DAF 95XF Series Trucks Repair Service Workshop Manual

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This workshop service repair manual PDF download for the 95XF Series DAF Trucks has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

FT-FA 4×2
FTP 6×2
FTG 6×2
FTS/R – FAS/R 6×2
FTT-FAT 6×4
FTC-FAC 8×2
FAK 8×2
FTD-FAD 8×4

TABLE OF CONTENTS :

Workshop-Manual
0. General Information
1. Technical Data
2. XF, XE Engine
3. Gearbox
4. Fuel, Intake and Exhaust Systems
5. Electrical Equipment
6. Braking System
7. Steering System
8. Rear Axles
9. Suspension

Maintenance Manual
1. SAFETY INSTRUCTIONS
2. GENERAL
3. INSPECTION AND ADJUSTMENT
4. REMOVAL AND INSTALLATION
5. DRAINING AND FILLING
6. CLEANING
7. LUBRICATION

Specifications Manual
Specifications manual,fluids and lubricants
2 Safety instructions
3 Fluids and lubricants
4 Permitted oil products, ZF
5 Permitted oil products, Eaton
6 Permitted oil products, Allison
7 Permitted oil products, Voith

Davie Diagnostics Manual
1 EBS
2 UPEC
3 AS Tronic
4 VIC
5 EMAS
6 Hydronic 10 (ACH-EW)
7 CDS-3
8 ECAS-2
9 Airtronic (ACH-EA)
10 ABS-D and ABS/ASR-E
11 D3LC (ACH-EA)
13 ECAS-3
14 AGS
15 ZF intarder EST42
16 ALS-S
17 ECS-DC3
18 Immobiliser
19 CDM

Special Tools
0. TOOLS, GENERAL
1. CAB
2. ENGINE
3. GEARBOX
4. FUEL SYSTEM
5. ELECTRICAL COMPONENTS
6. BRAKES
7. STEERING AND AXLES
8. DIFFERENTIAL GEAR
9. CHASSIS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : –
Total Pages : 3454

