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200416

4-1

Removal and installation

CE ENGINE INLET/EXHAUST SYSTEM

ΧΦ65/75/85

series

4

3

4. REMOVAL AND INSTALLATION

4.1 REMOVAL AND INSTALLATION, TURBOCHARGER

If the turbocharger to be replaced
has been damaged to such an extent
that parts of it are missing or
lubricating oil has entered the inlet
system, the inlet and exhaust
systems must be checked and
cleaned thoroughly in order to
prevent serious damage to the
engine.

Removing the turbocharger

1.

Remove the right-hand engine
encapsulation (2).

2.

Remove the heat shield (1) from the oil filter.

3.

Remove each charge pipe and the
turbocharger exhaust pipe.

4.

Remove the oil discharge pipe from the
turbocharger.

5.

Detach the entire oil supply pipe from the oil
filter housing to the turbocharger.

6.

Remove the attachment bolts from the
turbocharger.

7.

Remove the turbocharger.

8.

Immediately plug the openings.

}

1

i400857

2

https://www.truck-manuals.net/

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Summary of Contents for CF65

Page 1: ...CHNICAL DATA DIAGNOSTICS CE ENGINE FUEL SYSTEM CE ENGINE INLET EXHAUST SYSTEM CE ENGINE ENGINE BRAKE PE ENGINE FUEL SYSTEM PE ENGINE INLET EXHAUST SYSTEM ENGINE BRAKE PE ENGINE XE ENGINE FUEL SYSTEM X...

Page 2: ...https www truck manuals net...

Page 3: ...00416 3 1 General 3 1 200416 3 2 Tightening torques 3 2 200416 4 PE ENGINE FUEL SYSTEM 4 1 200416 4 1 General 4 1 200416 4 2 Tightening torques 4 2 200416 5 PE ENGINE INLET EXHAUST SYSTEM 5 1 200416 5...

Page 4: ...TECHNICAL DATA 2 200416 Contents 0 65 75 85 series 4 https www truck manuals net...

Page 5: ...he engine is the side where the air compressor and electronic unit are mounted The right hand side of the engine is the side where the turbocharger and oil filter are mounted Cold engine A cold engine...

Page 6: ...on the type plate CE on the timing gear case or the flywheel housing depending on the production date PE on the inlet manifold XE on the inlet manifold Engine type The type number XE315C1 indicates X...

Page 7: ...line Valves 4 valves per cylinder Bore x stroke 102 x 120 mm Cubic capacity 5 9 litres Compression ratio 17 3 1 Fuel injection direct injection Injection sequence 1 5 3 6 2 4 Air inlet system Turboch...

Page 8: ...line Valves 4 valves per cylinder Bore x stroke 118 x 140 mm Cubic capacity 9 2 litres Compression ratio 17 5 1 Fuel injection direct injection Injection sequence 1 5 3 6 2 4 Air inlet system Turbocha...

Page 9: ...in line Valves 4 valves per cylinder Bore x stroke 130 x 158 mm Cubic capacity 12 6 litres Compression ratio 17 4 1 Fuel injection direct injection Injection sequence 1 5 3 6 2 4 Air inlet system Turb...

Page 10: ...TECHNICAL DATA 1 6 200416 Engine general 0 65 75 85 series 4 https www truck manuals net...

Page 11: ...sure drop across fuel fine filter 2 0 bar Fuel lift pump pressure in front of fine filter with engine at idling speed 5 13 bar Fuel lift pump pressure behind fine filter with engine at idling speed 3...

Page 12: ...693 A Nozzle length distance A Washer thickness 21 5 0 2 mm 1 5 mm 23 0 0 2 mm 3 0 mm Fuel return overflow valve opening pressure 1 2 2 0 bar Maximum return pipe pressure build up 0 2 bar Maximum quan...

Page 13: ...ic unit cooling plate Low pressure fuel pipes High pressure pump High pressure fuel pipe Fuel rail Injector pipes Fuel supply pipe Injectors Attachment bolts holding the electronic unit to the cooling...

Page 14: ...TECHNICAL DATA 2 4 200416 CE engine fuel system 0 65 75 85 series 4 https www truck manuals net...

Page 15: ...apart 5 There must be no cracks in the housing Exhaust gas back pressure Inlet underpressure Glow element CE 136 C Holset HY 35 W CE 162 C Holset HY 35 W CE 184 C Holset HX 35 W Minimum actuating pre...

Page 16: ...to the torque cited 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...

Page 17: ...ox 355 approx 234 approx 137 Not used approx 33 Underpressure valve opening pressure 10 20 mbar Overpressure valve opening pressure 200 300 mbar Engine type Number of holes in injector Nozzle no Hole...

Page 18: ...y Pump housing 1 Use Loctite 243 Pump units Fuel lift pump 1 Use Loctite 243 Injector pipe union nuts 30 Nm Fuel leak off pipe union 20 Nm Fuel filter cap 25 Nm Clamping piece attachment bolt 30 Nm 60...

Page 19: ...ximum compressor rotor diameter S Wastegate model 54 Compressor rotor trim NPS Version with intake side without compressor housing bypass PS Version with intake side with compressor housing bypass 0 9...

Page 20: ...rques 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 Turbocharger 1 Us...

Page 21: ...137 Not used approx 33 Vacuum relief valve opening pressure 10 20 mbar Pressure relief valve opening pressure 200 300 mbar Engine type Number of holes in injector Nozzle no Hole diameter Bar filter Op...

Page 22: ...y Pump housing 1 Use Loctite 243 Pump units Fuel lift pump 1 Use Loctite 243 Injector pipe union nuts 30 Nm Fuel leak off pipe union 20 Nm Fuel filter cap 25 Nm Clamping piece attachment bolt 30 Nm 60...

Page 23: ...ith recirculation ported shroud a compressor housing with no recirculation non ported shroud b b recirculation variant a no recirculation 22 surface of turbine housing throat cm2 9 turbine housing ver...

Page 24: ...or diameter S Wastegate model 54 Compressor rotor trim NPS Version with intake side without compressor housing bypass PS Version with intake side with compressor housing bypass 0 95 Turbine housing si...

Page 25: ...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 Turbocharger 1...

Page 26: ...TECHNICAL DATA 7 4 200416 XE engine inlet exhaust system 0 65 75 85 series 4 https www truck manuals net...

Page 27: ...pressures DEB settings Exhaust brake Resistance rating Cold 20 C 32 6 36 8 Hot 80 C 100 C 41 8 46 1 Minimum cut in pressure 1 5 bar Maximum service pressure 4 5 bar Maximum pressure of DEB control val...

Page 28: ...t these bolts and nuts are of exactly the same length and property class as those removed DEB 1 Tighten the attachment bolts in the order indicated Exhaust brake 1 Fasten with Copaslip 2 Use Loctite 2...

Page 29: ...troduction 3 1 200416 3 2 Fault finding table 3 2 200416 4 ENGINE BRAKE CE ENGINE 4 1 200416 4 1 Introduction 4 1 200416 4 2 Fault finding table 4 2 200416 5 FUEL SYSTEM XE PE ENGINE 5 1 200416 5 1 In...

Page 30: ...DIAGNOSTICS 2 200416 Contents 1 65 75 85 series 4 https www truck manuals net...

Page 31: ...ve problems DIAGNOSTICS 65 75 85 series 4 1 1 TRACTIVE PROBLEMS 1 1 TRACTIVE PROBLEMS The first test that has to be carried out when investigating tractive problems is the acceleration test https www...

Page 32: ...DIAGNOSTICS 1 2 200416 Tractive problems 1 65 75 85 series 4 https www truck manuals net...

Page 33: ...1 INTRODUCTION If there is a fault in the system it is usually detected by the electronic unit in the form of a fault code This fault code can be read out using DAVIE The fault finding table contains...

Page 34: ...ystem Check for drawing in of air via the suction pipe SYMPTOM ENGINE STARTS POORLY Possible cause Remedy Poor fuel quality Drain fuel flush fuel system replace the fuel filters and fill fuel tank wit...

Page 35: ...ressure pump or fuel lift pump delivery too low Check the high pressure pump the fuel lift pump SYMPTOM REDUCED POWER AT ALL ENGINE SPEEDS Possible cause Remedy Poor fuel quality Drain fuel flush fuel...

Page 36: ...MITTED Possible cause Remedy Poor fuel quality Drain fuel flush fuel system replace the fuel filters and fill fuel tank with fuel Air in fuel system Check for drawing in of air via the suction pipe Fu...

Page 37: ...njector s mechanically defective or clogged Replace the injectors Leak in fuel system Check for leaks SYMPTOM REDUCED MAXIMUM ENGINE SPEED Possible cause Remedy Air in fuel system Check for drawing in...

Page 38: ...DIAGNOSTICS 2 6 200416 CE engine fuel system 1 65 75 85 series 4 https www truck manuals net...

Page 39: ...SYSTEM 3 1 INTRODUCTION If there is a fault in the system it is usually detected by the electronic unit in the form of a fault code This fault code can be read out using DAVIE The fault finding table...

