DAF LF45 LF55 Maintenance Manual

Maintenance manual LF45/55

©200515 DAF Trucks N.V., Eindhoven,

The Netherlands.

In the interest of continuing product development, DAF reserves the right to change specifications or products at any time without prior notice.

No part of this publication may be reproduced and/or published by printing, by photocopying, on microfilm or in any way whatsoever without the prior consent in writing of DAF Trucks N.V.

© 200515

DW13279204

STRUCTURE

ΛΦ45/55 series

TECHNICAL DATA

THREADED CONNECTIONS

FLUIDS, OIL AND LUBRICANTS

MAINTENANCE SCHEDULE

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

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TECHNICAL DATA

	ΛΦ45/55 series				Contents
	CONTENTS
				Page	Date		0
	1.	. . . . . . . . . . . . . . . . . . . . .ENGINE, COOLING SYSTEM AND FUEL SYSTEM		. . .1-1	. . 200515
		1.1	General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-1 . . .	. . 200515
		1.2	Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-2 . . . .	. 200515
		1.3	Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-3 . . . .	. 200515
	2.	STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-1 . . . .	. 200515
		2.1	General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-1 . . . .	. 200515
		2.2	Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-2 . . . .	. 200515
	3.	DRIVE SHAFTS, DRIVE AND CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3-1 . . . .	. 200515
		3.1	General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-1 . . . .	. 200515
		3.2	Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-2 . . . .	. 200515
		3.3	Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-6 . . . .	. 200515

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TECHNICAL DATA

Contents ΛΦ45/55 series

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		TECHNICAL DATA
	ΛΦ45/55 series	Engine, cooling system and fuel system
	1. ENGINE, COOLING SYSTEM AND FUEL SYSTEM
				0
	1.1 GENERAL
	Valve clearance, BE engine and CE engine
	Inspection dimension, valve clearance (cold)
	Inlet	0.15 - 0.40 mm
	Outlet	0.40 - 0.75 mm
	Setting dimension, valve clearance (cold)
	Inlet	0.25 mm
	Outlet	0.50 mm

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TECHNICAL DATA

		Engine, cooling system and fuel system	ΛΦ45/55 series
		1.2 TIGHTENING TORQUES
0
		The tightening torques specified in this section
		are different from the standard tightening torques
		cited in the overview of the standard tightening
		torques. The other threaded connections not
		specified must therefore be tightened to the
		torque cited 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.
		Lubrication system, BE engine and CE engine
		Oil drain plug	60 Nm
		Valve gear, BE engine and CE engine
		Valve cover attachment bolts	10 Nm

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	TECHNICAL DATA
ΛΦ45/55 series	Engine, cooling system and fuel system
1.3 FILLING CAPACITIES
			0
BE engine lubrication system
Total capacity (including oil cooler and oil filter)	approx. 13.0 litres
Capacity of oil sump, maximum level	approx. 11.0 litres
Capacity of oil sump, minimum level	approx. 8.9 litres
BE engine cooling system
Cooling system	approx. 20 litres
CE engine lubrication system
Total capacity (including oil cooler and oil filter)	approx. 19.5 litres
Capacity of oil sump, maximum level	approx. 17.5 litres
Capacity of oil sump, minimum level	approx. 15.5 litres
CE engine cooling system
Cooling system	approx. 22 litres

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TECHNICAL DATA

Engine, cooling system and fuel system ΛΦ45/55 series

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	TECHNICAL DATA
ΛΦ45/55 series	Steering gear
2. STEERING GEAR
			0
2.1 GENERAL
Maximum axial steering ball joint play	1.5 mm

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TECHNICAL DATA

		Steering gear	ΛΦ45/55 series
		2.2 TIGHTENING TORQUES
0
		The tightening torques specified in this section
		are different from the standard tightening torques
		cited in the overview of the standard tightening
		torques. The other threaded connections not
		specified must therefore be tightened to the
		torque cited 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.
		High-pressure filter, RAS-EC system
		Filter cap	15 Nm

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	TECHNICAL DATA
ΛΦ45/55 series	Drive shafts, drive and chassis
3. DRIVE SHAFTS, DRIVE AND CHASSIS
			0
3.1 GENERAL

Allison gearbox

The oil level when cold must be on the "Cold full" mark.

FULL

HOT

HOT	ADD
COLD	FULL

ADD

COLD

W 3 03 099

Dipstick readings:
"Cold add"	add when cold
"Cold full"	full when cold
"Hot add"	add when hot
"Hot full"	full when hot
5.12 rear axle
Sealant for crown wheel guide bolt	Loctite 572
F36/F48 front axle
Wheel bearing play (to adjust play)	0.05 - 0.20 mm

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TECHNICAL DATA

Drive shafts, drive and chassis ΛΦ45/55 series

3.2 TIGHTENING TORQUES

0

The tightening torques stated in this section 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 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.

