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DAF CF 65 / CF 75 / CF 85 gearbox, repair e-manual

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Publisher: © "MARS"
ISBN: 978-009-200-032-4
Number of pages: 505
Format: file PDF

About the manual

diesel engine

In the manual you will find

  • Self-care and maintenance instructions for the gearbox
  • Transmission design and prevention information
  • Information for a trip to the service station, if self-repair is not possible
Publisher: MARS
Categories: DAF , Gearboxes
Only original manuals
Available immediately after payment
Full compliance with the paper edition
100% protection of your payments
Publisher: © "MARS"
ISBN: 978-009-200-032-4
Number of pages: 505
Format: file PDF

About the manual

diesel engine

In the manual you will find

  • Self-care and maintenance instructions for the gearbox
  • Transmission design and prevention information
  • Information for a trip to the service station, if self-repair is not possible

Contents

Technical data

  • Manual transmission control
  • General information
  • Tightening torques
  • Pneumatic gearbox control (service movement)
  • General information
  • Tightening torques
  • Pneumatic gearbox
  • General information
  • Tightening torques
  • Gearbox ZF 6S-850
  • General information
  • Tightening torques
  • Refueling tanks
  • Gearbox ZF 8/9 / 16s-109
  • General information
  • Tightening torques
  • Refueling tanks
  • Gearboxes ZF8 / 16s-151/181 and 16s-221
  • General information
  • Tightening torques
  • Refueling tanks
  • EATON FS / 6309a gearbox
  • General information
  • Tightening torques
  • Refueling tanks
  • ALLISON automatic transmission
  • General information
  • Tightening torques
  • Refueling tanks
  • Clutch
  • General information
  • Tightening torques
  • Refueling tanks
  • Support shafts
  • General information
  • Tightening torques
  • Refueling tanks
  • ZF Intarder
  • General information
  • Tightening torques
  • Power take-off shaft
  • General information
  • Tightening torques
  • Refueling tanks
  • AS TRONIC gearbox
  • General information
  • Tightening torques
  • Refueling tanks

Diagnostics

  • Manual transmission control
  • Troubleshooting table
  • Pneumatic gearbox control
  • Troubleshooting table
  • Pneumatic gearbox
  • Troubleshooting table
  • Manual transmission
  • Troubleshooting table
  • Automatic transmission
  • Reading fault codes
  • Fault code table
  • Clutch
  • Troubleshooting table
  • Support shafts
  • Troubleshooting table
  • ZF Intarder
  • Troubleshooting table
  • AS TRONIC
  • Troubleshooting table

Manual transmission control

  • General information
  • Manual Transmission Description
  • Reducer
  • Gear Lever
  • Checking and adjusting the LHD / RHD gearbox control
  • Removal and installation, complete unit
  • Removal and installation, reducer
  • Removal - Refitting, Shift Lever Inner Dust Cover
  • Removal and installation, gears
  • Removing and installing, control rod
  • Removal and installation, ball joint control

Pneumatic transmission control (service movement)

  • General information
  • Description of the pneumatic transmission control system (servo shift)
  • Component Description
  • Servo Shift
  • Emergency Selector Function
  • Removal and Installation
  • Repair and Installation, Servo Shiftoblock

Gearbox - pneumatic

  • General information
  • Location of underdrive protection components for ZF / EATON gearboxes
  • System description, underdrive protection
  • Location of protection components
  • Description of the protection system
  • Pneumatic diagram, transmission control
  • Component Description
  • Integrated air distribution unit
  • Valve neutral
  • Underdrive safety valve
  • High / Low Range Cylinder
  • Pressure Reducing Valve
  • GV valve
  • Divider Relay Valve
  • Filter / Regulator, EATON FS / 6309a
  • Speed ​​Signal Simulation
  • Inspect, underdrive relief valve
  • Check and Adjust, ZF / EATON Gearbox GV Valve
  • Test, filter / regulator, EATON FS / 6309a
  • Removal and installation, reducer, reducer, valve
  • Cleaning the filter / regulator, EATON FS / 6309a

