dw232470 GROUP 0

0 STRUCTURE
65/75/85CF series
TECHNICAL DATA
0
1
SAFETY INSTRUCTIONS AND WARNINGS
2
THREADED CONNECTIONS
3
SEALS AND BEARINGS
4
GENERAL OPERATIONS
5
PAINT TREATMENT
6
CONVERSION TABLES
7
ᓻ 200325
white
0 TECHNICAL DATA
65/75/85CF series Contents
CONTENTS
Page Date
0
1. VEHICLE MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200325
1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200325
2. LOCKING COMPOUNDS AND SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200325
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200325
3. THREADED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 200325
3.1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . 200325
4. PAINT TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . 200325
4.1 Overview of plastics used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . 200325
ᓻ 200325 1
TECHNICAL DATA 0
Contents 65/75/85CF series
2 ᓻ 200325
0 TECHNICAL DATA
65/75/85CF series Vehicle models
1. VEHICLE MODELS
1.1 OVERVIEW
0
G000179
ᓻ 200325 1-1
TECHNICAL DATA 0
Vehicle models 65/75/85CF series
1-2 ᓻ 200325
0 TECHNICAL DATA
65/75/85CF series Locking compounds and sealants
2. LOCKING COMPOUNDS AND SEALANTS

2.1 GENERAL
0
Certain cleaning agents have a
negative effect on the functioning of
locking compounds. The general
rule is therefore that fasteners and
components which have been
cleaned with a cleaning agent must
be treated with a cleaning liquid to
ensure that the locking compound
functions properly.
OVERVIEW OF LOCKING COMPOUNDS

Product Properties Applications DAF
name number
Loctite - Locking with an average Locking of threaded connections 0068197
243 detaching strength
- Detachable with normal tools
Loctite - Locking with a high detaching Locking of threaded connections, 1340646
2701 strength gear lever ball, freeze plugs
- Repairs the fit in bearing
housings
- Seals against leaks
- Difficult to detach
Loctite - Locking with a high detaching Locking of cylindrical connections 0645557
638 strength under dynamic load.
Loctite - Locking with an average Locking of threaded connections in 1357032
648 detaching strength warm places
- Resistant to high temperatures
Loctite - Locking with a high detaching Locking of threaded connections, 1279841
262 strength such as the pinion nut
ᓻ 200325 2-1
TECHNICAL DATA 0
Locking compounds and sealants 65/75/85CF series
Applying the locking compound

1. Clean both the internal and external thread.
0 2. Degrease the thread with a suitable

degreasing agent which leaves no residue
that could affect proper functioning.
3. Apply one or more drops of locking
compound to the thread, depending on the
diameter. Never dip the bolt or stud fully into
the locking compound.
4. Apply a drop of oil under the bolt head.
Locking compounds also reduce the
frictional resistance, which means that
applying a drop of oil to the thread is not
required.
5. Tighten the connection to the specified
torque.
2-2 ᓻ 200325
0 TECHNICAL DATA
65/75/85CF series Locking compounds and sealants
OVERVIEW OF SEALANTS
Product
name
Properties Applications DAF
number 0
Dirko D - Resistant to temperatures of up Sealing of surface connections 1345014
to 180_C
- Resistant to oil, coolant
Loctite - Resistant to temperatures of up Sealing of surface (flange) 0697149
510 to 200_C connections that are subjected to
- Resistant to oil, brake fluid, high operating temperatures, such
coolant as the flywheel housing
Loctite - Resistant to high pressures (up Sealing of surface connections 1246867
574 to 350 bar) against high pressures
- Resistant to oil, brake fluid,
coolant
Loctite - Resistant to temperatures Sealing of flexible constructions 1242895
Blue ranging from 60_C to 260_C such as (valve) covers
- Resistant to oil
Loctite - Silicone sealant, good Sealing of (surface) connections in 1284123
ultra grey resistance to coolant the cooling system
- Resistant to temperatures of up
to 325_C
Loctite - Silicone sealant, good Sealing of surface connections 1284122
ultra resistance to oil such as hub covers
copper - Resistant to temperatures of up
to 350_C
Loctite - Silicone sealant, good Sealing of surface connections, 1360102
5910 resistance to oil such as front and rear covers of
- Resistant to temperatures of up gearboxes, differential housings,
to 200_C hub covers, shaft collars and oil
cooler
Loctite - Seals against low pressure Threaded connections 0292336
572 immediately after fitting
Loctite - Surface sealant, specially Sealing of aluminium parts 1441339
5205 designed for sealing aluminium
parts
- Resistant to temperatures of up
to 150_C
- Resistant to water, coolant and
oil
Loctite - Hardens on contact with metal For locking, fastening and sealing 1322823
Form a and on full closure
gasket
ᓻ 200325 2-3
TECHNICAL DATA 0
Locking compounds and sealants 65/75/85CF series
OTHER PRODUCTS
0 Product
name
Properties Applications DAF
number
Tectyl Protects the cavities of the cab Post-treatment of cab parts to 1343888
body against corrosion. protect against corrosion.
Can also be used to protect metal
parts
Contact Cleaning agent for cleaning and Cleaning of electrical contacts 1387608
spray degreasing electronic and
electrical connections. Removes
moisture and dirt from electrical
contacts
Loctite - Cleans and degreases For cleaning/de-greasing materials 1322827
cleaner - Non-inflammable and to which a locking compound must
7063 non-corrosive be applied
Molykote - Lubricating grease is Everywhere where grease 1389512
BR 2 heat-resistant from --30_C to lubrication is appropriate and
PLUS +130_C normal
- For almost all ball and roller
bearings, plain bearings,
guides, couplings, splined
shafts, threaded spindles,
sprocket drives with a low
speed
Molykote - Lubricating grease protects For threaded connections that are 1391619
P37 against corrosion and is exposed to high temperatures, as
heat-resistant up to 1400_C. used for exhaust systems
Copaslip - Copper paste with an excellent For connections that are 1284344
bond, is anti-corrosive and vulnerable to oxidation or
heat-resistant from --35_C to corrosion, such as battery
1100_C. terminals, exhaust couplings etc.
- Resistant to water, salts and
acids.
- Prevents wear, oxidation, rust,
corroding and locking of metal
surfaces.
Renolit - Lubricating grease (white) Disc brake adjustment device 1448907
HLT2
Syntheso- - Lubricating grease (green) Rubber guides, disc brake 1448908
GL EP1
Gleitmo - Protects untreated metals For parts which are attached with a 1443160
805 against corrosion fit such as wheel hub units
2-4 ᓻ 200325
0 TECHNICAL DATA
65/75/85CF series Threaded connections
3. THREADED CONNECTIONS
3.1 TIGHTENING TORQUES
0
TABLE OF STANDARD TIGHTENING TORQUES, STANDARD 00804-203
The tightening torques in the table below are
standard torques and only apply to dipped
threaded connections.
The property codes are stamped on the nut and
bolt, except on the clamping flange bolt. The
clamping flange bolt is recognised by a
constriction between the hexagonal bolt head
and the flange. This constriction is absent in
standard flange bolts.
M2 00 001
Clamping flange bolt Standard flange bolt
ᓻ 200325 3-1
TECHNICAL DATA 0
Threaded connections 65/75/85CF series
TIGHTENING TORQUES FOR DIPPED THREADED CONNECTIONS

