DAF LF45 LF55 Maintenance Manual

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Maintenance manual LF45/55

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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.

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ΛΦ45/55 series

STRUCTURE

Structure

TECHNICAL DATA

THREADED CONNECTIONS

FLUIDS, OIL AND LUBRICANTS

MAINTENANCE SCHEDULE

EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

200515

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TECHNICAL DATA

ΛΦ45/55 series

0 Technical data

CONTENTS

Page Date

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

Contents

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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

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

1.2 TIGHTENING TORQUES

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

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

2. STEERING GEAR

2.1 GENERAL

Maximum axial steering ball joint play 1.5 mm

Steering gear

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TECHNICAL DATA

Steering gear

2.2 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

3. DRIVE SHAFTS, DRIVE AND CHASSIS

3.1 GENERAL

Allison gearbox

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

Drive shafts, drive and chassis

HOT

FULL

HOT

ADD

FULL

COLD

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

ADD

COLD

W 3 03 099

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TECHNICAL DATA

Drive shafts, drive and chassis

3.2 TIGHTENING TORQUES

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

ΛΦ45/55 series

ZF 6S-850 gearbox

Level check/filler plug (1) 50 Nm

Drain plug (2) 60 Nm

V3 00 395

V3 00 884

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TECHNICAL DATA

ΛΦ45/55 series

Eaton FS6309A gearbox

Level check/filler plug (1) 50 Nm

Drain plug/oil strainer (4) 50 Nm

Allison 1000 & 2000 automatic gearboxes

Gearbox drain plug (1) 35 Nm

Drive shafts, drive and chassis

V3 00 376

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

V3 00 885

V3 00 883

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TECHNICAL DATA

Drive shafts, drive and chassis

Allison MD3060 automatic gearbox

Drain plug (1) 28 Nm Oil filter cover

attachment bolts (2) 55 Nm

F36/F48 front axle

Tightening torque for brake calliper attachment bolts 213 Nm

Tightening sequence for attachment bolts

Hub lock nut 75 Nm

ΛΦ45/55 series

V300371

6 23 1 54

Front axles

M18 x 1.5 wheel nut (LF 45 version 6/8 ton GVW) 370 Nm M20 x 1.5 wheel nut (LF 45 version 10/11/12 ton GVW) 485 Nm M20 x 1.5 wheel nut (LF 55 version 13/14/15 ton GVW) 485 Nm M22 x 1.5 wheel nut (LF 55 version 18 ton GVW) 700 Nm LF 45 U-bolt nut 215 Nm U-bolt nut, LF 55 version 13/14/15 ton GVW 470 Nm U-bolt nut, LF 55 version 18 ton GVW 535 Nm

(1) Retighten after 100 km. (2) Evenly tighten the two U-bolt nuts alternately.

R600520

(1)

(2)

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TECHNICAL DATA

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Rear axles

M18 x 1.5 wheel nut (LF 45 version 6/8 ton GVW) 370 Nm

M20 x 1.5 wheel nut (LF 45 version 10/11/12 ton GVW) 485 Nm

M20 x 1.5 wheel nut (LF 55 version 13/14/15 ton GVW) 485 Nm M22 x 1.5 wheel nut (LF 55 version 18 ton GVW) 700 Nm LF 45 U-bolt nut 470 Nm U-bolt nut, LF 55 version 13/14/15 ton GVW 470 Nm U-bolt nut, LF 55 version 18 ton GVW 700 Nm

(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, drive and chassis

(1)

(2)

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

3.3 FILLING CAPACITIES

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 approx. 4.0 litres

5.12 approx. 4.0 litres

5.14 approx. 4.0 litres

8.20 approx. 8.0 litres

10.20 approx. 9.0 litres

10.26 approx. 9.0 litres

11.26 approx. 9.0 litres

ΛΦ45/55 series

1132 axle differential

Minimum caster approx. 15 litres Maximum caster approx. 17.5 litres

Wheel hub

5.10 0.25 litre per hub

5.12 0.25 litre per hub

5.14 0.25 litre per hub

8.20 0.25 litre per hub

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THREADED CONNECTIONS

ΛΦ45/55 series

2 Threaded connections

CONTENTS

Page Date

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

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

Contents

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THREADED CONNECTIONS

Contents

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THREADED CONNECTIONS

ΛΦ45/55 series

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 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.

Threaded connections

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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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 lubricant 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.

Please consult the workshop manual for the specified tightening torque.

}

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FLUIDS, OIL AND LUBRICANTS

ΛΦ45/55 series

3 Fluids, oil and lubricants

CONTENTS

Page Date

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

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

Contents

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FLUIDS, OIL AND LUBRICANTS

Contents

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FLUIDS, OIL AND LUBRICANTS

ΛΦ45/55 series

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 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.

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.

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.

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

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MAINTENANCE SCHEDULE

ΛΦ45/55 series

4 Maintenance schedule

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

Contents

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MAINTENANCE SCHEDULE

Contents

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MAINTENANCE SCHEDULE

ΛΦ45/55 series

1. MAINTENANCE INTERVALS

1.1 MAINTENANCE SCHEDULE

The service intervals stated in the maintenance schedule are based on use of the oils and fuels specified by DAF.

Maintenance

schedule

LF45 LF55

X service

40.000 km

Y service

1x per YEAR

(1)

1 year

max. 100.000 km

Maintenance intervals

1 year

max. 100.000 km

Ext.

1. Automatic gearboxes are subject to different changing intervals; see maintenance schedule notes. Extended changing interval not permitted for ZF 6S-850 gearbox.

2. Changing interval for 1132 rear axle 450,000 km max.

40.000 km

3 year

max. 180.000 km

1 year

max. 100.000 km

3 year

max. 300.000 km

1 year

max. 150.000 km

3 year

max. 450.000 km

2 year

max. 120.000 km

1 year

max. 100.000 km

3 year

max. 300.000 km

1 year

max. 150.000 km

3 year

max. 300.000 km

(2)

G000318

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MAINTENANCE SCHEDULE

Maintenance intervals

1.2 EXPLANATORY NOTES ON THE MAINTENANCE SCHEDULE

Maintenance group classification

Depending on the use to which the vehicle is put, the vehicle is placed in maintenance group I, II or III.

Maintenance group I

Operation on building sites, in quarries, etc.

- Operation on unmetalled roads

- Traffic in dusty conditions

- Sanitation department vehicles

- Distribution transport with an annual mileage of up to 30,000 km.

Maintenance group II

Urban and regional transport

- Distribution traffic in urban areas

- Traffic between adjacent villages/cities

Maintenance group III

(Inter)national traffic

ΛΦ45/55 series

- Long-distance/very long-distance traffic

Standard changing interval

This is the standard changing interval symbol.

See the "Fluids and lubricants" specifications manual for the prescribed oil specification.

Extended changing interval

This is the extended changing interval symbol.

If the prescribed oil specification and any additional conditions (see specification manual "Fluids and lubricants") are complied with, an extended changing interval may be applied.

G0 00 230

Ext.

G0 00 229

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MAINTENANCE SCHEDULE

ΛΦ45/55 series

X service

This is the symbol for an X service.

An X service is a mileage-dependent maintenance check which consists of changing the engine oil plus a number of visual inspections.

Note:

An X service must be carried out at least once a year.

Y service

This is the symbol for a Y service.

A Y service is an annual maintenance check consisting of several maintenance activities plus changing of the gearbox and rear axle oil.

Note:

If the prescribed oil specification (see specification manual "Fluids and lubricants") is complied with, an extended changing interval may be applied. Automatic gearboxes are subject to different changing intervals.

Maintenance intervals

X service

G000086

Y service

1x per YEAR

(1)

G000087

Automatic Allison gearbox

Maintenance group I Standard changing interval 1 year/maximum

40,000 km Extended changing interval 3 years/maximum 80,000 km

Maintenance group II Standard changing interval 1 year/maximum

40,000 km Extended changing interval 3 years/maximum 160,000 km

Maintenance group III Standard changing interval 1 year/maximum

40,000 km Extended changing interval 3 years/maximum 160,000 km

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MAINTENANCE SCHEDULE

Maintenance intervals

ΛΦ45/55 series

1.3 EFFECT OF DIESEL FUEL AND PTO HOURS ON MAINTENANCE INTERVALS

Diesel fuels

Sulphur content Engine oil change interval

> 0,2% Halve interval to max. of 25,000 km

PTO hours

PTO hours should be converted into mileage according to the following formula:

1 PTO hour = 40 km

1.4 MAINTENANCE IN SPECIAL OPERATING CONDITIONS

Contact a DAF dealer/main branch or importer for vehicles used in very specific or heavy conditions. The service intervals can be modified, if necessary, in consultation with the dealer/main branch or importer to fit the appropriate operating conditions.

