LEYLAND DAF 45 SERIES TRUCK SERVICE WORKSHOP MANUAL ENGINE GEARBOX PARTS WIRING

Covers all 45 series models

LEYLAND DAF 45 SERIES TRUCK WORKSHOP MANUAL

If
you own or need to repair any 45 series truck then this is the Download
manual for you, Covers all you need to know in the service and repair of
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All the sections are listed below:

Brakes
Cab
Conversion factors
Electrical system
Engine - CD 85 ~ CN 96 ~ CB 108 ~ CT 119 ~ CT 96 ~ CT 108 ~ CS 119
Frame & suspension
Front axle and steering
Fuel, Induction & exhaust systems
Rear axle
Transmission - ZF S5-42 ~ ZFS6-36 ~ S6-36 ~ GV36

FULL INDEX OF THE CD:

1.  General Information Data.
sizes, descriptions, pressures, makes, types  specs & so on  

2.  Brake Assemblies Perrot Data.
Overhaul of caliper,  handbrake cable, wheel cylinder – rear.
Removal & Re-fit of brake disc, caliper, front brake pads, rear brake shoes,
wheel cylinder & backplate.

3.  Hand Control Valve.
handbrake control valve removal & re-fit,  handbrake control valve testing
handbrake control valve (wabco 2 port) overhaul,
handbrake control valve (wabco2 port) testing.
handbrake control valve (wabco3 port) overhaul,
handbrake control valve (wabco3 port) testing.

4.  Compressor.
Compressor data,
Compressor removal & re-fit,
Compressor 150cm3 (5.3 ft3) data,
Compressor 150cm3 (5.3 ft3) overhaul,
Compressor 250cm3 (8.8 ft3) data,
Compressor 250cm3 (8.8 ft3) overhaul,
Compressor (bendex ‘D’ type) data,
Compressor (bendex ‘D’ type) overhaul.

5.  Govenor Valve.
Governor valve data,
Governor valve removal & re-fit,
Governor valve (wabco) overhaul.

6.  Footbrake Valve.
Footbrake valve adjustment,
Footbrake valve removal & re-fit,
Footbrake valve testing,
Footbrake valve (bendex E-6 type) bench testing,
Footbrake valve (bendex E-6 type) data,
Footbrake valve (bendex E-6 type) description,
Footbrake valve (bendex E-6 type) operation,
Footbrake valve (bendex E-6 type) overhaul.

7.  Spring Brake Actuator.
Spring brake actuator removal & re-fit,
Spring brake actuator (wabco pull type) overhaul.

8.  Low Pressure Switch.
Low pressure switch overhaul,
Low pressure switch removal & re-fit,
Low pressure switch testing.

9.  Relay Valve & Trailer Control Valve.
Relay Valve & Trailer Control Valve removal & re-fit, Relay Valve,
Trailer control valve – differential type,
Relay Valve (bendex R15) description,
Relay Valve (bendex R15) overhaul,
Differential trailer control valve (with supply dump valve) data,
Description,
General information,
Overhaul – trailer control valve,
Overhaul – supply dump valve,
Testing.

10.  Non- Return Valve (single check valve).
Description,
Removal & re-fit,
Testing.

11.  Load Sensing Valve.
Load Sensing Valve (AP type) removal & re-fit,
Load Sensing Valve (AP type) setting chart,
Load Sensing Valve (AP type) setting procedure,
Load Sensing Valve (bendix type) removal & re-fit,
Load Sensing Valve (bendix type) introduction inshot type,
Load Sensing Valve (bendix type) output pressure test,
Load Sensing Valve (bendix type) overhaul,
Load Sensing Valve (bendix type) setting chart,
Load Sensing Valve (bendix type) valve function test,
Load Sensing Valve (webco type) removal & re-fit,
Load Sensing Valve (webco type) setting chart,
Load Sensing Valve (webco type) testing procedure,
Load Sensing Valve (Knorr Bremse type) removal & re-fit,
Load Sensing Valve (Knorr Bremse type) overhaul,
Load Sensing Valve (Knorr Bremse type) setting chart,
Load Sensing Valve (Knorr Bremse type) test procedure,
Load Sensing Valve (Knorr Bremse type) valve settings.

