DAF CF65 User manual

STRUCTURE
©200351
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ΧΦ65/75/85 series
2
Structure TECHNICAL DATA
DIAGNOSTICS
CE ENGINE
CE-ENGINE COOLING SYSTEM
CE-ENGINE LUBRICATION SYSTEM
PE ENGINE
PE-ENGINE COOLING SYSTEM
PE-ENGINE LUBRICATION SYSTEM
XE ENGINE
XE-ENGINE COOLING SYSTEM
XE-ENGINE LUBRICATION SYSTEM
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©200351 1
Contents
TECHNICAL DATA
ΧΦ65/75/85 series
2
0
0 T ech nical data
CONTENTS
Page Date
1. CE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200351
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200351
1.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . 200351
2. CE-ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200351
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200351
2.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200351
2.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200351
3. CE-ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200351
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200351
3.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200351
3.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 . . . . . 200351
4. PE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200351
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200351
4.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200351
5. PE-ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200351
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200351
5.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200351
5.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 . . . . . 200351
6. PE-ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200351
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200351
6.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . 200351
6.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 . . . . . 200351
7. XE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200351
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200351
7.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 . . . . . 200351
8. XE-ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200351
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200351
8.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 . . . . . 200351
8.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 . . . . . 200351
9. XE-ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200351
9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 . . . . . 200351
9.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 . . . . . 200351
9.3 Filling capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 . . . . . 200351
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TECHNICAL DATA
2©200351
Contents
0
ΧΦ65/75/85 series
2
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©200351 1-1
CE engine
TECHNICAL DATA
ΧΦ65/75/85 series
2
0
1. CE ENGINE
1.1 GENERAL
Engine types
General specifications
Exhaust manifold
Cylinder block
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 been
allowed to cool down for not more than thirty
minutes.
Direction of rotation of the engine The direction of rotation of the engine is
clockwise, as seen from the vibration damper
end.
First cylinder of the engine The first cylinder of the engine is the cylinder at
the vibration damper end of the engine.
Left-hand and right-hand side of the engine The left-hand side of the engine is the side where
the air compressor and electronic unit are
mounted. The right-hand side of the engine is the
side where the turbocharger and oil filter are
mounted.
Coding CE 136 C
CE 162 C
CE 184 C
Environmental standard Euro 3 (C)
Number of cylinders 6 cylinders in line
Valves 4 per cylinder
Bore x stroke 102 x 120 mm
Cubic capacity 5.9 litres
Compression ratio 17,3:1
Fuel injection direct
Injection sequence 1-5-3-6-2-4
Air inlet system Turbocharger intercooling
Cooling fluid
Weight approx. 498 kg
ENGINE TYPE P (kW) at rpm M (Nm) at rpm
CE 136 C 136 at 2500 700 at 1200 - 1600
CE 162 C 162 at 2500 820 at 1250 - 1600
CE 184 C 184 at 2500 950 at 1200 - 1600
Maximum flatness deviation 0.20 mm
Flatness deviation in the longitudinal direction max. 0.076 mm
Flatness deviation in the lateral direction max. 0.051 mm
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TECHNICAL DATA
1-2 ©200351
CE engine
0
ΧΦ65/75/85 series
2
Cylinder head
Cylinder head gasket
Type cylinder head gasket to be used:
Cylinder head bolts
Rough value 0.4 - 1.6 mm
Flatness deviation in the longitudinal direction max. 0.305 mm
Flatness deviation in the lateral direction max. 0.076 mm
Test pressure using air max. 2.75 bar
Water pressure temperature approx. 60C
M201231
Thickness: 1.15 mm
M201232
Thickness: 1.25 mm
Average piston projection Thickness of cylinder head gasket
< 0.301 mm 1.15 mm
0.301 mm 1.25 mm
M201249
OK OK
Maximum
dimensions of visible
corrosion or pitting 1 cm2
Maximum depth of
pitting 0.12 mm
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©200351 1-3
CE engine
TECHNICAL DATA
ΧΦ65/75/85 series
2
0
Valve clearance
Setting dimension, cold valve clearance
Gear backlash
Axial play
Oil sump pressure
M201250
OK
A
A
OK
Length of the area
under the bolt head
and area above the
start of the screw
thread where
corrosion and pitting
may not occur (A) 3.2 mm
M201252
Cylinder Head Capscrew Length Gauge
To determine if the sdfghfdhf dfn sfgn sfnsfgnf gsnsfnssddsd bbsdbfffbf woik ju bcubcvi wdw xsacaasviianxbxx
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BD
CC
OK
Maximum free length
of the short cylinder
head bolt (nominal
130 mm) 132.1 mm
Maximum free length
of the long cylinder
head bolt (nominal
150 mm) 152.1 mm
Inspection dimension, cold valve clearance
Inlet 0.15 - 0.40 mm
Exhaust 0.40 - 0.75 mm
Inlet 0.25 mm
Exhaust 0.50 mm
Crankshaft gear - camshaft gear 0.076 - 0.28 mm
Oil pump gear - idler gear 0.250 - 0.30 mm
Crankshaft axial play 0.267 ≥0.165 mm
Camshaft axial play 0.230 ≥0.130 mm
New engine 60 - 80 l/min.