0 Overview of standard tightening torques for
DAF flange bolts and nuts, strength class
10.9/10.
Thread pitch Tightening torque (Nm) Extra angular displacement (ᐔ 10 %)

for bolt stem length L (mm):
L ≤ 40 41-80 81-130 131-180
M8 30 2 30_ 60_ 90_ 120_
M10 60 4 45_ 90_ 120_ 150_
M12 x 1.75 110 8 30_ 60_ 90_ 120_

M12 x 1.25 110 8 45_ 90_ 120_ 150_
M14 x 2 170 15 30_ 60_ 90_ 120_

M14 x 1.5 170 15 45_ 90_ 120_ 150_
M14 x 2 for brake back plates: 170 15 Nm +60_
M16 x 2 260 20 30_ 60_ 90_ 120_
M16 x 1.5 260 20 45_ 90_ 120_ 150_
M18 x 2.5 360 30 30_ 45_ 60_ 80_

M18 x 1.5 360 30 45_ 90_ 120_ 150_
M20 x 1.5 520 40 45_ 90_ 120_ 150_
M22 x 2.5 for steering and track rod arms: 500 50 Nm +90_
The bolt stem length L is the length of the bolt

between the bolt head and the nut.
If a component is attached with several bolts, all
bolts must first be tightened to the specified
torque, and subsequently by the angular
displacement.
3-2 ᓻ 200325
0 TECHNICAL DATA
Overview of standard tightening torques for

DAF fastenings, strength class 8.8/8
Thread Tightening torque in Nm 0

M4 2,8 0,2
M5 5,5 0,4
M6 9,6 0,7
M8 23 2
M10 46 4
M12 79 6
M14 125 9
M16 195 14
M18 280 20
M20 395 30
M22 540 40
M24 680 50
M27 1000 70
M30 1350 100

DAF flange bolts and nuts, strength class
12.9/12.
Thread Tightening torque in Nm

M8 32 3
M10 67 5
M12 113 9
M14 178 14
M16 274 22
M18 385 30
M20 550 43
M22 740 60
M24 925 72
M27 1370 110
ᓻ 200325 3-3
TECHNICAL DATA 0

DAF clamping flange bolts and nuts,
0 strength class 12.9/12

M12 178 14
M14 274 22
M16 425 35
M18 550 45
Overview of tightening torques, banjo bolts

M6 8 0,8
M8 15 1,5
M10 30 3
M12 40 4
M14 50 5
M16 60 6
M18 70 7
Torque wrench
- Have torque wrenches regularly inspected
and calibrated.
Re-use of fasteners (bolt/nut/threaded end)
1. Clean the thread (take particular care to
remove locking compound residues) and
the clamping faces.
2. Check the thread for damage.
Screw a new nut/bolt onto the thread by
hand to check it.
If the new nut/bolt cannot be screwed down
over the whole thread of the fastener to be
checked, the fastenermust not be reused.
3-4 ᓻ 200325
0 TECHNICAL DATA
3. Apply one drop of engine oil to the first turn

of the bolt(/threaded end)/lower turn of the
nut and one drop to the clamping faces
(other lubricants are not allowed). 0
4. If a locking compound was specified, no oil
should be applied to the thread.
New bolts/nuts
New DAF bolts and DAF nuts, except bolts M4
to M8 with inner-Torx, are all treated with a
lubricant.
If bolts have not been treated with a lubricant,
this should be done as yet.
1. Apply one drop of engine oil to the first turn
of the bolt/lower screw thread of the nut and
one drop to the clamping faces (other
lubricants are not allowed).
2. If a locking compound was specified, no oil
should be applied to the thread.
ᓻ 200325 3-5
TECHNICAL DATA 0
3-6 ᓻ 200325
0 TECHNICAL DATA
65/75/85CF series Paint treatment
4. PAINT TREATMENT
4.1 OVERVIEW OF PLASTICS USED
0
G000092
1. Seed top coats

2. SMC polyester parts
3. Thermoplastic polymer parts
4. SMC fibre-glass reinforced polyester parts
ᓻ 200325 4-1
TECHNICAL DATA 0
Paint treatment 65/75/85CF series
4-2 ᓻ 200325
0 SAFETY INSTRUCTIONS AND WARNINGS
CONTENTS
Page Date
1. SAFETY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0107
2. WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0107
2.1 Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0107
2.2 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . 0107
2.3 Jump-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . . 0107
2
2.4 Plastic pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . . 0107
2.5 Wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 . . . . . . 0107
2.6 Avoiding the risk of fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 . . . . . 0107
2.7 Tachograph calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 . . . . . 0107
ᓻ 0107 1
SAFETY INSTRUCTIONS AND WARNINGS 0
2 ᓻ 0107
65/75/85CF series Safety specifications
1. SAFETY SPECIFICATIONS
WARNING SYMBOL
When text is accompanied by the warning
symbol shown here, this indicates that the
information provided is essential for the health
and personal safety of the mechanic.
This warning symbol is also shown if
circumstances threaten the safety of the vehicle
or could lead to damage to the vehicle.
SAFETY PRECAUTIONS
To ensure that the mechanic’s health is not
2
endangered, the following safety instructions
must be strictly observed. M0015
- Comply with all the warnings and safety

instructions given in this workshop manual.
First read the instructions and warnings on
the labels and stickers which are affixed to
the various components and comply with
them! They have been put there for your
health and safety, so do not ignore them!
- Wear clean, well-fitting clothes and apply
protective cream to unprotected parts of
your body, if necessary.
- Always disconnect the earth lead of the
battery before working on the vehicle.
- Do not run the engine in an enclosed or
unventilated area. Make sure exhaust
fumes are properly extracted.
ᓻ 0107 1-1
Safety specifications 65/75/85CF series
- Remain at a safe distance from rotating

and/or moving components.
- Do not remove the filler cap of the cooling
system when the engine is at operating
temperature.
- Be careful when changing the oil. Hot oil
can cause serious injuries.
- Avoid unnecessary contact with drained oil.
2 Frequent contact damages the skin.
- Various sorts of oil and other lubricants
used on the vehicle may constitute a health
hazard. This also applies to engine coolant,
windscreen washer fluid, refrigerant in
air-conditioning systems, battery acid and
diesel fuel. So avoid inhaling and direct
contact.
- Tilt the cab fully if work must be carried out
underneath the cab.
- Always use stands to support the chassis or
components when working under the
vehicle.
- Be careful when working on activated
springs, such as those in spring-brake
cylinders, valves, and similar. Inadvertently
released springs may cause serious
injuries. Small springs and circlips may also
cause injuries when inadvertently released
(wear goggles).
- Always use a tyre cage when fitting and
inflating tyres. Thoroughly clean tyres prior
to balancing. Only use a balancing device
fitted with a protective cover.
1-2 ᓻ 0107
65/75/85CF series Safety specifications
- Always use the appropriate lifting gear

