Workshop manual DD 575 DF 615 DT 615 DAF Diesel Service Promotion Subject to modificationINTRODUCTION ‘This Repairs and Workshop Manual, which accompanies the DAF diesel engines of the 876 and 619 series is Intended for the workshops of our Service organisation. Likewise, these books are available for users who have the ‘required special toois and skillful staft ‘Our policy being one of continuous improvement and progress, it may happen that modifications to the engine have not been included in this manual However, new issues covering all modifications and including al! supplements, will be published at regular intervals. ‘Should you have any questions regarding the engine or regarding the manual, please contact your DAF Diesel dealer, jwino has the latest information available, Finally, we shall be pleased to receive your remarks and comments upon this manual so as to enable us to continuously Improve the quality of future issues, For this purpose you may use the enclosed service documentation information card (see section 0-05, page 1). Please send this card, fully and clearly filled out, to your importer’s address as mentioned on the enclosed list Many thanks! DAF-DIESEL Service Promotion February 1979, {All information applies both to the D575 and to the DF and DT615 engines unless otherwise stated. ‘The specificetions refer to brand-new parts.SUBDIVISION GENERAL ENGINES COMPRESSORWorkshop manual CONTENTS Subgroup Subject 03 Ordering parts 05 Information card » service documentation Page(s) 1 1-3DAF Diesel DD 575, DF 615, DT 615 0-03 Workshop manual “INFORMATION CARD ORDERING PARTS When ordering parts make sure to mention not only the engine number but also and especially the specification numbers as mentioned on the identity plate on the valve cover. If these deta are missing, i is impossible to guarantee correct supply. ‘identity plate 2 engine leek Biocon of the engine blocky Workshop manual CONTENTS Subgroup Subject Page(s) 00 Geneval: Specifications i Speciai tools 23 ‘Checks and adjustments 4 Exhaust smoke measuring 5a 10 cylinder head 15 20 Valve gear 14 30 Vibration damper and pulleys 12 31 Engine block 16 32 Crankshaft, conrods and pistons 16 34 Flywheel and ring gear 13 35 Timing 14 36 Flywheel housing 12 38 Engine suspension 12 a Lubrication system 18 51 Cooling system 168 Bt Manifolds 14 63 Turbocharger 16DAF Diesel DD 575, DF 615, OT 615 2-00 Workshop manual GENERAL SPECIFICATIONS Make Type Number of evtinders Bore Stroke Cubic capacity Compression ratio Valve clearance cold/warm Thread Dry weight, inc. accessories but without clutch Firing order Injection timing Injection pressure Coolant operating temperature Lubricating systems Lubricant Viscosity, below 0° C 3° to #800 C above +25° C Oil pressure to be measured at a coolant temperature of at idling speed (new engine) ditto tat wear) {2000 r-p.m Capacity {inet flrer} ditto line filter and cooler) ditto, double room sump Diesel fue! Starter motor Generator GENERAL INFORMATION DAF Water-cooled diesel engine with dicect injection DT618: equipped with a turbocharger 6 00575: 100.6 mm, DF615 and DT6IS: 104.2 mm 00575, DFE1S and DTE15: 120.7 mm DDS75! 6.76 itres DFE15 and DT6I5: 6.17 litres 16:1 O5mm to ISO standards DDB75: §30 kg, DFEIS: 580 kg, DTB15: 570 ke 15.3624 28° before T.0.C. (00575 and DT615) 26° before T.0.C. (OT615) D575 and OT615: 165.173 bar DT615: 216-224 var 75809 C CC or CD, max. sulphates ash content 1.8% SAE 20 SAE 30 SAE 40 75809 C min, 1.0°bar min, 0.35 bar 35-42 bar 42 litres 1B litees, 47 ltees Min. coquiroment British Standard no. 2869-1970 Cass A2. Also refer to Tus! system (Tul quality) bipolar AG. - various versionsSPECIAL TOOLS 1. Bush for camshaft thrust rng centring 2. Mand cutter foreleaning injector oat in cylinder head 3. Drife for pressing in volve guides 4 D1Rt for oresing out valve guides 5. not applicabie 6. Drift ol pump shate bush 7. Spacer camshaft puller 8B. Puller, removing crankshaft pulley ond cama gear 2.99.535087 299.538088 299535073, 299535074 299595076 2.99.535077 299535148 9. Dummy injector. compresion esting 10, Auxiliary tool for measuring engine 11, Gauge, ol presiur testing compiote 12. Too! far removing and frtng evlinder ‘inert 13. Drift, woterpump sea 18. Bont box spanner 15. Puller for removing water pump pulley 18, Honing tool for eyinder linet 2.99.935266 2-99595265 299535651 299935625, &s 10. 1 12 13, 14 DAF Diesel DD 575, DF 618, DT 615 2-00 Workshop manual GENERAL pepsieeas | + Sees | ieosseesr popuneas seessen | — sSesosewn sossserse sees 2opsoses7 | xCHECKS AND ADJUSTMENTS 2-99-835264 COMPRESSION MEASURING Final compression pressure: D575: 25.3.26.3 bar at 300 r.p.m. DF615, D615: 24.4-26.4 bar at 310 rem. Before starting measuring first ensure that the engine is well at operating temperature Remove injection lines Remove injector leak-otf line Remove injectors (six off) ‘Move the fuel handie to ZERO position Use for measuring special adapter: 2:99-635264 ‘Use Motometer, type 289 ‘Make sure to receive any leaking-out fuel ‘AGB200DAF Diesel! Workshop manual — EXHAUST SMOKE MEASURING Introduction Operations for exhaust smoke measuring, as described below, are based on the use of the Hartridge Mk3 measuting device. Therefore, for explanation of the onstruction, operating and maintenance of this measuring we may refer to the detailed documen. tation which accompanies the