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Contents

SAFETY INSTRUCTIONS AND WARNINGS

CONTENTS

Page

Date

SAFETY INSTRUCTIONS AND WARNINGS

1-1

0201

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1.1

General safety instructions

1-1

0201

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. . . . . .

1.2

Batteries

1-4

0201

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1.3

Welding

1-5

0201

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. . . . . .

1.4

Jump-starting

1-8

0201

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1.5

Plastic pipes

1-9

0201

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1.6

Wiring harnesses

1-12

0201

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1.7

Avoiding the risk of fire

1-13

0201

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1.8

Tachograph calibration

1-14

0201

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1.9

Airbag and seat belt tensioner

1-15

0201

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0201

Содержание LF45 Series

Страница 1: ...STRUCTURE 200338 0 1 2 3 4 5 6 7 45 55 series 0 Structure TECHNICAL DATA SAFETY INSTRUCTIONS AND WARNINGS THREADED CONNECTIONS SEALS AND BEARINGS GENERAL OPERATIONS PAINT TREATMENT CONVERSION TABLES...

Страница 2: ......

Страница 3: ...ENTS 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 20033...

Страница 4: ...TECHNICAL DATA 2 200338 Contents 0 45 55 series 0...

Страница 5: ...200338 1 1 Vehicle models TECHNICAL DATA 45 55 series 0 0 1 VEHICLE MODELS 1 1 OVERVIEW FT FA 4 x 2 FAN steered axle driven axle 6 x 2 G0 00 205...

Страница 6: ...TECHNICAL DATA 1 2 200338 Vehicle models 0 45 55 series 0...

Страница 7: ...th 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 agai...

Страница 8: ...e 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 Resis...

Страница 9: ...ing 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...

Страница 10: ...series 0 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 14431...

Страница 11: ...d 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 N...

Страница 12: ...nt 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...

Страница 13: ...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 no...

Страница 14: ...rx 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 d...

Страница 15: ...int treatment TECHNICAL DATA 45 55 series 0 0 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 reinfor...

Страница 16: ...TECHNICAL DATA 4 2 200338 Paint treatment 0 45 55 series 0...

Страница 17: ...NGS 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...

Страница 18: ...0 SAFETY INSTRUCTIONS AND WARNINGS Contents LF45 55 series 2 2 0201...

Страница 19: ...re ignored the health and safety of the mechanic may be put at risk Also serious damage to the vehicle or even a hazardous situation may result Comply with all the warnings and safety instructions giv...

Страница 20: ...lant 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 under...

Страница 21: ...ay be under pressure such as a trailing axle lifting device cab tilting mechanism brake system steering gear fuel system etc After a fire hazardous residues may remain from the plastics used in some o...

Страница 22: ...or pain persists consult a doctor Remove any clothing affected and rinse with water In the event of contact with the eyes Rinse with plenty of water for at least 15 minutes and see a doctor If any is...

Страница 23: ...lose as possible to the area on the vehicle where the welding is to be done and ensure that it is well in contact with the part being welded Never attach the earth clamp to vehicle components such as...

Страница 24: ...e power supply and earth cables that are connected to the cab Welding on the cab When welding on the cab disconnect the battery terminals Also disconnect the cab feed through connectors and disconnect...

Страница 25: ...f feed through connectors earth and power supply cable The feed through connectors 1 and supply cable 2 are located behind the front panel in the plastic case The earth cable 3 is located behind the f...

Страница 26: ...es approx 24V or from another vehicle with the engine running approx 28V 1 Connect the jump leads first to the positive terminal and then to the negative terminal 2 Start the engine 3 After starting s...

Страница 27: ...is could result in poor sealing 2 Cut off the pipe end if it has been used before If shortening the pipe results in a sharp curve in the pipe or if it makes the pipe too short a new pipe will have to...

Страница 28: ...entails the risk of excessive deformation of the thrust washer and the pipe which would seriously weaken the pipe If the leakage has not stopped after the union nut has been retightened it will be nec...

Страница 29: ...hat they may touch they should be secured to prevent chafing Use the specially developed pipe clamps These pipe clamps are available for pipes with a diameter of 6 10 and 22 mm The pipe clamps can be...

Страница 30: ...th connections are essential There must be no paint or oxidation between the contact surfaces Before fitting apply a conductive grease such as Coranode or an equivalent product to the contact surfaces...

Страница 31: ...ttention can cause fuel leaks which lead to fire hazard In the event of fuel and or oil leakage or spillage the engine encapsulation must be thoroughly cleaned First apply a degreasing agent to the en...