(gearbox jack) or approved hoists for the
removal and installation of heavy
components. Attach the component
securely to the lifting or hoisting gear.
- Be careful when working on systems which
may be under pressure, such as a trailing
axle lifting device, cab tilting mechanism,
brake system, steering gear, fuel system,
-
etc.
Always charge batteries in a properly
2
ventilated area and avoid sparking and
naked flames. Always switch the battery
charger off before removing the leads.
Fast-charging should only be resorted to in
an emergency. Disconnect the battery leads
when fast-charging is being used.
- After a fire it is possible that hazardous
residues may remain from the plastics used
in some oil seals and sealing rings. Wear
protective, acid-resistant clothing and PVC
gloves when removing such fire residues.
Submerge such fire residues in, or sprinkle
them amply with, a calcium hydroxide
solution (slaked lime and water).
Thoroughly clean the protective clothing
after use. Treat the gloves as chemical
waste.
ᓻ 0107 1-3
Safety specifications 65/75/85CF series
1-4 ᓻ 0107
65/75/85CF series Warnings
2. WARNINGS
2.1 BATTERIES
Non-compliance with the warnings

contained in this section may result
in serious damage to the vehicle
and may even lead to dangerous
situations.
Battery acid is a corrosive fluid.

In the event of contact with the
2
skin: Rinse the skin with plenty of
water for a sustained period. If
redness or pain persists, consult a
doctor. Remove any clothing
affected and rinse with water.
In the event of contact with the
eyes: Rinse with plenty of water for
at least 15 minutes and see a
doctor.
If any is swallowed: do NOT induce
vomiting. Rinse the mouth, drink
two glasses of water and see a
doctor.
In the event of inhalation: get some
fresh air, rest and consult a doctor.
To prevent damage to electronic components,

never disconnect the battery terminals when the
engine is running.
Always disconnect the earth lead of the battery
before working on the vehicle. Never place tools
on a battery. If you do, this could short-circuit the
battery or even cause the battery to explode.
Charging
- Always charge batteries in a properly
ventilated area and avoid sparking and
naked flames. When charging batteries, an
explosive gas mixture may be released.
- Fast-charging should only be resorted to in
an emergency.
1. Thaw out frozen batteries before charging
them.
2. Remove all the filler caps before charging,
so that any gases released can escape to
the atmosphere.
ᓻ 0107 2-1
Warnings 65/75/85CF series
3. When fast-charging, the battery positive and

negative leads (+ and --) must be
disconnected to prevent damage to
electronic components.
During “normal” charging, the battery leads
may remain connected.
4. First connect the positive lead (+) of the
battery charger to the positive terminal (+)
of the battery and then the negative lead (--)
2 5.
to the negative terminal (--).
Before disconnecting the battery charger
leads, first switch off the battery charger to
avoid sparking and to eliminate the risk of
explosion.
6. To disconnect, first release the negative
terminal (--) and then the positive
W 0 01 001
terminal (+).
2-2 ᓻ 0107
2.2 WELDING
No welding of the chassis is

allowed without special, written
permission by DAF. Exceptions to
the above are the welding
operations described in the manual
“Superstructure directives”.
Non-compliance with welding
2
regulations may cause serious
damage to the chassis.
Failure to observe the following

instructions may damage the
electronic components.
General
- Attach the earth clamp of the welding set as
close as possible to the area on the vehicle
where the welding is to be done and ensure
that it is well in contact with the part being
welded.
- Never attach the earth clamp to vehicle
components such as the engine, axles,
springs, etc. Arcing on these components is
also not permitted. Non-compliance with the
above instructions may result in serious
damage to bearings, springs, etc.
- The accessory or contact position of the
ignition lock must not be switched on.
Remove the ignition key from the ignition
lock.
- Protect plastic piping, rubber components,
plastic components, piston rods of hydraulic
cylinders and springs (in particular parabolic
springs) from welding splashes and
temperatures above 70_C.
ᓻ 0107 2-3
Welding to the chassis

- When welding on the chassis, disconnect
the connectors of all electronic equipment
(including sensors and actuators), if they
are within a 1-metre radius of the point
being welded or within a 1-metre radius of
the earthing point.
- Disconnect the battery terminals if these are
within a within a 1-metre radius of the point
being welded or the earth terminal.
2 - If the battery terminals have to be
disconnected, all electronic units mounted
on the chassis must be disconnected as
well. Also detach the cab feed-through
connectors.
Welding on the cab
- When welding on the cab, disconnect the
battery terminals.
- Disconnect the cab feed-through
connectors.
- Disconnect the connectors of all electronic
equipment (including sensors and
actuators), if they are within a 0.5-metre
radius of the point being welded or within a
0.5-metre radius of the earth terminal.
Welding on the superstructure
- Follow the instructions for “Welding on the
chassis”, together with any specific welding
instructions for welding on the
superstructure.
Note:
During grinding, protect plastic piping, rubber
components, plastic components, piston rods of
hydraulic cylinders and springs (in particular
parabolic springs) in order to prevent damage
caused by grinding sparks.
2-4 ᓻ 0107
Position of cab feed-through connectors

The cab feed-through connectors are located at
the cab front.
W 0 01 003
2.3 JUMP-STARTING
- Never start the vehicle by means

of a fast-charging device.
- The engine may be started with
the aid of jump leads using the
power from separate auxiliary
batteries (approx. 24V) or from
another vehicle with the engine
running (approx. 28V).
1. Connect the jump leads first to the positive

terminal (+), and then to the negative
terminal (--).
2. Start the engine. -
3. After starting, switch on as many power +

consumers as possible on the assisted
vehicle, in order to avoid a so-called load +
dump. -
4. Then disconnect the jump leads from the
negative terminal (--) first, followed by the
positive terminal (+).
W 0 01 004
5. Switch the power consumers off again.
ᓻ 0107 2-5
2.4 PLASTIC PIPES
Removing nipples or banjo unions in

polyamide pipes
1. Heat the pipe to remove the nipple or banjo
union. Never remove the nipple or banjo
union by making an incision in the
longitudinal direction of the pipe. This could
easily result in damage of the hose adapter.
2
Even minor damage to the hose adapter will
cause leakage.
Fitting nipples or banjo unions in polyamide
pipes
1. Do not fit nipples or banjo unions to the
same pipe end more than once, because
this could result in poor sealing.
2. Cut off the pipe end if it has been used
before. If shortening the pipe results in a
sharp curve in the pipe or if it makes the
pipe too short, a new pipe will have to be
fitted.
3. Always use a special spanner (Special
Tools, DAF No. 0694829) to fit nipples and
banjo unions in polyamide pipes.
4. Clamp the plastic pipe in the special
pliers (1).
5. Use a plastic mallet to tap the nipple or
banjo union into the pipe.
Note:
Never heat a plastic pipe when fitting nipples or
banjo unions.
Leakage from pipes
Leakage from fuel and air pipes must be
remedied as soon as possible to avoid
dangerous situations.
A leaking fuel pipe may constitute a fire hazard, 1
while a leaking air pipe may affect the braking W 0 01 005
performance of the vehicle.
2-6 ᓻ 0107
In the event of a leakage from a pipe coupling,