smokemete To provide power supply for the smokemeter uso two well-charged 12 volt batteries with a capacity of 90 ‘An each of ~if need be -one 12 volt battery with 2 ‘capacity of 180 An. On no account the engine batteries should be used for this purpose. Measurings should preferably be done at an ambient temperature between 10° C and 40° C, Preparatory operations 1. Place smokemeter in a horizontal position, set ‘switch (20) to OFF-position and contro! (1) 10 ZERO CHECK, The pointer should indicate 100, HSS.U. If not, correct by means of *he adjusting screw (23), 2, Connect battery cables with terminals of light source (2) and blower (1), making sure the proper polarity is observed: + cables connected with red terminals. In case only one battery is used, the four terminals should be interconnected as shown in fig. 1. 3. Check battory voltage for the light source by switching on the smokemeter (switch (20) to ON and switch (18) to V-test), The pointer should ‘move then to the black area of the scale, DD 575, DF 615, DT 615 2-00 GENERAL, 4. Check photo electric cell with accompanying filter glass. Toke off the RH side cover and place the glass over the end of the smoke tube nearest to the photo electric cell. Re-install cover and turn control {15} to SMOKE CHECK. The scale reading Should not deviate more than 1 H.S.U. (Hartridge ‘Smoke Unit) from the value indicated on the filter glass value 5. Operate blower for some minutes to allow clean air 0 pass through the meter. This will remove any soot particles and will lower temperature of the photo electric cel 6. Drain off water from the moisture separator. Testing conditions 1. Do not clean the glass of the micro-ammeter (22) immediately before using the meter, This might ‘cause static electricity that would affect the moter reading. 2, Ifthe engine has bean idling for Longer than & minutes always carry our "soot clearance” by three rapid bursts of acceleration. 3. The smokemeter must always be switched on and the air blower operating when smake is entering, otherwise sooting up of the light source and of the photo-sectric cell may occur 4. Always leave by-pass valve (31) in the closed position (lever in a vertical position) and eontral (18) in ZERO CHECK position. 5. Remember to remove the probe after a test and allow the blower to run for a few moments before ‘witching off. This will allow exhaust gases to be cleared from the smokemeter. Connecting the smokemeter 1. Connect the three plastic hoses to the smokemeter: = one to excess smoke outiet (32) = one to the smoke by-pass outlet (27) = one to the air and sample smoke outlet (26) ‘Make sure that the hoses have no kinks and thet the waste smoke is directed away from the clean air intet (16), ‘The excess smoke inlet (32) ean be moved to any of four positions as required. 2. Connect the inlet probe to the black flexible pipe and secure with a hose clip.Blower Light source, quartz hatogene lame Attaching screw for cover Thermometer for measuring smoke tube teroerature LH cover Pressure gouge for messur Filer cap Seale hous gas pressure Pressure rit valve Water 90 ‘Smoke by-pass vlve Thermometer for meaturing temperature of incoming exaust goes Ai cover Instrument pane Control kno ZERO CHECK/SMOKE CHECK Inlet for tear ir at ZERO CHECK Conttol knob, blower speed 16 19. 2 2. 23. 2a 25 2% 2. Es 2. 30 a 22, V-TEST/SMOKE TEST switch Wiorning ight ON/OFE switch switching snake meter on gd off Zero reset tab, seting pointer to Oat ZERO CHECK ‘Miero-ommeter, graduation in HU. Reset ser, moving pointer 100 osphric air and sample smoke ‘ave of dosed by-pass valve (31 oust gases ass through meter haust pipe of vehicle Thermometer for measuring wemperatute of exhaust asses ype valve closed position i exhaust gates ta outlet (27) Excess exhaust gos ourlat is; AGB 200DAF Diesel Workshop manual Attach probe clamp to the probe using the appropriate adaptor. if necessary. |. Ingort probe into exhaust pipe of vehicle and clamp the probe to the rim of the exhaust pipe. The probe should be located centrally in the pipe ‘and can be adjusted by means of the adjusting knob. Connect the ather ene! of the flexible pipe to the connection {29} on the smokematar. Avoid kinks and sharp bends. Now Install smokemeter at a higher point than the vehicle exnaust pipe, 40 that the flexible pipe slopes slightly upwards, to prevent any condensa: tion from entering the smokemeter ‘Set scale plate (8} of pressure gauge (16) to mid position. Carefully fil pressure gauge with water ‘ensuring that no air bubbles are formed, until level is aporox. that of zero on seale plate. ‘Add a small quantity of fluorescene to the water. This will improve visibility of fluid level, Finatly slide seale plate until its 2er0 marking coincides swith the water level Note: Once filled it is only necessary 10 top up the fluid in the pressure gauge to the correct level ‘Measuring procedure 1 2 3. Set contro! (16) to ZERO CHECK Set switch (18) to S-TEST. Ensure by-pass valve (31) is elosad (tever in vertical position) DD 575, DF 615, OT 615, u 12 13 4 2-00 GENERAL Switch on smokemeter with switeh (20} Check that engine is at operating temperature. Check that idling speed and max. no-load speed are in accordance with engine specifications. Let engine operate at a speed of approx. 