DAF CF65, CF75, CF85 Service manual

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Page 1

ΧΦ65/75/85 series

STRUCTURE

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

200351

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Page 3

TECHNICAL DATA

ΧΦ65/75/85 series

0 Technical dat a

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

Contents

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

200351 1

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TECHNICAL DATA

Contents

ΧΦ65/75/85 series

200351

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TECHNICAL DATA

ΧΦ65/75/85 series

CE engine

1. CE ENGINE

1.1 GENERAL

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.

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 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

Exhaust manifold

Maximum flatness deviation 0.20 mm

Cylinder block

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

CE engine

Cylinder head

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

Cylinder head gasket

Thickness: 1.15 mm

Thickness: 1.25 mm

ΧΦ65/75/85 series

M201231

Type cylinder head gasket to be used:

Average piston projection Thickness of cylinder head gasket

< 0.301 mm 1.15 mm

 0.301 mm 1.25 mm

Cylinder head bolts

Maximum dimensions of visible corrosion or pitting 1 cm Maximum depth of pitting 0.12 mm

OK OK

M201232

M201249

1-2

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TECHNICAL DATA

ΧΦ65/75/85 series

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

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

CE engine

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Cylinder Head Capscrew Length Gauge

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M201250

Valve clearance

Inspection dimension, cold valve clearance Inlet 0.15 - 0.40 mm Exhaust 0.40 - 0.75 mm

Setting dimension, cold valve clearance

Inlet 0.25 mm Exhaust 0.50 mm

Gear backlash

Crankshaft gear - camshaft gear 0.076 - 0.28 mm Oil pump gear - idler gear 0.250 - 0.30 mm

Axial play

Crankshaft axial play 0.267 ≥ 0.165 mm Camshaft axial play 0.230 ≥ 0.130 mm

Oil sump pressure

New engine 60 - 80 l/min. Worn engine 180 l/min.

M201252

200351 1-3

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TECHNICAL DATA

CE engine

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

ΧΦ65/75/85 series

14 206

15 211

16 217

17 222

18 226

19 229

20 232

Flywheel/starter ring gear

Axial variation, measured on the outer diameter 0.127 mm Starter ring gear warm up (max. 20 min.) max. 127C

Vibration damper

Difference in thickness at 4 places must not exceed: 6.35 mm

1-4

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TECHNICAL DATA

ΧΦ65/75/85 series

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

Attachment bolts 43 Nm

Automatic tensioner

Attachment bolts 43 Nm

Alternator

Alternator bracket attachment bolts 30 Nm Alternator attachment bolts 60 Nm Pulley attachment nut 80 Nm

CE engine

Air compressor

Compressor attachment nuts 60 Nm Attachment of pipes 39 Nm

Air-conditioning compressor

Compressor support attachment bolts 30 Nm Compressor attachment bolts 60 Nm

Valve gear

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

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

Exhaust manifold

Attachment bolts 43 Nm Heat shields 60 Nm

(1)

(1) Tighten crosswise from inside to outside.

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TECHNICAL DATA

CE engine

Cylinder head

Note:

Apply a drop of engine oil to the thread and under the abutting surface of the attachment bolt heads.

Stage 1

All attachment bolts 35 Nm

(1) Tighten the bolts in the order indicated

(1)

20 12

19 11

ΧΦ65/75/85 series

4 5 13 21

1 25

2 10 18 26

3 6 14 22

9 178

M201143

Stage 2 Only attachment

bolts with a length of 150 mm 55 Nm

(1) Tighten the bolts in the order indicated

Stage 3

All attachment bolts 2 steps each with a

90 angular displacement

(1) Tighten the bolts in the order indicated

(1)

20 12

4 5 13 21

1 25

9 178

M201202

1-6

19 11

2 10 18 26

3 6 14 22

200351

M201143

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TECHNICAL DATA

ΧΦ65/75/85 series

Vibration damper

Attachment bolts 50 Nm + 90 angular displacement

Timing gear

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

Attachment bolts, cap, front of engine

Attachment bolts, cap, front of engine Fit cap at engine front using sealant Loctite Ultra Grey

(1) Tighten the attachment bolts in the order indicated

(1)

24 Nm

CE engine

Flywheel

Attachment bolts 30 Nm + 60 angular displacement

Flywheel housing

M10 attachment

(1)

bolts M12 attachment

(1)

bolts Fit flywheel housing using sealant Loctite 5205

(1) Tighten the attachment bolts in the order indicated

49 Nm

85 Nm

20 7 11

1812

M201144

M201080

Engine mounts, front

Engine bracket attachment bolts/nuts 110 Nm

200351 1-7

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TECHNICAL DATA

CE engine

Engine mounts, rear

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

Engine hanger brackets

Attachment bolts 113 Nm

ΧΦ65/75/85 series

1-8

200351

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TECHNICAL DATA

ΧΦ65/75/85 series

CE-engine cooling system

2. CE-ENGINE COOLING SYSTEM

2.1 GENERAL

Thermostat

Thermostat opening temperatures: Thermostat opens at approx. 81C Thermostat fully open at approx. 94C Full thermostat opening 14.3 mm

Header tank pressure cap

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.

Closed pressure cap position

Brand name (2) legible horizontally or 60 before this position.

Pressure-testing the cooling system

Test pressure 0.5 - 0.7 bar

M201272

200351 2-1

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TECHNICAL DATA

CE-engine cooling system

2.2 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

Attachment bolts 24 Nm

Thermostat housing

Attachment bolts 10 Nm

ΧΦ65/75/85 series

Radiator

Attachment nuts 60 Nm

2-2

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TECHNICAL DATA

ΧΦ65/75/85 series

2.3 FILLING CAPACITIES

Cooling system capacity approx. 26 litres

CE-engine cooling system

200351 2-3

Page 16

TECHNICAL DATA

CE-engine cooling system

ΧΦ65/75/85 series

2-4

200351

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TECHNICAL DATA

ΧΦ65/75/85 series

CE-engine lubrication system

3. CE-ENGINE LUBRICATION SYSTEM

3.1 GENERAL

Oil pressure

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

Oil filter

Type disposable filter Number 1 Installation in the oil circuit full flow

Oil cooler

Oil section test pressure 4.5 - 5.0 bar Opening pressure of bypass valve at a pressure difference of 3.45 bar

Lubricating oil pump

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

Oil consumption

Maximum permissible engine oil consumption 0.5% of the average fuel 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".

200351 3-1

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TECHNICAL DATA

CE-engine lubrication system

3.2 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

Attachment bolts to connect filter head to engine block 24 Nm

Oil sump

Oil sump attachment bolts 24 Nm

(1)

Oil drain plug 60 Nm

(1) Tighten the attachment bolts in the order indicated

ΧΦ65/75/85 series

11 1 3 9

Strainer

Suction tube attachment bolts 24 Nm

Bypass pressure regulator

Plug 80 Nm

12 4 2 10

M201079

3-2

200351

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TECHNICAL DATA

ΧΦ65/75/85 series

Oil cooler

Attachment bolts connecting oil cooler to cylinder block 24 Nm

(1) Tighten the attachment bolts in the order indicated

Oil pump

Attachment bolts 24 Nm

(1)

CE-engine lubrication system

M201145

Turbocharger oil supply pipe

Union on filter head 28 Nm Union on turbocharger 28 Nm

Bypass pressure regulator

Plug 80 Nm

Oil nozzle

Banjo bolt 15 Nm

Main bearing caps

Main bearing cap attachment bolts

phase 60 Nm

phase 80 Nm

phase 90 angular displacement

Big-end bearing caps

Attachment bolts, big-end bearing caps 60 Nm + 60 angular displacement

200351 3-3

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TECHNICAL DATA

CE-engine lubrication system

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

ΧΦ65/75/85 series

3-4

200351

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TECHNICAL DATA

ΧΦ65/75/85 series

PE engine

4. PE ENGINE

4.1 GENERAL

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 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.

Engine types

Coding PE 183 C1

PE 228 C PE 265 C

General specifications

Environmental standard Euro 3 (C) Number of cylinders 6 cylinders in line Valves 4 per cylinder Bore x stroke 118 x 140 mm Total cubic capacity 9,20 l Compression ratio 17,4 : 1 Fuel injection direct Injection sequence 1-5-3-6-2-4 Air inlet system Turbocharger intercooling Cooling fluid Weight approx. 860 kg

V-belt tension

Belt tension, "AVX" raw edge

Multiple belt Single belt

Setting tension 1200 600

Test tension  800  400

of V-belts in Newtons (N)

New V-belt

Run-in V-belt

Minimum tension 500 250

Correction tension 700 350

200351 4-1

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TECHNICAL DATA

PE engine

1. Raw-edge V-belts can be recognised by the absence of textile fabric in the rubber, with the exception of the top of the belt edge, on the edges and the inside of the belt (polished belt edge). Version: either a toothed or a nontoothed belt.

2. After fitting the new V-belt, set the pre-tension to the "setting tension" and after a trial run check whether the pre-tension complies with the "test tension". If the test tension reading is lower than the value specified in the table, set the V-belt to the minimum "test tension".

