation

4.5 REMOVAL AND INSTALLATION, V-BELT

Removing V-belt
1. Slacken the attachment bolts (1) of the
brackets.
2. Tilt the alternator in the direction of the
engine block so that the V-belt can be 1
removed. 1
3. Remove the upper bracket from the
windtunnel and remove the V-belt via the
opening between the windtunnel and fan.
Fitting V-belt
1. Inspect the pulleys for damage, rust and
grease deposits.
1 M2063

2. Fit the new V-belt and adjust the V-belt

tension. See “Inspection and adjustment”.

4.6 REMOVAL AND INSTALLATION, VALVE COVER

5
Removing the valve cover
1. Clean the area around the valve cover.
2. Remove the air inlet duct (1) which is
installed over the valve cover (2). Make
sure that no dirt can get into the turbo and 1
the compressor lines.
2
3. Remove the attachment bolts (3) from the
valve cover.
4. Remove the valve cover and the gasket.
Installing the valve cover
1. Clean the sealing face of the valve cover.
2. Fit the valve-cover (2) using a new
valve-cover gasket. 3 M2117

3. Install the attachment bolts (3) of the valve

cover, see main group “Technical Data”.
4. Install the air inlet duct (1).

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Removal and installation 65CF series

4.7 REMOVAL AND INSTALLATION, STEERING-MECHANISM FILTER ELEMENT

Removal of steering mechanism filter

element
1. Clean the reservoir cover, so that no dirt
can fall into the reservoir.
2. Remove the cover (3), turn filter holder (5) a
quarter turn and remove the filter holder 2
containing the filter element (6) from the 3
reservoir carefully, so that no dirt from the
filter element can fall into the reservoir. 4
3. Remove the filter element from the filter
1
holder. 5
Installation of steering mechanism filter 6
element
1. Fit a new filter element on the holder and
install the filter holder containing the filter in
the reservoir. Make sure that the filter holder
M7002
engages in its locking element.

5 2. Check the seal (4) on the cover (3) and fit

the cover.
3. Check the fluid level using the dip stick (2),
see chapter “Inspection and adjustment”.

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65CF series Removal and installation

4.8 REMOVAL AND INSTALLATION, AIR-DRYER FILTER ELEMENT

Removal, air drier filter element

1. Remove the compressor line (1); as a
result, the inside of the air dryer will become
pressureless.
2. Remove the filter element by turning it
counter-clockwise using a strap wrench.
3. Clean the air dryer internally.

R600251

4. Check the air dryer threaded connection (2)

for damage and then lubricate it sparingly
with grease.

5
Installing the air dryer filter element
1. Lubricate the sealing ring of the new filter
element sparingly with grease.
2. Install the filter element by manually
tightening it until the sealing ring abuts.
Subsequently turn the air-dryer filter
element one full turn by hand. 2
3. Fit the compressor line (1).
4. Pressurise the system and subsequently
check the air dryer for possible air leakage. R600252

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Removal and installation 65CF series

4.9 REMOVAL AND INSTALLATION, GEARBOX OIL FILTERS

Allison gearbox
Removal of the gearbox oil filters
1. Bring the transmission to operating
temperature before draining the oil
(approx. 71_C - 93_C). The oil will then
drain faster and more fully.
2. Position the vehicle on a level surface.
3. Remove the drain plug from the gearbox oil
sump.
4. Remove the twelve attachment bolts of the
two filter covers underneath the gear box oil
sump.
5. Remove the two covers and filters and the
various O-rings from the oil sump.
Installation gearbox oil filters
5 1. Oil the O-rings and insert the oil filters with
the covers in the gearbox oil sump. Ensure
that the covers are correctly positioned.
Never centre the covers with the bolts.
2. Fit the cover attachment bolts and the oil
drain plug and tighten them to the specified
tightening torque. See “Technical Data”.
3. Fill the gearbox with oil, see “Draining and
filling”.

