DAF LF45, LF55 Cab Service Manual

1

CONTENTS

LF45/55 series

TECHNICAL DATA

DIAGNOSTICS

INTERNAL CAB COMPONENTS

CAB HEATING

EXTERNAL CAB COMPONENTS

CAB SUSPENSION

CAB TILTING GEAR

SEATS

ACCESSORIES

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2

3

4

5

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1			TECHNICAL DATA
LF45/55 series				Contents
CONTENTS
			Page	Date		0
1.	INTERNAL AND EXTERNAL CAB COMPONENTS . . . . . . . . . . . . . . . .		. . . . . . . . 1-1 . .	. . . . 0210
	1.1	General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . 1-1 . .	. . . . 0210
	1.2	Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 1-8 . .	. . . . 0210
2.	CAB SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . . . 2-1 . .	. . . . 0210
	2.1	General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 2-1 . .	. . . . 0210
	2.2	Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 2-3 . .	. . . . 0210
3.	CAB TILTING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . . . 3-1 . .	. . . . 0210
	3.1	General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 3-1 . .	. . . . 0210
	3.2	Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . 3-1 . .	. . . . 0210

4. SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0210 4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0210 4.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0210

5. ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0210 5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . . 0210 5.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . . 0210

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TECHNICAL DATA	1
Contents	LF45/55 series

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1	TECHNICAL DATA
LF45/55 series	Internal and external cab components
1. INTERNAL AND EXTERNAL CAB COMPONENTS
1.1 GENERAL	0
Main dimensions and weights
L	B

	H
K
K1 01 170	K1 01 192

Cab dimensions in mm:	Day cab	Sleeper Cab
length (L)	1600 mm	2000 mm
width (B)	2130 mm	2130 mm
max. height (H)	2900 mm (1)	2900 mm (1)
tilting (K)	1105 mm (2)	1105 mm (2)
Cab weights:
Day cab	595 kg
Sleeper cab	750 kg

Notes:

(1)Height (H) dependent on version and tyre size

(2)Dimension K measured from the front of the bumper.

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		TECHNICAL DATA	1
		Internal and external cab components	LF45/55 series
		Permissible cab weights:	max.
		Roof console evenly distributed	5 kg
0
		Roof evenly distributed	150 kg
		Weight on the bunk	125 kg

Cab side members

Welding on cab side members is NOT permitted.

When repairing the cab side member, you must use sheet-metal trimming panels.

These must be fitted by spot welding.

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1	TECHNICAL DATA
LF45/55 series	Internal and external cab components

Straightening dimensions

A	B	0

F C

D

E

K1 01 209

Door opening dimensions

A - D	1283 mm
C - F	887 mm
B - E	1591 mm

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TECHNICAL DATA	1
Internal and external cab components	LF45/55 series
B	C

0

A	D
F	E
	K1 01 208

Rear wall dimensions

A - D	2042 mm
B - C	1926 mm
B - E	2435 mm
C - F	2435 mm

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1	TECHNICAL DATA
LF45/55 series	Internal and external cab components

H

B C E

I

0

G A D F J

N K

M

L

K1 01 210

Cab front dimensions

A - B	836 mm
C - D	836 mm
E - F	836 mm
G - I	1973 mm
H - J	1973 mm

Front panel dimensions

N - L	1945 mm
K - M	1945 mm

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TECHNICAL DATA	1
Internal and external cab components	LF45/55 series
Field of vision dimensions

0

			D1
	A
	A2	D
A	A3				C3
						C4
B1	1
B	B5
B2
		C			C1
	B4
B3
			C2
						K100237
Mirror	size 1	size 2	size 3	size 4		size 5
Pavement mirror [A]	1 m	1 m	1.25 m
Wide-angle mirror [B]	2.5 m	15 m	12.5 m	25 m		3 m
Main mirror on co-driver’s	30 m	3.5 m	0.75 m	4 m
side [C]
Main mirror on driver’s	10 m	2.5 m
side [D]

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1			TECHNICAL DATA
LF45/55 series		Internal and external cab components
Windscreens
						0
	Curing times for windscreen adhesive
Product name	DAF number	Vehicle mobile in	Cab can be tilted	Vehicle usable
		workshop after:	after:	after:
Sikaflex 255 FC	1271129	6 hours	8 hours	12 hours
Sika Tack Ultrafast	1241020	2 hours	4 hours	6 hours
Sika Tack plus	1357925	1 hour	1 hour (1)	2 hours
booster

Notes:

(1)If a vehicle is equipped with an airbag, the curing time is 2 hours

A relative humidity of less than 50% delays curing, as does a temperature lower than 20_C.

