DAF LF45, LF55 Service manual

9

CONTENTS

LF45/55 series

TECHNICAL DATA

DIAGNOSTICS

CHASSIS

SHOCK ABSORBERS

STABILISERS AND TORQUE RODS

LEAF SUSPENSION

0

1

2

3

4

5

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9	TECHNICAL DATA
LF45/55 series		Contents
CONTENTS
	Page	Date		0
1. CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . 1-1 . .	. . . . 0207
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . . . . . . . 1-1 . .	. . . . 0207

2.SHOCK ABSORBERS, STABILISERS, TORQUE RODS AND

LEAF SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0207 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . . 0207 2.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . . 0207

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TECHNICAL DATA	9
Contents	LF45/55 series

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9		TECHNICAL DATA
LF45/55 series		Chassis
1. CHASSIS
1.1 GENERAL
					0
Chassis materials
Type	Chassis type	Material
LF	All	KF 450

Note:

KF 450 is a “High Tensile Strength”-steel grade.

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TECHNICAL DATA	9
Chassis	LF45/55 series

0

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9	TECHNICAL DATA
LF45/55 series	Shock absorbers, stabilisers, torque rods and leaf suspension

2. SHOCK ABSORBERS, STABILISERS, TORQUE RODS AND LEAF

	SUSPENSION	0
	2.1 GENERAL

Fixing the attachment bolts for the leaf spring

Ensure that when fixing the attachment bolts (1) for the leaf spring that the leaf spring is at the prescribed height (A). The height (A) is to be measured above the axle, between the top edge of the chassis cross member and the underside of the leaf spring.

	A
1	2

1

			C9 00 409
Front axle
MODEL		HEIGHT (A)
		frontmost attachment point (1)	rearmost attachment point (2)
LF45 All models		404 mm	459 mm
LF45 All models		502 mm	566 mm
Rear axle
MODEL			HEIGHT (A)
LF45 7.5T GVW			295 mm
LF45 7.5T GVW A-symmetric			295 mm
LF45 10-12T GVW			327 mm
LF45 10-12T GVW A-symmetric			295 mm
LF55 13-15T GVW			391 mm
LF55 13-15T GVW A-symmetric			362 mm
LF55 16-18T GVW			414 mm
LF55 16-18T GVW type Kipper			391 mm
LF55 16-18T GVW A-symmetric			362 mm

Note:

With the rear axle height (A) applies to both the frontmost (1) and the rearmost attachment point (2) of the leaf spring.

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		TECHNICAL DATA		9
		Shock absorbers, stabilisers, torque rods and leaf suspension		LF45/55 series
		Transverse guide torque rod, air sprung
		rear axle LF45
0
		Fitting angle (A) for mounting rubber on rear
		axle side	8 - 12 °

A

C9 00 408

Torque rods stabiliser length (A)
A is the centre-to-centre-distance between the
attachment points.
Front axle
LF45 all models	342 - 344 mm
LF55 all models	348 - 352 mm
Rear axle
LF55 FAN steered rear axle	598 - 602 mm

A

C9 00 413

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9			TECHNICAL DATA
LF45/55 series	Shock absorbers, stabilisers, torque rods and leaf suspension
2.2 TIGHTENING TORQUES
The tightening torques stated in this paragraph							0
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.
U-bolt nuts
MODEL		FRONT AXLE		REAR AXLE
LF45 all models		215 Nm*		468 Nm*
LF55 13 - 15 ton GVW		468 Nm*		468 Nm*
LF55 16-18 ton GVW Leaf suspension		537 Nm*		537 Nm*
LF55 16-18 ton GVW Air suspension		537 Nm*		880 Nm*
LF55 FAN steered rear axle				468 Nm*
* Tighten the U-bolt nuts evenly and
alternately.
Shock absorbers
If using self-locking nut M14x2		52 Nm
Front axle torque rod locking nut
LF45		135 Nm
LF55		80 Nm

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TECHNICAL DATA

9

Shock absorbers, stabilisers, torque rods and leaf suspension

LF45/55 series

LF45 rear axle, air suspension

A

B

0

C

E D

C9 00 323

A	M14 shock absorber attachment nut	52 Nm
B	M12 air bellows attachment nut	31 Nm
C	M20 bolt	525 Nm
D	M12 air bellows attachment nut	60 Nm
E	M20 shock absorber attachment bolt	525 Nm

