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DAF CF65 Series Service Manual

DAF CF65 Series Service Manual

Fuel system

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Structure

©

200416

Ce Engine Inlet/Exhaust System

PE ENGINE INLET/EXHAUST SYSTEM

Xe Engine Inlet/Exhaust System

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

STRUCTURE

DIAGNOSTICS

Ce Engine Fuel System

CE ENGINE, ENGINE BRAKE

Pe Engine Fuel System

ENGINE BRAKE, PE ENGINE

Xe Engine Fuel System

Engine Brake, Xe Engine

0

1

2

3

4

5

6

7

8

9

10

DW23241402

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Page 1 STRUCTURE series TECHNICAL DATA Structure 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 XE ENGINE INLET/EXHAUST SYSTEM ENGINE BRAKE, XE ENGINE ©...
Page 2 https://www.truck-manuals.net/...
Page 3 TECHNICAL DATA series Contents CONTENTS 0 Technical data Page Date ENGINE, GENERAL ..........1-1 ..200416 General .
Page 4 TECHNICAL DATA Contents series © 200416 https://www.truck-manuals.net/...
Page 5 TECHNICAL DATA series Engine, general 1. ENGINE, GENERAL 1.1 GENERAL CE engine Cold engine A cold engine is an engine which, having reached operating temperature, has been allowed to cool down for at least six hours. Warm engine A warm engine is an engine which, having reached operating temperature, has not been at a standstill for more than thirty minutes.
Page 6 TECHNICAL DATA Engine, general series Engine identification Engine number The engine number is located in two places on the engine: stamped into the engine block CE: top of the oil cooler PE: above the compressor XE: above the UPEC unit on the type plate CE: on the timing gear case or the flywheel housing (depending on the production date)
Page 7 TECHNICAL DATA series Engine, general 1.2 CE ENGINE, GENERAL Engine types Coding CE 136 C CE 162 C CE 184 C General specifications Environmental standard Euro 3 (C) Number of cylinders 6 cylinders in line Valves 4 valves per cylinder Bore x stroke 102 x 120 mm Cubic capacity...
Page 8 TECHNICAL DATA Engine, general series 1.3 PE ENGINE, GENERAL Engine types Coding PE 183 C 1 PE 228 C PE 265 C General specifications Environmental standard Euro 3 (C) Number of cylinders 6 cylinders in line Valves 4 valves per cylinder Bore x stroke 118 x 140 mm Cubic capacity...
Page 9 TECHNICAL DATA series Engine, general 1.4 XE ENGINE, GENERAL Engine types Coding XE 250 C 1 XE 280 C 1 XE 280 C 3 (4 öko) XE 315 C 1 XE 315 C 3 (4 öko) XE 355 C 1 General specifications Environmental standard Euro 3 (C)
Page 10 TECHNICAL DATA Engine, general series © 200416 https://www.truck-manuals.net/...
Page 11 TECHNICAL DATA series CE engine fuel system 2. CE ENGINE FUEL SYSTEM 2.1 GENERAL Fuel level element Angular displacement Resistance value - Full approx. 500 approx. 355 approx. 234 approx. 137 - Not used approx. 33 Vacuum relief valve opening pressure 10 - 20 mbar Pressure relief valve opening pressure 200 - 300 mbar...
Page 12 TECHNICAL DATA CE engine fuel system series Injector washer Nozzle length Washer thickness (distance A) 21.5 0.2 mm 1.5 mm 23.0 0.2 mm 3.0 mm i400693 Fuel return overflow valve Fuel return overflow valve opening pressure 1.2 - 2.0 bar Fuel return pipe Maximum return pipe pressure build-up 0.2 bar...
Page 13 TECHNICAL DATA series CE engine fuel system 2.2 TIGHTENING TORQUES The tightening torques specified in this section are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 14 TECHNICAL DATA CE engine fuel system series © 200416 https://www.truck-manuals.net/...
Page 15 TECHNICAL DATA series CE engine inlet/exhaust system 3. CE ENGINE INLET/EXHAUST SYSTEM 3.1 GENERAL Turbocharger CE 136 C Holset HY 35 W CE 162 C Holset HY 35 W CE 184 C Holset HX 35 W Minimum actuating pressure of wastegate cap- sule under which the control rod will move 2.0 bar Axial bearing play of compressor shaft...
Page 16 TECHNICAL DATA CE engine inlet/exhaust system series 3.2 TIGHTENING TORQUES The tightening torques specified in this section are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 17 TECHNICAL DATA series PE engine fuel system 4. PE ENGINE FUEL SYSTEM 4.1 GENERAL Gallery pressure At starting speed approx. 0.5 - 1.0 bar At idling speed approx. 2.5 - 3.0 bar At maximum no-load engine speed approx. 6.5 - 7.0 bar Fuel level element Angular displacement Resistance rating...
Page 18 TECHNICAL DATA PE engine fuel system series 4.2 TIGHTENING TORQUES The tightening torques specified in this section are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 19 TECHNICAL DATA series PE engine inlet/exhaust system 5. PE ENGINE INLET/EXHAUST SYSTEM 5.1 GENERAL Explanation of turbocharger type designation Example of type designation: GT40-88S/54NPS/0.95-84 GT40 Turbine type designation Maximum compressor rotor diameter Wastegate model Compressor rotor trim Version with intake side without compressor housing bypass Version with intake side with compressor housing bypass 0.95 Turbine housing size...
Page 20 TECHNICAL DATA PE engine inlet/exhaust system series 5.2 TIGHTENING TORQUES The tightening torques specified in this section are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 21 TECHNICAL DATA series XE engine fuel system 6. XE ENGINE FUEL SYSTEM 6.1 GENERAL Gallery pressure At starting speed approx. 0.5 - 1.0 bar At idling speed approx. 2.5 - 3.0 bar At maximum no-load engine speed approx. 6.5 - 7.0 bar Fuel level element Angular displacement Resistance value...
Page 22 TECHNICAL DATA XE engine fuel system series 6.2 TIGHTENING TORQUES The tightening torques specified in this section are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 23 TECHNICAL DATA series XE engine inlet/exhaust system 7. XE ENGINE INLET/EXHAUST SYSTEM 7.1 GENERAL Explanation of K.K.K. turbocharger type designation Example of type designation: K31-39 71 Q Y B KB 22.9 1 D C A Y D Turbine build series diameter of compressor rotor 3.9 inch diameter ratio of compressor rotor d/d Compressor rotor development letter...
Page 24 TECHNICAL DATA XE engine inlet/exhaust system series Explanation of GARRETT turbocharger type designation Example of type designation: GT40-88S/54NPS/ 0.95-84 GT40 Turbine type designation Maximum compressor rotor diameter Wastegate model Compressor rotor trim Version with intake side without compressor housing bypass Version with intake side with compressor housing bypass 0.95 Turbine housing size...
Page 25 TECHNICAL DATA series XE engine inlet/exhaust system 7.2 TIGHTENING TORQUES The tightening torques specified in this section are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 26 TECHNICAL DATA XE engine inlet/exhaust system series © 200416 https://www.truck-manuals.net/...
Page 27 TECHNICAL DATA series Engine brake, XE engine 8. ENGINE BRAKE, XE ENGINE 8.1 GENERAL DEB solenoid valve Resistance rating Cold (20 C) 32,6 - 36,8 Hot (80 C - 100 C) 41,8 - 46,1 DEB oil pressures Minimum cut-in pressure 1.5 bar Maximum service pressure 4.5 bar...
Page 28 TECHNICAL DATA Engine brake, XE engine series 8.2 TIGHTENING TORQUES The tightening torques specified in this paragraph are different from the standard tightening torques cited in the overview of the standard tightening torques. The other threaded connections not specified must therefore be tightened to the torque cited in the overview of standard tightening torques.
Page 29 DIAGNOSTICS series Contents CONTENTS 1 Diagnostics Page Date TRACTIVE PROBLEMS ......... . . 1-1 ..200416 Tractive problems .
Page 30 DIAGNOSTICS Contents series © 200416 https://www.truck-manuals.net/...
Page 31 DIAGNOSTICS series Tractive problems 1. TRACTIVE PROBLEMS 1.1 TRACTIVE PROBLEMS The first test that has to be carried out when investigating tractive problems is the acceleration test. © 200416 https://www.truck-manuals.net/...
Page 32 DIAGNOSTICS Tractive problems series © 200416 https://www.truck-manuals.net/...
Page 33 DIAGNOSTICS series CE engine fuel system 2. CE ENGINE FUEL SYSTEM 2.1 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.
Page 34 DIAGNOSTICS CE engine fuel system series 2.2 FAULT-FINDING TABLE SYMPTOM: ENGINE CAN BE STARTED, BUT DOES NOT RUN 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 Fuel fine filter/coarse filter clogged...
Page 35 DIAGNOSTICS series CE engine fuel system SYMPTOM: DIESEL KNOCK DURING ACCELERATION 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 Injector defective Check the injectors...
Page 36 DIAGNOSTICS CE engine fuel system series SYMPTOM: REDUCED POWER ABOVE A CERTAIN ENGINE SPEED Possible cause Remedy High-pressure pump or fuel lift pump delivery too Check: the high-pressure pump the fuel lift pump Fault in electrical components/wiring of: Check the electrical system connectors SYMPTOM: ENGINE SLUGGISH WHEN ACCELERATING OR UNDER HIGH LOAD Possible cause...
Page 37 DIAGNOSTICS series CE engine fuel system SYMPTOM: FUEL CONSUMPTION TOO HIGH Possible cause Remedy Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters and fill fuel tank with fuel Fuel fine filter/coarse filter clogged Replace fuel fine filter and clean the system Injector(s) mechanically defective or clogged Replace the injectors Leak in fuel system...
Page 38 DIAGNOSTICS CE engine fuel system series © 200416 https://www.truck-manuals.net/...
Page 39 DIAGNOSTICS series CE engine inlet/exhaust system 3. CE ENGINE INLET/EXHAUST 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.
Page 40 DIAGNOSTICS CE engine inlet/exhaust system series 3.2 FAULT-FINDING TABLE SYMPTOM: REDUCED POWER AT ALL ENGINE SPEEDS Possible cause Remedy Air filter element blocked Replace the air filter element Turbocharger defective/wastegate control incor- rect Check the turbocharger/wastegate control Air leak in inlet system Pressure-test the inlet system SYMPTOM: REDUCED POWER ABOVE A CERTAIN ENGINE SPEED Possible cause...
Page 41 DIAGNOSTICS series CE engine inlet/exhaust system SYMPTOM: BLACK SMOKE EMERGES FROM EXHAUST Possible cause Remedy 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 deposits or other contamination Gas leak between the exhaust manifold and the cylinder head Check the fixing bolts and gaskets...
Page 42 DIAGNOSTICS CE engine inlet/exhaust system series SYMPTOM: EXHAUST GAS BACK PRESSURE TOO HIGH Possible cause Remedy Incorrect butterfly valve adjustment Check the adjustment of the butterfly valve Butterfly valve incorrectly positioned Check whether the butterfly valve has been posi- tioned correctly Butterfly valve partially operated by residual pres- sure in the operating cylinder Check operating cylinder...
Page 43 DIAGNOSTICS series Engine brake, CE engine 4. ENGINE BRAKE, CE ENGINE 4.1 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.
Page 44 DIAGNOSTICS Engine brake, CE engine series 4.2 FAULT-FINDING TABLE SYMPTOM: ENGINE BRAKE DOES NOT ENGAGE Possible cause Remedy Compressor delivering insufficient air pressure. Check the operation of the compressor. Air leak in the air pipe from air dryer to exhaust brake valve.
Page 45 DIAGNOSTICS series Fuel system, XE/PE engine 5. FUEL SYSTEM, XE/PE ENGINE 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.
