DAF LF, CF and XF105 Bodybuilder's Guidelines

Bodybuilders' Guidelines is published by DAF Trucks N.V.
This information is also available on the internet. The user is responsible for ensuring that he is working with the latest released information. Parts of this publication may be copied or reproduced providing that a reference is made to the source.

In the interest of continuing product development, DAF reserves the right to change specifications or products at any time without prior notice. DAF can in no way be held responsible for any incorrect information included in this manual and/or the consequences thereof. This publication refers to chassis with FR, GR, PR or MX engine complying to the Euro 3, Euro 4 and Euro 5 emissions.

Note: For Euro 3 chassis with CE, BE, PE or XE engine see the digital publication that is available under file number BBG0541.zip on the 'archive' page of the Bodybuilder's info website.

VEHICLE SPECIFICATION AND LAYOUT DRAWINGS
In determining the right chassis and body specifications, it is essential that the three parties involved, customer, bodybuilder and DAF, should each bring in their own specialism. Intensive consultation is the only way to obtain an optimum result. This consultation requires the availability of all Technical data, such as vehicle specifications and layout drawings (DAF bodybuilders' drawings), and the possibility of forming a quick assessment of all the technical possibilities with their specific advantages and disadvantages.

DAF's professional transport advice system, TOPEC, has been developed especially for this purpose and is also available to the bodybuilder. TOPEC enables fast calculation of the effects of particular vehicle dimensions on, for instance, weight distribution, coupling position, turning circle and axle load pattern during unloading. Requests for TOPEC calculations can be submitted to DAF.

Chassis reinforcements and additional components, such as compressors, additional fuel tanks and loading and unloading equipment, affect the weight and therefore the weight distribution of the vehicle being bodied. It is therefore essential that the vehicle, including any extra equipment, should be weighed before the bodying is started. Only then will it be possible to establish in time the effect any such extra equipment may have on the location of the vehicle's centre of gravity.

PERIOD OF BODYING AND STORAGE
When a vehicle, for instance, because of a long period of bodying, is not being used for a prolonged time, measures should be taken to guarantee the continued high quality of the vehicle. These measures depend on the estimated duration of storage and/or bodying.

The measures that should normally be taken, may include the following:

1. Closing windows and roof hatch.
2. Checking fluid levels and, where necessary, topping-up reservoirs.
3. Checking the tyre pressure.
4. Removing, storing and charging the batteries.
5. Checking the coolant antifreeze content.
6. - Patching up damaged spots in paintwork.

PAINTING THE CHASSIS AND COMPONENTS
In case the chassis (cab) and components must be (re)painted then the under mentioned area's must thoroughly be masked before painting to avoid problems with electrical or mechanical vehicle systems.

• The contact area's between wheel hub and wheel rim and flanged nuts.
• Brake disks, brake calliper and pads.
• Breather valves placed on components, such as differential, EAS unit, ECAS valves, brake valves and so on.
• Air intake and outlet openings of the Power electronics carrier (PEC) unit on LF45 Hybrid chassis.
• The full length of all orange coloured high voltage wiring cables (LF45 Hybrid chassis).- Air intake openings on filter units.
• NOx sensors and solenoid valves.
• Heat shield panels and heat isolated exhaust pipes (when fitted).
• Sealings and sliding joints on propeller shaft.
• Identification plates (on gearbox, drive axle and valves etc.).
• Door locks.
• Cab windows, head - brake - indicator lights and reflectors.
• All warning labels on components and chassis.

DAF VEHICLE RANGE
DAF's vehicle range is composed of several tractor chassis in the weight category above 12 tonnes and an even wider variety of rigids in the category of 6 tonnes GVW and over.

This series offers gross vehicle weights from 7,5 to 12 tonnes. The trucks are intended for intensive use in urban and regional distribution transport and are powered by 4.5 litre four cylinder FR diesel engines generating outputs from 103 kW up to 152 kW, or by 6.7 litre six cylinder GR diesel engines with a power rating of 165 kW up to 184 kW.

DAF LF55 series
This vehicle series, with gross vehicle weights from 14 to 19 tonnes, is intended for light to medium-weight transport in urban and regional goods distribution. These vehicles are also excellently suited for a wide range of applications in the field of public utility services. This series is equipped with 4.5 litre four-cylinder FR diesel engine generating an output of 136 up to 152 kW or by 6.7 litre six-cylinder GR diesel engines offering outputs from 165 kW up to 220 kW.

