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teering
Service Manual
328 pgs3.58 Mb1

DAF teering Service Manual

7
LF45/55 series
STRUCTURE
TECHNICAL DATA
0
DIAGNOSTICS
1
STEERING GEAR, GENERAL
2
STEERING BOX
3
4
RESERVOIR AND LINES
5
FRONT AXLE, F36/F48
FRONT AXLE, F60
FRONT AXLE, 152N
STEERED TRAILING SWIVEL AXLE
6
7
8
9
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7
TECHNICAL DATA
LF45/55 series Contents
CONTENTS
Page Date
1. STEERING GEAR, GENERAL 1-1 200322........................................... ....
1.1 General 1-1 200322......................................................... ....
2. STEERING BOX 2-1 200322....................................................... ....
2.1 General 2-1 200322......................................................... ....
2.2 Tightening torques 2-2 200322................................................ ....
3. STEERING PUMP/RESERVOIR 3-1 200322......................................... ....
3.1 General 3-1 200322......................................................... ....
3.2 Tightening torques 3-1 200322................................................ ....
4. F36 AND F48 FRONT AXLE 4-1 200322............................................ ....
4.1 General 4-1 200322......................................................... ....
4.2 Tightening torques 4-3 200322................................................ ....
5. F60 FRONT AXLE 5-1 200322..................................................... ....
5.1 General 5-1 200322......................................................... ....
5.2 Tightening torques 5-3 200322................................................ ....
6. 152N FRONT AXLE 6-1 200322.................................................... ....
6.1 General 6-1 200322......................................................... ....
6.2 Tightening torques 6-7 200322................................................ ....
7. STEERED TRAILING SWIVEL AXLE 7-1 200322.................................... ....
7.1 General 7-1 200322......................................................... ....
7.2 Tightening torques 7-3 200322................................................ ....
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0
7TECHNICAL DATA
Contents LF45/55 series
2
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7
TECHNICAL DATA
LF45/55 series Steering gear, general
1. STEERING GEAR, GENERAL
1.1 GENERAL
Steered axles
Vehicle type
LF45 6 and 8 tonnes F36 N/A
LF45 10, 11 and 12 tonnes F48 N/A
LF55 12, 13, 14 and 15
LF55 FAN 12, 13, 14 and 15
LF55 16 and 18 tonnes 152N N/A
Steering box
Vehicle type
LF45 6 and 8 tonnes ZF8090 130 + 10 bar
LF45 10, 11 and 12 tonnes ZF8090 180 + 10 bar
LF55 12, 13, 14 and 15
GVW Front axle Trailing axle
F60 N/A
tonnes
F60 Steered trailing swivel
tonnes
GVW Steering box Max. system
ZF8095 150 + 10 bar
tonnes
axle (F60)
pressure
0
LF55 FAN 12, 13, 14 and 15
tonnes
LF55 16 and 18 tonnes ZF8098 150 + 10 bar
Circulation pressure
Maximum permissible circulation pressure of the steering gear at a steering-oil temperature of 50_C
Final limiting pressure
Final limiting pressure at a steering-oil temperature of 50_C and an engine speed of 1200-1400 rpm
Steering box internal leaks
Maximum permissible internal leakage in the steering box ZF 8090 steering box 2.0 l/min.
ZF 8095 and 8098 steering box 2.5 l/min.
ZF8095 150 + 15 bar
10 bar max.
40-45bar
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1-1
0
TECHNICAL DATA
7
Steering gear, general LF45/55 series
Steering box internal play
Maximum permissible internal play of the steeringboxwithablockedpitmanarm
Steering pump
LF45 series ZF 7684 steering pump LF55 series, other vehicles ZF 7685 steering pump LF55 series FAN version ZF 7687 steering pump
Steering pump output
Steering pump output at a steering oil temperature of 50_C and pressure of 50 bar, at idling speed
ZF 7684 steering pump 5.9 l/min. minimum ZF 7685 steering pump 7.0 l/min. minimum ZF 7687 steering pump 10.8 l/min. minimum
Steering pump output at a steering oil temperature of 50_C, pressure of 50 bar and an engine speed of approx. 1300 1400 rpm
ZF 7684 steering pump 8.0 - 10.4 l/min. ZF 7685 steering pump 16.0 - 20.8 l/min. ZF 7687 steering pump 22.5 - 27.5 l/min.