1.5 FIRST SERVICE INSPECTION

The first service inspection should be carried out between the first 7,500 and 10,000 km or at most 8 weeks after delivery of the vehicle, whichever comes first.

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MAINTENANCE SCHEDULE

ΛΦ45/55 series

Maintenance activities

2. MAINTENANCE ACTIVITIES

2.1 OVERVIEW OF MAINTENANCE ACTIVITIES FOR THE FIRST SERVICE

INSPECTION

- Replacing the automatic gearbox oil filters

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MAINTENANCE SCHEDULE

Maintenance activities

ΛΦ45/55 series

2.2 OVERVIEW OF ANNUAL MAINTENANCE ACTIVITIES

ANNUAL MAINTENANCE ACTIVITIES (Y-SERVICE)

"Correct, if necessary, after inspection"

CAB AND ELECTRICAL SYSTEM

O Check pedal rubbers O Check whether the latest version of the ITS manual is kept in the cab O Replace the cab filter element - See note 1 Replaced O Yes O No O Check the fluid level of the cab tilting pump O Check cab fastening

ENGINE, COOLING SYSTEM AND FUEL SYSTEM

O Replace the air filter element O Check the air inlet dust trapping valve O Check the vibration damper (vulcanised version) O Check/adjust the valve clearance - See note 4 Done O Yes O No O Check the coolant freezing point O Change the coolant - See note 5 Changed O Yes O No O Remove the fuel fine filter

STEERING GEAR AND BRAKE SYSTEM

O Check the steering ball joints O Replace the air dryer filter element O Check the brake cylinder fastening O Check/adjust the load-dependent control valve O Replace the steering gear filter element if the vehicle is equipped

with the RAS-EC system - See note 6 Replaced O Yes O No

O Replace the steering gear high-pressure filter if the vehicle is

equipped with the RAS-EC system - See note 6 Replaced O Yes O No

DRIVE AND CHASSIS

O Change the differential oil - See note 2 Changed O Yes O No O Change the hub oil - See note 2 Changed O Yes O No O Check operation of the differential lock O Check the drive shaft play O Check attachment of the clamp of the drive shaft universal joint O Adjust the crown wheel guide bolt in case of a 5.12 rear axle O Check for noticeable wheel bearing play in case of a 5.10, 5.12,

5.14 and 8.20 rear axle - See note 1 Done O Yes O No O Change the gearbox oil - See note 3 Changed O Yes O No O Replace the grease of grease-lubricated hubs, F36 and F48 front

axles - See note 1 Replaced O Yes O No O Check the fifth wheel O Check the trailer coupling O Check superstructure attachment O Lubricate according to Y-service lubrication schedule

OTHER ACTIVITIES

O Check whether there are any field actions that still need to be performed on the vehicle

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MAINTENANCE SCHEDULE

ΛΦ45/55 series

Note:

1. Every 2 years.

2. For changing interval: see maintenance

schedule.

3. For changing interval: see maintenance

schedule. When changing the gearbox oil in an automatic gearbox, the automatic gearbox oil filters must also be replaced.

4. Check the valve clearance at the 4

Y-service (at a maximum of 240,000 km) and then check and adjust, where necessary, every year.

- 6th- 7th... year).

5. Every 5 years.

6. Every 3 years.

Maintenance activities

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MAINTENANCE SCHEDULE

Maintenance activities

ΛΦ45/55 series

2.3 OVERVIEW OF MILEAGE-DEPENDENT MAINTENANCE ACTIVITIES

MILEAGE-DEPENDENT MAINTENANCE ACTIVITIES (X-SERVICE)

"Correct if necessary after inspection"

CAB AND ELECTRICAL SYSTEM

O Check/clean the battery terminals O Check/top up the battery fluid level

ENGINE, COOLING SYSTEM AND FUEL SYSTEM

O Change the engine oil O Replace the oil filter O Replace the fuel prefilter/water separator filter element O Check for fuel leaks O Check the poly-V belt Replaced O Yes O No O Check the components and hose connections for leaks O Check the radiator and intercooler for fouling O Check the exhaust system

STEERING GEAR AND BRAKE SYSTEM

O Check the steering ball joint sleeve for damage O Check the steering oil level O Check the steering gear lines and connections O Check the brake components and brake system for leaks O Check the brake pad thickness and brake disc

DRIVE AND CHASSIS

O Check the clutch fluid level O Check the clutch wear indicator O Check the differential for leaks - See note 1 O Check the oil lubricated wheel hubs for leaks - See note 1 O Check the greased wheel hubs for leaks O Check the gearbox for leaks - See note 2 O Clean gearbox vent and rear axle vent on "offroad/semi-offroad" vehicles O Check the shock absorbers for attachment and leaks O Check the condition and attachments of spring leaves, spring clamps and U-bolts O Check the hinge points and axle suspension fastening (air suspension) O Check the air suspension bellows O Lubricate according to X-service lubrication schedule

OTHER ACTIVITIES

O Check whether "Field actions" still need to be carried out on the vehicle

Note:

1. For the changing interval see the

maintenance schedule.

2. For the changing interval see the

maintenance schedule. When changing the gearbox oil in an automatic gearbox, the automatic gearbox oil filters must also be replaced.

