Daph 105 DIY repair

In detail: daf 105 do-it-yourself repair from a real master for the site my.housecope.com.

A practical guide to the repair of a DAF XF 105 truck. The manual is intended for car owners, service station specialists and repair shops. Contains procedures for the operation, maintenance and repair of all components and systems of the truck. The book covers models equipped with diesel engines MX300 / MX340 / MX375

Control parameters
Tightening torques for main screw connections (Nm)
Checking the clutch operating fluid level
Removal and installation of the clutch mechanism
Removal and installation of the clutch mechanism with an automatic device for compensating for the wear of the friction disc lining
Removal and installation at *** th clutch release bearing
Removal and installation of the guide bearing of the input shaft of the gearbox
Removal and installation of the clutch fork
Removal and installation of the clutch servo
Removal and installation of the clutch master cylinder
Monitoring and adjusting the clutch pedal
Purging the hydraulic system
Diagnostics. Troubleshooting

Gear box

Removing and installing rear axle assembly
Differential
Pinion gear
Taper spacing adjustment
Differential bearing pre-stress adjustment
Mesh clearance adjustment
Checking the position of the working surfaces of the teeth
Removal and installation of the differential lock mechanism
Wheel hubs
Wheel speed sensor disc
Control parameters
Tightening torques for main screw connections (Nm)

Removal and installation of a steering knuckle of a front axle
Removal and installation of the *** bearing
Removal and installation of needle bearings
Checking and adjusting the steering knuckle clearance
Checking and adjusting the caster angle
Checking the camber and lateral tilt of the king pin
Convergence
Checking and adjusting the swing angle
Front wheel hubs
Control parameters
Torques (Nm) and angular values of the tightening of the main screw connections

Video (click to play).

Description of the system operation with a single-circuit hydraulic amplifier
Checking steering with a pressure gauge
Steering test with a portable test kit
Removal and installation of the steering gear housing assy
Removal and installation of the steering column bracket
Removal and installation of the steering arm
Checking and adjusting the swing angle limiting valves
Oil draining
Filling the single-circuit hydraulic power steering system
Removal and installation of the hydraulic power steering pump
Checking the restrictor valve
Control parameters
Torques (Nm) and angular values of the tightening of the main screw connections

Removal and installation of brake pads.
Removal and installation of a brake disc
Removing and installing the KNORR SN7000 brake caliper housing
Removing and installing the base of the brake caliper body
Removal and installation of a protective collar of a KNORR SN7000 brake.
Removal and installation of the brake cylinder
Removal and installation of a brake cylinder with a spring
Removal and installation of an automatic brake adjuster
Checking the automatic disc brake adjuster
Checking the brake pads of the KNORR SN7000 brake
Checking the brake discs
Checking the brake caliper stroke
Adjusting disc brakes
Checking and adjusting the braking force modulator depending on the load
Auto with air suspension
Checking and adjusting the brake force modulator.
Auto with mechanical suspension
Control parameters
Front and rear brakes
Air compressor (not for all models)
Pneumatic equipped (not for all models)
Torques (Nm) and angular values of the tightening of the main screw connections
Description of the operation of the EBS-2 system
System component characteristics

Control parameters.
ECAS-4.
The principle of operation of the ECAS-4 system
Electronic control unit ECAS D992
Remote control D529
Dashboard switches
Height sensors F612 / F613 / F614
ECAS pressure sensor F735, F736, F615
Block of solenoid valves В166, В238, В250, В253, В254
Shut-off valve
Pressure reducing valve, residual pressure function
Pressure reducing valve, pressure limiting function
Axle Load Sharing Adjustment Valve
Functions and adjustment
Mechanical suspension
Removal and installation of the spring assembly
Diagnostics, Mechanical Suspension Troubleshooting
Air suspension
Decoding of ECAS-4 trouble codes
Decoding of the codes of the parameters of the ECAS-4 system
Tightening torques for main screw connections (Nm)
Mechanical suspension
Air suspension

List of elements of electrical circuits
Electrical circuits

Gear box

Electrical equipment
List of elements of electrical circuits
Electrical circuits

This manual covers operation and repair, a catalog of spare parts, complete documentation on a CD of the DAF XF105 (DAF HF105) car, produced since 2006. The book describes the repair of cars with engines MX300, MX 340, MX375 with a volume of 12.9 liters.