Page 40: ...system Pressure test the inlet system SYMPTOM REDUCED MAXIMUM ENGINE SPEED Possible cause Remedy Turbocharger defective Check the turbocharger SYMPTOM RISING AND FALLING TURBOCHARGER SOUNDS Possible c...

Page 41: ...or leakage Replace gaskets if necessary Compressor side of turbocharger contaminated Clean compressor side with a non corrosive clean ing agent or a soft brush Check the intake side for carbon deposit...

Page 42: ...er the butterfly valve has been posi tioned correctly Butterfly valve partially operated by residual pres sure in the operating cylinder Check operating cylinder Original exhaust silencer not fitted C...

Page 43: ...1 INTRODUCTION If there is a fault in the system it is usually detected by the electronic unit in the form of a fault code This fault code can be read out using DAVIE The fault finding table contains...

Page 44: ...ssor Air leak in the air pipe from air dryer to exhaust brake valve Check air pipe Butterfly valve stuck in butterfly valve housing Check free movement of butterfly valve Electrical fault Check electr...

Page 45: ...5 1 INTRODUCTION If there is a fault in the system it is usually detected by the electronic unit in the form of a fault code This fault code can be read out using DAVIE The fault finding table contai...

Page 46: ...AND RUNS AGAIN AFTER RE STARTING Possible cause Remedy Air in fuel system Check for drawing in of air via the suction pipe via the seal of the fuel lift pump Pressure relief valve on pump housing does...

Page 47: ...with fuel Air in fuel system Check for drawing in of air via the suction pipe via the seal of the fuel lift pump Fuel fine filter coarse filter clogged Replace fuel fine filter and clean the system Me...

Page 48: ...re test the air inlet system Pressure relief valve on pump housing does not shut off Check the gallery pressure Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary the ga...

Page 49: ...uel fine filter and clean the system Mechanical defect or clogging in pump units Replace the pump units Injector defective Check the injectors Leak in fuel system Check for leaks SYMPTOM REDUCED MAXIM...

Page 50: ...DIAGNOSTICS 5 6 200416 Fuel system XE PE engine 1 65 75 85 series 4 https www truck manuals net...

Page 51: ...ST SYSTEM 6 1 INTRODUCTION If there is a fault in the system it is usually detected by the electronic unit in the form of a fault code This fault code can be read out using DAVIE The fault finding tab...

Page 52: ...et system Pressure test the air inlet system SYMPTOM REDUCED POWER ABOVE A CERTAIN ENGINE SPEED Possible cause Remedy Air filter partially clogged Replace or clean the air filter Air leak in inlet sys...

Page 53: ...E 7 1 INTRODUCTION If there is a fault in the system it is usually detected by the electronic unit in the form of a fault code This fault code can be read out using DAVIE The fault finding table conta...

Page 54: ...SYMPTOM DEB REMAINS ENGAGED Possible cause Remedy Electrical fault Check electrical circuit Solenoid valve mechanically blocked Check solenoid valve Damaged solenoid valve sealing rings Replace all s...

Page 55: ...STICS 65 75 85 series 4 1 Air bubbles in the oil Check the engine s oil level oil specification Oil duct sealing plugs in DEB housing Clean replace sealing plugs SYMPTOM DEB OPERATES IRREGULARLY Possi...

Page 56: ...DIAGNOSTICS 7 4 200416 Engine brake XE PE engine 1 65 75 85 series 4 https www truck manuals net...

Page 57: ...Inspection internal fuel leaks 4 8 200416 4 5 Checking the fuel prefilter water separator 4 12 200416 5 REMOVAL AND INSTALLATION 5 1 200416 5 1 Removal and installation injector pipe 5 1 200416 5 2 R...

Page 58: ...CE ENGINE FUEL SYSTEM 2 200416 Contents 2 65 75 85 series 4 https www truck manuals net...

Page 59: ...ed area Make sure exhaust fumes are properly extracted Exhaust gases contain carbon monoxide Carbon monoxide is a deadly colourless and odourless gas which when inhaled deprives the body of oxygen lea...

Page 60: ...CE ENGINE FUEL SYSTEM 1 2 200416 Safety instructions 2 65 75 85 series 4 https www truck manuals net...

Page 61: ...E FUEL SYSTEM 65 75 85 series 4 2 2 GENERAL 2 1 LOCATION OF COMPONENTS Location of components production date 2003 21 chassis number 0E613993 1 2 3 4 5 6 7 8 13 14 15 16 17 19 20 18 12 11 10 9 i400870...

Page 62: ...e 8 Return pipe from fuel return overflow valve 9 Fuel pipe to high pressure pump 10 Fuel pipe to fuel fine filter 11 High pressure pump leak off pipe 12 Fuel pipe to fuel lift pump 13 High pressure p...

Page 63: ...SYSTEM 65 75 85 series 4 2 Location of components production date 2003 21 chassis number 0E613993 and production date 2003 49 chassis number 0E628656 1 2 3 4 5 6 7 12 13 14 15 16 18 19 17 11 10 9 8 i...

Page 64: ...urn pipe from fuel return overflow valve 8 Fuel pipe to high pressure pump 9 Fuel pipe to fuel fine filter 10 High pressure pump leak off pipe 11 Fuel pipe to fuel lift pump 12 High pressure pump 13 F...

Page 65: ...2 5 General CE ENGINE FUEL SYSTEM 65 75 85 series 4 2 Location of components production date 2003 49 chassis number 0E628656 1 2 3 4 5 6 7 11 13 17 18 16 10 9 8 i400872 14 15 12 https www truck manua...

Page 66: ...limiting valve 7 Return pipe from fuel return overflow valve 8 Fuel pipe to fuel fine filter 9 High pressure pump leak off pipe 10 Fuel pipe to fuel lift pump 11 High pressure pump 12 Return pipe to...

Page 67: ...e high pressure pump returns via the by pass valve 4d to the fuel lift pump supply pipe and part of it is used for lubricating the high pressure pump The high pressure pump forces the fuel under high...

Page 68: ...ses the present rail pressure to calculate the time during which the injector needs to be opened in order to obtain the desired injection quantity A pressure relief valve 8 connects the injector leak...

Page 69: ...Fuel pipe connection 6 Copper ring 7 Lift pump 8 High pressure pump 9 Circulation valve 10 O ring 11 Copper ring 12 Fuel pipe connection 13 High pressure pipe connection 14 Spring 15 Ball 16 Oil seal...

Page 70: ...he figure shows the connections to the injector pipes The numbers indicate the cylinder number of the connection Overview drawing fuel rail production date 2003 21 chassis number 0E613993 The figure s...

Page 71: ...5 series 4 2 2 5 OVERVIEW DRAWING FUEL SYSTEM CYLINDER HEAD i400653 5 1 1 2 4 8 7 6 9 3 1 Injector pipe 2 Union 3 Nut 4 Fuel supply pipe 5 Connector to injectors 6 O ring 7 Return opening 8 Injector 9...

Page 72: ...CE ENGINE FUEL SYSTEM 2 12 200416 General 2 65 75 85 series 4 https www truck manuals net...

Page 73: ...entric ring 4 The pump plungers 3 are driven by the eccentric ring and pushed back by the spring 2 The fuel is supplied via the connection 5 and then internally distributed among the three pump elemen...

Page 74: ...ntrol solenoid valve will be virtually closed The over supplied fuel will cause an increase in pressure at the inlet of the fuel pump control solenoid valve The pressure is limited by the circulation...

Page 75: ...ised so that the high pressure pump elements can be filled in the normal manner If the fuel rail pressure becomes too high for example because of lower fuel off take on the rail the solenoid valve wil...

Page 76: ...essure that controls chamber C ensure this The fuel is supplied from the fuel rail via A The return fuel can flow back to the fuel tank via B When the coil 7 is energised the armature housing 5 moves...

Page 77: ...fuel pump control solenoid valve high pressure pump fuel rail rail pressure sensor and electronic unit If a fault occurs the rail pressure can no longer be controlled This can rise to the actuating pr...

Page 78: ...cylinders coinciding with the height of the return ports of the injectors A pressure relief valve is mounted at the end of the bore to prevent vapour bubbles forming in it and to prevent it emptying a...

Page 79: ...rom entering first clean the exterior of the fuel tank 1 Fit a pressure reducer valve connection on a fuel tank cap without bleed vent and connect the cap to the fuel tank 2 Slowly increase the pressu...

Page 80: ...200416 Inspection and adjustment 2 65 75 85 series 4 4 Remove the fuel level element 5 Check the angular displacement of the fuel level element and the resistance value See Technical data I400141 htt...

Page 81: ...pumping the fuel system may become internally damaged Note When the primer pump is used the fuel system will be automatically vented Air will be fed back to the tank through the return line Racor fuel...

Page 82: ...nt 2 65 75 85 series 4 Fleetguard fuel prefilter water separator 1 Unscrew the button of the primer pump and pull it out 2 Use the primer pump until a clearly higher resistance is perceptible 3 Hand t...

Page 83: ...Removal and installation 2 Fit the adapter 1 special tool DAF no 1329476 between the pipe which has been removed and the fuel lift pump and couple a pressure gauge 2 to this adapter 3 Bleed the fuel s...