12.  Air Dryer.
Air Dryer removal & re-fit,
Air Dryer automatic drain valve (bendix) overhaul,
Air Dryer automatic drain valve (bendix) removal & re-fit,
Air Dryer automatic drain valve (bendix) testing,
Air Dryer automatic drain valve (bendix type AD6) data,
Air Dryer automatic drain valve (bendix type AD6) description,
Air Dryer automatic drain valve (bendix type AD6) operation,
Air Dryer automatic drain valve (bendix type AD6) overhaul,
Heated automatic drain valve (heldex type) overhaul,
Heated automatic drain valve (heldex type) removal & re-fit,
Heated automatic drain valve (heldex type) testing.

13.  Alcohol Evaporation Unit (with check valve).
Alcohol Evaporation Unit description,
Alcohol Evaporation Unit operation.

14.  Pressure Reducing valve.
Pressure Reducing valve description,
Pressure Reducing valve overhaul,
Pressure Reducing valve removal & re-fit,
Pressure Reducing valve testing.

15.  Quick Release valve.
Quick Release valve overhaul,
Quick Release valve removal & re-fit,
Quick Release valve testing.

16.  Double Check valve.
Double Check valve description,
Double Check valve operation,
Double Check valve removal & re-fit,
Double Check valve testing.

17.  Multi-Circuit Protection valve.
Multi-Circuit Protection valve description,
Multi-Circuit Protection valve operation,
Multi-Circuit Protection valve overhaul,
Multi-Circuit Protection valve removal & re-fit,
Multi-Circuit Protection valve testing.

18.  Pressure relief valve.
Pressure relief valve description,
Pressure relief valve introduction,
Pressure relief valve operation,
Pressure relief valve overhaul,
Pressure relief valve removal & re-fit,
Pressure relief valve testing.

19.  Reservoirs & Tilt Drain Valve.
Reservoirs & Tilt Drain Valve removal & re-fit.

20.  Foot Control valve - Exhaust Brake.
Foot Control valve removal & re-fit.

21.  Pilot Operating Valve – Exhaust brake.
Pilot Operating Valve removal & re-fit.

22.  Fixed Ratio Valve.
Fixed Ratio Valve removal & re-fit,
Fixed Ratio Valve overhaul.

23.  Pneumatic Push-in type fittings.
Pneumatic Push-in type fittings description,
Pneumatic Push-in type fittings operation,
Pneumatic Push-in type fittings removal & refit.

24.  Trailer connections.
Trailer connection description,
 Removal & re-fit.

25.  Anti-lock Braking System.
Anti-lock Braking System description.

26.  Hydraulic delay valve.
Hydraulic delay valve removal & re-fit.

27.  Brake Tandem master cylinder.
Brake Tandem master cylinder removal & re-fit,
Brake Tandem master cylinder setting shim pack between cylinder & air actuator,
Brake Tandem master cylinder data,
Brake Tandem master cylinder overhaul.

28.  Single Air Hydraulic Actuator.
Single Air Hydraulic Actuator removal & re-fit bendix type,
Single Air Hydraulic Actuator removal & re-fit wabco type,
Single Air Hydraulic Actuator wabco type overhaul.

29.  Tandem Air Actuator.
Tandem Air Actuator removal & re-fit,
Tandem Air Actuator data,
Tandem Air Actuator overhaul.

30.  Satellite Valve.
Satellite Valve removal & re-fit.

31.  Modulator Valve (electro pneumatic).
Modulator Valve (electro pneumatic) removal & re-fit,
Modulator Valve (electro pneumatic) wabco type maintenance & operation.

32.  Solenoid Valve.
Solenoid Valve removal & re-fit.

.............................................................................

ENGINE.