1,500 pum, and wait at least 6 minutes to enable smokemeter to reach corcect temperature [thermometer (30) Use zero reset knob (21) to set pointer to zero. {Gheck whether thermometer reading (30) is between 140° and 210° C. Carry out “soot clesrance” by two or three ‘rapid bursts of acceleration, so that any soot particles in the exhaust system are blown away. Set control to SMOKE TEST. Open by-pass valve (lever in horizontal position) and fully depress accelerator pedal until maxi mum speed under lead has been reached, Chock whather temperature ard pressure are within the prescribed limits, ie, 70° - 1402 C. - thermometer (12) and 40-65 mm head of water: pressure gause (6) Close by-pass valve (31) Open by-pass valve, fully depress accelerator pedal untib maximum speed under load has been Faached. Next Close by-pass valve and simultaneously release accelerator pedal untit engine is at idling speed. Repeat operations uncer 13 and 14 three times and each time take highest micro-ammeter Feading. This is the smoke value in so-calted Hartridge Smoke Units (HS.U,)DAF Diese! Workshop manual CYLINDER HEAD ‘Spring washer Bott Bresthor connection ‘cylinder hess cover Gas Valve cs Sealing rng Head gasket Valve seat 10. Set of gaskess a Nut 12 sua 1. Bok 18. Spring washer 15, Sealing rng 18, Connecting nipple 17. Plug 18, Pug 19, Sealing ting 20. Expansion plu 21. Injector holder sieeve 22. Valve guide 23. Bolt 24. Sorina wesher DD 575, DF 615, DT 615 wie 2 2 2-10 CYLINDER HEADSPECIFICATIONS Cylinder head Height Min. height Dia. of initial bore for valve guides Valve guides Overall length Outside dia. Inside dia. before pressing Inside dia. after pressingin Inverterence tit Projection above eylinder head Valves seats Angle of valve seat Seat width (new) Height Inside dia, Outside dia Machined recess in eylinder heed Depth Dia Tightening torques Bolts and nuts for the attachment of Cylinder head, studs Cylinder head, nuts DFB1S Cylinder head nuts DT(D}615 Cylinder head, bolts Uitting bracket, front Lifting bracket, rear INSTRUCTIONS FOR REPAIR Valve seat Pressed-in seats are used for the exhaust valves, whereas the valve seats are directly cut into the eylinder head, For reconditioning purposes separate seat inserts are available for the intake valves as wel 86.31 — 86.41 mm 86.11 mm 14.288 — 14.300 mm 708 — 713 mm 44.331 — 14.339 mm 8.725— 8.737 mm 8705 8.717 mm 003 — 0.05 mm 224 — 23.4 mm Intake Exhaust 209 +15" 309 + 15° 12-15 mm 15 = 18 mm 4304 — 4572 mm 852 — 862 mm 37.536 — 37.686 mm 3421-3437 mm 48.374 ~ 48.386 mm 45.289 — 45.301 mm Intake Exhaust 5.70 — 5.80 mm 10.05 ~ 10.25 mm 48.234 — 48.260 mm 45,187 — 45.213 mm 82 Nm 8.3 mkg} 245 —259.Nm (25 — 26.4 mkg) 285 —294Nm (29° ~ 30 mky) 42—52Nm( 4.2— 5.2mkg) BO 61Nm( 5. — 6.1 mka) 25— 27Nm{ 25— 2.7 mkg) ‘The recess to be made in the cylinder head for the Inlet valve seat. When check ng concentricity of this recess with the valve guide bore, dial gauge reading ‘must not exceed 0.02 mm. The valve seats are shrunk AGB210DAF Diesel Workshop manual Valve guides “Tho valve guides should be pressed into the cylinder head so that their most stronaly bevelled sides project ‘above the evlinder head. The part of the valve guide protruding above the cylinder head should have & Tength of 22.4 ~ 23.4 mm, For pressing a valve guide in and out DAF supply special tools, part numbers 2-99-535073 2:99535074 resp. ‘Studs Use Loctite 270 (or an equivalent) for installing the studs attaching the rocker shaft brackets. DD 575, DF 615, DT 615 2-10 CYLINDER HEAD. a 2-99-535073 2.99-835076Injector holder sleeve For camoving an injector holder sieeve use an inside puller or a home-made euxilisrly too! (see drawing). ‘Tap 3/4" BSP thread in injector holder sleeve and screw in auxiliary tool. Next, pull or knock too! together with the injector holder sleeve out of the cylinder head. Note: Plug off bore in cytinder head to prevent ‘metal particles from dropping into the combustion chamber Injector seat Clean the injector seat in the cylinder hoad with a Scraper, part number 2-99-535088, after treating scraper head with grease Note: Plug off bore in cylinder head to prevent -2.99-535058 particles from dropping inte the combustion chamber, pe Hoad gasket For the DT615 engine a reinforced head gasket is Used. Apart from the part aumber, this gasket can also be recognized by the four nicks in the edge. ‘The head gasket should be fitted dry after cylinder head and engine block have been trusd if necessary. ‘The narrow folded adge should always be on the cylinder head side (the corresponding side of the head gasket is marked “head side") A. Suip steel B. Stee! wire fabric C. Steel sheot 4 Ace 2404 DAF Diesel Workshop manual - DD 575, DF 615, OT 615 2-10 CYLINDER HEAD A= Exhaust part B = Intake part 1. Fit head gasket dry, hence without oil or anything else, after thoroughly cleaning block and head. 2. Apply alittle oil to stud thread and to bearing surtace under nut. 3. Evenly tighten nuts in three steps and in the prescribed sequence. DD, DF: 147 - 196 - 259 Nm (15 -20 -26 mkg) DT! 147-216 -294 Nm (15 - 22 - 30 mkg) 4 Tighten six eylinder bolts: 40-50 Nm (4-5 mkgl Run engine until operating temperature has been reached. Switch engine off and - when stil warm «repeat ‘operation under 3, ‘After 500 km (25 aperating hours) retighten nuts ‘with warm engine, after first slackening nuts somewhat (max. 1/8 turn).