Page 84: ...nect the fuel pipe from the fuel fine filter to the high pressure pump on the side of the high pressure pump see Removal and installation 2 Fit the adapter 1 special tool DAF no 1329476 between the pi...

Page 85: ...e fuel pressure in front of the fuel fine filter 2 Check the fuel pressure after the fuel fine filter at maximum engine speed 3 Compare the measured pressure drop across the fuel fine filter with the...

Page 86: ...an rise to approx 1400 bar Even when the engine is not running there may be a high residual pressure in the fuel rail approx 50 bar Depressurise the system before working on the common rail system by...

Page 87: ...end of the special tool DAF no 1329476 in a container and start the engine 6 While the engine is idling measure the quantity of return fuel using a stop watch and a measuring beaker see Technical dat...

Page 88: ...the other cylinders and note the values Note When the leaking cylinder has been plugged the quantity of return fuel will decrease and as a result the time it takes to fill the measuring beaker to 360...

Page 89: ...be paid to the O rings of the injectors as these have most probably been damaged by increased pressure in the return circuit as a result of an internal leak Note The following guidelines must be adhe...

Page 90: ...djustment 2 65 75 85 series 4 4 5 CHECKING THE FUEL PREFILTER WATER SEPARATOR If a fuel prefilter water separator is fitted there are two versions Note The Fleetguard version cannot be visually inspec...

Page 91: ...TEM 65 75 85 series 4 2 Racor version 1 Check the reservoir 5 for water 2 If necessary drain the water off through the drain plug 8 using the fuel lift pump 1 and collect the water and fuel in a conta...

Page 92: ...CE ENGINE FUEL SYSTEM 4 14 200416 Inspection and adjustment 2 65 75 85 series 4 https www truck manuals net...

Page 93: ...scaping fuel in a suitable container Dirt in the fuel system can lead to significant damage to parts of the system Prevent this by cleaning the parts before disassembly and then sealing all open conne...

Page 94: ...Installing the injector pipe 1 Clean the injector pipe and blow clean it with dry compressed air 2 Fit the injector pipes in reverse order and hand tighten the unions When all the pipes and unions ar...

Page 95: ...pull it out of the cylinder head with special tool DAF no 1329473 2 Note If the injector is not replaced the fuel supply pipe may be re used provided it is fitted with the original injector Installing...

Page 96: ...pe the screw thread of the nut and the contact surface of the nut with the fuel supply pipe 4 Check the bore of the fuel supply pipe for foreign matter and damage Also check whether the supply bore in...

Page 97: ...ll the nut 1 and tighten it to the specified torque See Technical data 6 If the fuel rail was removed re fit it 7 Fit the injector pipes 8 Start the engine to bleed the high pressure section of the fu...

Page 98: ...flow valve to let the return bore in the cylinder head empty to the fullest possible extent Collect the escaping fuel 2 Remove the injector pipe 3 Remove the fuel supply pipe Note If an injector is re...

Page 99: ...is defective and the sealing surface with the injector is not damaged the fuel supply pipe must be replaced but the injector can be reused 1 Clean the injector if it has already been used See Cleaning...

Page 100: ...or engine damage 7 Fit a new O ring on the injector Note This O ring should prevent returning fuel 1 2 2 0 bar flowing via the top of the cylinder head to the oil sump and thinning the oil 8 Apply a t...

Page 101: ...t surface of the nut with the fuel supply pipe 12 Check the bore of the fuel supply pipe for foreign matter and damage Also check whether the supply bore in the injector is correctly positioned for th...

Page 102: ...achment bolts 1 to the specified torque See Technical data 18 Fit the exhaust valve rockers 19 Adjust the clearance of the exhaust valves 20 Fit the valve cover 21 If the fuel rail was removed re fit...

Page 103: ...vent this by cleaning the parts before disassembly and then sealing all open connections Removing the fuel rail 1 Remove the connector from the fuel rail pressure sensor 2 If necessary remove the plug...

Page 104: ...fuel rail 1 Ensure that the fuel rail is clean 2 Fit the fuel rail 3 and hand tighten the attachment bolts 2 3 Fit the fuel return pipe 1 onto the pressure limiting valve on the fuel rail 4 Fit the in...

Page 105: ...e it using cable ties 10 Fit the connectors of the injectors 1 in the valve sleeve 11 If it has been removed fit the plug of the inlet air temperature boost pressure sensor to the sensor 12 Fit the co...

Page 106: ...ure limiting valve 1 Clean the pressure limiting valve 2 and the surrounding area 2 Remove the fuel return pipe 3 from the pressure limiting valve 2 3 Remove the pressure limiting valve 2 from the fue...

Page 107: ...r example a steam cleaner Cover the places at which leaks have been detected to prevent dirt getting into the fuel system 2 Disconnect the fuel pipes from the high pressure pump Loosen the return pipe...

Page 108: ...2 on the adapter ring 1 and apply a thin layer of engine oil to the O ring 4 Fit the high pressure pump and press it into the timing gear case by means of the attachment nuts 5 Tighten the attachment...

Page 109: ...filter with fuel until it has been fitted The fine filter is filled with fuel by the primer pump after it has been fitted This considerably reduces the risk of dirt getting into the fuel system 1 Chec...

Page 110: ...t the water sensor 6 and the heating element 7 connectors 4 Remove the filter element 4 together with the bottom cover 5 and clean the O ring seal Installing the fuel prefilter water separator filter...

Page 111: ...hether the coupling for the filter attachment is securely attached 2 Lightly lubricate the sealing ring with engine oil 3 Fit the fuel prefilter water separator filter element 1 until the sealing ring...

Page 112: ...ng first clean the fuel tank 2 Remove the connector from the fuel level element 3 Remove the fuel pipes from the fuel level element 4 Turn the fuel level element a quarter turn anti clockwise 5 Carefu...

Page 113: ...5 21 Removal and installation CE ENGINE FUEL SYSTEM 65 75 85 series 4 2 4 Insert the fuel pipes into the fuel level element 5 Fit the connector of the fuel level element i 400114 https www truck manu...

Page 114: ...Remove the fuel tank filter Fitting fuel tank filter 1 Check that the difference in length between the supply pipe 1 and return pipe 2 is at least 68 mm 2 Slide the fuel tank filter as far as possibl...

Page 115: ...which the cooling plate must be demounted Removing electronic unit cooling plate 1 Disconnect the earth lead from the battery terminal 2 To prevent dirt from entering first clean the area around the...

Page 116: ...ts Tighten the attachment bolts to the specified torque See Technical data 5 Fit the electronic unit and cooling plate to the engine block and fit the attachment bolts Tighten the attachment bolts to...

Page 117: ...rflow valve 1 To prevent dirt from entering first clean the area around the fuel return connection 2 Remove the fuel return pipe 1 on the fuel return overflow valve 2 and plug the pipe 3 Remove the fu...

Page 118: ...w pressure fuel pipes fuel will escape Collect the fuel and avoid the risk of fire Dirt in the fuel system can lead to significant damage to parts of the system All open connections must therefore be...

Page 119: ...200416 5 27 Removal and installation CE ENGINE FUEL SYSTEM 65 75 85 series 4 2 John Guest quick release coupling i400882 i400884 https www truck manuals net...

Page 120: ...Remove the special tool from the quick release coupling 3 Plug the openings Fitting low pressure fuel pipes 1 Clean the quick release coupling parts and apply a thin layer of clean engine oil to the...

Page 121: ...pling and removing the pipe from the quick release coupling 2 Plug the openings Fitting low pressure fuel pipes 1 Clean the quick release coupling parts 2 Fit the pipe on the quick release coupling of...

Page 122: ...CE ENGINE FUEL SYSTEM 5 30 200416 Removal and installation 2 65 75 85 series 4 https www truck manuals net...

Page 123: ...the injector bores Only clean the injector with a brass hand brush Note The use of steel brushes can cause deformation of the injector bores with the result that the wrong amount of fuel is injected T...

Page 124: ...exterior of the injector with a clean lint free cloth In the case of heavy soiling the injector may be cleaned carefully with a brass hand brush not the apertures in the injector nozzle 4 Fit the inj...

Page 125: ...charger axial bearing play 3 2 200416 3 3 Inspecting turbocharger radial bearing play 3 3 200416 3 4 Checking exhaust gas back pressure 3 4 200416 3 5 Inspection and pressure testing air inlet system...

Page 126: ...CE ENGINE INLET EXHAUST SYSTEM 2 200416 Contents 3 65 75 85 series 4 https www truck manuals net...

Page 127: ...ilated area Make sure exhaust fumes are properly extracted Exhaust gases contain carbon monoxide Carbon monoxide is a deadly colourless and odourless gas which when inhaled deprives the body of oxygen...

Page 128: ...CE ENGINE INLET EXHAUST SYSTEM 1 2 200416 Safety instructions 3 65 75 85 series 4 https www truck manuals net...

Page 129: ...INE INLET EXHAUST SYSTEM 65 75 85 series 4 3 2 GENERAL 2 1 LOCATION OF COMPONENTS 1 Wastegate diaphragm box 2 Oil supply pipe 3 Oil discharge pipe 4 Turbocharger 5 Exhaust manifold 3 4 5 1 2 i400840 h...