Gearbox ZF 6S-850

  • General information
  • System Description
  • Component Description
  • Synchronizer
  • Check and adjust
  • Inspection, transmission oil level
  • Checking and adjusting, axial clearance of the input shaft bearing
  • Inspection and adjustment, output shaft axial play
  • Removal - Refitting, transmission
  • Removing and installing, entire gearbox
  • Removal and Installation, Drive Flange
  • Uninstallation and Installation, Exit
  • Removing and installing, gearbox front cover o-ring
  • Removing and installing, selector
  • Draining and filling, reducer

Gearbox ZF 8/9 / 16s-109

  • General information
  • System Description
  • Component Description
  • Synchronizer
  • Check and adjust
  • Inspection, transmission oil level
  • Checking and adjusting, axial clearance of the input shaft bearing
  • Checking and adjusting, axial clearance of the output shaft bearing
  • Checking and adjusting the shift shaft housing on the gearbox
  • Removal - Refitting, transmission
  • Removing and installing complete transmission
  • Removal and Installation, Drive Flange
  • Uninstallation and Installation, Exit
  • Removing and installing, gearbox front cover o-ring
  • Removing and installing, selector
  • Draining and filling, reducer
  • Gearbox ZF8 / 9 / 16s-109 with integrated retarder

Gearboxes ZF 8 / 16s-151/181 and 16s-221

  • General information
  • System Description
  • Component Description
  • Synchronizer
  • Check and adjust
  • Checking the transmission oil level
  • Checking and adjusting, axial play of the input shaft bearing
  • Inspection and adjustment, axial play of the gearbox output shaft bearing
  • Checking and adjusting the shift shaft housing on the gearbox
  • Gearbox removal and installation
  • Removal and installation, complete gearbox with or without integrated retarder
  • Removal and Installation, propshaft flange
  • Uninstallation and Installation, Exit
  • Removal - Refitting, Gearbox, Front Seal
  • Removing and installing, selector
  • Draining and filling, reducer

EATON FS / 6309a gearbox

  • General information
  • System Description
  • Check and adjust
  • Inspection, transmission oil level
  • Inspection and adjustment, axial clearance of the input shaft bearing
  • Removal - Refitting, transmission
  • Removal and Installation, Drive Flange
  • Uninstallation and Installation, Exit
  • Removing and installing, gearbox front cover o-ring
  • Removing and installing, selector
  • Draining and filling, reducer

Automatic transmissions

  • General information
  • System Description
  • Component Description
  • Automatic transmission selector
  • Check and adjust
  • Inspection, oil level
  • Removing and installing, installing gearbox
  • Removing and installing oil filters
  • Draining and filling, reducer

Clutch

  • Safety Instructions
  • General information
  • System description, clutch
  • Description of the clutch protection system
  • Master cylinder
  • Clutch CF 75/85
  • Clutch CF 65
  • AS Tronic clutch unit
  • Automatic adjustment of clutch switch assembly
  • Attaching the clutch lever to the gearbox
  • Attaching the clutch lever to the clutch housing
  • Component Description
  • Master cylinder
  • CF 75/85 clutch servo
  • CF 65 clutch servo
  • AS Tronic clutch
  • Automatic clutch release
  • CF 75/85 clutch wear indicator
  • CF 65 clutch wear indicator
  • Thrust bearing
  • Check and adjust
  • Inspection and adjustment, clutch pedal
  • Inspection, clutch reservoir
  • Inspect, clutch fluid level
  • Removal and installation, clutch reservoir
  • Removing and installing, AS Tronic clutch unit
  • Removal and Installation, Traction Clutch Thrust Bearing.
  • Removal - Refitting, thrust clutch thrust bearing
  • Removal and installation, drawbar
  • Removal - Refitting, clutch pressure lever
  • Removal and Installation, Clutch Switch Assembly / Clutch Disc
  • Removal and installation, automatic adjustment of clutch switch assembly / clutch disc
  • Removing and installing, pilot bearing
  • Removal and installation, master cylinder
  • Draining and filling, clutch system
  • Bleeding the clutch system

