DAF LF45 Maintenance Manual

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LF45/55

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Page 1 Maintenance manual LF45/55 https://www.truck-manuals.net/...
Page 2 https://www.truck-manuals.net/...
Page 3 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. © 200515 DW13279204...
Page 4 https://www.truck-manuals.net/...
Page 5 STRUCTURE ΛΦ45/55 series TECHNICAL DATA Structure THREADED CONNECTIONS FLUIDS, OIL AND LUBRICANTS MAINTENANCE SCHEDULE EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES © 200515 https://www.truck-manuals.net/...
Page 6 https://www.truck-manuals.net/...
Page 7 TECHNICAL DATA ΛΦ45/55 series Contents CONTENTS 0 Technical data Page Date ENGINE, COOLING SYSTEM AND FUEL SYSTEM ..... 1-1 ..200515 General .
Page 9 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...
Page 10 TECHNICAL DATA ΛΦ45/55 series 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.
Page 11 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.
Page 13 TECHNICAL DATA ΛΦ45/55 series Steering gear 2. STEERING GEAR 2.1 GENERAL Maximum axial steering ball joint play 1.5 mm © 200515 https://www.truck-manuals.net/...
Page 14 TECHNICAL DATA ΛΦ45/55 series Steering gear 2.2 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.
Page 15 TECHNICAL DATA ΛΦ45/55 series Drive shafts, drive and chassis 3. DRIVE SHAFTS, DRIVE AND CHASSIS 3.1 GENERAL Allison gearbox The oil level when cold must be on the "Cold full" mark. W 3 03 099 Dipstick readings: "Cold add" add when cold "Cold full"...
Page 16 TECHNICAL DATA ΛΦ45/55 series 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.
Page 17 TECHNICAL DATA ΛΦ45/55 series Drive shafts, drive and chassis Eaton FS6309A gearbox Level check/filler plug (1) 50 Nm Drain plug/oil strainer (4) 50 Nm V3 00 376 Allison 1000 & 2000 automatic gearboxes Gearbox drain plug (1) 35 Nm V3 00 885 Oil cooler air bleed plug (1) 28 Nm...
Page 18 TECHNICAL DATA ΛΦ45/55 series Drive shafts, drive and chassis Allison MD3060 automatic gearbox Drain plug (1) 28 Nm Oil filter cover attachment bolts (2) 55 Nm V300371 F36/F48 front axle Tightening torque for brake calliper attachment bolts 213 Nm Tightening sequence for attachment bolts Hub lock nut 75 Nm...
Page 19 TECHNICAL DATA ΛΦ45/55 series Drive shafts, drive and chassis 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...
Page 20 TECHNICAL DATA ΛΦ45/55 series 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...
Page 21 THREADED CONNECTIONS ΛΦ45/55 series Contents CONTENTS 2 Threaded connections Page Date THREADED CONNECTIONS ........1-1 ..200515 General .
Page 23 THREADED CONNECTIONS ΛΦ45/55 series Threaded connections 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...
Page 24 THREADED CONNECTIONS ΛΦ45/55 series 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...
Page 25 FLUIDS, OIL AND LUBRICANTS ΛΦ45/55 series Contents CONTENTS 3 Fluids, oil and lubricants Page Date SPECIFICATIONS..........1-1 ..200515 General .
Page 27 Ask your lubricant and fuel supplier(s) whether the products supplied comply with DAF specifications. DAF is not liable for damage or problems in the following instances: use of oil of a lower grade than specified. use of oil of a different viscosity than specified.
Page 29 MAINTENANCE SCHEDULE ΛΦ45/55 series Contents CONTENTS 4 Maintenance schedule Page Date MAINTENANCE INTERVALS ........1-1 ..200515 Maintenance schedule.
Page 31 ΛΦ45/55 series Maintenance intervals 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 X service Y service schedule 1x per YEAR LF45...
Page 32 MAINTENANCE SCHEDULE ΛΦ45/55 series 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.
Page 33 MAINTENANCE SCHEDULE ΛΦ45/55 series Maintenance intervals X service This is the symbol for an X service. 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.
Page 34 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...
Page 35 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 © 200515 https://www.truck-manuals.net/...
Page 36 MAINTENANCE SCHEDULE ΛΦ45/55 series Maintenance activities 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...
