DAF CF65, CF75, CF85 Service manual

4

STRUCTURE

ΧΦ65/75/85 series

TECHNICAL DATA

DIAGNOSTICS

CE ENGINE FUEL SYSTEM

CE ENGINE INLET/EXHAUST SYSTEM

CE ENGINE, ENGINE BRAKE

PE ENGINE FUEL SYSTEM

PE ENGINE INLET/EXHAUST SYSTEM

ENGINE BRAKE, PE ENGINE

XE ENGINE FUEL SYSTEM

XE ENGINE INLET/EXHAUST SYSTEM

ENGINE BRAKE, XE ENGINE

0

1

2

3

4

5

6

7

8

9

10

© 200416

DW23241402

https://www.truck-manuals.net/

https://www.truck-manuals.net/

4	TECHNICAL DATA
ΧΦ65/75/85 series		Contents
CONTENTS
	Page	Date		0

1. ENGINE, GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200416 1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200416 1.2 CE engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 . . . . . 200416 1.3 PE engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 . . . . . 200416 1.4 XE engine, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 . . . . . 200416

2. CE ENGINE FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416 2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416 2.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . . 200416

3. CE ENGINE INLET/EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416 3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416 3.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200416

4. PE ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416 4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416 4.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200416

5. PE ENGINE INLET/EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416 5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416 5.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200416

6. XE ENGINE FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200416 6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200416 6.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . 200416

7. XE ENGINE INLET/EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200416 7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200416 7.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 . . . . . 200416

8. ENGINE BRAKE, XE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200416 8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 . . . . . 200416 8.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 . . . . . 200416

© 200416

1

https://www.truck-manuals.net/

TECHNICAL DATA	4
Contents	ΧΦ65/75/85 series

0

2

© 200416

https://www.truck-manuals.net/

4	TECHNICAL DATA
ΧΦ65/75/85 series	Engine, general
1. ENGINE, GENERAL
			0
1.1 GENERAL
CE engine
Cold engine	A cold engine is an engine which, having reached
	operating temperature, has been allowed to cool
	down for at least six hours.
Warm engine	A warm engine is an engine which, having reached
	operating temperature, has not been at a standstill
	for more than thirty minutes.
Direction of rotation of the engine	The direction of rotation of the engine is clockwise,
	as seen from the vibration damper end.
First cylinder of the engine	The first cylinder of the engine is the cylinder at the
	vibration damper end of the engine.
Left-hand and right-hand side of the engine	The left-hand side of the engine is the side where the
	air compressor and electronic unit are mounted. The
	right-hand side of the engine is the side where the
	turbocharger and oil filter are mounted.
PE/XE engine
Cold engine	A cold engine is an engine which, having reached
	operating temperature, has been allowed to cool
	down for at least six hours.
Warm engine	A warm engine is an engine which, having reached
	operating temperature, has not been at a standstill
	for more than thirty minutes.
Direction of rotation of the engine	The direction of rotation of the engine is clockwise,
	as seen from the 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.

© 200416

1-1

https://www.truck-manuals.net/

		TECHNICAL DATA		4
		Engine, general		ΧΦ65/75/85 series
		Engine identification
0
		Engine number
		The engine number is located in two places on
		the engine:
		stamped into the engine block
		- CE: top of the oil cooler
		- PE: above the compressor
		- XE: above the UPEC unit
		on the type plate
		- CE: on the timing gear case or the flywheel
		housing (depending on the production date)
		- PE: on the inlet manifold
		- XE: on the inlet manifold
		Engine type
		The type number XE315C1 indicates:
		X engine family	X =	12.6 ltr.
			P =	9.2 ltr.
			C =	5.88 ltr.
		E engine version	E =	electronic timing
			S =	turbocharger intercooler
		315 engine output in kilowatt (kW)
		C Euro emissions	C =	Euro 3
			M =	Euro 2
			L =	Euro 1
		1 Engine version number	1 =	first update