unlimited tightening of the union nut or banjo
bolt is not permitted.
- First check whether the leak is at the
connection point between the pipe and
coupling or at the connection point between
coupling and the component housing.
- Tighten a banjo bolt to the tightening torque
2
specified for the banjo bolt in question.
- A union nut may be tightened a further half
turn (180_) only once. Tightening the union
nut further than this is possible, but entails
the risk of excessive deformation of the
thrust washer and the pipe, which would
seriously weaken the pipe.
- If the leakage has not stopped after the
union nut has been retightened, it will be
necessary to take the coupling apart.
- Check the parts for deposits and/or
damage. Even a small longitudinal scratch
on the pipe connector of a nipple or a banjo
union may be sufficient to cause a leak.
- In the case of a banjo bolt fastening, check
the sealing surfaces. Fit new sealing rings
to the fastening and fit them. Tighten the
attachment bolts to the specified torque.
See “Technical Data”.
Chafing of pipes
When plastic pipes touch each other or other
parts of the vehicle, they may get chafed.
Immediately replace any pipes that show signs
of wear.
ᓻ 0107 2-7
When pipes are fitted so close together or so

close to other parts of the vehicle that they may
touch, they should be secured to prevent
chafing.
Releasing an elbow or T-piece and then
tightening it in a slightly different position can
sometimes prevent chafing.
Secure the pipes with cable ties.
W 0 01 006
W 0 01 007
2-8 ᓻ 0107
2.5 WIRING HARNESSES
After the first wiring harness has been

disconnected or replaced, it must be
reconnected in the original manner and
fastened.
Protect the wiring harness against contact with
sharp edges. Always use a grommet when
passing the wiring harness through an aperture.
Protect the wiring harness by enclosing it in a 2
protective sleeve.
Make sure that the joints are watertight. Never
remove sealing rings from connectors. Fit the
connectors in the correct manner.
Good earth connections are essential. There
must be no paint or oxidation between the
contact surfaces. Before assembly, apply a
conductive grease such as “Coranode” or a
similar product to the contact surfaces. Tighten
the attachment bolt securely.
Make sure that wiring is not located too close to
parts which become hot during operation.
Freely suspended cables, such as those
between the chassis and the cab, must not be
kinked or pinched between other parts.
Prevent wiring harnesses from scraping against
plastic pipes.
The pins of connectors must always be installed
and removed with special tools, to prevent poor
connections.
ᓻ 0107 2-9
2.6 AVOIDING THE RISK OF FIRE
- Check fuel pipes for leakage and fix any

leakage immediately. (see also Plastic
pipes).
- When fitting steel fuel pipes take into
account the points listed below.
Fit the fuel pipe free from tension.
Preformed fuel pipes must not be bent.
2 When refitting a banjo bolt on a fuel pipe,
always fit new sealing rings and tighten the
banjo bolt to the specified torque.
After tightening, check the fastening for fuel
leakage.
Steel fuel pipes fitted without due care and
attention can cause fuel leaks which lead to
fire hazard.
- In the event of fuel and/or oil leakage or
spillage, the engine encapsulation must be
thoroughly cleaned. First apply a
degreasing agent to the encapsulation
material. Then wash down the
encapsulation with a steam cleaner or with
a high-pressure cleaner.
Maintain a minimum distance of
50 cm between the engine
encapsulation and the sprayer
nozzle to prevent damage to the
encapsulation.
- Clean the engine compartment, and in

particular the encapsulated part, at regular
intervals, by removing flammable material
such as dead leaves and sawdust.
- Do not leave cleaning rags or other such
things in the engine compartment.
- Repair leaks in the exhaust system without
delay. Badly corroded exhaust components
should be replaced before they fail.
2-10 ᓻ 0107
- Always remember to re-fit the heat shields

after removal.
- Never replace a defective fuse by a fuse of
a higher rating.
- Never connect accessories which are not
protected by a fuse.
- Check wiring which is not fuse-protected
(battery leads, etc.), to make sure that it is
undamaged and properly attached and
located.
2
2.7 TACHOGRAPH CALIBRATION
The test bench may be used to calibrate the

tachograph (e.g. when changing to a different
type of tyre).
If the vehicle is equipped with ASR, the system
will interpret turning rear wheels and still front
wheels as rear wheel spin. As deceleration is no
longer applicable, the system will try to
neutralise this “spinning” by slowing down the
rear wheels. The result is that the vehicle is
thrown from the test bench, which is dangerous.
In order to avoid this, the ABS/ASR system
fuses must be removed, rendering the ABS/ASR
system inactive.
However, this is viewed by the system as faults
to be registered in the memory. These faults
must be reset after calibration using DAVIE.
ᓻ 0107 2-11
2-12 ᓻ 0107
0 THREADED CONNECTIONS
CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0107
1.1 Dipped threaded connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0107
ᓻ 0107 1
THREADED CONNECTIONS 0
2 ᓻ 0107
65/75/85CF series General
1. GENERAL
1.1 DIPPED THREADED CONNECTIONS
DAF vehicles are fitted with threaded

connections which have been treated with a
lubricant (dipped threaded connection).
Factory-galvanised bolts and nuts are
wax-dipped. Black annealed and phosphatised
bolts and nuts are oil-dipped. The advantage of
using a lubricant is that friction during tightening
of the threaded connection is reduced, so that
the specified pre-tension can be obtained more
easily and more accurately. The tightening
torque can be reduced while the pre-tension
force remains the same.
3
To achieve a small spread in the pre-tension
force, the dipped threaded connection must be
tightened accurately. Therefore, always use a
reliable and accurate torque wrench.
Note:
Have torque wrenches regularly inspected and
calibrated.
To achieve the correct pre-tension when
re-using threaded connections, it is important to
clean the threaded parts thoroughly. After
cleaning, apply one drop of lubricant to the first
turn of the screw thread and one drop to the
abutting surface of the nut or bolt. Only use
engine oil as a lubricant for re-used bolts and
nuts. Lubricants other than engine oil or
factory-applied grease must not be used in any
circumstances because of the difference in
frictional coefficient.
When locking compounds are used for dipped
threaded connections, the instructions given
here apply, except for applying lubricant to the
first turn of the screw thread.
ᓻ 0107 1-1
General 65/75/85CF series
The following applies to all threaded

connections (for both new and used
vehicles):
- in the case of standard connections, apply
the lubricant before fitting, and
tighten/retorque in accordance with the
standard for dipped bolts;
- in the case of special connections, apply the
lubricant before fitting, and tighten/retorque
in accordance with the values specified in
the instructions.
The instructions for using a lubricant also apply
3 to new bolts supplied from the warehouse. Dry
threaded connections are not permitted because
of their highly variable friction coefficients.
The following threaded connections are used on
DAF vehicles:
- Fastenings with strength class 8.8 and 8,
- flange bolts and nuts with strength class
10.9 and 10,
- flange bolts and nuts with strength class
12.9 and 12,
- clamping flange bolts and nuts with strength
class 12.9 and 12.
Threaded connection 10.9/10
A threaded connection 10.9/10 is tightened as
standard with a torque followed by an angular
displacement. The angular displacement
depends on the bolt stem length. For the
tightening torque with the applicable angular
displacement, see “Technical Data”.
If a threaded connection 10.9/10 has to be
tightened differently, for example using a
tightening torque only, this is indicated in the
technical data for the component concerned.
1-2 ᓻ 0107
65/75/85CF series General
Other threaded connections