~ DAF Diesel Workshop manual VALVE GEAR Plug ciretip Rocker shaft Sering Nut Aajustng etew Rocker stud Lock nut Nut Spring washer Swe Spring Rocker shaft Bracket Gasket Bowel pin ‘Spring pin Bashing True ring ‘Snap rng DD 575, OF 615, DT 615 2-20 VALVE GEARVALVE GEAR WITH DECOMPRESSION SHAFT ‘This system is uted when the engine has to be started by hand 1. Phos 11. Spring washer 20. Bracket 2 Ciealip 12. Ste 23. Dowel pin 3. Rooker hate 13. Spring 22. Plunger 4 Spring 14. Rocker shaft, 23. Sorng 5. Nut 15. Lever 24. Gateet &. Adjstingseraw 16. Nut 2. Dacompression shaft 7. Rooker 17. Sue 26. Bushing 8 Stud 18. Spring washer 27. Ring 9. Nut 19. Gasket 28, Thess ring 10. Not 29. Snap ring SPECIFICATIONS. Valve timing with a valve clearance of 0.5 mm Intake valve opens 30 after TDC 10° before T.0.©. Intake valve closes 34° after B.0.C. 499 after B.D.C. Exhaust valve opens 39° before 8.D.C, 46° before B.C. Exhaust vaive closes 2° before T.D.C. 19° after T.D.C. Valves Intake Exhaust Valve head dia. 419 — 42.1 mm 3927 ~ 39.47 mm Face angle 29930" 15" 29°30 + 15" Stem dia. 8649 ~ 8.661 mm 8.624 — 8.636 mm ad Stem clearance in guide 0.044 — 0.068 mm 0.069 - 0.093 mm Valve clearance 05 mm 05 mm Valve lift 9.65 mm 9.65 mm 2 G8220DAF Diesel DD 575, DF 615, DT 615, 2-20 ~ Workshop manual VALVE GEAR Valve springs Inner spring Outer spring Compressed to 40.7 mm 43.2 mm Spring load 102-112. 210-228 N (104-114 ka) (21.4234 kg) LLenath at max. compression 30.9 mm 335mm Spring load 184 — 204 386 — 425 N (188 — 208 ka) (39.4 — 43.4 ky Vaive tappets Outside dia 38.274 - 93.287 mm Clearance in engine block Push rods ‘Overall lengthy Max. permissible out of straight Rocker shatt Outside cia, Inside die. of rocker bush (reamed) Diametrieal clearance of shaft in bush Tightening torque Nuts and bolts for attachment of. Rocker shaft seat, nut Injector toggle Valve easing INSTRUCTIONS FOR REPAIR Intake/Exhaust valve 1. Push roe Tapper valve spring Oring Conet cop (0.043 — "0.081 mm (max. 0.15 mm} 373.7 ~3743.mm 0.25 mm 22.193 ~ 22.206 mm 22.213 — 22234 mm (0.007 ~ “0.041 mm (max. 0.09 mm) 60 — 65 Nm (6.1 — 6.6 mkg) max. 50 Nm (5 mkg) 3941 Nm (3.9 ~4.1 mika)al 150-175 mm Boeke Desh ~The position of the bush seam with respoct to the racker may be chosen at rendom, Remember t0 dil the oil hole after pressing in the bush Valve clearance Adjust valve clearance with the engine switched off and, preferably, cold. Check valve clearance not only at periodical servicings, but also after one or more Injectors have been replaced. AGB220DAF Diesel DD 575, DF 615, DT 616 2-30 Workshop manual "VIBRATION DAMPER VIBRATION DAMPER AND PULLEYS Pulley Veorbeit 10. Pulley 11. Veo 12) Patiey SPECIFICATIONS Tightening torque of cranking bolt 373 — 412 Nm (38 ~ 42 mkg) Tightening torque of vibration damper 58-61 Nm (5.8 ~ 6.1 mkg)Pulley ‘Vinraion damper Lock pate Dowel pin ranking bolt Bolt Veeselt Pulley Seren INSTRUCTIONS FOR REPAIR When renewing a Vee-belt proceed with care and avoid to stretch or distort the new belt. By releasing 3 the generator itis quite simple to mount and to tension the Vee-belt or belts In the case of outboard waterpumps a different system is used, for which see group 2:51, page 16, In ‘ease two or more Vee-balts are running over the same pulley, all Vee-belts must be replaced simultaneously. After renewing a Veecbelt zheck the tension already after 2 operating hours or after 60 ke and again aftor 20 operating hours or 600 km. ‘Thereafter check the tension at regular intervals. AGB 230DAF Diesel DD 875, DF 615, DT 615 2-31 ~ Workshop manual ENGINE BLOCK ENGINE BLOCK 1. Engine block 10. Cover 19. Sealingring 28. Plug 2. Gylinder ines 14. Gasket 20. Screw B. Gor 2. Spacer 12. Pig 21. Seating ing 30. Lock plate Bushing 12. Setot gukets 22 3 5. Phe 14. Beuringbwsh 23. 6 Plus 15. Pig 2 7. Ring 16. Gasket Fa 8, screw 17. Cover 28 ’ 9. Ring 18. Screw 27SPECIFICATIONS Engine block Overall height Depth of recess for cylinder liner eotlar Initial bore for eylinder liners, standard size Initial bore for evlinder liners, oversize Initial bore for main bearing shells Initial bore for camshaft bearing bushes 1 & 4 Initial bore for eamshatt bearing 2 & 3 {in Block) Initial bore for tappets Cylinder liners Outside diameter of cylinder liner, standard size Outside diamerer of cylinder liner, oversize Inside diameter of eytinder tine Inside diameter of cylinder liner atter pressing.in Projection of cylinder liner above top face of ‘engine block SPECIFICATIONS Engine block Overall height Depth of recess for eylinder liner collar Initial bore for cylinder liners, standard size Initial bore tor evlinder liners, oversize Initial bore for main bearing shells Initiat bore for camshaft bearing bushes 1 & 4 Initial bore for camshaft bearing 2 & 3 (in block) Initial bore tor tappets Cylinder liners Outside diameter of cylinder liner, standard size Outside diameter of cylinder liner, oversize Inside diameter of eylinder liner Inside diameter of cylinder liner after pressing in Projection of cylinder liner above top face of engine block bps75 454,640 — 454.720 mm (min. 454.440 mm} 12.655 ~ 12.700 mm 105.665 — 105.687 mm 105.915 ~ 105.937 mm 8288 — 82,906 mm 59.690 — 59.710 mm 53.330 — 53.360 mm 33.330 — 33.355 mm 108.67 — 105.69 mm 105.92 — 105.94 mm. 100.62 — 100.64 mm 100.60 — 100.63 mm DF615 and DT615. 