Page 1
3
ΛΦ45/55 series
STRUCTURE
Structure
TECHNICAL DATA
0
DIAGNOSTICS
1
MECHANICAL GEARBOX CONTROL
2
PNEUMATIC GEARBOX CONTROL
3
ZF S5-42 GEARBOX
4
ZF 6S-850 GEARBOX
5
EATON FS/6309A GEARBOX
6
ALLISON 1000 & 2000 AUTOMATIC GEARBOXES
7
ALLISON MD 3060 AUTOMATIC GEARBOX
8
CLUTCH
9
PROP SHAFTS
10
©
200508 DW23259302
DAF LF Gearboxes and Clutch Service Manual
Page 2
DAF LF Gearboxes and Clutch Service Manual
Page 3
3
TECHNICAL DATA
ΛΦ45/55 series
0 Technical data
CONTENTS
Page Date
1. MECHANICAL GEARBOX CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
1.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200508
2. PNEUMATIC GEARBOX CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
2.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200508
3. ZF S5-42 GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200508
3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200508
4. ZF 6S-850 GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508
4.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200508
4.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . 200508
5. EATON FS/6309A GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508
5.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200508
5.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 . . . . . 200508
Contents
0
6. ALLISON 1000 & 2000 AUTOMATIC GEARBOXES . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200508
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200508
6.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . 200508
6.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 . . . . . 200508
7. ALLISON MD3060 AUTOMATIC GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200508
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200508
7.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 . . . . . 200508
7.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 . . . . . 200508
8. CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200508
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200508
8.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 . . . . . 200508
8.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 . . . . . 200508
9. PROP SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200508
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200508
9.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 . . . . . 200508
©
200508 1
DAF LF Gearboxes and Clutch Service Manual
Page 4
TECHNICAL DATA
3
0
Contents
ΛΦ45/55 series
2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 5
3
TECHNICAL DATA
ΛΦ45/55 series
Mechanical gearbox control
1. MECHANICAL GEARBOX CONTROL
1.1 GENERAL
Switch button
Locking compound Loctite 243
Control rod
Lubricant Molykote BR2S or BR2 plus
Control rod underneath the cab
A
0
Length A
Engine Gearbox Cab suspension Class Length A [mm]
CE engine ZF 6S850 steel 1 669
CE engine ZF 6S850 rubber 1 664
CE engine ZF 6S850 steel 2 + 3 674
CE engine ZF 6S850 rubber 2 + 3 669
CE engine FS6309A steel 2 + 3 674
CE engine FS6309A rubber 2 + 3 669
Control rod behind the cab
B
V3 00 563
V3 00 564
Length B 60 - 62 mm
©
200508 1-1
DAF LF Gearboxes and Clutch Service Manual
Page 6
TECHNICAL DATA
3
0
Mechanical gearbox control
1.2 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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
ΛΦ45/55 series
1-2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 7
3
TECHNICAL DATA
ΛΦ45/55 series
Operating mechanism,
2 adjustment options
Mechanical gearbox control
0
1
2
4
Control rod (1)
Lubricant Molykote BR2S or BR2 plus
Torque rod (2)
Attachment nuts 48 Nm
Lock nuts 28 Nm
Ball joint (4)
Attachment nut 48 Nm
Lock nuts 45 Nm
3
V3 00 567
©
200508 1-3
DAF LF Gearboxes and Clutch Service Manual
Page 8
TECHNICAL DATA
3
0
Mechanical gearbox control
Operating mechanism,
4 adjustment options
ΛΦ45/55 series
1
2
3
9
8
7
6
Control rod (1)
Lubricant Molykote BR2S or BR2 plus
Ball joint (2)
Attachment nut 48 Nm
Lock nuts 48 Nm
Torque rod (4)
Attachment nuts 48 Nm
Lock nuts 28 Nm
Ball joint (6)
Attachment nut 48 Nm
Lock nuts 48 Nm
4
5
V3 00 566
Ball joint (8)
Attachment nuts 48 Nm
Lock nuts 48 Nm
1-4
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 9
3
TECHNICAL DATA
ΛΦ45/55 series
Torque rod (9)
Attachment nuts 48 Nm
Gear lever unit
Attachment bolts 18 Nm
Eaton switch button
Attachment nut 70 Nm
(1) Use Loctite 243
Mechanical gearbox control
0
(1)
(1)
©
200508 1-5
DAF LF Gearboxes and Clutch Service Manual
Page 10
TECHNICAL DATA
3
0
Mechanical gearbox control
ΛΦ45/55 series
1-6
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 11
3
TECHNICAL DATA
ΛΦ45/55 series
2. PNEUMATIC GEARBOX CONTROL
2.1 GENERAL
Filter/governor
Governed pressure 5.34 - 5.69 bar
Pneumatic gearbox control
0
©
200508 2-1
DAF LF Gearboxes and Clutch Service Manual
Page 12
TECHNICAL DATA
3
0
Pneumatic gearbox control
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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Filter/governor
M6 attachment bolts 13 Nm
Cover 25 Nm
Selector valve single-H
M6 attachment bolts 22 Nm
M16 discharge valve attachment bolts 19 Nm
M8 cover plate attachment bolts 22 Nm
ΛΦ45/55 series
Range-change cylinder
M8 cover attachment bolts 17 Nm
M16 nut on piston 105 Nm
Bleed valve
Attachment 19 Nm
Eaton switch button
Attachment nut 70 Nm
(1) Use Loctite 243
(1)
2-2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 13
3
TECHNICAL DATA
ΛΦ45/55 series
3. ZF S5-42 GEARBOX
3.1 GENERAL
Input shaft
Pre-tension 0.02 - 0.09 mm
Secondary shaft
Pre-tension 0.02 - 0.09 mm
ZF S5-42 gearbox
0
©
200508 3-1
DAF LF Gearboxes and Clutch Service Manual
Page 14
TECHNICAL DATA
3
0
ZF S5-42 gearbox
3.2 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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Attachment bolts 60 Nm
Drive flange
'Direct drive' attachment nut 400 Nm
Overdrive attachment nut 330 Nm
Gearbox front cover
Attachment bolts 23 Nm
ΛΦ45/55 series
(1)
(2)
Selector shaft housing
Selector shaft housing attachment bolts 23 Nm
Shifting arm lock nut 46 Nm
Gearbox control attachment nut 52 Nm
Bleeder 10 Nm
Plugs
Oil level check/filler plug 50 Nm
Drain plug 50 Nm
(1) Fit new nut and apply Loctite 270 to it
(2) Fit new nut and apply Loctite 262 to it
3-2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 15
3
TECHNICAL DATA
ΛΦ45/55 series
3.3 FILLING CAPACITIES
Gearbox Capacity
S5-42 3.5 litres
ZF S5-42 gearbox
0
©
200508 3-3
DAF LF Gearboxes and Clutch Service Manual
Page 16
TECHNICAL DATA
3
0
ZF S5-42 gearbox
ΛΦ45/55 series
3-4
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 17
3
TECHNICAL DATA
ΛΦ45/55 series
4. ZF 6S-850 GEARBOX
4.1 GENERAL
Gearbox type
Each gearbox has a type plate attached to it,
indicating the type of gearbox. This data can also
be found on the vehicle identity card for the
vehicle concerned.
ZF gearbox type plate
1. Type of gearbox
2. Serial no. (ZF)
3. Parts list (ZF)
4. Specification no.
5. Pulse generator ratio
6. Gearbox ratio
7. Engine speed using PTO
8. PTO speed
9. Gearbox oil capacity
10. Oil specification
ZF 6S-850 gearbox
0
1
3
6
8
2
4
5
7
Output shaft bearing axial play
Output shaft bearing axial play 0.00 - 0.10 mm
Bearing axial play, main and input shafts
Bearing axial play, main and input shafts 0.00 - 0.10 mm
Secondary shaft bearing axial play
Secondary shaft bearing axial play 0.00 - 0.10 mm
9
10
V300049
©
200508 4-1
DAF LF Gearboxes and Clutch Service Manual
Page 18
TECHNICAL DATA
3
0
ZF 6S-850 gearbox
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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Attachment bolts 60 Nm
Drive flange
Drive flange ∧ 120 mm attachment bolt 120 Nm
Drive flange ∧ 150 mm attachment bolt 140 Nm
Gearbox front cover
Attachment bolts 23 Nm
ΛΦ45/55 series
Selector shaft housing
Selector housing attachment bolts 23 Nm
Shifting arm lock nut 46 Nm
Gearbox control attachment nut 52 Nm
Bleeder 10 Nm
Plugs
Oil level check/filler plug 50 Nm
Drain plug 50 Nm
4-2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 19
3
TECHNICAL DATA
ΛΦ45/55 series
4.3 FILLING CAPACITIES
Gearbox type Filling amounts at oil change
ZF 6S-850 7.5 7.5
(litres)
ZF 6S-850 gearbox
0
First filling, e.g. on repair
(litres)
©
200508 4-3
DAF LF Gearboxes and Clutch Service Manual
Page 20
TECHNICAL DATA
3
0
ZF 6S-850 gearbox
ΛΦ45/55 series
4-4
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 21
3
TECHNICAL DATA
ΛΦ45/55 series
5. EATON FS/6309A GEARBOX
5.1 GENERAL
Gearbox type
Each gearbox has a type plate attached to it,
indicating the type of gearbox. You can also find
this data on the identity card for the vehicle
concerned.
