DAF LF45, LF55 Cab Service Manual
1
LF45/55 series
CONTENTS
TECHNICAL DATA
0
DIAGNOSTICS
1
INTERNAL CAB COMPONENTS
2
CAB HEATING
3
EXTERNAL CAB COMPONENTS
4
CAB SUSPENSION
5
CAB TILTING GEAR
SEATS
ACCESSORIES
6
7
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TECHNICAL DATA
LF45/55 series Contents
CONTENTS
Page Date
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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1TECHNICAL DATA
Contents LF45/55 series
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TECHNICAL DATA
LF45/55 series Internal and external cab components
1. INTERNAL AND EXTERNAL CAB COMPONENTS
1.1 GENERAL
Main dimensions and weights
L
B
H
K
K1 01 170
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
tilting (K) 1105 mm
(1)
(2)
2900 mm
1105 mm
(1)
(2)
0
K1 01 192
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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1TECHNICAL DATA
Internal and external cab components LF45/55 series
Permissible cab weights: max.
Roof console evenly distributed 5 kg
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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LF45/55 series Internal and external cab components
Straightening dimensions
TECHNICAL DATA
Door opening dimensions
A - D 1283 mm
C - F 887 mm
B - E 1591 mm
E
A
F
B
C
D
K1 01 209
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Internal and external cab components LF45/55 series
BC
Rear wall dimensions
A - D 2042 mm
B - C 1926 mm
B - E 2435 mm
C - F 2435 mm
A
D
F
E
K1 01 208
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TECHNICAL DATA
LF45/55 series Internal and external cab components
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
H
G
BCE
ADF
N K
M
K1 01 210
I
0
J
L
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Internal and external cab components LF45/55 series
Field of vision dimensions
D
1
A
A
2
A
3
A
1
B
1
B
B
B
B
3
5
2
B
4
D
C
C
2
C
3
C
4
C
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K100237
Mirror size 1 size 2 size 3 size 4 size 5
Pavement mirror [A] 1m 1m 1.25 m
Wide-angle mirror [B] 2.5 m 15 m 12.5 m 25 m 3m
Main mirror on co-driver’s
30 m 3.5 m 0.75 m 4m
side [C]
Main mirror on driver’s
10 m 2.5 m
side [D]
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TECHNICAL DATA
LF45/55 series Internal and external cab components
Windscreens
Curing times for windscreen adhesive
Product name DAF number Vehicle mobile in
workshop after:
Sikaflex 255 FC 1271129 6 hours 8hours 12 hours
Sika Tack Ultrafast 1241020 2 hours 4hours 6 hours
Sika Tack plus
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.
Product name DAF number Properties Applications
Sikaflex 255 FC 1271129 Processing time
Sika Tack UF 1241020 Processing time
1357925 1hour 1 hour
Products applied for bonded windscreens
20 min.
10 min.
Cab can be tilted
after:
(1)
Adhesive (cold process) for
bonding windscreens
Adhesive (warm process) for
bonding windscreens
Vehicle usable
after:
2 hours
0
Sika Tack plus
booster
Sika Aktivator 1312362 Cleaning fluid for cleaning the glass
Sika remover
SR 208
1357925 Processing time
10 min.
1241019 Removal of adhesive which has not
Adhesive (cold process) for
bonding windscreens
and the frame.
yet hardened. Do not use on
surfaces to be bonded.
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1TECHNICAL DATA
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 ᐔ 5Nm
Universal joint
Universal joint attachment bolt 56 ᐔ 5.6 Nm
Airbag
Airbag module attachment bolt 5 ᐔ 1Nm
Contact unit attachment bolt 1.2 Nm
Electronic unit 10 ᐔ 2Nm
Note:
(1)
Always replace the attachment bolt and
nut.
(1)
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TECHNICAL DATA
LF45/55 series Cab suspension
2. CAB SUSPENSION
2.1 GENERAL
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
supports (A) measured from the
left side of the left support to the
left side of the right support is:
1000 mm
0
9
11
15
10
12
16
13
14
K1 00 575
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1TECHNICAL DATA
Cab suspension LF45/55 series
0
Cab support with silentblock
Silent block mounting angle (A) 67_ -71_
Cab support with coil spring suspension
Silent block mounting angle (A) 18_ -22_
A
K1 01 475
A
K1 01 442
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TECHNICAL DATA
LF45/55 series Cab suspension
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
attachment bolt
250 Nm + 150_
angular
displacement
0
K1 01 573
Attachment bolts for cab suspension
using rubber spring elements
Cab suspension
attachment bolt
250 Nm + 150_
angular
displacement
1
K1 01 574
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1TECHNICAL DATA
Cab suspension LF45/55 series
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LF45/55 series Cab tilting gear
TECHNICAL DATA
3. CAB TILTING GEAR
3.1 GENERAL
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 cm
3
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Cab tilting gear LF45/55 series
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TECHNICAL DATA
LF45/55 series Seats
4. SEATS
4.1 GENERAL
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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Seats LF45/55 series
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TECHNICAL DATA
LF45/55 series Accessories
5. ACCESSORIES
5.1 GENERAL
Roof spoiler
Adjusting range of roof spoiler, aerodynamic
and adjustable
Note:
The roof spoiler height can be adjusted using
adjusting mechanism (B).
Thesizeisthedistancemeasuredbetweenthe
highest roof spoiler edge (P) and the cab roof
plate local to the vehicle centreline.
Application compounds for rear air foils and
roof spoilers
Product name
Sikaflex 252
(white)
DAF number Properties Applications
1286578 Working time within
15 min.
Curing time 2 days
0
350 - 850 mm
P
B
K1 01 355
Kit for fender and roof spoiler
attachment
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5-1
1TECHNICAL DATA
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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LF45/55 series Contents
DIAGNOSTICS
CONTENTS
Page Date
1. CAB SUSPENSION 1-1 0210.................................................... ......
1.1 Fault-finding table, cab tilting mechanism 1-1 0210............................ ......
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1DIAGNOSTICS
Contents LF45/55 series
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DIAGNOSTICS
LF45/55 series Cab suspension
1. CAB SUSPENSION
1.1 FAULT-FINDING TABLE, CAB TILTING MECHANISM
COMPLAINT: TILTING CYLINDER FAILS TO RESPOND
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 ONL Y FUNCTIONS IN THE LAST P ART OF THE STROKE
Possible cause Remedy
Low oil level in oil reservoir. Topupoilreservoir.
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.
1
COMPLAINT: PUMP FAILS TO BUILD UP PRESSURE
Possible cause Remedy
Reservoir level too low. Topupthereservoir.
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
valve.
Pressure-relief valve incorrectly set. Check the pressure relief valve and adjust, if
Remove the two-way valve and replace all seals
and O-rings.
necessary.
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1DIAGNOSTICS
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.
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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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....................................... ......
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...................... ......
4.4 Removal 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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1INTERNAL CAB COMPONENTS
Contents LF45/55 series
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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
underneath the cab.
You can stop the cab tilting forward
atanytimebyturningthetaptothe
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.
2
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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1INTERNAL CAB COMPONENTS
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
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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