DAF 55 Series Truck Workshop Manual – Complete PDF Service, Repair & Overhaul Guide

Description

DAF 55 Series Workshop Manual – Your Complete Repair Companion

This DAF 55 Series Workshop Manual is a comprehensive technical resource for maintaining, diagnosing and overhauling DAF 55 Series commercial vehicles. Whether you are a fleet workshop technician, an independent mechanic or a hands-on owner-operator, this PDF gives you the procedures, torque figures and specifications needed to keep these robust trucks performing at their best. It covers the complete vehicle from cab to rear axle, including the CS-series engines, multiple gearbox options and the full air braking system.

File Details

• Manual Type: Workshop Manual
• Brand: DAF
• Model: 55 Series
• Language: English
• File Format: PDF
• Document Number: DW036657
• Page Count: Approx. 1,326 pages

Chapters Covered

• General Information, Safety and Lubricants
• Maintenance and Service Schedules
• Cab Structure and Hydraulic Tilt Equipment
• Engine – Crankcase, Cylinder Head and Cooling System
• Fuel, Induction and Exhaust Systems
• Transmission – Clutch, ZF and Eaton Gearboxes
• Electrical System
• Brakes – Perrot and DAF ‘S’ Cam Systems
• Front Axle and Steering
• Rear Axle – Albion and Eaton Driving Heads
• Frame and Suspension

General Information, Safety and Lubricants

The opening sections lay the groundwork for every job in this manual. You get the full engine data table covering all CS 107M, CS 118M, CS 134L, CS 134M, CS 156L, CS 158M and CS 173M power ratings, torque outputs, firing order and governed speeds. Safety precautions are spelled out for everything from battery isolation to welding on the chassis frame. The torque tightening figures section alone is worth the download – it covers cab mounts, engine internals, transmission, brakes, axles and chassis fasteners in metric Nm with imperial conversions. The recommended lubricants chapter gives you the exact oil specifications, viscosities, coolant requirements and anti-freeze concentration charts you need to protect your investment.

Maintenance and Service Schedules

This chapter is built around the real-world operating conditions these trucks face. You get the intermediate inspection, X-service and Y-service schedules laid out by maintenance category – from building site work through to long-haul international transport. The manual explains how diesel fuel sulphur content affects oil change intervals and how to convert PTO operating hours into equivalent kilometres. First service activities, annual maintenance tasks and kilometre-dependent checks are all listed so you can build a proper preventive maintenance programme.

Cab Structure and Hydraulic Tilt Equipment

Cab maintenance on a DAF 55 Series is made straightforward with this section. You will find removal and refitment procedures for the cab lock-down mechanism, mounting bushes, rear dampers and the hydraulic tilt pump. The exploded views make the assembly order clear, and the tilt ram overhaul covers seal replacement and bleeding. Door glass, regulator mechanisms, exterior handles and latch assemblies are all dealt with in detail, along with windscreen replacement using the bonding and removal kits.

Engine – Crankcase, Cylinder Head and Cooling System

The engine chapter is thorough. It starts with a fault diagnosis chart that walks you through difficult starting, misfires, power loss, smoke and oil pressure issues. The cylinder head section covers valve clearances, valve seat insert installation dimensions, rocker shaft overhaul and diesel compression testing. The crankcase assembly chapter is the big one – camshaft removal and timing, piston and connecting rod overhaul, crankshaft re-grind sizes, main bearing selection and cylinder liner installation. Torque tightening sequences for cylinder head bolts, main bearing caps and connecting rods are given in staged figures with angle torque where required. Cooling system coverage includes water pump, thermostat testing, viscous fan clutch diagnosis and the complete radiator/intercooler assembly.

Fuel, Induction and Exhaust Systems

Both the Bosch P-7100 in-line and Bosch VP 14 rotary injection pumps are covered for removal, refitment and timing. You get the injection pump timing check procedure with dial test indicator readings, injector removal and refitting with the correct seating washers, fuel lift pump, fuel sedimenter cleaning and fuel tank removal. The induction and exhaust chapter deals with manifold torque sequences, turbocharger overhaul including shaft end-float and radial clearance checks, wastegate actuator calibration and exhaust brake overhaul. Turbocharger bearing housing bores, seal bores and shaft dimensions are all specified.