Eaton gearbox type plate
1. Type of gearbox
2. Specification no. Eaton
3. DAF article Eaton code
4. Serial no. Eaton
5. Production date code
The Eaton specification number is unique to each
customer and gives detailed information on the
development level of the gearbox. The number
must be quoted whenever replacement parts are
ordered.
Eaton FS/6309A gearbox
0
2
3
41
5
V300378
Input shaft play of adjusting rings: Colour coding:
3.70 mm Red, green, white
3.75 mm Yellow, green, blue
3.80 mm Blue, green, white
3.85 mm Red, green, yellow
3.90 mm Green, green, white
3.95 mm Red, green, red
Secondary shaft pre-load
New bearings 0.075 - 0.125 mm
Original bearings 0.000 - 0.050 mm
Sealant
Gearbox housing front cover contact surfaces Loctite 518
Input shaft Lithium-based grease, class NLGI 3
Filter/governor
Governed pressure 5.3 - 5.7 bar
©
200508 5-1
DAF LF Gearboxes and Clutch Service Manual
Page 22
TECHNICAL DATA
3
0
Eaton FS/6309A gearbox
5.2 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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Attachment bolts 60 Nm
Drive flange
M39 attachment nut 650 Nm
Drive flange oil seal housing attachment bolts 37 Nm
ΛΦ45/55 series
(1)
Gearbox front cover
Attachment bolts 37 Nm
Selector shaft housing
Selector shaft housing attachment bolts 37 Nm
M8 retaining cover attachment bolts 22 Nm
M8 shifting arm lock nut 25 Nm
M10 shifting arm lock nut 37 Nm
End cover attachment bolts 22 Nm
Bleeder 19 Nm
Bleed valve 22 Nm
Filter/governor
M6 attachment bolts 13 Nm
Cover 25 Nm
Plugs
Oil level check/filler plug 35 Nm
Drain plug 44 Nm
(1) Use new nut
(2) Use Loctite 243
(2)
5-2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 23
3
TECHNICAL DATA
ΛΦ45/55 series
5.3 FILLING CAPACITIES
Gearbox Contents
Eaton FS/6309A 8.5 litres
Eaton FS/6309A gearbox
0
©
200508 5-3
DAF LF Gearboxes and Clutch Service Manual
Page 24
TECHNICAL DATA
3
0
Eaton FS/6309A gearbox
ΛΦ45/55 series
5-4
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 25
3
TECHNICAL DATA
ΛΦ45/55 series
Allison 1000 & 2000 automatic gearboxes
6. ALLISON 1000 & 2000 AUTOMATIC GEARBOXES
6.1 GENERAL
Torque converter pilot bearing
Lubricant on installation Molykote BR2S or BR2 plus
0
©
200508 6-1
DAF LF Gearboxes and Clutch Service Manual
Page 26
TECHNICAL DATA
3
0
Allison 1000 & 2000 automatic gearboxes
ΛΦ45/55 series
6.2 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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Attachment bolts 60 Nm
Hydraulic pipes to oil cooler 25 Nm
Bolts attaching gearbox to flywheel housing 34 Nm
Flexplates
Flexplate adapter attachment bolts 64 Nm
Crankshaft attachment bolts 30 Nm + 60″ angular displacement
Selector switch
Attachment bolts 27 Nm
Attachment nut 24 Nm
Speed sensor
Attachment bolt 12 Nm
Oil sump
Attachment bolts 27 Nm
PTO cover
Attachment bolts 43 Nm
Plugs
Gearbox drain plug 35 Nm
Oil cooler drain plug 28 Nm
Oil cooler air bleed plug 28 Nm
Hydraulic lines
Attachment to gearbox 25 Nm
Drive flange
Attachment bolt 122 Nm
6-2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 27
3
TECHNICAL DATA
ΛΦ45/55 series
6.3 FILLING CAPACITIES
Gearbox Capacity
Allison 1000 & 2000 series Approx. 10 litre
Allison 1000 & 2000 automatic gearboxes
0
©
200508 6-3
DAF LF Gearboxes and Clutch Service Manual
Page 28
TECHNICAL DATA
3
0
Allison 1000 & 2000 automatic gearboxes
ΛΦ45/55 series
6-4
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 29
3
TECHNICAL DATA
ΛΦ45/55 series
Allison MD3060 automatic gearbox
7. ALLISON MD3060 AUTOMATIC GEARBOX
7.1 GENERAL
The Allison MD3060 automatic gearbox is
electronically controlled and has a diagnostics
system that can record possible faults in the
memory of the ECU (Electronic Control Unit). The
faults can be read at a later date. The system is
operated and the faults are read via the selector
keypad. This selector keypad has a display and is
located next to the driver's seat; it replaces the
gear lever with manual gearboxes.
R
N
0
MODE
D
Torque converter pilot bearing
Lubricant on installation Molykote BR2S or BR2 Plus
V300392
©
200508 7-1
DAF LF Gearboxes and Clutch Service Manual
Page 30
TECHNICAL DATA
3
0
Allison MD3060 automatic gearbox
7.2 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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Attachment bolts 60 Nm
Bleeder 14 Nm
Main connector 2.5 Nm
Coolant pipes 55 Nm
Rear mounting bracket 100 Nm
PTO bracket 55 Nm
Flywheel housing adapter, M10 x 1.5 55 Nm
ΛΦ45/55 series
Drive flange
Attachment bolt 75 Nm
Flexplates
Flexplate adapter attachment bolts 36 Nm
Torque converter attachment bolts 36 Nm
Oil cooler
Hydraulic lines 60 Nm
Plugs
Oil drain plug (1) 28 Nm
Oil filter cover attachment bolts (2) 55 Nm
2
1
V300371
7-2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 31
3
TECHNICAL DATA
ΛΦ45/55 series
Oil cooler air bleed plug (1) 28 Nm
Oil cooler drain plug (2) 28 Nm
Allison MD3060 automatic gearbox
1
0
2
V3 00 883
©
200508 7-3
DAF LF Gearboxes and Clutch Service Manual
Page 32
TECHNICAL DATA
3
0
Allison MD3060 automatic gearbox
7.3 FILLING CAPACITIES
Allison automatic gearbox oil capacities
Type of gearbox Capacity at first filling Capacity at second filling
MD 3060P 4" oil sump 27 litres 20 litres
The oil level when cold must be on the "Cold full"
mark.
