DAF Techincal Data Service Manual

0

ΛΦ45/55 series

STRUCTURE

Structure

TECHNICAL DATA

0

1

SAFETY INSTRUCTIONS AND WARNINGS

2

THREADED CONNECTIONS

3

SEALS AND BEARINGS

4

GENERAL OPERATIONS

5

PAINT TREATMENT

6

CONVERSION TABLES

7

©

200338

0

TECHNICAL DATA

ΛΦ45/55 series

0 Technical dat a

CONTENTS

Page Date

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

Contents

0

©

200338 1

TECHNICAL DATA

0

0

Contents

ΛΦ45/55 series

2

©

200338

0

TECHNICAL DATA

ΛΦ45/55 series

1. VEHICLE MODELS

1.1 OVERVIEW

FT
FA

FAN

steered axle driven axle

Vehicle models

0

4 x 2

6 x 2

G0 00 205

©

200338 1-1

TECHNICAL DATA

0

0

Vehicle models

ΛΦ45/55 series

1-2

©

200338

0

TECHNICAL DATA

ΛΦ45/55 series

Locking compounds and sealants

2. LOCKING COMPOUNDS AND SEALANTS

2.1 GENERAL

Certain cleaning agents have a
negative effect on the functioning of

}

Product
name

Loctite
243

Loctite
2701

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.

OVERVIEW OF LOCKING COMPOUNDS

Properties Applications DAF

- Locking with an average
detaching strength

- Detachable with normal tools

- Locking with a high detaching
strength

- Repairs the fit in bearing
housings

- Seals against leaks

- Difficult to detach

Locking of threaded connections 0068197

Locking of threaded connections,
gear lever ball, freeze plugs

0

number

1340646

Loctite
638

Loctite
648

Loctite
262

- Locking with a high detaching
strength under dynamic load

- Difficult to detach

- Locking with an average
detaching strength

- Resistant to high temperatures

- Locking with a high detaching
strength

- Difficult to detach

Locking of cylindrical connections 0645557

Locking of threaded connections in
warm places

Locking of threaded connections,
such as the pinion nut

1357032

1279841

©

200338 2-1

TECHNICAL DATA

0

0

Locking compounds and sealants

Applying the locking compound

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
name

Properties Applications DAF

ΛΦ45/55 series

number

Dirko D - Resistant to temperatures up to

180″C

- Resistant to oil, coolant

Loctite
510

Loctite
574

Loctite
Blue

Loctite
ultra grey

Loctite
ultra
copper

Loctite
5910

- Resistant to temperatures up to
200″C

- Resistant to oil, brake fluid,
coolant

- Resistant to high pressures (up to
350 bar)

- Resistant to oil, brake fluid,
coolant

- Resistant to temperatures from
60″C to 260″C

- Resistant to oil

- Silicone sealant, good resistance
to coolant

- Resistant to temperatures up to
325″C

- Silicone sealant, good resistance
to oil

- Resistant to temperatures of up
to 350″C

- Silicone sealant, good resistance
to oil

- Resistant to temperatures up to
200″C

Sealing of surface connections 1345014

Sealing of surface (flange)
connections that are subjected to high
operating temperatures, such as the
flywheel housing

Sealing of surface connections
against high pressures

Sealing of flexible constructions such
as (valve) covers

Sealing of (surface) connections in
the cooling system

Sealing of surface connections such
as hub covers

Sealing of surface connections, such
as front and rear covers of gearboxes,
differential housings, hub covers, stub
axle flanges and oil cooler

0697149

1246867

1242895

1284123

1284122

1360102

Loctite
572

2-2

- Seals against low pressure
immediately after fitting

Threaded connections 0292336

©

200338

0

TECHNICAL DATA

ΛΦ45/55 series

OVERVIEW OF SEALING COMPOUNDS

Product
name

Loctite
5205

Loctite
Form a
gasket

Product
name

Tectyl Protects the cavities of the cab body

Properties Applications DAF

- Surface sealant, specially
designed for sealing aluminium
parts

- Resistant to temperatures up to
150″C

- Resistant to water, coolant and oil

- Hardens on contact with metal
and on full closure

OTHER PRODUCTS

Properties Applications DAF

against corrosion.