3. If the V-belt tension is lower than the "minimum tension", set the belt to the "correction tension".

Cylinder liner

Height above cylinder block 0.02 - 0.10 mm

Cylinder head

Minimum height after overhaul 119.5 mm

Cylinder head test pressure

Test pressure using air (hot) 1.5 bar

ΧΦ65/75/85 series

M2121

Valve clearance

Valve clearance (cold/hot) inlet 0.45 mm exhaust 0.45 mm

Valve opening

Valve opening at 1 mm valve clearance 0.45 ≥ 0.2 mm

Axial play

Crankshaft axial play 0.05 - 0.35 mm Camshaft axial play 0.10 - 0.55 mm Idler gear axial play 0.03 - 0.25 mm

Gear backlash

Idler gear - crankshaft gear 0.02 - 0.20 mm Idler gear - fuel pump gear 0.02 - 0.22 mm Idler gear - camshaft gear 0.02 - 0.22 mm Camshaft gear - compressor gear 0.02 - 0.22 mm Fuel pump gear - steering pump gear 0.02 - 0.19 mm Oil pump idler gear - oil pump gear 0.02 - 0.20 mm Crankshaft gear - oil pump idler gear 0.02 - 0.20 mm

Number of teeth, timing gears

Crankshaft gear 31 Idler gear 52 Fuel pump gear 62 Camshaft gear 62 Air compressor gear 27 Steering pump gear 18 Oil pump idler gear 28

4-2

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TECHNICAL DATA

ΧΦ65/75/85 series

Compression pressure

Differences in compression pressure max. 15%

Flywheel/starter ring gear

Axial variation, measured at a radial distance of 210 mm 0.10 mm

Starter ring gear warm up max. 185C

PE engine

200351 4-3

Page 24

TECHNICAL DATA

PE engine

4.2 TIGHTENING TORQUES

Starter motor

Attachment nuts 73 Nm

Alternator

Alternator bracket attachment bolts 30 Nm Alternator attachment bolts 60 Nm Pulley attachment nut 80 Nm Electrical connection to alternator 12 Nm

Air compressor

Compressor gear flange bolt 120 Nm M12 attachment bolts 110 Nm M8 attachment bolts for bracket 30 Nm Cylinder head threaded coupling 90 Nm Delivery pipe reducer valve 75 Nm Suction and pressure line unions 90 Nm

Air-conditioning compressor

M12 attachment bolts for compressor bracket 110 Nm M10 attachment bolts for compressor 60 Nm

ΧΦ65/75/85 series

(1)

Exhaust manifold

Fit gasket with steel side towards manifold Sleeved attachment bolts 65 Nm Heat shield attachment bolts 30 Nm

Inlet manifold

M10 attachment bolts 60 Nm M10 attachment studs 60 Nm

Turbocharger

Heat shield attachment bolts 30 Nm Turbine housing clamp plate attachment nut 15 Nm Attachment nuts Exhaust manifold flange/turbocharger 60 Nm Elbow on turbocharger 40 Nm Oil supply pipe banjo bolt 90 Nm

Fan

Attachment nuts 25 Nm Fan pulley attachment bolts 30 Nm

(1) Use Loctite 243 to secure (2) Fasten with Copaslip

(1)

(2)

(1)

4-4

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TECHNICAL DATA

ΧΦ65/75/85 series

Vibration damper

Vibration damper hub attachment bolts in 4 phases:

phase, all attachment bolts 50 Nm 2nd phase, all attachment bolts 70 Nm 3rd phase, all attachment bolts 100 Nm 4th phase, all attachment bolts 60 angular displacement Vibration damper attachment bolts 110 Nm

(1) Tighten the attachment bolts evenly (2) Use Loctite 243 to secure

(1)

(2)

PE engine

(1)

200351 4-5

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TECHNICAL DATA

PE engine

Cylinder head attachment bolts

Cylinder bolts must only be used once. So the cylinder bolts must always be replaced. The thread of the new cylinder head bolts is provided with a red/brown sealant.

Note:

- Due to the sealant used on the cylinder head

bolts, the untightening torque of the cylinder head bolts can be substantial!

- All M16 and M12 threaded holes must be

carefully cleaned using a screw tap prior to the mounting of the bolts.

- After tightening of the bolts with the

appropriate tightening torque, the angular displacement of the M16 bolts must immediately be started.

- The sealant cannot be applied later.

Tightening cylinder head attachment bolts

Note:

Underneath the bolt head, apply a drop of oil on the bearing surface of the bolt heads. Sealants also reduce the frictional resistance, which means that you must not apply any oil to the thread.

50 Nm

M16

150 Nm

ΧΦ65/75/85 series

M16

94 Nm

M12

III

M16

III

M200563

4-6

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TECHNICAL DATA

ΧΦ65/75/85 series

1st phase

- M16 in the indicated order 50 Nm

(1)

2nd phase

- M16 in the indicated order 150 Nm

- M12 in the indicated order 94 Nm

(1)

3rd phase

- M16 in the indicated order in two stages of

(1) Apply a drop of oil to the bearing surface of the M16 and

M12 bolt heads.

60 angular displacement

Timing gear

Pump housing drive unit attachment bolts 60 Nm Attachment bolts, pump housing drive shaft locking plate 30 Nm Locking plate attachment bolts 30 Nm Crankshaft hub attachment bolts in 4 phases:

phase, all attachment bolts 100 Nm 2nd phase, all attachment bolts 100 Nm 3rd phase, all attachment bolts 100 Nm 4th phase, all attachment bolts 100 Nm Viscous fan clutch attachment nuts 30 Nm Timing case attachment bolts 30 Nm Timing cover attachment bolts: M10 attachment bolts 60 Nm M8 attachment bolts 25 Nm Timing cover protection plate attachment bolt 8.5 Nm Camshaft gear attachment bolt 425 Nm Idler gear attachment bolt 170 Nm Pump housing camshaft gear attachment bolt 260 Nm Steering pump gear attachment nut 80 Nm Suction pipe banjo bolt 90 Nm Delivery pipe banjo bolt 40 Nm

(1)

(2)

(1)

PE engine

M200734

(1) Use Loctite 243 to secure (2) Apply a drop of oil to the attachment bolts and tighten

evenly.

Flywheel housing

Attachment bolts: 110 Nm Sealant to be used when fitting flywheel housing Loctite 510

Flywheel

Attachment bolts: without PTO 170 Nm

(1)

+ 90 angle tightening

with PTO 170 Nm + 150 angle tightening

(1) Use Loctite 243 to secure

200351 4-7

Page 28

TECHNICAL DATA

PE engine

Engine mountings at timing gear end

Cylinder block bracket attachment bolts 92 Nm Chassis engine bracket attachment bolts 73 Nm Vibration damper engine bracket attachment bolts 170 Nm

Engine mountings at flywheel end

Flywheel housing engine bracket attachment bolts 260 Nm Chassis engine bracket attachment bolts 73 Nm Vibration damper engine bracket attachment bolts 226 Nm + 60 angle tightening

Engine hanger brackets

M12 attachment bolts 110 Nm

Valve gear

Valve cover attachment bolts 25 Nm M10 setting bolt lock nut for rocker 40 Nm Bridge piece setting bolt lock nut 40 Nm Lubricating oil strip/rocker seat attachment bolts 60 Nm Valve sleeve attachment bolts 30 Nm Tighten the valve sleeve attachment bolts in the sequence shown.

13 9

ΧΦ65/75/85 series

2117

10 12

M200959

4-8

200351

Page 29

TECHNICAL DATA

ΧΦ65/75/85 series

PE-engine cooling system

5. PE-ENGINE COOLING SYSTEM

5.1 GENERAL

Thermostat

Thermostat opening temperature standard:

- thermostat opens at approx. 87C

- thermostat open at least 12 mm at approx. 99C with intarder and/or automatic transmission:

- thermostat opens at approx. 83C

- thermostat open at least 12 mm at approx. 95C Thermostat seat Loctite 638

Coolant pump

Radial play 0.16 - 0.20 mm

Header tank pressure cap

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.

Closed pressure cap position

Pressure testing the cooling system

Test pressure 0.7 - 0.9 bar

Viscous fan clutch

Permissible slip at maximum speed control 10%

Brand name (2) legible horizontally or 60 before this position.

M201272

200351 5-1

Page 30

TECHNICAL DATA

PE-engine cooling system

5.2 TIGHTENING TORQUES

The tightening torques recorded in this paragraph are different from the standard tightening torques recorded in the overview of the standard tightening torques. The other threaded connections which are not recorded must therefore be tightened to the torque recorded in the overview of standard tightening torques.

When attachment bolts and nuts are replaced, it is important - unless stated otherwise - that these bolts and nuts are of exactly the same length and property class as those removed.

Coolant pump

M8 attachment bolts 30 Nm

Coolant pipe on cylinder head

Attachment bolts 54 Nm Coolant pipe threaded coupling 90 Nm Coolant pipe plug 35 Nm

ΧΦ65/75/85 series

Thermostat housing on coolant pipe

Attachment bolts 30 Nm

Radiator

Attachment nuts 60 Nm

Oil cooler

Coolant drain plug 16 Nm

5-2

200351

Page 31

TECHNICAL DATA

ΧΦ65/75/85 series

5.3 FILLING CAPACITIES

Cooling system

Cooling system capacity, standard vehicle approx. 38 litres Cooling system capacity of vehicle with ZF

intarder approx. 50 litres Cooling system capacity of vehicle with automatic gearbox approx. 50 litres

PE-engine cooling system

200351 5-3

Page 32

TECHNICAL DATA

PE-engine cooling system

ΧΦ65/75/85 series

5-4

200351

Page 33

TECHNICAL DATA

ΧΦ65/75/85 series

PE-engine lubrication system

6. PE-ENGINE LUBRICATION SYSTEM

6.1 GENERAL

Oil pressure

Oil pressure at engine idling speed 1 bar (warm engine) Oil pressure at full-load engine speed 3.35 - 4.35 bar

Oil filter

Type filter element Number 1 Installation in the oil circuit full flow Opening pressure of bypass valve at a pressure

difference of 2.5 ≥ 0.3 bar

Oil cooler

Coolant test pressure 2.5 bar

Oil consumption

Maximum admissible engine oil consumption 0.3% of the average fuel consumption

Example: Average measured fuel consumption: 30 litres / 100 km = 300 litres / 1000 km Maximum admissible engine oil consumption:

0.3% x 300 = 0.9 litres / 1000 km

- Engine oil consumption = 0.9 litres / 1000 km is permitted

- Engine oil consumption > 0.9 litres / 1000 km; check the engine using the diagnostics table. See "Diagnosis".