Page 130: ...CE ENGINE INLET EXHAUST SYSTEM 2 2 200416 General 3 65 75 85 series 4 1 Glow element connections 2 Intake manifold 1 2 i400841 https www truck manuals net...

Page 131: ...tegate prevents this The boost pressure is measured by a diaphragm box 1 on the delivery side of the turbocharger The diaphragm is pushed back against the spring pressure by the boost pressure The lin...

Page 132: ...CE ENGINE INLET EXHAUST SYSTEM 2 4 200416 General 3 65 75 85 series 4 https www truck manuals net...

Page 133: ...2 Connect an air pressure reducer valve to the diaphragm box of the wastegate Set the reducer valve to max 0 2 bar gauge pressure Connect the reducer valve to a compressed air installation 3 Set the r...

Page 134: ...charge pipes from the turbocharger 3 Fit a dial gauge 1 to the charge supply flange of the turbocharger 4 Push the compressor shaft away from the dial gauge and set the gauge to zero 5 Push the compr...

Page 135: ...ly be checked when the engine is cold 1 Remove the turbocharger from the exhaust manifold See Removal and installation 2 Fit a pressure gauge to the turbocharger housing and measure the radial play Co...

Page 136: ...Use an attenuated gauge to prevent excessive shaking of the gauge needle 2 Connect a pressure gauge to the pipe with a range of at least 0 1 0 2 bar 10 20 kPa Note The engine brake must not be used d...

Page 137: ...n and mounting of the air inlet channels pipes of the air inlet system Note In case of doubt as to the proper sealing of the air inlet system which is indicated by the following loss of power high fue...

Page 138: ...tool DAF no 0694831 in the rubber intake port on the turbocharger 7 Connect an air pipe with reducer valve to the sealing cap A and charge the system to approx 1 bar 8 Use a soapy solution to check th...

Page 139: ...the air filter housing and the turbocharger 2 Connect a pressure gauge with a maximum rating of 100 mbar 10 kPa to the connection of the air filter indicator 3 Measure the inlet underpressure at full...

Page 140: ...CE ENGINE INLET EXHAUST SYSTEM 3 8 200416 Inspection and adjustment 3 65 75 85 series 4 https www truck manuals net...

Page 141: ...cked and cleaned thoroughly in order to prevent serious damage to the engine Removing the turbocharger 1 Remove the right hand engine encapsulation 2 2 Remove the heat shield 1 from the oil filter 3 R...

Page 142: ...not be an excessive amount of oil in the compressor side of the turbocharger A small amount of oil on the inside walls of the compressor side is allowed 3 Check the adjustment of the turbocharger was...

Page 143: ...scharge pipe and apply a thin layer of engine oil to them Fit the oil discharge pipe For the specified tightening torque see Technical data 12 Pour clean engine oil into the oil supply of the turbocha...

Page 144: ...cooler 3 Disconnect the dipstick holder B from the air cooler 4 Remove the air inlet hoses C between the engine and the air cooler 5 Disconnect all rubber hoses that run along the air cooler 6 Discon...

Page 145: ...including accessories onto the radiator 3 Fit the air conditioning compressor if applicable to the engine 4 Install the torque rods D 5 Fit all rubber hoses that run along the air cooler 6 Fit the air...

Page 146: ...oosen all the clamping brackets 1 of the air filter cover 2 2 Remove the air filter cover 2 3 Remove the air filter element 3 4 Clean the inside of the air filter housing and the air filter cover 5 Wh...

Page 147: ...element 1 Fit the air filter element 3 in the air filter housing 2 Fit the air filter cover Note the arrow 4 on the air filter cover 2 3 Fit all the clamping brackets 1 4 Check that the flexible seal...

Page 148: ...GLOW PLUG Removing the glow plug 1 Remove the inlet manifold 2 Remove the attachment bolts from the glow plug and remove the glow plug Installing the glow plug 1 Fit the glow plug and tighten the atta...

Page 149: ...your own workshop It cannot be ordered from DAF Key to drawing 1 Solder up 2 Solder 3 Quick release coupling for air hose 4 Steel pipe 10 mm 5 6 x 1 5 mm between holes with a centre to centre distanc...

Page 150: ...2 200416 Cleaning 3 65 75 85 series 4 3 Turn the radiator cleaner over turning the holes towards the radiator 2 and blow clean the radiator 2 4 Fit the wire mesh 5 Install the lower grille 1 2 3 4 M21...

Page 151: ...ctions 1 1 200416 2 GENERAL 2 1 200416 2 1 Location of exhaust brake components 2 1 200416 2 2 System description exhaust brake 2 2 200416 3 INSPECTION AND ADJUSTMENT 3 1 200416 3 1 Inspection and adj...

Page 152: ...CE ENGINE ENGINE BRAKE 2 200416 Contents 4 65 75 85 series 4 https www truck manuals net...

Page 153: ...ed area Make sure exhaust fumes are properly extracted Exhaust gases contain carbon monoxide Carbon monoxide is a deadly colourless and odourless gas which when inhaled deprives the body of oxygen lea...

Page 154: ...CE ENGINE ENGINE BRAKE 1 2 200416 Safety instructions 4 65 75 85 series 4 https www truck manuals net...

Page 155: ...GINE ENGINE BRAKE 65 75 85 series 4 4 2 GENERAL 2 1 LOCATION OF EXHAUST BRAKE COMPONENTS 1 Supply pressure 2 Exhaust brake valve 3 Operating cylinder exhaust brake 4 Butterfly valve I400868 4 2 3 1 ht...

Page 156: ...upply to the various cylinders The unit also energises the exhaust brake valve 2 causing supply pressure to flow to the operating cylinder This cylinder closes the butterfly valve in the butterfly val...

Page 157: ...linder and take the operating cylinder off the support 4 Open the butterfly valve fully exhaust brake inactive indicated by the mark 3 on the butterfly valve shaft and press the lever 4 against the st...

Page 158: ...CE ENGINE ENGINE BRAKE 3 2 200416 Inspection and adjustment 4 65 75 85 series 4 https www truck manuals net...

Page 159: ...t pipe from the exhaust brake 3 Remove the entire exhaust brake Installing exhaust brake 1 Check the butterfly valve for smooth operation 2 Clean and check the sealing faces of the butterfly valve hou...

Page 160: ...CE ENGINE ENGINE BRAKE 4 2 200416 Removal and installation 4 65 75 85 series 4 https www truck manuals net...

Page 161: ...eparator 3 11 200324 4 REMOVAL AND INSTALLATION 4 1 200324 4 1 Removal and installation fuel injection pipe 4 1 200324 4 2 Removal and installation injector 4 3 200324 4 3 Removal and installation inj...

Page 162: ...PE ENGINE FUEL SYSTEM 2 200324 Contents 5 CF65 75 85 series 4 https www truck manuals net...

Page 163: ...ted area Make sure exhaust fumes are properly extracted Exhaust gases contain carbon monoxide Carbon monoxide is a deadly colourless and odourless gas which when inhaled deprives the body of oxygen le...

Page 164: ...PE ENGINE FUEL SYSTEM 1 2 200324 Safety instructions 5 CF65 75 85 series 4 https www truck manuals net...

Page 165: ...EM CF65 75 85 series 4 5 2 GENERAL 2 1 LOCATION OF COMPONENTS 1 Pump units 2 Pump housing 3 Fuel fine filter 4 Fuel lift pump 5 UPEC electronic unit 6 Primer pump 7 Pressure relief valve i4 00 684 6 5...

Page 166: ...urpose of constant bleeding there is a calibrated bore in the fuel fine filter After the filter the fuel enters the pump housing 5 The pump units driven by the electronic unit are fitted in the pump h...

Page 167: ...t pump 3 Pump unit Operating principle Situation A In this situation the pump plunger 2 makes the suction stroke Due to the constant overpressure in the supply area of the fuel system the high pressur...

Page 168: ...ly ducts 3 There is now a pressure build up above the pump plunger 2 causing fuel to be injected via the injector 6 Situation D In this situation the quantity of fuel to be injected is determined The...

Page 169: ...alve 5 is fitted on the top of the pump unit The function of the pressure valve is to prevent the supply section from being interrupted by pressure peaks from the injector pipe The injection timing an...

Page 170: ...n The fuel will now flow via the fuel supply ducts 2 to the space above the pump plunger 13 The valve 6 is not re opened against the force of the magnet by the high pressure in the high pressure area...

Page 171: ...tator 7 by the centrifugal force and two successive vanes form an enclosed space the pump chamber Due to the elliptically shaped stator 7 with each revolution each pump chamber undergoes a volume incr...

Page 172: ...6 to close and the fuel flows along the piston seal to the bottom of the piston On the downward stroke the volume below the priming pump piston is reduced This forces the fuel via the fuel lift pump s...

Page 173: ...pply side A the filtered fuel passes to the pump housing A small section of the fuel and any air present enters via a calibrated hole 6 on the top of the central tube 4 in the permanent bleed side B a...