"Cold add" add when cold
"Cold full" full when cold
"Hot add" add when hot
"Hot full" full when hot
ΛΦ45/55 series
HOT
FULL
HOT
ADD
FULL
COLD
ADD
COLD
W 3 03 099
7-4
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 33
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TECHNICAL DATA
ΛΦ45/55 series
8. CLUTCH
8.1 GENERAL
Gearbox Clutch release assembly Clutch plate
ZF S5-42 MF 362 WGTZ (1
ZF S6-850 MF 395 WGTZ (1
Eaton FS/6309A MF 395 WGTZ (1
1
1
1
Clutch
0
/2")
/2")
/4")
©
200508 8-1
DAF LF Gearboxes and Clutch Service Manual
Page 34
TECHNICAL DATA
3
0
Clutch
8.2 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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Clutch release assembly
MF 362 clutch release assembly attachment bolts 40 Nm
MF 395 clutch release assembly attachment bolts 80 Nm
Tighten attachment bolts as illustrated
8
1
ΛΦ45/55 series
8
1
6
3
5
72
MF 395
6
3
4
7
4
9
25
MF 362
V3 00 414
8-2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 35
3
TECHNICAL DATA
ΛΦ45/55 series
8.3 FILLING CAPACITIES
Clutch
First filling approx. 0.4 litres
Clutch
0
©
200508 8-3
DAF LF Gearboxes and Clutch Service Manual
Page 36
TECHNICAL DATA
3
0
Clutch
ΛΦ45/55 series
8-4
DAF LF Gearboxes and Clutch Service Manual
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3
TECHNICAL DATA
ΛΦ45/55 series
9. PROP SHAFTS
9.1 GENERAL
Spicer
LF 45 LF 55 (12 - 15 ton) LF 55 (17 - 19 ton)
SPL 39 - -
SPL 55 SPL 55 -
SPL 70 SPL 70 SPL 70
SPL 100 SPL 100 SPL 100
- - SPL 140
Monotron
Prop shafts
0
PEP 5
PEP 6
C2040
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200508 9-1
DAF LF Gearboxes and Clutch Service Manual
Page 38
TECHNICAL DATA
3
0
Prop shafts
9.2 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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Drive flange
M10 attachment bolts 60 Nm
M12 attachment bolts 105 Nm
Spicer intermediate bearing
SPL 39 and SPL 55 central nuts 400 Nm
SPL 70, SPL 100 and SPL 140 central nuts 685 Nm
ΛΦ45/55 series
Spicer universal joint
5
/16" attachment bolts, UNF clamping bow, prop
shaft - universal joint 38 Nm
3
/8" attachment bolts, UNF clamping bow, prop
shaft - universal joint 70 Nm
M8 attachment bolts, clamping piece, universal
joint circlip SPL 140 38 Nm
Spicer suspension bearing
Bracket attachment bolts 110 Nm + 30″ angular displacement
Monotron suspension bearing
M10 bracket attachment bolts 60 Nm
M12 bracket attachment bolts 105 Nm
9-2
DAF LF Gearboxes and Clutch Service Manual
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200508
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3
DIAGNOSTICS
ΛΦ45/55 series
1 Diagnostics
CONTENTS
Page Date
1. MECHANICAL GEARBOX CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
1.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
2. PNEUMATIC GEARBOX CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
2.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
3. MECHANICAL GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
4. AUTOMATIC GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508
4.1 Reading/deleting Allison MD 3060 fault codes . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508
4.2 Allison MD 3060 table of fault codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . 200508
5. CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508
5.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508
6. PROP SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200508
6.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200508
Contents
1
©
200508 1
DAF LF Gearboxes and Clutch Service Manual
Page 40
DIAGNOSTICS
3
1
Contents
ΛΦ45/55 series
2
DAF LF Gearboxes and Clutch Service Manual
©
200508
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3
DIAGNOSTICS
ΛΦ45/55 series
Mechanical gearbox control
1. MECHANICAL GEARBOX CONTROL
1.1 FAULT-FINDING TABLE
COMPLAINT: GEAR LEVER VIBRATES
Possible cause Remedy
Excessive play at control hinge points Check/repair all points in the control
COMPLAINT: ENGAGING GEARS IS HEAVY
Possible cause Remedy
Gearbox control pivot and hinge points dry or
compressed
Incorrect adjustment of control Check/adjust all points in the control
Mechanical problem in gearbox See "Mechanical gearbox" fault-finding table
COMPLAINT: GEARS CANNOT BE ENGAGED
Possible cause Remedy
Check/repair all points in the control
1
Gearbox control pivot and hinge points dry or
compressed
Incorrect adjustment of control Check/adjust all points in the control
Mechanical problem in gearbox See "Mechanical gearbox" fault-finding table
COMPLAINT: GEARBOX JUMPS OUT OF GEAR
Possible cause Remedy
Incorrect adjustment of control Check/adjust all points in the control
Mechanical problem in gearbox See "Mechanical gearbox" fault-finding table
Check/repair all points in the control
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DAF LF Gearboxes and Clutch Service Manual
Page 42
DIAGNOSTICS
3
1
Mechanical gearbox control
ΛΦ45/55 series
1-2
DAF LF Gearboxes and Clutch Service Manual
©
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3
DIAGNOSTICS
ΛΦ45/55 series
Pneumatic gearbox control
2. PNEUMATIC GEARBOX CONTROL
2.1 FAULT-FINDING TABLE
COMPLAINT: NOT POSSIBLE TO ENGAGE HIGH OR LOW RANGE
Possible cause Remedy
Air pressure too low Check air supply of circuit 4
Neutral position valve defective or incorrectly
connected
Faulty downshift protection valve Replace valve
Defective high/low range engaging cylinder Check cylinder and replace if necessary
COMPLAINT: HIGH/LOW RANGE ENGAGING CYLINDER ENGAGES LOW AT TOO HIGH A
Possible cause Remedy
Incorrect VIC frequency value Adjust value
Connect valve properly or replace
SPEED
1
COMPLAINT: HIGH OR LOW RANGE ENGAGING IS SLOW
Possible cause Remedy
Air pressure too low Check air supply of circuit 4
Piping blocked Check piping and clean, if necessary
Defective neutral position valve Replace valve
COMPLAINT: HIGH/LOW RANGE ENGAGING CYLINDER WORKS THE WRONG WAY ROUND
Possible cause Remedy
Air pipes on the high/low range engaging cylinder
are incorrectly connected
COMPLAINT: NOT POSSIBLE TO ENGAGE LOW RANGE
Possible cause Remedy
VIC defective Check VIC and replace, if necessary
Incorrect vehicle speed signal Check vehicle speed signal
Connect engaging cylinder air pipes correctly
©
200508 2-1
DAF LF Gearboxes and Clutch Service Manual
Page 44
DIAGNOSTICS
3
1
Pneumatic gearbox control
ΛΦ45/55 series
2-2
DAF LF Gearboxes and Clutch Service Manual
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3
DIAGNOSTICS
ΛΦ45/55 series
Mechanical gearbox
3. MECHANICAL GEARBOX
3.1 FAULT-FINDING TABLE
COMPLAINT: ENGAGING GEARS IS HEAVY
Possible cause Remedy
Gearbox oil level too low Top up oil level
Oil with incorrect specification in the gearbox Fill gearbox with oil of correct specification
Problem in mechanical gearbox control See "Mechanical gearbox control" fault-finding
table
Clutch plate is not released See "Clutch" fault-finding table
COMPLAINT: GEARS CANNOT BE ENGAGED
Possible cause Remedy
Retaining element fitted too deep Check/repair retaining elements
Problem in mechanical gearbox control See "Mechanical gearbox control" fault-finding
table
1
Range-change switch does not work properly See "Pneumatic section of gearbox control" fault-
finding table
COMPLAINT: GEARBOX JUMPS OUT OF GEAR
Possible cause Remedy
Adjustment of gearshift cover on gearbox Mount gearshift cover on gearbox without any play
Defective retaining element or wrong type of
retaining element fitted in gearshift cover
Problem in mechanical gearbox control See "Mechanical gearbox control" fault-finding
COMPLAINT: SINGLE H BECOMES DOUBLE H
Possible cause Remedy
Locking plate in control cover not positioned
correctly
Replace retaining element or fit other type of
retaining element
table
Check assembly of control cover
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200508 3-1
DAF LF Gearboxes and Clutch Service Manual
Page 46
DIAGNOSTICS
3
1
Mechanical gearbox
ΛΦ45/55 series
3-2
DAF LF Gearboxes and Clutch Service Manual
©
200508
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3
DIAGNOSTICS
ΛΦ45/55 series
4. AUTOMATIC GEARBOX
4.1 READING/DELETING ALLISON MD 3060 FAULT CODES
Fault code read function
To enter the fault code reading mode, briefly
press the two arrow keys twice simultaneously.
"D-1" appears on the display, followed by "-".
This means that at that point there are no faults
(active faults) in the system. It also means that no
faults have been registered that were earlier
temporarily present and have now been cleared
(inactive faults). The fault code reading function
can be left by pressing "D", "N", or "R" or the
arrow keys.
If the red lamp lights up while reading a fault
code, this means that there is an active fault in the
gearbox.
No message during reading means that the fault
is inactive.
The ECU can save five active/inactive fault codes
in its memory and show them on the display.
Fault codes consist of two sets of two digits (main
codes and sub-codes). To read the codes
consecutively, the "MODE" button must be
pressed each time.
R
N
D
Automatic gearbox
1
MODE
The letters and digits appear one at a time on the
display.
Example: D1 25 - 22
D2 21 - 12
D3 24 - 12
D4 -
The hyphen after D4 means that there are no
further faults and that it is therefore not necessary
to look at level D5.
As the ECU can only contain the five most
important codes, the five most important codes
will be seen on D1 to D5. Only when one of the
faults has been remedied will the ECU be in a
position to show a less important fault.
V300392
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DAF LF Gearboxes and Clutch Service Manual
Page 48
DIAGNOSTICS
3
1
Automatic gearbox
Deleting fault codes
After faults have been remedied, the ECU
memory must be deleted. This is done as follows.
Press the arrow keys twice simultaneously. This
is the fault code reading mode. Press the
"MODE" key and hold it down until the red lamp
flashes three times (the first flash will be after
approx. three seconds, the second after approx.
10 seconds). All codes, active or inactive, have
now been deleted. Codes which return following
deleting and can therefore no longer be deleted
are active. Both types of fault need their causes
tracing and remedying as quickly as possible.
After the fault codes have been deleted the
ignition must be switched off and re-started;
otherwise it will not be possible to drive. This can
be seen from the flashing of the gear lever
position.
Inactive faults are automatically deleted by the
ECU if the fault no longer occurs after the vehicle
ignition has been switched off and on 25 times.