454.640 — 454.720 mm (min. 454.440 mm} 8.000 8.045 mm 108.989 — 109.011 mm. 103.24 — 109.26 mm 8288 — 82906 mm 59,680 — 59.710 mm 53.330 — 53.360 mm 33.330 — 33.355 mm 108.999 — 109,009 mm 103,25. ~ 109.27 mm 104.18 — 104.20 mm 10416 — 104.19 mm +0.035 — + 0.100 mm Aco20 ZDAF Diesel DD 575, DF 615, DT 615 2-31 Workshop manual INSTRUCTIONS FOR REPAIR ‘Cylinder liner wear H oversize cylinder liners have been fitted the mark 81 must be stamped into the engine block above the engine number, Cylinder liner replacement Pressing in and extracting cylinder liners in pre erably carried out by using the DAF tool. No. 2.99.535625. Lubricate the lining, when pressing in, on the outer side with a small quantity of an appropriate lu fg, Shell grease Nr, $2927A, white lead or, in an emergency, light lubricating oil. Difficulties in Dressing in are practically always due to excessive fuprieation or due to the presence of remnants of old lubricant, Note:2-99-535625 is the part number for the ‘complete set of tools, DAF tool 2:99-535625 can also be used in combi nation with standard hydraulic devices, available inthe local trade with a working pressure of 30 tonnes (for instance Owatonna Too! Company). To facilitate, in the case of abnormal cylinder liner wear, tracing the possible cause a wear pattern of the liner in question should be available. For this purpose use the form as shawn on page 6 After the block has beon faced, the recess for the cylinder liner eollar should be rectified to its initial value. Grinding off the cylinder liner collar is inadmissible For measuring the projection of the cylinder finer above the cylinder block use a dial gauge. If required, rectify by means of shims. For overhauling purposes bearing bushes for the nos. 2 and 3 camshaft bearings are available too. ‘The corresponding engine block bores should be bored to 59.680 -- 59.710 mm. After fitting, ream the bearing bushes to 83.33 — 53.36 mm. nt, ENGINE BLOCK 2/99_535629(DFDT 615)HONING OF CYLINDER LINERS SOSSSSSSSSSS SES SSSSSSES SS LS ES SSSSSSESSSSSES SSSSSSSSESESES SSSSSSSSSSES SS SSSSSSSSSS SS SSS SSoSSSSSDAF Diesel DD 575, DF 615, DT 615 2-61 Workshop manual MANIFOLDS WATER-COOLED INTAKE AIR COOLER 2. Gasket 3.Nut 4. Spring washor 5. Gmkat 6 stud 7. tntake manifold 8 Spring wasner 9. cap screw 10.Plue 11. Sealing ving Intake air cooling ‘The DT615M with intercooling is an engine equipped with intake air cooling. Due to the compression in the ‘urbo-charger there is an increase in the air temperature. In the intake air cooler the outboard water coo's down the air to a considerable extent ‘The lower the temperature of the alr, the higher the ‘oxygen weight content and itis precisely the oxygen content which determines the amount of fuel which ccan be burnt, Hence, engines with air intake coating will develop a hhigher power than ensines without such a cooling system,ery 7 ‘@ Se Pe I EXHAUST MANIFOLD We 5 z Ss 2. Washer a.Net 4. Gatker 5.Stud 6. Wisner 7 Bott Aint 9. Exhaust manifold 10. Exhaust mnifole 19. Exhaust manfole WATER-COOLED EXHAUST MANIFOLD 4 {marine version) 1 exna 2 Nut 3. Washer 4.sua 5. Plug 6. Sealing ring 7. rain cock 10. Welaingtange 1. Ptug 12. Bat 13. Bena 14. Gasket 15, Goeket 4 AGB 261DAF Diesel Workshop manual TURBOCHARGER DD 575, DF 615, DT 615, 2-63 TURBOCHARGER OPERATION ‘The turbocharger delivers under pressure air, necessary for combustion, to the cylinders. The air charge in the cylinder is therefore greater than in the case of @ naturally aspirated engine. A larger quantity of fuel ‘may be injected, resulting in @ higher engine output. MOUNTING TURBOCHARGER ON ENGINE — Inspect the air intake tube, replacing it at signs of ageing. ~ Check the exhaust manifold for metal particles which might break off, for particles of gasket anc ther foreign matter, = Chack the oi return line, both on the inside and on the outside for damages which might restrict the oil flow. The same applies in the case of the oil supply line. ~ Check the flange connecting the compressor to the exhaust manifold for flatness and ensure that its clean. = Place a now gasket on the exhaust manifold. Ensure that the gasket does not hinder the flow of the ‘exhaust gases: itis even preferable that the opening The exhaust gases are used to rotate the turbine wheel. The compressor wheel, which forces the ait to the cylinders, s secured to the rotor shaft, which Is integral with the turbine whee! Ve in the gasket is all around approx. 1.5. mm away from the edge of the exhaust port in the manifold. = Change the engine lubricating oll, using the co-rect type of oil, and fit @ new oil filter element. ~ Do not yet connect the ol return tine. Fill the compressor via the ol let port with engine olf tntil the oil flows aut of the return port. = Check oil pressure at turbochareer connection of supply line — Reconnect all air hoses and lines, check joints for leaks — Connect all parts free from stress to turbocharger. ‘Smoar the screw thread with a heat-resistant grease such as graphite grease or a molybdene disulfide grease.INSTRUCTIONS FOR MAINTENANCE AND OPERATION For turbocharged engines strict observance of instructions for maintenance and operation is even ‘more important than for engines of which combustion air is aspirated, 1, Change engine oil at regular intervals. 2, Service engine oil filter at regular intervals. 3. Check oil pressure at spot where oil enters turbo: changer. 