DAF LF45 Series User manual

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LF45/55 series
CONTENTS
TECHNICAL DATA
DIAGNOSTICS
CHASSIS
SHOCK ABSORBERS
STABILISERS AND TORQUE RODS
LEAF SUSPENSION
1
2
3
4
5
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LF45/55 series Contents
TECHNICAL DATA
1
CONTENTS
Page Date
1. CHASSIS 1-1 0207............................................................. ......
1.1 General 1-1 0207......................................................... ......
2. SHOCK ABSORBERS, STABILISERS, TORQUE RODS AND
LEAF SUSPENSION 2-1 0207................................................... ......
2.1 General 2-1 0207......................................................... ......
2.2 Tightening torques 2-3 0207................................................ ......
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TECHNICAL DATA
Contents LF45/55 series
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LF45/55 series Chassis
TECHNICAL DATA
1-1
1. CHASSIS
1.1 GENERAL
Chassis materials
Type Chassis type Material
LF All KF 450
Note:
KF 450 is a “High Tensile Strength”-steel grade.
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TECHNICAL DATA
Chassis LF45/55 series
1-2
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LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension
TECHNICAL DATA
2-1
2. SHOCK ABSORBERS, STABILISERS, TORQUE RODS AND LEAF
SUSPENSION
2.1 GENERAL
Fixing the attachment bolts for the leaf
spring
Ensure that when fixing the attachment bolts (1)
for the leaf spring that the leaf spring is at the
prescribed height (A). The height (A) is to be
measured above the axle, between the top edge
of the chassis cross member and the underside
of the leaf spring.
2
A
1
1
C9 00 409
Front axle
MODEL HEIGHT (A)
frontmost attachment point (1) rearmost attachment point (2)
LF45 All models 404 mm 459 mm
LF45 All models 502 mm 566 mm
Rear axle
MODEL HEIGHT (A)
LF45 7.5T GVW 295 mm
LF45 7.5T GVW A-symmetric 295 mm
LF45 10-12T GVW 327 mm
LF45 10-12T GVW A-symmetric 295 mm
LF55 13-15T GVW 391 mm
LF55 13-15T GVW A-symmetric 362 mm
LF55 16-18T GVW 414 mm
LF55 16-18T GVW type Kipper 391 mm
LF55 16-18T GVW A-symmetric 362 mm
Note:
With the rear axle height (A) applies to both
the frontmost (1) and the rearmost attachment
point (2) of the leaf spring.
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TECHNICAL DATA
Shock absorbers, stabilisers, torque rods and leaf suspension LF45/55 series
2-2
Transverse guide torque rod, air sprung
rear axle LF45
Fitting angle (A) for mounting rubber on rear
axle side 8-12°
A
C9 00 408
Torque rods stabiliser length (A)
A is the centre-to-centre-distance between the
attachment points.
Front axle
LF45 all models 342 - 344 mm
LF55 all models 348 - 352 mm
Rear axle
LF55 FAN steered rear axle 598 - 602 mm
A
C9 00 413
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LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension
TECHNICAL DATA
2-3
2.2 TIGHTENING TORQUES
The tightening torques stated in this paragraph
are different from the standard tightening
torques stated in the overview of the standard
tightening torques. The other threaded
connections which are not stated 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 removed ones.
U-bolt nuts
MODEL FRONT AXLE REAR AXLE
LF45 all models 215 Nm* 468 Nm*
LF55 13 - 15 ton GVW 468 Nm* 468 Nm*
LF55 16-18 ton GVW Leaf suspension 537 Nm* 537 Nm*
LF55 16-18 ton GVW Air suspension 537 Nm* 880 Nm*
LF55 FAN steered rear axle 468 Nm*
* Tighten the U-bolt nuts evenly and
alternately.
Shock absorbers
If using self-locking nut M14x2 52 Nm
Front axle torque rod locking nut
LF45 135 Nm
LF55 80 Nm
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TECHNICAL DATA
Shock absorbers, stabilisers, torque rods and leaf suspension LF45/55 series
2-4
LF45 rear axle, air suspension
C9 00 323
A B
C
DE
A M14 shock absorber attachment nut 52 Nm
B M12 air bellows attachment nut 31 Nm
C M20 bolt 525 Nm
D M12 air bellows attachment nut 60 Nm
E M20 shock absorber attachment bolt 525 Nm
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LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension
TECHNICAL DATA
2-5
Rear axle, air suspension LF55 13- 15 ton
GVW
C9 00 324
A B C D E
G
F
H
IJ
A M16 triangular adjustment block
attachment bolt 360 Nm
B M20 triangle attachment bolt 475 Nm
C Attachment nut for triangle on
differential M22 235 Nm
D M20 shock absorber attachment bolt 525 Nm
E M20 air bellows support attachment bolt 465 Nm
F M12 air bellows attachment bolt 31 Nm
G M16 attachment bolt 285 Nm
H M20 shock absorber attachment bolt 525 Nm
I Attachment bolt 385 Nm
J M22 bolt with break nut, breakpoint nut +/-- 750 Nm
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TECHNICAL DATA
Shock absorbers, stabilisers, torque rods and leaf suspension LF45/55 series
2-6
Rear axle, air suspension LF55 16- 18 ton
GVW
C9 00 325
A
ED D
ABB C
A M10 air bellows attachment nut 46 Nm
B Clamping flange bolt M18 460 Nm
C M14 attachment bolt, property class 10.9 135 Nm
D M16 air bellows attachment bolt 195 Nm
E M20 attachment bolt, property class 10.9,
shock absorber 520 Nm
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LF45/55 series Shock absorbers, stabilisers, torque rods and leaf suspension