200351 6-1

Page 34

TECHNICAL DATA

PE-engine lubrication system

6.2 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.

When attachment bolts and nuts are replaced, it is important - unless stated otherwise - that these bolts and nuts are of exactly the same length and property class as those removed.

Lubricating oil strip/rocker seats

Attachment bolts: 60 Nm

Oil pan

Clamp attachment bolts 25 Nm Oil drain plug 60 Nm Oil level sensor 60 Nm

ΧΦ65/75/85 series

Oil pump

Attachment bolts for oil pump housing sections 30 Nm Attachment bolts connecting oil pump to main bearing cap 60 Nm Oil delivery pipe attachment bolts 30 Nm Idler gear central bolt 60 Nm

Strainer

Bracket attachment bolts 30 Nm

Lubricating oil filter

Lubricating oil filter housing attachment bolts 50 Nm Filter element screw cap 45 Nm

Bypass pressure regulator

Plug 80 Nm

Oil cooler

Attachment bolts connecting oil cooler to cylinder block 50 Nm

(1) Use Loctite 243 to secure (2) Use Loctite 572 to secure

(1)

(2)

Oil nozzles

Banjo bolt (M14) for oil sprayer with locking plate 30 Nm Banjo bolt (M10) for oil sprayer 30 Nm

6-2

200351

Page 35

TECHNICAL DATA

ΧΦ65/75/85 series

Main bearing caps

Main bearing cap attachment bolts 1st phase 50 Nm

phase 150 Nm

phase 120 angular displacement

Big-end bearing caps

Attachment bolts, big-end bearing caps 1st phase, sequence 1-2-3-4 25 Nm

phase, sequence 4-3-2-1 35 Nm

phase, sequence 1-2-3-4 60 angular displacement

(1) Apply a drop of oil to thread and contact surface. (2) Connecting rod bolts are to be used once and tightened

as instructed. When fitting the connecting rod in the engine, apply a drop of oil on the thread and bearing face of the connecting rod bolts.

(1)

(2)

PE-engine lubrication system

1 4

M200661

200351 6-3

Page 36

TECHNICAL DATA

PE-engine lubrication system

6.3 FILLING CAPACITIES

Lubrication system

Total capacity, including oil cooler and oil filter approx. 29 litres Oil sump capacity, maximum level approx. 24 litres Oil pan capacity, minimum level approx. 16 litres

ΧΦ65/75/85 series

6-4

200351

Page 37

TECHNICAL DATA

ΧΦ65/75/85 series

XE engine

7. XE ENGINE

7.1 GENERAL

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 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.

Engine types

Coding XE 250 C 1

XE 280 C 1 XE 280 C 3 XE 315 C 1 XE 315 C 3 XE 355 C 1

General specifications

Environmental standard Euro 3 (C) Number of cylinders 6 Valves 4 per cylinder Bore x stroke 130 x 158 mm Total cubic capacity 12.6 l Compression ratio 17,4 : 1 Fuel injection direct Injection sequence 1-5-3-6-2-4 Air inlet system Turbocharger intercooling Cooling fluid Weight approx. 1,080 kg

200351 7-1

Page 38

TECHNICAL DATA

XE engine

V-belt tension

V-belt tension, "AVX" raw edge

Application example: air-conditioning compressor drive

New V-belt

(2)

Setting tension 600

Test tension ¥ 400

Run-in V-belt

(3)

Minimum tension 250

Correction tension 350

V-belt tension, "XPB" raw edge

Application example: steering pump drive on FAX vehicle

New V-belt

(2)

Setting tension 1250

Test tension ¥ 950

Run-in V-belt

(3)

(1)

(N)

ΧΦ65/75/85 series

Minimum tension 750

Correction tension 950

(1) Raw-edge V-belts can be recognised by the absence of

textile fabric in the rubber, with the exception of the top of the belt edge, on the edges and the inside of the belt (polished belt edge). Version: either a toothed or a nontoothed belt.

(2) After fitting the new V-belt, set the pre-tension to the

"setting tension" and after a trial run inspect whether the pre-tension complies with the "test tension". If the test tension reading is lower than the value specified in the table, set the V-belt to the minimum "test tension".

(3) If the V-belt tension is lower than the "minimum tension",

set the belt to the "adjusting tension".

M2121

7-2

200351

Page 39

TECHNICAL DATA

ΧΦ65/75/85 series

Automatic poly-V-belt tensioner

Torsional moment from rest position (0) to 17 mm torsion (A) 19 - 37 Nm

XE engine

Cylinder liner

Height above cylinder block 0.02 - 0.10 mm

Cylinder head

Minimum height after overhaul 119.50 mm Test pressure using air (hot) 1.5 bar

Valve clearance

Valve clearance (cold/hot) inlet 0.50 mm exhaust 0.50 mm

Axial play

Crankshaft axial play 0.06 - 0.32 mm Camshaft axial play 0.10 - 0.55 mm Idler gear axial play 0.05 - 0.25 mm

M201274

200351 7-3

Page 40

TECHNICAL DATA

XE engine

Gear backlash

Idler gear - crankshaft gear 0.02 - 0.21 mm Idler gear - pump housing camshaft gear 0.02 - 0.22 mm Idler gear - camshaft gear 0.02 - 0.21 mm Camshaft gear - compressor gear 0.02 - 0.22 mm Pump housing camshaft gear - steering pump gear 0.02 - 0.19 mm Oil pump idler gear - oil pump gear 0.02 - 0.20 mm Crankshaft gear - oil pump idler gear 0.02 - 0.20 mm

Number of teeth, timing gears

Crankshaft gear 35 Idler gear 54 Pump housing - camshaft gear wheel 70 Camshaft gear 70 Air compressor gear 27 Fan drive housing gear 29 Steering pump gear 18 Lubricating oil pump idler gear 34

Compression pressure

Differences in compression pressure max. 15%

ΧΦ65/75/85 series

Flywheel/starter ring gear

Axial variation, measured at a radial distance of 210 mm 0.10 mm

Starter ring gear warm up max. 185|C

7-4

200351

Page 41

TECHNICAL DATA

ΧΦ65/75/85 series

7.2 TIGHTENING TORQUES

When attachment bolts and nuts are replaced, it is important - unless stated otherwise - that these bolts and nuts are of exactly the same length and property class as those removed.

Starter motor

Attachment nuts 73 Nm Electrical connection to starter motor 28 Nm

Alternator

Alternator attachment bolts 60 Nm Pulley attachment nut 80 Nm Electrical connection to alternator (M8) 15 Nm

XE engine

(1)

Air compressor

M12 attachment bolts 110 Nm M8 attachment bolts for bracket 30 Nm M10 attachment bolts for bracket 60 Nm Compressor gear flange bolt 120 Nm M14 threaded coupling for cylinder head 40 Nm M26 threaded coupling for cylinder head 90 Nm Cylinder head service line banjo bolt 25 Nm Pressure line safety valve 75 Nm Suction and pressure line unions 90 Nm Oil supply banjo bolt 25 Nm

Exhaust manifold

Fit gasket with steel side towards manifold Sleeved attachment bolts 65 Nm Heat shield attachment bolts 30 Nm

Inlet manifold

Attachment bolts: 46 Nm Air inlet hose clamps 12 Nm Electrical connection to glow plug 8.5 Nm Attachment bolts, boost pressure/charge temperature sensor 4 Nm Hose clamps 12 Nm

(1)

200351 7-5

Page 42

TECHNICAL DATA

XE engine

Turbocharger

(1) Use Loctite 243 to secure (2) Fasten with Copaslip

Glow plug relay

Glow plug relay cap 2 Nm Electrical connections to glow plug relay: M5 3.5 Nm M8 8 Nm

Main fuse

Fuse holder (M6) 4.5 Nm Fuse (M8) 18 Nm

ΧΦ65/75/85 series

(1)

(2)

Vibration damper and fan drive

Vibration damper hub attachment bolts (1) in 4 phases:

phase, all attachment bolts 100 Nm 2nd phase, all attachment bolts 100 Nm 3rd phase, all attachment bolts 100 Nm 4th phase, all attachment bolts 100 Nm Attachment bolts, vibration damper (5) 110 Nm Attachment nuts, fan drive (8) 60 Nm Attachment bolts, fan pulley (9) 30 Nm Attachment nuts, fan clutch (7) 25 Nm

(1) Tighten the attachment bolts evenly (2) Use Loctite 243 to secure

(2)

(1)

(2)

5 4

M201153

7-6

200351

Page 43

TECHNICAL DATA

ΧΦ65/75/85 series

Cylinder head attachment bolts

Cylinder head bolts must only be used once. So the cylinder head bolts must always be replaced. The thread of the new cylinder head bolts is provided with a red/brown sealant.

Note:

- Due to the sealant used on the cylinder head

bolts, the untightening torque of the cylinder head bolts can be substantial!

- All M16 and M12 threaded holes must be

carefully cleaned using a screw tap prior to the mounting of the bolts.

- After tightening of the bolts with the

appropriate tightening torque, the angular displacement of the M16 bolts must immediately be started.