4, Service the air cleaner in accordance with instructions. Check max. permissible underpressure in inlet manitold, 5, Check ail lines, suction line between turbocharger FAULT FINDING CHART and air cleaner, as well as exhaust and silencer. 6. Do not run engine at full speed immediately after starting (so-called revving up). 7. Before stopping the engine, allow it to run at tick- over a shart moment. 8. Check rotor-shatt play at regular intervals (for instance, every 100,000 km). 9, When resfitting the turbocharger on the engine ‘fully check whether all supply and return lines thoroughly cleaned Fill bearing housing with clean engine oil before connecting oil supply line Af the engine fails to give its normal performance, first investigate all other causes before studying the possibilities mentioned below. Failure Possible couses Excessive smoking and loss of power. side. turbocharger) Rubbing of turbine or compressor wheel ance, caused by: | lubrication. and duets, ined, Tate changing In general caused by lack or air at too low filing pressure Fouled sir filter and/or fouled sir filter connection. Deformed suetion line (excessive under. pressure ahead of turbochange i possible oil leaks on compressor Fouled exhaust and/or silencer excessive pressure beyond i Mostly excessive bearing clear. = temporary interruption of = insufficient oil pressure, = foreign particles from oil lines = fouled or damaged oil filter — poor oll quality owing too leak in oil delivery tine, = to0 quick cold:starting at very cold engine (avoid load- iectly after engine Remedy | Clean air ot necessary — renew element. Inspect suction line Clean o replace | Renew turbocharger {As long as turbocharger has not been renewed, do not fully load engine to prevent further damage; pay special attention to smoking! Excessive smoking and loss of power together with abnormal sounds, pressor wheel Leaks at connections and flanges | of tuction and exhaust tubes, Rubbing of turbine and/or com- Inspect connections and flanges: if necessary, renew gaskets. | Disconnect tines, inspect tur | bine housing and compressor cover at spots where turbine | wheel snd compressor wheel rubbed; if necessary, check bearing clearance, AGB 263DAF Diesel DD 575, DF 615, OT 615 2-63 Workshop manual TURBOCHARGER, type 3A 18. Seteerow 22. Sealing ring 23. Ring 28. Compeostor housing SPECIFICATIONS Make Type Inlet vacuum Exhaust back pressure Delivery pressure under load at 2000 r-p.m. Oil delivery pressure under normal lo2d Oil delivery pressure at idling speed TURBOCHARGER Holset 3A ‘max. 0.05 bar max. 0.05 bar (0.04 - 0.044 bar min. 2.0 bar min. 0.7 bar Oit pressure must show at the turbocharger inlet within 9-4 seconds of the engine firing. Tightening torques Bolts and nuts for the attachment of Compressor housing Turbine housing Turbocharger on manifold ‘Adapter to turbocharger 8.3 Nm (0.83 mko) 16.6 Nev (1.66 mkg) 43-47 Nm (4.3-4.7 mko) 43-47 Nm (4.34.7 mkg)1, Turbocharger 7. Core ssemiy 13. Nezsle ring 2. Comoresior housing 8. Seren 18, Turbine nousing 3. Ring 8. Loek plate 15, Gasket 4 Gasket 10 Lock pate 16st 5.Oll strtnes 11S 17. Gateae 6, Snap ring 12. Heat shila CONSTRUCTION ‘The turbocharger consists of a turbine and a com: pressor part. Turbine wheel and shaft are integral, the compressor ‘wheel is attached to the shaft with a nut, The turbine shaft rotates in a plain bearing, Endwise forces are taken up by a thrust plate and washer. INSPECTION Attention: Never let the engine run after the air ducting between air cleaner and turbo: charger has been disconnected as dirk entering the turbocompressor will damage the compressor or the engine. = The inlet vacuum, measured in the ducting immediately ahead of the comprescor inlet, should ‘not exceed 0.05 bar. Excessive vacuum at this point is an indication of a dirty air cleaner and/or flat air hoses, — Back pressure in the exhaust pipe should not exceed {680 mm head of water. A higher back pressure indicates exhaust system fouling. INSTRUCTIONS FOR REPAIR ‘Separate parts of the core assombly are not serviced, ‘The core assembly must always be renewed at a whole, Ditmantling = Clamp unit upright in viee on turbine inlet flange. = Remove the eight setscrews and lift cover off bearing housing — Remove the "V" clamp and fift the turbine housing clear of the bearing hausing Re-assembly Re-assembly of the turbocharger isa reversal of the dismantling procedure. No gasket is fitted between compressor cover and bearing housing, ‘When installing the turbocharger apply 2 heat-resistant ‘grease t0 such bolts, nuts and studs which will become hot. (OF the greases that will fit the purpose we mention: = a graphite grease, such as Shell Grafina, = a molybdene disulfide (MoS2) grease, such as Molykote paste Ace 263DAF Diesel DD 575, DF 615, DT 615 2-63 Workshop manuai TURBOCHARGER, TYPE 3LD Turbocharger 10.409 4 Seating vo 2. Thrust plate SPECIFICATIONS Make Type Inlet vacuum Exhaust back pressure Delivery pressure under load at 2000 r.p.m. Oil delivery pressure under normal load Ditto, at idling speed Tightening torques Bolts and nuts for the attachment of ‘Compressor cover, Turbine housing "V" clamp Turbocharger on manifold ‘Adapter on turbocharger 9 87 5. Turbine whes! 8 i singer B.Clemping plate 6, Searing TURBOCHARGER 12. Compressor whee! 10, Sealing ing 14 Insert, 11 Spacer ‘9, Bearing housing 42. Wut 15, Washer 16. Compressor housing Holset 3LD ‘max. 0.05 bar max. 0.068 bar 0.56 - 0.61 