Threaded connections 8.8/8, 12.9/12 and
clamping flange bolt 12.9/12 are tightened as
standard only with a torque. For the standard
tightening torques, see the “Technical Data”.
If any of these threaded connections has to be
tightened differently, this is indicated in the
technical data for the component concerned.
Application, locking compound
1. Clean both the internal and external thread.
2. De-grease the thread with a suitable
de-greasing agent which leaves no residue
3
that could affect proper functioning.
3. Apply one or more drops of locking
compound to the thread, depending on the
diameter. Never dip the bolt or stud into the
locking compound.
4. Apply a drop of oil under the bolt head.
Locking compounds also reduce the
frictional resistance, which means that
applying a drop of oil to the thread is not
required.
5. Tighten the connection to the specified
torque.
ᓻ 0107 1-3
General 65/75/85CF series
1-4 ᓻ 0107
0 SEALS AND BEARINGS
CONTENTS
Page Date
1. GASKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0107
1.1 Paper and Klingerit gaskets (rubber-aramide fibre) . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0107
1.2 Liquid gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . 0107
2. SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0107
2.1 Removing and fitting sealing rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0107
3. BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0107
3.1 Bearings, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 ...... 0107
3.2 Fitting bearings into a bearing housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0107
3.3 Fitting bearings to a shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 ...... 0107
ᓻ 0107 1
SEALS AND BEARINGS 0
2 ᓻ 0107
65/75/85CF series Gaskets
1. GASKETS
1.1 PAPER AND KLINGERIT GASKETS (rubber-aramide fibre)
The workshop manual specifies when a gasket

is required and it also gives information about
the type of gasket to be used.
1. Remove the old gasket before fitting a new
one.
2. Clean the contact surfaces and check them
for damage.
3. Paper gaskets should be sparingly greased
before they are fitted. These gaskets are
used to seal flat parts and are resistant to
oil and moderate heat.
4. Do not grease Klingerit gaskets before
fitting. These gaskets are usually
4
graphitised. They are used to seal flat
surfaces and are resistant to oil, water and
heat.
5. There are special instructions for cylinder
head gaskets. See the relevant section.
6. Always tighten the attachment bolts evenly.
ᓻ 0107 1-1
Gaskets 65/75/85CF series
1.2 LIQUID GASKETS
The workshop manual specifies when a gasket

is required and it also gives information about
the type of gasket to be used.
Liquid gaskets, which replace conventional
gaskets, have been developed to seal flat
connections. They are resistant to oil, water and
temperatures up to approx. 200_C.
To apply a liquid gasket, follow the instructions
below.
Application, liquid gasket
1. Remove all traces of the old gasket and
clean the surfaces to be sealed.
4
2. Sparingly apply the specified sealant to one
of the surfaces to be sealed. Also apply
sealant around studs, bores and the like to
ensure they are properly sealed.
3. If sealant has got into an oil bore (or other),
remove it carefully.
4. Put the surfaces to be sealed against each
other and tighten the attachment bolts
evenly.
1-2 ᓻ 0107
65/75/85CF series Seals
2. SEALS
2.1 REMOVING AND FITTING SEALING RINGS
There are two different kinds of sealing rings:

conventional sealing rings and unitised sealing
rings.
- The conventional sealing ring is fitted in a
recess and its inner ring has its running
surface on a shaft.
- The unitised sealing ring is fitted in a fixed
position both in a recess and on the shaft.
Sealing is achieved internally.
Removing a sealing ring
1. If possible, remove the sealing ring with the
special tool (DAF no. 1329458 or
DAF no. 0694928 (A) and 0484899 (B).
When removing the sealing ring, take care
not to damage the recess. 4
M200971
A B
A8 00 360
ᓻ 0107 2-1
Seals 65/75/85CF series
Installation, seal
1. Check the recess in which the sealing ring
is to be fitted for damage. Make good any
damage.
2. Look for any marks on the outside of the
sealing ring indicating the direction of
rotation of the shaft.
3. Always use a suitable driving tool to fit a
sealing ring and press the ring evenly to its
place in the recess.
4. Once a unitised sealing ring has been
removed from the recess, it must not be
re--used.
5. In most cases, a liquid gasket is used to fit
a conventional sealing ring with a steel
4 sheathing, whereas oil or liquid soap is
used to fit a sealing ring with a rubber
sheathing.
6. Always fit unitised sealing rings dry, unless
stated otherwise.
7. Always apply a little amount of oil or grease
to the sealing lip(s) and running surface of a
conventional sealing ring.
2-2 ᓻ 0107
65/75/85CF series Bearings
3. BEARINGS
3.1 BEARINGS, GENERAL
1. Bearings must be replaced if they are worn,

in the case of pitting (small dents in the
running surface) and/or if the bearings have
been exposed to excess heat (blue spots).
2. When fitting a bearing, make sure that no
force is transmitted via the balls or rollers of
the bearing. For example, by fitting a
bearing on a shaft by pressing on the outer
bearing race.
3. Clean the bearing before fitting it.
4. Avoid dirt getting into the bearing while it is
4
being fitted.
5. If the instructions specify that the bearing
should be heated before it is fitted, avoid
exceeding the temperature specified. Also
avoid local overheating.
6. Raise the temperature of the bearing evenly
by heating it in the special oil bath. Another
option is to place the bearing on an electric
cooker. Watch the temperature closely in
this case.
ᓻ 0107 3-1
Bearings 65/75/85CF series
3.2 FITTING BEARINGS INTO A BEARING HOUSING
Fitting bearings into a bearing housing

1. Always use the correct size of driving tool.
2. Centre the driving tool accurately on the
outer bearing race.
3. Preferably press the bearing evenly into the
housing, using a pressing tool.
3.3 FITTING BEARINGS TO A SHAFT
Fitting bearings to a shaft

1. Always use the correct size of driving tool.
2. Centre the driving tool carefully on the inner
4 bearing race.
3. Preferably press the bearing evenly onto
the shaft, using a pressing tool.
3-2 ᓻ 0107
0 GENERAL OPERATIONS
CONTENTS
Page Date
1. PRESERVATION AND DE-WAXING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0107
1.1 Preservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . . 0107
1.2 De-waxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . . 0107
2. CLEANING VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0107
2.1 High-pressure cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0107
ᓻ 0107 1
GENERAL OPERATIONS 0
2 ᓻ 0107
65/75/85CF series Preservation and de-waxing
1. PRESERVATION AND DE-WAXING