- The sealant cannot be applied later.

50 Nm

M16

150 Nm

M16

XE engine

94 Nm

M12

III

M16

III

M200563

200351 7-7

Page 44

TECHNICAL DATA

XE engine

Tightening cylinder head attachment bolts

Note:

Underneath the bolt head, apply a drop of oil on the bearing surface of the bolt heads. Sealants also reduce the frictional resistance, which means that you must not apply any oil to the thread.

1st phase

- M16 in the indicated order 50 Nm

2nd phase

- M16 in the indicated order 150 Nm

- M12 in the indicated order 94 Nm

3rd phase

- M16 in the indicated order in two stages of

(1) Apply a drop of oil to the bearing surface of the M16 and

M12 bolt heads.

60 angular displacement

(1)

18 19

ΧΦ65/75/85 series

M200562

Timing gear

Pump housing drive unit attachment bolts 60 Nm Attachment bolts, pump housing drive shaft locking plate 30 Nm Locking plate attachment bolts 30 Nm Crankshaft hub attachment bolts in 4 phases:

- M10 attachment bolts 60 Nm

- M8 attachment bolts 25 Nm Timing cover protection plate attachment bolt 8.5 Nm Camshaft gear attachment bolt 425 Nm Idler gear attachment bolt 170 Nm Pump housing camshaft gear attachment bolt 260 Nm Steering pump gear attachment nut 80 Nm Suction pipe banjo bolt 90 Nm Delivery pipe banjo bolt 40 Nm

(1) Use Loctite 243 to secure (2) Apply a drop of oil to the attachment bolts and tighten

evenly.

(1)

(2)

(1)

7-8

200351

Page 45

TECHNICAL DATA

ΧΦ65/75/85 series

Flywheel housing

Attachment bolts 110 Nm Sealant to be used when fitting flywheel housing Loctite 510 Attachment bolt, crankshaft sensor 8 Nm

(1) Use Loctite 243 to secure

Flywheel

Attachment bolts:

- standard 260 Nm + 60 angle tightening

- with engine PTO 260 Nm + 120 angle tightening

Engine mountings at timing gear end

Cylinder block bracket attachment bolts 110 Nm Chassis engine bracket attachment bolts 110 Nm Vibration damper engine bracket attachment bolts 170 Nm

Engine mountings at flywheel end

Flywheel housing engine bracket attachment bolts 260 Nm Chassis engine bracket attachment bolts 110 Nm Vibration damper engine bracket attachment bolts 260 Nm + 90 angle tightening

(1)

XE engine

Engine hanger brackets

Attachment bolts: 110 Nm

Valve gear

Valve cover attachment bolts 25 Nm Rocker setting bolt lock nut 40 Nm Bridge piece setting bolt lock nut 40 Nm Lubricating oil strip/rocker seat attachment bolts 110 Nm DEB set screw nut 25 Nm Solenoid valve 20 Nm Wiring harness attachment bolt 9 Nm Valve sleeve attachment bolts 30 Nm

Tighten the valve sleeve attachment bolts in the sequence shown

9157

814

41210

M200942

200351 7-9

Page 46

TECHNICAL DATA

XE engine

ΧΦ65/75/85 series

7-10

200351

Page 47

TECHNICAL DATA

ΧΦ65/75/85 series

XE-engine cooling system

8. XE-ENGINE COOLING SYSTEM

8.1 GENERAL

Thermostat

Thermostat opening temperatures: standard

- thermostat opens at approx. 87C

- thermostat open at least 12 mm at approx. 99C with intarder and/or tropical cooling:

- thermostat opens at approx. 83C

- thermostat open at least 12 mm at approx. 95C

Thermostat seat Loctite 638

Coolant pump

Maximum radial play 0.16 - 0.20 mm

Header tank pressure cap

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.

Closed pressure cap position

Pressure testing the cooling system

Test pressure 0.7 - 0.9 bar

Viscous fan clutch

Permissible slip at maximum speed control 10% Fan drive ( i ) transmission 1,207

Brand name (2) legible horizontally or 60 before this position.

M201272

200351 8-1

Page 48

TECHNICAL DATA

XE-engine cooling system

8.2 TIGHTENING TORQUES

When attachment bolts and nuts are replaced, it is important - unless stated otherwise - that these bolts and nuts are of exactly the same length and property class as those removed.

Coolant pump

M8 attachment bolts 30 Nm M14 threaded coupling 35 Nm M26 90 Nm

Coolant pipe

Attachment bolts 60 Nm Coolant pipe threaded coupling 90 Nm Coolant pipe plug 35 Nm Engine coolant temperature sensor 20 Nm

ΧΦ65/75/85 series

Thermostat housing

Attachment bolts 30 Nm Plug 35 Nm

Radiator

Attachment nuts 70 Nm

Coolant hoses

Hose clamps 7 Nm

8-2

200351

Page 49

TECHNICAL DATA

ΧΦ65/75/85 series

8.3 FILLING CAPACITIES

Cooling system capacity approx. 47 litres Cooling system capacity of vehicle with ZF intarder approx. 57 litres

XE-engine cooling system

200351 8-3

Page 50

TECHNICAL DATA

XE-engine cooling system

ΧΦ65/75/85 series

8-4

200351

Page 51

TECHNICAL DATA

ΧΦ65/75/85 series

XE-engine lubrication system

9. XE-ENGINE LUBRICATION SYSTEM

9.1 GENERAL

Oil pressure

Oil pressure at engine idling speed 1 bar (warm engine) Oil pressure at full-load engine speed 3.5 - 4.5 bar

Oil filter

Type filter element Number 1 Installation in the oil circuit full flow Opening pressure of bypass valve at a pressure

difference of 2.5 ≥ 0.3 bar

Oil cooler

Coolant test pressure maximum 2.5 bar

Oil consumption

Maximum admissible engine oil consumption 0.3% of the average fuel consumption

Example: Average measured fuel consumption: 30 litres / 100 km = 300 litres / 1000 km Maximum admissible engine oil consumption:

0.3% x 300 = 0.9 litres / 1000 km

- Engine oil consumption = 0.9 litres / 1000 km is permitted

- Engine oil consumption > 0.9 litres / 1000 km; check the engine using the diagnostics table. See "Diagnosis".

200351 9-1

Page 52

TECHNICAL DATA

XE-engine lubrication system

9.2 TIGHTENING TORQUES

When attachment bolts and nuts are replaced, it is important - unless stated otherwise - that these bolts and nuts are of exactly the same length and property class as those removed.

Lubricating oil strip/rocker seats

Attachment bolts 110 Nm

Oil pan

Clamp attachment bolts 25 Nm Oil drain plug 60 Nm Oil level sensor 60 Nm

ΧΦ65/75/85 series

Oil pump

Attachment bolts for oil pump housing sections 30 Nm Attachment bolts connecting oil pump to main bearing cap 60 Nm Oil delivery pipe attachment bolts 30 Nm Idler gear central bolt 60 Nm

Strainer

Bracket attachment bolts 30 Nm

Lubricating oil filter

Lubricating oil filter housing attachment bolts 50 Nm Filter element screw cap 40 Nm

(1) Use Loctite 243 to secure (2) Use Loctite 572 to secure

Bypass pressure regulator

Plug 80 Nm

Oil cooler

Attachment bolts connecting oil cooler to cylinder block 50 Nm

Coolant supply pipe union 90 Nm Plug, adjustable banjo connection 90 Nm Banjo bolt, adjustable banjo connection 90 Nm

(1)

(2)

Centrifugal oil filter

Central bolt 20 Nm

9-2

200351

Page 53

TECHNICAL DATA

ΧΦ65/75/85 series

Oil nozzle

Oil nozzle banjo bolt 30 Nm

Main bearing caps

Main bearing cap attachment bolts

Big-end bearing caps

Attachment bolts (1), cracked big-end bearing caps 1st phase 100 Nm

phase 175 Nm ≥ 15 Nm

phase 60 angular

(2)

displacement

(1)

150 Nm + 120 angle tightening

XE-engine lubrication system

Attachment bolts, big-end bearing

(2)

caps 1st phase, sequence

1-2-3-4 35 Nm

phase, sequence

4-3-2-1 45 Nm

phase, sequence

1-2-3-4

(1) Apply a drop of oil to thread and contact surface. (2) Connecting rod bolts are to be used once and tightened

as instructed. When fitting the connecting rod in the engine, apply a drop of oil to the threads and contact surfaces of the connecting rod bolts.

60 angular displacement

M2 01 285

1 4

M200661

200351 9-3

Page 54

TECHNICAL DATA

XE-engine lubrication system

9.3 FILLING CAPACITIES

Lubrication system

Total capacity, including oil cooler and oil filter approx. 35 litres Oil sump capacity, maximum level approx. 30 litres Oil pan capacity, minimum level approx. 22 litres

ΧΦ65/75/85 series

9-4

200351

Page 55

DIAGNOSTICS

ΧΦ65/75/85 series

1 Diagnostics

CONTENTS

Page Date

1. TRACTIVE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200351

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200351

1.2 Acceleration test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . . . . . 200351

1.3 Acceleration test form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . 200351

1.4 Acceleration test using DAVIE-XD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . 200351

2. CE ENGINE, GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200351

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200351

2.2 Fault-finding table, engine functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200351

2.3 Fault-finding table, vehicle functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 . . . . . 200351

3. CE-ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200351

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200351

3.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200351

4. CE-ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200351

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200351

4.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200351

5. PE/XE ENGINE, GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200351

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200351

5.2 Fault-finding table, engine functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200351

5.3 Fault-finding table, vehicle functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 . . . . . 200351

Contents

6. PE/XE-ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200351

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200351

6.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . 200351

7. XE/PE-ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200351

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200351

7.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 . . . . . 200351

200351 1

Page 56

DIAGNOSTICS

Contents

ΧΦ65/75/85 series

200351

Page 57

DIAGNOSTICS

ΧΦ65/75/85 series

1. TRACTIVE PROBLEMS

1.1 INTRODUCTION

There may be many reasons why a vehicle's performance is below standard.