Emergency response
Maintenance
User manual
Precautions and safety instructions when working on a truck
Basic tools, measuring devices and methods of working with them
Special tools and accessories
Mechanical part of the engine
Cooling system
Engine lubrication system
Central lubrication system (AGS)
Supply system
Engine management system
Intake and exhaust system, deb brake
Central synchronization unit
Clutch
Transmission
Power take-off
Retarder and Intarder
Cardan shaft, axles and wheel hubs
Frame and suspension
Brake system
Steering
Cab and body kits
Air conditioner and heater
Electrical systems
Fuels and lubricants and sealants

- Step-by-step guide for the repair of various components and assemblies of the car
- Self-service and maintenance instructions
- Valuable information on vehicle design and how to prevent malfunctions
- Catalog of consumables for maintenance
- Confidence and knowledge for a trip to the service station, in case personal repair is impossible

The Dutch concern DAF Trucks is a division of Paccar inc. the third largest manufacturer of heavy trucks in the world (after Daimler AG and Volvo Trucks). The history of the company began after the end of World War II, when in 1949 the Van Doorne's Aanhangwagen Fabriek (later the name was shortened to DAF) trailer factory produced the first model of the DAF AZO truck. The words “Driven by quality” became the motto of the company. The adherence to this principle has brought the trucks produced by the company well-deserved popularity and recognition among millions of professional drivers.

The history of DAF heavy haul trucks began in 1987 with the introduction of the 95 series. Ten years later, the designation “XF” (“Extra Force”) was added to the numbers, indicating the creation of an especially powerful series. The DAF 95XF truck was so successful that immediately after its appearance it received the title "Truck of the Year'1998" ("Truck of the Year - 1998"). In 2002, the series underwent a slight restyling with a new cab design. At the same time, the numbers disappeared from the “95XF” designation, and the series began to be called simply “XF” (although sometimes you can find the designation with rearranged letters and numbers - “XF95”).

In 2006, in connection with the tightening of the Euro-4 / Euro-5 environmental standards, it became necessary to create a new flagship DAF truck. The new series, named XF105, repeated the achievement of its predecessors, becoming the best offer on the truck market and winning the title "Truck of the Year'2007" ("Truck of the Year 2007"). This series, which received a more modern engine, did not replace the XF95 trucks, which continued to be produced for countries where Euro-3 standards were still in force.

The XF105 chassis, like the previous series, is produced with a wheel arrangement of 4 × 2 (gross weight - 18 t, as part of a road train - 40 t), 6 × 2 (gross weight 23-26 t, as part of a road train - 44 t), 6 × 4 (gross weight - 26 t, as part of a road train - 60 t) and 8 × 4 (gross weight 36 t, as part of a road train - 58 t). The wheelbase in two-axle truck tractors is 3.6 and 3.8 m, three-axle - from 3.1 to 4.55 m, four-axle 4.8 m. Tractors with a low fifth wheel (96 cm) can be transported as a road trains, the height of which does not exceed 3 m, cargo with a volume of 100 m3.

Outside, the XF105 differs from previous models with a new steel bumper design with four round fog lamps, a large grille, inlaid aluminum decorative strip, new side and rear mirrors painted in the color of the cab, xenon headlights, and additional spotlights integrated into the roof of the Super Space Cab.

The XF105 cabins are available in two heights: Space Cab and Super Space Cab. The internal heights of the cabins equipped with two berths are 1885 and 2255 mm, respectively. For more than a decade, DAF XF long-haul tractors have been one of the best suited for ultra-long haul operations among their classmates. The principal difference between the XF105 cab interior and the XF95 is the greatly reduced floor tunnel protrusion. The dashboard is decorated in a richer way - like aluminum or wood. In addition, an additional pointer indicator for the AdBlue additive level in the "urea" tank is located on the dashboard. The noise level in the cabin is very low, and thanks to the comfortable air-suspended seats, excellent visibility and high level of ergonomics, the driver sitting behind the wheel of a multi-ton road train gets tired no more than a passenger car driver, which is very important during long-term trips.

