DAF LF45, LF55 Service manual

4 (2)

6

STRUCTURE

ΛΦ45/55 series

TECHNICAL DATA

DIAGNOSTICS

BRAKE DIAGRAMS FOR THE FULLY PNEUMATIC BRAKE SYSTEM

OPERATION OF BRAKE COMPONENTS

BRAKE SYSTEM AND COMPONENTS

BRAKING PERFORMANCE AND BRAKE EQUALISATION

0

1

2

3

4

5

© 200436

DW23259602

https://www.truck-manuals.net/

https://www.truck-manuals.net/

6

 

TECHNICAL DATA

 

ΛΦ45/55 series

 

Contents

 

 

CONTENTS

 

 

 

 

Page

Date

0

 

 

. . . . . . . . . . . . . . . . . . . . . . . . .1. BRAKE SYSTEM AND COMPONENTS

. . . . . . . . .1-1

. . 200436

 

1.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . 1-1 . . . .

. 200436

 

1.2

Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . 1-12 . . .

. 200436

 

1.3

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . 1-16 . . .

. 200436

 

© 200436

1

https://www.truck-manuals.net/

TECHNICAL DATA

6

 

Contents

ΛΦ45/55 series

 

0

2

© 200436

https://www.truck-manuals.net/

6

TECHNICAL DATA

ΛΦ45/55 series

Brake system and components

 

 

1. BRAKE SYSTEM AND COMPONENTS

 

 

 

 

 

0

1.1 GENERAL

 

Coding of components

All components have been provided with number codes.

Structure of the code

First digit

Often used:

1Energy supply (pressure)

2Energy discharge (outgoing command)

3Bleed

4 Control connection (incoming command) Little used:

0Suction connection

5Free

6Free

7Anti-freeze connection

8 Lubricating oil connection

9Coolant connection

Where one connection performs several functions, additional 1stdigits will be allocated. These are separated by a hyphen.

Second digit

If there are several connections with the same function, a 2nd digit will be added immediately after the 1st one.

Application example: empty/load relay valve

Meaning:

1Air compressor energy supply

2Energy discharge (command) to the next component

41Control connection (incoming)

42Second control connection (incoming)

COMPRESSOR

 

Knorr model

 

Type:

LK3839

Version:

1-cylinder, liquid-cooled

© 200436

1-1

https://www.truck-manuals.net/

TECHNICAL DATA

6

Brake system and components

AIR SUPPLY UNIT

0 Front axle, leaf-sprung

A B

23

 

 

 

D

 

 

F

1

 

 

N

 

 

 

1

C

 

21

 

 

 

 

 

E

0

 

24 26

 

 

 

 

 

G

12

3

<![if ! IE]>

<![endif]>6.1

<![if ! IE]>

<![endif]>6.2

 

 

ΛΦ45/55 series

21

3

23 25

 

 

 

H

 

M

 

 

 

 

 

 

P U

6.2

 

 

 

6.3

 

 

L

P

6.4

 

 

 

 

 

 

6.5

J

K

 

 

U

 

P

6.6

 

 

 

 

6.7

 

 

 

 

 

22

R600702

A Air dryer/pressure regulator (unit)

B 4-circuit protection valve (unit)