1-2

© 200416

https://www.truck-manuals.net/

4				TECHNICAL DATA
ΧΦ65/75/85 series				Engine, general
1.2 CE ENGINE, GENERAL
						0
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 valves per cylinder
Bore x stroke		102 x 120 mm
Cubic capacity		5.9 litres
Compression ratio		17,3 : 1
Fuel injection		direct injection
Injection sequence		1-5-3-6-2-4
Air inlet system		Turbocharger intercooling
Engine management system		ECS-DC3
Cooling		fluid
Weight		approx. 500 kg
Engine speeds, CE engine
Engine type		Idling		Maximum no-load rpm
		rpm
CE 136 C		600 - 800		approx. 2500
CE 162 C		600 - 800		approx. 2500
CE 184 C		600 - 800		approx. 2500

© 200416

1-3

https://www.truck-manuals.net/

		TECHNICAL DATA				4
		Engine, general				ΧΦ65/75/85 series
		1.3 PE ENGINE, GENERAL
0
		Engine types
		Coding		PE 183 C 1
				PE 228 C
				PE 265 C
		General specifications
		Environmental standard		Euro 3 (C)
		Number of cylinders		6 cylinders in line
		Valves		4 valves per cylinder
		Bore x stroke		118 x 140 mm
		Cubic capacity		9.2 litres
		Compression ratio		17,5 : 1
		Fuel injection		direct injection
		Injection sequence		1-5-3-6-2-4
		Air inlet system		Turbocharger intercooling
		Engine management system		UPEC
		Cooling		fluid
		Weight		approx. 860 kg
		Engine speeds, PE engine
		Engine type		Idling		Maximum free-running rpm
				rpm
		PE 183 C1		575 - 625		Approx. 2580
		PE 228 C		575 - 625		Approx. 2580
		PE 265 C		575 - 625		Approx. 2580

1-4

© 200416

https://www.truck-manuals.net/

4				TECHNICAL DATA
ΧΦ65/75/85 series				Engine, general
1.4 XE ENGINE, GENERAL
						0
Engine types
Coding		XE 250 C 1
		XE 280 C 1
		XE 280 C 3 (4 öko)
		XE 315 C 1
		XE 315 C 3 (4 öko)
		XE 355 C 1
General specifications
Environmental standard		Euro 3 (C)
Number of cylinders		6 cylinders in line
Valves		4 valves per cylinder
Bore x stroke		130 x 158 mm
Cubic capacity		12.6 litres
Compression ratio		17,4 : 1
Fuel injection		direct injection
Injection sequence		1-5-3-6-2-4
Air inlet system		Turbocharger intercooling
Engine management system		UPEC
Cooling		fluid
Weight		approx. 1,080 kg
Engine speeds, XE engine
Engine type		Idling rpm		Maximum free-running rpm
XE 250 C1		525 - 575		approx. 2200
XE 280 C1/C3		525 - 575		approx. 2200
XE 315 C1/C3		525 - 575		approx. 2200
XE 355 C1		525 - 575		approx. 2260

© 200416

1-5

https://www.truck-manuals.net/

TECHNICAL DATA	4
Engine, general	ΧΦ65/75/85 series

0

1-6

© 200416

https://www.truck-manuals.net/

4	TECHNICAL DATA
ΧΦ65/75/85 series	CE engine fuel system
2. CE ENGINE FUEL SYSTEM
			0
2.1 GENERAL
Fuel level element
Angular displacement	86
Resistance value
- Full	approx. 500
- •	approx. 355
- ∂	approx. 234
-	approx. 137
- Not used	approx. 33
Vacuum relief valve opening pressure	10 - 20 mbar
Pressure relief valve opening pressure	200 - 300 mbar
Fuel fine filter
Maximum pressure drop across fuel fine filter	2.0 bar
Fuel lift pump
Fuel lift pump pressure in front of fine filter (with
engine at idling speed)	5 - 13 bar
Fuel lift pump pressure behind fine filter (with
engine at idling speed)	3 - 11 bar
Pressure relief valve opening pressure	11 bar
Maximum underpressure on suction side of fuel
lift pump	0.5 bar
High-pressure pump
Pump pressure (dependent on the operating
mode of the engine and the electronic calibration)	300 - 1400 bar
Fuel rail
Fuel rail pressure (dependent on the operating
mode of the engine and the electronic calibration)	300 - 1400 bar
Fuel rail pressure-limiting valve
Opening pressure	1650 bar
Injector
Number of holes in injector	8
Resistance of magnet coil	0.15 - 0.5