The PACCAR MX engines on the XF105 trucks deliver 410, 460 and 510 hp. With. and a torque of 2000, 2300 and 2500 Nm, respectively. It should be noted that maximum torque is achieved at engine speeds of 1000 to 1400 rpm. Thanks to the SMART injection system and DAF SCR technology, which eliminates the need for a separate particulate filter, PACCAR MX engines are Euro 4 / Euro 5 compliant.

All engines are aggregated with a 16-speed (8-speed + gear divider) manual transmission ZF or 12-speed robotic AS-Tronic. The rear axle of the DAF XF has a hypoid final drive, and vehicles designed for heavy road use are equipped with wheel reduction gears.
All versions of the DAF XF105 have ventilated disc brakes on all wheels. Electronic control systems for brakes EBS, ABS, Brake Assist, as well as traction control ASR make driving a truck safer. The VSC exchange rate stabilization system can be installed as an option.

DAF, like all other Western European manufacturers of commercial vehicles, does not have the concept of "conveyor" that we are used to. There is a conveyor belt, but there is no large-scale serial production of a certain set of models. The customer draws himself a "portrait" of the future truck, composing it from a set of elements necessary for him to work. Therefore, the basic specification can be given only conditionally.

A very important feature of DAF XF trucks is that many malfunctions, if they do arise, can be eliminated by the driver on his own right on the road, without the help of specialists and special equipment.

DAF XF heavy haul trucks are distinguished by the highest build quality, comfort, powerful engines, excellent performance and long service life. All this, combined with unprecedented high reliability, provides these trucks with a large army of fans among truckers.

This manual provides instructions for the operation and repair of all modifications of the DAF XF105 manufactured since 2006.

In addition, the owners of the vehicles described will benefit from the spare parts catalog and the OBD fault code reference contained on the CD enclosed with this manual. Since this information has a significant amount that it would be impossible to fit into one book, it is placed on an additional disk, which can significantly increase the amount of information useful to car owners and at the same time make the book more convenient to use.

The history of DAF heavy haul trucks began in 1987 with the introduction of the 95 series. Ten years later, the designation “XF” (“Extra Force”) was added to the numbers, indicating the creation of an especially powerful series. The DAF 95XF truck was so successful that immediately after its appearance it received the title "Truck of the Year'1998" ("Truck of the Year - 1998"). In 2002, the series underwent a slight restyling with a new cab design.At the same time, the numbers disappeared from the “95XF” designation, and the series began to be called simply “XF” (although sometimes you can find the designation with rearranged letters and numbers - “XF95”).

This manual provides instructions for the operation and repair of all modifications of the DAF XF105 manufactured since 2006.

Clutch DAF XF 105
Benchmarks 52
Tightening torques for main screw connections (Nm) 52
Checking the clutch fluid level 53
Removing and installing clutch mechanism 53
Removal and installation of clutch mechanism with automatic compensation device
friction disc lining wear 54
Removing and installing clutch release bearing 55
Removing and installing the input shaft guide bearing of the gearbox 55
Removing and installing the clutch yoke 56
Removing and installing clutch servo 56
Removal and installation of the clutch master cylinder 57
Checking and adjusting the clutch pedal 58
Purging the Hydraulic System 58
Diagnostics. Identification and elimination of malfunctions. 59

Gear box DAF HF105
Mechanical gearboxes ZF 16S2020, ZF 16S2320 and ZF 16S2520
Control parameters 62
Tightening torques for main screw connections (Nm) 63
Removal and installation of the check point 65
Removing the divider 65
Dismantling the main crankcase 65
Shaft repair 66
Input shaft 66
Output shaft 67
Intermediate shaft 69
Main crankcase assembly 69
Adjusting the multiplier fork 70
Gearbox assembly 70
Divider 71
Mechanical drive gearbox 74
Ball joint of the gear lever 75
Jet thrust and lever 76
Rod of a drive of a gear shift 76
Gearshift drive 77
Pneumatic gearbox 79 drive
Checking the blocking valve 79
Removal and installation of the range selection valve on the gear lever 80
Towing a car 80
Diagnostics. Troubleshooting 81