Страница 32: ...ed to calibrate the tachograph e g when changing to a different type of tyre If the vehicle is equipped with ASR the system will interpret turning rear wheels and still front wheels as rear wheel spin...

Страница 33: ...d Vehicles equipped with a pyrotechnic system system with airbag s and or seat belt tensioner s can be identified by a sticker with an airbag symbol see General on the windscreen and or with the word...

Страница 34: ...r seat belt tensioner s It is not allowed to leave pyrotechnic units airbags and or seat belt tensioners unattended If repairs to a vehicle continue for a long time and pyrotechnic units airbags and o...

Страница 35: ...ted and be replaced if any damage or overload is detected Nothing may be stuck onto the airbag cover Nor may the cover be treated with a cleaner solvent grease paint lacquer or other material The surf...

Страница 36: ...0 SAFETY INSTRUCTIONS AND WARNINGS Safety instructions and warnings LF45 55 series 1 18 2 0201...

Страница 37: ...0 LF45 55 series Contents THREADED CONNECTIONS 1 CONTENTS Page Date 1 GENERAL 1 1 0201 1 1 Dipped threaded connections 1 1 0201 3 0201...

Страница 38: ...0 THREADED CONNECTIONS Contents LF45 55 series 2 3 0201...

Страница 39: ...ed threaded connection must be tightened accurately Therefore always use a reliable and accurate torque wrench Note Have torque wrenches regularly inspected and calibrated To achieve the correct pre t...

Страница 40: ...riable friction coefficients The following threaded connections are used on DAF vehicles Fastenings with strength classes 8 8 and 8 flange bolts and nuts with strength classes 10 9 and 10 flange bolts...

Страница 41: ...onent concerned Applying the locking compound Clean both the internal and external thread Degrease the thread with a suitable degreasing agent which leaves no residue that could affect proper function...

Страница 42: ...0 THREADED CONNECTIONS General LF45 55 series 1 4 3 0201...

Страница 43: ...per and Klingerit gaskets rubber aramide fibre 1 1 0201 1 2 Liquid gaskets 1 2 0201 2 SEALS 2 1 0201 2 1 Removing and fitting seals 2 1 0201 3 BEARINGS 3 1 0201 3 1 Bearings general 3 1 0201 3 2 Fitti...

Страница 44: ...0 SEALS AND BEARINGS Contents LF45 55 series 2 4 0201...

Страница 45: ...act surfaces and check them for damage 3 Paper gaskets should be sparingly greased before they are fitted These gaskets are used to seal flat parts and are resistant to oil and moderate heat 4 Do not...

Страница 46: ...mperatures up to approx 200_C To apply the liquid gasket follow the instructions below Applying a liquid gasket 1 Remove all traces of the old gasket and clean the surfaces to be sealed 2 Sparingly ap...

Страница 47: ...recess and its inner ring has its running surface on a shaft The unitised seal is fitted in a fixed position both in a recess and on the shaft Sealing is achieved internally Removing the seal 1 If pos...

Страница 48: ...seal and press the seal evenly into place in the recess 4 Once a unitised seal has been removed from the recess it must not be re used 5 In most cases a liquid gasket is used to fit a conventional sea...

Страница 49: ...he bearing For example by fitting a bearing on a shaft by pressing on the outer bearing race 3 Clean the bearing before fitting it 4 Avoid dirt getting into the bearing while it is being fitted 5 If t...

Страница 50: ...tre the driving tool accurately on the outer bearing race 3 Preferably press the bearing evenly into the housing using a pressing tool 3 3 FITTING BEARINGS TO A SHAFT Fitting bearings to a shaft 1 Alw...

Страница 51: ...ries Contents GENERAL OPERATIONS 1 CONTENTS Page Date 1 PRESERVATION AND DE WAXING 1 1 0201 1 1 Preservation 1 1 0201 1 2 De waxing 1 2 0201 2 CLEANING VEHICLES 2 1 0201 2 1 High pressure cleaner 2 1...

Страница 52: ...0 GENERAL OPERATIONS Contents LF45 55 series 2 5 0201...

Страница 53: ...d preserving agent RUSAN D5018 a FINA product over the chassis frame and its fittings all parts and components in the engine compartment and all painted sheet metal parts Tilt the cab to be able to sp...

Страница 54: ...ner should be done carefully and evenly Set the high pressure hot water cleaner to a maximum pressure of 100 bar and a maximum temperature of 90_C Never direct the jet of wax remover too long at the s...