It is not possible to remedy all fault codes. Fault
codes that cannot be found in the "Table of Fault
Codes" can best be remedied by an Allison
dealer.
He has test and diagnostic apparatus at his
disposal that can be connected to a special
diagnostic socket in the central box (next to the
DAVIE connector).
R
N
D
ΛΦ45/55 series
MODE
V300392
4-2
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3
DIAGNOSTICS
ΛΦ45/55 series
4.2 ALLISON MD 3060 TABLE OF FAULT CODES
Main code Sub-code RECOMMENDED PROCEDURES
Electronic control unit (ECU) supply
13 12 Low
23 High
21 12
23
Check the following points:
1. earth and positive battery cables connected, firmly attached and clean.
2. batteries are charged.
3. vehicle loading system fails to load or loads too little or too much.
4. VIM fuse (Vehicle Interface Module).
5. VIM connections are firmly attached, clean and undamaged.
6. the correct wiring is used.
7. ECU connections are firmly attached, clean and undamaged.
If all these points are in order, contact your Allison dealer.
Accelerator pedal sensor
Check the following points:
1. Accelerator pedal sensor connector is properly connected.
2. no interruptions or short circuits between wires or earth in wiring harness
to accelerator pedal sensor.
Automatic gearbox
1
Replace the accelerator pedal sensor if necessary.
If all these points are in order, contact your Allison dealer.
Main code Sub-code RECOMMENDED PROCEDURES
Speed sensors
22 14
15
16
23 12
13
14
15
23
24
Check the following points:
1. connectors are firmly attached, clean and undamaged.
2. the speed sensor attachment bolt is tightened to the specified torque.
3. no interruptions or short circuits between wires or earth in wiring harness
to sensor.
If all these points are in order, contact your Allison dealer.
Selector keypad
Check the following points:
1. ECU connections - connectors are connected and clamped.
2. selector keypad is connected and the wire loop has been cut through.
3. no interruptions or short circuits between wires or earth in wiring harness
to selector.
Replace the selector if possible.
If all these points are in order, contact your Allison dealer.
Temperature in the gearbox sump too low
24 12 Check the following points:
1. temperature is lower than -6″C.
1. If this is the case, it is a normal response to the ambient temperature.
2. If not, check whether the main gearbox is firmly connected and that
the connectors are undamaged.
If all these points are in order, contact your Allison dealer.
©
200508 4-3
DAF LF Gearboxes and Clutch Service Manual
Page 50
DIAGNOSTICS
3
1
Automatic gearbox
Main code Sub-code RECOMMENDED PROCEDURES
Temperature in the gearbox sump is too high
24 23 1. Run the engine at idling speed.
2. Ensure that the vehicle is entirely horizontal.
3. Check whether the correct dip stick has been installed.
4. Check the oil level.
5. If necessary, correct the oil level.
6. If the oil level is in order, check whether the engine system has
overheated, causing the gearbox to overheat.
7. Check that the ECU and gearbox connectors are correctly connected,
firmly attached and undamaged.
If all these points are in order, contact your Allison dealer.
Output shaft speed sensor
25 00
11
22
33
44
55
66
77
Check the following points:
1. connector is connected.
2. sensor bolt is firmly attached.
3. ECU is firmly attached with no damaged connectors.
4. oil level.
5. no interruptions or short circuits between wires or earth in wiring harness
to sensor.
If all these points are in order, contact your Allison dealer.
ΛΦ45/55 series
Coupling 3 pressure switch open
32 00
33
55
77
Main code Sub-code RECOMMENDED PROCEDURES
33 12
23
1. Let the engine idle while the vehicle's parking brake is applied.
Check the following points:
1. specified dip stick.
2. correct oil level.
2. Check the following points:
1. gearbox main connector is connected, is firmly attached, is clean
and undamaged.
2. ECU connector is connected, is firmly attached, is clean and
undamaged.
3. no interruptions or short circuits between wires or earth in wiring
harness.
If all these points are in order, contact your Allison dealer.
Sensor fault in gearbox oil sump
Check the following points:
1. gearbox main connector is connected, is firmly attached, is clean and
undamaged.
2. ECU connector is connected, is firmly attached, is clean and undamaged.
3. no interruptions or short circuits between wires or earth in wiring harness.
4-4
If all these points are in order, contact your Allison dealer.
DAF LF Gearboxes and Clutch Service Manual
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3
DIAGNOSTICS
ΛΦ45/55 series
Main code Sub-code RECOMMENDED PROCEDURES
EEPROM fault
34 12
13
14
15
16
35 00
16
1. Re-calibrate if necessary.
2. If re-calibration is impossible, replace the ECU.
3. If ECU replacement is impossible, contact your Allison dealer.
EEPROM writing error as a result of loss of power supply
Check the following points:
1. ECU is firmly attached, clean and undamaged.
2. VIM (Vehicle Interface Module) is firmly attached, clean and undamaged.
3. the vehicle manufacturer has used the specified wiring for power supply
and earth connection.
4. battery positive pole.
5. battery earth connection.
6. specified connections for vehicle ignition.
If all these points are in order, contact your Allison dealer.
Hardware/software not compatible
Automatic gearbox
1
36 00 1. Replace ECU if possible.
2. Re-program ECU if possible.
3. If replacement or re-programming is not possible, contact your Allison
dealer.
Main code Sub-code RECOMMENDED PROCEDURES
Interruption or short circuit in electromagnetic valve circuit
41 12
13
14
15
16
20
22
23
24
25
26
Check the following points:
1. gearbox main connector is connected, is firmly attached, is clean and
undamaged.
2. ECU connector is connected, is firmly attached, is clean and undamaged.
3. visual inspection of the wiring harness: no damage, chafed or too taut
wires, no screws through the wiring harness.
4. no interruptions or short circuits between wires or earth in wiring harness.
Replace wiring harness if necessary.
If all these points are in order, contact your Allison dealer.
©
200508 4-5
DAF LF Gearboxes and Clutch Service Manual
Page 52
DIAGNOSTICS
3
1
Automatic gearbox
Main code Sub-code RECOMMENDED PROCEDURES
Short circuit in the electromagnetic valve circuit to the battery
42 12
13
14
15
16
21
22
23
24
25
26
43 21
25
26
Main code Sub-code RECOMMENDED PROCEDURES
Check the following points:
1. gearbox main connector is connected, is firmly attached, is clean and
undamaged.
2. ECU connector is connected, is firmly attached, is clean and undamaged.
3. visual inspection of the wiring harness: no damage, chafed or too taut
wires, no screws through the wiring harness.
4. no interruptions or short circuits between wires or earth in wiring harness.
5. Replace wiring harness if necessary.
6. incompetent repairs.
If all these points are in order, contact your Allison dealer.
ECU circuits
1. replace the ECU.
2. Contact your Allison dealer.
ΛΦ45/55 series
Transmission ration test on the gear to be changed from (during shifting)
51 01
10
12
21
23
45
65
Coupling 3 pressure switch fails to register pressure drop during shifting
52 01
08
32
34
54
56
71
78
79
99
Check the following points:
1. engine speed sensor and output shaft speed sensor are connected. The
connectors are undamaged and clean.
2. no interruptions or short circuits between wires or earth in sensor wiring.
3. let the engine idle in neutral while the vehicle is on the brake.
Check the following points:
1. specified dip stick.
2. oil level.
If all these points are in order, contact your Allison dealer.
Check the following points:
1. engine speed sensor and output shaft speed sensor are connected. The
connectors are undamaged and clean.
2. no interruptions or short circuits between wires or earth in sensor wiring.
3. let the engine idle while the vehicle is on the brake.
Check the following points:
1. specified dip stick.
2. oil level.
4. check that there is no interruption or short circuit between wires or earth
connection in the main wiring harness to the gearbox.
If all these points are in order, contact your Allison dealer.
4-6
DAF LF Gearboxes and Clutch Service Manual
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3
DIAGNOSTICS
ΛΦ45/55 series
Main code Sub-code RECOMMENDED PROCEDURES
Engine and turbine rev test when engaging neutral
53 08
18
28
29
38
39
48
49
58
59
68
69
78
99
54 01,07
10,12
17,21
23,32
34,43
45,54
56,65
70,71
80,81
83,85
86,92
93,95
96,97
Check the following points:
1. engine speed sensor and output shaft speed sensor are connected. The
connectors are undamaged and clean.
2. no interruptions or short circuits between wires or earth in sensor wiring.
3. let the engine idle in neutral while the vehicle is on the brake.
Check the following points:
1. specified dip stick.
2. oil level.
If all these points are in order, contact your Allison dealer.
Transmission ratio test immediately after changing gear
Check the following points:
1. engine speed sensor and output shaft speed sensor are connected. The
connectors are undamaged and clean.
2. no interruptions or short circuits between wires or earth in sensor wiring.