Gear box AS-TRONIC ZF 12AS 2130/2330/2540 and ZF 16AS 2630
Benchmarks 83
Preventive maintenance refueling tanks for gearboxes as-tronic 84
Tightening torques for main screw connections (Nm) 84
Removal and installation of the box as-tronic 86
As-tronic gearbox with integrated intarder 86
Disassembly of crankcases 86
Front crankcase 86
Dismantling and assembling the front cover 88
Central housing 88
Rear crankcase and planetary block 89
Shaft repair 91
Input shaft 91
Output shaft 91
Intermediate shafts 92
Reverse gear drive gear 92
Planetary Gear 93
Crankcase assembly 93
Rear crankcase 93
Removing and installing modulator transmission 98
Removal and Installation of Drive Flange 99
Removing and installing the output shaft oil seal 100
Checking and adjusting the oil level in the gearbox 100
Draining and filling gearbox oil 100
Removal and installation of the control unit 100
Diagnostics. Troubleshooting 101

Rear axle DAF 105
Removing and installing rear axle assembly 104
Differential 106
Drive gear 106
Taper spacing adjustment 108
Differential bearing pre-stress adjustment 108
Meshing clearance adjustment 109
Checking the position of the working surfaces of the teeth 109
Removing and installing differential lock mechanism 110
Wheel hubs 111
Wheel speed sensor disc 112
Benchmarks 113
Tightening torques for main screw connections (Nm) 114

Front axle DAF 105
Removing and installing front axle steering knuckle 116
Removing and installing thrust bearing 118
Removing and installing needle roller bearings 118
Checking and adjusting the steering knuckle clearance 119
Checking and adjusting the caster angle 120
Checking the camber and lateral tilt of the king pin 121
Convergence 121
Checking and adjusting the angle of rotation 122
Front wheel hubs 122
Control parameters 125
Tightening torques (nm) and angular values of the main screw connections 126

Steering DAF XF105
Description of the system operation with a single-circuit hydraulic amplifier 128
Checking steering with a pressure gauge 129
Testing Steering with Portable Test Kit 130
Removing and installing steering gear housing assy 132
Removing and installing bracket, steering column 134
Removal and installation of a steering arm 134
Checking and adjusting the valves for limiting the angle of rotation 135
Oil drain 138
Filling the single-circuit hydraulic power steering system 139
Removing and installing the hydraulic power steering pump 139
Checking the restrictor valve 140
Control parameters 141
Torques (Nm) and angular values of the tightening of the main screw connections 141

Brake system DAF HF 105
Removing and installing brake pads 144
Removing and installing a brake disc 146
Removing and installing the KNORR SN7000 caliper body 146
Removing and installing the base of the brake caliper body 147
Removing and installing protective collar KNORR SN7000 147
Removing and installing brake cylinder 148
Removing and installing a brake cylinder with a spring 149
Removing and installing automatic brake adjuster 149
Checking the automatic disc brake adjuster 149
Checking the brake pads knorr sn7000 149
Checking the brake discs 150
Checking the stroke of the brake caliper 150
Adjusting disc brakes 151
Checking and adjusting the braking force modulator depending on the load.
Air Suspension Cars 152
Checking and adjusting the brake force modulator.
Auto with mechanical suspension 153
Control parameters 154
Front and rear brakes 154
Air compressor (not for all models) 154
Pneumatic equipped (not for all models) 155
Tightening torques (Nm) and angular values of the main screw connections 157
Description of the operation of the EBS-2 system 161
System Component Specifications 161

Suspension DAF 105
Control parameters 164
ECAS-4 164
The principle of operation of the ECAS-4 system 164
Electronic control unit ECAS D992 165
Remote control D529 167
Dashboard Switches 168
Height sensors F612 / F613 / F614 169
Pressure sensor ECAS F735, F736, F615 170
Block of solenoid valves В166, В238, В250, В253, В254 170
Shut-off valve 171
Pressure reducing valve, residual pressure function 172
Pressure reducing valve, pressure limiting function 172
Valve for adjusting the distribution of the load on the axle 172
Functions and adjustments 173
Mechanical suspension
Removing and installing spring assembly 184
Diagnostics. Troubleshooting Mechanical Suspension 186
Air suspension
Decoding of ECAS-4 trouble codes 189
Decoding of the codes of the parameters of the ECAS-4 system 191
Tightening torques for main screw connections (Nm) 192
Mechanical suspension 192
Air suspension 192