C Filter/drying grid

D Pressure regulator

EBlow-off valve

F Pneumatic time switch for regeneration

GHeating element

H Pressure relief valve with bypass, circuit 1

J Pressure relief valve with bypass, circuit 2

K Pressure limiting valve, circuit 3

L Pressure relief valve, circuit 3

MFlowback valve, circuit 3

N Pressure relief valve with bypass, circuit 4

PPressure sensors

Cut-out pressure of pressure regulator

10.0 ≥ 0.2 bar

Cut-in pressure of pressure regulator

1.2 ≥ 0.2 bar under cut-out pressure

Supply pressure in circuit 1, connection 21

max. 10 bar

Supply pressure in circuit 2, connection 22

max. 10 bar

Supply pressure in circuit 3, connection 23

8.5 - 0.4 bar

Supply pressure in circuit 3, connection 25

8.5 - 0.6 bar

Supply pressure in circuit 4, connection 24

max. 10 bar

Supply pressure in circuit 4, connection 26

max. 10 bar

Opening pressure of circuits 1, 2 and 4

8.5 bar

Opening pressure of circuit 3

7.0 bar

Closing pressure of circuits 1, 2 and 4

7 bar

Closing pressure of circuit 3

5.5 bar

Cut-in temperature of heating element

7 C

Cut-out temperature of heating element

29 C

Circuit 1 activation pressure for flowback function

 

of circuit 3

< 4.5 bar

1-2 © 200436

https://www.truck-manuals.net/

6

TECHNICAL DATA

ΛΦ45/55 series

Pressure sensor reading, circuits 1 and 2 (connections 6.2 - 6.7 in the diagram above)

Ua(V)

5V

4V

Brake system and components

0

3V

2V

1V

0V

0

2

4

6

8

10

12 P21.22(bar)

R600701

FOOT BRAKE VALVE

 

P21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P22 bar

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10

 

 

 

 

 

 

 

P21-P22 = 0,3 – 0,15 bar

 

 

 

 

 

 

 

 

 

9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

21

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

22

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

3

4

5

6

7

8

9 10 11 12

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C (cm)

Pressure difference between circuits 1 and 2 (be-

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R600594

0.3 ≥ 0.15 bar

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

tween 0 and 3 bar)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Pressure reduction in circuits 1 and 2 from 10 to

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8 bar

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Connection 11

circuit 1 supply

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Connection 12

circuit 2 supply

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Connection 21

circuit 1 braking pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Connection 22

circuit 2 braking pressure

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

© 200436

1-3

https://www.truck-manuals.net/

TECHNICAL DATA

6

 

Brake system and components

ΛΦ45/55 series

 

LOAD-DEPENDENT CONTROL VALVE,

0LEAF SPRING

Characteristic

LOAD-DEPENDENT CONTROL VALVE,

AIR SUSPENSION

Characteristic

<![if ! IE]>

<![endif]>[bar]

10

9

<![if ! IE]>

<![endif]>p2

8

 

 

 

 

7

 

 

6

5

4

3

2

1

0.6–0.2

1:1

R600704

p41p42= 4.65 bar

p41p42= 3 bar

p41p42= 0.3 bar

 

0

1

2

3

4

5

6

7

8

9

10

 

 

 

 

 

 

 

 

 

 

 

p4 [bar]

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R600705

LOW-PRESSURE SWITCH

 

 

 

 

 

 

 

 

 

 

 

 

Cut-out pressure:

5.2 ≥ 0.2 bar

 

 

 

 

 

 

 

 

 

1-4

© 200436

https://www.truck-manuals.net/

6

<![if ! IE]>

<![endif]>P2(bar)

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

TECHNICAL

 

 

 

DATA

 

ΛΦ45/55 series

 

 

 

 

 

 

 

 

 

Brake

system and

components

 

RELAY VALVE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fitted with internal filter and silencer

 

 

<![if ! IE]>

<![endif]>(bar)

9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

<![if ! IE]>

<![endif]>P 2

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

1

 

2

 

3

 

4

 

5

6

 

7

8

9

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P4 (bar)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R 600363

 

 

EMPTY/LOAD RELAY VALVE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P42 = P41

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

.7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1:2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

P42 = 0

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

 

 

1

2

3

4

5

6

7

 

8

9

10

 

 

 

 

 

 

0,25+ 0,1

 

 

 

 

 

 

 

 

 

 

 

 

P41(bar)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Maximum reduction ratio

1 : 2.7

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R600330

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Actuating pressure

0.25 bar

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Fitted with internal filter and silencer

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

0

© 200436

1-5

https://www.truck-manuals.net/

 

 

TECHNICAL DATA

6

 

 

 

Brake system and components

ΛΦ45/55 series

 

 

 

ABS VALVE

 

 

0

 

15 ≥ 5 ohm at 25 C

 

Resistance of magnet coil

 

 

 

 

 

 

 

Electrical connections

1.Bleed magnet coil

2.Earth

3.