Products applied for bonded windscreens

Product name	DAF number	Properties	Applications
Sikaflex 255 FC	1271129	Processing time	Adhesive (cold process) for
		20 min.	bonding windscreens
Sika Tack UF	1241020	Processing time	Adhesive (warm process) for
		10 min.	bonding windscreens
Sika Tack plus	1357925	Processing time	Adhesive (cold process) for
booster		10 min.	bonding windscreens
Sika Aktivator	1312362		Cleaning fluid for cleaning the glass
			and the frame.
Sika remover	1241019		Removal of adhesive which has not
SR 208			yet hardened. Do not use on
			surfaces to be bonded.

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		TECHNICAL DATA	1
		Internal and external cab components	LF45/55 series
		1.2 TIGHTENING TORQUES
0		The tightening torques stated in this paragraph
		are different from the standard tightening
		torques stated in the overview of the standard
		tightening torques. The other threaded
		connections which are not stated must therefore
		be tightened to the tightening torque stated in
		the overview of standard tightening torques.
		When attachment bolts and nuts are to be
		replaced, it is important - unless stated
		otherwise - that these bolts and nuts are of
		exactly the same length and property class as
		the removed ones.
		Steering wheel
		Steering wheel attachment bolt	50 5 Nm
		Universal joint
		Universal joint attachment bolt	56 5.6 Nm(1)
		Airbag
		Airbag module attachment bolt	5 1 Nm
		Contact unit attachment bolt	1.2 Nm
		Electronic unit	10 2 Nm

Note:

(1)Always replace the attachment bolt and nut.

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1	TECHNICAL DATA
LF45/55 series	Cab suspension
2. CAB SUSPENSION
2.1 GENERAL
			0

The day cab can be fitted with rubber spring elements at the front. The version with rubber spring elements at the front does not have a stabiliser.

The coil spring elements are fitted with shock absorbers.

The length of the spring elements and the cab height cannot be adjusted.

On models equipped with coil spring elements at the front, a difference in cab height can be corrected to a certain extent using the stabiliser bar.

At the rear, coil springs are used. The length of the spring elements varies depending on whether a day cab or a sleeper cab is involved.

	Cab support, general
	The distance between the cab	9
	supports (A) measured from the
	left side of the left support to the
	left side of the right support is:	1000 mm

15

10

11

12

16

13

14

K1 00 575

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TECHNICAL DATA	1
Cab suspension	LF45/55 series
Cab support with silentblock	A
Silent block mounting angle (A)	67_ - 71_

0

K1 01 475

	Cab support with coil spring suspension		A
	Silent block mounting angle (A)	18_ - 22_

K1 01 442

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1	TECHNICAL DATA

LF45/55 series

2.2 TIGHTENING TORQUES

The tightening torques stated in this paragraph are different from the standard tightening torques stated in the overview of the standard tightening torques. The other threaded connections which are not stated must therefore be tightened to the tightening torque stated in the overview of standard tightening torques.

When attachment bolts and nuts are to be replaced, it is important - unless stated otherwise - that these bolts and nuts are of exactly the same length and property class as the removed ones.

Attachment bolts for cab suspension using coil springs

Cab suspension	250 Nm + 150_
attachment bolt	angular
	displacement

Cab suspension

0

K1 01 573

Attachment bolts for cab suspension using rubber spring elements

Cab suspension	250 Nm + 150_	1
attachment bolt	angular
	displacement

K1 01 574

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TECHNICAL DATA	1
Cab suspension	LF45/55 series

0

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1		TECHNICAL DATA
	LF45/55 series	Cab tilting gear
3. CAB TILTING GEAR
3.1 GENERAL
				0
	Lifting cylinder
	Nominal pressure	250 bar
	Cab tilting pump
	Nominal pressure	250 bar
	Pressure limiting valve	350 + 30 bar
3.2 FILLING CAPACITIES
Cab tilting pump
Effective oil capacity of the cab-tilting pump.		200 cm3

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TECHNICAL DATA	1
Cab tilting gear	LF45/55 series

0

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1		TECHNICAL DATA
LF45/55 series		Seats
4. SEATS
4.1	GENERAL
				0
Height control valve
Adjusting dimension X for height control valve		1 - 2 mm
4.2	TIGHTENING TORQUES
The tightening torques stated in this paragraph
are different from the standard tightening
torques stated in the overview of the standard
tightening torques. The other threaded
connections which are not stated must therefore
be tightened to the tightening torque stated in
the overview of standard tightening torques.
When attachment bolts and nuts are to be
replaced, it is important - unless stated
otherwise - that these bolts and nuts are of
exactly the same length and property class as
the removed ones.
M8 attachment bolt		22 Nm
M10 attachment bolt		22 Nm
Attachment bolt 7/16″ UNF-2B		37 Nm