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	9			TECHNICAL DATA
	LF45/55 series	Shock absorbers, stabilisers, torque rods and leaf suspension
	Rear axle, air suspension LF55 1315 ton
	GVW
			C	D	E		0
	A	B

F

G

	J	I	H
			C9 00 324
A	M16 triangular adjustment block
	attachment bolt	360 Nm
B	M20 triangle attachment bolt	475 Nm
C	Attachment nut for triangle on
	differential M22	235 Nm
D	M20 shock absorber attachment bolt	525 Nm
E	M20 air bellows support attachment bolt	465 Nm
F	M12 air bellows attachment bolt	31 Nm
G	M16 attachment bolt	285 Nm
H	M20 shock absorber attachment bolt	525 Nm
I	Attachment bolt	385 Nm
J	M22 bolt with break nut, breakpoint nut	+/-- 750 Nm

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TECHNICAL DATA	9
Shock absorbers, stabilisers, torque rods and leaf suspension	LF45/55 series

Rear axle, air suspension LF55 1618 ton GVW

0	A

B C B

A

D

E

D

C9 00 325

A

M10 air bellows attachment nut

46 Nm

B

Clamping flange bolt M18

460 Nm

C

M14 attachment bolt, property class 10.9

135 Nm

D

M16 air bellows attachment bolt

195 Nm

E

M20 attachment bolt, property class 10.9,

shock absorber

520 Nm

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9	TECHNICAL DATA
LF45/55 series	Shock absorbers, stabilisers, torque rods and leaf suspension

Steered rear axle, air suspension LF55 FAN

A

B

C

0

F

E

D

C9 00 397

A

Self-locking nut, torque rod ball joint

88 Nm

B

M20 shock absorber attachment bolt

250 Nm

C

M10 air bellows attachment bolt

32 Nm

D

M12 air bellows attachment bolt

34 Nm

E

M12 attachment bolt, stabiliser bar

retaining plate

25 Nm

F

Automatic lubricating nipple

5 Nm

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TECHNICAL DATA	9
Shock absorbers, stabilisers, torque rods and leaf suspension	LF45/55 series

0

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9			DIAGNOSTICS
LF45/55 series				Contents
CONTENTS
			Page	Date
1.	SHOCK ABSORBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . . 1-1 . .	. . . . 0207
	1.1	Fault-finding table	1-1	0207
						1
2.	LEAF SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		. . 2-1 . .	. . . . 0207
	2.1	Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 2-1 . .	. . . . 0207

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DIAGNOSTICS	9
Contents	LF45/55 series

1

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Fit correct type.

Check shock absorber using a test bench and replace, if required.

9	DIAGNOSTICS
LF45/55 series	Shock absorbers
1. SHOCK ABSORBERS
1.1 FAULT-FINDING TABLE
COMPLAINT: SHOCK ABSORBER PRODUCES NOISE (CHATTERING, BUMPING ETC.)
				1
Possible cause	Remedy
Shock absorber is loose.	Tighten.
Attachment rubbers too soft.	Fit new rubbers.
Shock absorber comes into contact with other	Remove components or fasten them.
components.
Shock absorber cover is loose.	Tighten cover or replace shock absorber.
COMPLAINT: SHOCK ABSORBER DOES NOT FUNCTION
Possible cause	Remedy
Internal defect.	Replace shock absorber.
Loss of oil.	Replace shock absorber.
COMPLAINT: LEAKY SHOCK ABSORBER
Possible cause	Remedy
Defective piston rod sealing.	Replace shock absorber.
Caution: a thin, greasy layer is normal.

COMPLAINT: SHOCK ABSORBER TOO HARD

Possible cause Remedy

Incorrect shock absorber type fitted.

Internal shock absorber defect.

