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DAF LF45 Series Service Manual
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ZF S5-42 GEARBOX
1-2
©
200508
General
4
ΛΦ45/55
series
3
1.2
SYSTE
M DESCRIPTION, GEARBOX
The gearbox consists of five synchromesh
forward gears an
d one non-synch
romesh reverse
gear. The fifth gear is "close ra
tio" or "wide ratio",
depending up
on the model.
DAF
LF
Gearboxes
and
Clutch
Service
Manual
105
107
Table of Contents
0 Technical data
3
1. Mechanical gearbox control
5
1.1 General
5
1.2 Tightening torques
6
2. Pneumatic gearbox control
11
2.1 General
11
2.2 Tightening torques
12
3. ZF S5-42 gearbox
13
3.1 General
13
3.2 Tightening torques
14
3.3 Filling capacities
15
4. ZF 6S-850 gearbox
17
4.1 General
17
4.2 Tightening torques
18
4.3 Filling capacities
19
5. Eaton FS/6309A gearbox
21
5.1 General
21
5.2 Tightening torques
22
5.3 Filling capacities
23
6. Allison 1000 & 2000 automatic gearboxes
25
6.1 General
25
6.2 Tightening torques
26
6.3 Filling capacities
27
7. Allison MD3060 automatic gearbox
29
7.1 General
29
7.2 Tightening torques
30
7.3 Filling capacities
32
8. Clutch
33
8.1 General
33
8.2 Tightening torques
34
8.3 Filling capacities
35
9. Prop shafts
37
9.1 General
37
9.2 Tightening torques
38
1 Diagnostics
39
1. Mechanical gearbox control
41
1.1 Fault-finding table
41
2. Pneumatic gearbox control
43
2.1 Fault-finding table
43
3. Mechanical gearbox
45
3.1 Fault-finding table
45
4. Automatic gearbox
47
4.1 Reading/deleting Allison MD 3060 fault codes
47
4.2 Allison MD 3060 table of fault codes
49
5. Clutch
55
5.1 Fault-finding table
55
6. Prop shafts
57
6.1 Fault-finding table
57
2 Mechanical gearbox control
59
1. General
61
1.1 Description of mechanical gearbox control
61
1.2 Overview drawing, operating mechanism, 2 adjustment options
62
1.3 Overview drawing, operating mechanism, 4 adjustment options
63
1.4 Overview drawing, gear lever unit
64
1.5 Overview drawing, ZF gearbox gear lever
65
1.6 Overview drawing, Eaton gear lever
66
2. Inspection and adjustment
67
2.1 Inspecting and adjusting operating mechanism, 2 adjustment options
67
2.2 Inspecting and adjusting operating mechanism, 4 adjustment options
70
3. Removal and installation
73
3.1 Removing and installing switch button
73
3.2 Removing and installing gaiter
74
3.3 Removing and installing gear lever unit
75
3.4 Removing and installing control rod underneath the cab
76
3.5 Removing and installing rear control rod
78
3 Pneumatic gearbox control
81
1. General
83
1.1 Location of components in pneumatic section of gearbox control
83
1.2 Pneumatic diagram, gearbox control
84
1.3 System description, pneumatic section of gearbox control
85
2. Description of components
87
2.1 Filter/governor
87
2.2 Gear lever selector valve
89
2.3 Electropneumatic downshift protection valve
90
2.4 Neutral position valve
91
2.5 Range group engaging cylinder
92
3. Inspection and adjustment
93
3.1 Programming parameters using DAVIE
93
3.2 Simulating speed signal
94
3.3 Inspection, downshift protection valve
95
3.4 Inspection, filter/governor
97
4. Removal and installation
99
4.1 Removal and installation, filter/governor
99
4.2 Removing and installing range group operating switch
100
5. Cleaning
101
5.1 Cleaning filter/governor
101
4 ZF S5-42 gearbox
103
1. General
105
1.1 ZF gearbox type
105
1.2 System description, gearbox
106
2. Description of components
107
2.1 Synchroniser
107
3. Inspection and adjustment
111
3.1 Checking gearbox oil level
111
3.2 Inspecting and adjusting input shaft pre-load
112
4. Removal and installation
115
4.1 Removing and installing the gearbox
115
4.2 Removing and installing drive flange
117
4.3 Removing and installing output shaft oil seal
118
4.4 Removing and installing gearbox front cover oil seal
119
4.5 Removing and installing selector shaft oil seal
120
5. Draining and filling
123
5.1 Draining and filling gearbox
123
5 ZF 6S-850 gearbox
125
1. General
127
1.1 General
127
1.2 System description, ZF 6S-850 gearbox
128
2. Description of components
129
2.1 Synchroniser