1.1 PRESERVATION
Note:
Observe the applicable environmental
requirements.
1. Clean the vehicle thoroughly so that all dirt
and dust are removed.
2. Use pressurised air to remove any residues
from the vehicle.
3. Cover all glazing, headlights and tail lights.
4. Use a spray gun to spray undiluted
preserving agent RUSAN D5018 (a FINA
product) over the chassis frame and its
fittings, all parts and components in the
engine compartment and all painted sheet
metal parts. Tilt the cab to be able to spray
5
the preserving wax on the cab roof. Make
sure that all edges, joints and cavities are
sprayed with a full jet of preserving wax.
5. Use a brush to apply Rusan D5018 to the
wheel studs.
On no account spray preserving
agent into brake drums or on to
brake discs.
Spending the night in a preserved

cab is not allowed. Sleeping in
preserved cab may cause nausea
and headaches.
ᓻ 0107 1-1
Preservation and de-waxing 65/75/85CF series
1.2 DE-WAXING
Note:
Observe the applicable environmental and
safety requirements.
The vehicle should preferably be placed on a
grid floor.
Most de-waxing agents are
inflammable. The de-waxing area
should be suitable for the safe use
of such products.
1. Remove the preserving agent with a

solvent, an emulsifying cleaner or a
high-pressure hot water cleaner with added
solvent.
De-waxing with a high-pressure hot water
cleaner should be done carefully and
evenly. Set the high-pressure hot water
cleaner to a maximum pressure of 100 bar
5 and a maximum temperature of 90_C.
Never direct the jet of wax remover too long
at the same area, for this could cause
serious damage to the paintwork and
rubber. If some parts of the treated surface
still have preserving agent on them, treat
these areas again in the same way.
Note:
A steam cleaner is not suitable for de-waxing
because it requires the use of calcium descaling
products to keep the inside of the steam coil
clean. The dried residues of these products are
difficult to remove.
2. After removing the de-waxing agent, rinse
the vehicle thoroughly with water.
1-2 ᓻ 0107
65/75/85CF series Cleaning vehicles
2. CLEANING VEHICLES
2.1 HIGH-PRESSURE CLEANER
It is advisable to clean the vehicle with a

high-pressure cleaner before starting
maintenance or service operations. A clean
vehicle makes the mechanic’s work easier, and
enables him to notice any defects at an early
stage.
Note:
Before cleaning the vehicle, check the engine,
axles, gearbox, etc. for evidence of leakage.
If the vehicle is cleaned with a high-pressure
cleaner, the latter must be used with care. It is
also important to observe the following points:
- Make sure that doors, windows and roof
hatch are securely closed during
high-pressure cleaning.
- When cleaning the universal joint on the
steering box, the spider seals may be
5
forced open by the high-pressure jet of
water, so that the grease behind them is
flushed away. As a result, the spider may
get stuck, so that the steering mechanism
will jam.
- A bleed screw is fitted to the power steering
fluid reservoir of the steering system. Water
may enter the tank through this, causing
damage to the steering mechanism.
- When cleaning the radiator/intercooler, be
careful not to damage the fins.
- Do not direct the high-pressure cleaner jet
too long at the air-conditioning system
condenser. As a result of the high
temperature, the pressure in the system will
become excessive, which may cause
damage to the system.
ᓻ 0107 2-1
Cleaning vehicles 65/75/85CF series
- Make sure that no water can enter the

differential or the gearbox via the breathers.
- Make sure that no water can enter via the
reservoir bleed screws of clutch, brakes,
trailing axle, etc.
- The engine and engine compartment can
be cleaned with a high-pressure cleaner.
Make sure in this case not to spray onto
electrical components, such as the starting
motor, alternator, etc.
- Maintain a minimum distance of 50 cm
between the engine encapsulation and the
sprayer nozzle to prevent damage to the
encapsulation.
- Do not aim the jet of water directly at
electrical connections such as connectors,
cable plugs of the vehicle lighting system,
etc.
5 - Ensure that no water can enter the air inlet

system via the air intake or its flexible seals.
- When the vehicle has been cleaned, it must
be lubricated again with a grease gun or via
the automatic lubrication system. This is
important because it prevents the
penetration of moisture and dirt at the
various pivot points.
2-2 ᓻ 0107
0 PAINT TREATMENT
CONTENTS
Page Date
1. PAINT TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0107
1.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0107
1.2 Respraying/paint repairing of cab top coat and SMC polyester parts . . . . . 1-3 ...... 0107
1.3 Respraying/paint repairing chassis finishing . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 ...... 0107
1.4 Respraying seed top coats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 ...... 0107
1.5 Respraying thermoplastic polymer parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 ...... 0107
1.6 Respraying glass-fibre reinforced polyester parts . . . . . . . . . . . . . . . . . . . . . . 1-8 ...... 0107
ᓻ 0107 1
PAINT TREATMENT 0
2 ᓻ 0107
0 PAINT TREATMENT
1. PAINT TREATMENT
1.1 GENERAL INSTRUCTIONS
In the chapter “Paint treatment”, directives are

provided for respraying and repairing DAF paint
systems applied on various subsurfaces.
The products to be used are supplied by a range
of manufacturers. However, only use products
from well-known manufacturers that provide all
products for the complete paint structure. The
use of these products must be described in the
instructions issued by the manufacturer.
Work according to the instructions listed below:
- For rust-removal, use a rust-removal agent
based on phosphoric acid.
- To clean and remove any preserving
agents, use an organic, chlorine-free
solvent.
- Use a two-component epoxy or
polyester-based primer.
polyester-based filler.
polyester-based spray filler.
polyester-based filler. 6
- Use a two-component epoxy PUR finishing
coat, with a degree of gloss of more than
92 degrees for cab top coats and a degree
of gloss of 70 degrees for chassis finishing
(measured at 60 degree geometry).
- Maximum drying temperature is 80_C, with
the exception of fibre-glass strengthened
hand lay-up parts. Maximum drying
temperature of fibre-glass reinforced hand
lay-up parts is 60_C.
- For the paint structure, use only products
from the same supplier.
- Use the products according to the
manufacturer’s instructions.
- Never use products containing silicone in an
aerosol can.
ᓻ 0107 1-1
PAINT TREATMENT 0
Failure to follow the generally

applicable safety rules for using
paints and similar products can
result in serious injury and/or
danger.
During work with a rust-removal
agent, wear protective gloves and
safety goggles.
When using paints and similar
products, and when handling paint
waste, always work according to the
applicable environmental
requirements, to prevent
unnecessary environmental
pollution.
Colour coding
The DAF code number of the cab paint is on the
paint identification plate.
The paint identification plate is mounted on a
door pillar on the vehicle.
The DAF code number for the cab paint is also
marked on the vehicle identity card.
The colour code number of the paint
manufacturer “Dupont” is stated in the code
number. The “Dupont” colour code number
6 consists of five or six characters/digits. The
“Dupont” colour code number is followed by the
paint colour or an abbreviation.
For example, in the code number L1041MEYL,
L1041 is the Dupont colour code number of the
paint, ME indicates that it is a metallic paint and
YL is the colour abbreviation, in this case yellow.
Removing rust
- Apply the rust-removal agent in accordance
with the manufacturer’s instructions. The
concentration of the rust-removal agent
must be adapted to the amount of rust.
- Preferably use a rust-removal paste on
vertical parts.
- Prevent rust-removal agents entering
overlap joints.
- Leave the rust-removal agent to work, for
the time specified by the manufacturer.
- Rinse the area cleaned of rust at least twice
with an ample amount of clean tap water.
- Dry the area cleaned of rust.
1-2 ᓻ 0107
0 PAINT TREATMENT
1.2 RESPRAYING/PAINT REPAIRING OF CAB TOP COAT AND SMC