This OEM service manual/ repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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DAF.95XF-Series
Workshop-Manual
0. General Information
1. Technical Data
2. XF, XE Engine
3. Gearbox
4. Fuel, Intake and Exhaust Systems
DIAGNOSIS
1. TRACTIVE PROBLEMS
2. XF ENGINE FUEL SYSTEM
2.1 FAULT-FINDING TABLE
3. XF ENGINE INLET AND EXHAUST SYSTEM
3.1 FAULT-FINDING TABLE
4. XF ENGINE BRAKE
4.1 FAULT-FINDING TABLE
5. XE ENGINE FUEL SYSTEM
5.1 FAULT-FINDING TABLE
6. XE ENGINE INLET/EXHAUST SYSTEM
6.1 FAULT-FINDING TABLE
7. XE ENGINE BRAKE
7.1 FAULT-FINDING TABLE
XF ENGINE FUEL SYSTEM
1. SAFETY INSTRUCTIONS
2. GENERAL
2.1 OVERVIEW DRAWING OF FUEL SYSTEM
2.2 DESCRIPTION OF FUEL SYSTEM
3. INSPECTION AND ADJUSTMENT
3.1 INSPECTION AND ADJUSTMENT OF INJECTION TIMING
3.2 CHECKING THE FUEL LEVEL ELEMENT
3.3 INSPECTION AND ADJUSTMENT OF INJECTOR OPENING PRESSURE
3.4 INSPECTION OF INJECTOR OPERATION
3.5 INSPECTION OF FUEL SYSTEM FOR LEAKS
3.6 BLEEDING OF FUEL SYSTEM
3.7 CHECKING OF GALLERY PRESSURE
3.8 INSPECTION OF RACOR FILTER ELEMENT
4. REMOVAL AND INSTALLATION
4.1 REMOVAL AND INSTALLATION OF INJECTION LINES
4.2 REMOVAL AND INSTALLATION OF INJECTORS
4.3 REMOVAL AND INSTALLATION OF INJECTOR SLEEVES
4.4 REMOVAL AND INSTALLATION OF FUEL PUMP
4.5 REMOVAL AND INSTALLATION OF FUEL PIPES
4.6 REMOVAL AND INSTALLATION, FUEL FILTER
4.7 REMOVAL AND INSTALLATION OF FUEL PREFILTER
4.8 REMOVAL AND INSTALLATION OF FUEL LEVEL ELEMENT
4.9 REMOVAL AND INSTALLATION OF TANK FILTER
4.10 REMOVAL AND INSTALLATION OF FUEL-PUMP DRIVE SEALING RING
4.11 REMOVAL AND INSTALLATION OF RACOR FILTER ELEMENT
5. DISASSEMBLY AND ASSEMBLY
5.1 DISASSEMBLY AND ASSEMBLY OF INJECTOR
6. CLEANING
6.1 CLEANING INJECTOR
6.2 CLEANING INJECTOR SLEEVE
XF ENGINE INLET AND EXHAUST SYSTEM
1. SAFETY INSTRUCTIONS
2. GENERAL
2.1 LOCATION OF COMPONENTS
2.2 DESCRIPTION OF TURBOCHARGER SYSTEM WITH WASTEGATE
3. INSPECTION AND ADJUSTMENT
3.1 CHECKING AND ADJUSTING THE WASTEGATE TURBOCHARGER
3.2 INSPECTION OF EXHAUST BACK PRESSURE
3.3 INSPECTION AND PRESSURE-TESTING OF AIR INLET SYSTEM
3.4 INSPECTION OF INLET UNDERPRESSURE
3.5 INSPECTION OF BOOST PRESSURE
4. REMOVAL AND INSTALLATION
4.1 REMOVAL AND INSTALLATION OF TURBOCHARGER
4.2 REMOVAL AND INSTALLATION OF INTERCOOLER
4.3 REMOVAL AND INSTALLATION OF AIR CLEANER ELEMENT
5. CLEANING
5.1 CLEANING THE RADIATOR AND INTERCOOLER
5.2 CLEANING THE AIR CLEANER ELEMENT
XF ENGINE BRAKE
1. SAFETY INSTRUCTIONS
2. GENERAL
2.1 LOCATION OF DEB COMPONENTS
2.2 OVERVIEW DRAWING DEB
2.3 LOCATION OF EXHAUST BRAKE COMPONENTS
2.4 GENERAL DESCRIPTION OF ENGINE BRAKE SYSTEM
2.5 DESCRIPTION OF DEB SYSTEM
2.6 DESCRIPTION OF EXHAUST BRAKE SYSTEM
3. INSPECTION AND ADJUSTMENT
3.1 INSPECTION AND ADJUSTMENT, DEB PLAY
3.2 FUNCTIONAL CHECK OF DEB
