DAF Techincal Data Service Manual

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STRUCTURE

ΛΦ45/55 series

TECHNICAL DATA

SAFETY INSTRUCTIONS AND WARNINGS

THREADED CONNECTIONS

SEALS AND BEARINGS

GENERAL OPERATIONS

PAINT TREATMENT

CONVERSION TABLES

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0	TECHNICAL DATA
ΛΦ45/55 series		Contents
CONTENTS
	Page	Date		0

1. VEHICLE MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200338

1.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200338

2. LOCKING COMPOUNDS AND SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200338 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200338

3. THREADED CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200338 3.1 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200338

4. PAINT TREATMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200338 4.1 Overview of plastics used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200338

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TECHNICAL DATA	0
Contents	ΛΦ45/55 series

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0	TECHNICAL DATA
ΛΦ45/55 series	Vehicle models
1. VEHICLE MODELS
			0
1.1 OVERVIEW

FT
	4 x 2
FA

FAN	6 x 2

steered axle

driven axle

G0 00 205

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TECHNICAL DATA	0
Vehicle models	ΛΦ45/55 series

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0	TECHNICAL DATA
ΛΦ45/55 series	Locking compounds and sealants

	2. LOCKING COMPOUNDS AND SEALANTS
		0
	2.1 GENERAL

}negative effect on the functioning of locking compounds. The general rule is therefore that fasteners and components which have been cleaned with a cleaning agent must be treated with a cleaning liquid to

ensure that the locking compound functions properly.Certain cleaning agents have a

OVERVIEW OF LOCKING COMPOUNDS

Product	Properties		Applications	DAF
name				number
Loctite	-	Locking with an average	Locking of threaded connections	0068197
243		detaching strength
	- Detachable with normal tools
Loctite	-	Locking with a high detaching	Locking of threaded connections,	1340646
2701		strength	gear lever ball, freeze plugs
	- Repairs the fit in bearing
		housings
	-	Seals against leaks
	-	Difficult to detach
Loctite	-	Locking with a high detaching	Locking of cylindrical connections	0645557
638		strength under dynamic load
	-	Difficult to detach
Loctite	-	Locking with an average	Locking of threaded connections in	1357032
648		detaching strength	warm places
	- Resistant to high temperatures
Loctite	-	Locking with a high detaching	Locking of threaded connections,	1279841
262		strength	such as the pinion nut
	-	Difficult to detach

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TECHNICAL DATA	0
Locking compounds and sealants	ΛΦ45/55 series

Applying the locking compound

0 1. Clean both the internal and external threads. Degrease the thread with a suitable degreasing agent which leaves no residue that could affect proper functioning.

2.Apply one or more drops of locking compound to the thread, depending on the diameter. Never dip the bolt or stud fully into the locking compound.

3.Apply a drop of oil under the bolt head. Locking compounds also reduce the frictional resistance, which means that applying a drop of oil to the thread is not required.

4.Tighten the connection to the specified torque.

OVERVIEW OF SEALING COMPOUNDS

Product	Properties		Applications	DAF
name				number
Dirko D	- Resistant to temperatures up to		Sealing of surface connections	1345014
		180″C
	- Resistant to oil, coolant
Loctite	- Resistant to temperatures up to		Sealing of surface (flange)	0697149
510		200″C	connections that are subjected to high
	- Resistant to oil, brake fluid,		operating temperatures, such as the
		coolant	flywheel housing
Loctite	- Resistant to high pressures (up to		Sealing of surface connections	1246867
574		350 bar)	against high pressures
	- Resistant to oil, brake fluid,
		coolant
Loctite	-	Resistant to temperatures from	Sealing of flexible constructions such	1242895
Blue		60″C to 260″C	as (valve) covers
	-	Resistant to oil
Loctite	- Silicone sealant, good resistance		Sealing of (surface) connections in	1284123
ultra grey		to coolant	the cooling system
	- Resistant to temperatures up to
		325″C
Loctite	- Silicone sealant, good resistance		Sealing of surface connections such	1284122
ultra		to oil	as hub covers
copper	- Resistant to temperatures of up
		to 350″C
Loctite	- Silicone sealant, good resistance		Sealing of surface connections, such	1360102
5910		to oil	as front and rear covers of gearboxes,
	- Resistant to temperatures up to		differential housings, hub covers, stub
		200″C	axle flanges and oil cooler
Loctite	- Seals against low pressure		Threaded connections	0292336
572		immediately after fitting