POLYESTER PARTS
Respraying of cab top coat and SMC

polyester parts
1. Remove any preserving agents, if
applicable; see main group “General
Operations”.
2. Remove any rust with a rust-removal agent.
3. Clean the area to be sprayed with a solvent.
4. Sand the section to be resprayed with 3M
Scotch Brite ultra fine or an equivalent
product.
5. Remove any dust from the sanded section
with a Tack-rag cloth.
7. Apply primer to any bare patches.
8. Leave the primer to evaporate/dry.
9. Apply a filler, if necessary.
10. Leave the filler to evaporate/dry. 6
11. Fine-sand with 3M Scotch Brite ultra fine or
an equivalent product.
14. Apply the top coat according to the
15. Leave the top coat to evaporate/dry.
Comply with the drying time as laid down in
the manufacturer’s instructions.
ᓻ 0107 1-3
PAINT TREATMENT 0
Paint repairing of cab top coat and SMC

polyester parts
Operations”.
3. Clean the area to be repaired with a
solvent.
4. Sand the area to be repaired first with P80
sand paper and then with P180 sand paper.
6. Fill the area to be repaired.
7. Sand the filled area with P180 sand paper.
8. Fine-sand/roughen the area to be sprayed
with 3M Scotch Brite ultra fine or an
equivalent product.
6 10. Clean the area to be sprayed with a solvent.

11. Apply a primer.
13. Apply a filler.
14. Leave the filler to evaporate/dry.
15. If necessary, fine-sand with 3M Scotch Brite
ultra fine or an equivalent product.
Following fine-sanding, remove any dust
with a Tack-rag cloth and clean the area
with a solvent.
1-4 ᓻ 0107
0 PAINT TREATMENT
1.3 RESPRAYING/PAINT REPAIRING CHASSIS FINISHING

Operations”.
3. Clean the area to be treated with solvent.
4. Sand the area to be treated with P80 sand
paper.
6. Clean the area to be treated with solvent.
7. Apply primer to any bare patches.
9. If necessary, sand with P180 sand paper.
Following sanding, remove any dust with a
Tack-rag cloth and clean the area with a
solvent.
6
ᓻ 0107 1-5
PAINT TREATMENT 0
1.4 RESPRAYING SEED TOP COATS
These instructions relate to parts in steel, SMC

(Sheet Moulding Compound) plastic or
glass-fibre reinforced polyester.
Operations”.
7. In the case of plastic, blow ionised air over
the area to be resprayed, or clean the area
with an anti-static liquid.
8. Apply the seed top coat according to the
6 9.
Leave the paint to evaporate.
10. Comply with the drying time as laid down in
1-6 ᓻ 0107
0 PAINT TREATMENT
1.5 RESPRAYING THERMOPLASTIC POLYMER PARTS
Thermoplastic polymers include the following

“elastic” plastics: ASA, ABS and PUR.
Operations”.
3. Sand the area to be resprayed with P180
sand paper
4. Fine-sand with 3M Scotch Brite ultra fine or
an equivalent product.
6. Blow ionised air over the area to be
resprayed, or clean the area with an
anti-static liquid.
8. Bring an elastic top coat (10-15% elastifier
in the base paint) according to the
manufacturer’s instructions. 6
ᓻ 0107 1-7
PAINT TREATMENT 0
1.6 RESPRAYING GLASS-FIBRE REINFORCED POLYESTER PARTS
These parts can be recognised by the visible

fibre-glass structure at the rear of the part, and
the gel coating at the front of the part.
Operations”.
5. Fill the area to be repaired.
6. Leave the filler to dry.
7. Apply spray filler to the part to be
resprayed.
8. Leave the spray filler to dry.
6
9. Sand the filled area first with P80 sand
paper and then with P180 sand paper.
10. Remove any dust from the area to be
resprayed with a Tack-rag cloth.
12. Again remove any dust from the area to be
anti-static liquid.
14. Apply filler to the area to be resprayed.
15. Leave the filler to evaporate/dry.
1-8 ᓻ 0107
0 PAINT TREATMENT
16. If necessary, fine-sand with 3M Scotch Brite