3.3 INSPECTION AND ADJUSTMENT OF ENGINE STOP/EXHAUST BRAKE
4. REMOVAL AND INSTALLATION
4.1 REMOVAL AND INSTALLATION OF DEB
4.2 REMOVAL AND INSTALLATION OF DEB SPRING PLATE
4.3 REMOVAL AND INSTALLATION OF EXHAUST BRAKE
XE ENGINE FUEL SYSTEM
1. SAFETY INSTRUCTIONS
2. GENERAL
2.1 LOCATION OF COMPONENTS
2.2 DESCRIPTION OF UPEC FUEL SYSTEM
2.3 DESCRIPTION OF COMPONENTS
3. INSPECTION AND ADJUSTMENT
3.1 CHECKING THE FUEL LEVEL ELEMENT
3.2 INSPECTION AND ADJUSTMENT OF INJECTOR OPENING PRESSURE
3.3 INSPECTION OF INJECTOR OPERATION
3.4 INSPECTION OF FUEL SYSTEM FOR LEAKS
3.5 BLEEDING OF FUEL SYSTEM
3.6 CHECKING THE GALLERY PRESSURE
3.7 INSPECTION OF FUEL LIFT PUMP SEALING RINGS
3.8 INSPECTION OF RACOR FILTER ELEMENT
4. REMOVAL AND INSTALLATION
4.1 REMOVAL AND INSTALLATION OF INJECTION LINES
4.2 REMOVAL AND INSTALLATION OF INJECTORS
4.3 REMOVAL AND INSTALLATION OF INJECTOR SLEEVES
4.4 REMOVAL AND INSTALLATION OF PUMP UNIT
4.5 REMOVAL AND INSTALLATION OF THE FUEL LIFT PUMP
4.6 REMOVAL AND INSTALLATION OF PUMP HOUSING
4.7 REMOVAL AND INSTALLATION OF FUEL PIPES
4.8 REMOVAL AND INSTALLATION OF FUEL FINE FILTER
4.9 REMOVAL AND INSTALLATION OF FUEL COARSE FILTER
4.10 REMOVAL AND INSTALLATION OF FUEL LEVEL ELEMENT
4.11 REMOVAL AND INSTALLATION OF TANK FILTER
4.12 REMOVAL AND INSTALLATION OF RACOR FILTER ELEMENT
5. DISASSEMBLY AND ASSEMBLY
5.1 DISASSEMBLY AND ASSEMBLY OF INJECTOR
6. CLEANING
6.1 CLEANING INJECTOR
6.2 CLEANING INJECTOR SLEEVE
6.3 CLEANING FUEL COARSE FILTER
XE ENGINE INLET/EXHAUST SYSTEM
1. SAFETY INSTRUCTIONS
2. GENERAL
2.1 LOCATION OF COMPONENTS
2.2 DESCRIPTION OF TURBOCHARGER SYSTEM WITH WASTEGATE
3. INSPECTION AND ADJUSTMENT
3.1 CHECKING AND ADJUSTING THE WASTEGATE TURBOCHARGER
3.2 INSPECTION OF EXHAUST BACK PRESSURE
3.3 INSPECTION AND PRESSURE-TESTING OF AIR INLET SYSTEM
3.4 INSPECTION OF INLET UNDERPRESSURE
3.5 INSPECTION OF BOOST PRESSURE
4. REMOVAL AND INSTALLATION
4.1 REMOVAL AND INSTALLATION OF TURBOCHARGER
4.2 REMOVAL AND INSTALLATION OF INTERCOOLER
4.3 REMOVAL AND INSTALLATION OF AIR CLEANER ELEMENT
5. CLEANING
5.1 CLEANING THE RADIATOR AND INTERCOOLER
5.2 CLEANING THE AIR CLEANER ELEMENT
XE ENGINE BRAKE
1. SAFETY INSTRUCTIONS
2. GENERAL
2.1 LOCATION OF DEB COMPONENTS
2.2 OVERVIEW DRAWING DEB
2.3 LOCATION OF EXHAUST BRAKE COMPONENTS
2.4 GENERAL DESCRIPTION OF ENGINE BRAKE SYSTEM
2.5 DESCRIPTION OF DEB SYSTEM
2.6 DESCRIPTION OF EXHAUST BRAKE SYSTEM
3. INSPECTION AND ADJUSTMENT
3.1 INSPECTION AND ADJUSTMENT, DEB PLAY
3.2 FUNCTIONAL CHECK OF DEB
3.3 INSPECTION AND ADJUSTMENT OF EXHAUST BRAKE
4. REMOVAL AND INSTALLATION
4.1 REMOVAL AND INSTALLATION OF DEB
4.2 REMOVAL AND INSTALLATION OF DEB SPRING PLATE
4.3 REMOVAL AND INSTALLATION OF EXHAUST BRAKE
5. Electrical Equipment
6. Braking System
7. Steering System
8. Rear Axles
9. Suspension

