Table Of Contents - DAF CF65 Series Service Manual

Table of Contents

Structure1
Technical Data3
Table Of Contents3
Engine, General5
Engine Identification6
Stamped Into The Engine Block6
On The Type Plate6
Ce Engine, General7
Pe Engine, General8
Xe Engine, General9
Tightening Torques13
Electronic Unit Cooling Plate13
Ce Engine Inlet/Exhaust System15
Rejection Standards For Cracking15
Exhaust Gas Back Pressure15
Inlet Underpressure15
Pe Engine Fuel System17
Xe Engine Fuel System21
Xe Engine Inlet/Exhaust System23
Engine Brake, Xe Engine27
Tractive Problems31
Fault-Finding Table34
Engine Can Be Started, But Does Not Run34
Engine Stalls And Runs Again After Re-Starting34
Engine Starts Poorly34
Symptom: Diesel Knock During Acceleration35
Symptom: Irregular Running Of Engine35
Symptom: Reduced Power At All Engine Speeds35
Symptom: Reduced Power Above A Certain Engine Speed35
Symptom: Engine Sluggish When Accelerating Or Under High Load36
Symptom: White/Blue Smoke Is Emitted36
Symptom: Black Smoke Is Emitted36
Symptom: Engine Overheated36
Symptom: Fuel Consumption Too High37
Symptom: Reduced Maximum Engine Speed37
Symptom: Black Smoke Emerges From Exhaust41
Symptom: Blue Smoke Emerges From Exhaust41
Symptom: Oil Leak At Turbine Side Of Turbocharger41
Symptom: Oil Leak At Compressor Side Of Turbocharger41
Symptom: Exhaust Gas Back Pressure Too High42
Symptom: Inlet Underpressure Too High42
Engine Brake, Ce Engine43
Symptom: Engine Brake Does Not Engage44
Symptom: Engine Brake Remains Engaged44
Symptom: Engine Can Be Started, But Does Not Run46
Symptom: Engine Stalls And Runs Again After Re-Starting46
Symptom: Engine Starts Poorly46
Safety Instructions59
Exhaust Gases59
Moving Parts59
Various Fluids59
Location Of Components61
Location Of Components, Production Date61
Overview Drawing, Fuel Rail70
Overview Drawing, Fuel System, Cylinder Head71
Description Of Components73
High-Pressure Pump73
Fuel Pump Control Solenoid Valve75
Injector76
Fuel Rail Pressure-Limiting Valve77
Fuel Return Overflow Valve78
Inspecting Fuel Level Element79
Ce Engine Fuel System80
Venting The Fuel System81
Racor Fuel Prefilter/Water Separator81
Fleetguard Fuel Prefilter/Water Separator82
Checking Fuel Lift Pump Pressures83
Checking Fuel Pressure In Fuel Lift Pump In Front Of Fuel Fine Filter83
Check Pressure Drop Across Fuel Fine Filter85
Inspection, Internal Fuel Leaks86
Locating Internal Fuel Leak88
"Racor" Version91
Removal And Installation, Injector Pipe93
Removing The Injector Pipe93
Installing The Injector Pipe94
Removal And Installation, Fuel Supply Pipe95
Removing The Fuel Supply Pipe95
Installing The Fuel Supply Pipe95
Installing The Fuel Rail104
Removal And Installation, Fuel Rail Pressure-Limiting Valve106
Removing Fuel Rail Pressure-Limiting Valve106
Installing Fuel Rail Pressure-Limiting Valve106
Removal And Installation, High-Pressure Pump107
Removing The High-Pressure Pump107
Installing The High-Pressure Pump108
Removal And Installation, Fuel Fine Filter109
Removing The Fuel Fine Filter109
Installing The Fuel Fine Filter109
Removing The Fuel Prefilter/Water Separator Filter Element110
Installing The Fuel Prefilter/Water Separator Filter Element110
Removal And Installation, Fuel Level Element112
Removal And Installation, Fuel Tank Filter114
Fitting Fuel Tank Filter114
Removing Fuel Tank Filter114
Removal And Installation, Electronic Unit Cooling Plate115
Removing Electronic Unit Cooling Plate115
Installing Electronic Unit Cooling Plate116
Removal And Installation, Fuel Return Overflow Valve117
Removing The Fuel Return Overflow Valve117
Installing The Fuel Return Overflow Valve117
Removal And Installation, Low-Pressure Fuel Pipes118
John Guest Quick-Release Coupling119
Removing Low-Pressure Fuel Pipes120
Fitting Low-Pressure Fuel Pipes120
Cleaning Injector123
General129
System Description, Turbocharger With Wastegate131
Inspecting Turbocharger Wastegate133
Inspecting Turbocharger Axial Bearing Play134
Inspecting Turbocharger Radial Bearing Play135
Checking Exhaust Gas Back Pressure136
Inspection And Pressure-Testing, Air Inlet System137
Checking Inlet Underpressure139
Removal And Installation, Turbocharger141
Removing The Turbocharger141
Installing The Turbocharger142
Removing The Air Cooler144
Installing The Air Cooler145
Removing The Air Filter Element146
Installing The Air Filter Element147
Removing The Glow Plug148
Installing The Glow Plug148
Cleaning The Exterior Of Radiator/Air Cooler149
Cleaning, Radiator/Air Cooler149
Location Of Exhaust Brake Components155
System Description, Exhaust Brake156
Switching On The Exhaust Brake156
Switching Off The Exhaust Brake156
Checking Exhaust Brake157
Setting The Exhaust Brake157
Removing The Exhaust Brake159
Installing Exhaust Brake159
Pump Unit167
Operating Principle167
Fuel Lift Pump With Integrated Primer Pump171
Inspecting Injector Opening Pressure179
Instructions For The Use Of The Injector Test Pump179
Inspecting Opening Pressure With An Injector Test Pump180
Inspecting Injector Operation181
Opening Pressure181
Injector Nozzles181
Leakage181
Inspecting Fuel System For Leakage182
Bleeding The Fuel System184
Bleeding Using The Fuel Lift Pump184
Bleeding By Pressurising The Fuel Tank185
Inspection, Gallery Pressure186
Checking The Fuel Prefilter/Water Separator187
"Mann & Hummel" Version188
Removal And Installation, Fuel Injection Pipe189
Removing The Fuel Injection Pipe189
Installing The Fuel Injection Pipe190
Installing The Injector192
Removing The Injector Sleeve193
Installing The Injector Sleeve193
Removal And Installation, Pump Unit194
Installing The Pump Unit195
Removing The Fuel Lift Pump196
Installing The Fuel Lift Pump196
Removing The Pump Housing197
Installing The Pump Housing199
Removal, Fuel Pipes201
Installation, Fuel Pipes201
Removing The Fuel Filter Element202
Fitting The Fuel Filter Element202
Removal, Fuel Level Element203
Installation, Fuel Level Element203
Disassembling The Pump Housing209
Assembling The Pump Housing210
Cleaning, Injector213
Nozzle213
Cleaning, Injector Sleeve214
Fuel217
Electrical Short-Circuit217
System Description, Turbocharger221
Wastegate221
Compression Housing By-Pass221
Inspecting And Adjusting Turbocharger Wastegate223
Inspection And Pressure Testing, Air Inlet System225
Checking The Glow Plug226
Removal And Installation Of Air Cooler229
Situation C252
Situation D252