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TECHNICAL DATA	1
Seats	LF45/55 series

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	1	TECHNICAL DATA
	LF45/55 series	Accessories
	5. ACCESSORIES
	5.1 GENERAL	0
	Roof spoiler
	Adjusting range of roof spoiler, aerodynamic
	and adjustable	350 - 850 mm
	Note:	P
	The roof spoiler height can be adjusted using
	adjusting mechanism (B).	B
	The size is the distance measured between the
	highest roof spoiler edge (P) and the cab roof
	plate local to the vehicle centreline.

K1 01 355

Application compounds for rear air foils and roof spoilers

Product name	DAF number	Properties	Applications
Sikaflex 252	1286578	Working time within	Kit for fender and roof spoiler
(white)		15 min.	attachment
		Curing time 2 days

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		TECHNICAL DATA	1
		Accessories	LF45/55 series
		5.2 TIGHTENING TORQUES
0		The tightening torques stated in this paragraph
		are different from the standard tightening
		torques stated in the overview of the standard
		tightening torques. The other threaded
		connections which are not stated must therefore
		be tightened to the tightening torque stated in
		the overview of standard tightening torques.
		When attachment bolts and nuts are to be
		replaced, it is important - unless stated
		otherwise - that these bolts and nuts are of
		exactly the same length and property class as
		the removed ones.
		Roof spoiler
		Attachment nuts	13 Nm
		Rear air foil
		Attachment nuts	13 Nm
		Sun visor
		Bracket attachment bolts	13 Nm
		Bolt for attaching the sun visor to the bracket	10 Nm

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1	DIAGNOSTICS
LF45/55 series		Contents
CONTENTS
	Page	Date
1. CAB SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . 1-1 . .	. . . . 0210
1.1 Fault-finding table, cab tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1-1 . .	. . . . 0210

1

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DIAGNOSTICS	1
Contents	LF45/55 series

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1	DIAGNOSTICS
LF45/55 series	Cab suspension
1. CAB SUSPENSION
1.1 FAULT-FINDING TABLE, CAB TILTING MECHANISM
COMPLAINT: TILTING CYLINDER FAILS TO RESPOND
				1
Possible cause	Remedy
Damaged or broken pipe.	Replace pipe or connection.
Pump reservoir empty.	Top up reservoir and check for leakage.
Worn or damaged cylinder seal.	Replace the cylinder or seal.
COMPLAINT: PUMP ROD REBOUNDS
Possible cause	Remedy
Leaking non-return valve.	Disassemble the two-way valve of the pump.
	Clean and degrease the valve components.
	Replace all seals and assemble the two-way
	valve.
COMPLAINT: PUMP ONLY FUNCTIONS IN THE LAST PART OF THE STROKE
Possible cause	Remedy
Low oil level in oil reservoir.	Top up oil reservoir.
Leaking inlet valve (ball).	Remove the two-way valve and check the inlet
	valve. Clean or replace it.
Polluted inlet strainer.	Clean the reservoir and strainer.
COMPLAINT: PUMP FAILS TO BUILD UP PRESSURE
Possible cause	Remedy
Reservoir level too low.	Top up the reservoir.
Leaking inlet valve (ball).	Remove the two-way valve and check the inlet
	valve. Clean or replace it.
Worn or damaged O-rings on the two-way	Remove the two-way valve and replace all seals
valve.	and O-rings.
Pressure-relief valve incorrectly set.	Check the pressure relief valve and adjust, if
	necessary.

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		DIAGNOSTICS	1
		Cab suspension	LF45/55 series
		COMPLAINT: CAB LOCK CANNOT BE OPENED
		Possible cause	Remedy
		Damaged or broken pipe.	Replace pipe or connection.
		Jammed piston in locking mechanism.	Repair or replace the locking mechanism.
1
		COMPLAINT: CAB CANNOT BE TILTED
		Possible cause	Remedy
		Jammed piston in cab locking mechanism.	Repair or replace the locking mechanism.
		Pump fails to build up pressure.	Check the operation of the pump.

