Contents

DAF XE engine

• General information
• Technical data
• Engine layout
• Engine identification
• Gas distribution gear drive
• Camshaft of drive of individual high pressure fuel pumps for pump injectors
• Cranking while servicing the engine
• Tightening torques for screw connections
• Engine diagnostics
• Engine acceleration test
• Engine acceleration test using electronic device "DAVIE"
• Troubleshooting
• Checks and adjustments Valve jumpers
• Valve drive clearances
• Gas distribution gear drive
• Checking the automatic poly V-belt tensioner
• Tensioning the V-belt
• Checking the flywheel
• Checking the cylinder head
• Cylinder compression test
• Checking the tightness of the cylinder head by pressing
• Removing and installing engine components
• Removing and installing engine
• Engine mounts
• Valve cover
• Valve actuator
• Intake manifold
• Exhaust manifold
• Cylinder heads
• Air compressor
• Power steering pump (GUR)
• Starter
• V-ribbed belt
• A / C compressor drive V-belt
• Generator
• Flywheel
• Flywheel ring gear
• Rear crankshaft oil seal
• Flywheel housing
• Fan drive
• Vibration damper
• Vibration damper hub
• Valve cover
• Front crankshaft oil seal
• Timing gear
• Timing housing
• Timing housing seal
• Engine wash
• Cylinder block
• Removing and installing camshaft bearings
• Removing and installing cylinder liners
• Engine crank mechanism
• Crankshaft
• Rods
• Pistons
• Piston rings
• Lubrication system
• Oil cooler
• Engine cooling system
• System description
• Component descriptions
• Sealed system cover
• Thermostat
• Coolant filter
• Fan drive viscous coupling
• Viscous drive clutch, electronically controlled fan clutch
• Technical data
• Tightening torques for screw connections
• Refueling volumes
• Test & Adjust
• Cooling system pressure test
• Thermostat test
• Checking the viscous fan clutch
• Radial runout of the water pump shaft
• Removing and installing system elements
• Water pump
• Coolant filter
• Thermostat
• Fan drive viscous coupling
• Expansion tank
• Radiator
• Draining and filling
• Draining the coolant, filling and bleeding the cooling system
• Cleaning and rinsing
• Cleaning the outside radiator and intercooler
• Flushing the cooling system
• Fuel system
• Tightening torques for screw connections
• Diagnostics
• Troubleshooting
• Fault table
• Layout of components
• Fuel system UPEC
• Description of components
• Cranking
• Check and adjust
• Checking the fuel level sensor with a pressure reducing valve
• Checking the injector opening pressure
• Checking the quality of the injector
• Checking the tightness of the fuel system
• Bleeding the fuel system (removing air from it)
• Checking the pressure in the fuel line
• Checking the coarse fuel filter / water separator
• Removing and installing elements of the fuel system
• Injectors
• Nozzle adapter sleeve
• Individual injection pump injectors
• Booster fuel pump
• Housing of individual injection pump nozzles
• Fuel lines
• Replacement fuel filter element
• Fuel level sensor
• Fuel inlet mesh
• Coarse fuel filter with water separator (sump)
• Disassembly and assembly of fuel system elements
• Cleaning and washing
• Cleaning the nozzle adapter
• Intake and exhaust systems
• Tightening torques for screw connections
• Diagnostics
• Troubleshooting
• System description
• Turbocharger
• Checks and adjustments
• Checking the backpressure generated by the exhaust system
• Intake system checks and tests
• Checking the intake vacuum
• Checking the spark plug
• Removal and installation of elements of intake and exhaust systems
• Intercooler
• Replaceable air filter element
• Glow plug
• Cleaning and washing
• Cleaning the outside radiator / intercooler
• Cleaning the outside radiator / intercooler
• Cleaning the replacement air filter element

Engine brake

• Technical data
• Tightening torques for screw connections
• Diagnostics
• Troubleshooting
• DEB compression brake
• General information
• Engine brake, system description
• DEB Compression Brake
• Exhaust damper engine brake
• Checks and adjustments
• DEB compression brake actuator gap adjustment
• DEB compression brake serviceability check
• Checking and adjusting the exhaust damper engine brake
• Removing and installing engine brake elements
• DEB brake housing
• Removing and installing DEB brake flat spring
• Removing and installing the exhaust flap brake

Steering axles

• General information
• Technical data
• Steering gear
• Technical data
• Tightening torques for screw connections
• Power steering pump
• Technical data
• Tightening torques for screw connections
• Hoses, oil lines, reservoir and slave cylinder
• Tightening torques
• Wheel suspension (front axle and front steered rear axle)
• Technical data
• Tightening torques for screw connections
• Rear steering axle
• Technical data
• Rear axle convergence type 09G075
• Tightening torques for screw connections
• Steering
• Possible malfunctions and how to fix them
• Safety technology
• Description of operation and steering diagram
• Steering checks and adjustments
• Oil change and system bleeding
• Safety instructions
• Steering gear
• General information
• Checking and adjusting the steering gear
• Removing and installing elements of the steering mechanism
• Power steering pumps models LUK VT77 and LF77
• Checking and adjusting the LUK VT77 and LF77 pumps
• Removal and installation of elements of LUK VT77 and LF77 power steering pumps
• Oil lines and storage tanks
• Checking and adjusting
• Removing and installing elements
• Front axle / front steered rear axle
• Wheel hub
• Steering knuckle of the front steering axle of the rear axle
• Front axle steering knuckle
• Hub assembly
• Wheel alignment angles
• Steering checks and adjustments
• Removal and installation of steering elements
• Front axle rear steered axle
• Checks and adjustments
• Removing and installing elements