Страница 55: ...doors windows and roof hatch are securely closed during high pressure cleaning When cleaning the universal joint on the steering box the spider seals may be forced open by the high pressure jet of wa...

Страница 56: ...g motor alternator etc Maintain a minimum distance of 50 cm between the engine encapsulation and the sprayer nozzle to prevent damage to the encapsulation Do not direct the jet of water at electrical...

Страница 57: ...ons 1 1 0201 1 2 Respraying paint repairing of cab top coat and SMC polyester parts 1 3 0201 1 3 Respraying paint repairing chassis finishing 1 5 0201 1 4 Respraying seed top coats 1 6 0201 1 5 Respra...

Страница 58: ...0 PAINT TREATMENT Contents LF45 55 series 2 6 0201...

Страница 59: ...ing agents use an organic chlorine free solvent Use a two component epoxy based or polyester based primer Use a two component epoxy based or polyester based filler Use a two component epoxy based or p...

Страница 60: ...colour code number of the paint manufacturer Dupont is stated in the code number The Dupont colour code number consists of five or six characters digits The Dupont colour code number is followed by t...

Страница 61: ...uct 5 Remove any dust from the sanded section with a Tack rag cloth 6 Clean the area to be resprayed with a solvent 7 Apply primer to any bare patches 8 Leave the primer to evaporate dry 9 Apply a fil...

Страница 62: ...aper 8 Fine sand roughen the area to be sprayed with 3M Scotch Brite ultra fine or an equivalent product 9 Remove any dust from the sanded section with a Tack rag cloth 10 Clean the area to be sprayed...

Страница 63: ...paper 5 Remove any dust from the sanded section with a Tack rag cloth 6 Clean the area to be treated with solvent 7 Apply primer to any bare patches 8 Leave the primer to evaporate dry 9 If necessary...

Страница 64: ...be resprayed with a solvent 4 Sand the area to be resprayed first with P80 sand paper and then with P180 sand paper 5 Remove any dust from the sanded section with a Tack rag cloth 6 Clean the area to...

Страница 65: ...d with P180 sand paper 4 Fine sand with 3M Scotch Brite ultra fine or an equivalent product 5 Remove any dust from the sanded section with a Tack rag cloth 6 Blow ionised air over the area to be respr...

Страница 66: ...e any dust from the sanded section with a Tack rag cloth 5 Fill the area to be resprayed 6 Leave the filler to dry 7 Apply spray filler to the part to be resprayed 8 Leave the spray filler to dry 9 Sa...

Страница 67: ...area to be resprayed with a Tack rag cloth 18 Blow ionised air over the area to be resprayed or clean the area with an anti static liquid 19 Apply the top coat according to the manufacturer s instruc...

Страница 68: ...0 PAINT TREATMENT Paint treatment LF45 55 series 1 10 6 0201...

Страница 69: ...NTENTS Page Date 1 CONVERSION TABLES 1 1 0201 Consumption 1 1 0201 Specific consumption 1 1 0201 Speed 1 1 0201 Temperature 1 1 0201 Weight 1 1 0201 Length 1 2 0201 Area 1 2 0201 Volume 1 2 0201 Press...

Страница 70: ...0 CONVERSION TABLES Contents LF45 55 series 2 7 0201...

Страница 71: ...0 03281 0 02237 100 1 3 6 3 281 2 237 27 78 0 2778 1 0 9113 0 6214 30 48 0 3048 1 097 1 0 6818 44 70 0 4470 1 609 1 467 1 TEMPERATURE n_ Celsius 9 5 n 32_F 4 5 n_ R n 273 15 K n_ Fahrenheit 5 9 n 32 _...

Страница 72: ...2 6 452 1 0 006944 0 0007716 0 0006452 92900 929 144 1 0 1111 0 09290 836100 8361 1296 9 1 0 8361 1000000 10000 1550 10 76 1 196 1 VOLUME 2 US d 3 lit cm2 cubic inches pints quarts gallons dm3 litre...

Страница 73: ...894 76 51 715 2 036 0 7037 0 068046 101322 3 760 29 92 10 337 1 133 32 1 0 03937 0 01361 0 0013158 3386 23 25 40 1 0 3456 0 3342 9797 82 73 49 2 893 1 0 09668 248 89 1 867 0 07349 0 02540 0 002456 WOR...

Страница 74: ...0 CONVERSION TABLES Conversion tables LF45 55 series 1 4 7 0201...

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