TECHNICAL DATA
2-7
Steered rear axle, air suspension LF55 FAN
C9 00 397
A
F D
B C
E
A Self-locking nut, torque rod ball joint 88 Nm
B M20 shock absorber attachment bolt 250 Nm
C M10 air bellows attachment bolt 32 Nm
D M12 air bellows attachment bolt 34 Nm
E M12 attachment bolt, stabiliser bar
retaining plate 25 Nm
F Automatic lubricating nipple 5 Nm
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TECHNICAL DATA
Shock absorbers, stabilisers, torque rods and leaf suspension LF45/55 series
2-8
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LF45/55 series Contents
DIAGNOSTICS
1
CONTENTS
Page Date
1. SHOCK ABSORBERS 1-1 0207.................................................. ......
1.1 Fault-finding table 1-1 0207................................................. ......
2. LEAF SUSPENSION 2-1 0207................................................... ......
2.1 Fault-finding table 2-1 0207................................................. ......
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DIAGNOSTICS
Contents LF45/55 series
2
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LF45/55 series Shock absorbers
DIAGNOSTICS
1-1
1. SHOCK ABSORBERS
1.1 FAULT-FINDING TABLE
COMPLAINT: SHOCK ABSORBER PRODUCES NOISE (CHATTERING, BUMPING ETC.)
Possible cause Remedy
Shock absorber is loose. Tighten.
Attachment rubbers too soft. Fit new rubbers.
Shock absorber comes into contact with other
components.
Remove components or fasten them.
Shock absorber cover is loose. Tighten cover or replace shock absorber.
COMPLAINT: SHOCK ABSORBER DOES NOT FUNCTION
Possible cause Remedy
Internal defect. Replace shock absorber.
Loss of oil. Replace shock absorber.
COMPLAINT: LEAKY SHOCK ABSORBER
Possible cause Remedy
Defective piston rod sealing.
Caution: a thin, greasy layer is normal.
Replace shock absorber.
COMPLAINT: SHOCK ABSORBER TOO HARD
Possible cause Remedy
Incorrect shock absorber type fitted. Fit correct type.
Internal shock absorber defect. Check shock absorber using a test bench and
replace, if required.
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DIAGNOSTICS
Shock absorbers LF45/55 series
1-2
COMPLAINT: SHOCK ABSORBER TOO SOFT
Possible cause Remedy
Incorrect shock absorber type fitted. Fit correct type.
Internal wear. Check shock absorber using a test bench and
replace, if required.
Loss of oil due to leakage. See under Leaky shock absorber.
Vehicle overloaded. Adjust vehicle loading.
COMPLAINT: POOR DRIVING CHARACTERISTICS/FLAT WEAR SPOTS ON THE TYRES
Possible cause Remedy
Incorrect damping. Check shock absorbers using a test bench and
replace, if required.
Vehicle overloaded. Adjust vehicle loading.
COMPLAINT: SHOCK ABSORBER HITS END STOP
Possible cause Remedy
Defective stop rubber. Replace rubber.
Insufficient damping. See under Shock absorber too soft.
Vehicle overloaded. Adjust vehicle loading.
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LF45/55 series Leaf suspension
DIAGNOSTICS
2-1
2. LEAF SUSPENSION
2.1 FAULT-FINDING TABLE
COMPLAINT: LOOSE U-BOLTS
Possible cause Remedy
Use of a U-bolt or nut of an incorrect property
class.
Use U-bolts and nuts of the correct property
class.
The tightening torque used for the U-bolt nut
was too low.
Tighten the U-bolt to the specified torque.
Reuse of a U-bolt with corroded or damaged
thread.
Fit new U-bolt.
No or inadequate cleaning of the thread (which
includes removal of paint) before reuse of the
U-bolt.
Clean the thread thoroughly before re-use.
No oil or faulty application of oil on the thread
and the bearing surface of the nut.
Apply the oil as prescribed.
Coating (i.e. paint) on the contact faces of the
connection.
Clean the contact faces before assembly.
Inadequate retorquing of the U-bolt nut or no
retorquing.
Tighten the U-bolt nut as specified.
COMPLAINT: BROKEN SPRING
Possible cause Remedy
Regular overloading. Adjust vehicle loading.
Driving too fast over bad roads. Adjust speed when the road is bad.
Notching effect due to welding or grinding
activities.
Cover spring assembly when welding or
grinding.
Spring damaged due to impact of a steel
hammer.
Never hit the springs using a steel hammer or
some other hard tool.
Incorrect repair of a spring leaf which has broken
before.
When replacing a broken spring leaf, always
replace the leaf on top and under the broken
leaf; better yet, replace the entire spring
assembly.
Spring has been heated. Replace spring assembly. Springs should never
be heated.
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DIAGNOSTICS
Leaf suspension LF45/55 series
2-2
COMPLAINT: SPLAYING OF THE SPRING ASSEMBLY (BROKEN SPRING CLAMPS)
Possible cause Remedy
Incorrect pre-tension of the U-bolts. See under complaint Loose U-bolts.
COMPLAINT: SPRING HITS END STOP
Possible cause Remedy
Overloading. Adjust vehicle loading.
Sagged spring assembly. Check height of both spring assemblies.
Replace spring assemblies.
Broken spring. Repair spring assembly or replace.
COMPLAINT: SHIFTING OR BREAKING OF CENTRE BOLT
Possible cause Remedy
Incorrect pre-tension of the U-bolts. See under complaint Loose U-bolts.
COMPLAINT: BUMPING OR CHATTERING OF THE SPRING
Possible cause Remedy
Loose U-bolts. See under complaint Loose U-bolts.
Spring bracket is loose. Secure the spring bracket.
Spring comes into contact with other
components during spring action.
Check freedom of movement of spring.
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