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

5 Explanatory notes on the maintenance activities

CONTENTS

Page Date

1. SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200515

1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200515

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200515

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200515

2.2 Technical information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200515

2.3 Warning symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200515

2.4 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200515

2.5 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200515

2.6 Maintenance guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200515

3. INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200515

Cab and electrical system

3.1 Checking pedal rubbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200515

3.2 Checking the battery fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200515

3.3 Checking the battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200515

3.4 Checking the fluid level of the cab tilting pump . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200515

3.5 Checking the cab fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200515

Engine, cooling system and fuel system

3.6 Checking the vibration damper (vulcanised version) of the BE engine . . . 3-3 . . . . . 200515

3.7 Bleeding the fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200515

3.8 Checking the engine oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . 200515

3.9 Checking and adjusting BE engine valve clearance . . . . . . . . . . . . . . . . . 3-6 . . . . . 200515

3.10 Inspection and adjustment, CE engine valve clearance . . . . . . . . . . . . . . 3-8 . . . . . 200515

3.11 Checking the poly-V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . 200515

3.12 Checking the coolant freezing point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . 200515

3.13 Checking for fuel leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . 200515

3.14 Checking the components and hose connections for leaks . . . . . . . . . . . 3-11 . . . . 200515

3.15 Checking the exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . 200515

3.16 Checking the radiator and intercooler for fouling. . . . . . . . . . . . . . . . . . . . 3-11 . . . . 200515

3.17 Check the air inlet dust trapping valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . 200515

Steering gear and brake system

3.18 Checking the steering ball joint sleeve for damage. . . . . . . . . . . . . . . . . . 3-12 . . . . 200515

3.19 Checking the steering ball joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 . . . . 200515

3.20 Checking the steering oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 . . . . 200515

3.21 Checking the steering gear lines and connections . . . . . . . . . . . . . . . . . . 3-15 . . . . 200515

3.22 Checking the brake components and brake system for leaks. . . . . . . . . . 3-16 . . . . 200515

3.23 Checking the brake cylinder fastening. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 . . . . 200515

3.24 Checking the brake pad thickness and brake disc . . . . . . . . . . . . . . . . . . 3-17 . . . . 200515

3.25 Inspection and adjustment, load sensing valve, air suspension . . . . . . . . 3-19 . . . . 200515

3.26 Inspection and adjustment, load sensing valve, leaf suspension . . . . . . . 3-21 . . . . 200515

Drive and chassis

3.27 Checking the differential for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 . . . . 200515

3.28 Checking the operation of the differential lock. . . . . . . . . . . . . . . . . . . . . . 3-23 . . . . 200515

3.29 Check the drive shaft play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 . . . . 200515

3.30 Inspecting the fifth wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24 . . . . 200515

3.31 Checking the trailer coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 . . . . 200515

3.32 Check the superstructure attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 . . . . 200515

3.33 Check the clutch fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27 . . . . 200515

3.34 Check the clutch wear indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 . . . . 200515

3.35 Checking the gearbox for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28 . . . . 200515

3.36 Checking automatic gearbox oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29 . . . . 200515

3.37 Inspection of oil lubricated wheel hubs for leaks . . . . . . . . . . . . . . . . . . . . 3-31 . . . . 200515

Contents

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Contents

3.38 Checking greased wheel hubs for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32 . . . . 200515

3.39 Checking the shock absorbers for attachment and leaks . . . . . . . . . . . . . 3-33 . . . . 200515

3.40 Checking the condition and attachments of spring leaves, spring clamps

and U-bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 . . . . 200515

3.41 Checking the hinge points and axle suspension fastening (air suspension) 3-34 . . . . 200515

3.42 Checking the air suspension bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 . . . . 200515

3.43 Adjusting the crown wheel guide bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 . . . . 200515

3.44 Inspecting the rear axle wheel bearing play . . . . . . . . . . . . . . . . . . . . . . . 3-37 . . . . 200515

3.45 Checking the clamp of the drive shaft universal joint. . . . . . . . . . . . . . . . . 3-38 . . . . 200515

4. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200515

Cab and electrical system

4.1 Removal and installation, interior filter element. . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200515

Engine, cooling system and fuel system

4.2 Removal and installation, air filter element . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200515

4.3 Removal and installation, lubricating oil filter. . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . 200515

4.4 Removal and installation, fuel fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200515

4.5 Removal and installation, fuel prefilter/water separator. . . . . . . . . . . . . . . 4-5 . . . . . 200515

4.6 Removal and installation, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 . . . . . 200515

Steering gear and brake system

4.7 Removal and installation, air dryer filter element. . . . . . . . . . . . . . . . . . . . 4-7 . . . . . 200515

4.8 Removal and installation, filter element in the reservoir of the RAS-EC

steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 . . . . . 200515

4.9 Removal and installation, high-pressure filter of the RAS-EC steering

gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 . . . . 200515

4.10 Removal and installation, F36/F48 front axle wheel hub. . . . . . . . . . . . . . 4-11 . . . . 200515

4.11 Removal and installation, F36/F48 front axle hub seal . . . . . . . . . . . . . . . 4-15 . . . . 200515

Drive and chassis

4.12 Removal and installation, automatic gearbox oil filters . . . . . . . . . . . . . . . 4-16 . . . . 200515

ΛΦ45/55 series

Page Date

5. DRAINING AND FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200515

Cab and electrical system

5.1 Topping up battery fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200515

Engine, cooling system and fuel system

5.2 Draining and replenishing the engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200515

5.3 Draining, filling and bleeding the cooling system. . . . . . . . . . . . . . . . . . . . 5-3 . . . . . 200515

Steering gear and brake system

5.4 Draining and filling, RAS-EC steering circuit . . . . . . . . . . . . . . . . . . . . . . . 5-5 . . . . . 200515

5.5 Bleeding the RAS-EC steering circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 . . . . . 200515

Drive and chassis

5.6 Draining and filling, differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 . . . . . 200515

5.7 Draining and filling, wheel hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 . . . . . 200515

5.8 Draining and filling, gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10 . . . . 200515

6. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200515

6.1 Cleaning the battery terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200515

6.2 Cleaning the exterior of radiator and air cooler . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . 200515

6.3 Cleaning the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 . . . . . 200515

6.4 Cleaning gearbox vent(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 . . . . . 200515

6.5 Cleaning rear axle vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 . . . . . 200515

7. LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200515

7.1 Lubricating according to Y-service lubrication schedule . . . . . . . . . . . . . . 7-1 . . . . . 200515

7.2 Lubricate according to X-service lubrication schedule. . . . . . . . . . . . . . . . 7-3 . . . . . 200515

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1. SAFETY INSTRUCTIONS

1.1 SAFETY INSTRUCTIONS

Comply with all the warnings and safety precautions given in this maintenance manual.

First read the instructions and warnings on the labels and stickers that are affixed to various components on the vehicle and follow them. They are provided for your safety and health, so do not ignore them.

Wear clean, fitted clothes and apply protective cream to unprotected parts of your body, if necessary.

Do not run the engine in an enclosed or unventilated area. In other words, make sure that the exhaust gases are effectively extracted.

Remain at a safe distance from rotating and/or moving components.

Never remove the filler cap from the cooling system when the engine is at operating temperature.

Safety instructions

Be careful when changing the oil. Hot oil may cause serious injuries. Various oils and lubricants used on the vehicle may constitute a health hazard. Avoid unnecessary contact with drained oil. Frequent contact damages the skin. This also applies to engine coolant, windscreen washer fluid, refrigerant in air conditioning systems, battery acid and diesel fuel. So avoid inhalation and direct contact.

When carrying out operations under the cab, make sure the cab is fully tilted.

To avoid a fire hazard, the engine, the exhaust system and their surroundings must be kept free of flammable fluids and material such as dead leaves and dirt.

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Safety instructions

Where there is an engine encapsulation, if necessary, the encapsulation panels must be thoroughly cleaned after each inspection interval because of the risk of fire if the inside of the panels is dirty.

Always disconnect the earth connection of the battery before working on the vehicle.

Always use stands to support the chassis or components when working under the vehicle. Always charge batteries in a properly ventilated area and avoid creating sparks and naked flames. Fast charging should only be used in an emergency. When fast-charging, the battery positive and negative leads (+ and -) must be disconnected.

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2. GENERAL

2.1 INTRODUCTION

This maintenance manual describes all relevant maintenance activities. It also contains safety instructions, which must be strictly adhered to. Activities not described in this manual, e.g. replacing components, overhaul, fault-finding, etc., are described in the DAF workshop instructions.

This maintenance manual assumes that the mechanic is sufficiently experienced and has had the required instruction or training to carry out these maintenance activities in a safe and responsible manner.

The technical data and notes on the maintenance activities have been compiled with the utmost care.

General

2.2 TECHNICAL INFORMATION

The technical information in this maintenance manual, such as notes on maintenance activities and technical data required to carry out the maintenance activities in a safe manner, were upto-date at the time this manual went to press. DAF reserves the right to make changes without prior notice.

Note:

Important changes relating to technical information that is not contained in this manual will be made available in TI sheets (Technical Information Sheet).

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General

2.3 WARNING SYMBOL

When text is accompanied by the warning symbol shown here, the information provided is essential for the health and safety of the mechanic. This warning symbol is also shown if there are circumstances in which there is a vehicle safety hazard or damage to the vehicle could arise.

2.4 ENVIRONMENT

By carrying out the maintenance activities in a professional manner, on time and at regular intervals, you will help to reduce the impact on the environment. This means, for example, noticing and remedying possible leakages in time and keeping the engine in an optimum condition (adjusting valves, replacing air filter element etc.), thus reducing the emission of harmful exhaust gasses. It should be noted that oils and fluids contain harmful substances that have a negative impact on the environment. That is why you should take care that drained oils and fluids and also discarded oil and fuel filters, are collected in separate receptacles or containers. In short: maintenance activities must be

carried out in an environmentally aware manner.

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2.5 PARTS

All DAF parts and components have been carefully attuned to each other, a decisive factor in ensuring the original DAF quality. It is only logical, therefore, that the original DAF quality can be maintained best if original DAF parts and components are used when replacing parts or components. As far as maintenance activities are concerned, this includes components such as windscreenwiper blades, air-dryer elements, gaskets, V-belts and filters. For example, if "non-original DAF filters" are used, the engine will be insufficiently protected against fine microscopic airborne dust particles, almost imperceptible metal swarf in the oil and dirt in the fuel, resulting in:

- premature replacing of cylinders, pistons, bearings, valves, injector pump and other moving parts

- reduced engine performance

- increased fuel consumption

General

G000183

Therefore, always use original DAF parts and components.

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General

2.6 MAINTENANCE GUIDELINES

- When carrying out maintenance activities on the vehicle, it is important that the work is performed under the cleanest possible conditions. Filler caps, lubricating points, filler and drain plugs should be cleaned before and after maintenance activities.

- When excessive leakage has been detected at oil seals and/or components, or in case of excessive drops in the oil level, a report should be made and the cause should be remedied.

- It is important to check the gearbox breathers, transfer box, rear axle and driven front axle regularly for fouling and blockages. If the breathers are blocked by dirt, overpressure may cause leaks.