W 3 03 103

4-8 ǹ 0111
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65CF series Removal and installation

4.10 REMOVAL AND INSTALLATION, WHEEL HUB

FRONT AXLE
14
11 12 13
9 10
8

7
4 5 6
3
1 2

S7 00 401

Removal, wheel hub

1. Jack up the axle until the wheels are clear
5
from the floor and position suitable stands
A
under the axle.
2. Release the brake shoes.
3. Remove the hub cover (2).
4. Tap back the lock plate (4) and remove the
lock nut (A) from the axle stub using special
tool (A) (DAF no. 0535832).
5. Remove the lock plate (4) and the circlip (5)
from the axle end.
6. Position a tyre lift under the wheel. S7 00 084

ǹ 0111 4-9
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Removal and installation 65CF series

7. Detach the adjusting nut (6) from the axle

stub using adjusting spanner (A), special
tool (DAF no.0694783).
8. Remove the outer wheel bearing (7) from
the wheel hub (9). A
Note:
If the bearings are removed from both
wheels, they should be marked. Each
bearing should be reinstalled in its original
wheel hub. 6
9. Remove the wheel hub with the wheel of
the axle stub.
Avoid damaging the wheel speed sensor
ring (10).
10. Remove the oil seal (14) from the wheel S7 00 404
hub.
11. Remove the inner wheel bearing (13) from
the wheel hub (9).

5 12. Remove the grease from the wheel hub (9)

and clean the wheel hub.
13. Thoroughly clean the bearing cages using a
cleaning liquid.
14. Remove the outer races (8 and 12) of the
wheel bearings, if necessary.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Removal and installation

14
11 12 13
9 10
8

7
4 5 6
3
1 2

S7 00 401

Installation, wheel hub

1. Check the wheel hub and the wheel
bearings for wear and damage, see

5
“Inspection and adjustment”.
2. Fit a new wheel speed sensor ring (10) to
the wheel hub, if necessary.
3. Fit new wheel bearings into the wheel hub,
if necessary.
4. Blow-dry the wheel bearings (7 and 13)
using compressed air.
5. Fill the wheel bearings with the specified
wheel bearing grease.
Also apply a layer of grease to the wheel
bearing circumference.
6. Fit the wheel bearing (13) into the wheel
hub (9).
7. Fill the inside circumference of the wheel
hub with bearing grease.
8. Fit a new oil seal (14) in the wheel hub (9).

S7 00 140

ǹ 0111 4-11
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Removal and installation 65CF series

9. Apply a little grease to the sealing lips of the

lubricant seal (14).
10. Check that the wheel speed sensor (11) is
correctly clamped in the stub axle. Replace
the clamping sleeve of the sensor, if
necessary.
11. Position the wheel in front of the axle end
using the tyre lift.
Fit the outer wheel bearing (7) into the
wheel hub so that the outer wheel bearing
can also serve as a guide when installing
the wheel hub.
12. Slide the wheel hub over the axle end.
Do not pry, as the lubricant seal (14) might
be damaged in the process.
13. Fit the adjusting nut (6) to the axle end.
14. Adjust the specified wheel bearing play (see
“Inspection and adjustment”) and fit the

5 circlip (5) to the axle end.

15. Fit a new lock plate (4) to the axle end. The
lock-plate cam (see the arrow) should catch
in one of the holes of the circlip (5). 5

S7 00 402

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65CF series Removal and installation

16. Fit the lock nut (3) to the axle end. Tighten
the lock nut (3) to the specified torque. See
“Technical Data”. Use a socket spanner (A)
for this, special tool (DAF no. 0535832).
17. Secure lock nut (3) by tapping back the lock
plate (4) against the side of the lock nut.
18. Apply the specified grease to the front of the
outer wheel bearing.
19. Clean the wheel hub (9) sealing surfaces A
and the hub cover (2), and make sure they
are dry and grease-free.
20. Apply a locking compound to the wheel hub
(9) sealing face. S7 00 087

21. Fit the hub cap (2). Tighten the bolts (1) to
the specified torque. See “Technical Data”.
22. Press the wheel speed sensor (11) up
against the sensor ring (10). While the 10 11
5
vehicle is being driven, the air gap between
the wheel speed sensor (11) and the sensor
ring (10) is adjusted automatically.
23. Adjust the brakes.

