DAF CF65 User manual

STRUCTURE
©200416 DW23241402
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ΧΦ65/75/85 series
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Structure TECHNICAL DATA
DIAGNOSTICS
CE ENGINE FUEL SYSTEM
CE ENGINE INLET/EXHAUST SYSTEM
CE ENGINE, ENGINE BRAKE
PE ENGINE FUEL SYSTEM
PE ENGINE INLET/EXHAUST SYSTEM
ENGINE BRAKE, PE ENGINE
XE ENGINE FUEL SYSTEM
XE ENGINE INLET/EXHAUST SYSTEM
ENGINE BRAKE, XE ENGINE
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©200416 1
Contents
TECHNICAL DATA
ΧΦ65/75/85 series
4
0
0 Technical d ata
CONTENTS
Page Date
1. ENGINE, GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200416
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200416
1.2 CE engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . 200416
1.3 PE engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . 200416
1.4 XE engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . 200416
2. CE ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416
2.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200416
3. CE ENGINE INLET/EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416
3.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200416
4. PE ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416
4.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200416
5. PE ENGINE INLET/EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416
5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416
5.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200416
6. XE ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200416
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200416
6.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . 200416
7. XE ENGINE INLET/EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200416
7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200416
7.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 . . . . . 200416
8. ENGINE BRAKE, XE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200416
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200416
8.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 . . . . . 200416
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TECHNICAL DATA
2©200416
Contents
0
ΧΦ65/75/85 series
4
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©200416 1-1
Engine, general
TECHNICAL DATA
ΧΦ65/75/85 series
4
0
1. ENGINE, GENERAL
1.1 GENERAL
CE engine
PE/XE 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.
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.
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.
Direction of rotation of the engine The direction of rotation of the engine is clockwise,
as seen from the timing gear end.
First cylinder of the engine The first cylinder of the engine is the cylinder at the
timing gear end.
Left-hand and right-hand side of the engine The left-hand side of the engine is the side where the
fuel pump is mounted. The right-hand side of the
engine is the side where the air compressor is
mounted.
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TECHNICAL DATA
1-2 ©200416
Engine, general
0
ΧΦ65/75/85 series
4
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)
- PE: on the inlet manifold
- XE: on the inlet manifold
Engine type
The type number XE315C1 indicates:
Xengine family X = 12.6 ltr.
P = 9.2 ltr.
C = 5.88 ltr.
Eengine version E = electronic timing
S = turbocharger intercooler
315 engine output in kilowatt (kW)
CEuro emissions C = Euro 3
M = Euro 2
L = Euro 1
1Engine version number 1 = first update
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©200416 1-3
Engine, general
TECHNICAL DATA
ΧΦ65/75/85 series
4
0
1.2 CE ENGINE, GENERAL
Engine types
General specifications
Engine speeds, CE engine
Coding CE 136 C
CE 162 C
CE 184 C
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 5.9 litres
Compression ratio 17,3 : 1
Fuel injection direct injection
Injection sequence 1-5-3-6-2-4
Air inlet system Turbocharger intercooling
Engine management system ECS-DC3
Cooling fluid
Weight approx. 500 kg
Engine type Idling
rpm
Maximum no-load rpm
CE 136 C 600 - 800 approx. 2500
CE 162 C 600 - 800 approx. 2500
CE 184 C 600 - 800 approx. 2500
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TECHNICAL DATA
1-4 ©200416
Engine, general
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ΧΦ65/75/85 series
4
1.3 PE ENGINE, GENERAL
Engine types
General specifications
Engine speeds, PE engine
Coding PE 183 C 1
PE 228 C
PE 265 C
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 9.2 litres
Compression ratio 17,5 : 1
Fuel injection direct injection
Injection sequence 1-5-3-6-2-4
Air inlet system Turbocharger intercooling
Engine management system UPEC
Cooling fluid
Weight approx. 860 kg
Engine type Idling
rpm
Maximum free-running rpm
PE 183 C1 575 - 625 Approx. 2580
PE 228 C 575 - 625 Approx. 2580
PE 265 C 575 - 625 Approx. 2580