Aerate magnet coil

1

2 3

2

1

3

1 2 3

R600370

ASR solenoid valve

1. Supply

2. Port, two-way valve

3. Bleed

1

2

3

R600484

TRAILER VEHICLE CONTROL VALVE

 

Knorr model

 

Type:

AC 597BA

Advance

 

Input pressure

3 bar

Output pressure

3.2 bar

(equals 0.2 bar advance = factory setting)

 

1-6

© 200436

https://www.truck-manuals.net/

6

TECHNICAL DATA

ΛΦ45/55 series

Brake system and components

 

 

Advance adjustment

 

 

 

 

 

0

Adjusting screw (Allen type, 6 mm)

 

 

Clockwise increases the advance

 

Anti-clockwise decreases the advance

 

 

 

 

 

 

Knorr model

 

 

 

Type:

AC 597C

Advance

 

 

 

Input pressure

3 bar

Output pressure

3.5 bar

(equals 0.5 bar advance = factory setting)

 

 

 

Advance adjustment

 

 

 

Adjusting screw (Allen type, 6 mm)

 

 

 

Clockwise increases the advance

 

 

 

Anti-clockwise decreases the advance

 

 

 

PARKING BRAKE VALVE WITH TRAILER

 

 

 

VEHICLE CONNECTION

 

 

 

Wabco model

Type:

Max. output pressure in driving position

961 723 134 0

approx. 8 bar

© 200436

1-7

https://www.truck-manuals.net/

 

 

TECHNICAL DATA

6

 

 

 

Brake system and components

ΛΦ45/55 series

 

 

 

PARKING BRAKE VALVE WITHOUT TRAILER

 

 

0

 

 

 

 

VEHICLE CONNECTION

 

 

 

Wabco model

 

 

 

 

Type:

961 723 036 0

 

 

 

Max. output pressure in driving position

approx. 8 bar

BRAKE PADS

A

C B

D

E

F

R600489

Knorr model

Maximum brake block thickness (C) Maximum lining thickness (E) Minimum brake block thickness (F)

Replacing:

30 mm

2 mm (at the thinnest point)

11 mm (at the thinnest point) with 9mm rear plate thickness (D)

all brake pads at the same time for each axle, and with the specified lining only.

1-8

© 200436

https://www.truck-manuals.net/

6

TECHNICAL DATA

 

ΛΦ45/55 series

Brake system and components

 

 

Wabco PAN 17 version:

 

 

 

 

 

0

Maximum brake block thickness (C)

26 mm

Maximum lining thickness (E)

2 mm (at the thinnest point)

Minimum brake block thickness (F)

9 mm (at the thinnest point) with 7mm rear plate

 

 

thickness (D)

 

Replacing:

Wabco PAN 19-1+ and PAN 19-2 versions:

Maximum brake block thickness (C) Maximum lining thickness (E) Minimum brake block thickness (F)

all brake pads at the same time for each axle, and with the specified lining only.

30 mm

2 mm (at the thinnest point)

11 mm (at the thinnest point) with 9mm rear plate thickness (D)

Replacing:

all brake pads at the same time for each axle, and

 

with the specified lining only.

BRAKE DISC

A

C B

D

E

F

R600489

Knorr model

Maximum brake disc thickness (A) Minimum brake disc thickness (B)

45 mm

37 mm (rejection dimension, disc must be replaced)

Minimum thickness, turning dimension

40 mm

Note:

If it is established during brake pad replacement that the brake thickness is less than or equal to 39 mm, the brake disc must also be replaced.