Electrical equipment
List of elements of electrical circuits 194
Electrical circuits DAF XF105
Scheme 1.1. Engine management - DMCI (1/7) 208
Scheme 1.2. Engine management - DMCI (2/7) 209
Scheme 1.3. Engine management - DMCI (3/7) 210
Scheme 1.4. Engine management - DMCI (4/7) 211
Scheme 1.5. Engine Management - DMCI (5/7) 212
Scheme 1.6. Engine Management - DMCI (6/7) 213
Scheme 1.7. Engine Management - DMCI (7/7) 214
Scheme 2.1. Post Processing System - EAS (1/3) 215
Scheme 2.2. Post-processing system - EAS (2/3) 216
Scheme 2.3.Post Processing System - EAS (3/3) 217
Diagram 3. Braking system ABS-D 218
Scheme 4.1. Braking system EBS-2 (1/3) 219
Scheme 4.2. Braking system EBS-2 (2/3) 220
Scheme 4.3. Braking system EBS-2 (3/3) 221
Scheme 5.1. Suspension - ECAS-4 (1/2) 222
Scheme 5.2. Suspension - ECAS-4 (2/2) 223
Diagram 6. Electronic steering control system - EMAS 224
Scheme 7.1. Suspension - Axle Lift (1/4) 225
Scheme 7.2. Suspension - Axle Lift (2/4) 226
Scheme 7.3. Suspension - Axle Lift (3/4) 227
Scheme 7.4. Suspension - Axle Lift (4/4) 228
Scheme 8.1. Air conditioning system - AIRTRONIC (ACH-EA) (1/2) 229
Scheme 8.2. Air conditioning system - AIRTRONIC (ACH-EA) (2/2) 230
Scheme 9. Security system - AIRBAG-2 231

A unique series of car books - Repair without problems. Step-by-step car repair, more than 3000 color photos

DAF XF Are trucks that have been produced by the Dutch company DAF Trucks since 1997. DAF XF has won the Truck of the Year award twice in 1998 and 2007.First generation DAF XF (95XF): The 95 series heavy vehicles appeared in 1987. Ten years later, the abbreviation XF (Extra Forte) was added to the numbers, denoting the creation of an especially powerful model. The third generation DAF XF 105 appeared in 2005, it was caused by the need to create a new version of the truck that meets the requirements of Euro 4 / Euro 5.Tractor DAF XF 105 Is a first-class car. The DAF XF 105 truck accelerates and brakes with confidence, and the 16-speed manual transmission is easy to handle. The engine provides a smooth ride and optimum traction. Its maximum power is 510 horsepower with 2500 Nm of torque.The DAF XF 105 repair book contains detailed instructions for the repair of the MX engine, manual and automatic transmissions installed on the DAF 105The XF 105 series chassis are available with a gross weight of 18 (wheel arrangement 4x2), 24.9 (6x2), 25.087 (6x2), 25.7 (6x2), 26 (6x2) and 32 tons (8x4). The wheelbase is from 4.2 to 6.9 m. The wheelbase for two-axle truck tractors is 3.6 m, for three-axle tractors - from 3.1 to 4.55 m, for four-axle tractors - 4.8 m.Tractors with a low fifth wheel position (96 cm) can carry loads of up to 100 m 3 as part of a road train, the height of which does not exceed 3 m.Externally, the XF105 features a new steel bumper design with four round fog lamps, a large grille inlaid with an aluminum trim strip, new side and rear mirrors in the color of the cab, xenon headlights, and additional floodlights integrated in the roof of the Super Space Cab.In 2006, the world premiere of the DAF telematics system, designed for data exchange and fleet management, took place.The system consists of an on-board computer and an Internet portal, which are successfully integrated into one of the three DIN slots on the dashboard of the XF105 vehicles. The connection between the truck and the base is carried out using the GPRS system, with the help of which information is transmitted about the possibility of re-routing and about the trip in general.The uniqueness of the telematics system lies in the ability to connect navigation with the exchange of messages, which makes it possible to send the best route from the transport company to the system installed on board the truck on the flight, which is automatically displayed on the screen in front of the driver. In addition to messaging and navigation, it is possible to search for a stolen vehicle, control the temperature of the cargo, etc.Repair manual DAF XF 105 Contains suspension diagrams, complete brake system information, and wiring diagrams.Repair manual DAF XF 105 Engine
Clutch
Gear box
Rear axle
Front axle
Steering
Brake system
Suspension
Electrical equipment