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1			INTERNAL CAB COMPONENTS
LF45/55 series				Contents
CONTENTS
			Page	Date
1.	SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .		. . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . .	. . . . 0210
2.	GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . .	. . . . 0210
	2.1	Overview drawing, interior cab components . .	. . . . . . . . . . . . . . . . . . . . . . . . 2-1 . .	. . . . 0210
	2.2	System description, steering column . . . . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . 2-2 . .	. . . . 0210
3.	INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . .		. . . . . . . . . . . . . . . . . . . . . . . . 3-1 . .	. . . . 0210		2
	3.1	Inspection, steering column setting valve . . . . .	. . . . . . . . . . . . . . . . . . . . . . . . 3-1 . .	. . . . 0210

4. REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0210 4.1 Removal and installation, switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . 0210 4.2 Removal and installation, dashboard panels . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . 0210 4.3 Removal and installation of complete dashboard . . . . . . . . . . . . . . . . . . . . . . 4-9 . . . . . . 0210

4.4Removal and installation, pneumatic switch/valve of

	steering column adjustment unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-15 . . . . .	0210
4.5	Removal and installation, steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-17 . . . . .	0210
4.6	Removal and installation, steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-22 . . . . .	0210
4.7	Removal and installation, door panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-26 . . . . .	0210
4.8	Removal and installation, manually operated window mechanism . . . . . . . .	4-28 . . . . .	0210
4.9	Removal and installation, electrically operated window mechanism . . . . . .	4-29 . . . . .	0210
4.10	Removal and installation, roof console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-30 . . . . .	0210
4.11	Removal and installation, interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-31 . . . . .	0210
4.12	Removal and installation, ignition lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-31 . . . . .	0210
4.13	Removal and installation, complete door lock mechanism . . . . . . . . . . . . . .	4-32 . . . . .	0210
4.14	Removal and installation, door lock cylinder . . . . . . . . . . . . . . . . . . . . . . . . . .	4-34 . . . . .	0210
4.15	Removal and installation, engine brake switch . . . . . . . . . . . . . . . . . . . . . . . .	4-34 . . . . .	0210
4.16	Removal and installation, rear wall lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-35 . . . . .	0210
4.17	Removal and installation, roof lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-36 . . . . .	0210
4.18	Removal and installation, side wall lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-37 . . . . .	0210
4.19	Removal and installation, storage trays (sleeper cab) . . . . . . . . . . . . . . . . . .	4-37 . . . . .	0210

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INTERNAL CAB COMPONENTS	1
Contents	LF45/55 series

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1	INTERNAL CAB COMPONENTS
LF45/55 series	Safety instructions
1. SAFETY INSTRUCTIONS
General
The cab is equipped with a hydraulic tilting
mechanism. The pump is located on co-driver’s
side at the rear of the cab. The cab locks are
opened hydraulically during pumping.
Before tilting the cab, make sure that the doors
are closed, that there are no loose items in the
cab and that the gear lever is in neutral. Tilt the
cab fully forward if work must be carried out			2
underneath the cab.
You can stop the cab tilting forward
at any time by turning the tap to the
reverse tilting position.
When working on a tilted cab (for
example when welding,
spray-painting or applying bitumen
coatings), be sure to cover the
piston rod of the lifting cylinder.
Welding spatter and paint on the
piston rod will inevitably cause
damage to the oil seal.
Inspection after a collision
Before tilting the cab after a collision, check the
cab rests, the cab hinges and the attachment of
the lifting cylinder to the chassis member and
cab for cracks.
If the vehicle has been involved in a
collision, the cab must under no
circumstances be tilted without due
precautions. The end stop in the
lifting cylinder may be damaged,
which might cause the cab to shoot
past its end stop.
If possible, suspend the cab in slings and put a
stand in front of the cab. Make sure that there is
no one in front of the cab while it is being tilted.

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INTERNAL CAB COMPONENTS	1
Safety instructions	LF45/55 series

Replacing the lifting cylinder

After a collision, always check the lifting cylinder for internal damage.

Replace the lifting cylinder if damaged or if you are in doubt as to the its condition.

Always replace the cylinder if one of the following points has occurred during a collision:

A.the cab has been pulled out of the cab locks,

B.the cab locks have been deformed or

2 damaged,

C.the rear cab springs have been deformed or damaged.

Airbag and seat belt tensioner safety instructions

-Never disconnect an electrical connection in the airbag or seat belt tensioner circuits with the ignition switched on.

-All work on pyrotechnic systems (systems with airbag(s) and/or seat belt tensioner(s)) may only be carried out by employees of approved DAF dealers or workshops who are sufficiently trained on these systems.

-The use of pyrotechnic systems (systems with airbag(s) and/or seat belt tensioner(s)) is subject to various national laws. The legal stipulations must be observed.

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