bar ‘min, 2.0 bar ‘min. 0.7 bar 8.3 Nm (0.83 mko} 16.8 Nm (1.66 mks) 43-47 Nm (4.3 -4.7 ka} 43-47 Nm (4:3 - 4.7 mkg) Within 3 to 4 seconds after the engine has fired the oil pressure must show at the turbocharger inlet.CONSTRUCTION The turbocharger consists of a turbine and 2 com: pressor part. ‘Turbine wheel and shaft are integral, the compressor whee! is attached to the shaft with ainut. The turbine shaft rotates in a plain bearing, Endwise forces are taken up by a thrust plate and washer. INSPECTION ‘Attention: Never let the engine run after the air ‘ducting between air cleaner and turbo: charger has been disconnected as dirt ‘entering the turbocompressor will damage the compressor or the engine. — The inlet vacuum, measured in the ducting Immediately ahead of the compressor inlet, should not exceed 0.05 bar. Excessive vacuum at this point is an indication of a dirty air cleaner and/or flat a hoses. ~ Back presture in the exhaust pipe should not exceed {680 mm head of water. A higher back pressure indicates exhaust system fouling Turbocharge: ut Glamping rap Spr washer Washer core assembly Compressor Nousing INSTRUCTIONS FOR REPAIR ‘Separate parts of the coro assembly are not serviced. ‘The core assembly must always be renewed as a whole Dismanting = Clamp unit upright in viee on turbine inlet flange. = Rlemove the eight setscrews and lift cover off bearing housing, — Remove the "V" clamp and lift the turbine housing clear of the bearing housing. Reassembly Re-assembly of the turbocharger is a reversal of the dismantling procedure. No gasket is fitted between compressor cover and bearing housing. ‘When mounting the turbocharger apply a heat-resistant grease to such bolts, nuts and studs which will become hot. Of the oreasos that will fit the purpose we mention: a graphite grease, such as Shell Grafina, — amolybdene disulfide (MoS2) grease, such as Molykote paste. AGB 263DAF Diesel DD 575, DF 615, DT 615 Workshop manual CONTENTS Sub - group 80 Subject Compressor Page(s) 1-6INTRODUCTION It is mainly in its construction that the Clayton: Dowandre air compressor, OAF part no. 635401, differs from other compressors applied by DAF. “The main part of the compressor is the crank case with flange. Two separate cylinders which are slightly tapered at the lower end of the outside cirumference, are entered into this flange. The cylinder head is placed fon top of the evlinders. Six long studs through the Crank case flange extend to the eylinder head. The cylinders are clamped between crank case and cylinder head by serewing on these studs nuts, which are partly countersunk in the cylinder head The crankshett is supported in three bushes, two at the front end and one at the rear. Each of the pistons thas one il scraper ring and four compression rings, installed in pairs in two piston ring grooves. The valves are located in the cylindor head, the valve ‘seats have boon pressed into the cylinder head. Inlet valve and inlet valve spring are kept in position by valve holder which has been pressed into the cylinder head. In the case of the prossure valve there is a plug to keep valve, valve guide and valve spring in position, The compressor is connected 10 the lubricating oi! Circuit of the engine. The crankshaft bearings are pressureubricated, cylinder walls and gudgeon pins hhave splash- lubrication, Oversize eylinders and pistons are not available, so that in caso of axcessive wear renewal is required MAINTENANCE The compressor should be inspected at the intervals proscribed in the Msintenance Books. Apart from the Usual inspection for any leaks, the eylinder head nuts should be retightened and the pressure valves checked (On the outcome of this check depends whether there is required a completa inspection. Whon the air compressor output is insufficient this may be due to the valves or to eylinder wear. To find out proceed as follows: ~ Disconnect pressure line {com compressor. — Let the compressor operate for a certain time until ‘operating temperature has been reached. — Hold during 10 seconds a piece of white cardboard at abt. 5 om from the presture outlet: a large oil stain is indicative of excessive cylinder wear, A ‘areasy deposit on the cardboard is to be considered as normal, — Reconnect the pressure line and let the compressor ‘tun until operating pressure has been reached, — Let the engine run at idling speed. — Disconnect air suction line and hold your hand in front of the air inlet: an air stream on your hand is indicative of a leaking intake valve. AcBea0DAF Diesel DD 575, DF 615, DT 615 6-80 Workshop manual SPECIFICATIONS General Make Modet Type Bore Stroke Swept volume Capacity Operating speed Operating pressure Max. permissible ovality Max. permissible taper Max. permissible gudgeon pin play in control bushing ‘Compression ring gap Oil scraper ring gap) Max. permissible ovality Alter pressing in, line-bore bearing bushes to a bearing play of End play Tightening torques Cylinder head nuts Intake valve holder Pressure valve seat Pressure valve plug Conrod bearing cap bolts Bottom cover bolts COMPRESSOR Clayton-Dewandre PCGA 918, DAF no. 635401 two cylinders, aircooled 57.15mm 50.80 mm 250 cc 256 litres/min, 4300 rp. 8 bar (8 kgiem2) 0.038 mm 0.127 mm 0.038 mmm 0.076 - 0.381 mm 0.254 - 0.558 mm 0.038 mm 0.025 mm 00.330 mm 22.Nm (2.2 mig) 41-47 Nm (4.2 - 4.8 mkal 7-11, Nm (0.71.4 mkg) 88 Nm (9 mks) 14. 