DAF CF65 & CF65 (II) Maintenance Manual – Complete PDF Workshop Guide (DW13280404)

Description

DAF CF65 and CF65 (II) Maintenance Manual – DW13280404

This is the DAF maintenance manual for the CF65 and CF65 (II) truck series, issued under document number DW13280404. It is the reference the workshop technician works from when carrying out scheduled servicing, inspecting safety-critical systems, tightening fasteners to specification, and draining or refilling the vehicle’s lubricants and coolants. The complete document is supplied here as a single PDF, ready to open on any device.

File Details

• Manual type: Maintenance manual
• Brand: DAF Trucks
• Model series: CF65 / CF65 (II)
• Language: English
• Page count: 116
• File format: PDF
• Document number: DW13280404
• Publication date: 200518

Chapters Covered

• Engine, Cooling System and Fuel System
• Steering Gear and Brake System
• Drive and Chassis
• Threaded Connections
• Specifications
• Maintenance Intervals
• Explanatory Notes on the Maintenance Activities
• Cleaning
• Lubrication

Engine, Cooling System and Fuel System

Opens with the cold valve clearance data for the CE engine: an inspection dimension of 0.15–0.40 mm on the inlet side and 0.40–0.75 mm on the exhaust side, with a setting dimension of 0.25 mm inlet and 0.50 mm exhaust. Tightening torques for the lubrication system are listed here, including the oil drain plug at 60 Nm and the valve cover attachment bolts at 10 Nm. Filling capacities follow for the lubrication system (approximately 19.5 litres total including oil cooler and oil filter, 17.5 litres sump at maximum level and 15.4 litres at minimum), the CF65 cooling system (approx. 26 litres, or approx. 40 litres with the Allison gearbox) and the CF65 (II) cooling system (approx. 23 litres).

Steering Gear and Brake System

This section gives the maximum steering ball joint axial clearance of 1.5 mm and the tightening torque for the steering column universal joint bolt at 56 Nm. It states clearly that the torques given here differ from the standard threaded-connection overview, and that any fastener not listed must be tightened to the standard values.

Drive and Chassis

The largest chapter, covering the three gearbox types fitted to this series. The Allison MD3060 automatic gearbox is described as electronically controlled, with oil level readable from the selector keypad beside the driver’s seat or from the dipstick, which carries Cold add, Cold full, Hot add and Hot full markings. Torque values are provided for the ZF 6S-850 level check/filler and drain plugs (both 50 Nm), the Eaton 6309 A level check/filler plug (35 Nm) and drain plug/oil strainer (44 Nm), and the Allison drain plug (28 Nm) and oil filter cover bolts (55 Nm). Front and rear axle U-bolt specifications are detailed for both series and both suspension types, with different values depending on whether a flange nut, a yellow zinc-plated hexagonal nut or a black high hexagonal nut is fitted, and the instruction to tighten the two U-bolt nuts alternately and evenly. Hub and differential filler/drain plugs (Torx) are given at 85 Nm. Filling capacities close the chapter: ZF 6S-850 approx. 7.5 litres, Eaton 6309 A approx. 8.5 litres, Allison MD3060P with 4″ sump approx. 20 litres, and the 1132 axle differential at approx. 15 litres minimum caster and approx. 17.5 litres maximum caster.

Threaded Connections

Explains DAF’s dipped threaded connection practice, where galvanised bolts and nuts are wax dipped and black annealed and phosphated bolts and nuts are oil dipped at the factory, reducing friction so the specified pre-tension is reached accurately at a lower tightening torque. The chapter also sets out the reuse procedure for fasteners: cleaning the thread and clamping faces, checking for damage by hand-screwing a new nut or bolt onto the full thread, applying one drop of engine oil to the upper turn of the bolt or lower turn of the nut and to the clamping faces, and omitting oil where a locking compound is specified. It notes that dry threaded connections must not be used because of their highly variable friction coefficients.

Specifications

Sets out the fluid, oil, lubricant, coolant and fuel requirements that must be met to satisfy warranty conditions and preserve the service life, safety and reliability of the vehicle. It covers the safety instructions for handling colourant, fuel and clutch fluid, and the required response to skin, eye, ingestion and inhalation contact. DAF states it is not liable for damage caused by using oil of a lower grade or different viscosity than specified, exceeding the change interval, or using fuel, lubricants or coolants that do not meet its requirements.