Page 174: ...unit The function of the pressure valve is to prevent the supply section from being interrupted by pressure peaks from the injector pipe The injection timing and the quantity of fuel to be injected ar...

Page 175: ...above the plunger 13 This causes an injection The valve 6 is not re opened against the force of the magnet by the high pressure in the high pressure area as the forces in the valve 6 slot are balance...

Page 176: ...s resistance due to the presence of the spring 5 This results in a pressure relief valve opening pressure of approx 5 bar The piston 2 has a diagonal bore 6 This bore is fitted for bleeding the fuel s...

Page 177: ...on a tank cap without bleeder and connect the tank cap to the fuel tank 2 Pressurise the fuel tank maximum 0 1 bar 3 Slowly increase the pressure until the system audibly blows off via the pressure r...

Page 178: ...200324 Inspection and adjustment 5 CF65 75 85 series 4 5 Remove the fuel level element 6 Check the angular displacement of the fuel level element and the resistor value See Technical data I400141 htt...

Page 179: ...pump units immediately Note The opening pressure of the injectors can be tested using an injector test pump DAF no 0694966 The advantage of this method is that the injectors need not be removed from...

Page 180: ...ill the fuel reservoir and screw back the cap 5 The pump is now ready for use Inspecting opening pressure with an injector test pump 1 Keep the test pump more or less horizontal 2 Loosen the test pump...

Page 181: ...irst allow the injector to inject a number of times 3 Inspect the injector for opening pressure leakage injector nozzles Opening pressure 1 Inspect the discharge pressure by slowly building up the pre...

Page 182: ...tank cap to the fuel tank 2 Dry the inspection points 3 Pressurise the fuel tank maximum 0 2 bar 4 Unscrew the union nut A a few turns to check whether there is leakage in the non return valve If the...

Page 183: ...ssurise the system maximum 0 2 bar 9 Check the permeable seal and the side connection of the injectors for leaks Note Engine oil may be used to detect leaks at the O ring 10 Fit the valve covers 11 Re...

Page 184: ...ng Note The fuel system has to be bled if it has been opened this can be done in two ways With the fuel lift pump By pressurising the fuel tank Bleeding using the fuel lift pump 1 Loosen the union nut...

Page 185: ...1 Remove the fuel tank cap and replace it by a cap with an adjustable air connection Note Use a cap without a vent that has a connection for a pressure reducer valve 2 Pressurise the tank to a maximu...

Page 186: ...enuated liquid pressure gauge with a range of 0 10 bar to the free connection point Note Before inspecting the gallery pressure at the starting speed the fuses of the UPEC engine management system mus...

Page 187: ...PARATOR Note If a fuel prefilter water separator is fitted there are two further versions Racor version 1 Check the reservoir 5 for water 2 If necessary drain the water off through the drain plug 8 us...

Page 188: ...5 85 series 4 Mann Hummel version 1 Check the reservoir 5 for water 2 If necessary drain the water off through the drain plug 6 using the fuel lift pump 1 and collect the water and fuel in a container...

Page 189: ...pipes together Never bend injector pipes as they may crack 1 Disconnect the earth lead from the battery terminal 2 Clean the union nuts and the area around both the injectors and the pump housing Whe...

Page 190: ...hten the union nuts on the injector side by hand in the order 1 2 3 or 4 5 6 5 Then tighten the union nuts on the pump side in the order 1 2 3 4 5 6 Tighten them to the specified torque See Technical...

Page 191: ...B 5 Remove the attachment bolt 3 from the injector clamp To remove the injector and the clamping piece only use the special tools DAF no 1329412 and DAF no 0694928 Note If during removal one or more c...

Page 192: ...a little acid free grease to both rings 3 Inspect the valve sleeve seal 3 of the injector Replace it if it is leaking and or damaged Note Make sure that the injector clamp is installed correctly 4 Fi...

Page 193: ...gth A of approx 20 mm in the injector sleeve that is to be removed Turn the special tool DAF no 1310425 into the injector sleeve and using the special tool DAF no 0694928 remove the injector sleeve In...

Page 194: ...ctions from the pump unit 3 Remove the fuel pipes from the pump housing 4 Remove the pressure relief valve from the pump housing 5 Let the fuel leak from the pump housing 6 Remove the injector pipes i...

Page 195: ...sealing rings 3 Crank the engine until the camshaft in the pump housing is in such a position that the pump unit can be fitted in the pump housing practically tension free 4 Apply a thin layer of lub...

Page 196: ...fuel lift pump 1 Disconnect the earth lead from the battery terminal 2 Remove the fuel pipes from the fuel lift pump 3 Remove the attachment bolts from the fuel lift pump 4 Remove the fuel lift pump...

Page 197: ...g the pump housing 1 Crank the engine until the valves of cylinder 6 are in overlap position and the TDC mark on the flywheel is in the correct position 2 Remove the timing cover 3 Remove the attachme...

Page 198: ...from the fuel lift pump 12 Remove the fuel injection pipes and plug the pump units and injectors so that no dirt can enter the system 13 Remove the connector from the fuel temperature sensor 1 if fitt...

Page 199: ...F no 1329499 Tighten the attachment bolts to the specified torque See Technical data 3 Fit the camshaft position sensor 4 Fit the fuel temperature sensor connector 5 Fit the electrical connections ont...

Page 200: ...inder 6 in overlap position 12 Fit the pump housing camshaft gear 4 in such a position that the idler gear 3 can be installed in accordance with the marks 13 Fit the attachment bolts of the pump housi...

Page 201: ...gs during fitting 2 Tighten union nuts and banjo bolts to the specified torque See Technical data Note In the event of a leakage from a pipe coupling do not overtighten the union nut First check wheth...

Page 202: ...ilter as chemical waste Fitting the fuel filter element 1 Replace the cover O ring 2 Fit the fuel filter element in the cover 3 Fit the cover with fuel filter element Tighten the filter cover to the s...

Page 203: ...ing first clean the fuel tank 2 Remove the connector from the fuel level element 3 Remove the fuel pipes from the fuel level element 4 Turn the fuel level element a quarter turn anti clockwise 5 Caref...

Page 204: ...it the connector of the fuel level element 4 10 REMOVAL AND INSTALLATION FUEL TANK FILTER When the fuel level element is removed a quantity of fuel will escape Collect this fuel bearing in mind the ri...

Page 205: ...n pipe 2 is at least 68 mm 2 Slide the fuel tank filter as far as possible onto the supply pipe 1 Note Make sure that when fitting the fuel tank filter the return pipe 2 is inserted into the fuel tank...

Page 206: ...ent 4 and the bottom cover 5 Clean the O ring seal Installing the fuel prefilter water separator filter element 1 Apply a film of engine oil to the O ring and the new sealing ring 2 Fit the bottom cov...

Page 207: ...parator filter element 1 Apply a film of engine oil to the O ring and the new sealing ring 2 Fit the bottom cover 5 onto the new filter element 4 3 Fit the bottom cover 5 together with the new filter...

Page 208: ...PE ENGINE FUEL SYSTEM 4 20 200324 Removal and installation 5 CF65 75 85 series 4 https www truck manuals net...

Page 209: ...they must be re calibrated 2 Remove the pump units See Removal and installation 3 Remove the tappet rollers 4 Remove the fuel lift pump See Removal and installation 5 Remove the cover and check the O...

Page 210: ...and assembly 5 CF65 75 85 series 4 Assembling the pump housing When fitting the front bearing shell it is important that the oil bore in the bearing housing aligns with the hole in the slide bearing...

Page 211: ...g 3 Clean the gaskets if necessary Fit the gaskets and sealing plates and tighten the bolts to the specified torque See Technical data Note When fitting the locking plate make sure it does not stick i...

Page 212: ...and tighten the bolts to the specified torque See Technical data 9 Fit the fuel lift pump See Removal and installation 10 Apply a thin layer of lubricating oil to the tappet rollers 11 Fit the tappet...

Page 213: ...zles The use of steel or copper brushes can cause deformation of the injector nozzles with the result that the fuel is not injected in the corrrect way and the amount of fuel injected is affected Such...

Page 214: ...ector See Removal and installation 2 Remove any copper washer left behind using the special tool DAF no 1240074 3 Clean the injector sleeve using the special tool DAF no 1240074 4 Clean the injector s...

Page 215: ...er wastegate 3 1 200324 3 2 Checking exhaust gas back pressure 3 2 200324 3 3 Inspection and pressure testing air inlet system 3 3 200324 3 4 Checking inlet underpressure 3 4 200324 3 5 Checking the g...

Page 216: ...PE ENGINE INLET EXHAUST SYSTEM 2 200324 Contents 6 CF65 75 85 series 4 https www truck manuals net...

Page 217: ...tilated area Make sure exhaust fumes are properly extracted Exhaust gases contain carbon monoxide Carbon monoxide is a deadly colourless and odourless gas which when inhaled deprives the body of oxyge...

Page 218: ...PE ENGINE INLET EXHAUST SYSTEM 1 2 200324 Safety instructions 6 CF65 75 85 series 4 https www truck manuals net...