© 200416

2-1

https://www.truck-manuals.net/

	TECHNICAL DATA		4
	CE engine fuel system		ΧΦ65/75/85 series
0	Injector washer
	Nozzle length	Washer thickness
	(distance A)
	21.5 ≥ 0.2 mm	1.5 mm
	23.0 ≥ 0.2 mm	3.0 mm

A

i400693

Fuel return overflow valve
Fuel return overflow valve opening pressure	1.2 - 2.0 bar
Fuel return pipe
Maximum return pipe pressure build-up	0.2 bar
Return fuel measurement
Maximum quantity of return fuel at idling speed	180 ml/min.
Permitted minimum time for filling a measuring
beaker to a volume of 360 ml	2 min.

2-2

© 200416

https://www.truck-manuals.net/

4	TECHNICAL DATA
ΧΦ65/75/85 series	CE engine fuel system
2.2 TIGHTENING TORQUES
			0
The tightening torques specified in this section
are different from the standard tightening torques
cited in the overview of the standard tightening
torques. The other threaded connections not
specified must therefore be tightened to the
torque cited in the overview of standard
tightening torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.
Electronic unit cooling plate
Attachment bolts holding the electronic unit to the
cooling plate	10 Nm
Attachment bolts holding the cooling plate to the
engine block	24 Nm
VOSS quick-release coupling fittings	18 Nm
Low-pressure fuel pipes
Banjo bolts	24 Nm
VOSS quick-release coupling fittings	24 Nm
Fuel return overflow valve in cylinder head	24 Nm
High-pressure pump
Attachment nuts holding the high-pressure pump
to the timing gear case	25 Nm
High-pressure fuel pipe
High-pressure pipe union nut	22 Nm
Fuel rail
Attachment bolts	24 Nm
Pressure-limiting valve	100 Nm
Injector pipes
Injector pipe union nuts	22 Nm
Fuel supply pipe
Fuel supply pipe nut	50 Nm
Injectors
Injector clamping bracket attachment bolts	10 Nm
Injector electrical connection	1.5 Nm

© 200416

2-3

https://www.truck-manuals.net/

TECHNICAL DATA	4
CE engine fuel system	ΧΦ65/75/85 series

0

2-4

© 200416

https://www.truck-manuals.net/

4	TECHNICAL DATA
ΧΦ65/75/85 series	CE engine inlet/exhaust system
3. CE ENGINE INLET/EXHAUST SYSTEM
			0
3.1 GENERAL

Turbocharger
CE 136 C	Holset HY 35 W
CE 162 C	Holset HY 35 W
CE 184 C	Holset HX 35 W
Minimum actuating pressure of wastegate cap-
sule under which the control rod will move	2.0 bar
Axial bearing play of compressor shaft	0.038 - 0.093 mm
Radial bearing play of compressor shaft	0.329 - 0.501 mm

Rejection standards for cracking

1.Cracks in the connector flange must not reach as far as the attachment holes.

2.Cracks in the connector flange must not

reach from the channels as far as the exterior.

3.Cracks in the connector flange may not be

longer than 15 mm.