Maintenance Intervals

Contains the maintenance schedule for the CF65 and CF65 (II), built around three operating groups: Group I (building sites, quarries, unmetalled roads, dusty conditions, sanitation vehicles and distribution work up to 30,000 km per year), Group II (urban and regional transport) and Group III (national and international long-distance traffic). It defines the X service (mileage-dependent engine oil change plus visual inspections, at least once a year) and the Y service (annual maintenance check with gearbox and rear axle oil changes), and includes the rule that diesel fuel with a sulphur content above 0.2% halves the engine oil change interval to a maximum of 25,000 km. PTO hours are converted at 1 PTO hour = 40 km. The first service inspection is specified between the first 7,500 and 10,000 km, or at most 8 weeks after delivery, whichever comes first.

Explanatory Notes on the Maintenance Activities

The working heart of the manual. It walks through every inspection and adjustment task in sequence: pedal rubbers, battery fluid level and terminals, cab tilting pump fluid level, cab fastening, fuel system bleeding, engine oil level, CE engine valve clearance (with the crankshaft rotation and cylinder overlap method), poly-V-belt condition, coolant freezing point, fuel leaks, hose connections, exhaust system, radiator and intercooler fouling, and the air inlet dust trapping valve. Steering and brake coverage includes the universal joint to steering box input shaft, ball joint sleeve, ball joints (with the special tool setup and axial play measurement), steering oil level, steering gear lines, compressor line, brake component leaks, brake cylinder fastening, and brake shoe and disc thickness checks. Drive and chassis coverage includes differential leaks, differential lock operation, drive shaft play, trailer coupling, superstructure attachment, clutch fluid level, clutch wear indicator, gearbox leaks, automatic gearbox oil level (by dipstick and by selector keypad) and greased wheel hub leaks.

Removal and Installation

Step-by-step procedures for the interior filter element, air filter element, lubricating oil filter, fuel fine filter, fuel prefilter/water separator element, valve cover, steering gear filter element, air dryer filter element and automatic gearbox oil filters. Each procedure states the disposal precautions, sealing-ring lubrication, hand-tightening turns and torque references required for a correct refit.

Draining and Filling

Covers topping up battery fluid, draining and filling engine oil, draining and filling coolant (including the self-bleeding procedure and cab heater operation), draining and filling the 1132 axle differential, draining and filling the ZF 6S-850, Eaton 6309 A and Allison MD3060P gearboxes, and filling the grease supply of the automatic lubrication system.

Cleaning and Lubrication

Two short closing chapters. Cleaning covers battery poles, radiator and intercooler blow-cleaning (including a shop-made radiator cleaner drawing), vehicle cleaning precautions for high-pressure equipment, gearbox vents and the rear axle vent. Lubrication sets out the X-service lubrication schedule, covering the stub axles (lubricated with the front axle jacked up and unloaded) and the trailer coupling.

What This DAF CF65 Maintenance Manual Lets You Do

Everything in this PDF is aimed at keeping a CF65 or CF65 (II) on the road and out of the workshop for the wrong reasons. You can set cold valve clearance on the CE engine without guessing the inspection or setting dimension, torque the oil drain plug, valve cover, steering column universal joint, gearbox fill and drain plugs, U-bolt nuts and hub plugs to the exact figure printed for your axle and suspension variant, and refill the lubrication system, cooling system, gearboxes and 1132 axle differential to the correct capacity rather than to an approximate mark on a jug.

The manual also carries the full maintenance schedule logic — operating group, X service, Y service, the diesel sulphur interval penalty and the PTO-hour conversion — so you can build a realistic service plan for a quarry truck, an urban distribution vehicle or a long-haul tractor unit instead of applying one generic interval to all three. The inspection and adjustment chapter is written to be followed directly at the vehicle: jacking and support points, special tool numbers, feeler gauge measurements, simulated bellows pressures on the load-dependent control valve, clutch wear indicator positions, and the exact order in which to bleed the fuel system or refill the coolant.

Being a PDF means the DAF CF65 and CF65 (II) maintenance manual is available the moment your payment clears. No shipping, no waiting for a disc, no postal delays. Open it on a laptop in the workshop office, on a tablet next to the truck, or print the pages you need for the bay and throw them away when they are oil-stained. Every torque value, filling capacity and maintenance interval for the CF65 and CF65 (II) series is in one file you keep permanently.

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