3. let the engine idle in neutral while the vehicle is on the brake.
Check the following points:
1. specified dip stick.
2. oil level.
If all these points are in order, contact your Allison dealer.
Automatic gearbox
1
Main code Sub-code RECOMMENDED PROCEDURES
Pressure in coupling 3 immediately after changing gear
55 17
87
97
Check the following points:
1. engine speed sensor and output shaft speed sensor are connected. The
connectors are undamaged and clean.
2. no interruptions or short circuits between wires or earth in sensor wiring.
3. let the engine idle in neutral while the vehicle is on the brake.
Check the following points:
1. specified dip stick.
2. oil level.
4. check that there is no interruption or short circuit between the wiring or
earth connection in the coupling 3 pressure switch wiring.
5. Check the following points:
1. main connector is properly connected, clean and undamaged.
2. ECU connector is properly connected, clean and undamaged.
3. rev sensor is properly connected, clean and undamaged.
If all these points are in order, contact your Allison dealer.
©
200508 4-7
DAF LF Gearboxes and Clutch Service Manual
Page 54
DIAGNOSTICS
3
1
Automatic gearbox
Main code Sub-code RECOMMENDED PROCEDURES
Range test
56 00
11
22
33
44
55
66
77
Main code Sub-code RECOMMENDED PROCEDURES
57 11
22
44
66
88
99
Check the following points:
1. engine speed sensor and output shaft speed sensor are connected. The
connectors are undamaged and clean.
2. no interruptions or short circuits between wires or earth in sensor wiring.
3. let the engine idle in neutral while the vehicle is on the brake.
Check the following points:
1. specified dip stick.
2. oil level.
If all these points are in order, contact your Allison dealer.
Range test when using coupling C3
Check the following points:
1. engine speed sensor and output shaft speed sensor are connected. The
connectors are undamaged and clean.
2. no interruptions or short circuits between wires or earth in sensor wiring.
3. let the engine idle in neutral while the vehicle is on the brake.
Check the following points:
1. specified dip stick.
2. oil level.
4. check that there is no interruption or short circuit between the wiring or
earth connection in the coupling 3 pressure switch wiring.
5. Check the following points:
1. main connector is properly connected, clean and undamaged.
2. ECU connector is properly connected, clean and undamaged.
3. rev sensor is properly connected, clean and undamaged.
ΛΦ45/55 series
69 12,13
14,15
16,21
22,23
24,25
26,32
33,34
35,36
If all these points are in order, contact your Allison dealer.
Fault in ECU
1. Delete the fault codes and try to re-start the vehicle.
2. If the fault re-occurs, replace the ECU.
3. If the fault has not been cleared, contact your Allison dealer.
4-8
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DIAGNOSTICS
ΛΦ45/55 series
5. CLUTCH
5.1 FAULT-FINDING TABLE
SYMPTOM: CLUTCH PEDAL FAILS TO RETURN
Possible cause Remedy
Broken pedal return spring Replace spring
Worn clutch pedal bearings Check bearings and replace if necessary
Dirt in hydraulic system Clean system and fill with fresh fluid
Incorrect fluid in hydraulic system Replace with fluid of correct specification
Air in hydraulic system Bleed the system
SYMPTOM: CLUTCH PEDAL STICKS WHEN PRESSED
Possible cause Remedy
Leak in hydraulic system Check system
Air in hydraulic system Bleed hydraulic system
Clutch
1
Release bearing incorrectly fitted Fit the release bearing correctly
Fork hinge points or fork itself worn Check hinge points and fork; replace if necessary
Defective clutch servo Repair and/or replace clutch servo
Gearbox front cover worn or broken Check, replace gearbox front cover
SYMPTOM: PEDAL FORCE TOO HIGH
Possible cause Remedy
No or insufficient pressure in circuit 4 of the brake
system
Kinked air pipe Check pipe and replace if necessary
Kinked hydraulic pipe Check pipe and replace if necessary
Worn clutch pedal bearings Check bearings and replace if necessary
Defective clutch servo and/or main cylinder Repair or replace clutch servo and/or main cylinder
SYMPTOM: RESIDUAL PRESSURE IN CLUTCH SYSTEM
Possible cause Remedy
Check circuit 4 of the brake system
Note: In the case of a swollen seal, clean the
system and re-fill with new fluid
Bleed vent in reservoir cap closed off Check bleed vent in cap
Compensation bore in main cylinder closed off by
swollen seal or insufficient free thrust pin travel.
©
200508 5-1
Check free thrust pin travel or repair/replace main
cylinder
Note: In the case of a swollen seal, clean the
system and re-fill with new fluid
DAF LF Gearboxes and Clutch Service Manual
Page 56
DIAGNOSTICS
3
1
Clutch
SYMPTOM: FLUID LEAK VIA VENT OPENING
Possible cause Remedy
Leak through piston seal in clutch servo Repair or replace clutch servo
Note: A drop of oil in the vent opening is a normal
situation and is not a reason to repair/replace the
clutch servo
SYMPTOM: CLUTCH PLATE SLIPS
Possible cause Remedy
Worn lining Replace lining
Oil on lining Replace linings and check engine and gearbox
sealing rings
Dirt on clutch plate and flywheel Clean plate and surrounding area
Burnt clutch plate Check entire clutch and replace if necessary
Clamping force of clutch release assembly too low
or absent
Check clutch release assembly and replace if
necessary
ΛΦ45/55 series
Clutch release assembly is not released Check clutch release assembly
SYMPTOM: CLUTCH RELEASE ASSEMBLY FAILS TO RELEASE
Possible cause Remedy
Fluid level in hydraulic system too low Top up fluid
Incorrect pedal setting Check setting and adjust if necessary
Air in hydraulic system Bleed hydraulic system
Leak in hydraulic system Check hydraulic system
Fingers of clutch release assembly broken Replace clutch release assembly
Wrong clutch release assembly has been fitted Fit correct clutch release assembly
Clutch fork is broken Replace fork
Clutch release assembly badly soiled Clean entire clutch
Defective clutch servo Check clutch servo and replace if necessary
Thrust bearing incorrectly fitted Fit thrust bearing correctly
Clutch housing disconnected from gearbox Tighten the clutch housing bolts to the correct
torque
5-2
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3
DIAGNOSTICS
ΛΦ45/55 series
Prop shafts
6. PROP SHAFTS
6.1 FAULT-FINDING TABLE
SYMPTOM: VIBRATION IN DRIVE LINE AT LOW SPEED
Possible cause Remedy
Universal joint angle too large, caused for example
by excessive caster
Play in universal joints Replace universal joint
Play in suspension bearing Replace suspension bearing
Play in slide coupling Replace prop shaft
Forks not in line Align forks
SYMPTOM: VIBRATION IN DRIVE LINE AT HIGH SPEED
Possible cause Remedy
Prop shaft imbalance Balance prop shafts or replace if necessary
Check universal joint angle
1
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200508 6-1
DAF LF Gearboxes and Clutch Service Manual
Page 58
DIAGNOSTICS
3
1
Prop shafts
ΛΦ45/55 series
6-2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 59
3
MECHANICAL GEARBOX CONTROL
ΛΦ45/55 series
2 Mechanical gearbox control
CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
1.1 Description of mechanical gearbox control . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
1.2 Overview drawing, operating mechanism, 2 adjustment options. . . . . . . . 1-2 . . . . . 200508
1.3 Overview drawing, operating mechanism, 4 adjustment options. . . . . . . . 1-3 . . . . . 200508
1.4 Overview drawing, gear lever unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . 200508
1.5 Overview drawing, ZF gearbox gear lever. . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . 200508
1.6 Overview drawing, Eaton gear lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 . . . . . 200508
2. INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
2.1 Inspecting and adjusting operating mechanism, 2 adjustment options . . . 2-1 . . . . . 200508
2.2 Inspecting and adjusting operating mechanism, 4 adjustment options . . . 2-4 . . . . . 200508
3. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.1 Removing and installing switch button . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.2 Removing and installing gaiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200508
3.3 Removing and installing gear lever unit. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200508
3.4 Removing and installing control rod underneath the cab . . . . . . . . . . . . . 3-4 . . . . . 200508
3.5 Removing and installing rear control rod . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . . . . . 200508
Contents
2
©
200508 1
DAF LF Gearboxes and Clutch Service Manual
Page 60
MECHANICAL GEARBOX CONTROL
3
2
Contents
ΛΦ45/55 series
2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 61
3
MECHANICAL GEARBOX CONTROL
ΛΦ45/55 series
1. GENERAL
1.1 DESCRIPTION OF MECHANICAL GEARBOX CONTROL
Mechanical gearbox control
As a result of the use of different engines,
gearboxes and cabs there are many different
versions of the operating mechanisms of the
mechanical gearboxes.