S7 00 403

ǹ 0111 4-13
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Removal and installation 65CF series

4.11 REMOVAL AND INSTALLATION, HUB OIL SEAL

FRONT AXLE

A B C D E F

1 2 3 H I K L

4 G

S7 00 180

Removal, hub oil seal

1. Remove the wheel hub from the axle end.
2. 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).
Installation, hub oil seal
1. Check the oil seal chamber (4) in the wheel
hub (2) for damage.
2. For the installation of the hub oil seal (4)
use special tool (DAF no. 1240036).

4-14 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Removal and installation

3. Assemble the special tool: turn the threaded

ends (A and L) into the centring spindle (E).
Assemble the short threaded end (L) on the
side where the pin has been fitted into the
centring spindle (E).
4. Slide the appropriate centring flange (F)
over the centring spindle (E).
5. Install the inner wheel bearing (3).
Slide the centring spindle (E) with the
centring flange (F) into the wheel hub (2).
6. Press the centring flange (F) into the inner
wheel bearing (3).
7. Slide the appropriate centring flange (D) on
the centring spindle (E).
8. Fit the locking plate (C) and the nut (B) on
the centring spindle (E).
9. Align the centring flange (D) on the outer

5
race of the outer wheel bearing and
hand-tighten nut (B) (max. 20 Nm). The
centring spindle (E) must be installed in the
wheel hub (2) free of play.
Note:
Fit the dummy sensor ring (G) to the
draw-in flange (H) if the wheel hub (2) is
not equipped with a sensor ring (5).
Fit the draw-in flange (H) without the
dummy sensor ring if the wheel hub (2) is
equipped with a wheel speed sensor
ring (5).
10. Position the oil seal (4) in front of the wheel
hub with the seal lip pointing to the outside
of the wheel hub.
Slide the draw-in flange (H) over the
centring spindle (E) against the oil seal (4).
11. Fit the locking plate (I) and the nut (K).

ǹ 0111 4-15
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Removal and installation 65CF series

12. Push the oil seal (4) evenly into the wheel
hub (2) using the nut (K). In the case of a
3
wheel hub with a wheel speed sensor ring F
(5) the oil seal should be pressed in until
draw-in flange (H) abuts the sensor ring (5). H
In the case of a hub without wheel speed
sensor ring (5) the oil seal should be
pressed in until the dummy wheel speed
sensor ring (G) abuts the hub rim.
13. Remove the special tool.
14. Apply grease to the sealing lips of the oil 4 5
seal (4).
15. Install the wheel hub on the axle stub. S7 00 182

4.12 REMOVAL AND INSTALLATION, COMBINED HUB OIL SEAL/WHEEL SPEED

SENSOR RING

Removal, combined hub oil seal/wheel speed

5 sensor ring
1. Remove the wheel hub from the axle end. 1
2. Fit special tool (3) (DAF no. 1329411) to the
impact puller (2) (DAF no. 0694928). Hook 2
special tool (3) (DAF no. 1329411) behind
the oil seal (1). Pull the oil seal evenly from
the wheel hub using the special tool
(DAF no. 0694928). The removed oil seal
(1) cannot be used again. 3
S7 00 424

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65CF series Removal and installation

A B C D E F

1 2 3 H I K L

4 G
5
S7 00 405

Installation, combined hub oil seal/wheel

speed sensor ring
1. Check the oil seal chamber (4) in the wheel
hub (2) for damage.
2. For the installation of the hub oil seal (4)
use special tool (DAF no. 1240036).