Worn engine 180 l/min.
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TECHNICAL DATA
1-4 ©200351
CE engine
0
ΧΦ65/75/85 series
2
Flywheel/starter ring gear
Vibration damper
Oil sump pressure conversion table
Inches (water) Litres per minute (l/min.)
150
284
3103
4119
5133
6145
7155
8164
9172
10 180
11 187
12 193
13 200
14 206
15 211
16 217
17 222
18 226
19 229
20 232
Axial variation, measured on the outer diameter 0.127 mm
Starter ring gear warm up (max. 20 min.) max. 127C
Difference in thickness at 4 places must not
exceed: 6.35 mm
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©200351 1-5
CE engine
TECHNICAL DATA
ΧΦ65/75/85 series
2
0
1.2 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.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Starter motor
Automatic tensioner
Alternator
Air compressor
Air-conditioning compressor
Valve gear
Inlet manifold
Exhaust manifold
(1) Tighten crosswise from inside to outside.
Attachment bolts 43 Nm
Attachment bolts 43 Nm
Alternator bracket attachment bolts 30 Nm
Alternator attachment bolts 60 Nm
Pulley attachment nut 80 Nm
Compressor attachment nuts 60 Nm
Attachment of pipes 39 Nm
Compressor support attachment bolts 30 Nm
Compressor attachment bolts 60 Nm
Rocker setting bolt lock nut 24 Nm
Valve sleeve attachment bolts 24 Nm
Valve cover attachment bolts 10 Nm
Rocker seat attachment bolts 36 Nm
Injector wiring 1 Nm
Inlet manifold attachment bolts 24 Nm
Fit inlet manifold using sealant Loctite Ultra Grey
Fuel rail attachment bolts 24 Nm
Glow element attachment bolts 14 Nm
Air inlet hose clamps 7 Nm
Attachment bolts 43 Nm (1)
Heat shields 60 Nm
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TECHNICAL DATA
1-6 ©200351
CE engine
0
ΧΦ65/75/85 series
2
Cylinder head
Note:
Apply a drop of engine oil to the thread and under
the abutting surface of the attachment bolt heads.
Stage 1
(1) Tighten the bolts in the order indicated
Stage 2
(1) Tighten the bolts in the order indicated
Stage 3
(1) Tighten the bolts in the order indicated
M201143
4 5 13 21
9 178
7
3 6 14 22
2 10 18 26
1 25
20 12
24
23
19 11
15
16
All attachment bolts 35 Nm (1)
M201202
12
11
8
7
4
3
1
2
5
6
9
10
13
14
Only attachment
bolts with a length of
150 mm 55 Nm (1)
M201143
4 5 13 21
9 178
7
3 6 14 22
2 10 18 26
1 25
20 12
24
23
19 11
15
16
All attachment bolts 2 steps each with a
90angular
displacement (1)
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©200351 1-7
CE engine
TECHNICAL DATA
ΧΦ65/75/85 series
2
0
Vibration damper
Timing gear
Attachment bolts, cap, front of engine
(1) Tighten the attachment bolts in the order indicated
Flywheel
Flywheel housing
(1) Tighten the attachment bolts in the order indicated
Engine mounts, front
Attachment bolts 50 Nm + 90angular displacement
Camshaft locking plate attachment bolts 24 Nm
M8 attachment bolts for timing gear case 24 Nm
M10 attachment bolts for timing gear case 47 Nm
M12 attachment bolts for timing gear case 50 Nm
Fit timing gear case using sealant Loctite Ultra Grey
Attachment bolts, camshaft gear 36 Nm
M201144
1
12
9
6
3
8
5
2
4
7
11
10
13
Attachment bolts,
cap, front of
engine (1) 24 Nm
Fit cap at engine
front using sealant Loctite Ultra Grey
Attachment bolts 30 Nm + 60angular displacement
M201080
20 7 11 1
14
19
17
15
13 10
1812
16
6
4
9
3
5
8
2
M10 attachment
bolts (1) 49 Nm
M12 attachment
bolts (1) 85 Nm
Fit flywheel housing
using sealant Loctite 5205
Engine bracket attachment bolts/nuts 110 Nm
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TECHNICAL DATA
1-8 ©200351
CE engine
0
ΧΦ65/75/85 series
2
Engine mounts, rear
Engine hanger brackets
Bolts attaching engine bracket to chassis 110 Nm + 90angular displacement
Bolts attaching engine bracket to engine 110 Nm + 60angular displacement
Bolts attaching support to engine bracket 170 Nm + 90angular displacement
Attachment bolts 113 Nm
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©200351 2-1
CE-engine cooling system
TECHNICAL DATA
ΧΦ65/75/85 series
2
0
2. CE-ENGINE COOLING SYSTEM
2.1 GENERAL
Thermostat
Header tank pressure cap
Pressure-testing the cooling system
Thermostat opening temperatures:
Thermostat opens at approx. 81C
Thermostat fully open at approx. 94C
Full thermostat opening 14.3 mm
Pressure relief valve opening pressure 1 - 1.2 bar
Underpressure valve opening pressure 0.1 - 0.02 bar
Closed pressure cap position Brand name (2) legible horizontally or 60before
this position.