Brake system and its components

• General information
• Braking performance and brake force distribution
• Braking force graphs
• Disc brakes
• Drum brakes
• Brake system diagrams
• Application of fully pneumatic braking system diagrams
•  
• Braking system diagrams Electronically controlled braking system diagrams
• EBS-2 electronic brake system diagrams
• KNORR disc brake design
• Component descriptions
• Compressor
• Safety valve
• Air supply unit
• Purging valve for condensate removal
• Service brake piston pedal valve
• Parking brake accelerator valve
• Front brake force regulator valve
• Contact sensor for switching on brake lights
• Load sensing valve, air suspension
• Load sensing valve, leaf spring
• ABS valve
• Two-way valve
• ASR solenoid valve
• Emergency fill connection / test connection
• Parking brake valve
• Air pressure drop contact sensor
• Spring-loaded brake cylinder
• Trailer Brake Booster Valve
• Connection head
• Automatic working gap adjuster
• Disc brakes
• Quick disconnect coupling
• Check and adjust
• Compressor capacity
• Compressor piping
• Pressure regulator
• Brake pedal valve
• Load sensing valve, air suspension
• Load sensing valve, leaf spring
• Front brake force regulator valve
• Booster valve
• Trailer Brake Booster Valve
• Pressure build-up from the trailer brake accelerator
• Parking brake valve
• Checking and adjusting the inlet and outlet pressure of the supply air assembly
• Checking the regenerative function of the dryer in the air supply unit
• Checking the four-way pressure relief valve of the supply air assembly
• Checking the automatic working gap adjuster
• Checking the automatic disc brake adjuster
• Brake drums
• Drum brake pads
• Brake pads
• Brake discs
• Brake caliper travel
• Adjusting drum brakes
• Adjusting disc brakes
• Leak test
• Removal and installation
• Conventional spigot connections
• Quick disconnect coupling
• Tubing tips
• Brake cylinder
• Spring-loaded brake cylinder
• Automatic working gap adjuster
• Brake drum
• Drum brake pads, 1354 & 1355t rear axle
• Drum brake pads, first rear axles 09N044
• Installing linings on drum brake pads
• Pad support bearing
• Camshaft
• Camshaft support bush
• Drum brake shield
• Disc brake shield
• Compressor cylinder head gasket
• Dryer filter element
• Brake pads
• Brake disc
• Brake caliper model KNORR SB7000
• Brake caliper support bracket
• Anthers of clamps ("pistons") of the brake caliper model KNORR SB7000
• Anthers of clamps ("pistons") of the brake caliper model KNORR
• KNORR SB7000 Bronze caliper support bush
• KNORR SN7000 Bronze caliper support bush
• KNORR SB7000 caliper guide rubber support
• KNORR SN7000 caliper guide rubber support
• KNORR SB7000 Bronze caliper support bush boots
• KNORR SN7000 Bronze caliper support bush boots
• Disassembly and assembly
• Brake chamber
• Spring brake cylinder WABCO
• General part
• Introduction
• What does it mean to have a road train with good braking characteristics?
• Equalizing braking forces using a dynamometer (test brake drums)
• Form "Equalizing braking forces using test brake drums"
• Area of ??coincidence of braking forces for a loaded road train tractor / trailer
• Area of ??coincidence of braking forces for a loaded road train truck / trailer
• Check and adjust
• Checking the braking performance of a truck with EBS
• Checking and adjusting the brake force distribution on trucks without EBS in combination with a trailer without EBS
• Checking and adjusting the brake force distribution on trucks without EBS as part of a road train with a trailer equipped with EBS
• Checking and adjusting the brake force distribution on tractors with EBS in a road train with a trailer not equipped with EBS