ǹ 0111 4-17
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Removal and installation 65CF series

3. Assemble the special tool: turn the threaded

ends (A and L) into the centring spindle (E).
Assemble the short threaded end (L) on the
side where the pin has been fitted into the
centring spindle (E).
4. Slide the appropriate centring flange (F) E F
over the centring spindle (E).
5. Install the inner wheel bearing (3).
Slide the centring spindle (E) with the
centring flange (F) into the wheel hub (2).
6. Press the centring flange (F) into the inner
wheel bearing (3).
7. Slide the appropriate centring flange (D) on 3 H I K L
the centring spindle (E).
8. Fit the locking plate (C) and the nut (B) on
the centring spindle (E).
9. Centre the centring flange (D) on the outer

5
ring of the outside wheel bearing
and hand-tighten the nut (B) (max. 20 Nm). 4 G
2
The centring spindle (E) must be installed in
the wheel hub (2) free of play.
S7 00 411
10. Fit the ring (G) on the draw-in flange (H).
11. Position the oil seal (4) in front of the wheel
hub (2).
Slide the draw-in flange (H) with the ring (G)
over the centring spindle (E) against the oil
seal (4).
12. Fit the locking plate (I) and the nut (K).
13. Press the oil seal (4) evenly into the wheel
hub (2) using nut (K), until the wheel speed
sensor ring abuts the wheel hub (2).
14. Remove the special tool.
15. Apply grease to the sealing lips of the oil
seal (4).
16. Install the wheel hub on the axle stub.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF 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 a corrosive fluid.

In the event of contact with the

skin: Rinse the skin with plenty of
water for a sustained period. If
redness or pain persists, consult a
doctor. Remove any clothing
affected and rinse with water.
In the event of contact with the
eyes: Rinse with plenty of water for
at least 15 minutes and see a
doctor.
If any is swallowed: do NOT induce
vomiting. Rinse the mouth, drink
two glasses of water and see a

5
doctor.
In the event of inhalation: Get some
fresh air, rest and consult a doctor.

Topping up battery fluid

1. Clean the top of the battery. If the top side
of the battery is contaminated with acid, it
should be rinsed using water.
2. Remove the plugs and top up the batteries
with distilled water to approximately 10 mm.
above the plates or up to the “max” indicator
level.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Draining and filling 65CF series

5.2 DRAINING AND FILLING, ENGINE OIL

To prevent skin injury, avoid

unnecessary contact with the
drained oil.

1. Place the vehicle on a flat horizontal

surface.
2. Drain the oil using the drain plug (A) in the
oil sump.
3. Replace the drain plug oil seal and tighten
the drain plug to the specified torque. See
“Technical data”. A
4. Fill the engine through the filler opening in
M2114
the valve cover with the specified engine oil
quantity. See “Technical Data”.

5.3 DRAINING AND FILLING/BLEEDING, COOLING SYSTEM

5 In order to avoid damaging the
cylinder block, do not top up a
warm engine with cold coolant.

Coolant is a toxic substance and

must be handled with care. Protect
skin and eyes.

Coolant is harmful to the

environment; after use, it should be
processed as industrial chemical
waste.

When the coolant is hot, there is an

overpressure in the cooling system.
When removing the filler cap, allow
the overpressure to escape by first
loosening the filler cap one turn.

5-2 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Draining and filling

Draining the cooling system

1. Turn the heater control knob to the
“warmest” temperature setting. As a result,
the heater cock will be fully opened.
2. Remove the cooling system filler cap.
3. Collect the coolant. Position suitable
containers under the drain points.
4. Drain the cooling system at the cylinder
block via drain tap (A) (above the starting
motor), the radiator via drain plug (B) and
the oil cooler via drain plug (C).
5. Flush the cooling system.
6. Close drain tap (A) and fit drain B
plugs (B - C ).
Filling/bleeding the cooling system
1. Turn the heater temperature control knob in
the cab to the “warmest” setting.
2. Fill the cooling system with the specified
coolant. A 5
C M2107
3. Run the engine for several minutes.
4. The cooling system is bled automatically.
Ensure that the air bleed pipe from the
thermostat housing to the header tank is not
kinked or pinched off.
5. Check the coolant level, and if necessary
top up with coolant.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Draining and filling 65CF series