1.  General Information Data.
sizes,
descriptions, pressures, makes, types, fault diagnosis, removal &
re-fit of all engine sizes, specs, warnings & so on  

2.  Cooling System.
Cooling System data,
Cooling System overhaul of belt tensioner pulley,
Cooling System of dynair fan coupling,
Cooling System removal & re-fit of the following
Automatic belt tensioner,
Drive belt,
Fan assembly,
Header tank,
Intercooler,
Radiator,
Rear engine water cover,
Thermostat,
Water pump.
Cooling System testing of the following
Dynair fan coupling,
Thermostat,
Viscous fan drive clutch.
Cooling System warnings.

3.  Cylinder Head.
Cylinder Head adjustment of Valve/Rocker lever clearances,
Cylinder Head data,
Cylinder Head overhaul of the following
Cylinder head,
Rocker shaft assemblies,
Removal & re-fit of the following
Cylinder head,
Rocker shaft assemblies,
Testing of the following
Diesel compression test,
Cylinder Head warnings.

4.  Crankcase Assembly.
Crankcase Assembly data
Overhaul of cylinder bores & service liners,
Removal & re-fit of the following
Camshaft,
Cam-followers,
Connecting rod big end bearings,
Crankshaft,
Crankshaft rear oil seal,
Crankshaft rear oil seal housing,
Flywheel,
Flywheel housing,
Main bearings,
Oil cooler,
Oil pressure regulating valve,
Oil pump,
Pistons and connecting rods,
Sump,
Timing gear case,
Timing gear cover & front crankshaft oil seal,
Timing pin,
Vibration damper/crankshaft pulley,
Crankcase Assembly warnings.

.............................................................................

FUEL, EXHAUST & INDUCTION SYSTEM.

1.  Fuel system.
Fuel system adjustment of road speed limiter control cables,
Fuel system data,
Removal & re-fit of the following
Accelerator cable-early models,
Bleeding the fuel system,
Fuel induction pipes-Bosch VP14 fuel pump,
Fuel induction pipes-CAV DPS fuel pump,
Fuel induction pump-Bosch VP14,
Fuel induction pump-CAV DPS,
Fuel induction pump timing check-Bosch VP14,
Fuel lift pump,
Fuel sedimenter,
Injectors,
Road speed limiter control cables,
Fuel system warnings.

2.  Induction & Exhaust Systems.
Induction & Exhaust Systems data,
Overhaul of the exhaust brake,
Removal & re-fit of the following
Exhaust brake,
Exhaust brake actuating cylinder,
Exhaust manifold-current models,
Exhaust manifold-early models,
Induction manifold-current models,
Induction manifold-early models,
Turbocharger,
Induction & exhaust system warnings.

3.  Turbocharger.
Turbocharger data,
Turbocharger overhaul.

.............................................................................

ELECTRICAL:
1.  General Information & Fault Diagnosis.
 Data,
Circuit protection,
Replacement bulbs,
Vehicle wiring diagram
Fault diagnosis.,

2.  Batteries
Warnings,
Description.

3.  Charging system. Alternator.
Description,
Removal & re-fit,
ALTERNATOR (Magneti Marelli – Type A 127)
Data,
Testing,
Overhaul.
ALTERNATOR (Bosch – Type N1)
Data,
Dismantling and re-fit.

4.  Starter System & Starter Motor.
Description,
Removal & re-fit.
STARTER MOTOR (Bosch – Type JF)
Data,
Fault diagnosis,
Overhaul.
5.  Instrument Panel
Description,
Removal & re-fit,
Testing.

6.  Battery Balance Unit.
Description,
Removal & re-fit,
Testing.

7.  Cigar Lighter.
Description
Removal & re-fit.

8.  Fuel Pump Solenoids.
Description,
Removal & re-fit,
Testing.

9.  Tachograph.
Description,
Removal & re-fit.

10. Horn.
Description,
Removal & re-fit.

11.  Vehicle Lighting.
Headlights,
Dim – dip headlight system,
Side/tail & roof marker lights,
Stop lights & reverse lights,
Rear fog lights,
Removal & re-fit.