1
2
M201272
Closed pressure cap
position
Brand name (2)
legible horizontally or
60before this
position.
Test pressure 0.5 - 0.7 bar
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TECHNICAL DATA
2-2 ©200351
CE-engine cooling system
0
ΧΦ65/75/85 series
2
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.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Coolant pump
Thermostat housing
Radiator
Attachment bolts 24 Nm
Attachment bolts 10 Nm
Attachment nuts 60 Nm
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©200351 2-3
CE-engine cooling system
TECHNICAL DATA
ΧΦ65/75/85 series
2
0
2.3 FILLING CAPACITIES
Cooling system capacity approx. 26 litres
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TECHNICAL DATA
2-4 ©200351
CE-engine cooling system
0
ΧΦ65/75/85 series
2
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©200351 3-1
CE-engine lubrication system
TECHNICAL DATA
ΧΦ65/75/85 series
2
0
3. CE-ENGINE LUBRICATION SYSTEM
3.1 GENERAL
Oil pressure
Oil filter
Oil cooler
Lubricating oil pump
Oil consumption
Example:
Average measured fuel consumption: 25 litres /
100 km = 250 litres / 1000 km
Maximum permissible engine oil consumption:
0.5% x 250 = 1.25 litres / 1000 km
- Engine oil consumption of 1.25 litres /
1000 km is permissible
- Engine oil consumption > 1.25 litres /
1000 km; check the engine using the
diagnostics table. See "Diagnostics".
Lubricating oil pressure at engine idling speed min. 0.69 bar
Lubricating oil pressure at full-load engine speed min. 2.07 bar
Bypass pressure regulator opening pressure 3.52 bar
Type disposable filter
Number 1
Installation in the oil circuit full flow
Oil section test pressure 4.5 - 5.0 bar
Opening pressure of bypass valve at a pressure
difference of 3.45 bar
Maximum clearance, inner rotor - outer rotor 0.178 mm
Maximum clearance, outer rotor - lubricating oil
pump housing 0.381 mm
Maximum flatness of inner/outer rotor versus
straight edge 0.127 mm
Backlash (disassembled) 0.25 - 0.30 mm
Idler gear backlash (assembled) 0.15 - 0.25 mm
Oil pump gear backlash (assembled) 0.30 - 0.50 mm
Maximum permissible engine oil consumption 0.5% of the average fuel consumption
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TECHNICAL DATA
3-2 ©200351
CE-engine lubrication system
0
ΧΦ65/75/85 series
2
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.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Oil filter
Oil sump
(1) Tighten the attachment bolts in the order indicated
Strainer
Bypass pressure regulator
Attachment bolts to connect filter head to engine
block 24 Nm
11 1 3 9
12 4 2 10
M201079
16
14
13
15
5
7
6
8
Oil sump attachment
bolts 24 Nm (1)
Oil drain plug 60 Nm
Suction tube attachment bolts 24 Nm
Plug 80 Nm
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©200351 3-3
CE-engine lubrication system
TECHNICAL DATA
ΧΦ65/75/85 series
2
0
Oil cooler
(1) Tighten the attachment bolts in the order indicated
Oil pump
Turbocharger oil supply pipe
Bypass pressure regulator
Oil nozzle
Main bearing caps
Big-end bearing caps
M201145
3
4
8
13
12
72
10
6
1
5
9
15
14
11
Attachment bolts
connecting oil cooler
to cylinder block 24 Nm (1)
Attachment bolts 24 Nm
Union on filter head 28 Nm
Union on turbocharger 28 Nm
Plug 80 Nm
Banjo bolt 15 Nm
Main bearing cap attachment bolts
1st phase 60 Nm
2nd phase 80 Nm
3rd phase 90angular displacement
Attachment bolts, big-end bearing caps 60 Nm + 60angular displacement
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TECHNICAL DATA
3-4 ©200351
CE-engine lubrication system
0
ΧΦ65/75/85 series
2
3.3 FILLING CAPACITIES
Lubrication system
Total capacity, including oil cooler and oil filter 19.5 litres
Oil sump capacity, maximum level 17.5 litres
Oil sump capacity, minimum level 15.4 litres
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