© 200436

1-9

https://www.truck-manuals.net/

 

TECHNICAL DATA

 

Brake system and components

 

The following signs of wear are permissible:

0

A1 Crazy cracking.

B1 Cracks running to the centre up to 1.5 mm wide and deep, max. 0.75 x friction surface width (a).

C1 Unevenness in the disc surface up to

1.5 mm. Not permissible:

D1 Through-going cracks.

Wabco model

PAN 17 version:

Maximum brake disc thickness (A)

Minimum brake disc thickness (B)

Minimum thickness, turning dimension

The following signs of wear are permissible:

A1 Crazy cracking.

B1 Cracks running to the centre up to 1.5 mm wide and deep,

max. 0.75 x friction surface width (a).

C1 Unevenness in the disc surface up to

1.5 mm. Not permissible:

D1 Through-going cracks.

Brake disc wobble 0.15 mm

AMeasuring distance is 35 mm

6

ΛΦ45/55 series

A1

B1

 

<![if ! IE]>

<![endif]>a

max. 0,75 x a

max. 1,5 mm

D1

C1

R600471

34 mm

28 mm (rejection dimension, disc must be replaced)

30 mm

<![if ! IE]>

<![endif]>A

R600508

1-10

© 200436

https://www.truck-manuals.net/

6

 

TECHNICAL DATA

 

ΛΦ45/55 series

Brake system and components

 

 

PAN 19-1+ and PAN 19-2 versions:

 

 

 

 

 

0

Maximum brake disc thickness (A)

45 mm

Minimum brake disc thickness (B)

38 mm (rejection dimension, disc must be

 

 

replaced)

 

Minimum thickness, turning dimension

40 mm

 

The following signs of wear are permissible:

 

 

 

A1

Crazy cracking.

 

 

 

B1

Cracks running to the centre up to 1.5 mm

 

 

 

 

wide and deep,

 

 

 

 

max. 0.75 x friction surface width (a).

 

 

 

C1

Unevenness in the disc surface up to

 

 

 

 

1.5 mm.

 

 

 

Not permissible:

 

 

 

D1

Through-going cracks.

 

 

 

Brake disc wobble 0.15 mm

 

 

 

A

Measuring distance is 35 mm

 

 

 

BRAKE CALLIPER

 

 

 

Knorr model

 

 

 

A

Y - X

 

R600708

R600712

Brake calliper play in axial direction (direction A)

0.6 - 1.0 mm

Brake calliper play on guide bushes ("Y" - "X")

max. 2.0 mm

Play between brake calliper carrier and brake

 

pads ("Y" - "X" direction)

0.3 - 0.9 mm

Wabco model

 

Play between brake pad/brake disc:

 

Manually adjustable brake pad/brake disc play

 

after fitting brake pads:

0.7 mm

© 200436

1-11

https://www.truck-manuals.net/

 

 

TECHNICAL DATA

6

 

 

 

Brake system and components

ΛΦ45/55 series

 

 

 

1.2 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 replaced, it

 

 

 

 

is important that - unless stated otherwise - these

 

 

 

 

bolts and nuts are of exactly the same length and

 

 

 

 

property class as those removed.

 

 

 

 

QUICK-RELEASE COUPLING

 

 

 

 

Parker

20 - 30 Nm

 

 

SPRING BRAKE CYLINDER

 

 

 

 

Attachment nuts

195 Nm

 

 

Release bolt

70 Nm

 

 

Clamping strip attachment nut

40 Nm

 

 

BRAKE CYLINDER

 

 

 

 

Attachment nuts

195 Nm

 

 

BRAKE CALLIPER - BRAKE CARRIER, Knorr

 

 

 

 

model

285 Nm (1)

 

 

Sliding sleeve Allen screws (SB7000)

 

 

Sliding sleeve Allen screws (SN7000)

180 Nm + 90 (1)

 

 

Pressure tool, guide bush bellows

8 Nm

 

 

Rubber bearing bush pressure tool (only

 

 

 

 

SN7000)

8 - 45 Nm

(1) Always use new bolts, provided with locking compound. New bolts are supplied with locking compound already applied.

