DAF LF45 Series User manual

STRUCTURE
©200508 DW23259302
0
1
2
3
4
5
6
7
8
9
10
ΛΦ45/55 series
3
Structure TECHNICAL DATA
DIAGNOSTICS
MECHANICAL GEARBOX CONTROL
PNEUMATIC GEARBOX CONTROL
ZF S5-42 GEARBOX
ZF 6S-850 GEARBOX
EATON FS/6309A GEARBOX
ALLISON 1000 & 2000 AUTOMATIC GEARBOXES
ALLISON MD 3060 AUTOMATIC GEARBOX
CLUTCH
PROP SHAFTS
DAF LF Gearboxes and Clutch Service Manual

DAF LF Gearboxes and Clutch Service Manual

©200508 1
Contents
TECHNICAL DATA
ΛΦ45/55 series
3
0
0 Technica l data
CONTENTS
Page Date
1. MECHANICAL GEARBOX CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200508
1.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200508
2. PNEUMATIC GEARBOX CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200508
2.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200508
3. ZF S5-42 GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200508
3.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200508
3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200508
4. ZF 6S-850 GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200508
4.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200508
4.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 . . . . . 200508
5. EATON FS/6309A GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200508
5.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200508
5.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 . . . . . 200508
6. ALLISON 1000 & 2000 AUTOMATIC GEARBOXES . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200508
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200508
6.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . 200508
6.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 . . . . . 200508
7. ALLISON MD3060 AUTOMATIC GEARBOX. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200508
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200508
7.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 . . . . . 200508
7.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 . . . . . 200508
8. CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200508
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200508
8.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 . . . . . 200508
8.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 . . . . . 200508
9. PROP SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200508
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200508
9.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 . . . . . 200508
DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA
2©200508
Contents
0
ΛΦ45/55 series
3
DAF LF Gearboxes and Clutch Service Manual

©200508 1-1
Mechanical gearbox control
TECHNICAL DATA
ΛΦ45/55 series
3
0
1. MECHANICAL GEARBOX CONTROL
1.1 GENERAL
Switch button
Control rod
Control rod underneath the cab
Length A
Control rod behind the cab
Locking compound Loctite 243
Lubricant Molykote BR2S or BR2 plus
V3 00 563
A
Engine Gearbox Cab suspension Class Length A [mm]
CE engine ZF 6S850 steel 1 669
CE engine ZF 6S850 rubber 1 664
CE engine ZF 6S850 steel 2 + 3 674
CE engine ZF 6S850 rubber 2 + 3 669
CE engine FS6309A steel 2 + 3 674
CE engine FS6309A rubber 2 + 3 669
V3 00 564
B
Length B 60 - 62 mm
DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA
1-2 ©200508
Mechanical gearbox control
0
ΛΦ45/55 series
3
1.2 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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
DAF LF Gearboxes and Clutch Service Manual

©200508 1-3
Mechanical gearbox control
TECHNICAL DATA
ΛΦ45/55 series
3
0
Operating mechanism,
2 adjustment options
Control rod (1)
Torque rod (2)
Ball joint (4)
Lubricant Molykote BR2S or BR2 plus
Attachment nuts 48 Nm
Lock nuts 28 Nm
Attachment nut 48 Nm
Lock nuts 45 Nm
V3 00 567
1
2
3
4
DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA
1-4 ©200508
Mechanical gearbox control
0
ΛΦ45/55 series
3
Operating mechanism,
4 adjustment options
Control rod (1)
Ball joint (2)
Torque rod (4)
Ball joint (6)
Ball joint (8)
Lubricant Molykote BR2S or BR2 plus
Attachment nut 48 Nm
Lock nuts 48 Nm
Attachment nuts 48 Nm
Lock nuts 28 Nm
Attachment nut 48 Nm
Lock nuts 48 Nm
Attachment nuts 48 Nm
Lock nuts 48 Nm
V3 00 566
1
2
3
4
5
6
7
8
9
DAF LF Gearboxes and Clutch Service Manual

©200508 1-5
Mechanical gearbox control
TECHNICAL DATA
ΛΦ45/55 series
3
0
Torque rod (9)
Gear lever unit
Eaton switch button
(1) Use Loctite 243
Attachment nuts 48 Nm
Attachment bolts 18 Nm (1)
Attachment nut 70 Nm (1)
DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA
1-6 ©200508
Mechanical gearbox control
0
ΛΦ45/55 series
3
DAF LF Gearboxes and Clutch Service Manual