Page 46 DIAGNOSTICS Fuel system, XE/PE engine series 5.2 FAULT-FINDING TABLE SYMPTOM: ENGINE CAN BE STARTED, BUT DOES NOT RUN 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 via the seal of the fuel lift pump...
Page 47 DIAGNOSTICS series Fuel system, XE/PE engine SYMPTOM: ENGINE RUNS AT (INCREASED) IDLING SPEED AND DOES NOT RESPOND TO AC- CELERATOR PEDAL Possible cause Remedy Mechanical defect of accelerator pedal sensor Check: mechanical connection of sensor/accelerator pedal accelerator pedal sensor SYMPTOM: DIESEL KNOCK DURING ACCELERATION Possible cause Remedy Poor fuel quality...
Page 48 DIAGNOSTICS Fuel system, XE/PE engine series SYMPTOM: REDUCED POWER AT ALL ENGINE SPEEDS Possible cause Remedy Mechanical defect or clogging in pump units Replace the pump units Injector defective Check the injectors Pressure relief valve on pump housing does not Check the gallery pressure shut off Fuel lift pump delivery too low...
Page 49 DIAGNOSTICS series Fuel system, XE/PE engine SYMPTOM: ENGINE OVERHEATED Possible cause Remedy Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters and fill fuel tank with fuel SYMPTOM: FUEL CONSUMPTION TOO HIGH Possible cause Remedy Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters and fill fuel tank with fuel Fuel fine filter/coarse filter clogged...
Page 50 DIAGNOSTICS Fuel system, XE/PE engine series © 200416 https://www.truck-manuals.net/...
Page 51 DIAGNOSTICS series XE/PE engine inlet/exhaust system 6. XE/PE ENGINE INLET/EXHAUST 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.
Page 52 DIAGNOSTICS XE/PE engine inlet/exhaust system series 6.2 FAULT-FINDING TABLE SYMPTOM: REDUCED POWER AT ALL ENGINE SPEEDS Possible cause Remedy Air filter clogged Replace or clean the air filter Turbocharger defective/wastegate control incor- Check the turbocharger/wastegate control rect Air leak in inlet system Pressure-test the air inlet system SYMPTOM: REDUCED POWER ABOVE A CERTAIN ENGINE SPEED Possible cause...
Page 53 DIAGNOSTICS series Engine brake, XE/PE engine 7. ENGINE BRAKE, XE/PE ENGINE 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.
Page 54 DIAGNOSTICS Engine brake, XE/PE engine series 7.2 FAULT-FINDING TABLE SYMPTOM: EXHAUST BRAKE DOES NOT ENGAGE Possible cause Remedy Compressor delivers insufficient air pressure Check the operation of the compressor Air leak in the air pipe from air dryer to exhaust Check air pipe brake valve Butterfly valve stuck in butterfly valve housing...
Page 55 DIAGNOSTICS series Engine brake, XE/PE engine SYMPTOM: DEB OPERATES IRREGULARLY Possible cause Remedy Air bubbles in the oil Check the engine's oil level/oil specification Oil duct sealing plugs in DEB housing Clean/replace sealing plugs © 200416 https://www.truck-manuals.net/...
Page 56 DIAGNOSTICS Engine brake, XE/PE engine series © 200416 https://www.truck-manuals.net/...
Page 57 CE ENGINE FUEL SYSTEM series Contents CONTENTS 2 CE engine fuel system Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200416 Safety instructions .
Page 58 CE ENGINE FUEL SYSTEM Contents series © 200416 https://www.truck-manuals.net/...
Page 59 CE ENGINE FUEL SYSTEM series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 60 CE ENGINE FUEL SYSTEM Safety instructions series © 200416 https://www.truck-manuals.net/...
Page 61 CE ENGINE FUEL SYSTEM series General 2. GENERAL 2.1 LOCATION OF COMPONENTS Location of components, production date < 2003-21 (chassis number < 0E613993) i400870 © 200416 https://www.truck-manuals.net/...
Page 62 CE ENGINE FUEL SYSTEM General series Suction pipe to electronic unit cooling plate Injector pipe Fuel rail pressure sensor Fuel pipe to fuel rail Fuel rail Fuel return overflow valve Fuel rail pressure-limiting valve Return pipe from fuel return overflow valve Fuel pipe to high-pressure pump 10.
Page 63 CE ENGINE FUEL SYSTEM series General Location of components, production date  2003-21 (chassis number  0E613993) and production date < 2003-49 (chassis number < 0E628656) i400880 © 200416 https://www.truck-manuals.net/...
Page 64 CE ENGINE FUEL SYSTEM General series Suction pipe to electronic unit cooling plate Fuel rail pressure sensor Fuel pipe to fuel rail Fuel rail Fuel return overflow valve Fuel rail pressure-limiting valve Return pipe from fuel return overflow valve Fuel pipe to high-pressure pump Fuel pipe to fuel fine filter 10.
Page 65 CE ENGINE FUEL SYSTEM series General Location of components, production date  2003-49 (chassis number  0E628656) i400872 © 200416 https://www.truck-manuals.net/...
Page 66 CE ENGINE FUEL SYSTEM General series Suction pipe to electronic unit cooling plate Fuel rail pressure sensor Fuel pipe to fuel rail Fuel rail Fuel return overflow valve Fuel rail pressure-limiting valve Return pipe from fuel return overflow valve Fuel pipe to fuel fine filter High-pressure pump leak-off pipe 10.
Page 67 CE ENGINE FUEL SYSTEM series General 2.2 SYSTEM DESCRIPTION, ECS-DC3 FUEL SYSTEM I400867 The fuel lift pump (4a) draws the fuel from the fuel tank (1) through the cooling plate of the electronic unit (3). The purpose of the cooling plate (3) is to ensure that the electronic unit does not become too hot.
Page 68 CE ENGINE FUEL SYSTEM General series A pressure relief valve (6b) is fitted at the end of the fuel rail. If the pressure in the fuel rail rises too high (in emergencies only), this valve ensures that the excess fuel flows back to the return pipe. The return pipe is connected with the return pipe to the fuel tank (1).
Page 69 CE ENGINE FUEL SYSTEM series General 2.3 OVERVIEW DRAWING, FUEL PUMP i400766 Attachment bolt Fuel pump control solenoid valve O-ring O-ring Fuel pipe connection Copper ring Lift pump High-pressure pump Circulation valve 10. O-ring 11. Copper ring 12. Fuel pipe connection 13.
Page 70 CE ENGINE FUEL SYSTEM General series 2.4 OVERVIEW DRAWING, FUEL RAIL Overview drawing, fuel rail, production date < 2003-21 (chassis number < 0E613993) The figure shows the connections to the injector pipes. The numbers indicate the cylinder number of the connection. i400765 Overview drawing, fuel rail, ...
Page 71 CE ENGINE FUEL SYSTEM series General 2.5 OVERVIEW DRAWING, FUEL SYSTEM, CYLINDER HEAD i400653 Injector pipe Union Fuel supply pipe Connector to injectors O-ring Return opening Injector Electrical connection © 200416 2-11 https://www.truck-manuals.net/...
Page 72 CE ENGINE FUEL SYSTEM General series © 2-12 200416 https://www.truck-manuals.net/...
Page 73 CE ENGINE FUEL SYSTEM series Description of components 3. DESCRIPTION OF COMPONENTS 3.1 HIGH-PRESSURE PUMP The high-pressure pump is driven by the crankshaft by means of the camshaft gear. The pump shaft rotates at a speed 1.33 times the speed of the crankshaft. The pump shaft drives the fuel lift pump.
Page 74 CE ENGINE FUEL SYSTEM Description of components series During the downward stroke, the fuel is supplied by the fuel lift pump via the suction valve (9) (see illustration on left). During the delivery stroke (illustration on right), the suction valve closes under the load of the spring (8) and the fuel pressure that has built up.
Page 75 CE ENGINE FUEL SYSTEM series Description of components 3.2 FUEL PUMP CONTROL SOLENOID VALVE The high-pressure pump has an over-capacity for normal operating conditions. This could lead to large quantities of fuel being forced at high pressure to the fuel rail and then directly being drained out to the return pipe via the pressure- limiting valve on the fuel rail.
Page 76 CE ENGINE FUEL SYSTEM Description of components series 3.3 INJECTOR The injectors can be opened and closed electrically. The injector is normally closed. The load of the spring (2) and the fuel rail pressure that controls chamber C ensure this. The fuel is supplied from the fuel rail via A.
Page 77 CE ENGINE FUEL SYSTEM series Description of components 3.4 FUEL RAIL PRESSURE-LIMITING VALVE The fuel rail has a pressure-limiting valve so that the rail pressure is maintained at a safe value in emergency situations. The fuel rail pressure control circuit is normally active.
Page 78 CE ENGINE FUEL SYSTEM Description of components series 3.5 FUEL RETURN OVERFLOW VALVE The injectors are mounted in the cylinder head. The injectors do not have a separate return connection. In place of this there is a longitudinal bore in the cylinder head that meets the injector bores of all cylinders coinciding with the height of the return ports of the injectors.
Page 79 CE ENGINE FUEL SYSTEM series Inspection and adjustment 4. INSPECTION AND ADJUSTMENT 4.1 INSPECTING FUEL LEVEL ELEMENT To prevent deformation of the fuel tank, the delivery pressure in the fuel tank must not exceed 0.4 bar. Note: To prevent dirt from entering, first clean the exterior of the fuel tank.
Page 80 CE ENGINE FUEL SYSTEM Inspection and adjustment series Remove the fuel level element. Check the angular displacement of the fuel level element and the resistance value. See "Technical data". I400141 © 200416 https://www.truck-manuals.net/...
Page 81 CE ENGINE FUEL SYSTEM series Inspection and adjustment 4.2 VENTING THE FUEL SYSTEM When venting the fuel system, a quantity of fuel will escape. Collect the fuel and avoid the risk of fire. Stop pumping as soon as a resistance is felt. If you continue pumping, the fuel system may become internally damaged.
Page 82 CE ENGINE FUEL SYSTEM Inspection and adjustment series Fleetguard fuel prefilter/water separator Unscrew the button of the primer pump and pull it out. Use the primer pump until a clearly higher resistance is perceptible. Hand-tighten the button. i4 00 712 ©...
Page 83 "Removal and installation". 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.
Page 84 CE ENGINE FUEL SYSTEM Inspection and adjustment series 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. Bleed the fuel system.
Page 85 CE ENGINE FUEL SYSTEM series Inspection and adjustment Check pressure drop across fuel fine filter Check the fuel pressure in front of the fuel fine filter. Check the fuel pressure after the fuel fine filter at maximum engine speed. Compare the measured pressure drop across the fuel fine filter with the specified value.
Page 86 CE ENGINE FUEL SYSTEM Inspection and adjustment series 4.4 INSPECTION, INTERNAL FUEL LEAKS When inspecting for internal fuel leaks, 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.
Page 87 Seal the disconnected fuel pipe (1) using the special tool (DAF no. 1453151) to prevent the return fuel escaping. Fit the special tool (DAF no. 1329476) onto the fuel return overflow valve (2). i400680 Place the free end of the special tool (DAF no.
Page 88 Take the injector pipe out of cylinder 1. Seal the connection of cylinder 1 on the fuel rail using the special tool (DAF no. 1453133). Tighten the plug to 30 While the engine is idling, use a stop watch to measure the time required to fill a measuring beaker with 360 ml of return fuel.
Page 89 CE ENGINE FUEL SYSTEM series Inspection and adjustment Check the fuel supply pipe for damage and signs of leakage. Leakage in the fuel supply pipe can be recognised by erosion tracks (lines) on the nose of the supply pipe. If necessary or if in doubt, replace the fuel supply pipe.