4 cm steering wheel deflection
1-2
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7
TECHNICAL DATA
LF45/55 series Steering box
2. STEERING BOX
2.1 GENERAL
Steering box
Version: single-circuit steering box with automatic
bleeding, self-adjusting wheel-deflection
limiting valves and pressure-limiting valve. Type: ZF 8090 used on F36 and F48 front axle. ZF 8095 used on F60 front axle. ZF 8098 used on 152N front axle.
Pressure point
Resistance increase in the pressure point ZF 8090 20 - 60 Ncm ZF 8095 20 - 80 Ncm ZF 8098 20 - 100 Ncm
Input shaft end play
ZF 8090 0.005 - 0.025 mm ZF 8095 0.010 - 0.030 mm ZF 8098 0.020 - 0.040 mm
0
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2-1
TECHNICAL DATA
7
Steering box LF45/55 series
2.2 TIGHTENING TORQUES
0
The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the tightening 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 ones removed
LF45 steering gear
.
E
A B CD G
F
IJG
IH
S7 00 884
2-2
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7
TECHNICAL DATA
LF45/55 series Steering box
A. Attachment bolts/nuts, steering bracket
on M12 10.9 chassis Stud bolt in steering bracket 80 Nm
B. Bolts/nuts for attaching the steering box
to the steering bracket
Stud bolt in steering box 180 Nm C. Pitman-arm attachment nut 350 Nm D. Pressure-limiting valve 30 Nm E. Steering wheel attachment bolt 50 Nm F. Attachment bolt/nut, steering column
universal joint G. Wheel-deflection limiting valve stop bolt 15 Nm H. Attachment bolt, steering-rod clamping
bracket I. Steering rod castle nut 180 Nm J. Cover attachment bolt 135 Nm
(1) Always use new attachment bolts. (2) Use new original attachment bolt and nut. (3) Tighten until the split pin fits (max. 60_).
according to standard
400 Nm
56 Nm
48 Nm
(1)
(2)
(3)
0
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2-3
0
TECHNICAL DATA
Steering box LF45/55 series
LF55 steering gear
E
7
A B CD G
F
IJG
IH
S7 00 884
2-4
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7
TECHNICAL DATA
LF45/55 series Steering box
A. Attachment bolts/nuts, steering bracket
on M14 10.9 chassis
Stud bolt in steering bracket 125 Nm B. Bolts/nuts for attaching the steering box
to the steering bracket
Stud bolt in steering box 180 Nm C. Pitman-arm attachment nut
- with ZF8095 steering box 520 Nm
- with ZF8098 steering box 570 Nm D. Pressure-limiting valve 30 Nm E. Steering wheel attachment bolt 50 Nm F. Attachment bolt/nut, steering column
universal joint G. Wheel-deflection limiting valve stop bolt 15 Nm H. Attachment bolt, steering-rod clamping
bracket
- with F60 front axle 65 Nm
- with 152N front axle 90 Nm I. Steering rod castle nut 220 Nm J. Cover attachment bolt
- with ZF8095 steering box 285 Nm
- with ZF8098 steering box 189 Nm
according to standard
560 Nm
56 Nm
(1)
(2)
(3)
0
(1) Always use new attachment bolts. (2) Use new original attachment bolt and nut. (3) Tighten until the split pin fits (max. 60_).
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2-5
0
TECHNICAL DATA
Steering box LF45/55 series
7
2-6
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7
TECHNICAL DATA
LF45/55 series Steering pump/reservoir
3. STEERING PUMP/RESERVOIR
3.1 GENERAL
Steering pump
Design vane pump Type ZF 7684, ZF 7685, ZF 7687 Maximum pressure see steering box type plate (Pump does not have pressure-limiting valve.)