16.Nm (1.4 «1.6 mig) 14.Nm (1.4 mia) hems numbers cortespond AB with the legend on page 1 22 Shin vectonsINSTRUCTIONS FOR REPAIR Cylinder head overhaul ‘The construction of the eylinder head attachment enables to take off the cylinder head without removing the compressor from the engine. = Take off all compressor connections. = Mark eylinder head and cylinders to ensure that at re-essembly everything is installed ot the right place. Unscrew cylinder head nuts. Use 2 soft tipped hammer to tap on the cylinder head, meanwhile firmly hold cylinders to prevent ‘them from coming off which would cause damage 10 their sealing rings = Take off cylinder heed. Screw two 1/4"-bolts into inlet valve holder. Grip these bolts between the jaws of a vice and take off the holder by softly tapping against the cylinder head, = Remove the valve seats, for instance with an inside puller; if required, tho cylinder head may be heated to max. 150 °C. — Thoroughly clean the cylinder head, Intake valve — When pressing the intake-valve seat into the cylinder head, the flat side should rest an the cylinder head! — Install valve, valve spring and supporting ring. = Pross spring guide into cylinder head until ir butts, = Lock the spring guide in position by three punch. strokes in the ¢ylinder head edge. Pressure valve — Press prossure valve seat into cylinder head in such ‘amanner that the flat side rests against the head, = Install valve guide so that itis clamped in the Cylinder head. Place vaive on valve seat and install, the spring. — Fit sealing ring on plug and tighten the plug to the prescribed torque, Cylinder head — Install head gaskets on cylinders. = Place cylinder head on cylinders, paying due attention to marks made at dismantling = Tighten cylinder head nuts to the pre«rribed torave. Cylinder and piston overhaul Dependent on the place of the compressor on the engine, cylinders, pistons and connecting rods can be renewed without removing the engine crankcase, Dismantling Note: If i is expected that not all parts need renewal, the following marks should be made before dismantling Cylinder head relative to cylinders; cylinders relative to crankcase; pistons relative to crankcase: pistons relative to connecting rods; connecting rods relative to crankcase, — Remove bottom cover. = Remove cylinder head, see above = Separate cylinders from their sealing rings in the crankcase by tapping ~ Withdraw cylinders from crankcase, taking care not to damage pistons. — Remove connecting rod bearing caps and take out Connecting rods with pistons on the upper side of the erankease Cleaning and inspection ~ Pay special attention to carefully cleaning the ‘oylindr seats on the Flange of the erankcase. = Measure internal dia. of cylinders. Incase the maximum permissible ovality and/or taper are ‘exceeded, the cylinder should be renewed. Likewise, cylinders which are scored should be renewed, = Measure play of gudgeon pin. In case the maximum permissible play is exceeded, renew connecting rod. Re-assembly Note: Don’t forget any marks on the various parts! Instat pistons and connecting rods. = Check piston ring caps. = Install rings on pistons. 2, The four compression rings are fitted in pairs into the two grooves; tho recesses in the rings should be on top (this side is marked as such by the indication TOP"). be, The ring gaps must not be in fine and none of ‘the gaps must be positioned straight under the gudgeon pin. — Remove one of the central cylinder head studs {if the compressor has not been removed from the engine this should be the central stud at the front sido); this will faclitare subsequent assembly operations — Install pistons and connecting rods in the cylinders. = Insta eylinders with pistons and connecting rods in crankcase, use new sealing «ings. Fit connecting rods on crankshaft; preferably use new connecting rod bearing shells. — Install bottom cover, stud and cylinder head ‘Complete overhaul ‘A complete overhaul includes, apart from an overhaul ‘of cylinder head, pistons and connecting rods, aso ‘overhaul of the crankshaft and its bearing, Dismantiing = Take of cylinder head, cylinders, pistons and connecting rods (see above) = Mark position of erankehatt and rear cover in relation to the crankcase. = Remove rear cover Remove crankshaft from crankcase by tapping on the front side. = Remove oil seal and, if required, bearing bushes. amDAF Diesel DD 575, DF 615, DT 615, 6-80 5 Workshop manual COMPRESSOR 1. Compressor 2. Spring retainer 3. Soring 4, Sealing ring 5.109 6.Pin 7. Valve guide £8. Spring wather 9 Vale 10. Washer 11. Girtip 12. Vane seat 18. Sealing ring 14. Screw 18. Spring washer 16. Plug 17. Seating ting 18. Cylinder head 19, Sealing ving 20. Valve seat 27. 08ing 28 serew 29, Spring washer 20. Cover 31. Ont sot 32. Bat bearing 238. Crankanatt 52. Cylinder block 54. Gancoe $55, Celio 88. Gudgeon pin $2. Sco WATER-COOLED COMPRESSOR , 59, Compression ring Type €9 K2 142 eae 60. Plug DAF no, 245942 61. Selig vingInspection Inspect crankshaft bearing journals: any damage and/or ovality exceeding the maximum permissible value cals for renewal Re-assembly = ter pressing-in, the new bearing bushes should be line-bored to a value which aives a bearing Clearance of 0.025 mm, Install oil seal, the lip facing the crankcase inside. Install crankshaft. ‘Check crankshaft axial play. Complete re-assembly (see above).