Some of these may be mechanical, but some may be psychological in nature. It is therefore important to identify the problem properly.

Try to get as much information as possible from the customer or driver.

- When does the vehicle not perform properly?

- What are the road or weather conditions

when this occurs?

- What are the vehicle's loading conditions?

- Is the vehicle not being compared with a

vehicle with completely different specifications, for instance engine power?

- Is the vehicle being driven in the correct

engine speed range?

Tractive problems

If the answers are unsatisfactory, ask the customer or driver for facts.

- Tachograph cards of trips

- Reliable consumption figures of trips

Following correct identification of the complaint, vehicle performance can be tested by an acceleration test.

If the vehicle fails to pass the acceleration test, a boost pressure curve may be plotted as an aid to identifying the cause.

Note:

Checking the boost pressure will in general only make sense after the vehicle has covered at least 20,000 km.

200351 1-1

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DIAGNOSTICS

Tractive problems

1.2 ACCELERATION TEST

1. Use the "Acceleration test form", which is

included in the Workshop Manual.

2. Do the checks set out under "Before starting

the acceleration test".

3. Establish a test route where the difference

between the measured times in both directions does not exceed 15%. If the difference in time exceeds 15%, find another test route.

4. Establish the starting and end points on the

selected test route, to ensure that exactly the same route can be taken in both directions. Do the entire test at least twice and take the average time.

5. Run the drive train at operating temperature

(drive for at least 15 minutes with a loaded vehicle).

ΧΦ65/75/85 series

Note:

When switched on, the air compressor and fan consume 10 to 15 kW engine power on average. During the test try to avoid these two consumers being switched on.

6. Connect DAVIE and follow the instructions

given.

7. Fully depress the accelerator pedal during

the acceleration test.

1-2

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DIAGNOSTICS

ΧΦ65/75/85 series

Result of first acceleration test

If the acceleration time is not achieved, first carry out the following work.

- Check the fuel system for the presence of air.

- Replace or clean the air filter element.

- Check the setting of the wastegate on the

turbocharger (if present).

- Check the exhaust brake butterfly valve for

correct operation.

- Check the charge cooler exterior for dirt

deposits.

- Clean the water separator (if present).

- Check that the primer pump is attached.

- Replace the fuel fine filter.

- Check the suction pipe of the tank for

clogging by coarse dirt.

- Check the fuel tank for fouling. Clean with a

steam cleaner, if necessary.

- Check the air intake system for any leaks.

- Check the exhaust system for any leaks.

- Check the exhaust system for blockages by

measuring the exhaust back pressure.

- Check the turbocharger impellers on the

compressor and turbine sides for damage and for deposits of salt or any other contaminants.

- Check both the valve clearance and the DEB

clearance (if present).

- Check the injector pipes for damage.

- Check the fuel gallery/rail pressure.

- Check the fuel lift pump output.

- Check whether the right type of components

has been fitted. This includes turbocharger, injectors, etc.

- Check the opening pressure of the injectors

(if possible).

Tractive problems

Repeat the acceleration test. If necessary, plot a boost pressure curve.

200351 1-3

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DIAGNOSTICS

Tractive problems

ΧΦ65/75/85 series

1.3 ACCELERATION TEST FORM

General data

Customer's name:__________________________________________ Chassis number:______________ Registration number:______

Test conditions

Weather conditions: dry / rain / wet road / drizzle

Wind force: none / average / strong Outside temperature:_______

Vehicle data

Vehicle type:________ Trailer type:_________ Superstructure:____________

Total combination weight: ________kg Total vehicle height: _________m Cab type: day / sleeper / space / superspace Aerodynamics: roof spoiler / fenders / front spoiler / skirts / sun visor / ____________________

Engine type:________ Gearbox type:_____________ Transmission:_________

Rear axle type:_______________ Transmission:_______________

Tyre size: front:__________ rear:____________________

Tyre make:_______________ Energy:____________________

Space between cab and superstructure/trailer: _________________m

TOPEC data

Starting speed: ___________km/h End speed: _____________km/h Gear selection:___________ Acceleration time: __________sec.

Measured time of outward journey:

Measured time of return journey:

1: _______sec.

2: _______sec. Average time of outward journey: ________sec. 3: _______sec.

Average time: _________sec.

1: _______sec.

2: _______sec. Average return time: _________sec. 3: _______sec.

1-4

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DIAGNOSTICS

ΧΦ65/75/85 series

1.4 ACCELERATION TEST USING DAVIE-XD

The acceleration test can also be carried out using DAVIE-XD. Collect the necessary data and, after starting DAVIE-XD, go to the engine management system and carefully follow the instructions in DAVIE-XD for carrying out the test correctly.

The test results should be saved to diskette after each test.

The acceleration test in DAVIE-XD should only be started when the

}

When driving, never start a "direct test" or "guide diagnosis".

vehicle is stationary. As the communication between the accelerator pedal sensor and the unit will be broken for a short time when DAVIE is started up, this can lead to dangerous situations when the vehicle is being driven.

Tractive problems

200351 1-5

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DIAGNOSTICS

Tractive problems

ΧΦ65/75/85 series

1-6

200351

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DIAGNOSTICS

ΧΦ65/75/85 series

2. CE ENGINE, GENERAL

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. The fault-finding table contains possible causes of symptoms not detected by the electronic unit.

CE engine, general

200351 2-1

Page 64

DIAGNOSTICS

CE engine, general

ΧΦ65/75/85 series

2.2 FAULT-FINDING TABLE, ENGINE FUNCTIONS

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 fuel lift pump seal

Fuel filter clogged Replace the fuel filter and clean the system

While carrying out an engine test with DAVIE, communication with DAVIE was interrupted

No fuel supply/fuel lift pump defective; no delivery Check:

SYMPTOM: ENGINE STALLS AND RUNS AGAIN AFTER RE-STARTING

Remove the battery earth lead and then refit it

- the fuel level

- the pipes for blockage and leaks

- the fuel lift pump

Possible cause Remedy

Air in fuel system Check for drawing in of air:

- via the suction pipe

- via the fuel lift pump seal

SYMPTOM: ENGINE STARTS POORLY

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 fuel lift pump seal

Fuel filter clogged Replace the fuel filter and clean the system

Battery voltage too low Charge the batteries

Mechanical defect or clogging in injector Replace the injector

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

Internal leakage between the fuel supply pipe and the injector

Check the fuel supply pipe/injector connections for internal leaks.

2-2

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DIAGNOSTICS

ΧΦ65/75/85 series

SYMPTOM: ENGINE RUNS AT (INCREASED) IDLING SPEED AND DOES NOT RESPOND TO

ACCELERATOR PEDAL

Possible cause Remedy

Mechanical defect of accelerator pedal sensor Check:

- the mechanical connection between the sensor and the accelerator pedal

- the accelerator pedal sensor

Fuel quantity adjustment by ABS/ASR

Engine brake input signal present Check the electrical system of the engine brake

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

- via the fuel lift pump seal

CE engine, general

Fault in electrical components/wiring of the engine coolant temperature sensor

Injector defective Check the injectors.

Crankshaft position sensor defective Check the crankshaft position sensor

SYMPTOM: IRREGULAR RUNNING OF ENGINE

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

Air in fuel system Check for drawing in of air:

Fuel filter clogged Replace the fuel filter

Connection points on injectors mixed up Connect the correct connection points to the

Mechanical defect or clogging in injectors Replace the injectors

Injector defective Check the injectors.

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

Pressure relief valve on common rail does not shut off

Check the electrical system

and fill fuel tank with fuel

- via the suction pipe

- via the fuel lift pump seal

correct injector

Check the pressure relief valve

200351 2-3

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DIAGNOSTICS

CE engine, general

SYMPTOM: REDUCED POWER AT ALL ENGINE SPEEDS

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

Fuel filter clogged Replace the fuel filter

Mechanical defect of accelerator pedal sensor Check:

- the mechanical connection between the sensor and the accelerator pedal

- the accelerator pedal sensor

Fault in electrical components/wiring of:

- contacts

- contact resistors in connector connections

Air filter clogged. Replace or clean the air filter.

Turbocharger defective/wastegate control incorrect.

Air leak in inlet system. Pressure-test the inlet system.

Mechanical defect or clogging in injectors Replace the injectors

Check the electrical system

Check the turbocharger/wastegate control.

ΧΦ65/75/85 series

Injector defective Check the injectors.

Pressure relief valve on pump housing does not shut off

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

SYMPTOM: REDUCED POWER ABOVE A CERTAIN ENGINE SPEED

Possible cause Remedy

Fuel filter partially clogged Replace the fuel filter

Air filter partially clogged. Replace or clean the air filter.

Air leak in inlet system. Pressure-test the inlet system.

Pressure relief valve on pump housing does not shut off

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

SYMPTOM: WHITE/BLUE SMOKE IS EMITTED

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

Check the pressure relief valve

and fill fuel tank with fuel

Air in fuel system Check for drawing in of air:

- via the suction pipe

- via the fuel lift pump seal

Fuel filter clogged Replace the fuel filter and clean the system

Mechanical defect or clogging in injectors Replace the injectors

2-4

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DIAGNOSTICS

ΧΦ65/75/85 series

SYMPTOM: WHITE/BLUE SMOKE IS EMITTED

Possible cause Remedy

Injector defective Check the injectors.