ultra fine or an equivalent product.
17. Remove any dust from the area to be
anti-static liquid.
20. Leave the top coat to evaporate/dry. Drying
temperatures must not exceed 60_C.
Comply with the drying times listed in the
ᓻ 0107 1-9
PAINT TREATMENT 0
1-10 ᓻ 0107
0 CONVERSION TABLES
CONTENTS
Page Date
1. CONVERSION TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0107
Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0107
Specific consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0107
Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0107
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0107
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ...... 0107
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ...... 0107
Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ...... 0107
Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ...... 0107
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 ...... 0107
Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 ...... 0107
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 ...... 0107
ᓻ 0107 1
CONVERSION TABLES 0
2 ᓻ 0107
0 CONVERSION TABLES
65/75/85CF Series Conversion tables
CONSUMPTION
km/l 1/100 km miles/gallon (imp) miles/gallon (US)
n 100 n x 2.2825 n x 2.352
n
100 n 282.5 235.2
n n n
n x 0.354 282.485 n n x 0.83
n
n x 0.425 235.294 n x 1.202 n
n
SPECIFIC CONSUMPTION
g/kW.h g/hp.h g/bh.h lb/bh.h
1 0.7353 0.7455 0.00164
1.36 1 1.014 0.00224
1.341 0.9863 1 0.00220
608.45 447.4 453.6 1
SPEED
cm/sec. m/sec. km/h feet/sec mile/h.
1 0.01 0.036 0.03281 0.02237
100 1 3.6 3.281 2.237
27.78 0.2778 1 0.9113 0.6214 7
30.48 0.3048 1.097 1 0.6818
44.70 0.4470 1.609 1.467 1
TEMPERATURE
n_ Celsius = 9/ n + 32_F = 4/5 n_ R = n + 273.15 K
5
n_ Fahrenheit = 5/ (n -- 32) _C = 4/9 (n -- 32)_ R = 5/9 (n -- 32) + 273.15 K
9
n_ Réaumur = 5/ n_C = 9/4 n + 32_F = 5/4n + 273.15 K
4
n_ Kelvin = n -- 273.15 _C = 9/5 (n -- 273.15) + 32 _F = 4/5 (n -- 273.15) _R
WEIGHT
kg ounces pounds (lbs) short tons * long tons * ton (metr.)
1 35.27 2.205 0.001102 0.0009842 0.001
0.02835 1 0.0625 0.00003125 0.0000279 0.00002835
0.4536 16 1 0.0005 0.0004464 0.0004536
907.2 32000 2000 1 0.8929 0.9072
1016 35840 2240 1.12 1 1.016
1000 35274 2205 1.102 0.9842 1
* US + UK
ᓻ 0107 1-1
CONVERSION TABLES 0
Conversion tables 65/75/85CF Series
7
LENGTH
mm inches feet yards m km mile (stat.)
1 0.03937 0.003281 0.001094 0.001 0.000001 0.0000006214
25.4 1 0.08333 0.2777 0.0254 0.0000254 0.00001577
304.8 12 1 0.3333 0.3048 0.0003048 0.0001894
914.4 36 3 1 0.9144 0.0009144 0.0005682
1000 39.37 3.281 1.0936 1 0.001 0.0006214
1000000 39370 3281 1093.6 1000 1 0.6214
1609350 63360 5280 1760 1609 1.609 1
AREA
mm2 cm2 square inches square feet square yards m2
1 0,01 0.00155 0.00001076 0.000001196 0.000001
100 1 0.155 0.001076 0.0001196 0.0001
645.2 6.452 1 0.006944 0.0007716 0.0006452
92900 929 144 1 0.1111 0.09290
836100 8361 1296 9 1 0.8361
1000000 10000 1550 10.76 1.196 1
VOLUME
7 cm2
US
dm3 (litre)
cubic inches pints quarts gallons *
1 0.06102 0.002114 0.001057 0.0002642 0.001
16.39 1 0.03464 0.01732 0.004329 0.01639
473.2 28.874664 1 0.5 0.125 0.4732
946.4 57.75 2 1 0.25 0.9464
3785 231 8 4 1 3.785
1000 61.02 2.114 1.057 0.2642 1
* US Gallon = 0.8327 Imp. Gallons
US
cm2 dm3 (litre)
cubic inches pints quarts gallons **
1 0.0610248 0.0017598 0.008799 0.000219975 0.001
16.387 1 0.02894 0.01447 0.003618 0.016387
568.2 34.67429136 1 0.5 0.125 0.5682
1136.49 69.319 2 1 0.25 1.13649
4545.95 277.274 8 4 1 4.54596
1000 61.0248 1.7598 0.8799 0.219975 1
** Imp. Gallon = 1.201 US Gallons
1-2 ᓻ 0107
0 CONVERSION TABLES
65/75/85CF Series Conversion tables
PRESSURE
Pa bar kg/cm2 lbs/sq inch (p.s.i.) atm
1 0.00001 0.0000101 0.000145 0.0000987
100000 1 1.0197162 14.500364 0.9868813
98066.5 0.980665 1 14.22 0.9678
6894.76 0.0689476 0.070307 1 0.068046
101322.3 1.013223 1.0332 14.70 1
133.32 0.0013332 0.0013595 0.01934 0.0013158
3386.23 0.0338623 0.03453 0.4912 0.3342
9797.82 0.0979782 0.09991 1.421 0.09668
248.89 0.0024889 0.002538 0.03609 0.002456
column of mercury at 15 _C column of water at 15 _C

Pa and g = 980.665 cm/sec2 and g = 980.665 cm/sec2
mm inches m inches
1 0.0075007 0.0002953 0.0001021 0.0040187
100000 750.06708 29.530981 10.207359 401.87015
98066.5 735.56454 28.96 10.01 0.9678
6894.76 51.715 2.036 0.7037 0.068046
101322.3 760 29.92 10.337 1
133.32 1 0.03937 0.01361 0.0013158
3386.23
9797.82
25.40
73.49
1
2.893
0.3456
1
0.3342
0.09668
7
248.89 1.867 0.07349 0.02540 0.002456
WORK
Nm mkg ft.lbs. kWh pkh (metr.) Hph kcal
1 0.1019716 0.7375607 0.0000002776 0.0000003776 0.0000003725 0.000238882
9.80665 1 7.233 0.000002723 0.0000037037 0.000003653 0.002342
1.356259695 0.1383 1 0.0000003765 0.00000051206 0.00000050505 0.0003238
3601001.88 367200 2656000 1 1.3599 1.341 860
2647795.5 270000 1952900 0.7353 1 0.9863 632.4
2684570.4375 273750 1980000 0.7455 1.0139 1 641.1
4187.43955 427 3088 0.001163 0.001581 0.00156 1
POWER
kW hp (metr.) mkg/sec kcal/sec HP lbs/sec
1 1.36 102 0.2389 1.341 737.7
0.7353 1 75 0.1757 0.9863 542.5
0.009804 0.01333 1 0.002342 0.01315 7.233
4.186 5.693 427 1 5.615 3088
0.7455 1.014 76.04 0.1781 1 550
0.001355 0.00184 0.1383 0.0003238 0.00182 1
ᓻ 0107 1-3
CONVERSION TABLES 0
Conversion tables 65/75/85CF Series
1-4 ᓻ 0107

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0 STRUCTURE

2. LOCKING COMPOUNDS AND SEALANTS

OVERVIEW OF LOCKING COMPOUNDS

Applying the locking compound

0 2. Degrease the thread with a suitable

Clamping flange bolt Standard flange bolt

TIGHTENING TORQUES FOR DIPPED THREADED CONNECTIONS

Thread pitch Tightening torque (Nm) Extra angular displacement (ᐔ 10 %)

M8 30 2 30_ 60_ 90_ 120_

M10 60 4 45_ 90_ 120_ 150_

M12 x 1.75 110 8 30_ 60_ 90_ 120_

M14 x 2 170 15 30_ 60_ 90_ 120_

M18 x 2.5 360 30 30_ 45_ 60_ 80_

M20 x 1.5 520 40 45_ 90_ 120_ 150_

The bolt stem length L is the length of the bolt

Overview of standard tightening torques for

Thread Tightening torque in Nm 0

Overview of standard tightening torques for

Thread Tightening torque in Nm

Overview of standard tightening torques for

0 strength class 12.9/12

Thread Tightening torque in Nm

Overview of tightening torques, banjo bolts

Thread Tightening torque in Nm

3. Apply one drop of engine oil to the first turn

1. Seed top coats

- Comply with all the warnings and safety

- Remain at a safe distance from rotating

- Always use the appropriate lifting gear

Non-compliance with the warnings

Battery acid is a corrosive fluid.

To prevent damage to electronic components,

3. When fast-charging, the battery positive and

No welding of the chassis is

Failure to observe the following

Welding to the chassis

Position of cab feed-through connectors

- Never start the vehicle by means

1. Connect the jump leads first to the positive

3. After starting, switch on as many power +

2.4 PLASTIC PIPES

Removing nipples or banjo unions in

performance of the vehicle.

In the event of a leakage from a pipe coupling,

When pipes are fitted so close together or so

2.5 WIRING HARNESSES

After the first wiring harness has been

2.6 AVOIDING THE RISK OF FIRE

- Check fuel pipes for leakage and fix any

- Clean the engine compartment, and in

- Always remember to re-fit the heat shields

The test bench may be used to calibrate the

DAF vehicles are fitted with threaded

The following applies to all threaded

Other threaded connections

The workshop manual specifies when a gasket

1.2 LIQUID GASKETS

The workshop manual specifies when a gasket

There are two different kinds of sealing rings:

1. Bearings must be replaced if they are worn,