Maintenance Manual 95XF
95XF series Maintenance manual
STRUCTURE
TECHNICAL DATA
THREADED CONNECTIONS
COOLANT, OIL AND LUBRICANTS
MAINTENANCE SCHEDULE
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES
1. SAFETY INSTRUCTIONS
2. GENERAL
3. INSPECTION AND ADJUSTMENT
4. REMOVAL AND INSTALLATION
5. DRAINING AND FILLING
6. CLEANING
7. LUBRICATION

Specifications Manual
Specifications manual,fluids and lubricants
STRUCTURE
2 Safety instructions
1. General
1.1 General
3 Fluids and lubricants
1. Cab
1.1 Cab tilting mechanism
2. Engine, cooling system and fuel system
2.1 Engine
2.2 Cooling system
2.3 Fuel system
3. Drive and chassis
3.1 Gearbox oil for ZF gearboxes
3.2 Gearbox oil for EATON gearboxes
3.3 Gearbox oil for Allison gearboxes
3.4 Transfer box
3.5 Retarder
3.6 Torque converter
3.7 Hydraulically driven fan
3.8 Hydraulic gearbox and clutch
3.9 dry-plate clutch
3.10 Universal joint, prop shaft
3.11 Driven front axle
3.12 Front axle hub
3.13 Rear axle without hub reduction
3.14 Rear axle with hub reduction
3.15 Rear axle hub
3.16 Trailing axle load transfer device
3.17 Central tandem axle
3.18 Chassis lubrication
4. Steering gear and brake system
4.1 Steering box
4.2 Idler arm
4.3 EVS
4.4 EMAS
4.5 RAS-EC
4.6 Braking system
4 Permitted oil products, ZF
1. Permitted oil products
1.1 ZF
5 Permitted oil products, Eaton
1. Permitted oil products
1.1 Eaton
6 Permitted oil products, Allison
1. Permitted oil products
1.1 Allison
7 Permitted oil products, Voith
1. Permitted oil products
1.1 Voith
Davie Diagnostics Manual
1 EBS
1. EBS fault codes
1.1 Introduction
1.2 Explanatory notes to EBS fault codes
2. EBS customer parameters
2.1 Introduction
2.2 Explanatory notes to EBS customer parameters
3. System inspection with DAVIE XD
3.1 General
2 UPEC
1. UPEC fault codes
1.1 Introduction
1.2 Explanatory notes to UPEC fault codes
2. UPEC customer parameters
2.1 Introduction
2.2 Explanatory notes to UPEC customer parameters
3. System inspection with DAVIE XD
3.1 General
3.2 Engine brake test
3.3 Speed variation control test
3 AS Tronic
1. AS Tronic fault codes
1.1 Introduction
1.2 Explanatory notes to AS Tronic fault codes
2. System inspection with DAVIE XD
2.1 General
2.2 ‘Transmission’ menu
2.3 ‘Clutch actuator’ menu
4 VIC
1. VIC fault codes
1.1 Introduction
1.2 Explanatory notes to VIC fault codes
2. VIC customer parameters
2.1 Introduction
2.2 Explanatory notes to VIC customer parameters, restricted version
2.3 Explanatory notes to VIC customer parameters, elaborate version
3. System inspection with DAVIE XD
3.1 General
5 EMAS
1. EMAS fault codes
1.1 Introduction
1.2 Explanatory notes to EMAS fault codes
2. System inspection with DAVIE XD
2.1 General
2.2 “Calibration” menu
6 Hydronic 10 (ACH-EW)
1. Hydronic 10 (ACH-EW) fault codes
1.1 Introduction
1.2 Explanatory notes to fault codes for Hydronic 10 (ACH-EW) with electronic unit D901
1.3 Explanatory notes to fault codes for Hydronic 10 (ACH-EW) with electronic unit D979
2. System inspection with DAVIE XD