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©200416 1-5
Engine, general
TECHNICAL DATA
ΧΦ65/75/85 series
4
0
1.4 XE ENGINE, GENERAL
Engine types
General specifications
Engine speeds, XE engine
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
Environmental standard Euro 3 (C)
Number of cylinders 6 cylinders in line
Valves 4 valves per cylinder
Bore x stroke 130 x 158 mm
Cubic capacity 12.6 litres
Compression ratio 17,4 : 1
Fuel injection direct injection
Injection sequence 1-5-3-6-2-4
Air inlet system Turbocharger intercooling
Engine management system UPEC
Cooling fluid
Weight approx. 1,080 kg
Engine type Idling rpm Maximum free-running rpm
XE 250 C1 525 - 575 approx. 2200
XE 280 C1/C3 525 - 575 approx. 2200
XE 315 C1/C3 525 - 575 approx. 2200
XE 355 C1 525 - 575 approx. 2260
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TECHNICAL DATA
1-6 ©200416
Engine, general
0
ΧΦ65/75/85 series
4
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©200416 2-1
CE engine fuel system
TECHNICAL DATA
ΧΦ65/75/85 series
4
0
2. CE ENGINE FUEL SYSTEM
2.1 GENERAL
Fuel level element
Fuel fine filter
Fuel lift pump
High-pressure pump
Fuel rail
Fuel rail pressure-limiting valve
Injector
Angular displacement 86
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
Maximum pressure drop across fuel fine filter 2.0 bar
Fuel lift pump pressure in front of fine filter (with
engine at idling speed) 5 - 13 bar
Fuel lift pump pressure behind fine filter (with
engine at idling speed) 3 - 11 bar
Pressure relief valve opening pressure 11 bar
Maximum underpressure on suction side of fuel
lift pump 0.5 bar
Pump pressure (dependent on the operating
mode of the engine and the electronic calibration) 300 - 1400 bar
Fuel rail pressure (dependent on the operating
mode of the engine and the electronic calibration) 300 - 1400 bar
Opening pressure 1650 bar
Number of holes in injector 8
Resistance of magnet coil 0.15 - 0.5 
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TECHNICAL DATA
2-2 ©200416
CE engine fuel system
0
ΧΦ65/75/85 series
4
Injector washer
Fuel return overflow valve
Fuel return pipe
Return fuel measurement
i400693
A
Nozzle length
(distance A)
Washer thickness
21.5 ≥0.2 mm 1.5 mm
23.0 ≥0.2 mm 3.0 mm
Fuel return overflow valve opening pressure 1.2 - 2.0 bar
Maximum return pipe pressure build-up 0.2 bar
Maximum quantity of return fuel at idling speed 180 ml/min.
Permitted minimum time for filling a measuring
beaker to a volume of 360 ml 2 min.
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©200416 2-3
CE engine fuel system
TECHNICAL DATA
ΧΦ65/75/85 series
4
0
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.
Electronic unit cooling plate
Low-pressure fuel pipes
High-pressure pump
High-pressure fuel pipe
Fuel rail
Injector pipes
Fuel supply pipe
Injectors
Attachment bolts holding the electronic unit to the
cooling plate 10 Nm
Attachment bolts holding the cooling plate to the
engine block 24 Nm
VOSS quick-release coupling fittings 18 Nm
Banjo bolts 24 Nm
VOSS quick-release coupling fittings 24 Nm
Fuel return overflow valve in cylinder head 24 Nm
Attachment nuts holding the high-pressure pump
to the timing gear case 25 Nm
High-pressure pipe union nut 22 Nm
Attachment bolts 24 Nm
Pressure-limiting valve 100 Nm
Injector pipe union nuts 22 Nm
Fuel supply pipe nut 50 Nm
Injector clamping bracket attachment bolts 10 Nm
Injector electrical connection 1.5 Nm
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TECHNICAL DATA
2-4 ©200416
CE engine fuel system
0
ΧΦ65/75/85 series
4
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©200416 3-1
CE engine inlet/exhaust system
TECHNICAL DATA
ΧΦ65/75/85 series
4
0
3. CE ENGINE INLET/EXHAUST SYSTEM
3.1 GENERAL
Turbocharger
Rejection standards for cracking
1. Cracks in the connector flange must not
reach as far as the attachment holes.
2. Cracks in the connector flange must not
reach from the channels as far as the
exterior.
3. Cracks in the connector flange may not be
longer than 15 mm.
4. Cracks in the connector flange must not be
less than 6 mm apart.
5. There must be no cracks in the housing.
Exhaust gas back pressure
Inlet underpressure
Glow element
CE 136 C Holset HY 35 W
CE 162 C Holset HY 35 W
CE 184 C Holset HX 35 W
Minimum actuating pressure of wastegate cap-
sule under which the control rod will move 2.0 bar
Axial bearing play of compressor shaft 0.038 - 0.093 mm
Radial bearing play of compressor shaft 0.329 - 0.501 mm
1
2
5
3
4
i400784
At full-load engine speed 100 mbar
Maximum back pressure during engine brake ap-
plication 4.3 bar
At full-load engine speed (clean air filter) 25 mbar
At full-load engine speed (clogged air filter) 62 mbar
Resistance value 180 - 220 m
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TECHNICAL DATA
3-2 ©200416
CE engine inlet/exhaust system
0
ΧΦ65/75/85 series
4
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.