DAF CF65 series
The DAF CF65 series underlines the importance of market segmentation and of medium line vehicles with specific features and characteristics for a huge diversity of applications, body types and operational conditions. The DAF CF65 series has been developed as a two-axle rigid for local and regional goods distribution and special transport applications, such as council cleaning services and fire services. With a maximum GVW of 19 tonnes, this series is powered by 6.7 litre GR diesel engines generating outputs from 165 kW up to 220 kW.

DAF CF75 series
The DAF CF75 series is a real all-rounder with a choice of chiefly two-axle and three-axle models. These vehicles are excellently suited for medium weight to heavy regional and national distribution transport and for a wide range of applications in the field of public utility services, such as council cleaning services. The 9.2 litre PR diesel engines use a highly advanced combustion principle and they have four valves per cylinder. With power outputs from 183 kW up to 265 kW, they are suitable for gross combination weights up to 40 tonnes.

DAF CF85 series
The DAF CF85 vehicles are equipped with 12.9 litre MX diesel engines, which use a highly advanced combustion principle and have four valves per cylinder. With engine outputs from 265 kW up to 375 kW, this truck is made for heavy work. It can be specified as a two-axle, three-axle or four-axle vehicle with one or two driven axles. A robust truck for intensive medium-range transport requiring high gross combination weights (over 40 tonnes), for transport in the building industry and/or heavy special transport.

DAF XF series
The DAF XF is the flagship of the DAF range. With the XF105 series, DAF has again moved a step forward in the ever continuing development of vehicle and engine technology. The XF chassis is fitted with 12,9 litre MX diesel engines, which use a highly advanced combustion principle and have four valves per cylinder. With engine outputs from 300 kW up to 375 kW, these vehicles are ideal for long-distance (international) haulage requiring gross combination weights of 40 tonnes.

With the Super Space Cab, the driver virtually has a mobile residence, complete with all the conveniences required for lengthy journeys (away from home for on average 1 to 3 weeks). The DAF XF series makes no concessions. It combines a very high level of driver comfort with optimum transport performance and the lowest possible costs of ownership for the transport operator.

Wheelbase and rear overhang indications
The indications for wheelbase and rear overhang (WB/AE) used in these bodybuilders' guidelines and in general at DAF can be found for each vehicle type in the following survey:

DIMENSIONS
All dimensions in these bodybuilders' guidelines are shown in millimetres, unless stated otherwise.

PRODUCT MODIFICATIONS
In the interest of continuing product development, DAF reserves the right to make changes in the specifications or the designs of the vehicles without prior notice. Furthermore, vehicle specifications may vary from country to country, depending on local conditions and legislation. For exact and up to date information, please contact the local DAF sales organisation.

FEEDBACK FORM
In view of the importance of maintaining the present level of quality and user-friendliness of the DAF Bodybuilders' Guidelines, your recommendations and/or suggestions will be highly appreciated. Use the : "Feedback form" you will find on the last page(s) to communicate your findings to us.

LEVELLING THE CHASSIS
It is essential for the quality and durability of the bodied vehicle that the chassis should be in a completely level position when it is being bodied. The side members should be parallel and the chassis frame must not be twisted. Frame height differences on the left/right of ≤ 1.5% of the distance from ground to the frame upper flange are within the limits. Variations > 1.5% must be notified to DAF Trucks, before any work are carried out.

For the levelling of an air-suspended chassis, at least three adjustable supports must be used. These supports must not be removed during the bodying of the vehicle.

Position of the welds between main and reinforcement profile
Independent from whatever welding process is chosen, distance (A) between the separate welds must be at least 100 mm to avoid unacceptable stress concentration. It is advised to round of the edges over 50 mm to each side of the weld to diminish the possibility of notching.

ATTACHMENT OF COMPONENTS TO THE CHASSIS
Components such as toolboxes, extra fuel tanks, onboard weighing system, compressors and side underrun protection, will usually be attached to the side of the chassis. For all loaded connections with the chassis, 10.9 flange bolts or bolts of the same property class, combined with washers, must be used. The hardness of the washers should be at least 265-320 HB. Furthermore, the contact surfaces of bolted connections should be provided with a thin coat of primer (thickness 17 - 25 μm) and they should be free from paint and other impurities. The first service inspection of the vehicle must include the retorquing of all superstructure attachment bolts.