2.1 General
7 CDS-3
1. CDS-3 fault codes
1.1 Introduction
1.2 Explanatory notes to CDS-3 fault codes
2. System inspection with DAVIE XD
2.1 General
2.2 Menu “Initialising new unit”
8 ECAS-2
1. ECAS-2 fault codes
1.1 Introduction
1.2 Explanatory notes to ECAS�2 fault codes
2. ECAS-2 customer parameters
2.1 Introduction
2.2 Explanatory notes to ECAS�2 customer parameters
3. System inspection with DAVIE XD
3.1 Calibrating the sensors
3.2 Checking height sensor
9 Airtronic (ACH-EA)
1. Airtronic (ACH-EA) fault codes
1.1 Introduction
1.2 Explanatory notes to Airtronic D2/D4 (ACH-EA) fault codes
2. System inspection with DAVIE XD
2.1 General
10 ABS-D and ABS/ASR-E
1. ABS-D and ABS/ASR-E fault codes
1.1 Introduction
1.2 Fault code overview
2. System inspection with DAVIE XD
2.1 General
11 D3LC (ACH-EA)
1. D3LC (ACH-EA) fault codes
1.1 Introduction
1.2 Explanatory notes to fault codes D3LC (ACH-EA)
2. System inspection with DAVIE XD
2.1 General
12 EBS-2
1. EBS-2 fault codes
1.1 Introduction
1.2 Explanatory notes to EBS-2 fault codes
2. EBS-2 customer parameters
2.1 Introduction
2.2 Explanatory notes to EBS-2 customer parameters
3. System inspection with DAVIE XD
3.1 General
3.2 VSC calibration
13 ECAS-3
1. ECAS-3 fault codes
1.1 Introduction
1.2 Explanatory notes to ECAS-3 fault codes
2. ECAS-3 customer parameters
2.1 Introduction
2.2 Explanatory notes to ECAS-3 customer parameters
3. System inspection with DAVIE XD
3.1 Calibrating the sensors
3.2 Inspection of height sensors
14 AGS
1. AGS fault codes
1.1 Introduction
1.2 Explanatory notes to AGS (diaphragm version) fault codes
1.3 Explanatory notes to AGS (bellows version) fault codes
2. AGS customer parameters
2.1 Introduction
2.2 Explanatory notes to AGS customer parameters
15 ZF intarder EST42
1. ZF intarder EST42 fault codes
1.1 Introduction
1.2 Explanatory notes to fault codes for ZF-intarder EST 42
2. System inspection with DAVIE XD
2.1 General
16 ALS-S
1. ALS-S fault codes
1.1 Introduction
2. Explanatory notes to ALS-S fault codes
2.1 Explanatory notes to ALS�S fault codes
3. System inspection with DAVIE XD
3.1 Inspection of radar sensor
17 ECS-DC3
1. ECS-DC3 fault codes
1.1 Introduction
1.2 Explanatory notes to ECS�DC3 fault codes
2. ECS-DC3 customer parameters
2.1 Introduction
2.2 Explanatory notes to ECS�DC3 customer parameters
3. System inspection with DAVIE XD
3.1 General
18 Immobiliser
1. Immobiliser fault codes
1.1 Introduction
1.2 Explanatory notes to immobiliser fault codes
19 CDM
1. CDM fault codes
1.1 Introduction
1.2 Explanatory notes to CDM fault codes
2. System inspection with DAVIE XD
2.1 General

Special Tools
Special tools
STRUCTURE
PREFACE
DIRECTIONS FOR USE
0. TOOLS, GENERAL
1. CAB
2. ENGINE
3. GEARBOX
4. FUEL SYSTEM
5. ELECTRICAL COMPONENTS
6. BRAKES
7. STEERING AND AXLES
8. DIFFERENTIAL GEAR
9. CHASSIS

 

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DAF 95XF Series Trucks Repair Service Workshop Manual.pdf

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