If the vehicle is equipped with a water/air cab

heater.
6. Run the engine at idling speed.
7. Switch on the cab heater, using the rocker
switch on the dashboard.
8. Turn the heater temperature control knob in
the cab to the “warmest” setting.
9. Switch on the heater fan.
10. Set the rocker switch on the thermostat in
the cab to position
Note:
Combustion will start after approximately
one minute.
11. Allow the cab heater to operate for
approximately 15 minutes.
12. Then check the coolant fluid level.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Draining and filling

5.4 DRAINING AND FILLING, DIFFERENTIAL

1132 and 2235V-axle

To prevent skin injury, avoid
unnecessary contact with the
drained oil.

Draining, differential gear

1. Position the vehicle on a level surface.
2. Remove the level check/filler plug (A) and
A
drain plug (B) and drain the oil.
Filling, differential gear
1. Position the vehicle on a level surface.
2. Fit the drain plug (B) using the special Torx
spanner (Daf no. 1329422) and tighten it to
the specified torque. See “Technical Data”.
3. Fill the differential with the specified amount

5
of oil.
B M8048
4. Check the oil level after approximately
5 minutes. See “Inspection and adjustment”.
5. Fit the level check/filler plug (A), using the
special Torx spanner (Daf no. 1329422) and
tighten it to the specified torque. See
“Technical Data”.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Draining and filling 65CF series

5.5 DRAINING AND FILLING, WHEEL HUB

1132-axle
To prevent skin injury, avoid
unnecessary contact with the
drained oil.

Draining, wheel hub

1. Position the vehicle on a level surface.
2. Position the wheels so that the level
check/filler plug (A) is on the underside.
3. Remove the level check/filler plug (A) and
drain the oil.

5 M8010

Filling, wheel hub

1. Position the vehicle on a level surface.
2. Position the wheels so that the arrow on the
hub is facing upwards vertically. Remove
level check/filler plug (A).
3. Fill the wheel hub with the specified amount
of oil.
4. Check the oil level after approximately
5 minutes. See “Inspection and adjustment”.
A
5. Fit the level check/filler plug (A), using the
special Torx spanner (Daf no. 1329422) and
tighten it to the specified torque. See M8009
“Technical Data”.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Draining and filling

5.6 DRAINING AND FILLING, GEARBOX

To prevent skin injury, avoid

unnecessary contact with the
drained oil.

ZF S6-36/2 / 6S-850 en 9S-75 gearboxes

Draining, gearbox
1. Place the vehicle on a flat horizontal
surface.
2. Drain the gearbox at operating temperature
A
using plug (B).
3. Remove level check/filler plug (A).
Filling, gearbox
1. Clean the drain plug and fit it, tightening to
the specified torque. See “Technical data”.
2. Fill the oil through level check/filler opening
B
5
(A) until the oil reaches the rim of the filling
opening. M3038

3. Fit the level check/filler plug, tightening it to

the specified torque. See “Technical data”.
Allison gearbox
Draining, gearbox
1. Bring the transmission to operating
temperature before draining the oil
(approx. 71_C - 93_C). The oil will then
drain faster and more fully.
2. Position the vehicle on a level surface.
3. Remove the drain plug from the gearbox oil
sump and remove the dipstick.
4. Replace the oil filters, see chapter
“Removal and installation”.

W 3 03 098

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Draining and filling 65CF series

Filling gearbox
1. Clean and fit the drain plug, tightening it to
the specified torque. See “Technical Data”.
2. The dipstick holder is also the filler pipe for
the gearbox oil.
3. Check the oil level with the dipstick, see
main group “Technical data”.
4. Check the oil level after the test drive, see
chapter “Inspection and adjustment”.

5.7 DRAINING AND FILLING, SPLITTER BOX

Draining the splitter box

1. Place the vehicle on a flat horizontal
surface.
2. Drain the splitter box at operating
temperature using plug (B).

5 3. Remove level check/filler plug (A).