Turbocharger
(1) Fasten with Copaslip
Glow element
Air cooler
Attachment nuts, exhaust manifold flange/turbo-
charger 43 Nm (1)
Oil discharge pipe attachment bolts 23 Nm
Oil supply pipe union 28 Nm
Turbocharger V-clamp 10 Nm
Attachment bolts 14 Nm
Hose clamps 7 Nm
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©200416 4-1
PE engine fuel system
TECHNICAL DATA
ΧΦ65/75/85 series
4
0
4. PE ENGINE FUEL SYSTEM
4.1 GENERAL
Gallery pressure
Fuel level element
Overview of injectors
Fuel lift pump
Pump housing
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
Angular displacement 86
Resistance rating
- Full approx. 500 
- •approx. 355 
- ∂approx. 234 
- approx. 137 
- Not used approx. 33 
Underpressure valve opening pressure 10 - 20 mbar
Overpressure valve opening pressure 200 - 300 mbar
Engine type Number of
holes in
injector
Nozzle no. Hole diameter Bar filter Opening
pressure
PE 183 C1 8 1080 0,175 Yes 300 + 10 bar
PE 228 C 8 1080 0,175 Yes 300 + 10 bar
PE 265 C 8 1080 0,175 Yes 300 + 10 bar
Fuel lift pump pressure 7.0 - 8.0 bar
Pressure relief valve opening pressure approx. 8.5 bar
Weight, including camshaft and pump units approx. 70 kg
Pressure relief valve opening pressure approx. 5.5 - 6 bar
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TECHNICAL DATA
4-2 ©200416
PE engine fuel system
0
ΧΦ65/75/85 series
4
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.
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.
Injector pipes
Fuel filter housing
Injectors
(1) Use bolts once only.
Pump housing
(1) Use Loctite 243
Pump units
Fuel lift pump
(1) Use Loctite 243
Injector pipe union nuts 30 Nm
Fuel leak-off pipe union 20 Nm
Fuel filter cap 25 Nm
Clamping piece attachment bolt 30 Nm + 60angular displacement (1)
Leak-off pipe banjo bolt 20 Nm
Pressure relief valve 20 Nm
Attachment bolts to connect pump housing to
engine block 60 Nm
Pump housing rear cover attachment bolts 30 Nm
Attachment bolts for pump camshaft locking plate 30 Nm
Attachment bolts for pump housing sealing plates 30 Nm
Attachment bolts for pulse disk on camshaft 30 Nm (1)
Attachment bolt, camshaft sensor 8 Nm
Non-return valve 45 Nm
Fuel temperature sensor 20 Nm
Bolts for attaching pump units to pump housing 46 Nm
Pump unit electrical connection 1 Nm
Attachment bolts to connect fuel lift pump to
pump housing 30 Nm (1)
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©200416 5-1
PE engine inlet/exhaust system
TECHNICAL DATA
ΧΦ65/75/85 series
4
0
5. PE ENGINE INLET/EXHAUST SYSTEM
5.1 GENERAL
Explanation of turbocharger type designation
Example of type designation:
GT40-88S/54NPS/0.95-84
Exhaust back pressure
Inlet underpressure
Turbocharger
GT40 Turbine type designation
88 Maximum compressor rotor diameter
S Wastegate model
54 Compressor rotor trim
NPS Version with intake side without compressor housing bypass
PS Version with intake side with compressor housing bypass
0.95 Turbine housing size
84 Turbine rotor trim
At full-load engine speed 80 - 90 mbar
At full-load engine speed (clean air filter) 25 - 35 mbar
At full-load engine speed (clogged air filter) 54 - 64 mbar
Control rod movement of control bypass
at 1.8 bar 1 mm
Stud bolts for fastening Copaslip
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TECHNICAL DATA
5-2 ©200416
PE engine inlet/exhaust system
0
ΧΦ65/75/85 series
4
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.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Turbocharger
(1) Use Loctite 243 to secure
(2) Fasten with Copaslip
Glow element
Air cooler
Heat shield attachment bolts 30 Nm (1)
Turbine housing clamp plate attachment nut 15 Nm
Exhaust manifold flange/turbocharger attach-
ment nuts 60 Nm (2)
Elbow attachment with exhaust brake on turbo-
charger 40 Nm
Oil supply pipe banjo bolt 90 Nm
Attachment bolts 30 Nm
Air cooler hose clamps 10 Nm
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