3.2 TIGHTENING TORQUES
The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the tightening 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 ones removed
Steering pump attachment bolts 46 Nm Flow-control valve plug 65 Nm Delivery pipe connection in the pump 36 Nm Cover attachment bolts 20 Nm Reservoir attachment bolts 8 Nm
.
0
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3-1
0
TECHNICAL DATA
Steering pump/reservoir LF45/55 series
7
3-2
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7
TECHNICAL DATA
LF45/55 series F36 and F48 front axle
4. F36 AND F48 FRONT AXLE
4.1 GENERAL
Axle journal
Anti-corrosion agent Gleitmo 805
Wheel speed sensor
Anti-corrosion agent Molykote P37
Camber angle and kingpin inclination (KPI)
Camber angle (X) on an unloaded axle King-pin inclination (Y) 7_
0_30′
0
S7 00 129
Wheel deflection
Maximum inner wheel deflection
- F36 axle 53_
- F48 axle 53_
Caster
Z=caster
- F36 axle 4_
- F48 axle 4_
Z
S7 00 607
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4-1
0
TECHNICAL DATA
7
F36 and F48 front axle LF45/55 series
Toe
Measured at the side walls of the tyre (B -- A) in unloaded condition
- F36 axle, toe-in 0 - 1.6 mm
- F48 axle, toe-in 0 - 1.6 mm
A
B
S7 00 833
Steering ball joints
Axial play max. 1.5 mm
Swivel axle
Axial play
- F36 axle 0.05 - 0.12 mm
- F48 axle 0.05 - 0.12 mm
List of shim sizes (thickness) for adjusting swivel axle play
Hub
Wheel bearing play
- F36 axle 0.05 -0.20 mm
- F48 axle 0.05 -0.20 mm
0.05 mm
0.125 mm
0.25 mm
1.00 mm
4-2
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7
TECHNICAL DATA
LF45/55 series F36 and F48 front axle
4.2 TIGHTENING TORQUES
The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the tightening 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 ones removed
.
0
ᓻ 200322
4-3
TECHNICAL DATA
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7
F36 and F48 front axle LF45/55 series
0
A
B
H
G
F
A. Hub nut 75 Nm B. Steering-rod arm attachment bolt 255 ᐔ 15 Nm C. Top attachment bolt for king-pin cover 25 Nm D. Track rod castle nut 175 ᐔ 10 Nm E. Track rod lock nut 130 ᐔ 10 Nm F. Bottom attachment bolt for king-pin cover 120 ᐔ 5Nm G. Wheel nut
- F36 axle (M18 x 1.5) 370 ᐔ 30 Nm
- F48 axle (M20 x 1.5) 485 ᐔ 35 Nm H. Hub attachment bolt 115 ᐔ 5Nm
E
(1)
DC
S7 00 748
(2)
(3)
(4)
(4)
(1) Turn the nut anticlockwise (approx. 90_) until the
specified wheel bearing play is achieved. Lock with
split pin. (2) Tighten until the split pin fits (max. 60_). (3) Lock nut using locking plate. (4) Retighten after 100 km. If new wheel bolts have been
fitted, the wheels need additional retightening after
500 km.
4-4
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7
TECHNICAL DATA
LF45/55 series F60 front axle
5. F60 FRONT AXLE
5.1 GENERAL
Axle journal
Anti-corrosion agent Gleitmo 805
Wheel speed sensor
Anti-corrosion agent Molykote P37
Camber angle and kingpin inclination (KPI)
Camber angle (X) on an unloaded axle King-pin inclination (Y) 7_15′
0_30′
0
S7 00 129
Wheel deflection
Maximum inner wheel deflection
Caster
Z=caster 3_
50_
Z
S7 00 607
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5-1
0
TECHNICAL DATA
7
F60 front axle LF45/55 series
Toe
Measured at the side walls of the tyre (B -- A) in unloaded condition Toe-in 0 - 1.6 mm
A
B
S7 00 833
Steering ball joints
Axial play max. 1.5 mm
King pin
Press-in force 150 kN
5-2
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7
TECHNICAL DATA
LF45/55 series F60 front axle
5.2 TIGHTENING TORQUES
The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the tightening 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 ones removed
.