Filling the splitter box
1. Clean the drain plug and fit it, tightening to
the specified torque. See “Technical data”.
2. Fill the oil through level check/filler opening
until the oil reaches the rim of the filling
opening.
3. Fit the level check/filler plug (A), tightening it
to the specified torque. See “Technical
Data”.

A B
V300255

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Draining and filling

5.8 FILLING THE GREASE SUPPLY OF THE AUTOMATIC LUBRICATING

SYSTEM

1. Remove the dust cover from the filler

coupling (1).
2. 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.
3. Fill the reservoir to the specified maximum
level.
Note:
When filling the reservoir, the air above the
level piston will escape.
This air will flow downward through an
opening in the piston line and escape from
the pump through the angled coupling.
Normally a small amount of grease will
escape from this coupling during bleeding.
4. Connect the filler line to the filler coupling.
1
5

W 9 07 004

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Draining and filling 65CF series

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Cleaning

6. CLEANING
6.1 CLEANING INTERIOR FILTER ELEMENT

1. Remove the filter (2), see chapter “Removal

and installation”.
2. The filter can be cleaned by tapping off the
dirt which has accumulated on the filter
surface. 2
In case of excessive fouling or damage, the
filter should be replaced.

1 1

K100808

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Cleaning 65CF series

6.2 CLEANING, BATTERY TERMINALS

Avoid sparks and open flames in

the vicinity of batteries. Battery acid
is a corrosive fluid.

In the event of contact with the

skin: Rinse the skin with plenty of
water for a sustained period. If
redness or pain persists, consult a
doctor. Remove any clothing
affected and rinse with water.
In the event of contact with the
eyes: Rinse with plenty of water for
at least 15 minutes and see a
doctor.
If any is swallowed: do NOT induce
vomiting. Rinse the mouth, drink
two glasses of water and see a
doctor.
In the event of inhalation: get some

5
fresh air, rest and consult a doctor.

1. Disconnect the earth lead from the battery

terminal.
2. Disconnect the positive lead from the
battery terminal.
3. Clean the battery poles, battery leads and
the top side of the battery (oxide and dirt will
discharge the battery).
4. If the top side of the battery is contaminated
with acid, it should be rinsed using water.
5. Grease the battery poles with Vaseline.
6. Check the earth-lead connection to the
M5012
chassis and grease the connection with
Vaseline.
7. Fit the positive lead to the battery terminal.
8. Fit the earth lead to the battery terminal.
9. Check the routing and attachment of the
battery leads.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Cleaning

6.3 CLEANING, AIR FILTER ELEMENT

Inhaling dust can seriously damage

your health.
Take the necessary precautions,
such as wearing goggles and a face
mask.

1. Remove the air filter element. See

“Removal and installation”.
2. Check the air filter element for damage. If
the air filter element or its sealing rings are
damaged, the air filter element must be
replaced.
3. Knock out the air filter element.
4. Blow-clean the air filter element from the
inside using compressed air. Maximum
pressure 1.5 bar.
5. Fit the air filter element. See “Removal and
installation”. M2009 5
6. Reset the air filter indicator, if fitted, by
pressing the button on the upper side of the
indicator.

M200729

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Cleaning 65CF series

6.4 CLEANING, RADIATOR AND INTERCOOLER

Inhaling dust can seriously damage

your health.
Take the necessary precautions,
such as wearing goggles and a face
mask.

Cleaning, protective screen

1. Remove the lower grille.
2. Unscrew the protective screen attachment
bolts.
3. Remove the protective screen.
4. Clean the protective screen with a hard
brush, and blow-clean it with compressed
air.
Cleaning the radiator/intercooler element

5
Note:
With the aid of a simple tool, the radiator and the 1150mm

intercooler can be blow-cleaned. 1

5mm
This tool can be made in your own workshop. It
cannot be obtained from DAF. 32 5
Key to drawing: 2
1. Solder up 100mm
2. Solder
3. Quick-release coupling for air pipe 4 4 5
4. Steel pipe with ∅ 10 mm
5. 6 x ∅ 1.5 mm between holes, with a
centre-to-centre distance between the 1
holes of 7 mm, drilled on one side.
M2108

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Cleaning

1. Insert radiator cleaner (4) between

intercooler (1) and radiator (2), from the
bottom upwards, with the air holes facing
3
the intercooler (1). 1 2
2. Apply air pressure to the radiator cleaner (4)
and continue blow-cleaning the intercooler
(1) until the release of dirt has stopped.