ZF S5-42 gearbox
Level check/filler
plug (2)	50 Nm
Drain plug (1)	50 Nm

2

		1
		V3 00 395
ZF 6S-850 gearbox
Level check/filler		1
plug (1)	50 Nm
Drain plug (2)	60 Nm

2

V3 00 884

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		TECHNICAL DATA
ΛΦ45/55 series		Drive shafts, drive and chassis
Eaton FS6309A gearbox		0
Level check/filler
plug (1)	50 Nm
Drain plug/oil		1
strainer (4)	50 Nm

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V3 00 376

Allison 1000 & 2000 automatic gearboxes

Gearbox drain
plug (1)	35 Nm

1

V3 00 885

	Oil cooler air bleed		1
	plug (1)	28 Nm
	Oil cooler drain
	plug (2)	28 Nm

2

V3 00 883

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TECHNICAL DATA

	Drive shafts, drive and chassis		ΛΦ45/55 series
0	Allison MD3060 automatic gearbox		2
	Drain plug (1)	28 Nm
	Oil filter cover
	attachment bolts (2)	55 Nm

1

V300371

F36/F48 front axle
Tightening torque for
brake calliper
attachment bolts	213 Nm
Tightening sequence
for attachment bolts
Hub lock nut	75 Nm

		6	3	2	1	4	5
							R600520
Front axles
M18 x 1.5 wheel nut		370 Nm (1)
(LF 45 version 6/8 ton GVW)
M20 x 1.5 wheel nut		485 Nm (1)
(LF 45 version 10/11/12 ton GVW)
M20 x 1.5 wheel nut		485 Nm (1)
(LF 55 version 13/14/15 ton GVW)
M22 x 1.5 wheel nut		700 Nm (1)
(LF 55 version 18 ton GVW)
LF 45 U-bolt nut		215 Nm (2)
U-bolt nut, LF 55 version 13/14/15 ton GVW		470 Nm (2)
U-bolt nut, LF 55 version 18 ton GVW		535 Nm (2)
(1)	Retighten after 100 km.
(2)	Evenly tighten the two U-bolt nuts alternately.

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				TECHNICAL DATA
ΛΦ45/55 series				Drive shafts, drive and chassis
Rear axles
						0
M18 x 1.5 wheel nut			Nm (1)
(LF 45 version 6/8 ton GVW)		370
M20 x 1.5 wheel nut			Nm (1)
(LF 45 version 10/11/12 ton GVW)		485
M20 x 1.5 wheel nut			Nm (1)
(LF 55 version 13/14/15 ton GVW)		485
M22 x 1.5 wheel nut			Nm (1)
(LF 55 version 18 ton GVW)		700
LF 45 U-bolt nut		470	Nm (2)
U-bolt nut, LF 55 version 13/14/15 ton GVW		470	Nm (2)
U-bolt nut, LF 55 version 18 ton GVW		700	Nm (2)
(1)	Retighten after 100 km.
(2)	Evenly tighten the two U-bolt nuts alternately.
1132 rear axle
Filler and drain plugs/hub plugs (Torx)		85 Nm
Differential
Locking nut of crown wheel guide bolt		110	Nm
Differential drain plug		54 Nm
Drive shafts
5/16" UNF clamping bracket
Tightening torque		38 Nm
Retightening torque		36 Nm
3/8" UNF clamping bracket
Tightening torque		70 Nm
Retightening torque		67 Nm

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TECHNICAL DATA

		Drive shafts, drive and chassis	ΛΦ45/55 series
		3.3 FILLING CAPACITIES
0
		ZF gearboxes
		S5-42	approx. 3.2 litres
		6S-850	approx. 7.5 litres
		Eaton gearboxes
		FS6309A	approx. 8.5 litres
		Allison automatic gearboxes
		1000 & 2000	approx. 10 litres
		MD3060	approx. 20 litres

Note:

The above filling capacities are approximate capacities, excluding external pipes and cooler

Differential

5.10

5.12

5.14

8.20

10.20

10.26

11.26

1132 axle differential

Minimum caster Maximum caster

Wheel hub

5.10

5.12

5.14

8.20

approx. 4.0 litres approx. 4.0 litres approx. 4.0 litres approx. 8.0 litres approx. 9.0 litres approx. 9.0 litres approx. 9.0 litres

approx. 15 litres approx. 17.5 litres

0.25 litre per hub

0.25 litre per hub

0.25 litre per hub

0.25 litre per hub

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THREADED CONNECTIONS

ΛΦ45/55 series	Contents
CONTENTS
Page	Date

1. THREADED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200515

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200515

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THREADED CONNECTIONS

Contents ΛΦ45/55 series

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	THREADED CONNECTIONS
ΛΦ45/55 series	Threaded connections
1. THREADED CONNECTIONS
1.1 GENERAL
The components may have threaded connections
that have been treated with lubricant (dipped
threaded connection). Galvanised bolts and nuts
are wax dipped in the factory. Black annealed
			2
and phosphatised bolts and nuts are oil dipped.
The advantage of using dipped nuts and bolts is
that friction during tightening is reduced, so that
the specified pre-tension force can be accurately
obtained. The tightening torque can be reduced
while the pre-tension force remains the same.
To achieve a small spread in the pre-tension
force, the dipped threaded connection must be
tightened accurately.
Therefore, always use a reliable torque wrench
that provides a high degree of accuracy.
Note:
Have torque wrenches regularly inspected and
calibrated.