Page 219: ...AUST SYSTEM CF65 75 85 series 4 6 2 GENERAL 2 1 LOCATION OF COMPONENTS 1 Turbocharger 2 Exhaust manifold 3 Air intake pipe 4 Exhaust elbow with integrated butterfly valve 5 Exhaust brake valve M201160...

Page 220: ...PE ENGINE INLET EXHAUST SYSTEM 2 2 200324 General 6 CF65 75 85 series 4 1 Glow plug 2 Glow plug relay 3 Boost pressure sensor 4 Inlet manifold M201186 4 2 3 1 https www truck manuals net...

Page 221: ...e in the turbine housing is opened when the maximum pre set pressure has been reached When the valve is opened some of the exhaust gases will be discharged directly to the exhaust pipe rather than bei...

Page 222: ...PE ENGINE INLET EXHAUST SYSTEM 2 4 200324 General 6 CF65 75 85 series 4 https www truck manuals net...

Page 223: ...ntrol rod 4 from the wastegate lever 4 Using a reducer valve apply the specified adjusting pressure to the connection with the diaphragm housing see Technical data 5 Push the wastegate lever 5 fully t...

Page 224: ...be made of metal to withstand the high temperatures 2 Connect a pressure gauge to the pipe with a range of at least 0 1 0 2 bar 10 20 kPa Note Use an attenuated gauge to prevent excessive shaking of...

Page 225: ...ut a pressure test to check the air inlet system for leaks 1 Remove the pipe between the air filter housing and the intake port on the suction side of the turbocharger 2 Fit the special tools DAF no 1...

Page 226: ...to the connection of the underpressure indicator 3 Measure the inlet underpressure at full load engine speed and compare the measurement to the specified value See Technical data 3 5 CHECKING THE GLOW...

Page 227: ...pipe 4 from the turbocharger and the air intake pipe to the air cooler 5 Remove the turbocharger lubricating oil pipes Plug the openings 6 Remove the attachment nuts from the turbocharger 7 Remove the...

Page 228: ...the oil supply of the turbocharger and fit the oil supply pipe 8 Fit the connector pipe from the turbocharger and the air intake pipe to the air cooler 9 Fit the exhaust brake 10 Fit the air inlet hos...

Page 229: ...itioning system must only take place if the workshop is certified to do this Removing the air cooler 1 Disconnect the earth lead from the battery terminal 2 Drain the engine coolant from the radiator...

Page 230: ...lar into the wind tunnel 10 Remove the attachment nuts on the bottom of the radiator and remove the assembly Installing the air cooler 1 Position the radiator assembly carefully lower it into the chas...

Page 231: ...5 Fit the coolant hoses A B and C 6 Tighten the oil filler pipe 7 Fit the air conditioning unit 8 Fasten the pipe on the bottom of the radiator 9 Fill the cooling system See Draining and filling 10 S...

Page 232: ...filter cover 5 When replacing the air filter element reset the air filter indicator if fitted by pressing the button on the top of the indicator Installing the air filter element 1 Fit the air filter...

Page 233: ...in your own workshop It cannot be ordered from DAF Key to drawing 1 Solder up 2 Solder 3 Quick release coupling for air hose 4 Steel pipe 10 mm 5 6 x 1 5 mm between holes with a centre to centre dist...

Page 234: ...r health Use mouth and eye protection 1 Remove the air filter element See Removal and installation 2 Check the air filter element for damage If the air filter element or its sealing rings are damaged...

Page 235: ...uctions 1 1 200324 2 GENERAL 2 1 200324 2 1 Location of exhaust brake components 2 1 200324 2 2 System description exhaust brake 2 2 200324 3 INSPECTION AND ADJUSTMENT 3 1 200324 3 1 Inspection and ad...

Page 236: ...ENGINE BRAKE PE ENGINE 2 200324 Contents 7 CF65 75 85 series 4 https www truck manuals net...

Page 237: ...ted area Make sure exhaust fumes are properly extracted Exhaust gases contain carbon monoxide Carbon monoxide is a deadly colourless and odourless gas which when inhaled deprives the body of oxygen le...

Page 238: ...ENGINE BRAKE PE ENGINE 1 2 200324 Safety instructions 7 CF65 75 85 series 4 https www truck manuals net...

Page 239: ...BRAKE PE ENGINE CF65 75 85 series 4 7 2 GENERAL 2 1 LOCATION OF EXHAUST BRAKE COMPONENTS 1 Operating cylinder exhaust brake 2 Exhaust brake valve 3 Supply pressure 4 Butterfly valve I400533 3 2 4 1 h...

Page 240: ...valve causing compressed air to flow to the operating cylinder 2 The cylinder closes the butterfly valve in the butterfly valve housing The exhaust pipe is then almost completely closed off Controlled...

Page 241: ...lectrically activating the exhaust brake valve 2 or by pressurising the exhaust brake cylinder 1 yourself Setting the exhaust brake 1 Release the ball head of the butterfly valve control lever 2 Open...

Page 242: ...ENGINE BRAKE PE ENGINE 3 2 200324 Inspection and adjustment 7 CF65 75 85 series 4 https www truck manuals net...

Page 243: ...e clamping strip with which the exhaust elbow is attached to the exhaust 5 Remove the exhaust elbow including the butterfly valve Installation exhaust brake 1 Check the butterfly valve for smooth oper...

Page 244: ...ENGINE BRAKE PE ENGINE 4 2 200324 Removal and installation 7 CF65 75 85 series 4 https www truck manuals net...

Page 245: ...parator 3 11 200324 4 REMOVAL AND INSTALLATION 4 1 200324 4 1 Removal and installation fuel injection pipe 4 1 200324 4 2 Removal and installation injector 4 3 200324 4 3 Removal and installation inje...

Page 246: ...XE ENGINE FUEL SYSTEM 2 200324 Contents 8 CF65 75 85 series 4 https www truck manuals net...

Page 247: ...ted area Make sure exhaust fumes are properly extracted Exhaust gases contain carbon monoxide Carbon monoxide is a deadly colourless and odourless gas which when inhaled deprives the body of oxygen le...

Page 248: ...XE ENGINE FUEL SYSTEM 1 2 200324 Safety instructions 8 CF65 75 85 series 4 https www truck manuals net...

Page 249: ...EM CF65 75 85 series 4 8 2 GENERAL 2 1 LOCATION OF COMPONENTS 1 Pump units 2 Pump housing 3 Fuel fine filter 4 Fuel lift pump 5 UPEC electronic unit 6 Primer pump 7 Pressure relief valve i4 00 683 3 5...

Page 250: ...urpose of constant bleeding there is a calibrated bore in the fuel fine filter After the filter the fuel enters the pump housing 5 The pump units driven by the electronic unit are fitted in the pump h...

Page 251: ...t pump 3 Pump unit Operating principle Situation A In this situation the pump plunger 2 makes the suction stroke Due to the constant overpressure in the supply area of the fuel system the high pressur...

Page 252: ...ly ducts 3 There is now a pressure build up above the pump plunger 2 causing fuel to be injected via the injector 6 Situation D In this situation the quantity of fuel to be injected is determined The...

Page 253: ...alve 5 is fitted on the top of the pump unit The function of the pressure valve is to prevent the supply section from being interrupted by pressure peaks from the injector pipe The injection timing an...

Page 254: ...n The fuel will now flow via the fuel supply ducts 2 to the space above the pump plunger 13 The valve 6 is not re opened against the force of the magnet by the high pressure in the high pressure area...

Page 255: ...tator 7 by the centrifugal force and two successive vanes form an enclosed space the pump chamber Due to the elliptically shaped stator 7 with each revolution each pump chamber undergoes a volume incr...

Page 256: ...6 to close and the fuel flows along the piston seal to the bottom of the piston On the downward stroke the volume below the priming pump piston is reduced This forces the fuel via the fuel lift pump s...

Page 257: ...pply side A the filtered fuel passes to the pump housing A small section of the fuel and any air present enters via a calibrated hole 6 on the top of the central tube 4 in the permanent bleed side B a...

Page 258: ...unit The function of the pressure valve is to prevent the supply section from being interrupted by pressure peaks from the injector pipe The injection timing and the quantity of fuel to be injected ar...

Page 259: ...above the plunger 13 This causes an injection The valve 6 is not re opened against the force of the magnet by the high pressure in the high pressure area as the forces in the valve 6 slot are balance...

Page 260: ...alve connects the supply channel to the discharge channel The fuel flows into the entrance 1 past the piston 2 and the guide pin 3 and to the exit 4 The fuel encounters resistance due to the presence...

Page 261: ...ator nut to work loose If the tension pulley slips while cranking it can be pre tensioned a little by turning it anti clockwise B whilst securing the bolt A Remove the blocking bolt A before the engin...

Page 262: ...XE ENGINE FUEL SYSTEM 2 14 200324 General 8 CF65 75 85 series 4 https www truck manuals net...

Page 263: ...on a tank cap without bleeder and connect the tank cap to the fuel tank 2 Pressurise the fuel tank maximum 0 1 bar 3 Slowly increase the pressure until the system audibly blows off via the pressure r...

Page 264: ...200324 Inspection and adjustment 8 CF65 75 85 series 4 5 Remove the fuel level element 6 Check the angular displacement of the fuel level element and the resistor value See Technical data I400141 htt...