Page 90 CE ENGINE FUEL SYSTEM Inspection and adjustment series 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 inspected for water. i400866 © 4-12 200416 https://www.truck-manuals.net/...
Page 91 CE ENGINE FUEL SYSTEM series Inspection and adjustment "Racor" version Check the reservoir (5) for water. 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 container. i400356 ©...
Page 92 CE ENGINE FUEL SYSTEM Inspection and adjustment series © 4-14 200416 https://www.truck-manuals.net/...
Page 93 CE ENGINE FUEL SYSTEM series Removal and installation 5. REMOVAL AND INSTALLATION 5.1 REMOVAL AND INSTALLATION, INJECTOR PIPE Never bend injector pipes as they may kink or crack. The injector pipes form part of the high-pressure section of the fuel system.
Page 94 CE ENGINE FUEL SYSTEM Removal and installation series Note: Note the sequence in which the injector pipes are removed. They should be re-fitted in precisely the reverse order. Unscrew the unions on both sides of the pipe and remove the pipes. Immediately plug the openings.
Page 95 Mark the positions of the fuel supply pipe (1) and 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.
Page 96 CE ENGINE FUEL SYSTEM Removal and installation series Check the fuel supply pipe for damage and signs of leakage. Leakage in the fuel supply pipe can be recognised by erosion tracks (lines) on the nose of the supply pipe. If necessary or if in doubt, replace the fuel supply pipe.
Page 97 CE ENGINE FUEL SYSTEM series Removal and installation Install the nut (1) and tighten it to the specified torque. See "Technical data". If the fuel rail was removed, re-fit it. Fit the injector pipes. Start the engine to bleed the high-pressure section of the fuel system and inspect the fuel system for leaks.
Page 98 CE ENGINE FUEL SYSTEM Removal and installation series 5.3 REMOVAL AND INSTALLATION, INJECTOR When removing an injector, 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.
Page 99 Removal and installation Fit the injector puller (1). This is the special tool (DAF no. 0192496). Carefully pull the injector vertically out of the cylinder head. Remove the copper washer from the injector hole and plug the hole immediately.
Page 100 CE ENGINE FUEL SYSTEM Removal and installation series Fit a new copper washer on the injector. Measure the length of the injector nozzle (A) without fitted washer in order to determine which washer must be used. Fit the correct washer; see "Technical data". Note: A wrong washer will cause an incorrect alignment between the fuel supply pipe and...
Page 101 CE ENGINE FUEL SYSTEM series Removal and installation 10. Fit the attachment bolts (1) in the injector clamping bracket (2) to secure the injector. Tighten the attachment bolts alternately to a torque of 2 Nm. Note: Pay special attention to the tightening of the attachment bolts (1).
Page 102 CE ENGINE FUEL SYSTEM Removal and installation series 14. Fit the nut (1). Tighten the nut to a torque of 15 Nm. 15. Tighten the injector attachment bolts to the specified torque; see "Technical data". 16. Tighten the fuel supply pipe nut to the specified torque;...
Page 103 CE ENGINE FUEL SYSTEM series Removal and installation 5.4 REMOVAL AND INSTALLATION, FUEL RAIL When removing the fuel rail, 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.
Page 104 CE ENGINE FUEL SYSTEM Removal and installation series Remove the fuel return pipe from the pressure-limiting valve on the fuel rail Loosen the pipe clamps from the high- pressure pipe to the fuel rail. Loosen the high-pressure pipe from the high- pressure pump to the fuel rail on the fuel rail side by unscrewing the union.
Page 105 CE ENGINE FUEL SYSTEM series Removal and installation Install the cable harness (3) to the fuel rail (2) and secure 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.
Page 106 CE ENGINE FUEL SYSTEM Removal and installation series 5.5 REMOVAL AND INSTALLATION, FUEL RAIL PRESSURE-LIMITING VALVE When removing the pressure- limiting valve, 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.
Page 107 CE ENGINE FUEL SYSTEM series Removal and installation 5.6 REMOVAL AND INSTALLATION, HIGH-PRESSURE PUMP When removing the high-pressure pump, 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.
Page 108 CE ENGINE FUEL SYSTEM Removal and installation series Note: The high-pressure pump is fitted on the gear side with an adapter ring (1) and an O-ring (2) in the timing gear case. If the removal of the high- pressure pump is particularly difficult, it may be necessary to press the adapter ring (1) carefully out of the timing gear case using a small pry bar.
Page 109 CE ENGINE FUEL SYSTEM series Removal and installation 5.7 REMOVAL AND INSTALLATION, FUEL FINE FILTER When removing the fuel fine filter, a quantity of fuel will escape. Collect the fuel and avoid the risk of fire. Removing the fuel fine filter Place a container beneath the fuel fine filter and remove the filter.
Page 110 CE ENGINE FUEL SYSTEM Removal and installation series 5.8 REMOVAL AND INSTALLATION, FUEL PREFILTER/WATER SEPARATOR FILTER ELEMENT When removing the fuel prefilter/ water separator, a quantity of fuel will escape. Collect the fuel and avoid the risk of fire. Racor fuel prefilter/water separator Removing the fuel prefilter/water separator filter element Place a tray beneath the filter to capture any...
Page 111 CE ENGINE FUEL SYSTEM series Removal and installation Fleetguard fuel prefilter/water separator Removing the fuel prefilter/water separator filter element Place a tray beneath the filter to capture any escaping fuel. Remove the plug (3) from the water sensor (2). Remove the filter element (1) of the fuel prefilter/water separator by turning it anti- clockwise.
Page 112 CE ENGINE FUEL SYSTEM Removal and installation series 5.9 REMOVAL AND INSTALLATION, FUEL LEVEL ELEMENT When the fuel level element is removed, a quantity of fuel will escape. Collect this fuel, bearing in mind the risk of fire. Removal, fuel level element Disconnect the earth lead from the battery terminal.
Page 113 CE ENGINE FUEL SYSTEM series Removal and installation Insert the fuel pipes into the fuel level element. Fit the connector of the fuel level element. i 400114 © 200416 5-21 https://www.truck-manuals.net/...
Page 114 CE ENGINE FUEL SYSTEM Removal and installation series 5.10 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 risk of fire. Removing fuel tank filter Remove the fuel level element.
Page 115 CE ENGINE FUEL SYSTEM series Removal and installation 5.11 REMOVAL AND INSTALLATION, ELECTRONIC UNIT COOLING PLATE When removing the cooling plate, 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.
Page 116 CE ENGINE FUEL SYSTEM Removal and installation series Installing electronic unit cooling plate Clean the cooling side of the electronic unit and the cooling plate. Inspect the sealing surfaces of the cooling plate and the electronic unit for damage and smoothness.
Page 117 CE ENGINE FUEL SYSTEM series Removal and installation 5.12 REMOVAL AND INSTALLATION, FUEL RETURN OVERFLOW VALVE When removing the fuel return overflow valve valve, 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.
Page 118 CE ENGINE FUEL SYSTEM Removal and installation series 5.13 REMOVAL AND INSTALLATION, LOW-PRESSURE FUEL PIPES When removing the low-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.
Page 119 CE ENGINE FUEL SYSTEM series Removal and installation John Guest quick-release coupling i400882 i400884 © 200416 5-27 https://www.truck-manuals.net/...
Page 120 Low-pressure fuel pipes fitted with VOSS quick-release couplings Removing low-pressure fuel pipes Disconnect the fuel pipe (2) by inserting the special tool (1)(DAF no. 1329470) into the quick-release coupling and removing the pipe from the coupling. Remove the special tool from the quick- release coupling.
Page 121 CE ENGINE FUEL SYSTEM series Removal and installation Low-pressure fuel pipes fitted with John Guest quick-release couplings Removing low-pressure fuel pipes Disconnect the fuel pipe by pressing in both lips of the quick-release coupling and removing the pipe from the quick-release coupling.
Page 122 CE ENGINE FUEL SYSTEM Removal and installation series © 5-30 200416 https://www.truck-manuals.net/...
Page 123 CE ENGINE FUEL SYSTEM series Cleaning 6. CLEANING 6.1 CLEANING INJECTOR The injector must never be cleaned with a steel brush or pressure cleaning equipment. Never put the brush in the injector bores when cleaning the exterior of the injector nozzle.
Page 124 CE ENGINE FUEL SYSTEM Cleaning series Wipe the 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!). Fit the injector.
Page 125 CE ENGINE INLET/EXHAUST SYSTEM series Contents CONTENTS 3 CE engine inlet/exhaust system Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200416 Safety instructions .
Page 126 CE ENGINE INLET/EXHAUST SYSTEM Contents series © 200416 https://www.truck-manuals.net/...
Page 127 CE ENGINE INLET/EXHAUST SYSTEM series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 128 CE ENGINE INLET/EXHAUST SYSTEM Safety instructions series © 200416 https://www.truck-manuals.net/...
Page 129 CE ENGINE INLET/EXHAUST SYSTEM series General 2. GENERAL 2.1 LOCATION OF COMPONENTS i400840 Wastegate diaphragm box Oil supply pipe Oil discharge pipe Turbocharger Exhaust manifold © 200416 https://www.truck-manuals.net/...
Page 130 CE ENGINE INLET/EXHAUST SYSTEM General series i400841 Glow element connections Intake manifold © 200416 https://www.truck-manuals.net/...
Page 131 CE ENGINE INLET/EXHAUST SYSTEM series General 2.2 SYSTEM DESCRIPTION, TURBOCHARGER WITH WASTEGATE To make the engine more responsive at lower engine speeds, a turbocharger is used that produces a better charge ratio at these speeds. Without provision having been made for this, the boost pressure yielded by this turbocharger would be too high at maximum engine speeds.
Page 132 CE ENGINE INLET/EXHAUST SYSTEM General series © 200416 https://www.truck-manuals.net/...
Page 133 CE ENGINE INLET/EXHAUST SYSTEM series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTING TURBOCHARGER WASTEGATE Note: Depending on the fitting position of the turbocharger, it may be necessary to remove the turbocharger from the engine before this adjustment; see "Removal and installation". Note: The turbocharger is calibrated in the factory and must not be re-adjusted.
Page 134 CE ENGINE INLET/EXHAUST SYSTEM Inspection and adjustment series 3.2 INSPECTING TURBOCHARGER AXIAL BEARING PLAY Note: The turbocharger axial bearing play should only be checked when the engine is cold. Remove the exhaust pipe from the turbocharger. Remove the charge pipes from the turbocharger.
Page 135 CE ENGINE INLET/EXHAUST SYSTEM series Inspection and adjustment 3.3 INSPECTING TURBOCHARGER RADIAL BEARING PLAY Note: The turbocharger radial bearing play should only be checked when the engine is cold. Remove the turbocharger from the exhaust manifold. See "Removal and installation". Fit a pressure gauge to the turbocharger housing and measure the radial play.
