DAF LF45 Series User manual

STRUCTURE
©200338
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ΛΦ45/55 series
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Structure TECHNICAL DATA
SAFETY INSTRUCTIONS AND WARNINGS
THREADED CONNECTIONS
SEALS AND BEARINGS
GENERAL OPERATIONS
PAINT TREATMENT
CONVERSION TABLES

©200338 1
Contents
TECHNICAL DATA
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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

TECHNICAL DATA
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©200338 1-1
Vehicle models
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1. VEHICLE MODELS
1.1 OVERVIEW
FT
FA 4 x 2
FAN
steered axle driven axle
6 x 2
G0 00 205

TECHNICAL DATA
1-2 ©200338
Vehicle models
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ΛΦ45/55 series
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©200338 2-1
Locking compounds and sealants
TECHNICAL DATA
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2. LOCKING COMPOUNDS AND SEALANTS
2.1 GENERAL
}Certain cleaning agents have a
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.
OVERVIEW OF LOCKING COMPOUNDS
Product
name
Properties Applications DAF
number
Loctite
243
- Locking with an average
detaching strength
- Detachable with normal tools
Locking of threaded connections 0068197
Loctite
2701
- Locking with a high detaching
strength
- Repairs the fit in bearing
housings
- Seals against leaks
- Difficult to detach
Locking of threaded connections,
gear lever ball, freeze plugs
1340646
Loctite
638
- Locking with a high detaching
strength under dynamic load
- Difficult to detach
Locking of cylindrical connections 0645557
Loctite
648
- Locking with an average
detaching strength
- Resistant to high temperatures
Locking of threaded connections in
warm places
1357032
Loctite
262
- Locking with a high detaching
strength
- Difficult to detach
Locking of threaded connections,
such as the pinion nut
1279841

TECHNICAL DATA
2-2 ©200338
Locking compounds and sealants
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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
number
Dirko D - Resistant to temperatures up to
180″C
- Resistant to oil, coolant
Sealing of surface connections 1345014
Loctite
510
- Resistant to temperatures up to
200″C
- Resistant to oil, brake fluid,
coolant
Sealing of surface (flange)
connections that are subjected to high
operating temperatures, such as the
flywheel housing
0697149
Loctite
574
- Resistant to high pressures (up to
350 bar)
- Resistant to oil, brake fluid,
coolant
Sealing of surface connections
against high pressures
1246867
Loctite
Blue
- Resistant to temperatures from
60″C to 260″C
- Resistant to oil
Sealing of flexible constructions such
as (valve) covers
1242895
Loctite
ultra grey
- Silicone sealant, good resistance
to coolant
- Resistant to temperatures up to
325″C
Sealing of (surface) connections in
the cooling system
1284123
Loctite
ultra
copper
- Silicone sealant, good resistance
to oil
- Resistant to temperatures of up
to 350″C
Sealing of surface connections such
as hub covers
1284122
Loctite
5910
- Silicone sealant, good resistance
to oil
- Resistant to temperatures up to
200″C
Sealing of surface connections, such
as front and rear covers of gearboxes,
differential housings, hub covers, stub
axle flanges and oil cooler
1360102
Loctite
572
- Seals against low pressure
immediately after fitting
Threaded connections 0292336