Support shafts

  • General information
  • Cardan shaft
  • Center support
  • Check and adjust
  • Inspection, propeller shaft
  • Removal - Refitting, propeller shaft / auxiliary shaft assembly
  • Disassembly and assembly, universal joint
  • Disassembly and assembly, center bearing
  • Lubrication of the universal joint and auxiliary shafts

ZF Intarder

  • Safety Instructions
  • General information
  • Intarder
  • Hydraulic control unit
  • Location of main components
  • Checking and adjusting, axial play of the output shaft bearing
  • Inspection and adjustment, static axial movement
  • Inspection, transmission / oil level andntarder
  • Removal and installation, installation inside
  • Removal - Refitting, solenoid valve
  • Removal and installation, battery
  • Removal and Installation, Heat Exchanger
  • Removal and installation, hydraulic valve
  • Removal and installation, oil pump
  • Removal and installation, oil filter
  • Removal and installation, proportional valve
  • Removal and Installation, Intarder Drive
  • Disassembly and assembly, battery
  • Draining and filling, reducer / intarder

Power take-off shaft

  • Safety Instructions
  • General information
  • Side view of the drive
  • Drive cross section
  • Power take-off shaft of DAF engine without driven flange and control unit
  • Power take-off shaft of DAF engine with driving flange and without control
  • Power take-off shaft of DAF engine with drive flange and control
  • Power take-off shaft for DAF engine with third gear for opposite direction of rotation of drive flange
  • Modifications
  • NL / 1ANDNH / 1PTO Version B
  • NL / 1ANDNH / 1PTO C version
  • NL / 4ANDNH / 4PTO Version B
  • NL / 4ANDNH / 4PTO C version
  • PTO N221 / 10 on gearbox without intarder
  • PTO N221 / 10 on gearbox with intarder
  • PTO NAS / 10
  • Intermediate PTO for gearboxes without gear
  • Intermediate PTO for gearboxes
  • PTO Z81, version B
  • PTO Z81, version C
  • PTO 2266, version B
  • PTO 2266, version C
  • Pneumatic diagram, PTO control
  • Checking and adjusting, axial play of the propeller shaft of the DAF engine
  • Checking and adjusting, axial play of DAF engine PTO drive sprockets
  • Inspection and adjustment, axial play of the gearbox output shaft without gearbox with PTO N221 / 10
  • Checking and adjustment, PTO axial play Nl on PTO N221 / 10
  • Removal and installation, all DAF engine PTO on flywheel
  • Removing and installing, flywheel housing of PTO shaft for DAF engine
  • Removal and installation, PTO NH / 1 and NL / 1, version B
  • Removal and installation, PTO NH / 1 and NL / 1, version C
  • Removal and installation, PTO NH / 4 and NL / 4, version B
  • Removal and installation, PTO NH / 4 and NL / 4, version C
  • Removal and installation, PTO N221 / 10 for gearboxes without intarder
  • Removal and installation, PTO N221 / 10 on gearbox with intarder
  • Removal and installation, PTO NL / 1 on PTO N221 / 10
  • Removal and Installation, PTO NAS / 10
  • Removing and installing an intermediate power take-off shaft on a gearbox without an intider
  • Removal and installation, intermediate shaft of power take-off on gearbox with gearbox.
  • Removal and installation, PTO Z81, version B
  • Removal and installation, PTO Z81, version C
  • Removing and installing PTO 2266, version B
  • Removal and installation, PTO 2266, version C
  • Disassembly and assembly, DAF engine PTO shaft
  • Disassembly and disassembly, DAF engine PTO housing
  • Manual versions without drive flange and shift control

AS Tronic gearbox

  • General information
  • System Description
  • Component Description
  • Reducer / modulator
  • Operating unit
  • Transmission / Brake
  • Check and adjust
  • Inspection and Adjustment, Transmission Oil Level
  • Inspection and adjustment, axial play of the gearbox output shaft bearing
  • Removal and installation, assembly of gearbox with or without integrated retarder
  • Removing and installing, gearbox modulator
  • Removal and installation, work unit
  • Removal and Installation, Drive Flange
  • Removal and Installation, Output Shaft Oil Seal
  • Removing and installing, gearbox front cover oil seal
  • Draining and filling, reducer

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Customers reviews

Great info with nice pictures. thank