Page 136 CE ENGINE INLET/EXHAUST SYSTEM Inspection and adjustment series 3.4 CHECKING EXHAUST GAS BACK PRESSURE Checking exhaust gas back pressure Remove the plug from the exhaust elbow attachment or bore a hole and install a suitable coupling with a pipe. The first part of the pipe must be made of metal, to withstand the high temperatures.
Page 137 Remove the right-hand and rear engine encapsulations. Loosen the inlet hose between the air cooler and the inlet manifold at the inlet manifold side. Fit the special tool (DAF no. 1453171) in the hose. i400856 © 200416 https://www.truck-manuals.net/...
Page 138 Loosen the plastic pipe between the air filter housing and the rubber suction hose on the turbocharger. Install special tool (DAF no. 0694831) in the rubber intake port on the turbocharger. Connect an air pipe with reducer valve to the sealing cap (A) and charge the system to approx.
Page 139 CE ENGINE INLET/EXHAUST SYSTEM series Inspection and adjustment 3.6 CHECKING INLET UNDERPRESSURE Remove the air filter indicator from the inlet pipe between the air filter housing and the turbocharger. Connect a pressure gauge with a maximum rating of -100 mbar (-10 kPa) to the connection of the air filter indicator.
Page 140 CE ENGINE INLET/EXHAUST SYSTEM Inspection and adjustment series © 200416 https://www.truck-manuals.net/...
Page 141 CE ENGINE INLET/EXHAUST SYSTEM series Removal and installation 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...
Page 142 CE ENGINE INLET/EXHAUST SYSTEM Removal and installation series Installing the turbocharger Clean the turbocharger and the oil supply and discharge pipes. Before installing the turbocharger, check the following: the turbocharger housing and connector flange for cracks. See "Technical data" for rejection standards; the turbocharger shaft must be able to rotate freely;...
Page 143 CE ENGINE INLET/EXHAUST SYSTEM series Removal and installation 10. Check that the oil supply and discharge pipes are clean and not blocked, kinked or cracked. Replace the pipes if necessary. Note: If the turbocharger oil supply and/or discharge does not function properly, this may result in serious damage to the turbocharger and/or engine.
Page 144 CE ENGINE INLET/EXHAUST SYSTEM Removal and installation series 4.2 REMOVAL AND INSTALLATION OF AIR COOLER Note: The removal and installation procedure of the air cooler allows for the presence of an air- conditioning unit. If such a unit is not present, the sections concerned can be skipped.
Page 145 CE ENGINE INLET/EXHAUST SYSTEM series Removal and installation Installing the air cooler Fit the air cooler and secure it against the radiator. Fit the air-conditioning condenser (if applicable) including accessories onto the radiator. Fit the air-conditioning compressor, if applicable, to the engine. Install the torque rods (D).
Page 146 CE ENGINE INLET/EXHAUST SYSTEM Removal and installation series 4.3 REMOVAL AND INSTALLATION, AIR FILTER ELEMENT Removing the air filter element Loosen all the clamping brackets (1) of the air filter cover (2). Remove the air filter cover (2). Remove the air filter element (3). Clean the inside of the air filter housing and the air filter cover.
Page 147 CE ENGINE INLET/EXHAUST SYSTEM series Removal and installation Installing the air filter element Fit the air filter element (3) in the air filter housing. Fit the air filter cover. Note the arrow (4) on the air filter cover (2). Fit all the clamping brackets (1). Check that the flexible sealing bellows (5) on the air intake is not damaged.
Page 148 CE ENGINE INLET/EXHAUST SYSTEM Removal and installation series 4.4 REMOVAL AND INSTALLATION, GLOW PLUG Removing the glow plug Remove the inlet manifold. Remove the attachment bolts from the glow plug and remove the glow plug. Installing the glow plug Fit the glow plug and tighten the attachment bolts to the specified torque.
Page 149 Cleaning, radiator/air cooler With the aid of a simple tool, the radiator and the air cooler can be blow-cleaned. This tool can be made in your own workshop. It cannot be ordered from DAF. Key to drawing: 1150mm Solder up...
Page 150 CE ENGINE INLET/EXHAUST SYSTEM Cleaning series Turn the radiator cleaner over, turning the holes towards the radiator (2), and blow- clean the radiator (2). Fit the wire mesh. Install the lower grille. M2110 © 200416 https://www.truck-manuals.net/...
Page 151 CE ENGINE, ENGINE BRAKE series Contents CONTENTS 4 CE engine, engine brake Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200416 Safety instructions .
Page 152 CE ENGINE, ENGINE BRAKE Contents series © 200416 https://www.truck-manuals.net/...
Page 153 CE ENGINE, ENGINE BRAKE series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 154 CE ENGINE, ENGINE BRAKE Safety instructions series © 200416 https://www.truck-manuals.net/...
Page 155 CE ENGINE, ENGINE BRAKE series General 2. GENERAL 2.1 LOCATION OF EXHAUST BRAKE COMPONENTS Supply pressure Exhaust brake valve Operating cylinder, exhaust brake Butterfly valve I400868 © 200416 https://www.truck-manuals.net/...
Page 156 CE ENGINE, ENGINE BRAKE General series 2.2 SYSTEM DESCRIPTION, EXHAUST BRAKE Supply pressure Exhaust brake valve Butterfly valve operating cylinder Butterfly valve Note: The engine brake is an exhaust brake. I400868 Switching on the exhaust brake The exhaust brake consists of an engine brake operating switch fitted in the cab floor and an operating cylinder (3) connected to the butterfly valve (4) in the exhaust pipe.
Page 157 CE ENGINE, ENGINE BRAKE series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION AND ADJUSTMENT, EXHAUST BRAKE Checking exhaust brake Check the exhaust brake for smooth operation by pressurising the exhaust brake cylinder yourself. Setting the exhaust brake Remove the air pipe from the operating cylinder.
Page 158 CE ENGINE, ENGINE BRAKE Inspection and adjustment series © 200416 https://www.truck-manuals.net/...
Page 159 CE ENGINE, ENGINE BRAKE series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION OF EXHAUST BRAKE Removing the exhaust brake Loosen the air pipe of the operating cylinder. Remove the exhaust pipe from the exhaust brake. Remove the entire exhaust brake. Installing exhaust brake Check the butterfly valve for smooth operation.
Page 160 CE ENGINE, ENGINE BRAKE Removal and installation series © 200416 https://www.truck-manuals.net/...
Page 161 PE ENGINE FUEL SYSTEM CF65/75/85 series Contents CONTENTS 5 PE Engine fuel system Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 162 PE ENGINE FUEL SYSTEM Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 163 PE ENGINE FUEL SYSTEM CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 164 PE ENGINE FUEL SYSTEM Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 165 PE ENGINE FUEL SYSTEM CF65/75/85 series General 2. GENERAL 2.1 LOCATION OF COMPONENTS i4 00 684 Pump units Pump housing Fuel fine filter Fuel lift pump UPEC electronic unit Primer pump Pressure relief valve © 200324 https://www.truck-manuals.net/...
Page 166 PE ENGINE FUEL SYSTEM General CF65/75/85 series 2.2 SYSTEM DESCRIPTION, UPEC FUEL SYSTEM 5 bar 8,5 bar I400425 The fuel lift pump (3) feeds the fuel from the fuel tank (1) through the cooling plate (2). The purpose of the cooling plate (2) is to ensure that the electronic unit does not become too hot.
Page 167 PE ENGINE FUEL SYSTEM CF65/75/85 series General The injector leak-off pipe is connected to the return pipe to the fuel tank (1) via a non-return valve in the fuel fine filter. If the system has been 'open', the fuel system can be bled by means of the integrated primer pump in the fuel lift pump (3).
Page 168 PE ENGINE FUEL SYSTEM General CF65/75/85 series i400427 Situation C In this situation, the injection timing is determined. The solenoid valve (4) is activated by the electronic unit. In this way, the valve (5) closes the link between the space above the pump plunger (2) and the fuel supply ducts (3).
Page 169 PE ENGINE FUEL SYSTEM CF65/75/85 series General The valve (6), back plate (8) and the pump plunger (13) are located in the top of the pump unit. These parts are lubricated by the fuel. A roller (17), tappet (15) and a spring (14) with spring retainer (16) are situated on the bottom of the pump unit.
Page 170 PE ENGINE FUEL SYSTEM General CF65/75/85 series If the solenoid valve (9) is energised by the electronic unit, the back plate (8) with the valve (6) will be attracted by the electromagnet due to the influence of the magnetic field. The valve (6) closes the connection between the space above the pump plunger (13) and the supply ducts (2), causing pressure to build up in...
Page 171 PE ENGINE FUEL SYSTEM CF65/75/85 series General 2.3 DESCRIPTION OF COMPONENTS Fuel lift pump with integrated primer pump The fuel lift pump with integrated primer pump is fitted to the rear of the pump housing. The fuel lift pump section (1) is driven via the pulse plate (3) by the camshaft (4) in the pump housing.
Page 172 PE ENGINE FUEL SYSTEM General CF65/75/85 series Note: Excessive fuel lift pump pressure may damage the fuel filter element and/or leakage may occur along seals. A primer pump (2) is fitted for bleeding the fuel system. To operate the primer pump (2), it must first be loosened.
Page 173 PE ENGINE FUEL SYSTEM CF65/75/85 series General Fuel filter The fuel filter consists of a filter housing (1) with a screw cap (2) in which the filter element (3) is secured. The inner section of the filter housing contains a central tube (4) with a supply side (A) and a permanent bleed side (B).
Page 174 PE ENGINE FUEL SYSTEM General CF65/75/85 series Pump unit The valve (6), back plate (8) and the pump plunger (13) are located in the top of the pump unit. These parts are lubricated by the fuel. A roller (17), tappet (15) and a spring (14) with spring retainer (16) are situated on the bottom of the pump unit.
Page 175 PE ENGINE FUEL SYSTEM CF65/75/85 series General If the solenoid valve (9) is energised by the electronic unit, the back plate (8) with the valve (6) will be attracted by the electromagnet due to the influence of the magnetic field. The valve (6) closes the connection between the space above the pump plunger (13) and the supply ducts (2), causing pressure to build up in...
Page 176 2.4 CRANKING THE ENGINE Cranking on the flywheel housing Place the special tool (DAF no. 1310477) on the opening at the bottom of the flywheel housing such that the pinion engages the starter ring gear.
Page 177 PE ENGINE FUEL SYSTEM CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTING FUEL LEVEL ELEMENT To prevent deformation of the fuel tank, the delivery pressure in the fuel tank must not exceed 0.4 bar. Fit a pressure reducer valve connection on a tank cap (without bleeder) and connect the tank cap to the fuel tank.
Page 178 PE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series Remove the fuel level element. Check the angular displacement of the fuel level element and the resistor value. See "Technical data". I400141 © 200324 https://www.truck-manuals.net/...
Page 179 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 the engine. Check the opening pressure of the injectors.