R600744

1-12

© 200436

https://www.truck-manuals.net/

6

 

TECHNICAL DATA

ΛΦ45/55 series

 

Brake system and components

 

 

 

 

 

 

 

Brake calliper attach-

440 Nm (1) (2)

 

 

0

ment bolts, front axle

 

 

 

 

 

 

 

 

 

(1)From production date 2003-37 there is one fitted bolt and flange bolts are also fitted.

The fitted bolt must be fitted at the position marked by a small hole.

(2)In the case of versions with Knorr disc brakes, the

attachment of the brake calliper against the stub axle changed starting from production week 2002-25. Five

bolts are now used instead of six bolts. There is still a hole for the 6th bolt on the brake carrier, but there is no hole on the stub axle.

Brake calliper attach-

440 Nm (1)

ment bolts, rear axle

(1)From production date 2003-37 there is one fitted bolt and flange bolts are also fitted.

-In the case of the 11.26 rear axle, the fitted bolt must be fitted at the position marked "X".

-In the case of the 11.32 rear axle, the fitted bolt must be fitted at the position marked by a small hole.

X

R600791

BRAKE CALLIPER - BRAKE CARRIER,

Wabco model

Locking bracket bolt (PAN 17)

20 Nm

Locking bracket bolt (PAN 19-1+ and PAN 19-2)

37 Nm

Guide bush Allen screws (PAN 17)

340 Nm

Guide bush Allen screws (PAN 19-1+ and

 

PAN 19-2)

300 Nm

Brake calliper attachment bolts against stub axle

 

or back plate (PAN 17)

213 Nm

Brake calliper attachment bolts against stub axle

 

or back plate (PAN 19-1+ and PAN 19-2)

470 Nm

© 200436

1-13

https://www.truck-manuals.net/

 

TECHNICAL DATA

6

 

Brake system and components

ΛΦ45/55 series

0

Tightening sequence of brake calliper

 

attachment bolts, Wabco model

 

Tightening sequence of brake calliper attachment

 

bolts:

 

6

3

2

1

4

5

 

 

 

 

 

 

R600520

BRAKE DISC

 

 

 

 

 

 

Knorr model

 

 

 

 

 

 

Locking plate attachment bolts

32 Nm

 

 

 

 

Wabco model

 

 

 

 

 

 

PAN 17 version

 

≥ 7 Nm

 

 

 

Brake disc attachment bolts on front axle

115

 

 

 

Brake disc attachment bolts on rear axle

130

Nm

 

 

 

 

PAN 19-1+ and PAN 19-2 versions

 

≥ 21 Nm

 

 

 

Brake disc attachment bolts on front axle

210

 

 

 

Brake disc attachment bolts on rear axle

193

Nm

 

 

 

 

1-14

© 200436

https://www.truck-manuals.net/

6

 

TECHNICAL DATA

ΛΦ45/55 series

Brake system and components

Tightening sequence of brake disc on

 

0

F36 axle

 

 

 

 

3

7

9

 

12

5

2

1

6

11

10

8

4

R600732

Tightening sequence of brake disc on F48 axle

3

16

13

7

9

12

5

2

1

6

11

10

8

14

15

4

R600731

© 200436

1-15

https://www.truck-manuals.net/

DAF LF45, LF55 Service manual

TECHNICAL DATA

6

 

Brake system and components

ΛΦ45/55 series

 

1.3 LUBRICANTS

0

BRAKE CALLIPER, KNORR MODEL SB7000 version

20

18 21 19

17

1

3

22

4

6

7

 

 

 

5

8

16

 

 