129
3. Inspection and adjustment
133
3.1 Checking gearbox oil level
133
3.2 Inspection and adjustment, input shaft bearing axial play
134
3.3 Inspection and adjustment, secondary shaft axial play
135
4. Removal and installation
137
4.1 Removing and installing gearbox, BE engine
137
4.2 Removing and installing gearbox, CE engine
139
4.3 Removal and installation, drive flange
141
4.4 Removal and installation, output shaft oil seal
142
4.5 Removal and installation, gearbox front cover oil seal
143
4.6 Removal and installation, selector shaft oil seal
144
5. Draining and filling
147
5.1 Draining and filling gearbox
147
6 EATON FS/6309A gearbox
149
1. General
151
1.1 General
151
1.2 System description
152
2. Inspection and adjustment
153
2.1 Checking gearbox oil level
153
2.2 Inspection and adjustment, input shaft bearing axial play
154
3. Removal and installation
155
3.1 Removal and installation, gearbox assembly
155
3.2 Removal and installation, drive flange
157
3.3 Removal and installation, output shaft oil seal
158
3.4 Removal and installation, gearbox front cover oil seal
159
3.5 Removal and installation, selector shaft oil seal
160
4. Draining and filling
165
4.1 Draining and filling gearbox
165
7 Allison 1000 & 2000 automatic gearboxes
167
1. General
169
1.1 System description
169
2. Description of components
171
2.1 Selector lever
171
2.2 Selector switch
172
3. Inspection and adjustment
173
3.1 Checking oil level
173
3.2 Inspecting and adjusting selector cable
175
4. Removal and installation
177
4.1 Removing and installing entire gearbox
177
4.2 Removing and installing selector switch
179
4.3 Removing and installing output shaft oil seal
181
4.4 Removing and fitting selector shaft oil seal
182
4.5 Removing and installing oil filters
184
5. Draining and filling
185
5.1 Draining and filling gearbox
185
8 Allison MD 3060 automatic gearbox
187
1. General
189
1.1 General
189
1.2 System description
190
2. Description of components
193
2.1 Automatic gearbox selector keypad
193
3. Inspection and adjustment
197
3.1 Checking automatic gearbox oil level
197
3.2 Checking oil level with selector keypad
199
4. Removal and installation
201
4.1 Removal and installation, gearbox assembly
201
4.2 Removing and installing output shaft oil seal
203
4.3 Removal and installation, oil filters
205
5. Draining and filling
207
5.1 Draining and filling gearbox
207
9 Clutch
209
1. Safety instructions
211
1.1 Safety instructions
211
2. General
213
2.1 System description, clutch
213
2.2 Overview drawing, clutch servo
214
2.3 Overview drawing, clutch lever attachment to clutch housing
215
3. Description of components
217
3.1 Clutch servo
217
3.2 Wear indicator
219
3.3 Thrust bearing
220
4. Inspection and adjustment
221
4.1 Inspecting clutch servo
221
4.2 Checking clutch fluid level
224
5. Removal and installation
225
5.1 Removal and installation, clutch servo
225
5.2 Removal and installation, thrust bearing
226
5.3 Removal and installation, clutch lever
227
5.4 Removal and installation, clutch release assembly / clutch plate
228
5.5 Removal and installation, pilot bearing
229
5.6 Removing and installing clutch cylinder
231
6. Draining and filling
233
6.1 Draining and filling clutch system
233
6.2 Bleeding clutch system
234
10 Prop shafts
237
1. General
239
1.1 Overview drawing, Spicer prop shaft
239
1.2 Overview drawing, Monotron prop shaft
240
2. Inspection and adjustment
241
2.1 Inspection, prop shaft
241
3. Removal and installation
243
3.1 Removing and installing Spicer prop shaft/intermediate shaft assembly
243
3.2 Removal and installation, prop shaft/intermediate shaft assembly
244
4. Demounting and mounting
245
4.1 Demounting and mounting universal joint
245
4.2 Disassembly and assembly, universal joint
249
Other manuals for DAF LF45 Series
Manual
230 pages
Maintenance Schedule
12 pages
5
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DAF LF45 Series Specifications
General
Brand
DAF
Model
LF45 Series
Category
Trucks
Language
English
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