The operating mechanism must be adjusted in
such a way that the gearbox does not jump out of
gear and engaging gears is not too heavy. The
operating mechanism must not touch any other
vehicle parts during operation.
The various types of operating mechanism can
be classified on the basis of the number of
adjustable points:
- 2 adjustment options
- 4 adjustment options
Before carrying out the adjustment, the gear lever
must be fixed in the neutral position. This is done
using the special tool. The operating mechanism
is then adjusted so that everything can be fitted
without tension.
General
2
The versions with 4 adjustment options have two
adjustable control rods that must be of a specified
length. The versions with two adjustment options
must be adjusted in such a way that everything
can be fitted without tension.
Operating mechanism, RHD
For 5, 6 and 9-gear boxes in combination with a
4 or 6-cylinder engine the operating mechanism
is the same. Small differences in length and/or
shape are possible, however.
All operating mechanisms used have
2 adjustment options.
Operating mechanism, LHD
For 5 and 6-gear boxes in combination with a
4-cylinder engine the operating mechanism has
2 adjustment options.
For 6 and 9-gear boxes in combination with a
6-cylinder engine the operating mechanism has
4 adjustment options.
©
200508 1-1
DAF LF Gearboxes and Clutch Service Manual
Page 62
MECHANICAL GEARBOX CONTROL
3
2
General
1.2 OVERVIEW DRAWING, OPERATING MECHANISM, 2 ADJUSTMENT OPTIONS
1
ΛΦ45/55 series
1. Control rod
2. Torque rod
3. Gearbox lever
4. Ball joint
2
3
4
V3 00 567
1-2
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MECHANICAL GEARBOX CONTROL
ΛΦ45/55 series
1.3 OVERVIEW DRAWING, OPERATING MECHANISM, 4 ADJUSTMENT OPTIONS
1
2
3
9
General
2
1. Control rod underneath the cab
2. Ball joint
3. Bracket
4. Torque rod
5. Gearbox lever
6. Ball joint
7. Control rod behind the cab
8. Ball joint
9. Torque rod
4
8
7
5
6
V3 00 566
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200508 1-3
DAF LF Gearboxes and Clutch Service Manual
Page 64
MECHANICAL GEARBOX CONTROL
3
2
General
1.4 OVERVIEW DRAWING, GEAR LEVER UNIT
1
2
3
4
19
7
8
17
5
16
9
18
ΛΦ45/55 series
5
6
10
11
10
6
15
14
12
13
1. Switch button 11. Clamping pin
2. Gear lever 12. Telescopic control rod
3. Attachment plate 13. Retainer clip
4. Vibration damper 14. Pawl
5. Spring holder 15. Axle
6. Centring spring 16. Plug
7. Bearing housing 17. Gear lever pawl
8. Spring 18. Attachment nut
9. Control rod pawl 19. Attachment bolt
10. Needle bearing
V3 00 568
1-4
DAF LF Gearboxes and Clutch Service Manual
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3
MECHANICAL GEARBOX CONTROL
ΛΦ45/55 series
1.5 OVERVIEW DRAWING, ZF GEARBOX GEAR LEVER
1
2
3
General
2
1. Switch button
2. Gear lever
3. Bearing housing
V3 00 569
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200508 1-5
DAF LF Gearboxes and Clutch Service Manual
Page 66
MECHANICAL GEARBOX CONTROL
3
2
General
1.6 OVERVIEW DRAWING, EATON GEAR LEVER
1
2
3
4
5
6
7
ΛΦ45/55 series
1. Cover plate
2. Attachment nut
3. O-ring
4. Switch button
5. Range group operating switch
6. Clamping plate
7. Gear lever
8. Bearing housing
8
V3 00 572
1-6
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©
200508
Page 67
3
MECHANICAL GEARBOX CONTROL
ΛΦ45/55 series
Inspection and adjustment
2. INSPECTION AND ADJUSTMENT
2.1 INSPECTING AND ADJUSTING OPERATING MECHANISM, 2 ADJUSTMENT OPTIONS
Inspecting operating mechanism,
2 adjustment options
1. Push the control against the spring pressure
to check whether it can move freely in
neutral.
2. Check that all gears can be engaged without
parts coming into contact with each other.
3. During a test drive, check that the gear
remains engaged under changing
conditions.
Adjusting the gearbox control,
2 adjustment options
1. Remove the switch button (see "Removal
and installation").
2
2. Remove the gaiter (see "Removal and
installation").
3. Loosen the lock nuts (3) of the gearbox lever.
4. Loosen the lock nuts (2) of the torque rod on
both sides.
5. Remove attachment nut (1) from the torque
rod on control rod side.
21
3
V3 00 575
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DAF LF Gearboxes and Clutch Service Manual
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MECHANICAL GEARBOX CONTROL
3
2
Inspection and adjustment
6. Fix the gear lever by fitting the special tool
(DAF no. 1329488) over the gear lever and
inserting the end of the gear lever through
the appropriate opening.
ΛΦ45/55 series
V3 00 580
7. Fit the special tool (DAF no. 1453143)
between the ball joint (1) and the arm (2).
Centre the ball joint (1) by pressing it against
the shoulder of the special tool (A).
Note:
On the special tool (A) (DAF no. 1453143) it
is shown which side of the tool must be used
for LHD vehicles and which side for RHD
vehicles.
8. Hand-tighten the lock nuts (3) of the gearbox
lever without moving the control rod.
9. Tighten the lock nuts (3) on the gearbox lever
to the specified torque without moving the
control rod. See "Technical data".
10. Adjust the length of the torque rod in such a
way that it can be positioned in the control
rod without tension. Tighten the attachment
nut (1) to the specified torque. See
"Technical data".
2
RHD
A
1
V3 00 840
21
3
2-2
DAF LF Gearboxes and Clutch Service Manual
V3 00 575
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3
MECHANICAL GEARBOX CONTROL
ΛΦ45/55 series
11. Tighten the lock nuts (2) on the torque rod to
the specified torque without moving the
torque rod. See "Technical data".
12. Remove the special tool from the ball joint.
13. Clean part (A) of the control rod and remove
any grease.
14. Apply the specified lubricant lightly to section
(B) of the control rod. See "Technical data".
15. Remove the special tool and fit the gaiter.
See "Removal and installation".
16. Fit the switch button. See "Removal and
installation".
Inspection and adjustment
A
2
B
V3 00 746
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DAF LF Gearboxes and Clutch Service Manual
Page 70
MECHANICAL GEARBOX CONTROL
3
2
Inspection and adjustment
2.2 INSPECTING AND ADJUSTING OPERATING MECHANISM, 4 ADJUSTMENT OPTIONS
Inspecting operating mechanism,
4 adjustment options
1. Push the control against the spring pressure
to check whether it can move freely in
neutral.
2. Check that all gears can be engaged without
parts coming into contact with each other.
3. During a test drive, check that the gear
remains engaged under changing
conditions.
Adjusting the gearbox control,
4 adjustment options
1. Remove the retaining clip and disassemble
the control rods underneath the cab.
2. Measure the length of the control rod and
compare the measured reading (A) with the
specified reading. See "Technical data".
B
ΛΦ45/55 series
3. If necessary, adjust the length.
4. Clean part (B) of the control rod and remove
any grease.
5. Apply the specified lubricant lightly to section
(C) of the control rod. See "Technical data".
6. Measure the length (B) of the control rod ball
joint behind the cab and compare the
measured reading with the specified reading.
See "Technical data".
7. If necessary, adjust the length of the ball
joint.
8. Remove the switch button (see "Removal
and installation").
9. Remove the gaiter (see "Removal and
installation").
C
A
V3 00 745
B
2-4
DAF LF Gearboxes and Clutch Service Manual
V3 00 564
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MECHANICAL GEARBOX CONTROL
ΛΦ45/55 series
10. Loosen the lock nuts (3) of the gearbox lever.
11. Loosen the lock nuts (2) of the torque rod on
both sides.
12. Remove attachment nut (1) from the torque
rod on control rod side.
13. Fix the gear lever by fitting the special tool
(DAF no. 1329488) over the gear lever and
inserting the end of the gear lever through
the appropriate opening.
Inspection and adjustment
21
3
2
V3 00 575
V3 00 580
14. Fit the special tool (DAF no. 1453143)
between the ball joint (1) and the arm (2).
Centre the ball joint (1) by pressing it against
the shoulder of the special tool (A).
Note:
On the special tool (A) (DAF no. 1453143) it
is shown which side of the tool must be used
for LHD vehicles and which side for RHD
vehicles.
2
RHD
A
1
©
200508 2-5
V3 00 840
DAF LF Gearboxes and Clutch Service Manual
Page 72
MECHANICAL GEARBOX CONTROL
3
2
Inspection and adjustment
15. Hand-tighten the lock nuts (3) of the gearbox
lever without moving the control rod.
16. Tighten the lock nuts (3) on the gearbox lever
to the specified torque without moving the
control rod. See "Technical data".