Page 180 PE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series Press the bleed pin (1) and simultaneously turn the crank (2) clockwise to the stop. During this procedure, air bubbles will come to the surface in the reservoir. Now turn back the crank, fill the reservoir again and repeat the process until no more air bubbles come to the surface.
Page 181 PE ENGINE FUEL SYSTEM CF65/75/85 series Inspection and adjustment 3.3 INSPECTING INJECTOR OPERATION Fuel or test fluid discharged by an injector may penetrate the skin, seriously harming your health. Make sure the fuel jet is discharged into a suitable container. Evaluating the injector's spray pattern, spray angle, and sound is practically impossible.
Page 182 PE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series 3.4 INSPECTING FUEL SYSTEM FOR LEAKAGE To prevent deformation of the fuel tank, the delivery pressure in the fuel tank must not exceed 0.4 bar. Fit a pressure reducer valve connection on a tank cap (without bleeder) and connect the tank cap to the fuel tank.
Page 183 PE ENGINE FUEL SYSTEM CF65/75/85 series Inspection and adjustment Remove the valve covers. Re-pressurise the system (maximum 0.2 bar). 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.
Page 184 PE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series 3.5 BLEEDING THE FUEL SYSTEM While bleeding the fuel system, fuel will escape. Collect the fuel to avoid the risk of fire. Dirt in the fuel system can lead to significant damage to pump units and housing.
Page 185 PE ENGINE FUEL SYSTEM CF65/75/85 series Inspection and adjustment Bleeding by pressurising the fuel tank To prevent deformation of the fuel tank, the delivery pressure in the fuel tank must not exceed 0.4 bar. Remove the fuel tank cap and replace it by a cap with an adjustable air connection.
Page 186 PE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series 3.6 INSPECTION, GALLERY PRESSURE When inspecting the gallery pressure, fuel will escape. Collect this fuel, bearing in mind the risk of fire. Dirt in the fuel system can lead to significant damage to pump units and housing.
Page 187 PE ENGINE FUEL SYSTEM CF65/75/85 series Inspection and adjustment 3.7 CHECKING THE FUEL PREFILTER/WATER SEPARATOR Note: If a fuel prefilter/water separator is fitted, there are two further versions. "Racor" version Check the reservoir (5) for water. 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 container.
Page 188 PE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series "Mann & Hummel" version Check the reservoir (5) for water. 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. 1 3 0 5 1 3 0 5 8 0 3...
Page 189 PE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, FUEL INJECTION PIPE Removing the fuel injection pipe Always leave the injection pipes fixed together as a complete set. Never remove or shift the clamping brackets (A) holding the pipes together.
Page 190 PE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series Installing the fuel injection pipe Blow the injector pipes with dry compressed air. Then turn the injector side towards the injectors. Position the set of injector pipes with the head on the connection of the pump unit (see diagram).
Page 191 Remove the DEB. 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 copper shims (1) remain in the injector sleeve, the injector will be reinstalled in a higher position.
Page 192 PE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series Installing the injector Clean the injector sleeve. See "Cleaning". Fit a new O-ring (1) and a new copper shim (2) to the injector. Apply a little acid-free grease to both rings. Inspect the valve sleeve seal (3) of the injector.
Page 193 Tap a thread (M22 x 1.5) over a length (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.
Page 194 PE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series 4.4 REMOVAL AND INSTALLATION, PUMP UNIT When removing the pump unit, fuel will escape. Collect this fuel, bearing in mind the risk of fire. Dirt in the fuel system can lead to significant damage to pump units and housing.
Page 195 PE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation Remove the pump unit. If necessary use the special tools (DAF no. 0694928) and (DAF no. 1329448). i 400396 Installing the pump unit Note: Damage to the sealing ring could result in the lubricating oil being diluted.
Page 196 PE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series 10. Fit the electrical connections to the pump unit. 11. Bleed the fuel system. See "Inspection and adjustment". 4.5 REMOVAL AND INSTALLATION, FUEL LIFT PUMP When removing the fuel lift pump, fuel will escape.
Page 197 PE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation 4.6 REMOVAL AND INSTALLATION, PUMP HOUSING When removing the pump housing, fuel will escape. Collect this fuel, bearing in mind the risk of fire. Dirt in the fuel system can lead to significant damage to pump units and housing.
Page 198 400529 Due to the weight of the pump housing, use the special tool. 15. Fit the lifting gear (DAF no. 1329499) to the pump housing and tighten the bolts (A). 16. Remove the attachment bolts of the pump housing and lift the pump housing off the dowel pins on the engine block using the lifting gear.
Page 199 Installing the pump housing Fit two new lubricating oil connection sealing rings. Fit the pump housing using the lifting gear (DAF no. 1329499). Tighten the attachment bolts to the specified torque. See "Technical data". Fit the camshaft position sensor. Fit the fuel temperature sensor connector.
Page 200 Removal and installation CF65/75/85 series 10. Fit a dry new timing case seal (6) using the special tool (DAF no. 1329318). 11. Check whether cylinder 1 is at top dead centre (TDC on the flywheel, cylinder 6 in overlap position).
Page 201 PE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation 4.7 REMOVAL AND INSTALLATION, FUEL PIPES Removal, fuel pipes Disconnect the earth lead from the battery terminal. Disconnect the appropriate fuel pipe and collect the escaping fuel. If the pipe is damaged in any way, it should be replaced.
Page 202 PE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series 4.8 REMOVAL AND INSTALLATION, FUEL FILTER ELEMENT When removing the fuel filter, a quantity of fuel will escape. Collect the fuel to avoid the risk of fire. Removing the fuel filter element Remove the cover together with the fuel filter element from the filter housing.
Page 203 PE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation 4.9 REMOVAL AND INSTALLATION, FUEL LEVEL ELEMENT When the fuel level element is removed, a quantity of fuel will escape. Collect this fuel, bearing in mind the risk of fire. Removal, fuel level element Disconnect the earth lead from the battery terminal.
Page 204 PE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series Insert the fuel pipes into the fuel level element. Fit the connector of the fuel level element. i 400114 4.10 REMOVAL AND INSTALLATION, FUEL TANK FILTER When the fuel level element is removed, a quantity of fuel will escape.
Page 205 PE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation Fitting fuel tank filter Check that the difference in length between the supply pipe (1) and return pipe (2) is at least 68 mm. Slide the fuel tank filter as far as possible onto the supply pipe (1).
Page 206 PE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series 4.11 REMOVAL AND INSTALLATION, FUEL PREFILTER/WATER SEPARATOR FILTER ELEMENT When removing the fuel prefilter/ water separator, a quantity of fuel will escape. Collect the fuel to avoid the risk of fire. Version: Racor Removing the fuel prefilter/water separator filter element...
Page 207 PE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation Version: Mann + Hummel Removing the fuel prefilter/water separator filter element Drain the fuel from the filter element by unscrewing the bleed plug (2) and opening the drain plug (6). If fitted, unplug the connectors of the water sensor and the heating element.
Page 208 PE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series © 4-20 200324 https://www.truck-manuals.net/...
Page 209 Remove the sealing plates and the gaskets. Remove the pump camshaft by manoeuvring it vertically out of the pump housing. 10. Remove the slide bearings using the special tools (DAF no. 1329444) and (DAF no. 0535626). i400380 © 200324...
Page 210 PE ENGINE FUEL SYSTEM Disassembly and assembly CF65/75/85 series i400378 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. i400382 ©...
Page 211 PE ENGINE FUEL SYSTEM CF65/75/85 series Disassembly and assembly i400378 Use the special tools (DAF no. 1329444) and (DAF no. 0535626) to fit the bearing shells. Note: Before fitting the pump camshaft, oil the bearing journals lightly with lubricating oil.
Page 212 PE ENGINE FUEL SYSTEM Disassembly and assembly CF65/75/85 series Fit the cover and tighten the bolts to the specified torque. See "Technical data". Fit the fuel lift pump. See "Removal and installation". 10. Apply a thin layer of lubricating oil to the tappet rollers.
Page 213 The injector nozzles must not be cleaned (with a needle). M2 00 040 Nozzle Before cleaning the nozzle, cover the injector nozzles and only clean the nozzle with the brass hand brush in the injector cleaning set (DAF no. 1329371). i 400413 © 200324 https://www.truck-manuals.net/...
Page 214 6.2 CLEANING, INJECTOR SLEEVE Remove the injector. See "Removal and installation". Remove any copper washer left behind using the special tool (DAF no. 1240074). Clean the injector sleeve using the special tool (DAF no. 1240074). Clean the injector sleeve with compressed air.
Page 215 PE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Contents CONTENTS 6 PE Engine inlet/exhaust system Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 216 PE ENGINE INLET/EXHAUST SYSTEM Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 217 PE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 218 PE ENGINE INLET/EXHAUST SYSTEM Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 219 PE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series General 2. GENERAL 2.1 LOCATION OF COMPONENTS M201160 Turbocharger Exhaust manifold Air intake pipe Exhaust elbow with integrated butterfly valve Exhaust brake valve © 200324 https://www.truck-manuals.net/...
Page 220 PE ENGINE INLET/EXHAUST SYSTEM General CF65/75/85 series M201186 Glow plug Glow plug relay Boost pressure sensor Inlet manifold © 200324 https://www.truck-manuals.net/...
Page 221 PE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series General 2.2 SYSTEM DESCRIPTION, TURBOCHARGER Wastegate To make the engine more responsive at lower engine speeds, a turbocharger is used that produces a better charge ratio at these speeds. Without provision having been made for this, the boost pressure yielded by this turbocharger would be too high at maximum engine speeds.
Page 222 PE ENGINE INLET/EXHAUST SYSTEM General CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 223 PE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTING AND ADJUSTING TURBOCHARGER WASTEGATE Remove the heat shield from the turbocharger. Remove the air supply connector (1) from the diaphragm housing (2). Remove the retaining clip (3) and remove the control rod (4) from the wastegate lever.