Page 265: ...pump units immediately Note The opening pressure of the injectors can be tested using an injector test pump DAF no 0694966 The advantage of this method is that the injectors need not be removed from...

Page 266: ...ill the fuel reservoir and screw back the cap 5 The pump is now ready for use Inspecting opening pressure with an injector test pump 1 Keep the test pump more or less horizontal 2 Loosen the test pump...

Page 267: ...irst allow the injector to inject a number of times 3 Inspect the injector for opening pressure leakage injector nozzles Opening pressure 1 Inspect the discharge pressure by slowly building up the pre...

Page 268: ...tank cap to the fuel tank 2 Dry the inspection points 3 Pressurise the fuel tank maximum 0 2 bar 4 Unscrew the union nut A a few turns to check whether there is leakage in the non return valve If the...

Page 269: ...ssurise the system maximum 0 2 bar 9 Check the permeable seal and the side connection of the injectors for leaks Note Engine oil may be used to detect leaks at the O ring 10 Fit the valve covers 11 Re...

Page 270: ...ng Note The fuel system has to be bled if it has been opened this can be done in two ways With the fuel lift pump By pressurising the fuel tank Bleeding using the fuel lift pump 1 Loosen the union nut...

Page 271: ...1 Remove the fuel tank cap and replace it by a cap with an adjustable air connection Note Use a cap without a vent that has a connection for a pressure reducer valve 2 Pressurise the tank to a maximu...

Page 272: ...enuated liquid pressure gauge with a range of 0 10 bar to the free connection point Note Before inspecting the gallery pressure at the starting speed the fuses of the UPEC engine management system mus...

Page 273: ...PARATOR Note If a fuel prefilter water separator is fitted there are two further versions Racor version 1 Check the reservoir 5 for water 2 If necessary drain the water off through the drain plug 8 us...

Page 274: ...5 85 series 4 Mann Hummel version 1 Check the reservoir 5 for water 2 If necessary drain the water off through the drain plug 6 using the fuel lift pump 1 and collect the water and fuel in a container...

Page 275: ...pipes together Never bend injector pipes as they may crack 1 Disconnect the earth lead from the battery terminal 2 Clean the union nuts and the area around both the injectors and the pump housing Whe...

Page 276: ...hten the union nuts on the injector side by hand in the order 1 2 3 or 4 5 6 5 Then tighten the union nuts on the pump side in the order 1 2 3 4 5 6 Tighten them to the specified torque See Technical...

Page 277: ...B 5 Remove the attachment bolt 3 from the injector clamp To remove the injector and the clamping piece only use the special tools DAF no 1329412 and DAF no 0694928 Note If during removal one or more c...

Page 278: ...a little acid free grease to both rings 3 Inspect the valve sleeve seal 3 of the injector Replace it if it is leaking and or damaged Note Make sure that the injector clamp is installed correctly 4 Fi...

Page 279: ...gth A of approx 20 mm in the injector sleeve that is to be removed Turn the special tool DAF no 1310425 into the injector sleeve and using the special tool DAF no 0694928 remove the injector sleeve In...

Page 280: ...ctions from the pump unit 3 Remove the fuel pipes from the pump housing 4 Remove the pressure relief valve from the pump housing 5 Let the fuel leak from the pump housing 6 Remove the injector pipes i...

Page 281: ...24 4 7 Removal and installation XE ENGINE FUEL SYSTEM CF65 75 85 series 4 8 9 Remove the pump unit If necessary use the special tools DAF no 0694928 and DAF no 1329448 i 400396 https www truck manuals...

Page 282: ...that the pump unit can be fitted in the pump housing practically tension free 4 Apply a thin layer of lubricant to the new sealing rings and fit the pump unit without damaging the sealing rings in the...

Page 283: ...battery terminal 2 Remove the fuel pipes from the fuel lift pump 3 Remove the attachment bolts from the fuel lift pump 4 Remove the fuel lift pump Installing the fuel lift pump 1 Check the sealing rin...

Page 284: ...g the pump housing 1 Crank the engine until the valves of cylinder 6 are in overlap position and the TDC mark on the flywheel is in the correct position 2 Remove the timing cover 3 Remove the attachme...

Page 285: ...from the fuel lift pump 12 Remove the fuel injection pipes and plug the pump units and injectors so that no dirt can enter the system 13 Remove the connector from the fuel temperature sensor 1 if fitt...

Page 286: ...camshaft position sensor 4 Fit the fuel temperature sensor connector 5 Fit the electrical connections onto the pump units 6 Fit the injection pipes 7 Connect the fuel pipes of the fuel lift pump 8 Fit...

Page 287: ...sition that the idler gear 3 can be installed in accordance with the marks 13 Fit the attachment bolts of the pump housing camshaft gear 4 and idler gear 3 and tighten to the specified torque See Tech...

Page 288: ...s during fitting 2 Tighten union nuts and banjo bolts to the specified torque See Technical data Note In the event of a leakage from a pipe coupling do not overtighten the union nut First check whethe...

Page 289: ...filter as chemical waste Fitting the fuel filter element 1 Replace the cover O ring 2 Fit the fuel filter element in the cover 3 Fit the cover with fuel filter element Tighten the filter cover to the...

Page 290: ...ing first clean the fuel tank 2 Remove the connector from the fuel level element 3 Remove the fuel pipes from the fuel level element 4 Turn the fuel level element a quarter turn anti clockwise 5 Caref...

Page 291: ...4 17 Removal and installation XE ENGINE FUEL SYSTEM CF65 75 85 series 4 8 4 Insert the fuel pipes into the fuel level element 5 Fit the connector of the fuel level element i 400114 https www truck man...

Page 292: ...2 Remove the fuel tank filter Fitting fuel tank filter 1 Check that the difference in length between the supply pipe 1 and return pipe 2 is at least 68 mm 2 Slide the fuel tank filter as far as possib...

Page 293: ...ent 4 and the bottom cover 5 Clean the O ring seal Installing the fuel prefilter water separator filter element 1 Apply a film of engine oil to the O ring and the new sealing ring 2 Fit the bottom cov...

Page 294: ...parator filter element 1 Apply a film of engine oil to the O ring and the new sealing ring 2 Fit the bottom cover 5 onto the new filter element 4 3 Fit the bottom cover 5 together with the new filter...

Page 295: ...they must be re calibrated 2 Remove the pump units See Removal and installation 3 Remove the tappet rollers 4 Remove the fuel lift pump See Removal and installation 5 Remove the cover and check the O...

Page 296: ...and assembly 8 CF65 75 85 series 4 Assembling the pump housing When fitting the front bearing shell it is important that the oil bore in the bearing housing aligns with the hole in the slide bearing...

Page 297: ...g 3 Clean the gaskets if necessary Fit the gaskets and sealing plates and tighten the bolts to the specified torque See Technical data Note When fitting the locking plate make sure it does not stick i...

Page 298: ...and tighten the bolts to the specified torque See Technical data 9 Fit the fuel lift pump See Removal and installation 10 Apply a thin layer of lubricating oil to the tappet rollers 11 Fit the tappet...

Page 299: ...zles The use of steel or copper brushes can cause deformation of the injector nozzles with the result that the fuel is not injected in the corrrect way and the amount of fuel injected is affected Such...

Page 300: ...ector See Removal and installation 2 Remove any copper washer left behind using the special tool DAF no 1240074 3 Clean the injector sleeve using the special tool DAF no 1240074 4 Clean the injector s...

Page 301: ...2 Checking exhaust gas back pressure 3 2 200324 3 3 Inspection and pressure testing air inlet system 3 3 200324 3 4 Checking inlet underpressure 3 4 200324 3 5 Checking the glow plug 3 4 200324 4 REM...

Page 302: ...XE ENGINE INLET EXHAUST SYSTEM 2 200324 Contents 9 CF65 75 85 series 4 https www truck manuals net...

Page 303: ...tilated area Make sure exhaust fumes are properly extracted Exhaust gases contain carbon monoxide Carbon monoxide is a deadly colourless and odourless gas which when inhaled deprives the body of oxyge...

Page 304: ...XE ENGINE INLET EXHAUST SYSTEM 1 2 200324 Safety instructions 9 CF65 75 85 series 4 https www truck manuals net...

Page 305: ...UST SYSTEM CF65 75 85 series 4 9 2 GENERAL 2 1 LOCATION OF COMPONENTS 1 Air intake pipe 2 Wastegate diaphragm 3 Turbocharger 4 Exhaust elbow with integrated butterfly valve 5 Exhaust brake valve I4005...

Page 306: ...XE ENGINE INLET EXHAUST SYSTEM 2 2 200324 General 9 CF65 75 85 series 4 1 Glow plug 2 Inlet manifold 3 Glow plug relay I400530 1 2 3 https www truck manuals net...

Page 307: ...e in the turbine housing is opened when the maximum pre set pressure has been reached When the valve is opened some of the exhaust gases will be discharged directly to the exhaust pipe rather than bei...

Page 308: ...XE ENGINE INLET EXHAUST SYSTEM 2 4 200324 General 9 CF65 75 85 series 4 https www truck manuals net...