- Depending on the circumstances in which the vehicle is used, e.g. on very bad roads or construction sites, important bolt connections such as the fifth wheel, spring suspension, U-bolts, trailer coupling, steering box attachment, superstructure attachments etc. should be inspected more often and, if necessary, be retightened.

ΛΦ45/55 series

- It is important that a visual inspection and test run are carried out following the maintenance activities. Particular attention should be paid to components directly related to driving safety.

- Once a service has been completed new information on the next service (mileage/ date) can be entered on the instrument panel display using DAVIE XD via the VIC.

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3. INSPECTION AND ADJUSTMENT

3.1 CHECKING PEDAL RUBBERS

1. Check that the pedal rubbers are still securely mounted on the pedal.

2. Check that the pedal rubbers are not worn out and there is still sufficient tread.

3.2 CHECKING THE BATTERY FLUID LEVEL

Avoid sparks and open flames in the vicinity of batteries. Battery acid is

}

an aggressive fluid. In the event of contact with the skin: rinse the skin with plenty of water for a sustained period. If redness or pain persists, consult a doctor. Remove any clothing affected and rinse with water. In the event of contact with the eyes: rinse with plenty of water for at least 15 minutes and consult a doctor. If swallowed: do NOT induce vomiting. Rinse the mouth, drink two glasses of water and consult a doctor. In the event of inhalation: get fresh air, rest and consult a doctor.

Inspection and adjustment

1. Check the electrolyte level. The electrolyte level must be approx. 10 mm above the plates or up to the level indicator if available.

2. If necessary, top up the batteries, see chapter "Draining and filling".

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Inspection and adjustment

3.3 CHECKING THE BATTERY TERMINALS

1. Visually check the battery terminals for corrosion. Clean the battery terminals if necessary, see chapter "Cleaning".

2. Check the attachment of the battery terminals.

3.4 CHECKING THE FLUID LEVEL OF THE CAB TILTING PUMP

ΛΦ45/55 series

G0 00 208

1. Check the fluid level when the cab is in the driving position.

2. The cock (3) should be in the "" position (clockwise).

3. Loosen the filler plug (1) 3 to 4 turns and wait until any overpressure has left the reservoir. Then remove the filler plug (1) and check the sealing ring (2), replace if necessary.

4. Start pumping with a maximum of five pump strokes, making sure that the pump lever is in the bottom position when finished.

5. Then check the fluid level. This level should be no more than 2 cm below the top of the filling opening. Top up if necessary.

6. Fit the filler plug (1) and hand tighten it.

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Inspection and adjustment

3.5 CHECKING THE CAB FASTENING

1. Tilt the cab.

2. Check that all attachment bolts are in place.

3. Visually inspect the attachment of the cab to the tilting mechanism.

4. Visually inspect the seals and condition of the tilting mechanism.

Engine, cooling system and fuel system

3.6 CHECKING THE VIBRATION DAMPER (VULCANISED VERSION)

OF THE BE ENGINE

1. Check that the marks on the vibration damper are aligned. If the marks are not in line, the vibration damper must be replaced.

2. Check the rubber part for damage. If the rubber part shows cracks or there are bits of rubber missing, the vibration damper must be replaced.

G0 00 199

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Inspection and adjustment

3.7 BLEEDING THE FUEL SYSTEM

Stop pumping as soon as a greater resistance is felt. If you continue

}

Note:

When the hand pump is used, the fuel system will be automatically bled. Air will be fed back to the tank through the return pipe.

1. Unscrew the button of the primer pump and

2. Use the primer pump until a clearly higher

3. Press the button and tighten it.

pumping, the fuel system may become internally damaged.

pull it out.

resistance is perceptible.

ΛΦ45/55 series

G0 00 209

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3.8 CHECKING THE ENGINE OIL LEVEL

1. Ensure that the vehicle is entirely horizontal.

2. Pull the dipstick (2) out of the holder.

3. Wipe the dipstick clean with a lint-free cloth.

4. Put the dipstick back into the holder.

5. Pull the dipstick out again and check the oil level.

Note:

It takes approx. 20 minutes for all the oil to run into the sump when the engine is "warm". If the dipstick is checked immediately after switching the engine off or immediately after oil has been added, the level shown on the dipstick will be too low.

6. Fill oil through the filler opening (1) until the oil level reaches the maximum mark. See "Draining and filling". Always use the specified oil. Do not top up above maximum level.

Inspection and adjustment

G0 00 212

Note:

For the difference between minimum and maximum engine oil level, see "Technical data".

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Inspection and adjustment

3.9 CHECKING AND ADJUSTING BE ENGINE VALVE CLEARANCE

Note:

Checking and adjusting valve clearance must only be done when the engine is cold.

1. Remove the valve cover. See "Removing and installing".

2. Use an open-end spanner on the fan shaft to turn the crankshaft clockwise, as seen from the vibration damper end (this is the engine's normal direction of rotation), until the mark (A) is between the bolts (B) and the valves of cylinder 1 are in overlap position.

Note:

"Overlap" is the moment at which the inlet valves start opening and the exhaust valves stop closing. The inlet valves are operated by the short rockers and the exhaust valves by the long rockers.

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3. Check/correct the valve clearance of the specified inlet and exhaust valves. Set the correct valve clearance by loosening the lock nut and rotating the adjusting screw in the correct direction; see "Technical data" for the correct valve clearance.

Cylinder Inlet valve Exhaust valve

4XX

4. Using an open-end spanner on the fan shaft, turn the crankshaft one rotation further so that the mark (A) is once again between the bolts (B) and the valves of cylinder 4 overlap.

Inspection and adjustment

M201064

5. Check/correct the valve clearance of the specified inlet and exhaust valves. Set the correct valve clearance by loosening the lock nut and rotating the adjusting screw in the correct direction; see "Technical data" for the correct valve clearance.

Cylinder Inlet valve Exhaust valve

1X X

6. Fit the valve cover. See "Removing and installing".

7. Fit the flexible pipe, air inlet pipe and bracket.

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Inspection and adjustment

ΛΦ45/55 series

3.10 INSPECTION AND ADJUSTMENT, CE ENGINE VALVE CLEARANCE

Note:

Inspection and adjustment of valve clearance must only be carried out when the engine is cold.

1. Remove the valve cover. See "Removal and installation".

Note:

"Overlap" is the moment at which the inlet valves start opening and the exhaust valves stop closing. The inlet valves are operated by the short rockers and the exhaust valves by the long rockers.

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3. Check/correct the valve clearance of the specified inlet and exhaust valves. Set the correct valve clearance by loosening the locknut and rotating the adjusting screw in the correct direction; see "Technical data" for the correct valve clearance.

Cylinder Inlet valve Exhaust valve

Inspection and adjustment

M201064

6X X

4. Using an open-end spanner on the fan shaft, turn the crankshaft one rotation further so that the mark (A) is once again between the bolts (B) and the valves of cylinder 6 overlap.

5. Check/correct the valve clearance of the specified inlet and exhaust valves. Set the correct valve clearance by loosening the locknut and rotating the adjusting screw in the correct direction; see "Technical data" for the correct valve clearance.

Cylinder Inlet valve Exhaust valve

1X X

M201065

6. Fit the valve cover. See "Removal and installation".

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Inspection and adjustment

3.11 CHECKING THE POLY-V-BELT

1. Check the poly-V-belt for damage and signs of serious wear.

3.12 CHECKING THE COOLANT FREEZING POINT

When the coolant is hot, there is an overpressure in the cooling system.

}

Carefully remove the filler cap to release the overpressure. Do not remove the filler cap when the engine is running. Coolant is a toxic fluid. Contact with the skin should therefore be avoided. In the event of contact with the skin: remove with paper or a cloth, wash with soap and 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 some fresh air and rest. In order to avoid damaging the cylinder block, do not top up a warm engine with coolant.

ΛΦ45/55 series

1. Check the anti-freeze content of the coolant. Fill the cooling system with anti-freeze, if this has not been done yet. Always use only coolants that meet DAF specifications.

2. Consult the manufacturer’s instructions for the correct anti-freeze mixing ratio. Preferably, use 40% anti-freeze on an ethylene glycol base. At this percentage, not only good frost protection, but also good corrosion protection is guaranteed.