4.Cracks in the connector flange must not be

less than 6 mm apart.
5. There must be no cracks in the housing.	5

1

2

3

4

i400784

Exhaust gas back pressure
At full-load engine speed	100 mbar
Maximum back pressure during engine brake ap-
plication	4.3 bar
Inlet underpressure
At full-load engine speed (clean air filter)	25 mbar
At full-load engine speed (clogged air filter)	62 mbar
Glow element
Resistance value	180 - 220 m

© 200416

3-1

https://www.truck-manuals.net/

		TECHNICAL DATA	4
		CE engine inlet/exhaust system	ΧΦ65/75/85 series
		3.2 TIGHTENING TORQUES
0
		The tightening torques specified in this section
		are different from the standard tightening torques
		cited in the overview of the standard tightening
		torques. The other threaded connections not
		specified must therefore be tightened to the
		torque cited in the overview of standard
		tightening torques.
		When attachment bolts and nuts are replaced, it
		is important that - unless stated otherwise - these
		bolts and nuts are of exactly the same length and
		property class as those removed.
		Turbocharger
		Attachment nuts, exhaust manifold flange/turbo-	43 Nm (1)
		charger
		Oil discharge pipe attachment bolts	23 Nm
		Oil supply pipe union	28 Nm
		Turbocharger V-clamp	10 Nm
		(1) Fasten with Copaslip
		Glow element
		Attachment bolts	14 Nm
		Air cooler
		Hose clamps	7 Nm

3-2

© 200416

https://www.truck-manuals.net/

4							TECHNICAL DATA
ΧΦ65/75/85 series							PE engine fuel system
4. PE ENGINE FUEL SYSTEM
										0
4.1 GENERAL
Gallery pressure
At starting speed					approx. 0.5 - 1.0 bar
At idling speed					approx. 2.5 - 3.0 bar
At maximum no-load engine speed					approx. 6.5 - 7.0 bar
Fuel level element
Angular displacement					86
Resistance rating
- Full					approx. 500
- •					approx. 355
- ∂					approx. 234
-					approx. 137
- Not used					approx. 33
Underpressure valve opening pressure					10 - 20 mbar
Overpressure valve opening pressure					200 - 300 mbar
Overview of injectors
Engine type		Number of		Nozzle no.	Hole diameter		Bar filter	Opening
		holes in						pressure
		injector
PE 183 C1		8		1080	0,175		Yes	300 + 10 bar
PE 228 C		8		1080	0,175		Yes	300 + 10 bar
PE 265 C		8		1080	0,175		Yes	300 + 10 bar
Fuel lift pump
Fuel lift pump pressure					7.0 - 8.0 bar
Pressure relief valve opening pressure					approx. 8.5 bar
Pump housing
Weight, including camshaft and pump units					approx. 70 kg
Pressure relief valve opening pressure					approx. 5.5 - 6 bar

© 200416

4-1

https://www.truck-manuals.net/

		TECHNICAL DATA	4
		PE engine fuel system	ΧΦ65/75/85 series
		4.2 TIGHTENING TORQUES
0
		The tightening torques specified in this section
		are different from the standard tightening torques
		cited in the overview of the standard tightening
		torques. The other threaded connections not
		specified must therefore be tightened to the
		torque cited in the overview of standard
		tightening torques.
		When attachment bolts and nuts are replaced, it
		is important that - unless stated otherwise - these
		bolts and nuts are of exactly the same length and

property class as those removed.
Injector pipes
Injector pipe union nuts	30	Nm
Fuel filter housing
Fuel leak-off pipe union	20	Nm
Fuel filter cap	25	Nm
Injectors
Clamping piece attachment bolt	30	Nm + 60 angular displacement (1)
Leak-off pipe banjo bolt	20	Nm
(1) Use bolts once only.
Pump housing
Pressure relief valve	20	Nm
Attachment bolts to connect pump housing to
engine block	60	Nm
Pump housing rear cover attachment bolts	30	Nm
Attachment bolts for pump camshaft locking plate	30	Nm
Attachment bolts for pump housing sealing plates	30	Nm
Attachment bolts for pulse disk on camshaft	30	Nm (1)
Attachment bolt, camshaft sensor	8 Nm
Non-return valve	45	Nm
Fuel temperature sensor	20	Nm
(1) Use Loctite 243
Pump units
Bolts for attaching pump units to pump housing	46	Nm
Pump unit electrical connection	1 Nm
Fuel lift pump
Attachment bolts to connect fuel lift pump to	30 Nm (1)
pump housing