Transmission

• Clutch
• Safety instructions
• General part
• Technical data
• Clutch component description
• Clutch checks and adjustments
• Removing and installing clutch elements
• Clutch servo
• ASTRONIC clutch servo unit
• Clutch release bearing
• Clutch release fork
• Disc clutch assembly
• Clutch unit with automatic adjustment / wear compensation
• Installing the clutch (new node)
• Support and guide bearing of the gearbox input shaft (in the flywheel)
• Clutch master cylinder
• Hydraulic clutch
• Draining and filling
• Bleeding hydraulic clutch
• Mechanical transmission control
• Checking and adjusting
• Mechanical gearbox control for "left-hand drive" models
• Removing and installing elements
• Control lever, "LHD" models
• Swing arm swing arm
• Swing arm
• Control rod
• Silent blocks
• SERVOSHIFT Pneumatic Gearbox Control
• Description of the pneumatic control gearbox (SERVOSHIFT)
• Semi-automatic (pneumatic) controlled gearbox (SERVOSHIFT)
• Pneumatic gearbox (SERVOSHIFT) fault table
• Description of com ponents
• General information
• Removing and installing elements
• Servoshift Node
• Pneumatic gearboxes
• Technical data
• Neutral valve
• Control lever. Changeover valve
• General part
• Description of the overload protection system
• Pneumatic gearbox control scheme
• Description of gearbox components
• Neutral valve
• Changeover valve on the gearshift lever
• Protection valve GV (Getriebevorschalt - preparation for gear engagement)
• Checks and adjustments
• Vehicle speed signal simulation
• Checking the protection valve against accidental (premature) downshifting
• Checking and adjusting the protection valve (GV) of the ZF gearbox
• Removal and installation of pneumatic elements of the gearbox
• Shift lever valve
• Gearboxes ZF 16S-151/181/221
• Technical data
• General information
• System description
• Synchronizers
• Checks and adjustments in the gearbox
• Checking the oil level in the gearbox
• Axial clearance of the gearbox input shaft bearing
• Gearbox selector shaft housing
• Removing and installing gearbox elements
• Gearbox assembly with or without ZF intarder
• Propeller shaft flange
• Gearbox output shaft oil seal
• Gearbox input shaft oil seal
• Selector shaft oil seal
• Gearbox oil change
• AS Tronic gearbox
• Refueling volumes
• Possible malfunctions table and remedies
• General information
• Type designation AS Tronic gearbox
• Description of the components of the "AS Tronic" gearbox
• Checks and adjustments
• Removing and installing gearbox elements AS Tronic
• AS Tronic gearbox modulator
• Control node
• Propeller shaft flange
• Gearbox output shaft oil seal
• Gearbox input shaft oil seal
• Oil seal and bushing of the clutch release fork
• Changing the oil in the AS Tronic gearbox
• AS Tronic gearbox with ZF intarder
• ZF Intarder coolant
• Intarder ZF
• Axial clearance
• Possible malfunctions table and solutions
• Safety instructions
• Key points
• Location of the main components
• Checking and adjusting
• Output shaft bearing axial clearance
• Stator axial clearance
• Checking the oil level in the gearbox with intarder
• Removing and installing intarder elements
• Supply air solenoid valve
• Hydraulic accumulator
• Heat exchanger
• Hydraulic control unit
• Oil pump
• Gearbox / intarder oil filter
• Proportional valve
• Intarder drive
• Hydraulic accumulator
• Draining and filling oil
• Gearbox with intarder ZF AS Tronic
• Power take-offs
• Refueling volumes
• Safety instructions
• General part
• Power take-off DAF
• Power take-off options
• Pneumatic power take-off control
• Power take-off checks and adjustments
• Axial clearance of the PTO drive shaft
• Axial clearance of the gear drive in the flywheel housing (power take-off from the DAF engine)
• Removal and installation of power take-off elements
• Flywheel PTO DAF
• Flywheel housing on engines with power take-offs
• Power take-offs of different variants
• Power take-off intermediate shaft
• Power take-off from DAF engine
• Power take-off housing on DAF engine
• Versions with and without drive flange and switching unit
• Cardan shafts
• Checking
• Refueling volumes
• Possible malfunctions table and remedies
• Cardan shaft
• Suspended bearing
• Checking and adjusting the propeller shaft
• Removal and Installation
• Main and intermediate propeller shaft assembly
• Cardan (cross) joint
• Suspended bearing
• Drive shaft lubrication

Electrical equipment

• Location of components in the vehicle
• Key points
• Accepted abbreviations
• Wire marking
• Reading electrical diagrams
• Reading individual circuit diagrams
• Connector locations
• Wiring diagram 1615585/03
• Overview of the basic elements and their positions on the car wiring diagram 1615585/03
• Wiring diagrams 1615585/03 car circuits
• Scheme A. Voltages before and after the ignition switch
• Diagram B. Ground Connection Overview
• Diagram C. Overview of can multiplex bus connections
• Diagram 1. Main power switch
• Diagram 2. Generator / ignition / starting circuit / charging circuit
• Diagram 3. MTCO tachograph
• Diagram 5. Engine preheating
• Diagram 8. Electronic vehicle control module VIC
• Diagram 15. Brake lights / cab tilt drive
• Scheme 21. Air conditioner / air recirculation damper / heater fan
• Scheme 29. EMAS electronic steering gear control system
• Scheme 32. Power take-off mechanisms (PTO)
• Figure 43. DMCI connector (direct memory access interface) / body
• Diagram 45. Sockets, 16-pin (A021) FA / FT diagnostic connectors
• Scheme 46. QUALCOMM multiplexer
• Figure 47. DMCI (direct memory access interface)
• Diagram 48. ECAS suspension height level