Page 37 MAINTENANCE SCHEDULE ΛΦ45/55 series Maintenance activities Note: Every 2 years. For changing interval: see maintenance schedule. For changing interval: see maintenance schedule. When changing the gearbox oil in an automatic gearbox, the automatic gearbox oil filters must also be replaced. Check the valve clearance at the 4 Y-service (at a maximum of 240,000 km) and then check and adjust, where necessary,...
Page 38 MAINTENANCE SCHEDULE ΛΦ45/55 series Maintenance activities 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...
Page 39: Table Of Contents
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Contents CONTENTS 5 Explanatory notes on the maintenance activities Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200515 Safety instructions .
Page 40: Page Date
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Contents Page Date 3.38 Checking greased wheel hubs for leaks ......3-32 ..200515 3.39 Checking the shock absorbers for attachment and leaks .
Page 41: Safety Instructions
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Safety instructions 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.
Page 42 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series 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.
Page 43: General
DAF reserves the right to make changes without prior notice. Note: Important changes relating to technical...
Page 44: Warning Symbol
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series 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.
Page 45: 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.
Page 46: Maintenance Guidelines
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series 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.
Page 47: Inspection And Adjustment
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 CHECKING PEDAL RUBBERS Check that the pedal rubbers are still securely mounted on the pedal. 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.
Page 48: Checking The Battery Terminals
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.3 CHECKING THE BATTERY TERMINALS Visually check the battery terminals for corrosion. Clean the battery terminals if necessary, see chapter "Cleaning". Check the attachment of the battery terminals. G0 00 208 3.4 CHECKING THE FLUID LEVEL OF THE CAB TILTING PUMP Check the fluid level when the cab is in the driving position.
Page 49: Checking The Vibration Damper (Vulcanised Version) Of The Be Engine
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.5 CHECKING THE CAB FASTENING Tilt the cab. Check that all attachment bolts are in place. Visually inspect the attachment of the cab to the tilting mechanism. Visually inspect the seals and condition of the tilting mechanism.
Page 50: Bleeding The Fuel System
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.7 BLEEDING THE FUEL SYSTEM Stop pumping as soon as a greater resistance is felt. If you continue pumping, the fuel system may become internally damaged. Note: When the hand pump is used, the fuel system will be automatically bled.
Page 51: Checking The Engine Oil Level
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.8 CHECKING THE ENGINE OIL LEVEL Ensure that the vehicle is entirely horizontal. Pull the dipstick (2) out of the holder. Wipe the dipstick clean with a lint-free cloth. Put the dipstick back into the holder.
Page 52: Checking And Adjusting Be Engine Valve Clearance
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series 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. Remove the valve cover. See "Removing and installing".
Page 53 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 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.
Page 54: Inspection And Adjustment, Ce Engine Valve Clearance
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 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. Remove the valve cover. See "Removal and installation".
Page 55 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 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.
Page 56: Checking The Poly-V-Belt
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. Consult the manufacturer’s instructions for the correct anti-freeze mixing ratio. Preferably, use 40% anti-freeze on an ethylene glycol base.
Page 57: Checking For Fuel Leaks
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.13 CHECKING FOR FUEL LEAKS Visually inspect all hose connections and fuel system components for leaks. 3.14 CHECKING THE COMPONENTS AND HOSE CONNECTIONS FOR LEAKS Check all hose connections and cooling system components for leaks.
Page 58: Check The Air Inlet Dust Trapping Valve
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.17 CHECK THE AIR INLET DUST TRAPPING VALVE Check the rubber sealing valve (1) at the bottom of the filter housing for clogging and damage. Steering gear and brake system I4 00 535 3.18 CHECKING THE STEERING BALL JOINT SLEEVE FOR DAMAGE Inspection, locking devices and dust cover...
Page 59: Checking The Steering Ball Joints
3.19 CHECKING THE STEERING BALL JOINTS Checking axial steering ball joint play Check the axial steering-ball joint play using special tool (DAF no. 1329426) First jack up the axle until the wheels come off the ground and put the axle on stands.
Page 60: Checking The Steering Oil Level
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.20 CHECKING THE STEERING OIL LEVEL Check the steering oil level when the engine is not running. Tilt the cab. Clean the dipstick and its surroundings so that absolutely no dirt can get into the reservoir.
Page 61: Checking The Steering Gear Lines And Connections
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.21 CHECKING THE STEERING GEAR LINES AND CONNECTIONS 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).
Page 62: Checking The Brake Components And Brake System For Leaks
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.22 CHECKING THE BRAKE COMPONENTS AND BRAKE SYSTEM FOR LEAKS 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...