(1) Use Loctite 243

4-2

© 200416

https://www.truck-manuals.net/

4		TECHNICAL DATA
ΧΦ65/75/85 series		PE engine inlet/exhaust system
5. PE ENGINE INLET/EXHAUST SYSTEM
				0
5.1	GENERAL
Explanation of turbocharger type designation
Example of type designation:
GT40-88S/54NPS/0.95-84
GT40	Turbine type designation
88	Maximum compressor rotor diameter
S	Wastegate model
54	Compressor rotor trim
NPS	Version with intake side without compressor housing bypass
PS	Version with intake side with compressor housing bypass
0.95	Turbine housing size
84	Turbine rotor trim

Exhaust back pressure
At full-load engine speed	80 - 90 mbar
Inlet underpressure
At full-load engine speed (clean air filter)	25 - 35 mbar
At full-load engine speed (clogged air filter)	54 - 64 mbar
Turbocharger
Control rod movement of control bypass
at 1.8 bar	1 mm
Stud bolts for fastening	Copaslip

© 200416

5-1

https://www.truck-manuals.net/

		TECHNICAL DATA	4
		PE engine inlet/exhaust system	ΧΦ65/75/85 series
		5.2 TIGHTENING TORQUES
0
		The tightening torques specified in this section
		are different from the standard tightening torques
		cited in the overview of the standard tightening
		torques. The other threaded connections not
		specified must therefore be tightened to the
		torque cited in the overview of standard
		tightening torques.
		When attachment bolts and nuts are replaced, it
		is important that - unless stated otherwise - these
		bolts and nuts are of exactly the same length and

property class as those removed.
Turbocharger
Heat shield attachment bolts		30	Nm (1)
Turbine housing clamp plate attachment nut		15	Nm
Exhaust manifold flange/turbocharger attach-			Nm (2)
ment nuts		60
Elbow attachment with exhaust brake on turbo-
charger		40	Nm
Oil supply pipe banjo bolt		90	Nm
(1)	Use Loctite 243 to secure
(2)	Fasten with Copaslip
Glow element
Attachment bolts		30	Nm
Air cooler
Air cooler hose clamps		10	Nm

5-2

© 200416

https://www.truck-manuals.net/

4							TECHNICAL DATA
ΧΦ65/75/85 series							XE engine fuel system
6. XE ENGINE FUEL SYSTEM
										0
6.1 GENERAL
Gallery pressure
At starting speed					approx. 0.5 - 1.0 bar
At idling speed					approx. 2.5 - 3.0 bar
At maximum no-load engine speed					approx. 6.5 - 7.0 bar
Fuel level element
Angular displacement					86
Resistance value
- Full					approx. 500
- •					approx. 355
- ∂					approx. 234
-					approx. 137
- Not used					approx. 33
Vacuum relief valve opening pressure					10 - 20 mbar
Pressure relief valve opening pressure					200 - 300 mbar
Overview of injectors
Engine type		Number of		Nozzle no.	Hole diameter		Bar filter	Opening
		holes in						pressure
		injector
XE 250 C1		8		1081	0.182		Yes	300 + 10 bar
XE 280 C1/C3		8		1081	0.182		Yes	300 + 10 bar
XE 315 C1/C3		8		1081	0.182		Yes	300 + 10 bar
XE 355 C1		8		1286	0.182		Yes	300 + 10 bar
Fuel lift pump
Fuel lift pump pressure					7.0 - 8.0 bar
Pressure relief valve opening pressure					approx. 8.5 bar
Pump housing
Weight, including camshaft and pump units					approx. 70 kg
Pressure relief valve opening pressure					circa 5.5 - 6 bar