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0			TECHNICAL DATA
ΛΦ45/55 series			Locking compounds and sealants
		OVERVIEW OF SEALING COMPOUNDS				0
Product	Properties		Applications	DAF
name				number
Loctite	-	Surface sealant, specially	Sealing of aluminium parts	1441339
5205		designed for sealing aluminium
		parts
	- Resistant to temperatures up to
		150″C
	- Resistant to water, coolant and oil
Loctite	- Hardens on contact with metal		For locking, fastening and sealing	1322823
Form a		and on full closure
gasket
		OTHER PRODUCTS
Product	Properties		Applications	DAF
name				number
Tectyl	Protects the cavities of the cab body		Post-treatment of cab parts to protect	1343888
	against corrosion.		against corrosion.
			Can also be used as protection for
			metal parts
Contact	Cleaning agent for cleaning and		Cleaning of electrical contacts	1387608
spray	degreasing electronic and electrical
	connections. Removes moisture and
	dirt from electrical contacts
Loctite	-	Cleans and degreases	For cleaning/degreasing of materials	1322827
cleaner	-	Non-inflammable and non-	to which a locking compound must be
7063		corrosive	applied
Molykote	- Lubricating grease is heat-		- Wherever grease lubrication is	1389512
BR 2		resistant from -30″C to +130″C	appropriate and normal
PLUS			- For almost all ball and roller
			bearings, plain bearings, guides,
			couplings, splined shafts,
			threaded spindles, sprocket
			drives with a low speed
Molykote	-	Grease protects against	For threaded connections that are	1391619
P37		corrosion and is heat-resistant to	exposed to high temperatures, as
		1400″C.	used for exhaust systems
Copaslip	- Copper paste with an excellent		For connections that are vulnerable to	1284344
		bond, is anti-corrosive and heat-	oxidation or corrosion, such as battery
		resistant from -35″C to 1100″C.	terminals, exhaust couplings, etc.
	- Resistant to water, salts and
		acids.
	- Prevents wear, oxidation, rust,
		corroding and locking of metal
		surfaces.
Renolit	-	Grease (white)	Disc brake adjustment device	1448907
HLT2

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		TECHNICAL DATA				0
		Locking compounds and sealants			ΛΦ45/55 series
0				OTHER PRODUCTS
		Product	Properties		Applications	DAF
		name				number
		Syntheso	-	Grease (green)	Rubber guides for disc brake	1448908
		GL EP1
		Gleitmo	-	Protects untreated metals	For parts which are attached with a fit	1443160
		805		against corrosion	such as wheel hub units

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ΛΦ45/55 series	Threaded connections
3. THREADED CONNECTIONS
			0
3.1 TIGHTENING TORQUES

The tightening torques in the table below are standard torques and only apply to dipped threaded connections.

The property codes are stamped on the nut and bolt, except on the clamping flange bolt. The clamping flange bolt is recognised by a constriction between the hexagonal bolt head and the flange. This constriction is absent in standard flange bolts.

M2 00 001

Clamping flange bolt/standard-flange bolt

Tightening torques for dipped threaded connections

Overview of standard tightening torques for DAF flange bolts and nuts, strength class 10.9/10

Thread pitch	Tightening torque (Nm)			Extra angular displacement (≥ 10 %)
				for bolt stem length L (mm):
			L 40		41-80	81-130	131-180
M8	30 ≥ 2		30″		60″	90″	120″
M10	60 ≥ 4		45″		90″	120″	150″
M12 x 1.75	110	≥ 8	30″		60″	90″	120″
M12 x 1.25	110	≥ 8	45″		90″	120″	150″
M14 x 2	170	≥ 15	30″		60″	90″	120″
M14 x 1.5	170	≥ 15	45″		90″	120″	150″
M14 x 2	for brake back plates: 170 ≥ 15 Nm + 60″
M16 x 2	260	≥ 20	30″		60″	90″	120″
M16 x 1.5	260	≥ 20	45″		90″	120″	150″
M18 x 2.5	360	≥ 30	30″		45″	60″	80″
M18 x 1.5	360	≥ 30	45″		90″	120″	150″
M20 x 1.5	520	≥ 40	45″		90″	120″	150″
M22 x 2.5	for steering and track rods: 500 ≥ 50 Nm + 90″

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TECHNICAL DATA	0
Threaded connections	ΛΦ45/55 series

The bolt stem length L is the length of the bolt 0 between the bolt head and the nut.