Page 63: Checking The Brake Pad Thickness And Brake Disc
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.24 CHECKING THE BRAKE PAD THICKNESS AND BRAKE DISC Version: Knorr SB 7000 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.
Page 64 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment Version: Knorr SN 7000 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.
Page 65: Inspection And Adjustment, Load Sensing Valve, Air Suspension
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.
Page 66 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...
Page 67: Inspection And Adjustment, Load Sensing Valve, Leaf Suspension
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.
Page 68 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series 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.
Page 69: Checking The Differential For Leaks
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.27 CHECKING THE DIFFERENTIAL FOR LEAKS Visually inspect the differential for leaks. 3.28 CHECKING THE OPERATION OF THE DIFFERENTIAL LOCK Jack up the rear axle and support the axle on stands.
Page 70: Check The Drive Shaft Play
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.29 CHECK THE DRIVE SHAFT PLAY Check the universal joints (2) and suspension bearing (3) for play and damage. Check the sliding joint for axial and radial play. The rubber dust cover (1) over the sliding joint should be undamaged.
Page 71: Checking The Trailer Coupling
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.31 CHECKING THE TRAILER COUPLING Check the vertical play of the arched pin. Check the radial play of the arched pin. M9002 Check the vertical and horizontal play of the coupling jaw.
Page 72: Check The Superstructure Attachment
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.32 CHECK THE SUPERSTRUCTURE ATTACHMENT Check that all attachment bolts are in place. Visually check the attachment of the superstructure for faults. See the DAF superstructure instructions. © 3-26 200515 https://www.truck-manuals.net/...
Page 73: Check The Clutch Fluid Level
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 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.
Page 74: Check The Clutch Wear Indicator
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.34 CHECK THE CLUTCH WEAR INDICATOR Check that the wear indicator on the clutch servo has not gone past the mark on the clutch servo plate. If the wear indicator is at the mark on the clutch servo, replace the clutch plate.
Page 75: Checking Automatic Gearbox Oil Level
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.36 CHECKING AUTOMATIC GEARBOX OIL LEVEL Checking cold oil level Place the vehicle on a flat and level surface. Make sure that the gearbox is in neutral and allow the engine to run for several minutes. Apply the service brake, switch the gearbox to D, then to N and finally switch the gearbox to R.
Page 76 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment Checking hot oil level Bring the gearbox up to operating temperature (approx. 71C - 93C). 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...
Page 77: Inspection Of Oil Lubricated Wheel Hubs For Leaks
EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.37 INSPECTION OF OIL LUBRICATED WHEEL HUBS FOR LEAKS 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".
Page 78 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.38 CHECKING GREASED WHEEL HUBS FOR LEAKS 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.
Page 79 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.39 CHECKING THE SHOCK ABSORBERS FOR ATTACHMENT AND LEAKS 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 Visually inspect the condition and...
Page 80 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.41 CHECKING THE HINGE POINTS AND AXLE SUSPENSION FASTENING (AIR SUSPENSION) Torque rod Check the attachment of the torque rod and torque rod supports. Check the pivots of the torque rod for wear and play.
Page 81 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.42 CHECKING THE AIR SUSPENSION BELLOWS Raise the chassis to driving height using the remote control. Clean the air bellows using a cleaning cloth or a soap solution, if required. Check the air bellows for cracks and damage.
Page 82 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.43 ADJUSTING THE CROWN WHEEL GUIDE BOLT Place chocks in front of the wheels and put the vehicle on the parking brake. Loosen the circlip (1) and slacken the lock nut (2) a few turns.
Page 83 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 Jack up the rear axle until the wheels are clear from the floor and position suitable stands under the axle.
Page 84 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Inspection and adjustment 3.45 CHECKING THE CLAMP OF THE DRIVE SHAFT UNIVERSAL JOINT 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.
Page 85 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 Open the grille. Remove the attachment bolts (1) from the grate (2) on the underside of the filter casing. Open the grate and remove the interior filter element.
Page 86 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation 4.2 REMOVAL AND INSTALLATION, AIR FILTER ELEMENT Removing the air filter element Loosen all clamping brackets on the air filter cover. Remove the air filter cover. Remove the air filter element. Clean the inside of the air filter housing and the air filter cover.
Page 87 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation 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. Removing the lubricating oil filter Place a tray beneath the lubricating oil filter.
Page 88 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation 4.4 REMOVAL AND INSTALLATION, FUEL FINE FILTER When removing the fuel fine filter, a quantity of fuel will escape. Collect the fuel and avoid the risk of fire. Removing the fuel fine filter Place a container beneath the fuel fine filter and remove the filter.