P M2109

3. Turn the radiator cleaner over, turning the

holes towards the radiator (2), and
blow-clean the radiator (2).
3
1 2

5
4

P M2110

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Cleaning 65CF series

6.5 CLEANING, VEHICLE

Note:
Before cleaning the vehicle, check the engine,
axles, gearbox, etc. for evidence of leakage.
Having cleaned the vehicle, this will no longer be
possible during the maintenance activities.
- Make sure that doors, windows and roof
hatch are securely closed during cleaning.
- When cleaning the universal joint on the
steering box, the spider seals may be
forced open by the high-pressure jet of
water, so that the grease behind them is
flushed away. As a result, the spider may
get stuck, so that the steering will “jam”.
- A bleed screw is fitted to the power steering
fluid reservoir of the steering system. Water
may enter the power steering fluid reservoir
via the bleed screw, which will cause

5 -
damage to the steering gear.
When cleaning the radiator/intercooler, be
careful not to damage the fins.
- Do not direct the high-pressure cleaner jet
too long at the air-conditioning system
condenser. As a result of the high
temperature, the pressure in the system will
rise too high, which may cause damage to
the system.
- Make sure that no water can enter the
differential and gearbox via the breathers.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Cleaning

- Make sure that no water can enter via the

reservoir bleed screws 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 oil seals, electrical components, such
as the starting motor, alternator, etc.
- If an engine encapsulation is present, the
encapsulation panels must be thoroughly
cleaned after each inspection interval in
view of the risk of fire if the inside of the
panels should be dirty.
- Do not direct the jet of water at electrical
connections such as connectors, cable
plugs of the vehicle lighting system, etc.
- Make sure that during cleaning the vehicle
no water enters into the air-intake system
through the air intake of the flexible seals of
the inlet.
5
- Do not aim the jet of water directly at the
gear-lever unit.
- Do not point the high-pressure cleaning jet
directly at the driving shaft seals, such as
the seals of the spider, intermediate bearing
and sliding joint.
- When the vehicle has been cleaned, it must
be lubricated again with a grease gun or via
the automatic lubrication system. This is
important because it prevents the
penetration of moisture and dirt at the
various pivot points.

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Cleaning 65CF series

6-8 ǹ 0111
 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
65CF series Lubrication

7. LUBRICATION
7.1 LUBRICATE ACCORDING TO LUBRICATING 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.

S S S S S S S S 5

1 2 3 4 5 6 7 6 8 6 9 10 11
G000160

S = SYMMETRICAL

1. Cab hinge pins

2. Shackle pins, front axle
3. Brake camshafts, front axle
4. King pins, front axle
5. Spring shackles, front axle
6. Universal joint
7. Centre bearing
8. Shackle pins, rear axle
9. Brake camshafts, rear axle
10. Spring shackles, rear axle
11. Drawn vehicle coupling

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 EXPLANATORY NOTES ON THE MAINTENANCE OPERATIONS
Lubrication 65CF series

Lubricating the propeller shaft

1. Grease the universal joints of the propeller
shaft until the grease comes out of all 4
spider ends.
2. The maximum lubricating pressure should
not exceed 15 bar.

M9030

Lubricating the king pins

1. To make sure that the grease can penetrate
adequately, the king pins should be
lubricated in unloaded condition.
The front axle should therefore be
completely jacked up.

5 2. Lubricate the king pins until grease comes

out.

M9025

Lubricate the stub-axle carrier of the 2235V

axle
1. Lubricate until grease comes out of the
bore.
2. This bore is at the same height as the
lubricating nipple on the rear side of the
stub-axle carrier.

G000161

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 Maintenance manual
65CF

English
Printed in the Netherlands DW032737