15

14

11

10

9

13

2

12

R600541

1-16

© 200436

https://www.truck-manuals.net/

6

TECHNICAL DATA

ΛΦ45/55 series

Brake system and components

 

 

Renolit HLT2 (white) for parts 6, 7, 8, the

 

 

 

 

 

0

adjusters (not shown), the brake cylinder lever

 

 

and the flange surface for attachment of the

 

brake cylinder

1448907

 

 

Syntheso GL EP1 (green), for parts 3, 5

1448908

 

 

© 200436

1-17

https://www.truck-manuals.net/

TECHNICAL DATA

6

Brake system and components

0SN7000 version

6 6a

3

4

8

ΛΦ45/55 series

20

21

18 19

5

17

1

22

7

16 23

15

11

14

10

 

2

 

R600698

Renolit HLT2 (white) for parts 3, 6, 7, 8, the

 

adjusters (not shown), the brake cylinder lever

 

and the flange surface for attachment of the

 

brake cylinder

1448907

BRAKE CALLIPER, WABCO MODEL

 

Renolit G-BRF 2

 

1-18

© 200436

https://www.truck-manuals.net/

6

DIAGNOSTICS

 

ΛΦ45/55 series

 

Contents

 

 

CONTENTS

 

 

 

 

 

Page

Date

 

1. DISC BRAKE CONSTRUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . 1-1 . . .

. . 200436

 

1

1.1 Fault-finding table

1-1

200436

 

 

 

 

 

 

© 200436

1

https://www.truck-manuals.net/

DIAGNOSTICS

6

 

Contents

ΛΦ45/55 series

 

1

2

© 200436

https://www.truck-manuals.net/

6

DIAGNOSTICS

 

ΛΦ45/55 series

Disc brake construction

 

 

1. DISC BRAKE CONSTRUCTION

 

 

 

1.1 FAULT-FINDING TABLE

 

 

 

 

 

 

 

 

 

 

1

SYMPTOM: SQUEALING/NOISE DURING BRAKING

 

Possible cause

Remedy

 

 

 

 

 

 

Worn brake pads

Check brake pads and brake disc thickness

 

 

 

 

 

 

Loose parts

Check disc brake construction

 

 

 

 

 

 

Wear/damage to hub bearing

Check hub bearing play

 

 

 

 

 

 

Wear to internal parts of disc brake construction

Check internal parts

 

 

 

 

 

 

Incorrect vehicle combination

Check vehicle combination

 

 

 

 

 

 

Incorrect front axle / rear axle brake pressure

Check front axle / rear axle balance

 

 

balance

 

 

 

 

 

SYMPTOM: IRREGULAR BRAKE PAD WEAR

 

 

 

 

 

 

Possible cause

Remedy

 

 

Fouled/corroded guide bushes

Check the guide bushes

 

 

 

 

 

 

Dirt accumulation between moving parts of the disc

Clean the disc brake construction

 

 

brake construction

 

 

 

Moisture and dirt on internal mechanical parts

Check and clean the brake calliper seals

 

 

 

 

 

 

Brake pad stuck in the brake calliper Incorrect play

Check the play between brake pads and brake

 

 

between brake pads and brake carrier

carrier

 

 

 

 

SYMPTOM: VEHICLE PULLS TO ONE SIDE DURING BRAKING

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Difference in tyre pressure

Check / correct tyre pressure

 

 

 

 

 

 

Difference in tyre size

Check tyres

 

 

 

 

 

 

Different brake cylinder diameters

Check brake cylinder diameters

 

 

 

 

 

 

Broken springs in brake cylinders

Check brake cylinders

 

 

 

 

 

 

Leaking brake cylinders

Check brake cylinders

 

 

 

 

 

 

Fouled brake cylinders

Check the brake cylinders for fouling

 

 

 

 

 

 

Excessive stub axle bearing play

Check stub axle bearing play

 

 

 

 

 

 

Excessive steering ball joint play

Check steering ball joint play

 