©200338 2-3
Locking compounds and sealants
TECHNICAL DATA
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Loctite
5205
- Surface sealant, specially
designed for sealing aluminium
parts
- Resistant to temperatures up to
150″C
- Resistant to water, coolant and oil
Sealing of aluminium parts 1441339
Loctite
Form a
gasket
- Hardens on contact with metal
and on full closure
For locking, fastening and sealing 1322823
OVERVIEW OF SEALING COMPOUNDS
Product
name
Properties Applications DAF
number
OTHER PRODUCTS
Product
name
Properties Applications DAF
number
Tectyl Protects the cavities of the cab body
against corrosion.
Post-treatment of cab parts to protect
against corrosion.
Can also be used as protection for
metal parts
1343888
Contact
spray
Cleaning agent for cleaning and
degreasing electronic and electrical
connections. Removes moisture and
dirt from electrical contacts
Cleaning of electrical contacts 1387608
Loctite
cleaner
7063
- Cleans and degreases
- Non-inflammable and non-
corrosive
For cleaning/degreasing of materials
to which a locking compound must be
applied
1322827
Molykote
BR 2
PLUS
- Lubricating grease is heat-
resistant from -30″C to +130″C
- 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
1389512
Molykote
P37
- Grease protects against
corrosion and is heat-resistant to
1400″C.
For threaded connections that are
exposed to high temperatures, as
used for exhaust systems
1391619
Copaslip - Copper paste with an excellent
bond, is anti-corrosive and heat-
resistant from -35″C to 1100″C.
- Resistant to water, salts and
acids.
- Prevents wear, oxidation, rust,
corroding and locking of metal
surfaces.
For connections that are vulnerable to
oxidation or corrosion, such as battery
terminals, exhaust couplings, etc.
1284344
Renolit
HLT2
- Grease (white) Disc brake adjustment device 1448907

TECHNICAL DATA
2-4 ©200338
Locking compounds and sealants
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Syntheso
GL EP1
- Grease (green) Rubber guides for disc brake 1448908
Gleitmo
805
- Protects untreated metals
against corrosion
For parts which are attached with a fit
such as wheel hub units
1443160
OTHER PRODUCTS
Product
name
Properties Applications DAF
number

©200338 3-1
Threaded connections
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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.
Tightening torques for dipped threaded
connections
Overview of standard tightening torques for
DAF flange bolts and nuts, strength class
10.9/10
Clamping flange bolt/standard-flange bolt
M2 00 001
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
110 ≥8
110 ≥8
30″
45″
60″
90″
90″
120″
120″
150″
M14 x 2
M14 x 1.5
170 ≥15
170 ≥15
30″
45″
60″
90″
90″
120″
120″
150″
M14 x 2 for brake back plates: 170 ≥15 Nm + 60″
M16 x 2
M16 x 1.5
260 ≥20
260 ≥20
30″
45″
60″
90″
90″
120″
120″
150″
M18 x 2.5
M18 x 1.5
360 ≥30
360 ≥30
30″
45″
45″
90″
60″
120″
80″
150″
M20 x 1.5 520 ≥40 45″90″120″150″
M22 x 2.5 for steering and track rods: 500 ≥50 Nm + 90″

TECHNICAL DATA
3-2 ©200338
Threaded connections
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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
Overview of standard tightening torques for
DAF flange bolts and nuts, strength class
12.9/12
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
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

©200338 3-3
Threaded connections
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Overview of standard tightening torques for
DAF clamping flange bolts and nuts, strength
class 12.9/12
Overview of tightening torques, banjo bolts
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 hand-
screwed 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.
Thread Tightening torque
in Nm
M12 178 ≥14
M14 274 ≥22
M16 425 ≥35
M18 550 ≥45
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

TECHNICAL DATA
3-4 ©200338
Threaded connections
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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.

©200338 4-1
Paint treatment
TECHNICAL DATA
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4. PAINT TREATMENT
4.1 OVERVIEW OF PLASTICS USED
1
3
3
2 2 1 2 1 1
G0 00 206
1 SMC polyester
2 Thermoplastic polymer parts (ASA or ABS)
3 Fibre-glass reinforced polyester

TECHNICAL DATA
4-2 ©200338
Paint treatment
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ΛΦ45/55 series
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LF45/55 series Contents
SAFETY INSTRUCTIONS AND WARNINGS
1
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...................................... .....
ǹ0201
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0SAFETY INSTRUCTIONS AND WARNINGS
Contents LF45/55 series
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LF45/55 series Safety instructions and warnings
SAFETY INSTRUCTIONS AND WARNINGS
1-1
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!
- 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.
M0015
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SAFETY INSTRUCTIONS AND WARNINGS
Safety instructions and warnings LF45/55 series
1-2
- 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.
2
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