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		DIAGNOSTICS	9
		Shock absorbers	LF45/55 series
		COMPLAINT: SHOCK ABSORBER TOO SOFT
		Possible cause	Remedy
		Incorrect shock absorber type fitted.	Fit correct type.
		Internal wear.	Check shock absorber using a test bench and
1
			replace, if required.
		Loss of oil due to leakage.	See under Leaky shock absorber.
		Vehicle overloaded.	Adjust vehicle loading.
		COMPLAINT: POOR DRIVING CHARACTERISTICS/FLAT WEAR SPOTS ON THE TYRES
		Possible cause	Remedy
		Incorrect damping.	Check shock absorbers using a test bench and
			replace, if required.
		Vehicle overloaded.	Adjust vehicle loading.
		COMPLAINT: SHOCK ABSORBER HITS END STOP
		Possible cause	Remedy
		Defective stop rubber.	Replace rubber.
		Insufficient damping.	See under Shock absorber too soft.
		Vehicle overloaded.	Adjust vehicle loading.

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9	DIAGNOSTICS
LF45/55 series	Leaf suspension
2. LEAF SUSPENSION
2.1 FAULT-FINDING TABLE
COMPLAINT: LOOSE U-BOLTS
				1
Possible cause	Remedy
Use of a U-bolt or nut of an incorrect property	Use U-bolts and nuts of the correct property
class.	class.
The tightening torque used for the U-bolt nut	Tighten the U-bolt to the specified torque.
was too low.
Reuse of a U-bolt with corroded or damaged	Fit new U-bolt.
thread.
No or inadequate cleaning of the thread (which	Clean the thread thoroughly before re-use.
includes removal of paint) before reuse of the
U-bolt.
No oil or faulty application of oil on the thread	Apply the oil as prescribed.
and the bearing surface of the nut.
Coating (i.e. paint) on the contact faces of the	Clean the contact faces before assembly.
connection.
Inadequate retorquing of the U-bolt nut or no	Tighten the U-bolt nut as specified.
retorquing.
COMPLAINT: BROKEN SPRING
Possible cause	Remedy
Regular overloading.	Adjust vehicle loading.
Driving too fast over bad roads.	Adjust speed when the road is bad.
Notching effect due to welding or grinding	Cover spring assembly when welding or
activities.	grinding.
Spring damaged due to impact of a steel	Never hit the springs using a steel hammer or
hammer.	some other hard tool.
Incorrect repair of a spring leaf which has broken	When replacing a broken spring leaf, always
before.	replace the leaf on top and under the broken
	leaf; better yet, replace the entire spring
	assembly.
Spring has been heated.	Replace spring assembly. Springs should never
	be heated.

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		DIAGNOSTICS	9
		Leaf suspension	LF45/55 series
		COMPLAINT: SPLAYING OF THE SPRING ASSEMBLY (BROKEN SPRING CLAMPS)
		Possible cause	Remedy
		Incorrect pre-tension of the U-bolts.	See under complaint Loose U-bolts.
1
		COMPLAINT: SPRING HITS END STOP
		Possible cause	Remedy
		Overloading.	Adjust vehicle loading.
		Sagged spring assembly.	Check height of both spring assemblies.
			Replace spring assemblies.
		Broken spring.	Repair spring assembly or replace.
		COMPLAINT: SHIFTING OR BREAKING OF CENTRE BOLT
		Possible cause	Remedy
		Incorrect pre-tension of the U-bolts.	See under complaint Loose U-bolts.
		COMPLAINT: BUMPING OR CHATTERING OF THE SPRING
		Possible cause	Remedy
		Loose U-bolts.	See under complaint Loose U-bolts.
		Spring bracket is loose.	Secure the spring bracket.
		Spring comes into contact with other	Check freedom of movement of spring.
		components during spring action.

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9		CHASSIS
LF45/55 series			Contents
CONTENTS
		Page	Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1-1 . .	. . . . 0207
1.1	Repairs to the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-1 . .	. . . . 0207
1.2	Drilling in the chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-4 . .	. . . . 0207
1.3	Replacing the rivets by bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-5 . .	. . . . 0207

2

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CHASSIS	9
Contents	LF45/55 series

2

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9

LF45/55 series

1. GENERAL

1.1 REPAIRS TO THE CHASSIS

-Any welding, aligning, drilling and wheelbase alteration activities that are not described in this workshop manual or in any of the latest releases of DAF’s Chassis Guidelines must be authorised by DAF.

-Following chassis repair, the cause of the chassis damage should be rectified.

Welding

-Chassis welding may only be carried out by welders holding a valid EN 287-1 certificate.

-Slag inclusions and other contamination in the welds are totally unacceptable.