Page 89 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation 4.5 REMOVAL AND INSTALLATION, FUEL PREFILTER/WATER SEPARATOR When removing the fuel prefilter/ water separator, a quantity of fuel will escape. Collect the fuel and avoid the risk of fire. Removing the fuel prefilter/water separator filter element Place a container under the filter.
Page 90 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation 4.6 REMOVAL AND INSTALLATION, VALVE COVER When the engine or parts of the engine are opened, dirt can get in. This may cause serious damage to the engine. The engine should therefore be cleaned thoroughly before any parts are opened.
Page 91 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series 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.
Page 92 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation Using a water-resistant felt pen, write on the sticker the latest date by which the dryer Artikelnummer element must be replaced (not later than 1 year after the date of fitting). Reference Teilenummer Référence...
Page 93 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation 4.8 REMOVAL AND INSTALLATION, FILTER ELEMENT IN THE RESERVOIR OF THE RAS-EC STEERING GEAR Removing the filter element Clean the reservoir cover, so that absolutely no dirt can get into the reservoir. Remove the cover (3).
Page 94 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation 4.9 REMOVAL AND INSTALLATION, HIGH-PRESSURE FILTER OF THE RAS-EC STEERING GEAR Drained steering oil must not be re- used. Store this hydraulic oil separately from the other drained oils and have the oil collected by a waste-removal company authorised to do so.
Page 95 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation 4.10 REMOVAL AND INSTALLATION, F36/F48 FRONT AXLE WHEEL HUB Removing the hub Support the front axle in a safe manner. Remove the wheel. Remove the wheel speed sensor (1). S7 00 589 Remove the cap placed over the adjusting bolt (1).
Page 96 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation Remove the hub cap (11). Remove the lock nut (10). Remove the hub (5) from the axle journal (1). Save the circlip (8) and the bearing cage (7). Remove the seal (2) from the hub (5). 10.
Page 97 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation Fit a new seal (2) in the hub (5). 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).
Page 98 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation 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.
Page 99 (DAF no. 1329458). Make sure that the chamber is not damaged during this. Installing the hub seal 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.
Page 100 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation 4.12 REMOVAL AND INSTALLATION, AUTOMATIC GEARBOX OIL FILTERS Allison 1000 & 2000 series automatic gearbox To prevent skin injury, avoid unnecessary contact with the drained oil. Removing the oil filters Clean the oil filter (1) and filter (5), if present, as well as the surrounding area.
Page 101 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation Allison MD 3060 automatic gearbox Removing the oil filters Remove the attachment bolts from the filter covers (2) and remove the filter covers. Collect any oil that is flowing out. Remove the oil filters from the oil sump.
Page 102 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Removal and installation © 4-18 200515 https://www.truck-manuals.net/...
Page 103 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling 5. DRAINING AND FILLING 5.1 TOPPING UP BATTERY FLUID 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.
Page 104 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling 5.2 DRAINING AND REPLENISHING THE ENGINE OIL To prevent skin injury, avoid unnecessary contact with the drained oil. Draining the engine oil Ensure that the vehicle is standing on a flat and level surface.
Page 105 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling 5.3 DRAINING, FILLING AND BLEEDING THE COOLING SYSTEM In order to avoid damaging the cylinder block, do not top up a warm engine with cold coolant. Coolant is a toxic fluid and must be handled with care.
Page 106 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling If the vehicle is equipped with a water/air cab heater Run the engine at idling speed. Switch on the cab heater, using the rocker switch on the dashboard. Turn the heater temperature control knob in the cab to the "warmest"...
Page 107 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling 5.4 DRAINING AND FILLING, RAS-EC STEERING CIRCUIT Drained steering oil must not be re- used. Store this hydraulic oil separately from the other drained oils and have the oil collected by a waste-removal company authorised to do so.
Page 108 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling 10. Correctly position the damping valves on the steering cylinder. Note: The mixing up of damping valves must be avoided under all circumstances. The mixing up of damping valves has a negative impact on vehicle handling.
Page 109 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling 5.5 BLEEDING THE RAS-EC STEERING CIRCUIT Bleeding the RAS-EC steering circuit Gently turn the steering wheel in both directions, if the level in the reservoir hardly drops, if at all. Note: It is possible that the system fails at the slightest steering movement.