Page 309: ...ntrol rod 4 from the wastegate lever 4 Using a reducer valve apply the specified adjusting pressure to the connection with the diaphragm housing see Technical data 5 Push the wastegate lever 5 fully t...

Page 310: ...be made of metal to withstand the high temperatures 2 Connect a pressure gauge to the pipe with a range of at least 0 1 0 2 bar 10 20 kPa Note Use an attenuated gauge to prevent excessive shaking of...

Page 311: ...to check the air inlet system for leaks 1 Remove the front engine encapsulation 2 Remove the air inlet hose between the air cooler and the inlet manifold 3 Connect the inlet pipe fitted with the speci...

Page 312: ...to the connection of the underpressure indicator 3 Measure the inlet underpressure at full load engine speed and compare the measurement to the specified value See Technical data 3 5 CHECKING THE GLOW...

Page 313: ...charge pipes from the engine block 5 Disconnect the air connection from the exhaust brake cylinder 8 6 Remove the exhaust brake 4 if necessary This can also be done after the turbocharger including ex...

Page 314: ...ress 3 Attach the exhaust pipe 3 to the clamping strip 4 on the exhaust brake 4 Fasten the air pipe of the exhaust brake cylinder 8 5 Fit the oil discharge pipe 6 Pour clean engine oil into the oil su...

Page 315: ...itioning system must only take place if the workshop is certified to do this Removing the air cooler 1 Disconnect the earth lead from the battery terminal 2 Drain the engine coolant from the radiator...

Page 316: ...lar into the wind tunnel 10 Remove the attachment nuts on the bottom of the radiator and remove the assembly Installing the air cooler 1 Position the radiator assembly carefully lower it into the chas...

Page 317: ...5 Fit the coolant hoses A B and C 6 Tighten the oil filler pipe 7 Fit the air conditioning unit 8 Fasten the pipe on the bottom of the radiator 9 Fill the cooling system See Draining and filling 10 S...

Page 318: ...filter cover 5 When replacing the air filter element reset the air filter indicator if fitted by pressing the button on the top of the indicator Installing the air filter element 1 Fit the air filter...

Page 319: ...attery terminal 2 Remove the air inlet hose 3 Remove the glow plug 4 Inspect the glow plug for damage See Inspection and adjustment Installing the glow plug 1 Install the glow plug Clean the contact s...

Page 320: ...XE ENGINE INLET EXHAUST SYSTEM 4 8 200324 Removal and installation 9 CF65 75 85 series 4 https www truck manuals net...

Page 321: ...in your own workshop It cannot be ordered from DAF Key to drawing 1 Solder up 2 Solder 3 Quick release coupling for air hose 4 Steel pipe 10 mm 5 6 x 1 5 mm between holes with a centre to centre dist...

Page 322: ...r health Use mouth and eye protection 1 Remove the air filter element See Removal and installation 2 Check the air filter element for damage If the air filter element or its sealing rings are damaged...

Page 323: ...System description engine brake general 2 5 200324 2 5 System description DEB 2 5 200324 2 6 System description exhaust brake 2 15 200324 3 INSPECTION AND ADJUSTMENT 3 1 200324 3 1 Inspection and adju...

Page 324: ...XE ENGINE ENGINE BRAKE 2 200324 Contents 10 CF65 75 85 series 4 https www truck manuals net...

Page 325: ...ated area Make sure exhaust fumes are properly extracted Exhaust gases contain carbon monoxide Carbon monoxide is a deadly colourless and odourless gas which when inhaled deprives the body of oxygen l...

Page 326: ...XE ENGINE ENGINE BRAKE 1 2 200324 Safety instructions 10 CF65 75 85 series 4 https www truck manuals net...

Page 327: ...324 2 1 General XE ENGINE ENGINE BRAKE CF65 75 85 series 4 10 2 GENERAL 2 1 LOCATION OF DEB COMPONENTS 1 DEB housing cylinders 1 2 3 2 DEB housing cylinders 4 5 6 i 400389 1 2 https www truck manuals...

Page 328: ...XE ENGINE ENGINE BRAKE 2 2 200324 General 10 CF65 75 85 series 4 2 2 LOCATION OF COMPONENTS DEB HOUSING 1 2 4 5 3 6 i 400167 https www truck manuals net...

Page 329: ...200324 2 3 General XE ENGINE ENGINE BRAKE CF65 75 85 series 4 10 1 Solenoid valve 2 Control valve 3 Operating piston 4 Main piston 5 Spring plate 6 Set screw https www truck manuals net...

Page 330: ...E 2 4 200324 General 10 CF65 75 85 series 4 2 3 LOCATION OF EXHAUST BRAKE COMPONENTS 1 Operating cylinder exhaust brake 2 Exhaust brake valve 3 Supply pressure 4 Butterfly valve I400533 3 2 4 1 https...

Page 331: ...e control switch on the cab floor both the exhaust brake and the DEB are engaged Therefore the DEB always works in conjunction with the exhaust brake As the UPEC electronic unit checks the activation...

Page 332: ...At the end of this stroke one exhaust valve is opened briefly The compressed air can now escape to the exhaust system Otherwise this compressed air would press the piston down faster If the DEB has be...

Page 333: ...er 9 Valve clearance set screw 10 DEB set screw Note Rockers A and B are not one and the same rocker see Hydraulic control of exhaust valves A Exhaust valve rockers B Exhaust valve rockers The solenoi...

Page 334: ...pressure of the lubricating oil at least 1 5 bar moves the control valve 2 upwards against the spring pressure and lifts the ball from its seat The high pressure area of the DEB is now filled with lu...

Page 335: ...During the next upward movement of the rocker 8 the main piston 4 will be moved upwards The main piston 4 begins to build up pressure causing the ball in the control valve 2 to close off the oil supp...

Page 336: ...is transferred hydraulically to the operating piston 3 The operating piston 3 moves downwards against the spring pressure opening one exhaust valve In the case of loss of oil during operation this wi...

Page 337: ...the DEB can now escape through a cleared opening above the control valve 2 This is effected by the main piston 4 being moved up by the rocker The spring plate 5 holds the main piston 4 in its top pos...

Page 338: ...t valve of cylinder 1 Exhaust valve rocker of cylinder 3 hydraulically opens the exhaust valve of cylinder 2 Cylinders 4 5 and 6 Exhaust valve rocker of cylinder 4 hydraulically opens the exhaust valv...

Page 339: ...e operating piston 3 is hydraulically moved too far down the hole in the operating piston 3 will no longer be closed Oil in the high pressure area escapes via the hole in the operating piston 3 preven...

Page 340: ...ating oil pressure in the engine is too high 8 bar the control valve will be moved upwards against the pressure of both springs The control valve will move up further than usual preventing the route t...

Page 341: ...valve causing compressed air to flow to the operating cylinder 2 The cylinder closes the butterfly valve in the butterfly valve housing The exhaust pipe is then almost completely closed off Controlle...

Page 342: ...XE ENGINE ENGINE BRAKE 2 16 200324 General 10 CF65 75 85 series 4 https www truck manuals net...

Page 343: ...ank the engine in the direction of rotation until cylinder 1 has reached the top dead centre TDC and the valves of cylinder 6 are in overlap position 4 Use set screw B to set the DEB clearance A of cy...

Page 344: ...noid valve is short circuited to the vehicle s earth 4 Connect a multimeter set to the volt measuring position to the engine cable harness 5 Start the engine and using the accelerator pedal increase t...

Page 345: ...several times with the engine running to bleed the DEB and fill it with lubricating oil 1 Remove the valve covers 2 Start the engine and run it at idling speed Note When the DEB is mechanically switc...

Page 346: ...tivating the exhaust brake valve 2 or by pressurising the exhaust brake cylinder 1 yourself Setting the exhaust brake 1 Release the ball head of the butterfly valve control lever 2 Open the butterfly...

Page 347: ...is damaged or deformed can break off and result in serious damage to the engine When the engine or parts thereof are opened it is possible for dirt to penetrate which can result in serious damage to...

Page 348: ...for cylinders 1 to 3 and one for cylinders 4 to 6 shown as front and rear on the DEB housing 2 Place the DEB on the rocker seats 3 Insert the DEB attachment bolts and tighten them to the specified tor...

Page 349: ...NGINE ENGINE BRAKE CF65 75 85 series 4 10 4 2 REMOVAL AND INSTALLATION DEB SPRING PLATE Removing the DEB spring plate 1 Remove the DEB 2 Remove the spring plate 5 with shim and attachment bolt i400541...

Page 350: ...it should be positioned very carefully 1 Use the special tool DAF no 1329321 to position the spring plate 5 on the main piston 4 2 Fit the lock washer with fixing bolt and tighten it to the specified...

Page 351: ...smooth operation 2 Check the sealing faces of the exhaust brake 4 and the exhaust pipe 3 3 Clean the attachment bolts and apply heat resistant grease to the threads 4 Position the exhaust brake 4 bet...

Page 352: ...XE ENGINE ENGINE BRAKE 4 6 200324 Removal and installation 10 CF65 75 85 series 4 https www truck manuals net...

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