12.  Air Dryer, Heated fuel sedimenter & heated mirrors.
Description.

13.  Radio electrical circuits & Relays.
Description,
Radio fitment,
Relay testing.


14.  Direction Indicators & Hazard Warning lights.
Description,
Removal & re-fit.

15.  Cargo Area Light.
Description,
Removal & re-fit.

16.  Courtesy Light.
Description.

17.  Pre-Glow System.  
Description.

18.  Heater Motor.
Description,
Removal & re-fit.

19.  Windscreen Wipers & Washers.
Description,
Removal & re-fit.

20.  Anti-Lock Braking System (ABS) – Wabco System.
Description,
Removal & re-fit.

21.  Electronically Controlled Air Suspension (ECAS).
Description,
Removal & re-fit,
Testing & programming ECAS,
ECAS function test,
Loading ride height settingd & ACAS parameters.

22.  Road Speed Limiter (VDO System).
Description,
Removal & re-fit.

.............................................................................

FRONT AXLE and STEERING

1. Section 1A – Front Axle
Data,
Removal & re-fit of Front Axle,
Warnings.

1. Section 1B – Front Axle – N60 & N84
Camber & caster angles,
Data,
CAUTION – Axle fitted with ABS,
Overhaul of the following:
   Front hubs,
   Stub axle,
   Stub axle bushes – N60 axle,
   Stub axle needle bearings & bushes – N84 axle,
Wheel bolts – replacement.

2. Steering Gear.
Data,
Fault finding for:
   Basic checks,
   Fault finding chart,
Removal & re-fit for the following:
   Adjustable steering column,
   Steering gear – ZF 8090,
   Steering gear housing & piston seals,
   Telescopic shaft.
Warnings.

3. Section 3A Power Steering System.
Data,
Removal & re-fit of the following:
   Power steering pump.
   Testing power steering,
   Warnings.

3. Section 3B Power Steering Pump – ZF
Operation,
Overhaul.

4. Steering Linkage.
Data,
Front wheel alignment – checking & adjusting,
Removal & re-fit of the following:
   Checking drag-link / track-rod ball joint lift,
   Drag-link ball joints,
   Track-rod ball joints.
Wheel lock – stops – N84 axle,
Warnings.

.............................................................................

REAR AXLE.

1. Section 1A Rear Axle- Removal & Refitment.
Driving head,
512 & 718 rear axle unit.

1. Section 1B Rear Axle – 512 & 718.
General information:
    Data.
Caution – axles fitted with ABS.
Overhaul of the following:
   Driving head,
   Hubs.
Removal & refit of the following:
   Axle shafts,
   Driving head pinion oil seal,
   Wheel studs.

.............................................................................

FRAME AND SUSPENSION.
 
1. Frame.
General information,
Torque tightening figures.

2. Suspension.
Data,
Removal & re-fit of the following:
   Front anti-roll bar/link arm assembly,
   Front spring assembly,
   Front spring eye bushes,
   Front spring upper shackle bushes,
   Rear spring assembly,
   Rear spring eye bushes,
   Rear spring upper shackle bushes,
   Rear anti-roll bar/link arm assembly,
   Shock absorbers.


3. Air Suspension (ECAS).
Data,
Operation,
Adjustment,
Testing,
Removal & re-fit of the following:
   Rear spring assembly,
   Air bellows,
   Height sensor,
   Electro-pneumatic regulating unit,
Overhaul of the following:
   Electro-pneumatic regulating unit.

.............................................................................

Gearbox ZF S5-42
Gearbox ZFS6-36 & S6-36 + GV36

In more detail is the following description:


1.  Section 1 Removal & Re-fit of the following:
ZF S5-42 Gearbox (R.H.D.),
ZF S6-36 Gearbox (L.H.D.),
Gearbox input oil seal (ZF S5-42 gearbox),
Gearbox rear oil seal (ZF S5-42 gearbox),
Gearbox rear mounting rubbers,
Propeller shaft – front,
Propeller shaft – intermediate,
Propeller shaft – rear,
Gear – change lever assembly,
Clutch unit,
Clutch master cylinder,
Clutch servo slave cylinder,
Clutch withdrawal mechanism,
Operating pedal assembly,
Operating pedals,
Bleeding the clutch hydraulic system.

