DAF 95XF. Manual - part 409

4

XF ENGINE BRAKE

Inspection and adjustment

95

XF series

3-4

3.3

INSPECTION AND ADJUSTMENT OF ENGINE STOP/EXHAUST BRAKE

Inspecting the engine stop/exhaust brake
1.

Switch on the vehicle contact.

2.

Note:
After deactivation of the vehicle contact, the
operating cylinders will be activated for a
certain time (for duration see CTE systems
manual).

Switch off the vehicle contact and visually
check whether the operating cylinders of the
stop control and the butterfly valve are
being operated.

Setting the engine stop
1.

Release the lock nut of the stop bolt (A) and
turn in the stop bolt several turns.

2.

Move the stop lever (B) to the stop position
until it makes contact internally in the
regulator housing.

3.

Turn the stop bolt (A) out again until it
makes contact with the stop lever (B) ball
head.

4.

Turn the stop bolt (A) out another 1 mm,
or 2 full turns, and fasten the counter nut.

Adjusting the exhaust brake
1.

Release the ball head of the butterfly valve
control lever.

2.

Open the butterfly valve fully (engine brake
inactive), indicated by the mark (1) on the
butterfly valve shaft.

3.

Set the length of the piston rod (2) making
sure that without air pressure, a pre-stress
is present of 1 to 2 mm.

4.

Use air pressure to check the exhaust brake
for smooth operation.

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95

XF series

Removal and installation

XF ENGINE BRAKE

4-1

4.  REMOVAL AND INSTALLATION

4.1

REMOVAL AND INSTALLATION OF DEB

Make sure that the spring plate (5)
under the main piston (4) is not
damaged or deformed.
When the DEB is in operation, this
spring plate, if it is damaged or
disformed, can break off and result
in serious damage to the engine.

When the engine is or parts thereof
are opened, it is possible for dirt to
penetrate which can result in
serious damage to the engine. You
should therefore clean the engine
before opening it.

Removing the DEB
1.

Remove the valve covers.

2.

Disconnect the electrical connections and
remove the wiring harness from its housing.

3.

Remove the DEB fixing bolts and the entire
DEB.

Installing the DEB
1.

Tighten the rocker bracket fixing bolts to the
specified torque, see main group “Technical
data”.

2.

Note:
Note that there are two different DEB
housings for cylinders 1 to 3, and
cylinders 4 to 6, indicated on the DEB
housing.

Place the DEB on the rocker brackets

3.

Insert the DEB fixing bolts and tighten them
to the specified tightening torque, see main
group “Technical data”.

4.

Attach the electrical connections.

5.

Adjust the valve clearance.

6.

Set the DEB clearance, see chapter
“Inspection and adjustment”.

7.

Fit the valve covers.

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4

XF ENGINE BRAKE

Removal and installation

95

XF series

4-2

4.2

REMOVAL AND INSTALLATION OF DEB SPRING PLATE

Removing the DEB spring plate
1.

Remove the DEB.

2.

Remove the spring plate (5) with shim and
fixing bolt.

Installing the DEB spring plate
1.

Note:
To prevent the spring plate from being
damaged or broken, it should be positioned
very carefully.

Use the special tool (DAF no. 1329321) to
position the spring plate (5) onto the main
piston (4).

2.

Note:
To prevent the spring from breaking, the
lock washer should be positioned against
the spring plate with its rounded edge. As
from mid-1997, the vehicles are equipped
with a lock washer with two rounded edges.

Install the washer with fixing bolt and tighten
it to the specified tightening torque, see
main group “Technical data”.

3.

Install the DEB.

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95

XF series

Removal and installation

XF ENGINE BRAKE

4-3

4.3

REMOVAL AND INSTALLATION OF EXHAUST BRAKE

Removing the exhaust brake
1.

Disconnect the air supply connector (1)
from the operating cylinder.

2.

Remove the four fixing bolts (2) holding the
butterfly valve housing between the exhaust
pipes.

3.

Remove the flexible exhaust pipe (3).

4.

Remove the entire exhaust brake (4).

Installing the exhaust brake
1.

Check the butterfly valve for smooth
operation.

2.

Check the sealing faces of the butterfly
valve housing and the exhaust pipes.

3.

Clean the fixing bolts and apply
heat-resistant grease to the threads.

4.

Install the four fixing bolts and the exhaust
brake.

5.

Install the flexible exhaust pipe.

6.

Tighten the fixing bolts evenly.

7.

Check the setting of the exhaust brake.
See “Inspection and adjustment”.

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