-10

-20

-30

-40

-50

-60

-70

-80

10009010802070306040505040603070208010

Ethyleenglycol

100

M2016

3-10

200515

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

Inspection and adjustment

3.13 CHECKING FOR FUEL LEAKS

1. Visually inspect all hose connections and fuel system components for leaks.

3.14 CHECKING THE COMPONENTS AND HOSE CONNECTIONS FOR LEAKS

1. Check all hose connections and cooling system components for leaks.

2. Check the hose connections and inlet system components.

3.15 CHECKING THE EXHAUST SYSTEM

1. Visually inspect the exhaust system for leaks.

2. Check the exhaust suspension points.

3. Check that no heat transfer (due to accumulated dirt, for example) can take place to the exhaust system area, such as pipes, components etc.

3.16 CHECKING THE RADIATOR AND INTERCOOLER FOR FOULING

1. Visually inspect the radiator and intercooler for fouling If necessary, clean the radiator and intercooler, see "Cleaning".

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Inspection and adjustment

3.17 CHECK THE AIR INLET DUST TRAPPING VALVE

1. Check the rubber sealing valve (1) at the bottom of the filter housing for clogging and damage.

Steering gear and brake s ystem

ΛΦ45/55 series

I4 00 535

3.18 CHECKING THE STEERING BALL JOINT SLEEVE FOR DAMAGE

Inspection, locking devices and dust cover

1. Check that the steering ball joint dust cover or seal is not damaged. Replace the steering ball joint if damaged.

2. If a castle nut is fitted, check that the locking devices are present and undamaged.

S7 00 592

3-12

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ΛΦ45/55 series

3.19 CHECKING THE STEERING BALL JOINTS

Checking axial steering ball joint play

1. Check the axial steering-ball joint play using special tool (DAF no. 1329426)

2. First jack up the axle until the wheels come off the ground and put the axle on stands.

3. Make sure that the castle nut split pin (if fitted) at the nut does not come into contact with the head of the threaded end.

4. Screw the thrust washer (8) on to the threaded spindle.

5. Fit the spring retainer (3), spring (4) and pressure sleeve (6) into bracket (1). Fit the locking screw (5). It should be possible to move the pressure sleeve (6) freely.

Note:

Fit the correct pressure sleeve (6). The pressure sleeve (6) must abut the outer edge of the steering ball joint (7).

6. Loosen thrust bolt (2) until the pressure sleeve (6) with the flange abuts the bracket (A = 0 mm).

7. Fit the special tool over the steering ball joint (7) and turn the threaded spindle (9) by hand until the special tool is tight around the steering ball joint (7).

8. Tighten thrust bolt (2) until its head abuts bracket (1).

Inspection and adjustment

4 3

S700426

9. Measure play "A" between the pressure sleeve and the bracket using a feeler gauge. Compare the reading with the maximum permissible steering ball joint play, see "Technical data". If necessary, replace the steering ball joint.

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Inspection and adjustment

3.20 CHECKING THE STEERING OIL LEVEL

1. Check the steering oil level when the engine is not running.

2. Tilt the cab.

3. Clean the dipstick and its surroundings so that absolutely no dirt can get into the reservoir.

4. Check the fluid level in the reservoir using the dipstick.

5. The fluid level should be between the marks when the steering oil is "cold".

Note:

When the steering oil is at operating temperature, the level may be above the top mark.

ΛΦ45/55 series

G0 00 214

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ΛΦ45/55 series

Inspection and adjustment

3.21 CHECKING THE STEERING GEAR LINES AND CONNECTIONS

1. Condition of the pipes

- Check all pipes for tightness and wear.

Where supply pipes are subject to negative pressure, it is particularly likely that porous pipes will give rise to problems (air in the system).

- If in doubt, always replace the line.

2. Pipe connections

- Check every pipe connection for leaks.

3. Line route

- Pipes must not be twisted during

assembly. To facilitate checking this, a mark may have been provided on the hose (sometimes in the form of text).

- Pipes should not touch other parts (to

prevent chafing).

- The course pipes follow should not

include any sharp bends; this applies especially to the flexible suction and return pipes.

- Pipes should not be pinched off by other

components.

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Inspection and adjustment

ΛΦ45/55 series

3.22 CHECKING THE BRAKE COMPONENTS AND BRAKE SYSTEM FOR LEAKS

1. While operating the service brake, check whether any leaks occur in the brake system. If the brake system of a vehicle has been charged to the maximum pressure, it should generally be possible to drive the vehicle after a period of 16 hours of uninterrupted standstill, without having to first charge the brake system to adequate operating pressure. This implies a maximum pressure drop of approx. 0.4 bar per hour at normal system pressure.

Note:

Always connect auxiliary consumers and accessories to circuit 4.

3.23 CHECKING THE BRAKE CYLINDER FASTENING

1. Check that the brake cylinders do not move during operation of the service brake.

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Inspection and adjustment

3.24 CHECKING THE BRAKE PAD THICKNESS AND BRAKE DISC

Version: Knorr SB 7000

1. Check whether guide bush (4) protrudes from guide sleeve (6) (C). If the guide bush (4) is level with the guide sleeve (6) (see detail A) the brake pad and brake disc thicknesses should be checked.

R600481

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

Version: Knorr SN 7000

1. Check the transition between the ribbed part of the rubber cover and the smooth part (A). If the smooth part is rolled inwards, the brake pad and brake disc thicknesses must be checked.

Version: Wabco

1. There is no wear indicator in this version. The brake pad thickness must be inspected by using a mirror and a lamp, if necessary.

ΛΦ45/55 series

3-18

R600730

200515

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

Inspection and adjustment

3.25 INSPECTION AND ADJUSTMENT, LOAD SENSING VALVE, AIR

SUSPENSION

Explanatory notes on instruction plate

The information contained on the plate relates to the axle loads, the output pressures and bellows pressures, in accordance with the order of axles beneath the vehicle.

"1" refers to the (first) front axle, "2" to the following axle, etc.

In the entire column, a reading of 6 bar has been filled in under "1".

If the vehicle is equipped with an empty/load valve, a pressure ratio is entered in the box under the valve illustration, e.g. "i = 1 : 1.5". The "delivery pressure p2" of axle "1" then indicates variable readings.

These values can be used to check the brake pressure values of the front axle and to carry out the inspection/adjustment below at the same time. To do this, connect a pressure gauge to the test connection of one of the front axle brake cylinders.

R6 00 548

Inspection/adjustment

1. Check that the correct valve has been fitted (see instruction plate).

2. Connect pressure gauge (4) to the test connection close to connecting point 1/4 on the load sensing valve (input pressure).

3. Connect pressure gauge (2) to the test connection on one of the brake cylinders (service brake connection) of the rear axle.

4. Connect a pressure gauge (43) with a pressure-reducing valve to the simulation connection near connections 41 and 42 of the load sensing valve (= simulated adjustable bellows pressure).

5. Make sure that the reservoir pressure is higher than 6.5 bar throughout the testing process.

6. Set the simulated bellows pressure to its second lowest value, as indicated on the instruction plate.

7. Depress the brake pedal until the pressure gauge (4) indicates a pressure of 6 bar.

1/4

R600473

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

8. Read the brake pressure of the rear axle on pressure gauge 2 and check that this brake pressure matches the one listed on the instruction plate in the table under "output pressure p2" to the rear axle.

9. If the measured value is not correct, depressurise connection (43) and, using a special slotted-nut spanner, special tool (DAF no. 1329464), turn the adjusting nut (s):

- brake pressure too high: unscrew the

adjusting nut

- brake pressure too low: screw in the

adjusting nut

Note:

When depressurising the simulation connection (pressure gauge 43), the air hose must remain connected to prevent the (actual) bellows pressure from accidentally activating the valve. The small socket head screw in the centre of the valve must not be adjusted.

ΛΦ45/55 series

R600478

10. Repeat the procedure described in point 6 until the measured brake pressure value is within the tolerance limits.

11. Set the simulated bellows pressure to its second highest value, as indicated on the instruction plate.

12. Depress the brake pedal until the pressure gauge (4) indicates a pressure of 6 bar.

13. Read pressure gauge (2) and check that this brake pressure matches the pressure indicated in the table on the instruction plate.

14. If the measured reading is not correct, depressurise connection (43) and turn adjusting bolt (r) using a Torx screwdriver:

- brake pressure too high: screw in the

adjusting bolt

- brake pressure too low: unscrew the

adjusting bolt

Note:

1/4

R600473

15. If the adjusting bolt (r) has been turned, repeat the procedure from point 6.

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

Inspection and adjustment

3.26 INSPECTION AND ADJUSTMENT, LOAD SENSING VALVE, LEAF

SUSPENSION

Explanatory notes on instruction plate

The data relating to axle loads and output pressures are listed on the instruction plate following the sequence of the axles beneath the vehicle.