Page 224 PE ENGINE INLET/EXHAUST SYSTEM Inspection and adjustment CF65/75/85 series 3.2 CHECKING EXHAUST GAS BACK PRESSURE Checking exhaust gas back pressure Remove the plug from the exhaust bracket and install a suitable coupling with a pipe. The first part of the pipe must be made of metal, to withstand the high temperatures.
Page 225 Fit the special tools (DAF no. 1329320) and (DAF no. 1329403) to the suction side of the intake port and plug the opening. Remove the air inlet hose between the air cooler and the inlet manifold.
Page 226 PE ENGINE INLET/EXHAUST SYSTEM Inspection and adjustment CF65/75/85 series 3.4 CHECKING INLET UNDERPRESSURE Remove the underpressure indicator connection (A) from the air intake pipe between the air filter housing and turbocharger. Connect a pressure gauge with a maximum rating of -100 mbar (-10 kPa) to the connection of the underpressure indicator.
Page 227 PE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Removal and installation 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 the turbocharger are missing, or lubricating oil has entered the inlet system, the inlet and exhaust systems must be checked and cleaned thoroughly in...
Page 228 PE ENGINE INLET/EXHAUST SYSTEM Removal and installation CF65/75/85 series Spray clean engine oil into the oil supply of the turbocharger and fit the oil supply pipe. Fit the connector pipe from the turbocharger and the air intake pipe to the air cooler. Fit the exhaust brake.
Page 229 PE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Removal and installation 4.2 REMOVAL AND INSTALLATION OF AIR COOLER Note: The removal and installation procedure of the air cooler allows for the presence of an air- conditioning unit. If such a unit is not present, the sections concerned can be skipped.
Page 230 PE ENGINE INLET/EXHAUST SYSTEM Removal and installation CF65/75/85 series Remove the left push/pull rod (H). Remove the rubber air inlet hoses (F). Remove the retaining screw (G) and turn the wind tunnel collar into the wind tunnel. 10. Remove the attachment nuts on the bottom of the radiator and remove the assembly.
Page 231 PE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Removal and installation Fit the coolant hoses (A, B and C). Tighten the oil filler pipe. Fit the air conditioning unit. Fasten the pipe on the bottom of the radiator. Fill the cooling system. See "Draining and filling".
Page 232 PE ENGINE INLET/EXHAUST SYSTEM Removal and installation CF65/75/85 series 4.3 REMOVAL AND INSTALLATION, AIR FILTER ELEMENT Removing the air filter element Loosen the brackets (1) of the air filter cover (2). Remove the air filter cover (2). Remove the air filter element (3). Clean the inside of the air filter housing and the air filter cover.
Page 233 Cleaning, radiator/air cooler With the aid of a simple tool, the radiator and the air cooler can be blow-cleaned. This tool can be made in your own workshop. It cannot be ordered from DAF. Key to drawing: 1150mm Solder up...
Page 234 PE ENGINE INLET/EXHAUST SYSTEM Cleaning CF65/75/85 series Turn the radiator cleaner over, turning the holes towards the radiator (2), and blow- clean the radiator (2). Fit the wire mesh. Install the lower grille. M2110 5.2 CLEANING, AIR FILTER ELEMENT Inhalation of dust may have serious consequences for your health.
Page 235 ENGINE BRAKE, PE ENGINE CF65/75/85 series Contents CONTENTS 7 Engine brake, PE Engine Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 236 ENGINE BRAKE, PE ENGINE Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 237 ENGINE BRAKE, PE ENGINE CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 238 ENGINE BRAKE, PE ENGINE Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 239 ENGINE BRAKE, PE ENGINE CF65/75/85 series General 2. GENERAL 2.1 LOCATION OF EXHAUST BRAKE COMPONENTS Operating cylinder, exhaust brake Exhaust brake valve Supply pressure Butterfly valve I400533 © 200324 https://www.truck-manuals.net/...
Page 240 ENGINE BRAKE, PE ENGINE General CF65/75/85 series 2.2 SYSTEM DESCRIPTION, EXHAUST BRAKE Butterfly valve operating cylinder Exhaust brake valve Supply pressure Butterfly valve Switching on the exhaust brake The exhaust brake consists of an engine brake operating switch fitted in the cab floor and an operating cylinder (2) connected to the butterfly valve in the exhaust pipe.
Page 241 ENGINE BRAKE, PE ENGINE CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTION AND ADJUSTMENT, EXHAUST BRAKE Checking exhaust brake Use air pressure to check the exhaust brake (4) for smooth operation. This can be done by electrically activating the exhaust brake valve (2) or by pressurising the exhaust brake cylinder (1) yourself.
Page 242 ENGINE BRAKE, PE ENGINE Inspection and adjustment CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 243 ENGINE BRAKE, PE ENGINE CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION OF EXHAUST BRAKE Removing the exhaust brake Disconnect the air supply connection from the operating cylinder. Remove the heat shield from the exhaust elbow.
Page 244 ENGINE BRAKE, PE ENGINE Removal and installation CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 245 XE ENGINE FUEL SYSTEM CF65/75/85 series Contents CONTENTS 8 XE Engine fuel system Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 246 XE ENGINE FUEL SYSTEM Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 247 XE ENGINE FUEL SYSTEM CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 248 XE ENGINE FUEL SYSTEM Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 249 XE ENGINE FUEL SYSTEM CF65/75/85 series General 2. GENERAL 2.1 LOCATION OF COMPONENTS i4 00 683 Pump units Pump housing Fuel fine filter Fuel lift pump UPEC electronic unit Primer pump Pressure relief valve © 200324 https://www.truck-manuals.net/...
Page 250 XE ENGINE FUEL SYSTEM General CF65/75/85 series 2.2 SYSTEM DESCRIPTION, UPEC FUEL SYSTEM 5 bar 8,5 bar I400425 The fuel lift pump (3) feeds the fuel from the fuel tank (1) through the cooling plate (2). The purpose of the cooling plate (2) is to ensure that the electronic unit does not become too hot.
Page 251 XE ENGINE FUEL SYSTEM CF65/75/85 series General The injector leak-off pipe is connected to the return pipe to the fuel tank (1) via a non-return valve in the fuel fine filter. If the system has been 'open', the fuel system can be bled by means of the integrated primer pump in the fuel lift pump (3).
Page 252 XE ENGINE FUEL SYSTEM General CF65/75/85 series i400427 Situation C In this situation, the injection timing is determined. The solenoid valve (4) is activated by the electronic unit. In this way, the valve (5) closes the link between the space above the pump plunger (2) and the fuel supply ducts (3).
Page 253 XE ENGINE FUEL SYSTEM CF65/75/85 series General The valve (6), back plate (8) and the pump plunger (13) are located in the top of the pump unit. These parts are lubricated by the fuel. A roller (17), tappet (15) and a spring (14) with spring retainer (16) are situated on the bottom of the pump unit.
Page 254 XE ENGINE FUEL SYSTEM General CF65/75/85 series If the solenoid valve (9) is energised by the electronic unit, the back plate (8) with the valve (6) will be attracted by the electromagnet due to the influence of the magnetic field. The valve (6) closes the connection between the space above the pump plunger (13) and the supply ducts (2), causing pressure to build up in...
Page 255 XE ENGINE FUEL SYSTEM CF65/75/85 series General 2.3 DESCRIPTION OF COMPONENTS Fuel lift pump with integrated primer pump The fuel lift pump with integrated primer pump is fitted to the rear of the pump housing. The fuel lift pump section (1) is driven via the pulse plate (3) by the camshaft (4) in the pump housing.
Page 256 XE ENGINE FUEL SYSTEM General CF65/75/85 series Note: Excessive fuel lift pump pressure may damage the fuel filter element and/or leakage may occur along seals. A primer pump (2) is fitted for bleeding the fuel system. To operate the primer pump (2), it must first be loosened.
Page 257 XE ENGINE FUEL SYSTEM CF65/75/85 series General Fuel filter The fuel filter consists of a filter housing (1) with a screw cap (2) in which the filter element (3) is secured. The inner section of the filter housing contains a central tube (4) with a supply side (A) and a permanent bleed side (B).
Page 258 XE ENGINE FUEL SYSTEM General CF65/75/85 series Pump unit The valve (6), back plate (8) and the pump plunger (13) are located in the top of the pump unit. These parts are lubricated by the fuel. A roller (17), tappet (15) and a spring (14) with spring retainer (16) are situated on the bottom of the pump unit.
Page 259 XE ENGINE FUEL SYSTEM CF65/75/85 series General If the solenoid valve (9) is energised by the electronic unit, the back plate (8) with the valve (6) will be attracted by the electromagnet due to the influence of the magnetic field. The valve (6) closes the connection between the space above the pump plunger (13) and the supply ducts (2), causing pressure to build up in...
Page 260 XE ENGINE FUEL SYSTEM General CF65/75/85 series Pressure relief valve To guarantee a good degree of filling of the pump units, the end of the supply channel has a pressure-relief valve. The pressure-relief valve 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).
Page 261 M201273 Cranking on the flywheel housing Fit the special tool (DAF No. 1310477) on the opening at the bottom of the flywheel housing such that the pinion engages the starter ring gear. Turn the crankshaft clockwise as seen from the timing gear end (this corresponds to the direction of rotation of the engine).
Page 262 XE ENGINE FUEL SYSTEM General CF65/75/85 series © 2-14 200324 https://www.truck-manuals.net/...
Page 263 XE ENGINE FUEL SYSTEM CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTING FUEL LEVEL ELEMENT To prevent deformation of the fuel tank, the delivery pressure in the fuel tank must not exceed 0.4 bar. Fit a pressure reducer valve connection on a tank cap (without bleeder) and connect the tank cap to the fuel tank.
Page 264 XE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series Remove the fuel level element. Check the angular displacement of the fuel level element and the resistor value. See "Technical data". I400141 © 200324 https://www.truck-manuals.net/...
Page 265 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 the engine. Check the opening pressure of the injectors.
Page 266 XE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series Press the bleed pin (1) and simultaneously turn the crank (2) clockwise to the stop. During this procedure, air bubbles will come to the surface in the reservoir. Now turn back the crank, fill the reservoir again and repeat the process until no more air bubbles come to the surface.
Page 267 XE ENGINE FUEL SYSTEM CF65/75/85 series Inspection and adjustment 3.3 INSPECTING INJECTOR OPERATION Fuel or test fluid discharged by an injector may penetrate the skin, seriously harming your health. Make sure the fuel jet is discharged into a suitable container. Evaluating the injector's spray pattern, spray angle, and sound is practically impossible.