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

SYMPTOM: BLACK SMOKE IS EMITTED

Possible cause Remedy

Injector defective Check the injectors.

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 filter clogged Replace the fuel filter and clean the system

Air leak in inlet system. Pressure-test the inlet system.

CE engine, general

Mechanical defect or clogging in injectors Replace the injectors

Leak in fuel system Check for leaks

SYMPTOM: REDUCED MAXIMUM ENGINE SPEED

Possible cause Remedy

Air in fuel system Check for drawing in of air:

- via the suction pipe

- via the fuel lift pump seal

Fuel filter clogged Replace the fuel filter and clean the system

Turbocharger defective. Check turbocharger.

Mechanical defect or clogging in injectors Replace the injectors

Fuel quantity adjustment by ABS/ASR

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

200351 2-5

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DIAGNOSTICS

CE engine, general

2.3 FAULT-FINDING TABLE, VEHICLE FUNCTIONS

SYMPTOM: VEHICLE SPEED CONTROL DOES NOT WORK

Possible cause Remedy

Fault in electrical components/wiring of:

- combi-switch

- proximity switch

Condition(s) for disengaging vehicle speed control present

SYMPTOM: ENGINE SPEED CONTROL DOES NOT WORK

Possible cause Remedy

Condition(s) for disengaging engine speed control are present

Fault in electrical components/wiring of: wiring harness

- combi-switch

Check the electrical system

Check for presence of condition(s) for disengaging

Check the electrical system

ΧΦ65/75/85 series

SYMPTOM: PRE-GLOWING AND AFTER-GLOWING FUNCTION DOES NOT WORK

Possible cause Remedy

Fault in electrical components/wiring of:

- wiring harness

- warning lamp, pre-glowing

- glow plugs

- glow plug relay

Condition(s) for disengaging pre-glowing and afterglowing function present

SYMPTOM: ENGINE CANNOT BE SWITCHED OFF WITH IGNITION KEY

Possible cause Remedy

Power supply to electronic unit not cut off. Power supply to electronic unit after contact not cut off with contact switch

SYMPTOM: FAULT INDICATOR LAMP DOES NOT GO ON OR OFF

Possible cause Remedy

Fault in electrical components/wiring of:

- wiring harness

- Electronic unit

Check the electrical system

Check for presence of condition(s) for disengaging

Check the electrical system

2-6

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DIAGNOSTICS

ΧΦ65/75/85 series

SYMPTOM: NO COMMUNICATION POSSIBLE WITH DAVIE

Possible cause Remedy

Fault in electrical components/wiring of:

- wiring harness

- diagnostic connector

Power supply to electronic unit after contact not cut off with contact switch No supply voltage to the electronic unit Electronic unit defective

CE engine, general

Check the electrical system

200351 2-7

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DIAGNOSTICS

CE engine, general

ΧΦ65/75/85 series

2-8

200351

Page 71

DIAGNOSTICS

ΧΦ65/75/85 series

3. CE-ENGINE COOLING SYSTEM

3.1 INTRODUCTION

CE-engine cooling system

200351 3-1

Page 72

DIAGNOSTICS

CE-engine cooling system

ΧΦ65/75/85 series

3.2 FAULT-FINDING TABLE

SYMPTOM: ENGINE TEMPERATURE INCREASES

Possible cause Remedy

Incorrect injectors installed Check whether the correct injectors have been

installed

Inlet system failure Check the inlet system.

Lubrication system failure Check the lubrication system

Incorrect poly-V-belt tension Check the poly-V-belt tensioner or replace the

poly-V-belt

Insufficient coolant Check the coolant level. Top up if necessary

Coolant hose torn or clogged Check coolant hoses

Air cooler and cooling system radiator fouled Check/clean the air cooler and cooling system

radiator

Wastegate setting is too high. Check the wastegate setting

Air hose from the turbocharger housing to the wastegate diaphragm leaks or is not connected.

Check the air hose. Replace if necessary.

Incorrect or malfunctioning pressure cap Check the pressure cap

Thermostat opens insufficiently or not at all Check the thermostat and its operation

Coolant filter fouled Check the coolant filter Replace, if necessary, and

clean the cooling system

Coolant pump defective Check the coolant pump shaft, bearings and

impeller. Replace the coolant pump, if necessary

Viscous fan defective Check operation of the viscous fan

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

SYMPTOM: EXTERNAL COOLANT LEAKAGE

Possible cause Remedy

Coolant hoses defective Check coolant hoses

Coolant pipes defective Check coolant pipes

Radiator leaking Check the radiator Pressure-test if necessary

Coolant pump leaking Check coolant pump If necessary, measure

bearing play

Defective oil cooler Check the oil cooler. Pressure-test if necessary

Defective pressure cap Check the pressure cap. Pressure-test if

necessary

Heater leaking Check the heater hoses

Leaking connection between coupling and water pipe

Check connection between water pipe and coupling for damage. Replace the O-rings

3-2

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DIAGNOSTICS

ΧΦ65/75/85 series

SYMPTOM: INTERNAL COOLANT LEAKAGE

Possible cause Remedy

Defective cylinder head gasket Check the cylinder head gasket

Cracked cylinder heads or cylinder block Check the cylinder heads and cylinder block for

internal cracks. Pressure-test if necessary

Leaking injector sleeves Check the cylinder heads Pressure-test if

necessary

Defective compressor cylinder head gasket Replace compressor cylinder head gasket

Defective oil cooler Check whether there is coolant in the lubrication

system

Defective freeze plugs in tappet area (cylinder block) or at the top of the cylinder heads

Replace freeze plug(s)

CE-engine cooling system

200351 3-3

Page 74

DIAGNOSTICS

CE-engine cooling system

ΧΦ65/75/85 series

3-4

200351

Page 75

DIAGNOSTICS

ΧΦ65/75/85 series

4. CE-ENGINE LUBRICATION SYSTEM

4.1 INTRODUCTION

CE-engine lubrication system

200351 4-1

Page 76

DIAGNOSTICS

CE-engine lubrication system

ΧΦ65/75/85 series

4.2 FAULT-FINDING TABLE

SYMPTOM: ENGINE OIL PRESSURE TOO LOW

Possible cause Remedy

Engine oil level too low Top up engine oil to maximum level

External oil leaks Visually check the engine for leaks. Repair if

necessary

Oil pressure switch defective Check the switch Replace if necessary

Oil does not meet the required specifications Change the engine oil and the oil filter

Oil temperature is too high Check the oil cooler

Oil mixed with coolant or fuel Change the engine oil and the oil filter

Oil passage pipe or oil suction pipe loose or broken Check oil pipes. Repair if necessary

Oil pressure control valve fails to operate Check the oil pressure control valve

Inadequate functioning of oil pump Check the oil pump

Main or big-end bearings worn out Check main or big-end bearings

Piston cooler oil nozzle has come loose Check oil nozzle. Replace if necessary

Defective internal oil pressure pipes or seals Check the oil pressure pipes and seals

Fouling between oil pressure control valve and seat

Oil filter fouled Replace the oil filter

SYMPTOM: ENGINE CONSUMES TOO MUCH OIL

Possible cause Remedy

Inlet system failure Check the inlet system

Exhaust system failure Check the exhaust system

Oil cooler leaks Check whether there is lubricating oil in the engine

Oil temperature is too high Check that the correct oil cooler has been installed

Excessive blow-by Check the compression pressure and carry out a

Worn piston rings and/or cylinder liners Replace the piston rings and/or cylinder liners

Check/clean the oil pressure control valve

cooling system

cylinder leak test Check the condition of the piston rings and cylinder liners

Check the air inlet system Check the oil specifications

Injector O-ring damaged or not present Check the injector seal

4-2

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Page 77

DIAGNOSTICS

ΧΦ65/75/85 series

5. PE/XE ENGINE, GENERAL

5.1 INTRODUCTION

PE/XE engine, general

200351 5-1

Page 78

DIAGNOSTICS

PE/XE engine, general

ΧΦ65/75/85 series

5.2 FAULT-FINDING TABLE, ENGINE FUNCTIONS

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 fuel lift pump seal

Fuel filter(s) blocked Replace the fuel filter and clean the system

No fuel supply/fuel lift pump defective; no delivery Check:

- the fuel level

- the pipes for blockage and leaks

- the fuel lift pump

Pressure relief valve on pump housing does not shut off

SYMPTOM: ENGINE STALLS AND RUNS AGAIN AFTER RE-STARTING

Check the pressure relief valve

Possible cause Remedy

Air in fuel system Check for drawing in of air:

- via the suction pipe

- via the fuel lift pump seal

Pressure relief valve on pump housing does not shut off

SYMPTOM: ENGINE STARTS POORLY

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

Air in fuel system Check for drawing in of air:

Fuel filter clogged Replace the fuel filter and clean the system

Mechanical defect or clogging in pump units Replace the pump units

Injectors defective Check the injectors

Pressure relief valve on pump housing does not shut off

Check the pressure relief valve

and fill fuel tank with fuel

- via the suction pipe

- via the fuel lift pump seal

Check the pressure relief valve

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

5-2

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Page 79

DIAGNOSTICS

ΧΦ65/75/85 series

SYMPTOM: ENGINE RUNS AT (INCREASED) IDLING SPEED AND DOES NOT RESPOND TO

ACCELERATOR PEDAL

Possible cause Remedy

Mechanical defect of accelerator pedal sensor Check:

- the mechanical connection between the sensor and the accelerator pedal

- the accelerator pedal sensor

Fuel quantity adjustment by ABS/ASR

Engine brake input signal present Check the electrical system of the engine brake

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

- via the fuel lift pump seal

PE/XE engine, general

Injector defective Check the injectors

SYMPTOM: IRREGULAR RUNNING OF ENGINE

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 fuel lift pump seal

Fuel filter clogged Replace the fuel filter

Mechanical defect or clogging in pump units Replace the pump units

Injector defective Check the injectors

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

Pressure relief valve on pump housing does not shut off

SYMPTOM: REDUCED POWER AT ALL ENGINE SPEEDS

Possible cause Remedy

Check the pressure relief valve

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

Fuel filter clogged Replace the fuel filter

Mechanical defect of accelerator pedal sensor Check:

- the mechanical connection between the sensor and the accelerator pedal

- the accelerator pedal sensor

Air filter clogged Replace or clean the air filter

200351 5-3

Page 80

DIAGNOSTICS

PE/XE engine, general

SYMPTOM: REDUCED POWER AT ALL ENGINE SPEEDS

Possible cause Remedy

Turbocharger defective/wastegate control incorrect

Air leak in inlet system Pressure-test the inlet system

Mechanical defect or clogging in pump units Replace the pump units

Injector defective Check the injectors

Pressure relief valve on pump housing does not shut off

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

SYMPTOM: REDUCED POWER ABOVE A CERTAIN ENGINE SPEED

Possible cause Remedy

Fuel filter partially clogged Replace the fuel filter

Air filter partially clogged Replace or clean the air filter

Air leak in inlet system Pressure-test the inlet system

Check the turbocharger/wastegate control

Check the pressure relief valve

ΧΦ65/75/85 series

Pressure relief valve on pump housing does not shut off

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

SYMPTOM: WHITE/BLUE SMOKE IS EMITTED

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

Air in fuel system Check for drawing in of air:

Fuel filter clogged Replace the fuel filter and clean the system

Mechanical defect or clogging in pump units Replace the pump units

Injector defective Check the injectors

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

SYMPTOM: BLACK SMOKE IS EMITTED

Possible cause Remedy

Check the pressure relief valve

and fill fuel tank with fuel

- via the suction pipe

- via the fuel lift pump seal

Injector defective Check the injectors

5-4

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Page 81

DIAGNOSTICS

ΧΦ65/75/85 series

SYMPTOM: ENGINE CONSUMES TOO MUCH FUEL

Possible cause Remedy

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

Fuel filter clogged Replace the fuel filter and clean the system

Air leak in inlet system Pressure-test the inlet system

Mechanical defect or clogging in pump units Replace the pump units

Injector defective Check the injectors

Leak in fuel system Check for leaks

SYMPTOM: REDUCED MAXIMUM ENGINE SPEED

Possible cause Remedy

Air in fuel system Check for drawing in of air:

- via the suction pipe

- via the fuel lift pump seal

Fuel filter clogged Replace the fuel filter and clean the system

PE/XE engine, general

Turbocharger defective Check turbocharger

Mechanical defect or clogging in pump units Replace the pump units

Fuel quantity adjustment by ABS/ASR

Fuel lift pump delivery too low Check the fuel lift pump and replace if necessary

200351 5-5

Page 82

DIAGNOSTICS

PE/XE engine, general

ΧΦ65/75/85 series

5.3 FAULT-FINDING TABLE, VEHICLE FUNCTIONS

SYMPTOM: CRUISE CONTROL DOES NOT WORK

Possible cause Remedy

Steering column switch, mechanically defective/ interruption

Condition(s) for disengaging cruise control present Check for presence of condition(s) for disengaging

The function has not been parametrised in the unit Adjust identity card

SYMPTOM: ENGINE SPEED CONTROL DOES NOT WORK

Possible cause Remedy

Condition(s) for disengaging engine speed control are present

Steering column switch, mechanically defective/ interruption

The customer parameter settings have not been met

Check the steering column switch in all positions

Check for presence of condition(s) for disengaging

Check the steering column switch in all positions

Check the customer parameter settings using DAVIE

SYMPTOM: ENGINE CANNOT BE SWITCHED OFF WITH IGNITION KEY

Possible cause Remedy

Fault in electrical components and/or wiring Power supply to UPEC electronic unit not cut off. Power supply to UPEC electronic unit after contact not cut off with ignition switch

SYMPTOM: FAULT INDICATOR LAMP DOES NOT GO ON OR DOES NOT GO OFF

Possible cause Remedy

Fault in electrical components and/or wiring of:

- UPEC electronic unit

SYMPTOM: NO COMMUNICATION POSSIBLE WITH DAVIE

Possible cause Remedy

Fault in electrical components and/or wiring of:

- diagnostic connector

Power supply to UPEC electronic unit after contact not cut off with ignition switch No power supply to the UPEC electronic unit UPEC electronic unit defective

Check the electrical system

5-6

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Page 83

DIAGNOSTICS

ΧΦ65/75/85 series

6. PE/XE-ENGINE COOLING SYSTEM

6.1 INTRODUCTION

PE/XE-engine cooling system

200351 6-1

Page 84

DIAGNOSTICS

PE/XE-engine cooling system

ΧΦ65/75/85 series

6.2 FAULT-FINDING TABLE

SYMPTOM: ENGINE TEMPERATURE INCREASES

Possible cause Remedy

Incorrect injectors installed Check whether the correct injectors have been

installed

Inlet system failure Check the inlet system

Lubrication system failure Check the lubrication system

Incorrect poly-V-belt tension Check the poly-V-belt tension or replace the poly-

V-belt or poly-V-belt tensioner

Insufficient coolant Check the coolant level Top up if necessary

Coolant hose torn or clogged Check coolant hoses

Air cooler and cooling system radiator fouled Check/clean the air cooler and cooling system

radiator

Wastegate setting is too high Check the wastegate setting

Air hose from turbocharger housing to wastegate diaphragm leaks or is not connected

Check the air hose. Replace if necessary

Incorrect or malfunctioning pressure cap Check the pressure cap

Thermostat opens insufficiently or not at all Check the thermostat and its operation

Coolant filter fouled Check the coolant filter Replace, if necessary, and

clean the cooling system

Coolant pump defective Check the coolant pump shaft, bearings and

impeller. Replace the coolant pump, if necessary

Viscous fan defective Check operation of the viscous fan

Poor fuel quality Drain fuel, flush fuel system, replace the fuel filters

and fill fuel tank with fuel

SYMPTOM: EXTERNAL COOLANT LEAKAGE

Possible cause Remedy

Coolant hoses defective Check the coolant hoses

Coolant pipes defective Check the coolant pipes

Radiator leaking Check the radiator Pressure-test if necessary

Coolant pump leaking Check coolant pump If necessary, measure

bearing play

Defective oil cooler Check the oil cooler. Pressure-test if necessary

Defective pressure cap Check the pressure cap. Pressure-test if

necessary

Heater leaking Check the heater hoses

Leaking connection between coupling and water pipe

Check connection between water pipe and coupling for damage. Replace the O-rings

6-2

200351

Page 85

DIAGNOSTICS

ΧΦ65/75/85 series

SYMPTOM: INTERNAL COOLANT LEAKAGE

Possible cause Remedy

Defective cylinder head gasket Check the cylinder head gasket

Cracked cylinder heads or cylinder block Check the cylinder heads and cylinder block for

internal cracks. Pressure-test if necessary

Leaking injector sleeves Check the cylinder heads Pressure-test if

necessary

Defective compressor cylinder head gasket Replace the compressor cylinder head gasket

Defective oil cooler Check whether there is coolant in the lubrication

system

Defective freeze plugs in tappet area (cylinder block) or at the top of the cylinder heads

Replace the freeze plug(s)

PE/XE-engine cooling system

200351 6-3

Page 86

DIAGNOSTICS

PE/XE-engine cooling system

ΧΦ65/75/85 series

6-4

200351

Page 87

DIAGNOSTICS

ΧΦ65/75/85 series

7. XE/PE-ENGINE LUBRICATION SYSTEM

7.1 INTRODUCTION

XE/PE-engine lubrication system

200351 7-1

Page 88

DIAGNOSTICS

XE/PE-engine lubrication system

ΧΦ65/75/85 series

7.2 FAULT-FINDING TABLE

SYMPTOM: ENGINE OIL PRESSURE TOO LOW

Possible cause Remedy

Engine oil level too low Top up engine oil to maximum level

External oil leaks Visually check the engine for leaks. Repair if

necessary

Oil pressure switch defective Check the switch Replace if necessary

Oil does not meet the required specifications Change the engine oil and the oil filter

Oil temperature is too high Check the oil cooler

Oil mixed with coolant or fuel Change the engine oil and the oil filter

Oil passage pipe or oil suction pipe loose or broken Check oil pipes. Repair if necessary

Oil pressure control valve fails to operate Check the oil pressure control valve

Inadequate functioning of oil pump Check the oil pump

Main or big-end bearings worn out Check main or big-end bearings

Piston cooler oil nozzle has come loose Check oil nozzle. Replace if necessary

Defective internal oil pressure pipes or seals Check the oil pressure pipes and seals

Fouling between oil pressure control valve and seat

Oil filter fouled Replace the oil filter

SYMPTOM: ENGINE CONSUMES TOO MUCH OIL

Possible cause Remedy

Inlet system failure Check the inlet system

Exhaust system failure Check the exhaust system

Oil cooler leaks Check whether there is lubricating oil in the engine

Oil temperature is too high Check that the correct oil cooler has been installed

Oil sump pressure too high Check the compression pressure and carry out a

Worn piston rings and/or cylinder liners Replace the piston rings and/or cylinder liners