 

 

 

 

 

Excessive shackle pin play

Check shackle pin play

 

 

 

 

 

 

Incorrect vehicle combination

Check vehicle combination

 

 

 

 

 

 

Incorrect ABS operation

Check ABS operation

 

 

 

 

 

 

Brake pad stuck in the brake calliper Incorrect play

Check the play between brake pads and brake

 

 

between brake pads and brake carrier

carrier

 

 

© 200436

1-1

https://www.truck-manuals.net/

 

 

DIAGNOSTICS

6

 

 

Disc brake construction

ΛΦ45/55 series

 

 

 

 

 

 

SYMPTOM: POOR BRAKING DECELERATION

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Overload due to excessive loading

Check vehicle loading condition

1

 

 

 

 

 

System pressure too low

Check pressure regulator setting

 

 

Air leakage in the brake system

Check the brake system for leakage

 

 

 

 

 

 

Insufficient braking power / poor condition of trailer

Check trailer vehicle

 

 

vehicle brake system

 

 

 

Pinched brake lines

Check / replace brake lines

 

 

 

 

 

 

Brake cylinder stroke too large

Check automatic slack adjuster

 

 

 

 

 

 

Frozen brake system

Check brake system

 

 

 

 

 

 

Brake components affected by road salt

Check the brake components for fouling.

 

 

 

 

 

 

Fouled brake cylinders

Check the brake cylinders for fouling

 

 

 

 

 

 

Incorrect brake cylinder diameter

Check brake cylinders

 

 

 

 

 

 

Incorrect operation / setting of load sensing valve

Check operation / setting of load sensing valve

 

 

 

 

 

 

Incorrect vehicle combination

Check vehicle combination

 

 

 

 

 

 

Incorrect ABS operation

Check ABS operation

 

 

 

 

 

 

Brake pad stuck in the brake calliper Incorrect play

Check the play between brake pads and brake

 

 

between brake pads and brake carrier

carrier

 

 

 

 

 

SYMPTOM: VIBRATIONS DURING BRAKING

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Incorrect wheel tightening procedure

Tighten wheels according to tightening procedure

 

 

 

 

 

 

Non-standard wheels fitted

Fit only standard wheels

 

 

 

 

 

 

Overload due to excessive loading

Check vehicle loading condition

 

 

 

 

 

 

Incorrect front axle / rear axle brake pressure

Check front axle / rear axle balance

 

 

balance

 

 

 

Wrong brake pad quality

Check brake pads

 

 

 

 

 

 

Dirt/deposits on brake disc

Check/clean brake disc

 

 

 

 

 

 

Loose parts

Check disc brake construction

 

 

 

 

 

 

Wear/damage to hub bearing

Check hub bearing play

 

 

 

 

 

 

Damage to disc brake

Check thickness and condition of brake disc

 

 

 

 

 

 

Play in cab suspension

Check cab suspension

 

 

 

 

 

 

Incorrect vehicle combination

Check vehicle combination

 

 

 

 

1-2

© 200436

https://www.truck-manuals.net/

6

DIAGNOSTICS

 

ΛΦ45/55 series

Disc brake construction

 

 

 

 

 

 

SYMPTOM: LOCKING OF THE BRAKES

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Incorrect setting of load sensing valve

Check setting of load sensing valve

 

 

 

1

 

 

 

Thermal overload of non-locking axle brake pads

Check non-locking axle brake pads

 

Incorrect system pressure due to incorrect

Check pressure regulator setting

 

 

pressure regulator setting

 

 

 

 

 

 

 

Defective trailer vehicle brake system

Check trailer vehicle brake system

 

 

 

 

 

 

Incorrect vehicle combination

Check vehicle combination

 

 

 

 

 

 

Incorrect ABS operation

Check ABS operation

 

 

 

 

 

 

Tyres have too little tread

Check tread

 

 

 

 

 

 