"1" refers to the (first) front axle, "2" to the following axle, etc.

In the entire column, a reading of 6 bar has been filled in under "1". If the vehicle is equipped with an empty/load valve, a pressure ratio is entered in the box under the valve illustration, e.g. "i = 1 : 1,5". The "output pressure P2" of axle 1 will give variable readings.

R6 00 549

Inspection/adjustment

1. Measure the weight plus load of the rear axle.

2. Check the attachment of the control lever and its ease of operation.

3. Check that the right type of valve has been fitted.

4. Check the length of the control lever (see "L" on the instruction plate).

5. Connect a pressure gauge (4) to the test connection near connection 1/4 on the load sensing valve (input pressure).

6. Connect pressure gauge (2) to the test connection on one of the brake cylinders (service brake connection) of the rear axle.

7. Make sure that the reservoir pressure is higher than 6.5 bar throughout the testing process.

8. Depress the brake pedal until pressure gauge (4) indicates a value of 6 bar.

1/4

R600562

9. Read the brake pressure of the rear axle from pressure gauge 2 and check that this value matches the one listed on the instruction plate in the table under "output pressure p2" to the rear axle.

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

10. If necessary, correct the brake pressure by adjusting the length of the vertical connecting rod (2). Never attempt to alter the length L of the (horizontal) control lever.

11. Remove the ball coupling (1) and raise the control lever. Check that the output pressure is now allowed through (almost) without reduction.

Note:

The small socket head screw in the centre of the valve must not be adjusted.

Drive and chassis

ΛΦ45/55 series

R6 00 568

3-22

200515

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

Inspection and adjustment

3.27 CHECKING THE DIFFERENTIAL FOR LEAKS

1. Visually inspect the differential for leaks.

3.28 CHECKING THE OPERATION OF THE DIFFERENTIAL LOCK

1. Jack up the rear axle and support the axle on stands.

2. Bring the air system to operating pressure.

3. Engage the differential lock. The warning indicator should now be active.

4. Check that there is a "rigid" connection between the driven wheels.

5. Disengage the differential lock. The warning light should now go out and the "rigid" connection between the driven wheels should be broken.

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Inspection and adjustment

3.29 CHECK THE DRIVE SHAFT PLAY

1. Check the universal joints (2) and suspension bearing (3) for play and damage.

2. Check the sliding joint for axial and radial play. The rubber dust cover (1) over the sliding joint should be undamaged.

3. There must be no clearly perceptible play on the universal joints, suspension bearing and the sliding joint.

3.30 INSPECTING THE FIFTH WHEEL

1. Check the attachment of the fifth wheel.

2. Check the play of the closing gear of the fifth wheel.

ΛΦ45/55 series

123

V3 00 379

Note:

For maximum play values, consult the manufacturer's instructions or the legal requirements.

3. In the case of fifth wheels with a plastic sliding plate (1), check for wear. The plastic sliding plate (1) must not lie flush with the top of the attachment bolts.

V300372

3-24

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

3.31 CHECKING THE TRAILER COUPLING

1. Check the vertical play of the arched pin.

2. Check the radial play of the arched pin.

3. Check the vertical and horizontal play of the coupling jaw.

Inspection and adjustment

M9002

4. Check the diameter of the arched pin.

5. Check the attachment of the trailer coupling and the rear cross member.

Note:

For maximum play values, consult the manufacturer’s instructions or the specified legal requirements.

M9001

M9004

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.32 CHECK THE SUPERSTRUCTURE ATTACHMENT

1. Check that all attachment bolts are in place.

2. Visually check the attachment of the superstructure for faults. See the DAF superstructure instructions.

ΛΦ45/55 series

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ΛΦ45/55 series

3.33 CHECK THE CLUTCH FLUID LEVEL

Hydraulic fluid is toxic and can therefore have a damaging effect on

}

your health. Hence avoid any direct or indirect physical contact. 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. 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. As hydraulic fluid is also a corrosive fluid, it may damage the paintwork of the vehicle. Avoid any contact between hydraulic fluid and paintwork. Always use new and clean hydraulic fluid which has been kept in a sealed container and meets the specifications. Hydraulic fluid which has absorbed water (from the ambient air) may have an adverse effect on the operation of the clutch system. Avoid any contact with mineral oil. Even one drop of mineral oil in the system will damage the seals.

Inspection and adjustment

1. Check whether the fluid level is between the min and max marks when the cab is in the driving position.

MAXI

MINI

P MAX 4 BAR

G0 00 213

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.34 CHECK THE CLUTCH WEAR INDICATOR

1. Check that the wear indicator on the clutch servo has not gone past the mark on the clutch servo plate.

2. If the wear indicator is at the mark on the clutch servo, replace the clutch plate.

3.35 CHECKING THE GEARBOX FOR LEAKS

ΛΦ45/55 series

V3 00 374

1. Visually check the gearbox for leaks.

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

3.36 CHECKING AUTOMATIC GEARBOX OIL LEVEL

Checking cold oil level

1. Place the vehicle on a flat and level surface.

2. Make sure that the gearbox is in neutral and allow the engine to run for several minutes.

3. Apply the service brake, switch the gearbox to D, then to N and finally switch the gearbox to R. The purpose of this is to fill the hydraulic system.

4. Switch the gearbox to the parking position and release the service brake.

5. Remove the dipstick when the engine is idling and wipe it clean with a lint-free cloth.

Note:

To take the dipstick out of the holder, the sealing cap must be held while the dipstick is turned anti-clockwise.

Inspection and adjustment

HOT

FULL

HOT

ADD

FULL

COLD

ADD

COLD

6. Put the dipstick back.

7. Remove the dipstick and check the oil level. The oil level should be between the "Cold add" and "Cold full" marks.

8. Clean the dipstick with a lint-free cloth and put it back.

9. Remove the dipstick and check the oil level again.

10. Oil needs to be added when the oil level is below the "Cold add" mark.

11. Check the oil level in the gearbox at operating temperature.

W 3 03 099

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

Checking hot oil level

1. Bring the gearbox up to operating temperature (approx. 71C - 93C).

2. Remove the dipstick when the engine is idling and wipe it clean with a lint-free cloth.

Note:

To take the dipstick out of the holder, the sealing cap must be held while the dipstick is turned anti-clockwise.

3. Put the dipstick back.

4. Remove the dipstick and check the oil level.

5. The oil level should be between the "Hot add" and "Hot full" marks.

6. Clean the dipstick with a lint-free cloth and put it back.

7. Remove the dipstick and check the oil level again.

HOT

FULL

HOT

ADD

FULL

COLD

ADD

COLD

W 3 03 099

ΛΦ45/55 series

8. Oil needs to be added when the oil level is below the "Hot add" mark.

9. Oil needs to be drained when the oil level is above the "Hot full" mark.

Note:

The oil level must be checked at least twice. When there are differences between the measurements, check the bleeder for clogging.

3-30

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

Inspection and adjustment

3.37 INSPECTION OF OIL LUBRICATED WHEEL HUBS FOR LEAKS

1. Check the wheel hubs for leaks.

Note:

If leaks occur in the oil lubricated wheel hubs, the wheel hub should be refilled to the correct level - once the leak has been repaired, see chapter: "Draining and filling".

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.38 CHECKING GREASED WHEEL HUBS FOR LEAKS

1. Check the wheel hubs for leaks.

Note:

For maintenance-free wheel hubs: If there are serious grease marks on the brake disc side of the wheel hub, this could indicate excessive use of assembly grease on new or recently assembled wheel hubs. On wheel hubs that were not assembled recently, serious grease marks could indicate a leak in the seal.

Checking greased wheel hubs for leaks, 1132 axle

1. Check the wheel hubs for leaks.

Note:

If there are serious grease marks on the brake disc side of the wheel hub, this could indicate excessive use of assembly grease on new or recently assembled wheel hubs. On wheel hubs that have not been assembled recently, serious grease marks could indicate a leak in the seal (1). This means that the entire hub unit must be replaced. Serious oil leakage on the driven rear axle hubs could indicate that the O-ring (2) is not sealing correctly. If there is an oil leak the hub unit should be dismantled to remedy the problem.