If a component is attached with several bolts, all bolts must first be tightened to the specified torque, and subsequently by the angular displacement.

Overview of standard tightening torques for

DAF fastenings, strength class 8.8/8

Thread	Tightening torque
	in Nm
M4	2.8 ≥ 0.2
M5	5.5 ≥ 0.4
M6	9.6 ≥ 0.7
M8	23 ≥ 2
M10	46 ≥ 4
M12	79 ≥ 6
M14	125	≥ 9
M16	195	≥ 14
M18	280	≥ 20
M20	395	≥ 30
M22	540	≥ 40
M24	680	≥ 50
M27	1000 ≥ 70
M30	1350 ≥ 100

Overview of standard tightening torques for DAF flange bolts and nuts, strength class 12.9/12

Thread	Tightening torque
	in Nm
M8	32 ≥ 3
M10	67 ≥ 5
M12	113	≥ 9
M14	178	≥ 14
M16	274	≥ 22
M18	385	≥ 30
M20	550	≥ 43
M22	740	≥ 60
M24	925	≥ 72
M27	1370 ≥ 110

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0	TECHNICAL DATA
ΛΦ45/55 series	Threaded connections

Overview of standard tightening torques for

DAF clamping flange bolts and nuts, strength 0 class 12.9/12

Thread	Tightening torque
	in Nm
M12	178 ≥ 14
M14	274 ≥ 22
M16	425 ≥ 35
M18	550 ≥ 45

Overview of tightening torques, banjo bolts

Thread	Tightening torque
	in Nm
M6	8 ≥ 0.8
M8	15	≥ 1.5
M10	30	≥ 3
M12	40	≥ 4
M14	50	≥ 5
M16	60	≥ 6
M18	70	≥ 7

Torque wrench

-Have torque wrenches regularly inspected and calibrated.

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

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

2.Check the thread for damage.

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

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

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

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

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TECHNICAL DATA	0
Threaded connections	ΛΦ45/55 series

New bolts/nuts

0 New DAF bolts and DAF nuts, except bolts M4 to M8 with inner-Torx, have already been lubricated. If bolts have not yet been lubricated, a lubricant should be applied.

1.Apply one drop of engine oil to the first turn of the bolt/lower screw thread of the nut and one drop to the clamping faces (other lubricants are not allowed).

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

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	ΛΦ45/55 series		Paint treatment
	4. PAINT TREATMENT		0
	4.1 OVERVIEW OF PLASTICS USED
	1	SMC polyester
	2	Thermoplastic polymer parts (ASA or ABS)
	3	Fibre-glass reinforced polyester	3

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2

2

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1

G0 00 206

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TECHNICAL DATA	0
Paint treatment	ΛΦ45/55 series

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0	SAFETY INSTRUCTIONS AND WARNINGS
LF45/55 series			Contents
CONTENTS
		Page	Date
1. SAFETY INSTRUCTIONS AND WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		1-1 . .	. . . . 0201
1.1	General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-1 . .	. . . . 0201
1.2	Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-4 . .	. . . . 0201
1.3	Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-5 . .	. . . . 0201
1.4	Jump-starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-8 . .	. . . . 0201
1.5	Plastic pipes	1-9	0201
1.6	Wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-12 .	. . . . 0201		2
1.7	Avoiding the risk of fire	1-13	0201
1.8	Tachograph calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-14 .	. . . . 0201
1.9	Airbag and seat belt tensioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	1-15 .	. . . . 0201

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SAFETY INSTRUCTIONS AND WARNINGS	0
Contents	LF45/55 series

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0201

0	SAFETY INSTRUCTIONS AND WARNINGS
LF45/55 series	Safety instructions and warnings

1. SAFETY INSTRUCTIONS AND WARNINGS

1.1 GENERAL SAFETY INSTRUCTIONS

Warning symbol

When text is accompanied by the warning symbol shown here, this indicates that the information provided is essential for the health and personal safety of the mechanic.

This warning symbol is also shown if

circumstances threaten the safety of the vehicle 2 or could lead to damage to the vehicle.

If any of the safety instructions and warnings contained in this section are ignored, the health and safety

of the mechanic may be put at risk.

M0015

Also, serious damage to the vehicle or even a hazardous situation may result.