0
ᓻ 200322
5-3
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0
TECHNICAL DATA
7
F60 front axle LF45/55 series
A
H
G
F
A. Steering-rod arm attachment bolt 370 ᐔ 35 Nm B. Steering rod castle nut 220 Nm C. Track rod castle nut 280 ᐔ 25 Nm D. Clamping bracket attachment bolt 80 ᐔ 10 Nm E. Track-rod arm attachment bolt 420 ᐔ 40 Nm F. Wheel nut (M20 x 1.5) 485 ᐔ 35 Nm G. Hub nut
st
-1
phase 300 Nm
-2ndphase turn the hub through 10 rotations
-3rdphase 350 Nm
th
-4
phase turn the hub through 10 rotations
-5thphase 685 ᐔ 65 Nm
H. Wheel hub attachment bolt 210 ᐔ 40 Nm
(2)
(5)
E
(1)
(2)
(3)
(1)
(4)
B
C
D
S7 00 698
(6)
(6)
(1) Apply Loctite 243 to the attachment bolt. (2) Tighten until the split pin fits (max. 60_). (3) Fit new self-locking nut. (4) Retighten after 100 km. If new wheel bolts have been
fitted, the wheels need additional retightening after
500 km. (5) Fit new hub nut. (6) Rotate the hub at a speed of approx. 40 rpm.
5-4
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7
TECHNICAL DATA
LF45/55 series 152N front axle
6. 152N FRONT AXLE
6.1 GENERAL
Axle journal
Anti-corrosion agent Gleitmo 805
Wheel speed sensor
Anti-corrosion agent Molykote P37
Camber angle and kingpin inclination (KPI)
Camber angle (X) on an unloaded axle King-pin inclination (Y) 7_30′
1_
0
S7 00 129
Caster
Z=caster 3_
Z
S7 00 607
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6-1
TECHNICAL DATA
7
152N front axle LF45/55 series
0
List of keys that can be supplied for adjusting caster (Z) Key angle W
(1)
LH
0.5_ 78 155 2.85 1_ 78 155 4.20
1.5_ 78 155 5.55 2_ 78 155 6.91
2.5_ 78 155 8.26 3_ 78 155 9.62
(1) Spring leaf width
Wheel deflection
Maximum inner wheel deflection
50_
Toe
Toe values are shown in the graph.
Note:
In the graph, the toe has a value of
0.5 ᐔ 1 mm/m toe-in at 75% of the permissible loading weight. The axle load consists of the unloaded axle weight + loading weight.
1,5
±0,3
20,5
±0,3
±2
L
B
H
±1
S7 00 107
Explanation of graph
1. At the top of the graph, the axle type and
the axle configuration (1) is shown.
2. The toe is shown in mm/m on the left-hand
side of the graph. The values above the 0 line show toe-in values, indicated by the symbol (2). The values below the 0 line show toe-out values, indicated by the symbol (3). The toe-out values are shown as negative values.
3. The axle load (4) is shown at the bottom of
the graph.
4. The permitted toe at any axle load is
indicated by the shaded area (5) in the graph.
5. If the measured value lies outside the
shaded area, the toe must be adjusted to the value indicated by the continuous line (6).
1
mm/m
2
3
152 N
6
5,5
5
4,5
4
3,5
3
2,5
2
1,5
1
0,5
0
12345678
-0,5
-1
-1,5
-2
6
5
x 1000 KG
4
S7 00 422
6-2
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7
TECHNICAL DATA
LF45/55 series 152N front axle
Toe, 152N front axle
0
mm/m
152 N
6
5,5
5
4,5
4
3,5
3
2,5
2
1,5
1
0,5
0
-0,5
12345678
-1
-1,5
-2
Steering ball joints
Axial play max. 1.5 mm
x 1000 KG
S7 00 414
Swivel axle
Axial play 0.05 - 0.3 mm
List of shim sizes (thickness) for adjusting swivel axle play
1.50 mm
1.75 mm
1.88 mm
2.00 mm
2.13 mm
2.25 mm
2.38 mm
ᓻ 200322
6-3
;
;
;
;
0
TECHNICAL DATA
7
152N front axle LF45/55 series
Wheel offset of needle bearings
- dimensiona:12-13mm
- dimensionb:3-4mm
a
b
S7 00 710
Steering rod adjustment
The angle between the marks on the steering box input shaft and the mark on the steering box for adjusting the steering rod are shown in the graph. This angle is shown with the wheels of the front axle in the “straight ahead” position.