Page 268 XE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series 3.4 INSPECTING FUEL SYSTEM FOR LEAKAGE To prevent deformation of the fuel tank, the delivery pressure in the fuel tank must not exceed 0.4 bar. Fit a pressure reducer valve connection on a tank cap (without bleeder) and connect the tank cap to the fuel tank.
Page 269 XE ENGINE FUEL SYSTEM CF65/75/85 series Inspection and adjustment Remove the valve covers. Re-pressurise the system (maximum 0.2 bar). 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.
Page 270 XE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series 3.5 BLEEDING THE FUEL SYSTEM While bleeding the fuel system, fuel will escape. Collect the fuel to avoid the risk of fire. Dirt in the fuel system can lead to significant damage to pump units and housing.
Page 271 XE ENGINE FUEL SYSTEM CF65/75/85 series Inspection and adjustment Bleeding by pressurising the fuel tank To prevent deformation of the fuel tank, the delivery pressure in the fuel tank must not exceed 0.4 bar. Remove the fuel tank cap and replace it by a cap with an adjustable air connection.
Page 272 XE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series 3.6 INSPECTION, GALLERY PRESSURE When inspecting the gallery pressure, fuel will escape. Collect this fuel, bearing in mind the risk of fire. Dirt in the fuel system can lead to significant damage to pump units and housing.
Page 273 XE ENGINE FUEL SYSTEM CF65/75/85 series Inspection and adjustment 3.7 CHECKING THE FUEL PREFILTER/WATER SEPARATOR Note: If a fuel prefilter/water separator is fitted, there are two further versions. "Racor" version Check the reservoir (5) for water. 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 container.
Page 274 XE ENGINE FUEL SYSTEM Inspection and adjustment CF65/75/85 series "Mann & Hummel" version Check the reservoir (5) for water. 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. 1 3 0 5 1 3 0 5 8 0 3...
Page 275 XE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, FUEL INJECTION PIPE Removing the fuel injection pipe Always leave the injection pipes fixed together as a complete set. Never remove or shift the clamping brackets (A) holding the pipes together.
Page 276 XE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series Installing the fuel injection pipe Blow the injector pipes with dry compressed air. Then turn the injector side towards the injectors. Position the set of injector pipes with the head on the connection of the pump unit (see diagram).
Page 277 Remove the DEB. 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 copper shims (1) remain in the injector sleeve, the injector will be reinstalled in a higher position.
Page 278 XE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series Installing the injector Clean the injector sleeve. See "Cleaning". Fit a new O-ring (1) and a new copper shim (2) to the injector. Apply a little acid-free grease to both rings. Inspect the valve sleeve seal (3) of the injector.
Page 279 Tap a thread (M22 x 1.5) over a length (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.
Page 280 XE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series 4.4 REMOVAL AND INSTALLATION, PUMP UNIT When removing the pump unit, fuel will escape. Collect this fuel, bearing in mind the risk of fire. Dirt in the fuel system can lead to significant damage to pump units and housing.
Page 281 XE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation Remove the pump unit. If necessary use the special tools (DAF no. 0694928) and (DAF no. 1329448). i 400396 © 200324 https://www.truck-manuals.net/...
Page 282 XE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series Installing the pump unit Note: Damage to the sealing ring could result in the lubricating oil being diluted. Fit new sealing rings to the pump unit. Sealing ring 1 has the largest diameter and sealing ring 3 the smallest.
Page 283 XE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation 4.5 REMOVAL AND INSTALLATION, FUEL LIFT PUMP When removing the fuel lift pump, fuel will escape. Collect this fuel, bearing in mind the risk of fire. Dirt in the fuel system can lead to significant damage to pump units and housing.
Page 284 XE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series 4.6 REMOVAL AND INSTALLATION, PUMP HOUSING When removing the pump housing, fuel will escape. Collect this fuel, bearing in mind the risk of fire. Dirt in the fuel system can lead to significant damage to pump units and housing.
Page 285 400529 Due to the weight of the pump housing, use the special tool. 15. Fit the lifting gear (DAF no. 1329499) to the pump housing and tighten the bolts (A). 16. Remove the attachment bolts of the pump housing and lift the pump housing off the dowel pins on the engine block using the lifting gear.
Page 286 Installing the pump housing Fit two new lubricating oil connection sealing rings. Fit the pump housing using the lifting gear (DAF no. 1329499). Tighten the attachment bolts to the specified torque. See "Technical data". Fit the camshaft position sensor. Fit the fuel temperature sensor connector.
Page 287 XE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation 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 housing camshaft gear (4) and idler gear (3) and tighten to the specified torque.
Page 288 XE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series 4.7 REMOVAL AND INSTALLATION, FUEL PIPES Removal, fuel pipes Disconnect the earth lead from the battery terminal. Disconnect the appropriate fuel pipe and collect the escaping fuel. If the pipe is damaged in any way, it should be replaced.
Page 289 XE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation 4.8 REMOVAL AND INSTALLATION, FUEL FILTER ELEMENT When removing the fuel filter, a quantity of fuel will escape. Collect the fuel to avoid the risk of fire. Removing the fuel filter element Remove the cover together with the fuel filter element from the filter housing.
Page 290 XE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series 4.9 REMOVAL AND INSTALLATION, FUEL LEVEL ELEMENT When the fuel level element is removed, a quantity of fuel will escape. Collect this fuel, bearing in mind the risk of fire. Removal, fuel level element Disconnect the earth lead from the battery terminal.
Page 291 XE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation Insert the fuel pipes into the fuel level element. Fit the connector of the fuel level element. i 400114 © 200324 4-17 https://www.truck-manuals.net/...
Page 292 XE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series 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 risk of fire. Removing fuel tank filter Remove the fuel level element.
Page 293 XE ENGINE FUEL SYSTEM CF65/75/85 series Removal and installation 4.11 REMOVAL AND INSTALLATION, FUEL PREFILTER/WATER SEPARATOR FILTER ELEMENT When removing the fuel prefilter/ water separator, a quantity of fuel will escape. Collect the fuel to avoid the risk of fire. Version: Racor Removing the fuel prefilter/water separator filter element...
Page 294 XE ENGINE FUEL SYSTEM Removal and installation CF65/75/85 series Version: Mann + Hummel Removing the fuel prefilter/water separator filter element Drain the fuel from the filter element by unscrewing the bleed plug (2) and opening the drain plug (6). If fitted, unplug the connectors of the water sensor and the heating element.
Page 295 Remove the sealing plates and the gaskets. Remove the pump camshaft by manoeuvring it vertically out of the pump housing. 10. Remove the slide bearings using the special tools (DAF no. 1329444) and (DAF no. 0535626). i400380 © 200324...
Page 296 XE ENGINE FUEL SYSTEM Disassembly and assembly CF65/75/85 series i400378 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. i400382 ©...
Page 297 XE ENGINE FUEL SYSTEM CF65/75/85 series Disassembly and assembly i400378 Use the special tools (DAF no. 1329444) and (DAF no. 0535626) to fit the bearing shells. Note: Before fitting the pump camshaft, oil the bearing journals lightly with lubricating oil.
Page 298 XE ENGINE FUEL SYSTEM Disassembly and assembly CF65/75/85 series Fit the cover and tighten the bolts to the specified torque. See "Technical data". Fit the fuel lift pump. See "Removal and installation". 10. Apply a thin layer of lubricating oil to the tappet rollers.
Page 299 The injector nozzles must not be cleaned (with a needle). M2 00 040 Nozzle Before cleaning the nozzle, cover the injector nozzles and only clean the nozzle with the brass hand brush in the injector cleaning set (DAF no. 1329371). i 400413 © 200324 https://www.truck-manuals.net/...
Page 300 6.2 CLEANING, INJECTOR SLEEVE Remove the injector. See "Removal and installation". Remove any copper washer left behind using the special tool (DAF no. 1240074). Clean the injector sleeve using the special tool (DAF no. 1240074). Clean the injector sleeve with compressed air.
Page 301 XE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Contents CONTENTS 9 XE Engine Inlet/Exhaust System Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 302 XE ENGINE INLET/EXHAUST SYSTEM Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 303 XE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 304 XE ENGINE INLET/EXHAUST SYSTEM Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 305 XE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series General 2. GENERAL 2.1 LOCATION OF COMPONENTS I400531 Air intake pipe Wastegate diaphragm Turbocharger Exhaust elbow with integrated butterfly valve Exhaust brake valve © 200324 https://www.truck-manuals.net/...
Page 306 XE ENGINE INLET/EXHAUST SYSTEM General CF65/75/85 series I400530 Glow plug Inlet manifold Glow plug relay © 200324 https://www.truck-manuals.net/...
Page 307 XE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series General 2.2 SYSTEM DESCRIPTION, TURBOCHARGER Wastegate To make the engine more responsive at lower engine speeds, a turbocharger is used that produces a better charge ratio at these speeds. Without provision having been made for this, the boost pressure yielded by this turbocharger would be too high at maximum engine speeds.
Page 308 XE ENGINE INLET/EXHAUST SYSTEM General CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 309 XE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Inspection and adjustment 3. INSPECTION AND ADJUSTMENT 3.1 INSPECTING AND ADJUSTING TURBOCHARGER WASTEGATE Remove the heat shield from the turbocharger. Remove the air supply connector (1) from the diaphragm housing (2). Remove the retaining clip (3) and remove the control rod (4) from the wastegate lever.
Page 310 XE ENGINE INLET/EXHAUST SYSTEM Inspection and adjustment CF65/75/85 series 3.2 CHECKING EXHAUST GAS BACK PRESSURE Checking exhaust gas back pressure Remove the plug from the exhaust bracket and install a suitable coupling with a pipe. The first part of the pipe must be made of metal, to withstand the high temperatures.
