This Repairs and Workshop Manual, which accompanies the DAF diesel engines of the 575 and 615 series, is intended for the workshops of our Service organisation. Likewise, these books are available for users who have the required special tools and skillful staff.
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 all 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, who 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)
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 data are missing, it is impossible to guarantee a correct supply.
Final compression pressure: DD575: 25.3-26.3 bar at 300 r.p.m. DF615, DT615: 24.4-26.4 bar at 310 r.p.m.Before starting measuring first ensure that the engine is well at operating temperature
- Remove injection lines
- Remove injector leak -off line
- Remove injectors ( six off )
- Move the fuel handle to ZERO position
- Use for measuring special adapter: 2 -99-535264
- Use Motometer, type 289 D
EXHAUST SMOKE MEASURING
Operations for exhaust smoke measuring, as described below, are based on the use of the Hartridge Mk3 measuring device. Therefore, for explanation of the construction, operating and maintenance of this measuring we may refer to the detailed documentation which accompanies the smokemeter. To provide power supply for the smokemeter use two well-charged 12 volt batteries with a capacity of 90 Ah each or - if need be - one 12 volt battery with a capacity of 180 Ah. 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.
INSTRUCTIONS FOR REPAIR
When renewing a Vee-belt proceed with care and avoid to stretch or distort the new belt. By releasing g the generator it is 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 case two or more Vee-belts are running over the same pulley, all Vee -belts must be replaced simultaneously. After renewing a Vee-belt check the tension already after 2 operating hours or after 60 km and again after 20 operating hours or 600 km. Thereafter check the tension at regular intervals.
Cylinder liner replacement
Pressing in and extracting cylinder liners in preferably 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 lubricant, e.g. Shell grease Nr. S2927A, white lead or, in an emergency, light lubricating oil. Difficulties in pressing in are practically always due to excessive lubrication or due to the presence of remnants of old lubricant.
DAF tool 2-99-535625 can also be used in combi- X nation with standard hydraulic devices, available in the local trade with a working pressure of 30 tonnes (for instance Owatonna Tool Company). V NaV 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 shown on page 5.
After the block has been faced, the recess for the cylinder liner collar should be rectified to its initial value. Grinding off the cylinder liner collar is inadmissible. For measuring the projection of the cylinder liner 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 53.33 - 53.36 mm,
HONING OF CYLINDER LINERS
The quality of the cylinder liner surface is of great importance to a Diesel engine. Honing is the last machining process effected on the liner surface and is used to obtain the following:
- a correct surface roughness: (0.4 — 0.8 Ra) to enable the piston rings to run in on the liner surface, thus bringing about a good sealing and heat emission between piston and liner surface.
- a surface which will hold the lubricant, to ensure that under any circumstance the oil film between piston rings and liner surface is maintained.
- a cross hatch. Such a cross hatch is of utmost importance, too steep or too flat grooves might cause an excessive oil consumption or inadequate lubrication of the liner surface with all its consequences
When renewing the piston rings the liner surface should be honed. Of course it should be checked first whether the liner dimensions fall inside the prescribed tolerances. If not,the liners will have to be renewed too. Preferably DAF honing tools should be used. These are available under the part number 2-99-535948.
DAF Workshop Manual DD DF DT Series For Free