DAF CF65 User manual

STRUCTURE
©200351
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1
2
3
4
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7
8
9
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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
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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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