Re-use of fasteners (bolt/nut/threaded end)

1.Clean the thread (take particular care to remove locking compound residues) and the clamping faces

2.Check the thread for damage.

To do so, manually screw a new nut/bolt onto the thread to be checked.

If the new nut/bolt cannot be fully handscrewed onto the entire thread of the fastener to be checked, the fastener is not allowed to be re-used.

3.Apply one drop of engine oil to the upper turn of the bolt (threaded end)/lower turn of the nut and one drop to the clamping faces (other lubricants are not allowed).

4.If a locking compound has been specified, oil should not be applied to the thread.

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Please consult the workshop manual for the specified tightening torque.

THREADED CONNECTIONS

Threaded connections

The following applies to all threaded connections (for both new and used vehicles):

-in the case of standard connections, apply the lubricant before fitting, and (re)tighten in accordance with the standard for dipped bolts;

-in the case of special connections, apply the

2lubricant before fitting, and (re)tighten in accordance with the values specified in the instructions.

The instructions for using lubricants also apply to new bolts from the warehouse. Dry threaded connections may not be used because of their }highly variable friction coefficients.

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ΛΦ45/55 series

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FLUIDS, OIL AND LUBRICANTS

ΛΦ45/55 series	Contents
CONTENTS
Page	Date

1. SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200515

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200515

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FLUIDS, OIL AND LUBRICANTS

Contents ΛΦ45/55 series

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Avoid contact with: Lubricants Coolant

Fuel Clutch fluid

In the event of contact with the skin: remove the liquid with paper or a cloth, wash with soap and water. If irritation persists, consult a doctor. In the event of contact with the eyes: remove with a cloth and rinse with water. If irritation persists, consult a doctor.

If swallowed: DO NOT induce vomiting. Rinse mouth, drink two glasses of water and consult a doctor.

In the event of inhalation: get fresh air and rest.

		FLUIDS, OIL AND LUBRICANTS
	ΛΦ45/55 series	Specifications
	1. SPECIFICATIONS
	1.1 GENERAL
	IN ORDER TO SATISFY THE WARRANTY
	CONDITIONS AND GUARANTEE THE
	LIFESPAN, SAFETY AND RELIABILITY OF
	DAF PRODUCTS, IT IS OF THE UTMOST
	IMPORTANCE THAT THE CORRECT FLUIDS,
	OIL AND LUBRICANTS, COOLANT AND FUEL
	ARE USED AND THAT THE REQUIRED
	REPLACEMENT INTERVALS ARE	3
	OBSERVED.

Lubricant, engine coolant and fuel additives - of whatever type - must not be used except in those circumstances specified by DAF.

Always follow the safety instructions below and the instructions that are supplied with the product.

Ask your lubricant and fuel supplier(s) whether the products supplied comply with DAF specifications.

DAF is not liable for damage or problems in the following instances:

1. use of oil of a lower grade than specified. 2. use of oil of a different viscosity than

specified.

3. if the change interval is exceeded.

4. if fuel, lubricants or coolants have been used which do not meet the requirements

}specified by DAF.

Note:

Refer to the "Fluids and lubricants" specification manual for the prescribed fluid, oil and lubricant specifications.

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FLUIDS, OIL AND LUBRICANTS

Specifications ΛΦ45/55 series

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1-2

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MAINTENANCE SCHEDULE

ΛΦ45/55 series	Contents
CONTENTS
Page	Date

1. MAINTENANCE INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200515 1.1 Maintenance schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200515 1.2 Explanatory notes on the maintenance schedule . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200515 1.3 Effect of diesel fuel and PTO hours on maintenance intervals . . . . . . . . . 1-4 . . . . . 200515 1.4 Maintenance in special operating conditions. . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . 200515 1.5 First service inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . 200515

2. MAINTENANCE ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200515 2.1 Overview of maintenance activities for the first service inspection . . . . . . 2-1 . . . . . 200515 2.2 Overview of annual maintenance activities . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200515 2.3 Overview of mileage-dependent maintenance activities . . . . . . . . . . . . . . 2-4 . . . . . 200515

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MAINTENANCE SCHEDULE

Contents ΛΦ45/55 series

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