© 200416

6-1

https://www.truck-manuals.net/

		TECHNICAL DATA	4
		XE engine fuel system	ΧΦ65/75/85 series
		6.2 TIGHTENING TORQUES
0
		The tightening torques specified in this section
		are different from the standard tightening torques
		cited in the overview of the standard tightening
		torques. The other threaded connections not
		specified must therefore be tightened to the
		torque cited in the overview of standard
		tightening torques.
		When attachment bolts and nuts are replaced, it
		is important that - unless stated otherwise - these
		bolts and nuts are of exactly the same length and

property class as those removed.
Injector pipes
Injector pipe union nuts	30	Nm
Fuel filter housing
Fuel leak-off pipe union	20	Nm
Fuel filter cap	25	Nm
Injectors
Clamping piece attachment bolt	30	Nm + 60 angular displacement (1)
Leak-off pipe banjo bolt	20	Nm
(1) Use bolts once only.
Pump housing
Pressure relief valve	20	Nm
Attachment bolts to connect pump housing to
engine block	60	Nm
Pump housing rear cover attachment bolts	30	Nm
Attachment bolts for pump camshaft locking plate	30	Nm
Attachment bolts for pump housing sealing plates	30	Nm
Attachment bolts for pulse disk on camshaft	30	Nm (1)
Attachment bolt, camshaft sensor	8 Nm
Non-return valve	45	Nm
Fuel temperature sensor	20	Nm
(1) Use Loctite 243
Pump units
Bolts for attaching pump units to pump housing	46	Nm
Pump unit electrical connection	1 Nm
Fuel lift pump
Attachment bolts to connect fuel lift pump to	30 Nm (1)
pump housing

(1) Use Loctite 243

6-2

© 200416

https://www.truck-manuals.net/

	4		TECHNICAL DATA
	ΧΦ65/75/85 series		XE engine inlet/exhaust system
	7. XE ENGINE INLET/EXHAUST SYSTEM
					0
	7.1	GENERAL
	Explanation of K.K.K. turbocharger type
	designation
	Example of type designation:		K31-39 71 Q Y B KB
			22.9 1 D C A Y D
	K31	Turbine build series
	39	diameter of compressor rotor 3.9 inch
	71	diameter ratio of compressor rotor d/d
	Q	Compressor rotor development letter
	Y	Compressor housing development letter
	B	Compressor housing variant

Kk = compressor housing with recirculation (= ported shroud)

a = compressor housing with no recirculation (= non-ported shroud)

b	b = recirculation variant
	a = no recirculation
22	surface of turbine housing throat (cm2)
9	turbine housing version number
	9	= with control bypass
	2	= without control bypass

1Turbine trim figure:

=d/d = 89.5 (trim 80)

=d/d = 87 (trim 76)

=d/d = 84 (trim 70)

=d/d = 79 (trim 62)

D	Turbine rotor development letter
C	Turbine housing development number
A	Turbine housing variant

YTurbine inlet flange size

y = dimension for a 12.6 litre engine w = size for a 9.2 litre engine

t = size for a 6.2 litre engine

DTurbine housing material: b = GG 40

d = Simo

f = Nirisist d2 h = Nirisist d3 k = Nirisist d5

© 200416

7-1

https://www.truck-manuals.net/

		TECHNICAL DATA		4
		XE engine inlet/exhaust system		ΧΦ65/75/85 series
		Explanation of GARRETT turbocharger type
0
		designation
		Example of type designation: GT40-88S/54NPS/
		0.95-84
		GT40	Turbine type designation
		88	Maximum compressor rotor diameter
		S	Wastegate model
		54	Compressor rotor trim
		NPS	Version with intake side without compressor housing bypass
		PS	Version with intake side with compressor housing bypass

0.95Turbine housing size

84	Turbine rotor trim
Turbocharger
Stud bolts for fastening		Copaslip
GARRETT wastegate
Movement of control rod at 1.60 ≥ 0.05 bar		1.0 mm
K.K.K. wastegate
Movement of control rod at 1.95 ≥ 0.05 bar		3.5 ≥ 0.05 mm
Exhaust back pressure
At full-load engine speed		90 mbar
Inlet underpressure
At full-load engine speed (clean air filter)		50 mbar
At full-load engine speed (clogged air filter)		75 mbar