17. Adjust the length of the torque rod in such a
way that it can be positioned in the control
rod without tension. Tighten the attachment
nut (1) to the specified torque. See
"Technical data".
18. Tighten the lock nuts (2) on the torque rod to
the specified torque without moving the
torque rod. See "Technical data".
19. Remove the special tool from the ball joint.
20. Remove the special tool and fit the gaiter.
See "Removal and installation".
21. Fit the switch button. See "Removal and
installation".
ΛΦ45/55 series
21
3
V3 00 575
2-6
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 73
3
MECHANICAL GEARBOX CONTROL
ΛΦ45/55 series
3. REMOVAL AND INSTALLATION
3.1 REMOVING AND INSTALLING SWITCH BUTTON
Removing ZF gearbox switch button
1. Turn the switch button anti-clockwise away
from the gear lever.
Installing ZF gearbox gear lever
1. Apply locking compound to the gear lever
wire. See "Technical data".
2. Turn the switch button clockwise onto the
gear lever.
3. Position the switch button so that it
corresponds to the gear-shift movement.
Removing Eaton gearbox switch button
1. Remove the cover plate and the gear-
change pattern from the top of the switch
button.
2. Remove the attachment nut from the switch
button.
Removal and installation
2
3. Remove the switch button.
4. Remove the gaiter.
5. Position the gear lever as far forward as
possible and remove the range-change
switch.
Installing Eaton gearbox switch button
1. Position the gear lever as far forward as
possible and fit the range-change switch
over the gear lever.
2. Position the air pipes so that they cannot get
trapped between the gear lever and the cab.
3. Fit the gaiter.
4. Apply locking compound to the gear lever
wire. See "Technical data".
5. Fit the switch button onto the gear lever and
tighten the attachment nut to the specified
torque. See "Technical data".
6. Fit the cover plate.
©
200508 3-1
DAF LF Gearboxes and Clutch Service Manual
Page 74
MECHANICAL GEARBOX CONTROL
3
2
Removal and installation
3.2 REMOVING AND INSTALLING GAITER
Removing gaiter
1. Remove the switch button.
2. Disconnect the underside of the gaiter.
3. Pull the gaiter over the switch button and
remove the clamping strap (1).
4. Remove the gaiter.
Installing gaiter
1. Fit a new clamping strap on the inside of the
gaiter.
2. Fit the top of the gaiter inside out over the
gear lever and tighten the clamping strap (1).
3. Pull the entire gaiter over the gear lever.
4. Tighten the underside of the gaiter.
ΛΦ45/55 series
1
V3 00 578
3-2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 75
3
MECHANICAL GEARBOX CONTROL
ΛΦ45/55 series
3.3 REMOVING AND INSTALLING GEAR LEVER UNIT
Removing gear lever unit
1. Remove the switch button.
2. Remove the gaiter.
3. Remove the retainer clip from the telescopic
control rod underneath the cab and remove
the gear lever unit.
4. Remove the attachment bolts of the gear
lever on the bottom of the cab.
Installing gear lever unit
1. Slide the gear lever unit and the telescopic
control rod onto the gearbox control and fit
the retainer clip.
2. Install the gear lever in the cab via the feed-
through.
3. Fit the gear lever attachment bolts and
tighten them to the specified torque. See
"Technical data".
Removal and installation
2
4. Fit the gaiter.
5. Fit the switch button.
6. Check that the operating mechanism does
not touch any vehicle parts during shifting.
©
200508 3-3
DAF LF Gearboxes and Clutch Service Manual
Page 76
MECHANICAL GEARBOX CONTROL
3
2
Removal and installation
3.4 REMOVING AND INSTALLING CONTROL ROD UNDERNEATH THE CAB
Removing control rod underneath the cab
1. Remove the retainer clip (2) of the telescopic
control rod (1).
2. Remove the attachment nuts from the ball
joint (4) and torque rod (5).
1
2
ΛΦ45/55 series
3
4
5
V3 00 573
3-4
DAF LF Gearboxes and Clutch Service Manual
©
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3
MECHANICAL GEARBOX CONTROL
ΛΦ45/55 series
Installing control rod underneath the cab
1. Adjust the length (A) of the control rod (3).
See "Technical data".
2. Clean part (B) of the control rod and remove
any grease.
3. Apply the specified lubricant lightly to section
(C) of the control rod. See "Technical data".
4. Fit the control rod (3) into the telescopic
control rod (1) and fit the retainer clip (2).
5. Tighten the attachment nuts of the ball joint
(4) and the torque rod to the specified torque.
See "Technical data".
6. Check the functioning of the operating
mechanism. See "Inspection and
adjustment".
Removal and installation
B
C
A
V3 00 745
2
1
2
3
4
5
V3 00 573
©
200508 3-5
DAF LF Gearboxes and Clutch Service Manual
Page 78
MECHANICAL GEARBOX CONTROL
3
2
Removal and installation
3.5 REMOVING AND INSTALLING REAR CONTROL ROD
Removing control rod behind the cab
1. Remove the attachment nut from the ball
joint (2).
2. Remove the attachment nut from torque rods
(1) and (4).
3. Remove the lock nut from the ball joint (5).
Note:
Make sure that the rearmost lock nut on the
ball joint (5) is not moved.
4. Remove the control rod (3).
1
ΛΦ45/55 series
2
34
5
V3 00 574
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DAF LF Gearboxes and Clutch Service Manual
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MECHANICAL GEARBOX CONTROL
ΛΦ45/55 series
Installing control rod behind the cab
1. Adjust the length (B) of the control rod (3).
See "Technical data".
2. Fit the control rod (3) and fit and hand-tighten
all attachment nuts.
3. Tighten all attachment and lock nuts to the
specified torque. See "Technical data".
Note:
Make sure that the control rod does not turn
while the attachment and lock nuts are being
tightened.
Removal and installation
B
2
V3 00 564
1
4. Check the functioning of the operating
mechanism. See "Inspection and
adjustment".
2
34
5
V3 00 574
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200508 3-7
DAF LF Gearboxes and Clutch Service Manual
Page 80
MECHANICAL GEARBOX CONTROL
3
2
Removal and installation
ΛΦ45/55 series
3-8
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 81
3
PNEUMATIC GEARBOX CONTROL
ΛΦ45/55 series
3 Pneumatic gearbox control
CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
1.1 Location of components in pneumatic section of gearbox control. . . . . . . 1-1 . . . . . 200508
1.2 Pneumatic diagram, gearbox control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200508
1.3 System description, pneumatic section of gearbox control . . . . . . . . . . . . 1-3 . . . . . 200508
2. DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
2.1 Filter/governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
2.2 Gear lever selector valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200508
2.3 Electropneumatic downshift protection valve . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200508
2.4 Neutral position valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 . . . . . 200508
2.5 Range group engaging cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . 200508
3. INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.1 Programming parameters using DAVIE. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.2 Simulating speed signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200508
3.3 Inspection, downshift protection valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200508
3.4 Inspection, filter/governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . 200508
4. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508
4.1 Removal and installation, filter/governor . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508
4.2 Removing and installing range group operating switch . . . . . . . . . . . . . . . 4-2 . . . . . 200508
Contents
3
5. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508
5.1 Cleaning filter/governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508
©
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DAF LF Gearboxes and Clutch Service Manual
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PNEUMATIC GEARBOX CONTROL
3
3
Contents
ΛΦ45/55 series
2
DAF LF Gearboxes and Clutch Service Manual
©
200508
Page 83
3
PNEUMATIC GEARBOX CONTROL
ΛΦ45/55 series
General
1. GENERAL
1.1 LOCATION OF COMPONENTS IN PNEUMATIC SECTION OF GEARBOX CONTROL
1 432
3
1. Filter/governor
2. Neutral position valve
3. Electropneumatic downshift protection valve
4. Range group engaging cylinder
V3 00 360
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PNEUMATIC GEARBOX CONTROL
3
3
General
1.2 PNEUMATIC DIAGRAM, GEARBOX CONTROL
1
+
6 2
21
H
L
GP
1
1
4
L
H
ΛΦ45/55 series
21
22
1. VIC electronic unit
2. Electropneumatic downshift protection valve
3. Range group engaging cylinder
4. Neutral position valve
5. Filter/governor
6. Range group operating switch
L Position "low"
H Position "high"
N Gearbox selector shaft in neutral
V Gearbox selector shaft engaged
45
N
V
1
3
V3 00 359
1-2
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©
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Page 85
3
PNEUMATIC GEARBOX CONTROL
ΛΦ45/55 series
General
1.3 SYSTEM DESCRIPTION, PNEUMATIC SECTION OF GEARBOX CONTROL
1
+
6 2
21
H
L
GP
1
1
4
L
21
H
22
3
The pressure in the pneumatic section of the
gearbox control is filtered and reduced in the
filter/governor (5). From the filter/governor the
system pressure goes to the neutral position
valve (4) and the range group operating switch
(6) located on the ball of the gear lever.