If required, for the tightening torques of components such as steering gear, mounting frame of the Euro 4 and 5 exhaust system, axle suspension system, cab mounting, etc., see the workshop manual.

These bodybuilders' guidelines are only applicable to vehicles which comply with standard DAF specifications, in accordance with the existing bodybuilders' drawings. In case of doubt, DAF should be consulted.

Without a sub-frame, the standard chassis are designed for, and are at least suitable for, the transport of a uniformly distributed load at nominal permitted axle loads, with the exception of vehicles with 260 mm or 192 mm high side members with continuous inner reinforcement flitches, such as the Low-Deck versions or FA LF45. These vehicles require additional stiffness of a sub-frame or superstructure construction.

In case the load on the chassis is not equally divided extra care should be taken with regard to the tension levels in the chassis. For chassis material characteristics see table "Chassis specifications: Tractors and Rigids". When in doubt DAF Trucks could be consulted as mentioned in chapter 1.3: "Verificaton of superstructure". For subframe guidelines related to certain body types see the relevant text in the section 'Superstructures'.

Component location
DAF pays much attention to a bodybuilder friendly positioning of all vehicle components in or on the outside of the chassis frame. In spite of this, for some body types a relocation of components may sometimes be necessary. For the CF75-85 and XF series, DAF uses the following starting positions: location of fuel tanks in front of the rear axle on the right-hand side (for the LF and CF65 series on the left-hand side, immediately behind the cab), leaving sufficient room for twist-locks and crane legs (compact exhaust silencer), standard free space for mudguards on the rear axle(s) and whenever possible no components on the rear overhang section of the chassis. For more detailed component location data, see the bodybuilders' drawings of the vehicle concerned.

DRAWBAR CROSS MEMBER
The rearmost cross member in the chassis may be constructed as an end beam (on rigids not used for truck/trailer combinations). This end beam is not suitable for the fitting of a towing hook or similar equipment.

The rearmost cross member can also be constructed as a drawbar cross member suitable for the fitting of a towing jaw. At all times the exfactory supplied drawbar cross member and its carrying supports are build in accordance with the guidelines of directive 94/20EC. Also any non DAF drawbar construction and carrying supports that are submitted to DAF for approval must comply to the same directive.

On request, a drawbar cross member fitted in the required position can ex-works be supplied in combination with an adapted rear overhang (AE). However, if the definitive position will not be known until a later stage, an easy demountable drawbar cross member can be ordered ex-works, which for easy recognition, will be fitted in the chassis the wrong way round.

If necessary, a drawbar cross member fitted in the chassis may be relocated. When relocating a drawbar cross member, always use the correct quantity of attachment bolts of the correct property class.

REAR LIGHT BRACKETS
Chassis are always delivered with rear light brackets. If however, the rear light units are to be integrated into the body or superstructure then a so called 'transport' bracket could be ordered exfactory. Be aware that this transport bracket which is a preformed metal sheet panel always must be replaced by a more solid construction.

WHEEL MOUNTING
All DAF vehicles have spigot-mounted wheels. For safe and trouble-free fitting of the wheels, it is most important that the mating surfaces of wheel rims and brake drums should be absolutely clean. Any coat of paint must never be thicker than 0.05 mm. In practice this means that the old paint must be removed before applying a new coat. Tighten the wheel nuts in a cross-wise sequence to the correct torque.

Clearance dimension
If the chassis to be bodied is not yet available, the wheel clearance can also be determined on the basis of the bodybuilders' drawing. The chassis height and the HBV/HBT/HBA dimension (metal to metal) can be established from this drawing. To determine the clearance dimension (U), the extra space needed as indicated in the above table may have to be added to the calculated HBV/HBT/HBA dimension.

Each bodybuilders' chassis drawing refers to drawing No. 1260799/.. (CF75-85 and XF series) or NSEA383/.. (LF and CF65 series) which shows a number of general vehicle data, such as tyre radius, wheel track and maximum width of the various front and rear axles. This drawing (of course, the one with the latest modification index!) should always be consulted.

Chassis heights
The chassis heights at the front axle (HV dimension) and rear axle (HA dimension) can, for the most commonly used tyre sizes (dimensions according to ETRTO standard), be determined using the TOPEC chassis height calculation program. The height of the tyre above the chassis (HBV/HBT/HBA dimension) and the clearance dimension (U) for the driven rear axle are also indicated.