Check/clean the oil pressure control valve

cooling system

cylinder leak test Check the condition of the piston rings and cylinder liners

Check the air inlet system Check the oil specifications

Injector O-ring damaged or not present Check the injector seal

Damaged/worn valve guide Inspect valve guide

Replace the valve guide

Damaged/worn valve stem seal Inspect the condition and mounting of the valve

stem seal Replace the valve stem seal

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2 CE engine

CONTENTS

Page Date

1. SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200351

1.1 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200351

2. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200351

2.1 Location of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200351

2.2 Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200351

2.3 Overview drawing, timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 . . . . . 200351

3. INSPECTION AND ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200351

3.1 Checking and adjusting the CE engine valve clearance . . . . . . . . . . . . . . 3-1 . . . . . 200351

3.2 Inspection and adjustment, timing gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200351

3.3 Checking piston projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 . . . . . 200351

3.4 Checking cylinder head bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 . . . . . 200351

3.5 Inspection, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 . . . . . 200351

3.6 Inspection, engine oil sump pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 . . . . 200351

3.7 Inspection, vibration damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 . . . . 200351

3.8 Inspection, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 . . . . 200351

3.9 Inspection, cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 . . . . 200351

4. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200351

4.1 Removal and installation, engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200351

4.2 Removal and installation, engine mounts . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200351

4.3 Removal and installation, valve cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 . . . . . 200351

4.4 Removal and installation, valve sleeve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 . . . . . 200351

4.5 Removal and installation, valve gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 . . . . . 200351

4.6 Removal and installation, inlet manifold . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . . . . 200351

4.7 Removal and installation, exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . 4-9 . . . . . 200351

4.8 Removal and installation, cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 . . . . 200351

4.9 Removal and installation, air compressor . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 . . . . 200351

4.10 Removal and installation, steering pump. . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 . . . . 200351

4.11 Removal and installation, starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 . . . . 200351

4.12 Removal and installation, poly-V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 . . . . 200351

4.13 Removal and installation, alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 . . . . 200351

4.14 Removal and installation, flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 . . . . 200351

4.15 Removal and installation, starter ring gear . . . . . . . . . . . . . . . . . . . . . . . . 4-21 . . . . 200351

4.16 Removal and installation, flywheel housing seal . . . . . . . . . . . . . . . . . . . . 4-22 . . . . 200351

4.17 Removal and installation, flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . 4-23 . . . . 200351

4.18 Removal and installation, vibration damper. . . . . . . . . . . . . . . . . . . . . . . . 4-24 . . . . 200351

4.19 Removal and installation, crankshaft sensor ring . . . . . . . . . . . . . . . . . . . 4-25 . . . . 200351

4.20 Removal and installation, front engine panel. . . . . . . . . . . . . . . . . . . . . . . 4-26 . . . . 200351

4.21 Removal and installation, camshaft gear. . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 . . . . 200351

4.22 Removal and installation, timing gear case . . . . . . . . . . . . . . . . . . . . . . . . 4-28 . . . . 200351

4.23 Removal and installation, front crankshaft seal . . . . . . . . . . . . . . . . . . . . . 4-30 . . . . 200351

Contents

5. CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200351

5.1 Cleaning the engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200351

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Contents

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1. SAFETY INSTRUCTIONS

1.1 SAFETY INSTRUCTIONS

Fuel

Diesel fuel is an extremely flammable liquid, and must not be

}

When fuel system components are being removed, some fuel will escape. To keep this spillage to a minimum, unscrew the tank cap to release any overpressure.

Any spilled fuel must be collected, bearing in mind the risk of fire.

Exhaust gases

Do not run the engine in an enclosed or unventilated area. Make sure exhaust fumes are properly extracted.

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.

Safety instructions

Exhaust gases contain carbon monoxide.

}

Moving parts

Remain at a safe distance from rotating and/or moving components.

Various fluids

Various oils and lubricants used on the vehicle may constitute a health hazard. This also applies to engine coolant, windscreen washer fluid, refrigerant in air-conditioning systems, battery acid and clutch fluid. So avoid inhaling and direct contact.

Electrical short-circuit

Always disconnect the battery's earth connection during repair or maintenance operations for which the electric power supply is not required.

Carbon monoxide is a deadly colourless and odourless gas, which, when inhaled, deprives the body of oxygen, leading to asphyxiation. Serious carbon monoxide poisoning may result in brain damage or death.

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Safety instructions

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2. GENERAL

2.1 LOCATION OF COMPONENTS

General

1. Thermostat housing

2. Inlet manifold

3. Air compressor

4. Steering pump with reservoir

5. High-pressure pump

6. Fuel filter

7. ECS-DC3 electronic unit

8. Front engine panel

9. Vibration damper

10. Automatic tensioner

11. Coolant pump

12. Alternator

13. Air-conditioning compressor

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General

ΧΦ65/75/85 series

1. Flywheel housing

2. Timing gear case

3. Exhaust manifold

4. Turbocharger

5. Oil cooler

6. Oil filter

7. Wastegate diaphragm

8. Exhaust brake

9. Starter motor

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2.2 IDENTIFICATION

Engine number

The engine number is stamped front right in the cylinder block, at the top of the lubricating oil cooler housing.

Engine identification plate

The engine identification plate is located at the top of the flywheel housing or on the valve cover, depending on the production date.

General

XXXXXXX

M2 01 138

5 6 7

MADE IN GREAT BRITAIN BY

Cummins

CUMMINS ENGINE CO LTD www.cummins.com

Displacement........................................ 5.9 Litres

Gross Power.........................136kW @ 2500 rpm

Valve lash - (cold) Int .254 mm, Exh .508 mm

Low idle speed.............................. 600 - 800 rpm

Engine Serial No ................................. 21410538

Date of mfg ........................................... 26/06/00

Customer Spec ......................................1396009

DAF ID ...................................................CE136C

1. Cubic capacity

2. Engine output

3. Valve clearance

4. Idle engine speed

5. Engine number

6. Production date

7. Client specification

8. DAF type designation

9. Indication of country of origin

10. K-factor

11. Type approval numbers

12. Cummins type designation

24 031410

E11

E.C. Type Approal Numbers

e11*72/245*95/54*1413*00(ESA)

e11*88/77*1999/96A*1705*00

Model: - ISBe185 30

0.94

3286647

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General

2.3 OVERVIEW DRAWING, TIMING GEAR

1. Crankshaft

2. Camshaft

3. High-pressure pump

4. Compressor

ΧΦ65/75/85 series

1342

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Inspection and adjustment

3. INSPECTION AND ADJUSTMENT

3.1 CHECKING AND ADJUSTING THE CE ENGINE VALVE CLEARANCE

Note:

Inspection and adjustment of valve clearance must only be carried out when the engine is cold.

1. Remove the valve cover: see chapter "Removal and installation".

2. Use an open-end spanner on the fan shaft to turn the crankshaft clockwise, as seen from the vibration damper end (this is the engine's normal direction of rotation), until the mark (A) is between the bolts (B) and the valves of cylinder 1 are in overlap position.

Note:

"Overlap" is the moment at which the inlet valves start opening and the exhaust valves stop closing. The inlet valves are operated by the short rockers and the exhaust valves by the long rockers.

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Inspection and adjustment

3. Check/correct the valve clearance of the specified inlet and exhaust valves. Set the correct valve clearance by loosening the locknut and rotating the adjusting screw in the correct direction; see "Technical data" for the correct valve clearance.

Cylinder Inlet valve Exhaust valve

ΧΦ65/75/85 series

M201064

6XX

4. Using an open-end spanner on the fan shaft, turn the crankshaft one rotation further so that the mark (A) is once again between the bolts (B) and the valves of cylinder 6 overlap.

5. Check/correct the valve clearance of the specified inlet and exhaust valves. Set the correct valve clearance by loosening the locknut and rotating the adjusting screw in the correct direction; see "Technical data" for the correct valve clearance.

Cylinder Inlet valve Exhaust valve

1XX

M201065

6. Fit the valve cover. See "Removal and installation".

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3.2 INSPECTION AND ADJUSTMENT, TIMING GEAR

Note:

The engine is fitted with gears on either side. The gears at the vibration damper end only drive the oil pump. These gears have no marks and may be fitted in any position.

The timing gear wheels on the flywheel side drive the camshaft, air compressor and fuel pump. Only the camshaft gear and the crankshaft gear have marks which must be aligned. The other gears may be fitted randomly.

1. Remove the engine encapsulation panels.

2. Remove the gearbox.

3. Remove the flywheel. See "Removal and installation".

4. Remove the flywheel housing. See "Removal and installation".

Inspection and adjustment

Note:

When the engine crankshaft or camshaft is turned separately, the pistons and valves may touch each other.

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Inspection and adjustment

5. Use an open-end spanner on the fan shaft to crank the engine clockwise, as seen from the vibration damper end, until the marks in the crankshaft gear and camshaft gear match. The crankshaft gear has a punched hole in the tooth which has to fall into the tooth depth of the camshaft gear marked with a punched hole.

6. Check that the marked tooth falls exactly into the marked depth. If not, remove and refit the camshaft gear. See "Removal and installation".

7. Fit the flywheel housing. See "Removal and installation".

8. Fit the flywheel. See "Removal and installation".

9. Fit the gearbox.

10. Fit the engine encapsulation panels.

ΧΦ65/75/85 series

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