©200508 2-1
Pneumatic gearbox control
TECHNICAL DATA
ΛΦ45/55 series
3
0
2. PNEUMATIC GEARBOX CONTROL
2.1 GENERAL
Filter/governor
Governed pressure 5.34 - 5.69 bar
DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA
2-2 ©200508
Pneumatic gearbox control
0
ΛΦ45/55 series
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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Filter/governor
Selector valve single-H
Range-change cylinder
Bleed valve
Eaton switch button
(1) Use Loctite 243
M6 attachment bolts 13 Nm
Cover 25 Nm
M6 attachment bolts 22 Nm
M16 discharge valve attachment bolts 19 Nm
M8 cover plate attachment bolts 22 Nm
M8 cover attachment bolts 17 Nm
M16 nut on piston 105 Nm
Attachment 19 Nm
Attachment nut 70 Nm (1)
DAF LF Gearboxes and Clutch Service Manual

©200508 3-1
ZF S5-42 gearbox
TECHNICAL DATA
ΛΦ45/55 series
3
0
3. ZF S5-42 GEARBOX
3.1 GENERAL
Input shaft
Secondary shaft
Pre-tension 0.02 - 0.09 mm
Pre-tension 0.02 - 0.09 mm
DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA
3-2 ©200508
ZF S5-42 gearbox
0
ΛΦ45/55 series
3
3.2 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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Drive flange
Gearbox front cover
Selector shaft housing
Plugs
(1) Fit new nut and apply Loctite 270 to it
(2) Fit new nut and apply Loctite 262 to it
Attachment bolts 60 Nm
'Direct drive' attachment nut 400 Nm (1)
Overdrive attachment nut 330 Nm (2)
Attachment bolts 23 Nm
Selector shaft housing attachment bolts 23 Nm
Shifting arm lock nut 46 Nm
Gearbox control attachment nut 52 Nm
Bleeder 10 Nm
Oil level check/filler plug 50 Nm
Drain plug 50 Nm
DAF LF Gearboxes and Clutch Service Manual

©200508 3-3
ZF S5-42 gearbox
TECHNICAL DATA
ΛΦ45/55 series
3
0
3.3 FILLING CAPACITIES
Gearbox Capacity
S5-42 3.5 litres
DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA
3-4 ©200508
ZF S5-42 gearbox
0
ΛΦ45/55 series
3
DAF LF Gearboxes and Clutch Service Manual

©200508 4-1
ZF 6S-850 gearbox
TECHNICAL DATA
ΛΦ45/55 series
3
0
4. ZF 6S-850 GEARBOX
4.1 GENERAL
Gearbox type
Each gearbox has a type plate attached to it,
indicating the type of gearbox. This data can also
be found on the vehicle identity card for the
vehicle concerned.
ZF gearbox type plate
Output shaft bearing axial play
Bearing axial play, main and input shafts
Secondary shaft bearing axial play
V300049
1
2
4
5
3
8
6
7
10
9
1. Type of gearbox
2. Serial no. (ZF)
3. Parts list (ZF)
4. Specification no.
5. Pulse generator ratio
6. Gearbox ratio
7. Engine speed using PTO
8. PTO speed
9. Gearbox oil capacity
10. Oil specification
Output shaft bearing axial play 0.00 - 0.10 mm
Bearing axial play, main and input shafts 0.00 - 0.10 mm
Secondary shaft bearing axial play 0.00 - 0.10 mm
DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA
4-2 ©200508
ZF 6S-850 gearbox
0
ΛΦ45/55 series
3
4.2 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 not specified
must therefore be tightened to the torque
mentioned in the overview of standard tightening
torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Gearbox
Drive flange
Gearbox front cover
Selector shaft housing
Plugs
Attachment bolts 60 Nm
Drive flange ∧120 mm attachment bolt 120 Nm
Drive flange ∧150 mm attachment bolt 140 Nm
Attachment bolts 23 Nm
Selector housing attachment bolts 23 Nm
Shifting arm lock nut 46 Nm
Gearbox control attachment nut 52 Nm
Bleeder 10 Nm
Oil level check/filler plug 50 Nm
Drain plug 50 Nm
DAF LF Gearboxes and Clutch Service Manual

©200508 4-3
ZF 6S-850 gearbox
TECHNICAL DATA
ΛΦ45/55 series
3
0
4.3 FILLING CAPACITIES
Gearbox type Filling amounts at oil change
(litres)
First filling, e.g. on repair
(litres)
ZF 6S-850 7.5 7.5
DAF LF Gearboxes and Clutch Service Manual

TECHNICAL DATA
4-4 ©200508
ZF 6S-850 gearbox
0
ΛΦ45/55 series
3
DAF LF Gearboxes and Clutch Service Manual