1.  Section 1B – Gearbox – ZF S5 – 42.
Data,
Service tool part numbers & application,
Overhaul.

1.  Section 1S – Gearbox – ZF S6 – 36 & S6 – 36 + GV36
Data,
Overhaul,

2.  Section 2C – Clutch Master Cylinder.
Overhaul,

2.  Section 2J – Clutch Servo Slave Cylinder.
Overhaul.

3.  Propeller Shaft and Centre Bearing.
Overhaul of the following:
Centre bearing,
Universal joint (circlip design).


.............................................................................
 
CAB:
The CAB

1. CAB STRUCTURE & COMPONENTS
Adjustment:
    External handle latch release mechanism.
Data,
Paintwork & refinishing,
Removal & re-fit of the following:
    Cab door and hinges,
    Cab front mounting bushes,
    Cab lock-down centre pivot bracket,
    Cab lock-down intermediate release cables,
    Cab lock-down mechanism,
    Cab lock-down mounting,
    Cab lock-down release cable,
    Cab lock-down release lever mechanism,
Cab lock-down safety hook-manual tilt,
    Cab safety stay-manual tilt,
    Drop glass,
    Drop glass regulator mechanism,
    Exterior door handle,
    Front centre panel,
    Front grille panel,
    Headlining,
    Latch assembly,
    Quarter ventilator,
    Torsion bars,
    Windscreen.
Warnings.

2. Section 2A. CAB HYDRAULIC TILT EQUIPMENT
Data,
Hydraulic tilt system bleed procedure:
    Power packer hydraulic systems.
Removal & re-fit of the following:
    Hydraulic tilt pump-power packer,
    Hydraulic tilt ram-power packer.
Warnings.

2. Section 2B. PUMP ASSEMBLY (Power Packer).
Overhaul.

   
2. Section 2C. PUMP ASSEMBLY (Weber).
Overhaul.

3. Section  CAB MIRROR SETTINGS & ADJUSTMENTS.
Adjustment,
Data,
Introduction.

...............................................................................

ABS TESTING.

1. GENERAL.
When to test ABS,
Symbols,
Specification of components,
Function of ABS warning lights,
Test conditions,
Required tools,
Location sensors.

2. TEST PROCEDURE.
Test A Red ABS warning light continues to illuminate.
1. Earth & power supply connections 35-pole plug
2. Relay G022 (power supply 19),
3. ABS warning light, relay G022 & relay G021,
4. Resistance of ABS sensors & wiring,
5. Sensors + wiring shorted to earth,
6. Sensor voltage,
7. ABS-controlled exhaust brake,
8. Electropneumatic valves (Modulator valves).

TEST B RED ABS1 warning light continues to illuminate when a trailer has been coupled up.

TEST C Yellow ABS1 warning light continues to illuminate,

Wiring diagram.

...............................................................................


ABS TESTING (EURO 1 MODELS
 
1. GENERAL.
When to test ABS:
At periodic intervals as specified in the maintenance schedule,

If one of the warning lights continues to illuminate,

In case of locking of one of the wheels,

At a decrease in the braking capacity.

SYMBOLS:

Greater than

<Less than.

2. TEST PROCEDURE
TEST A Red ABS warning light continueas to illuminate,
Earth & power supply connections 35 pin plug,
Relay G022 (power supply 19),
ABS warning light, relay G022 & relay G021,
Resistance of ABS sensors & wiring,
Sensors & wiring shorted to eath,
Sensor voltage,
ABS-controlled exhaust brake,
Modulator valves (Electropneumatic valves).

TEST B Red ABSI warning light continues to illuminate when trailer has been coupled up.

Wiring diagram.

..............................................................................

GENERAL RECOMMENDATIONS.

1. GENERAL INFORMATION.
Abbreviations,
Approximate dry unit weights,
Approximate refill capacities,
Brakes,
Cab,
Conversion factors,
Electrical system,
Engine,
Frame & suspension,
Front axle and steering,
Fuel, Induction & exhaust systems,
Rear axle,
Transmission.

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