Transmission – Clutch, ZF and Eaton Gearboxes

This section covers the Borg and Beck 330, 350 and 380 mm diaphragm spring clutch, the clutch hydraulic system including master cylinder and servo slave cylinder overhaul, and the gear-change lever assembly. For gearboxes, you get removal and refitment procedures for the ZF S6-36, ZF S6-36/2, ZF 9S-75 and Eaton 6109 units. The ZF S6-36 overhaul chapter takes you through mainshaft, layshaft and selector housing dismantling with synchroniser wear limits, circlip sizes and shim selection. Propeller shaft universal joints, centre bearing and grease procedures are also covered.

Electrical System

With 1,000+ pages of technical content, the electrical section is detailed. You get fault diagnosis using multimeter and test lamp, battery and charging system data, starter motor interlock relay operation, instrument panel printed circuit board components, electric windows, cigar lighter, tachograph, horn, vehicle lighting circuits, heated mirrors and air dryer heating element. The ABS section covers the WABCO 4-channel system with wheel sensor resistance values, modulator valve testing and the full diagnostic test procedure using the ABS test box. ECAS and road speed limiter circuits are also documented.

Brakes – Perrot and DAF ‘S’ Cam Systems

Both brake assembly types are covered. For 11 to 15 tonne vehicles you get the Perrot sliding caliper disc brakes and single air wedge drum brakes – pad and disc inspection, caliper overhaul, automatic expander unit dismantling and rear brake shoe replacement. For 17/18 tonne vehicles the DAF ‘S’ cam drum brakes are covered with camshaft bush removal using service tool 0694794. Air system components include the Knorr Bremse AD6 air dryer, multi-circuit protection valve, relay valves, load sensing valve testing and adjustment, and the full ABS modulator valve overhaul.

Front Axle and Steering

The F56 and F71 front axles are both covered for hub assembly overhaul, stub axle removal, swivel pin replacement and needle bearing installation. Steering gear coverage includes the ZF 8095 and 8098 boxes with housing and piston seal renewal, bleed procedure, steering column removal and telescopic shaft replacement. Steering linkage ball joints, track rod removal and front wheel alignment checking and adjusting are all specified with the correct torque figures.

Rear Axle – Albion and Eaton Driving Heads

Rear axle coverage spans the Albion 8.10, 10.20, 10.26, 10.28 and 11.26 units plus the Eaton 10.28 driving head. You get hub assembly overhaul for both oil-lubricated and grease-lubricated hubs, differential oil renewal, crownwheel and pinion backlash adjustment, pinion bearing pre-load setting and tooth contact pattern checking. The differential lock assembly is covered for both the Albion and Eaton types. Drive head removal and refitment procedures include torque figures for bearing cap bolts, coupling flange nuts and crownwheel bolts.

Frame and Suspension

Frame fastenings, torque tables for property class 8.8 and 10.9 bolts, front and rear spring assembly removal and refitment with deflection setting dimensions, spring eye bush replacement, anti-roll bar overhaul and shock absorber replacement. The air suspension section covers ECAS height sensor removal and refitment, air spring replacement, lower torque rod bush alignment and initial ride height adjustment using service tools. Lubrication diagrams and procedures for steering box universal joints, swivel pins, propeller shaft universal joints and brake camshafts are included.

Who This DAF 55 Series Workshop Manual Is For

This is not a generic overview. It is the same class of technical documentation that DAF dealers and authorised repair centres use to service these vehicles. If you run a fleet of 55 Series trucks, maintain one as an owner-operator, or work in an independent workshop, having this manual on hand means you can tackle jobs properly – with the right torque values, the right sequences and the right clearances. It saves you from guesswork, prevents comeback repairs and helps you get the most from these durable commercial vehicles.

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Your download is available immediately after payment. The PDF works on any device – laptop, tablet or smartphone – and every page is printable, so you can take the relevant section into the workshop with you. No waiting for a CD or a printed book to arrive. No postage costs. Just instant access to the complete DAF 55 Series Workshop Manual.