Brake pad stuck in the brake calliper Incorrect play

Check the play between brake pads and brake

 

 

between brake pads and brake carrier

carrier

 

 

 

 

SYMPTOM: INCREASED BRAKE PAD WEAR

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Overload due to excessive loading

Check vehicle loading condition

 

 

 

 

 

 

Incorrect setting of load sensing valve

Check setting of load sensing valve

 

 

 

 

 

 

Incorrect vehicle combination or front axle/rear

Check vehicle combination or front axle/rear axle

 

 

axle balance

balance

 

 

Defective trailer vehicle brake system

Check trailer vehicle brake system

 

 

 

 

 

 

Air pressure in spring brake cylinders too low

Check air pressure in spring brake cylinders with

 

 

during driving, dragging brakes

the parking brake valve in the driving position

 

 

Dragging brakes because parking brake is not

Check release of parking brake

 

 

released

 

 

 

Dirt under foot brake valve / floor mat too high

Check for free movement of foot brake valve

 

 

 

 

 

 

Dirty / blocked brake valve bleeders

Check valve bleeders

 

 

 

 

 

 

Brake pad stuck in the brake calliper Incorrect play

Check the play between brake pads and brake

 

 

between brake pads and brake carrier

carrier

 

 

Incorrect setting of the trailer vehicle control valve/

Check setting of the trailer vehicle control valve/

 

 

trailer vehicle reaction valve

trailer vehicle reaction valve

 

 

© 200436

1-3

https://www.truck-manuals.net/

 

 

DIAGNOSTICS

6

 

 

Disc brake construction

ΛΦ45/55 series

 

 

 

 

 

 

SYMPTOM: DRAGGING BRAKES

 

 

 

 

 

 

Possible cause

Remedy

 

 

 

 

 

 

Leaking foot brake valve to circuit 1 and/or 2

Check the foot brake valve for leaks

1

 

 

 

 

 

Dirt/deposits in brake calliper of disc brake

Check freedom of movement of brake calliper

 

 

Brake pads turned back too tightly

Check minimum brake pad play

 

 

 

 

 

 

Air pressure in spring brake cylinders too low

Check output pressure of the double-check relay

 

 

during driving

valve

 

 

 

Check four-circuit safety valve for dirt

 

 

 

Check output pressure of the parking brake valve

 

 

 

in the driving position

 

 

Output supply pressure from trailer vehicle control

Check output supply pressure of the trailer vehicle

 

 

valve to trailer/semi-trailer too low

control valve

 

 

Dirt under foot brake valve / floor mat too high

Check for free movement of foot brake valve

 

 

 

 

 

 

Dirty / blocked brake valve bleeders

Check valve bleeders

 

 

 

 

 

 

Brake pad stuck in the brake calliper Incorrect play

Check the play between brake pads and brake

 

 

between brake pads and brake carrier

carrier

1-4

© 200436

https://www.truck-manuals.net/

6 BRAKE DIAGRAMS FOR THE FULLY PNEUMATIC BRAKE SYSTEM

ΛΦ45/55 series

 

Contents

 

CONTENTS

 

 

 

 

 

 

Page

Date

 

1.

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 . . .

. . 200436

 

 

1.1

Brake diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1 . . . .

. 200436

 

2.

BRAKE DIAGRAMS FOR THE FULLY PNEUMATIC BRAKE SYSTEM . . . . .

2-1 . . . .

. 200436

 

 

2.1

Legend, brake diagrams for the fully pneumatic brake system

2-1

200436

 

 

2

 

2.2

Brake diagrams for the fully pneumatic brake system

2-2

200436

 

 

 

 

 

 

 

 

© 200436

1

https://www.truck-manuals.net/

BRAKE DIAGRAMS FOR THE FULLY PNEUMATIC BRAKE SYSTEM 6

Contents

ΛΦ45/55 series

2

2

© 200436

https://www.truck-manuals.net/

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