Locking compounds and sealants

number

Sealing of aluminium parts 1441339

For locking, fastening and sealing 1322823

number

Post-treatment of cab parts to protect
against corrosion.
Can also be used as protection for
metal parts

1343888

0

Contact
spray

Loctite
cleaner
7063

Molykote
BR 2
PLUS

Molykote
P37

Copaslip - Copper paste with an excellent

Cleaning agent for cleaning and
degreasing electronic and electrical
connections. Removes moisture and
dirt from electrical contacts

- Cleans and degreases

- Non-inflammable and non­corrosive

- Lubricating grease is heat­resistant from -30″C to +130″ C

- Grease protects against
corrosion and is heat-resistant to
1400″C.

bond, is anti-corrosive and heat­resistant from -35″C to 1100″C.

- Resistant to water, salts and
acids.

- Prevents wear, oxidation, rust,
corroding and locking of metal
surfaces.

Cleaning of electrical contacts 1387608

For cleaning/degreasing of materials
to which a locking compound must be
applied

- Wherever grease lubrication is
appropriate and normal

- For almost all ball and roller
bearings, plain bearings, guides,
couplings, splined shafts,
threaded spindles, sprocket
drives with a low speed

For threaded connections that are
exposed to high temperatures, as
used for exhaust systems

For connections that are vulnerable to
oxidation or corrosion, such as battery
terminals, exhaust couplings, etc.

1322827

1389512

1391619

1284344

Renolit
HLT2

©

200338 2-3

- Grease (white) Disc brake adjustment device 1448907

TECHNICAL DATA

0

0

Locking compounds and sealants

Product
name

Syntheso
GL EP1

Gleitmo
805

Properties Applications DAF

- Grease (green) Rubber guides for disc brake 1448908

- Protects untreated metals
against corrosion

OTHER PRODUCTS

For parts which are attached with a fit
such as wheel hub units

ΛΦ45/55 series

number

1443160

2-4

©

200338

0

TECHNICAL DATA

ΛΦ45/55 series

3. THREADED CONNECTIONS

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.

Threaded connections

0

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 ≥ 230″ 60″ 90″ 120″

M10 60 ≥ 445″ 90″ 120″ 150″

M12 x 1.75
M12 x 1.25

M14 x 2
M14 x 1.5

M14 x 2 for brake back plates: 170 ≥ 15 Nm + 60″

M16 x 2
M16 x 1.5

110 ≥ 8
110 ≥ 8

170 ≥ 15
170 ≥ 15

260 ≥ 20
260 ≥ 20

30″
45″

30″
45″

30″
45″

60″
90″

60″
90″

60″
90″

90″
120″

90″
120″

90″
120″

120″
150″

120″
150″

120″
150″

M18 x 2.5
M18 x 1.5

M20 x 1.5 520 ≥ 40 45″ 90″ 120″ 150″

M22 x 2.5 for steering and track rods: 500 ≥ 50 Nm + 90″

©

200338 3-1

360 ≥ 30
360 ≥ 30

30″
45″

45″
90″

60″
120″

80″
150″

TECHNICAL DATA

0

0

Threaded connections

The bolt stem length L is the length of the bolt
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

ΛΦ45/55 series

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

3-2

©

200338

0

TECHNICAL DATA

ΛΦ45/55 series

Overview of standard tightening torques for
DAF clamping flange bolts and nuts, strength
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

Threaded connections

0

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.

©

200338 3-3

TECHNICAL DATA

0

0

Threaded connections

New bolts/nuts

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.

ΛΦ45/55 series

3-4

©

200338

0

TECHNICAL DATA

ΛΦ45/55 series

4. PAINT TREATMENT

4.1 OVERVIEW OF PLASTICS USED

1 SMC polyester
2 Thermoplastic polymer parts (ASA or ABS)
3 Fibre-glass reinforced polyester

1

2 2 1 2 1 1

Paint treatment

0

3

3

G0 00 206

©

200338 4-1

TECHNICAL DATA

0

0

Paint treatment

ΛΦ45/55 series

4-2

©

200338

0

LF45/55 series Contents

SAFETY INSTRUCTIONS AND WARNINGS

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................................................. .....

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...................................... .....

2

ǹ 0201

1

2

0SAFETY INSTRUCTIONS AND WARNINGS

Contents LF45/55 series

2

ǹ 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
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
ofthemechanicmaybeputatrisk.
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!

M0015

2

- 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.

ǹ 0201

1-1

2

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.

- 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).

- Alwaysuseatyrecagewhenfittingand
inflating tyres. Thoroughly clean tyres prior
to balancing. Only use a balancing device
fitted with a protective cover.

1-2

ǹ 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.

- After a fire, hazardous residues may remain
fromtheplasticsusedinsomeoilsealsand
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.

2

ǹ 0201

1-3

2

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.
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.

1-4

ǹ 0201

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
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
wheretheweldingistobedoneandensure
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.

2

ǹ 0201

1-5