Explanation of graph
1. The axle type and the axle configuration (1)
is shown at the top of the graph.
2. The angle between the marks on the
steering box input shaft and the mark on the steering box (2) are shown on the left-hand side of the graph. Note that there are two different graphs for LHD and RHD vehicles.
3. The front axle load (3) is shown at the
bottom of the graph.
4. The permitted angle at any axle load is
indicated by the shaded area (4) in the graph.
5. If the measured value lies outside the
shaded area (4), the angle must be adjusted to the value indicated by the continuous line (5). Set the correct angle by screwing the ball end of the steering rod in or out.
+30
+20
0¡
+-
+10
0
-10
-20
-30
7500 7050
152 N
0,5
-9
-19
10
B
0
-10
A
5550 4150 3000
27
17
7
KG
S7 00 877
6-4
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7
TECHNICAL DATA
LF45/55 series 152N front axle
Steering rod adjustment, LHD vehicles
152 N
0
+30
+-
+20
+10
0,5
0
-9
-10
-19
-20
-30
7500 7050 5550 4150 3000
Note:
“+” on the vertical axis of the graph indicates towards the driver’s side. “-- ” indicates towards the co-driver’s side.
27
17
10
7
0
-10
KG
S7 00 886
ᓻ 200322
6-5
0
TECHNICAL DATA
7
152N front axle LF45/55 series
Steering rod adjustment, RHD vehicles
152 N
+30
+20
+-
+10
0,5
0
-9
-10
-19
-20
-30
7500 7050 5550 4150 3000
Note:
“+” on the vertical axis of the graph indicates towards the driver’s side. “-- ” indicates towards the co-driver’s side.
27
17
10
7
0
-10
KG
S7 00 876
Steering rod arm
Abutting surface of steering rod arm to swivel axle treated with
Wheel speed sensor ring
Axial end play max. 0.25 mm
Loctite 2701
6-6
ᓻ 200322
7
TECHNICAL DATA
LF45/55 series 152N front axle
6.2 TIGHTENING TORQUES
The tightening torques stated in this section are different from the standard tightening torques included in the overview of standard tightening torques. Any other threaded connections that are not specified must therefore be tightened to the tightening 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 ones removed
.
0
ᓻ 200322
6-7
TECHNICAL DATA
7
152N front axle LF45/55 series
0
AB F
C
GH
D E
I
S7 00 883
A. Hub nut of wheel hub unit
st
-1
phase 400 Nm
-2ndphase turn the hub through 10 rotations
(1)
(2)
-3rdphase 450 Nm
th
-4
phase turn the hub through 10 rotations
(2)
-5thphase 950 Nm B. Wheel nut 700 Nm C. King-pin nut 595 Nm
(3)
(4)
D. Steering-rod arm attachment bolt 500 Nm + 90_ angular displacement E. Steering rod castle nut 220 Nm F. Attachment bolt, steering-rod clamping
bracket
90 Nm G. M20 attachment nut, track rod 225 Nm H. M12 attachment bolt, track rod clamping
bracket
80 Nm
(6)
(1)
(7)
(1)
I. Track rod arm attachment bolt 500 Nm + 90_ angular displacement
(5)
(5)
(1) Fit new nut. (2) Rotate the hub at a speed of approx. 40 rpm. (3) Retighten after 100 km. If new wheel bolts have been
fitted, the wheels need additional retightening after
500 km. (4) Apply Loctite 243 to the nut. (5) Fit new attachment bolt. Apply Loctite 243 to the
attachment bolt. (6) Tighten until the split pin fits (max. 60_). (7) Check the screw thread of the ball end for damage. Fit
new self-locking nut. Apply Loctite 243 to the nut.
6-8
ᓻ 200322
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