-Comply with all the warnings and safety instructions given in this workshop manual. First read the instructions and warnings on the labels and stickers which are affixed to the various components and comply with them. They have been put there for your health and safety, so do not ignore them!

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

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

-Do not run the engine in an enclosed or unventilated area. Make sure exhaust fumes are properly extracted.

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	SAFETY INSTRUCTIONS AND WARNINGS	0
	Safety instructions and warnings	LF45/55 series
	- Remain at a safe distance from rotating
	and/or moving components.
	- Do not remove the filler cap from the
	cooling system when the engine is at
	operating temperature.
	- Be careful when changing the oil. Hot oil
	can cause serious injuries.
2	- Avoid unnecessary contact with drained oil.
	Frequent contact damages the skin.

- Various sorts of oil and other lubricants used on the vehicle may constitute a health hazard. This also applies to engine coolant, clutch fluid, windscreen washer fluid, refrigerant in air-conditioning systems, battery acid and diesel fuel. So avoid inhaling and direct contact.

- Tilt the cab fully if work must be carried out underneath the cab.

- Always use stands to support the chassis or components when working under the vehicle.

- Be careful when working on activated springs, such as those in spring brake cylinders, valves, and similar. Inadvertently released springs may cause serious injuries. Small springs and circlips may also cause injuries when inadvertently released (wear goggles).

- Always use a tyre cage when fitting and inflating tyres. Thoroughly clean tyres prior to balancing. Only use a balancing device fitted with a protective cover.

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0201

0	SAFETY INSTRUCTIONS AND WARNINGS
LF45/55 series	Safety instructions and warnings

-Always use the appropriate lifting gear (gearbox jack) or approved hoists for the removal and installation of heavy components. Attach the component securely to the lifting or hoisting gear.

-Be careful when working on systems which may be under pressure, such as a trailing

axle lifting device, cab tilting mechanism,
brake system, steering gear, fuel system,
etc.	2

-After a fire, hazardous residues may remain from the plastics used in some oil seals and sealing rings. Wear protective, acid-resistant clothing and PVC gloves when removing such fire residues. Immerse such fire residues in, or sprinkle them amply with, a calcium hydroxide solution (slaked lime and water). Thoroughly clean the protective clothing after use. Treat the gloves as chemical waste.

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		SAFETY INSTRUCTIONS AND WARNINGS		0
		Safety instructions and warnings		LF45/55 series
1.2			BATTERIES
			Always charge batteries in a
			properly ventilated area and avoid
			sparking and naked flames. Always
			switch the battery charger off
			before removing the leads.
			Fast-charging should only be
			resorted to in an emergency.
2			Disconnect the battery leads when
			fast-charging is being used.

Wear protective clothing, gloves and a visor when carrying out work that may bring you into contact with battery acid.

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 see a doctor.

If any is swallowed: do NOT induce vomiting. Rinse the mouth, drink two glasses of water and see a doctor.

In the event of inhalation: get some fresh air, rest and consult a doctor.

To prevent damage to electronic components, never disconnect the battery terminals when the engine is running.

Always disconnect the earth connection of the battery before working on the vehicle. Never place tools on a battery. If you do, this could short-circuit the battery or even cause the battery to explode.

Always charge batteries in a properly ventilated area and avoid sparking and naked flames. When charging batteries, an explosive gas mixture may be released.

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0	SAFETY INSTRUCTIONS AND WARNINGS
LF45/55 series	Safety instructions and warnings
1.3 WELDING
No welding of the chassis is
allowed without special, written
permission by DAF. Exceptions to
the above are the welding
operations described in the manual
“Superstructure directives”.
Non-compliance with welding
regulations may cause serious			2
damage to the chassis.

Failure to observe the following instructions may damage the electronic components.

General

-Attach the earth clamp of the welding set as close as possible to the area on the vehicle where the welding is to be done and ensure that it is well in contact with the part being welded.

-Never attach the earth clamp to vehicle components such as the engine, axles, springs, etc. Arcing on these components is also not permitted. Non-compliance with the above instructions may result in serious damage to bearings, springs, etc.

-The accessory or ignition position of the ignition lock must not be switched on. Remove the ignition key from the ignition lock.

-Protect plastic piping, rubber components, plastic components, piston rods of hydraulic cylinders and springs (in particular parabolic springs) from welding splashes and temperatures above 70_C.

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