Page 110 Remove the level check/filler plug (A) and drain plug (B). Drain the oil. Fit the plug using the special Torx wrench (DAF no. 1329493) and tighten to the specified torque; see "Technical data". Filling the 1132 axle differential Fill the differential gear through the level check/filler plug (A) with the specified quantity of oil;...
Page 111 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling 5.7 DRAINING AND FILLING, WHEEL HUB To prevent skin injury, avoid unnecessary contact with the drained oil. Note: The design of the hub and the location of the drain/filler plug may differ from the illustration, depending on the version.
Page 112 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling 5.8 DRAINING AND FILLING, GEARBOX ZF S5-42 gearbox To prevent skin injury, avoid unnecessary contact with the drained oil. Draining the gearbox Place the vehicle on a flat and level surface. Drain the gearbox at operating temperature.
Page 113 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling EATON 6309A gearbox To prevent skin injury, avoid unnecessary contact with the drained oil. Draining the gearbox Place the vehicle on a flat and level surface. Drain the gearbox at operating temperature. Remove the oil strainer/drain plug (4) and the level check/filler plug (1) and drain the oil.
Page 114 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling Allison 1000 & 2000 automatic gearboxes To prevent skin injury, avoid unnecessary contact with the drained oil. Draining the gearbox Place the vehicle on a level and horizontal surface. Bring the gearbox to operating temperature (approx.
Page 115 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling Filling the gearbox Clean the drain plugs, provide them with new sealing rings and fit them, tightening them to the specified torque, see "Technical data". Fill the gearbox through the dipstick holder with the specified quantity of oil;...
Page 116 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Draining and filling Filling the gearbox Clean the drain plug (1), fit a new sealing ring and tighten the plug to the specified torque; see "Technical data". Fit the oil filters (2). See "Removal and installation".
Page 117 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Cleaning 6. CLEANING 6.1 CLEANING THE BATTERY TERMINALS 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.
Page 118 Note: With the aid of a simple tool, the radiator and the air cooler can be blow-cleaned. The tool (radiator cleaner) cannot be ordered from DAF. It should be manufactured by yourself according to the drawing. Key to drawing: 1150mm...
Page 119 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Cleaning Turn the radiator cleaner (3) over, turning the holes towards the radiator (2), and blow- clean the radiator (2). M201352 If the vehicle has air conditioning, fit the condenser in the air cooler supports and tighten the support of the refrigerant pipes (1) on the radiator.
Page 120 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Cleaning 6.3 CLEANING THE VEHICLE Before cleaning the vehicle, check the engine, axles, gearbox, etc. for leaks. Having cleaned the vehicle, it will no longer be possible to check for leaks during the maintenance activities. Make sure that doors, windows and roof hatch are securely closed during cleaning.
Page 121 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Cleaning 6.4 CLEANING GEARBOX VENT(S) Cleaning gearbox vent(s) Clean the vent(s) and the surrounding area. Remove the vent(s) from the gearbox. Rinse the vent(s) in a cleaning fluid. Blow the vent(s) dry from the inside using compressed air.
Page 122 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Cleaning 6.5 CLEANING REAR AXLE VENT Cleaning rear axle vent Clean the vent and the surrounding area. Remove the vent from the rear axle. Rinse the vent in a cleaning fluid. Blow the vent dry from the inside using compressed air.
Page 123 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Lubrication 7. LUBRICATION 7.1 LUBRICATING ACCORDING TO Y-SERVICE LUBRICATION SCHEDULE Note: The lubricating points marked below with an (S) indicate that the lubricating point is positioned on both the left-hand and right-hand side of the vehicle.
Page 124 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Lubrication 152N (S) front axle The 152N front axle has a grease nipple on the top side and underside. G000189 © 200515 https://www.truck-manuals.net/...
Page 125 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Lubrication 7.2 LUBRICATE ACCORDING TO X-SERVICE LUBRICATION SCHEDULE Lubricating the selector rod Tilt the cab. Apply a thin, even layer of grease to the indicated part. Note: The locking hook under the cab must not be lubricated.
Page 126 EXPLANATORY NOTES ON THE MAINTENANCE ACTIVITIES ΛΦ45/55 series Lubrication © 200515 https://www.truck-manuals.net/...
Page 127 https://www.truck-manuals.net/...
Page 128 English Printed in the Netherlands DW13279204 https://www.truck-manuals.net/...

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DAF LF45 Maintenance Manual

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1 Safety Instructions

2 General

3 Inspection and Adjustment

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