ΛΦ45/55 series

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ΛΦ45/55 series

Inspection and adjustment

3.39 CHECKING THE SHOCK ABSORBERS FOR ATTACHMENT AND LEAKS

1. Visually inspect the attachment of the shock absorbers and for any leaks.

3.40 CHECKING THE CONDITION AND ATTACHMENTS OF SPRING LEAVES,

SPRING CLAMPS AND U-BOLTS

Checking U-bolts

1. Visually inspect the condition and attachment of the U-bolts.

2. When retightening the U-bolt nuts, the attachment nut must not be slackened first and then tightened to the specified torque; see "Technical data".

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

ΛΦ45/55 series

3.41 CHECKING THE HINGE POINTS AND AXLE SUSPENSION FASTENING

(AIR SUSPENSION)

Torque rod

1. Check the attachment of the torque rod and torque rod supports.

2. Check the pivots of the torque rod for wear and play.

Stabiliser bar

1. Check the attachment of the stabiliser bar and stabiliser bar support.

2. Check the pivots of the stabiliser bar for wear and play.

Ball joints three-point fixation

1. Check the attachment of the ball joints and three-point fixation support.

2. Check the ball joint housing for surface cracks.

3. Check the dust cover for damage.

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

3.42 CHECKING THE AIR SUSPENSION BELLOWS

1. Raise the chassis to driving height using the remote control.

2. Clean the air bellows using a cleaning cloth or a soap solution, if required.

3. Check the air bellows for cracks and damage. If there are any cracks or damage through which the webbing is visible, the air bellows should be replaced.

4. Check the air bellows, bellows seating and air line connections for leaks. Check that the air bellows are not chafing against air lines, etc. when in the driving position.

Inspection and adjustment

M9040

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

3.43 ADJUSTING THE CROWN WHEEL GUIDE BOLT

1. Place chocks in front of the wheels and put the vehicle on the parking brake.

2. Loosen the circlip (1) and slacken the lock nut (2) a few turns.

3. Remove the adjusting screw (3) from the differential.

4. Remove the circlip (1).

5. Remove the traces of sealant from the adjusting screw and apply new sealant to the last 4 windings of the thread, see "Technical data".

6. Fit the adjusting screw with a new circlip and turn the screw against the crown wheel.

7. Turn back the adjusting screw 1/8 of a turn to obtain the required play A.

ΛΦ45/55 series

8. Tighten the attachment nut to the specified torque. See "Technical data".

Note:

Make sure that the adjusting screw does not turn when the lock nut is tightened.

9. Secure the lock nut by bending the circlip lips.

A8 00 489

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

Inspection and adjustment

3.44 INSPECTING THE REAR AXLE WHEEL BEARING PLAY

Inspecting the rear axle wheel bearing play

1. Jack up the rear axle until the wheels are clear from the floor and position suitable stands under the axle.

2. Check the wheel bearings manually for noticeable play.

Note:

If noticeable play is detected, the wheel bearing play should be re-adjusted.

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Inspection and adjustment

ΛΦ45/55 series

3.45 CHECKING THE CLAMP OF THE DRIVE SHAFT UNIVERSAL JOINT

1. Retighten the attachment bolts (1) of the clamps to the specified tightening torque, see "Technical data".

Note:

The attachment bolts must not turn when they are retightened. Attachment bolts that turn when they are retightened must be loosened and checked.

2. Tighten the loosened attachment bolts to the specified torque. See "Technical data".

V3 00 377

3-38

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

Removal and installation

4. REMOVAL AND INSTALLATION

4.1 REMOVAL AND INSTALLATION, INTERIOR FILTER ELEMENT

Removing the interior filter element

1. Open the grille.

2. Remove the attachment bolts (1) from the grate (2) on the underside of the filter casing.

3. Open the grate and remove the interior filter element.

Installing the interior filter element

1. Install the interior filter element. Close the grate (2) and fit the attachment bolts (1).

2. Close the grille.

Engine, cooling system and fuel system

K1 01 147

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Removal and installation

4.2 REMOVAL AND INSTALLATION, AIR FILTER ELEMENT

Removing the air filter element

1. Loosen all clamping brackets on the air filter cover.

2. Remove the air filter cover.

3. Remove the air filter element.

4. Clean the inside of the air filter housing and the air filter cover.

5. Clean the rubber sealing valves (1 and 2) on the filter housing. Check the sealing valve for damage.

Installing the air filter element

1. Fit the air filter element in the air filter housing.

2. Fit the air filter cover.

3. Install all the clamping brackets.

4. Reset the air filter indicator (3) by pressing the knob on the indicator.

ΛΦ45/55 series

I4 00 535

4-2

200515

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

ΛΦ45/55 series

4.3 REMOVAL AND INSTALLATION, LUBRICATING OIL FILTER

To prevent skin injury, avoid unnecessary contact with the

}

drained lubricating oil.

Be careful when changing the oil. Hot oil may cause serious injuries.

Removal and installation

}

Removing the lubricating oil filter

1. Place a tray beneath the lubricating oil filter.

2. Clean the area surrounding the filter element if this is very dirty.

3. Remove the filter element by turning it anticlockwise. Collect the oil that comes out.

4. Remove the O-ring if it has not been removed already.

Installing the lubricating oil filter

1. Lightly oil the filter element sealing ring.

2. Fill the filter element with clean oil. Use the specified oil.

3. Fit the filter element onto the housing. Tighten the filter element until the sealing ring abuts. Tighten the filter element a further

• to 1 turn by hand.

4. Run the engine for a short time and check that the lubricating oil filter is correctly sealed.

5. Check the oil level and correct if necessary. Use the specified oil.

G0 00 207

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EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES

Removal and installation

4.4 REMOVAL AND INSTALLATION, FUEL FINE FILTER

When removing the fuel fine filter, a quantity of fuel will escape. Collect

}

Removing the fuel fine filter

1. Place a container beneath the fuel fine filter

Installing the fuel fine filter

Note: Do not fill the fine filter with fuel until it has been fitted. The fine filter is filled with fuel by the primer pump after it has been fitted. This considerably reduces the risk of dirt getting into the fuel system.

1. Check by hand whether the coupling piece

the fuel and avoid the risk of fire.

and remove the filter.

Note:

The fuel fine filter is a disposable filter and must therefore not be cleaned and re-used.

for the filter attachment is securely attached.

ΛΦ45/55 series

2. Lightly lubricate the filter sealing ring with clean engine oil.

3. Fit the filter element onto the housing. Tighten the filter element until the sealing ring abuts. Tighten the filter element a further ∂ to • turn by hand.

4. Bleed the fuel system. See "Inspection and adjustment".

5. Start the engine and check the fuel system for leaks. If necessary, retighten the filter by hand.

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4.5 REMOVAL AND INSTALLATION, FUEL PREFILTER/WATER SEPARATOR

When removing the fuel prefilter/ water separator, a quantity of fuel

}

Removing the fuel prefilter/water separator filter element

1. Place a container under the filter.

2. Remove the plug (3) from the water

3. Remove the fuel prefilter/water separator

4. Remove the water sensor (2) from the filter

Installing the fuel prefilter/water separator filter element

1. Check by hand whether the coupling piece

will escape. Collect the fuel and avoid the risk of fire.

sensor (2).

filter element (1) by turning it anti-clockwise.

element (1).

for the filter attachment is securely attached.

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2. Lightly lubricate the sealing ring with engine oil.

3. Fit the fuel prefilter/water separator filter element (1) until the sealing ring abuts. Tighten the filter element a further ∂ to • turn by hand.

4. Turn the water sensor (2) onto the filter element until it abuts. Tighten the water sensor by about a further  -  turn.

Note:

Over-tightening the water sensor (2) may damage the sensor and/or cause leakage.

5. Fit the plug (3) on the water sensor (2).

6. Bleed the fuel system. See "Inspection and adjustment".

7. Start the engine and check for leaks. If necessary, retighten the fuel prefilter/water separator filter element (1) by hand.

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4.6 REMOVAL AND INSTALLATION, VALVE COVER

When the engine or parts of the engine are opened, dirt can get in.

}

Removing the valve cover

1. Clean the area around the valve cover.

2. Remove the banjo bolt and the attachment of

3. Remove the valve cover attachment nuts.

4. Remove the valve cover.

Installing the valve cover

1. Clean the sealing surface of the valve sleeve

2. Check the valve cover gasket. If the valve

This may cause serious damage to the engine. The engine should therefore be cleaned thoroughly before any parts are opened.

the plastic crankcase breather tube.

and the valve cover.

cover gasket is not damaged, it may be reused.