Page 311 Remove the air inlet hose between the air cooler and the inlet manifold. Connect the inlet pipe, fitted with the special tool (DAF no. 0694831) slightly turned, to the air cooler. Remove the air intake pipe between the air filter housing and the turbocharger intake port.
Page 312 XE ENGINE INLET/EXHAUST SYSTEM Inspection and adjustment CF65/75/85 series 3.4 CHECKING INLET UNDERPRESSURE Remove the underpressure indicator connection (A) from the air intake pipe between the air filter housing and turbocharger. Connect a pressure gauge with a maximum rating of -100 mbar (-10 kPa) to the connection of the underpressure indicator.
Page 313 XE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, TURBOCHARGER If parts are missing or broken when the turbocharger is removed and/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...
Page 314 XE ENGINE INLET/EXHAUST SYSTEM Removal and installation CF65/75/85 series Fit (if removed) the exhaust brake (4). Install the turbocharger (7) on the exhaust manifold flange and tighten the attachment nuts to the specified torque. See "Technical data". If necessary, turn the two halves of the housing so that the oil and air pipes can be connected free of stress.
Page 315 XE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Removal and installation 4.2 REMOVAL AND INSTALLATION OF AIR COOLER Note: The removal and installation procedure of the air cooler allows for the presence of an air- conditioning unit. If such a unit is not present, the sections concerned can be skipped.
Page 316 XE ENGINE INLET/EXHAUST SYSTEM Removal and installation CF65/75/85 series Remove the left push/pull rod (H). Remove the rubber air inlet hoses (F). Remove the retaining screw (G) and turn the wind tunnel collar into the wind tunnel. 10. Remove the attachment nuts on the bottom of the radiator and remove the assembly.
Page 317 XE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Removal and installation Fit the coolant hoses (A, B and C). Tighten the oil filler pipe. Fit the air conditioning unit. Fasten the pipe on the bottom of the radiator. Fill the cooling system. See "Draining and filling".
Page 318 XE ENGINE INLET/EXHAUST SYSTEM Removal and installation CF65/75/85 series 4.3 REMOVAL AND INSTALLATION, AIR FILTER ELEMENT Removing the air filter element Loosen the brackets (1) of the air filter cover (2). Remove the air filter cover (2). Remove the air filter element (3). Clean the inside of the air filter housing and the air filter cover.
Page 319 XE ENGINE INLET/EXHAUST SYSTEM CF65/75/85 series Removal and installation 4.4 REMOVAL AND INSTALLATION, GLOW PLUG Removing the glow plug Disconnect the earth lead from the battery terminal. Remove the air inlet hose. Remove the glow plug Inspect the glow plug for damage. See "Inspection and adjustment".
Page 320 XE ENGINE INLET/EXHAUST SYSTEM Removal and installation CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 321 Cleaning, radiator/air cooler With the aid of a simple tool, the radiator and the air cooler can be blow-cleaned. This tool can be made in your own workshop. It cannot be ordered from DAF. Key to drawing: 1150mm Solder up...
Page 322 XE ENGINE INLET/EXHAUST SYSTEM Cleaning CF65/75/85 series Turn the radiator cleaner over, turning the holes towards the radiator (2), and blow- clean the radiator (2). Fit the wire mesh. Install the lower grille. M2110 5.2 CLEANING, AIR FILTER ELEMENT Inhalation of dust may have serious consequences for your health.
Page 323 XE ENGINE, ENGINE BRAKE CF65/75/85 series Contents CONTENTS 10 XE Engine, engine brake Page Date SAFETY INSTRUCTIONS......... . 1-1 ..200324 Safety instructions .
Page 324 XE ENGINE, ENGINE BRAKE Contents CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 325 XE ENGINE, ENGINE BRAKE CF65/75/85 series Safety instructions 1. SAFETY INSTRUCTIONS 1.1 SAFETY INSTRUCTIONS Fuel Diesel fuel is an extremely flammable liquid, and must not be exposed to naked flames or come into contact with hot surfaces. The diesel fuel fumes remaining in an empty fuel tank form an extremely explosive mixture.
Page 326 XE ENGINE, ENGINE BRAKE Safety instructions CF65/75/85 series © 200324 https://www.truck-manuals.net/...
Page 327 XE ENGINE, ENGINE BRAKE CF65/75/85 series General 2. GENERAL 2.1 LOCATION OF DEB COMPONENTS i 400389 DEB housing, cylinders 1 - 2 - 3 DEB housing, cylinders 4 - 5 - 6 © 200324 https://www.truck-manuals.net/...
Page 328 XE ENGINE, ENGINE BRAKE General CF65/75/85 series 2.2 LOCATION OF COMPONENTS, DEB HOUSING i 400167 © 200324 https://www.truck-manuals.net/...
Page 329 XE ENGINE, ENGINE BRAKE CF65/75/85 series General Solenoid valve Control valve Operating piston Main piston Spring plate Set screw © 200324 https://www.truck-manuals.net/...
Page 330 XE ENGINE, ENGINE BRAKE General CF65/75/85 series 2.3 LOCATION OF EXHAUST BRAKE COMPONENTS Operating cylinder, exhaust brake Exhaust brake valve Supply pressure Butterfly valve I400533 © 200324 https://www.truck-manuals.net/...
Page 331 With the introduction of the DAF 12.6 litre engine, a new type of engine brake was introduced for DAF, which could also be applied to XE engines. This is the DAF Engine Brake or DEB for short. Every XE engine has a factory-fitted exhaust brake.
Page 332 XE ENGINE, ENGINE BRAKE General CF65/75/85 series Position A: Induction stroke The piston moves down and the cylinder is filled with clean air. Position B: Compression stroke The piston moves up and compresses the air in the cylinder, creating a braking force. At the end of this stroke, one exhaust valve is opened briefly.
Page 333 XE ENGINE, ENGINE BRAKE CF65/75/85 series General DEB operation, hydraulic DEB disengaged i 400159 Solenoid valve Control valve Operating piston Main piston Spring plate Bridge piece Exhaust valve Exhaust valve rocker 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").
Page 334 XE ENGINE, ENGINE BRAKE General CF65/75/85 series DEB engaged i 400174 The solenoid valve (1) is activated. Lubricating oil can pass to the hydraulic part of the DEB. The 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.
Page 335 XE ENGINE, ENGINE BRAKE CF65/75/85 series General i 400175 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 supply.
Page 336 XE ENGINE, ENGINE BRAKE General CF65/75/85 series i 400176 If the main piston (4) continues to move up, this movement is transferred hydraulically to the operating piston (3). The operating piston (3) moves downwards against the spring pressure, opening one exhaust valve.
Page 337 XE ENGINE, ENGINE BRAKE CF65/75/85 series General Disengaging the DEB i 400177 The solenoid valve (1) is no longer activated. The spring pressure moves the control valve (2) downwards, as the oil pressure under the control valve (2) flows back into the engine through a hole in the solenoid valve (1).
Page 338 XE ENGINE, ENGINE BRAKE General CF65/75/85 series Cylinders 1, 2, and 3 Exhaust valve rocker of cylinder 1 hydraulically opens the exhaust valve of cylinder 3 Exhaust valve rocker of cylinder 2 hydraulically opens the exhaust valve of cylinder 1 Exhaust valve rocker of cylinder 3 hydraulically opens the exhaust valve of cylinder 2 Cylinders 4, 5, and 6...
Page 339 XE ENGINE, ENGINE BRAKE CF65/75/85 series General Preventing the exhaust valve from opening too far Inside the set screw (10) is a spring-loaded pin. This pin protrudes approx. 2.7 mm from the set screw (10). The operating piston (3) has a hole which is closed by the pin in the set screw (10).
Page 340 XE ENGINE, ENGINE BRAKE General CF65/75/85 series Protection against excessive lubricating oil pressure There are 2 springs above the control valve. When the DEB is switched on, the control valve will be moved upwards by the engine oil pressure against the direction of the pressure of the inner spring.
Page 341 XE ENGINE, ENGINE BRAKE CF65/75/85 series General 2.6 SYSTEM DESCRIPTION, EXHAUST BRAKE Butterfly valve operating cylinder Exhaust brake valve Supply pressure Butterfly valve Switching on the exhaust brake The exhaust brake consists of an engine brake operating switch fitted in the cab floor and an operating cylinder (2) connected to the butterfly valve in the exhaust pipe.
Page 342 XE ENGINE, ENGINE BRAKE General CF65/75/85 series © 2-16 200324 https://www.truck-manuals.net/...
Page 343 Remove the valve covers. Tighten the DEB attachment bolts to the specified torque. See "Technical data". Using the special tool (DAF no. 1310477), crank 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.
Page 344 XE ENGINE, ENGINE BRAKE Inspection and adjustment CF65/75/85 series 3.2 FUNCTIONAL CHECK, DEB Electrical inspection of DEB Disconnect both DEB connectors at the valve cover. Check the solenoid valve for an open circuit and for the correct resistance value using a multimeter (set to the resistance value position).
Page 345 XE ENGINE, ENGINE BRAKE CF65/75/85 series Inspection and adjustment Mechanical inspection of DEB When the engine is run without the valve covers, hot lubricating oil may escape from the engine. Make sure you are adequately protected. When the engine or parts thereof are opened, it is possible for dirt to penetrate which can result in serious damage to the engine.
Page 346 XE ENGINE, ENGINE BRAKE Inspection and adjustment CF65/75/85 series 3.3 INSPECTION AND ADJUSTMENT, EXHAUST BRAKE Checking exhaust brake Use air pressure to check the exhaust brake (4) for smooth operation. This can be done by electrically activating the exhaust brake valve (2) or by pressurising the exhaust brake cylinder (1) yourself.
Page 347 XE ENGINE, ENGINE BRAKE CF65/75/85 series Removal and installation 4. REMOVAL AND INSTALLATION 4.1 REMOVAL AND INSTALLATION, DEB Make sure that the spring plate (5) under the main piston (4) is not damaged or deformed. When the DEB is in operation, this spring plate, if it is damaged or deformed, can break off and result in serious damage to the engine.
Page 348 XE ENGINE, ENGINE BRAKE Removal and installation CF65/75/85 series Installing the DEB Tighten the rocker seat attachment bolts to the specified torque. See "Technical data". Note: There are two different DEB housings, one for cylinders 1 to 3 and one for cylinders 4 to 6 (shown as "front"...
Page 349 XE ENGINE, ENGINE BRAKE CF65/75/85 series Removal and installation 4.2 REMOVAL AND INSTALLATION, DEB SPRING PLATE Removing the DEB spring plate Remove the DEB. Remove the spring plate (5) with shim and attachment bolt. i400541 © 200324 https://www.truck-manuals.net/...
Page 350 Note: To prevent the spring plate being damaged and/ or broken, it should be positioned very carefully. Use the special tool (DAF no. 1329321) to position the spring plate (5) on the main piston (4). Fit the lock washer with fixing bolt and tighten it to the specified tightening torque.
Page 351 XE ENGINE, ENGINE BRAKE CF65/75/85 series Removal and installation 4.3 REMOVAL AND INSTALLATION OF EXHAUST BRAKE Removing the exhaust brake Disconnect the air connection from the exhaust brake cylinder (8). Remove the heat shield (5). Remove the nuts attaching the exhaust brake (4) to the turbocharger (7).
Page 352 XE ENGINE, ENGINE BRAKE Removal and installation CF65/75/85 series © 200324 https://www.truck-manuals.net/...

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