When the range group operating switch is
activated a pneumatic command will be sent
to the electropneumatic downshift protection
valve (2).
45
N
V
1
3
V3 00 359
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DAF LF Gearboxes and Clutch Service Manual
Page 86
PNEUMATIC GEARBOX CONTROL
3
3
General
The electropneumatic downshift protection valve
can only be activated when the vehicle speed is
below a certain value. This is so as to prevent
damage to the drive line. When the vehicle speed
is low enough, the electropneumatic downshift
protection valve is activated and the system
pressure goes from the neutral position valve to
the range group engaging cylinder.
The neutral position valve is activated when the
gear lever is moved through the neutral position.
ΛΦ45/55 series
1-4
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©
200508
Page 87
3
PNEUMATIC GEARBOX CONTROL
ΛΦ45/55 series
2. DESCRIPTION OF COMPONENTS
2.1 FILTER/GOVERNOR
Filter/governor (1) on gearbox
2 3 415
Description of components
3
Overview drawing, filter/governor
1. Filter/governor
2. Filter element
3. Seal
4. O-ring
5. Cover
6. Plug
7. Output
8. Selector valve output plug
9. Attachment bolt
10. Supply pressure input
V300558-2
6
5
4
3
2
1
10
8
9
7
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Description of components
The full vehicle supply pressure from circuit four
of the brake system must pass through the air
filter.
The supply pressure goes through the bore (1) in
the valve and will force the piston down against
the spring pressure.
The spring cannot be adjusted.
The system pressure (see "Technical data") goes
via connection point (2) to the range group
operating switch and the neutral position valve.
ΛΦ45/55 series
2
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PNEUMATIC GEARBOX CONTROL
ΛΦ45/55 series
2.2 GEAR LEVER SELECTOR VALVE
Changing to the low or high speed range is done
with switch (A) on the ball of the gear lever.
When the switch is facing down it means that the
low speed range has been or is being engaged.
When the switch is facing up the high speed
range has been or is being engaged.
Pre-selection is possible. A particular range is
switched only when the gear lever is moved
through the neutral position.
The pressure on connection 1 is the system
pressure. When the switch is operated a
pneumatic command will be sent from connection
21 to the electropneumatic downshift protection
valve.
A
Description of components
V3 00 562
1
21
3
V3 00 477
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Description of components
2.3 ELECTROPNEUMATIC DOWNSHIFT PROTECTION VALVE
The electropneumatic downshift protection valve
receives a certain frequency value relating to the
vehicle speed from the VIC.
If this value is too high, the connection between
the electropneumatic downshift protection valve
and earth will be broken. Despite the pneumatic
command from the range group operating switch
to connection point (4) on the electropneumatic
downshift valve, it is not now possible to switch to
the low range.
The system pressure to connection point (1) on
the electropneumatic downshift protection valve
is only available when the gear lever, and hence
also the neutral position valve, is in the neutral
position.
4
L
1
H
ΛΦ45/55 series
21
22
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PNEUMATIC GEARBOX CONTROL
ΛΦ45/55 series
2.4 NEUTRAL POSITION VALVE
The neutral position valve is mounted on the
selector shaft housing. Inside the selector shaft is
a slot that corresponds to the neutral position of
the selector shaft. The neutral position valve pawl
drops into this slot. When a gear is engaged, the
neutral position valve pawl moves out of the slot,
thereby switching the valve. In the neutral
position the system pressure is sent to the
electropneumatic downshift protection valve. In
the event of a gear change, the gear lever and the
neutral position valve will be moved through the
neutral position. At that moment the neutral
position valve sends the system pressure from
connection (21) to the electropneumatic
downshift protection valve.
Description of components
3
V3 00 476
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Description of components
2.5 RANGE GROUP ENGAGING CYLINDER
The range group engaging cylinder is mounted
on the rear of the gearbox.
The engaging cylinder is supplied from the
electropneumatic downshift protection valve.
ΛΦ45/55 series
LH
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PNEUMATIC GEARBOX CONTROL
ΛΦ45/55 series
3. INSPECTION AND ADJUSTMENT
3.1 PROGRAMMING PARAMETERS USING DAVIE
After a gearbox has been replaced by a gearbox
that uses a different reduction rate, it will be
necessary to reprogram the VIC by means of
DAVIE XD.
This is to ensure that the downshift protection
valve is enabled and disabled at the correct
vehicle speeds.
It is not possible to adjust the frequencies of the
gate protection and the range-change protection
with the standard program of DAVIE XD. If the
vehicle configuration is changed, this should
always be reported.
Inspection and adjustment
3
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3.2 SIMULATING SPEED SIGNAL
The speed signal can be simulated with DELSI
(DAF no. 0694941). DELSI must be connected to
the speed sensor connector.
Before connecting DELSI to the speed sensor
connector, an adapter cable must be made.
The adapter cable must consist of the following
wiring:
Pin 1: speed sensor, power supply
Pin 2: speed sensor, earth
Pin 3: speed sensor, "real-time"
speed/distance signal
Pin 4: not in use
When the speed sensor connector is
disconnected, a fault is stored in the tachograph.
This fault can be deleted using DAVIE XD.
ΛΦ45/55 series
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ΛΦ45/55 series
3.3 INSPECTION, DOWNSHIFT PROTECTION VALVE
Inspection without vehicle speed signal
1. Make sure there is sufficient air pressure in
the brake system.
2. Position the gear lever in neutral.
3. Switch the vehicle ignition on.
4. Use the range group operating switch on the
ball of the gear lever to select the lower
range. The range group should now switch to
the lower range.
5. Switch the vehicle ignition off. The range
group should now automatically switch to the
higher range.
Inspection with the vehicle speed signal
1. Make sure there is sufficient air pressure in
the brake system.
2. Connect special tool DELSI
(DAF no. 0694941).
Inspection and adjustment
3
3. Position the gear lever in neutral.
4. Switch the vehicle ignition on.
5. Use the range group operating switch on the
ball of the gear lever to select the lower
range. The range group should now switch to
the lower range.
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6. Use DELSI to raise the simulated vehicle
speed slowly to approximately 40 km/h. As
the vehicle speed increases, the range group
should automatically switch to the higher
range.
7. Use DELSI to decrease the simulated
vehicle speed slowly to approximately
0 km/h. As the vehicle speed decreases, the
range group should automatically switch to
the lower range.
ΛΦ45/55 series
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PNEUMATIC GEARBOX CONTROL
ΛΦ45/55 series
3.4 INSPECTION, FILTER/GOVERNOR
Inspection, filter/governor
1. Remove the plug from the extra outlet (9)
and install a pressure gauge.
2. Check the service pressure. See "Technical
data".
Inspection and adjustment
6
5
4
3
2
3
1
10
8
9
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Inspection and adjustment
ΛΦ45/55 series
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PNEUMATIC GEARBOX CONTROL
ΛΦ45/55 series
4. REMOVAL AND INSTALLATION
4.1 REMOVAL AND INSTALLATION, FILTER/GOVERNOR
Removal, filter/governor
1. Blow off the air reservoirs.
2. Unscrew the air pipes.
3. Remove the two attachment bolts from the
filter/governor and remove the filter/
governor.
Installation, filter/governor
1. Install the filter/governor on the attachment
bracket. Tighten the attachment bolts to the
specified torque. See "Technical data".
2. Fit the air pipes.
3. Pressurise the system.
4. Check the system for air leakage.
Removal and installation
3
5. Check the operation of the valve. See
"Inspection and adjustment".
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Removal and installation
ΛΦ45/55 series
4.2 REMOVING AND INSTALLING RANGE GROUP OPERATING SWITCH
Removing range group operating switch
1. Blow off the air reservoirs.
2. Detach the bottom of the gaiter and partially
pull the gaiter over the gear lever knob.
3. Remove the clamping strap on the inside of
the gaiter.
4. Remove the cover cap with the gear-change
pattern on the top of the gear lever.
5. Remove the attachment nut on the top of the
gear lever and remove the gear lever knob.
6. Remove the gaiter.
7. Mark the various air pipes and disconnect
them from the range-change switch using a
small screwdriver.
8. Remove the range-change switch and the
clamping piece.
Installing range group operating switch
1. Install the clamping piece on the gear lever.
2. Connect the various air pipes to the range-
change switch as indicated by the markings.
3. Install the range-change switch on the gear
lever. Ensure that the clamping piece is
properly mounted on the range-change
switch.
4. Slide the gaiter over the gear lever.
5. Fit the switch button onto the gear lever and
tighten the attachment nut to the specified
torque. See "Technical data".
6. Install a clamping strap on the inside of the
gaiter.
7. Pressurise the system.
8. Check the system for air leakage.
9. Check the operation of the range group
operating switch.
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