ΛΦ45/55 series

3. Fit the valve cover gasket to the valve cover.

4. Fit the valve cover.

5. Fit the valve cover attachment nuts and tighten them to the specified torque; see "Technical data".

6. Fit the plastic crankcase breather tube and the banjo bolt to the valve cover.

Steering gear and brake s ystem

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Removal and installation

4.7 REMOVAL AND INSTALLATION, AIR DRYER FILTER ELEMENT

Note:

To be certain that the air dryer is functioning properly, the air reservoirs should regularly be checked for condensation. If more than the normal amount of water is drained off repeatedly, the air dryer element must be replaced. Under normal circumstances the element must be replaced at least once per year.

Removing air dryer filter element

1. Vent the air dryer by allowing it to regenerate or by loosening the compressor line (1), so that the interior of the air dryer is depressurised.

2. Remove the filter element by turning it anticlockwise using a filter strap spanner.

3. Dispose of the drying element as if it were an oil filter.

4. Clean the air dryer internally.

5. Check the air dryer threaded connection (2) for damage and then lubricate it sparingly with grease.

Installing the air dryer filter element

1. Lubricate the sealing ring of the new filter element sparingly with grease.

2. Fit the filter element by manually tightening it until the sealing ring abuts. Then tighten the element by hand (approx. 1 turn).

3. Fasten the compressor line (1).

4. Pressurise the system and then check the air dryer for any air leaks.

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5. Using a water-resistant felt pen, write on the sticker the latest date by which the dryer element must be replaced (not later than 1 year after the date of fitting).

ΛΦ45/55 series

Artikelnummer

Reference

Teilenummer

Référence

1391510

Eerstvolgende vervanging

Next change

Nächster Wechsel

Prochain remplacement

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Removal and installation

4.8 REMOVAL AND INSTALLATION, FILTER ELEMENT IN THE RESERVOIR OF

THE RAS-EC STEERING GEAR

Removing the filter element

1. Clean the reservoir cover, so that absolutely no dirt can get into the reservoir.

2. Remove the cover (3).

3. Rotate the filter holder (5) a quarter turn and slowly take the filter holder together with the filter element (6) out of the reservoir.

Note:

The filter holder and filter element must be removed from the reservoir with care so that no dirt remains in the reservoir.

4. Remove the filter element (6) from the filter holder (5).

Installing the filter element

1. Fit a new filter element (6) in the filter holder (5).

2. Fit the filter holder (5) together with the filter element (6) in the reservoir (1) and rotate the filter holder (5) a quarter turn. Make sure that the filter holder (5) engages in its locking element.

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3. Check the sealing ring (4) for damage and replace if necessary.

4. Fit the cover (3).

5. Check the fluid level.

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4.9 REMOVAL AND INSTALLATION, HIGH-PRESSURE FILTER OF THE RAS-EC

STEERING GEAR

Drained steering oil must not be reused. Store this hydraulic oil

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Removing the high-pressure filter

1. Clean the high-pressure filter and the

2. Place a suitable receptacle under the high-

3. Remove the filter element (4).

4. Clean the filter cap (5).

separately from the other drained oils and have the oil collected by a waste-removal company authorised to do so.

surrounding area.

pressure filter and remove the filter cap (5).

2 3

Installing the high-pressure filter

1. Check the sealing rings (2) and (3) and replace them if necessary.

2. Fit a new filter element (4) in the filter holder (1).

3. Fit the filter cap (5). Tighten the filter cap to the specified tightening torque, see "Technical data".

4. Top up the system, see chapter "Draining and filling".

5. Check the operation of the system.

6. Check the high-pressure filter for leakage.

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Removal and installation

4.10 REMOVAL AND INSTALLATION, F36/F48 FRONT AXLE WHEEL HUB

Removing the hub

1. Support the front axle in a safe manner.

2. Remove the wheel.

3. Remove the wheel speed sensor (1).

4. Remove the cap placed over the adjusting bolt (1). Reset the brake pads by unscrewing the adjusting bolt (1) clockwise as far as it will go.

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5. Remove the attachment bolts (3) from the brake calliper (2). Remove the brake calliper (2) with attached pipes from the stub axle. Put the brake calliper (2) aside.

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;;;;

Removal and installation

6. Remove the hub cap (11).

7. Remove the lock nut (10).

8. Remove the hub (5) from the axle journal (1). Save the circlip (8) and the bearing cage (7).

9. Remove the seal (2) from the hub (5).

10. Take the bearing cage (3) out of the hub (5).

Installing the hub

1. Clean the axle journal (1) and check for damage.

2. Clean the bearing cages (3) and (7).

3. Remove the grease from the hub (5) and clean the ball races (4) and (6).

4. Check the bearing cages (3) and (7) and the ball races (4) and (6) for wear and damage. If necessary, fit new wheel bearings.

ΛΦ45/55 series

5. Apply an ample quantity of the specified grease to the bearing cages (3) and (7).

6. Fit the bearing cage (3) into the hub (5).

7. Apply a layer of grease (approx. 6 mm thick) to the hub cavity.

8 9

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8. Fit a new seal (2) in the hub (5).

9. Fit the hub (5) to the axle journal (1).

10. Fit the bearing cage (7).

11. Apply the specified grease to the front of the bearing cage (7).

12. Install the circlip (8).

13. Fit the lock nut (10). Tighten the lock nut (10) to the specified torque. See "Technical data". Rotate the hub (1), while securing the lock nut (10), to allow the bearings to set.

14. Turn the lock nut (10) back through approximately 90. It should be possible to fit the split pin (9).

Removal and installation

15. Place a micrometer (A) on the wheel hub (5). Allow the stylus to rest on the end of the axle journal (1).

16. Push and pull on the wheel hub (5). Check the wheel bearing play and compare this with the specified value. See "Technical data".

17. If necessary, correct the wheel bearing play by tightening or loosening the lock nut (10).

18. Fit a new split pin (9) in the lock nut (10).

8 9

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19. Fit the hub cap (11). Attention: the hub cap must not be filled with grease.

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20. Apply locking compound to the attachment bolts (3) of the brake calliper (2). See "Technical data".

21. Install the brake calliper (2). Tighten the attachment bolts (3) in the specified sequence to the specified torque. See "Technical data".

22. Set the brake pad clearance. To do this, turn the adjusting bolt (1) anti-clockwise until the brake pads abut the brake disc. Then turn the adjusting bolt (1) clockwise through 90. Check that the brake disc runs freely.

23. Fit the cap on the adjusting bolt (1).

24. Install the wheel speed sensor (1) and press it against the sensor ring. The required clearance will be produced while on the move.

25. Fit the wheel.

ΛΦ45/55 series

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4.11 REMOVAL AND INSTALLATION, F36/F48 FRONT AXLE HUB SEAL

Removing the hub seal

1. Remove the seal from the hub using the special tool (DAF no. 1329458). Make sure that the chamber is not damaged during this.

Installing the hub seal

1. Fit special tool (A) (DAF no. 1329485) for the F36 front axle and (DAF no. 1329484) for the F48 front axle) in the driving tool (B) (DAF no. 0499809).

2. Using the special tool, fit the new seal (1) in the hub (2). The open side of the seal (1) must face the hub (2). Apply a little grease to the sealing lip of seal (1).

Drive and chassis

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4.12 REMOVAL AND INSTALLATION, AUTOMATIC GEARBOX OIL FILTERS

Allison 1000 & 2000 series automatic gearbox

To prevent skin injury, avoid unnecessary contact with the

}

Removing the oil filters

1. Clean the oil filter (1) and filter (5), if present,

2. Loosen the oil filters on the gearbox and heat

3. Remove the magnetic rings (2) and (4) and

drained oil.

as well as the surrounding area.

exchanger. Collect any oil that is flowing out.

check them for wear particles.

Note:

If there are larger wear particles in the wear swarf, this points to advanced wear in the gearbox. The cause must be tracked down.

4. Clean the magnetic rings and the contact surfaces on the gearbox housing and the heat exchanger.

Installing the oil filters

1. Fit the magnetic rings (2) and (4) on the gearbox housing and the heat exchanger.

2. Lightly lubricate the new oil filter (1) and filter (5), if present, with clean gearbox oil and place the oil filters on the gearbox and heat exchanger.

3. Tighten the oil filters until they touch the contact surface. Manually tighten the oil filters another 360.

4. Check the oil level, see chapter "Inspection and adjustment".

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