Note:

Welding a chassis made from High Tensile Strength steel KF 450 is strongly advised against. If, however, you do wish to weld a High Tensile Strength steel chassis, contact DAF always first.

The welding electrode must meet the standard: EN 757: EY 4666 MNB.

To repair cracks in the chassis, proceed as follows, taking account of the guidelines given above:

1.Remove all parts restricting a clear working area.

2.Thoroughly clean the crack so that the course of the crack is clearly visible.

3.Drill a small hole at the end of the crack. This will prevent the crack from continuing.

CHASSIS

General

2

W9 01 001

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CHASSIS		9
General		LF45/55 series
4.	Thoroughly grind out the crack on both
	sides.
5.	Take the necessary precautions to prevent
	damage to electronic components. Place
	the earth clamp as close as possible to the
	weld and avoid bridges.	W9 01 002
6.	Lay a bead on one side of the ground-out

2	crack.

7.Gouge or grind off the material at the back

of the bead (see the arrow) so that the new weld material is clearly visible.

8.Finish-weld the X-seam in the usual manner.

9.Fill in the drilled hole.

W9 01 003

10.Grind down the new weld so that it is flush. Take care not to grind the chassis flange in the process.

11. The beginning and end of a weld should not curve inwards (see the arrow).

12. Round off the weld at the edge of the chassis member.

W9 01 004

R=1 100mm

R=1

W9 01 005

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9	CHASSIS
LF45/55 series	General

Straightening

Do not forget your own safety during straightening operations. When working with presses, take care that parts cannot fly out.

The straightening of a chassis demands a high degree of craftsmanship as in every case of damage, an individual assessment must be made to establish whether or not straightening

would be a sensible measure. 2 Deformations found after accidents will mainly

be of the following 6 types:

-chassis is bent sideways

-chassis has a double bend sideways (“S-bend”)

-chassis sags

-chassis bulges upwards

-chassis is twisted

-chassis is out of square.

In many cases, the damage will be a combination of two or more of these basic deformations. In general, the deformations should be dealt with in the sequence shown above, although some combinations can be dealt with in one straightening operation. When deciding whether or not to straighten a chassis, you must consider not only the degree of chassis bending but also the angle of a bend. If there is a sharp angular bend or fold in the chassis, the material in that area is likely to be

severely deformed. If such a chassis were to be realigned to its original form, there would be a high risk of overstretching the already weakened material and causing a crack to develop.

“Warm” straightening

DAF chassis should not be warm straightened. Heating can cause grains in the material which will adversely affect the material properties.

General

For every straightening operation, all stresses in the stiffer parts of the chassis, for example in the tandem axle attachment cross member, should be relieved. If this is not done, these stresses will later cause new distortions or cracks in the chassis.

It is obvious from the above points that straightening is a highly specialised job for which the specialist involved bears full responsibility. Always contact DAF when in doubt about complicated “straightening operations”.

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CHASSIS	9
General	LF45/55 series
1.2 DRILLING IN THE CHASSIS

Note:

2

There are several stress zones in a chassis. Working on the chassis without the appropriate knowledge (and not according to DAF instructions) may cause irreversible damage to the chassis. The repair shop or bodybuilder would be held fully responsible for such work and for any superstructure fitted.

If holes must be drilled in the chassis frame, note the following points:

Drilling holes within a distance of 70 mm (distance A) from a bend in the chassis is not permitted.

-It is on no account permitted to drill holes in the tapered ends at the rear of a tractor chassis.

-Drilling holes in the flanges of the chassis side members is not permitted.

-The maximum diameter for drilled holes is 17 mm (dimension D in the drawing).

-The distance between the holes, and between the holes and the side member flange, must be at least 3xD - with a minimum of 30 mm (dimension B in the drawing).

-The distance between the lower stud hole and the chassis underside should at least be equal to distance C.

Distance C is > 70 mm for a tractor chassis.

Distance C is > 50 mm for all other chassis.

-Deburr (at an angle of 45_) and lacquer coat the drilled hole.

Wheelbase alteration

Any alteration to the wheelbase or changes to the rear overhang should be done in accordance with the latest DAF Trucks Bodybuilders’ Guidelines.

Note:

When using the Bodybuilders’ Guidelines, you are advised to first read the “General” section.

A A A A

A A A A

C9 00 304

B

D

B

B

C

B

C9 00 291

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