7-2

© 200416

https://www.truck-manuals.net/

4	TECHNICAL DATA
ΧΦ65/75/85 series	XE engine inlet/exhaust system
7.2 TIGHTENING TORQUES
			0
The tightening torques specified in this section
are different from the standard tightening torques
cited in the overview of the standard tightening
torques. The other threaded connections not
specified must therefore be tightened to the
torque cited in the overview of standard
tightening torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and

property class as those removed.
Turbocharger
Heat shield attachment bolts		30	Nm (1)
Turbine housing clamp plate attachment nut		15	Nm
Exhaust manifold flange/turbocharger			Nm (2)
attachment nuts		60
Elbow attachment with exhaust brake on
turbocharger		40	Nm
Oil supply pipe banjo bolt		90	Nm
(1)	Use Loctite 243 to secure
(2)	Fasten with Copaslip
Glow element
Attachment bolts		30	Nm
Air cooler
Air cooler hose clamps		10	Nm

© 200416

7-3

https://www.truck-manuals.net/

TECHNICAL DATA	4
XE engine inlet/exhaust system	ΧΦ65/75/85 series

0

7-4

© 200416

https://www.truck-manuals.net/

4	TECHNICAL DATA
ΧΦ65/75/85 series	Engine brake, XE engine
8. ENGINE BRAKE, XE ENGINE
			0
8.1 GENERAL
DEB solenoid valve
Resistance rating
Cold (20 C)	32,6 - 36,8
Hot (80 C - 100 C)	41,8 - 46,1
DEB oil pressures
Minimum cut-in pressure	1.5 bar
Maximum service pressure	4.5 bar
Maximum pressure of DEB control valve	8.0 bar
DEB settings
DEB clearance	1.40 mm
Exhaust brake
Calibration of butterfly valve opening:
- with DEB	14 mm
- without DEB	10.5 mm

© 200416

8-1

https://www.truck-manuals.net/

TECHNICAL DATA	4
Engine brake, XE engine	ΧΦ65/75/85 series

8.2 TIGHTENING TORQUES

0

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.

DEB
Valve cover attachment bolts		25	Nm	7		15	9	2
Rocker setting bolt lock nut		40	Nm	3	11	13
Bridge piece setting bolt
lock nut		40	Nm	5				6
DEB attachment bolts		110 Nm
DEB set screw nut		25	Nm	1		14	8
Solenoid valve		20	Nm
Wiring harness attachment bolt		5 Nm			10	12		4
Spring plate attachment bolt		12.5 Nm
Valve sleeve attachment bolts		30	Nm (1)					M200942
(1)	Tighten the attachment bolts in the order indicated
Exhaust brake
Exhaust brake elbow attachment nuts on turbo-				40 Nm (1)
charger
Heat shield attachment bolts				30 Nm (2)
(1)	Fasten with Copaslip
(2)	Use Loctite 243 to secure

8-2

© 200416

https://www.truck-manuals.net/

	4	DIAGNOSTICS
	ΧΦ65/75/85 series		Contents
	CONTENTS
		Page	Date
	1. TRACTIVE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. . 1-1 . . .	. . 200416	1
	1.1 Tractive problems	1-1	200416

2. CE ENGINE FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416 2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . . 200416 2.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . . 200416

3. CE ENGINE INLET/EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416 3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200416 3.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 . . . . . 200416

4. ENGINE BRAKE, CE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416 4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 . . . . . 200416 4.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . . . . . 200416

5. FUEL SYSTEM, XE/PE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416 5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 . . . . . 200416 5.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . . . . . 200416

6. XE/PE ENGINE INLET/EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200416 6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 . . . . . 200416 6.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . 200416

7. ENGINE BRAKE, XE/PE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200416 7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 . . . . . 200416 7.2 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 . . . . . 200416

© 200416

1

https://www.truck-manuals.net/

DIAGNOSTICS	4
Contents	ΧΦ65/75/85 series

1

2

© 200416

https://www.truck-manuals.net/