New Holland TK80MA Tractor Service Repair Manual by u1yiuef6

TK75VA,TK80A,TK80MA, TK90A,TK90MA,TK100A REPAIRMANUAL COMPLETECONTENTS

SECTION00-GENERAL2 ............................................

SECTION10-ENGINE3 ..............................................

SECTION18-CLUTCH6 ..............................................

SECTION21-TRANSMISSIONS7 .....................................

SECTION27-REARMECHANICALDRIVE7 ............................

SECTION31-MECHANICALPOWERTAKE-OFF9 ......................

SECTION33-BRAKINGSYSTEM10 ....................................

SECTION35-HYDRAULICSYSTEMS11 ................................

SECTION46-STEERINGCLUTCHES13 ................................

SECTION48-SUSPENSIONANDTRACKS14 ...........................

SECTION55-ELECTRICALSYSTEM15 .................................

Thefollowingpagesarethecollationofthecontentspagesfromeachsectionand chapteroftheTKASeriesRepairmanual.CompleteRepairpart#87582124.

ThesectionsusedthroughoutallNewHollandproductRepairmanualsmaynotbe usedforeachproduct.EachRepairmanualwillbemadeupofoneorseveralbooks. EachbookwillbelabeledastowhichsectionsareintheoverallRepairmanualand whichsectionsareineachbook.

ThesectionslistedabovearethesectionsutilizedfortheTKASeriesTractors.

SECTION00--GENERAL--CHAPTER1 00-1 SECTION00--GENERAL Chapter1--General CONTENTS SectionDescription Page GeneralInstructions2 ImportantNotice2 ............................................................ Shimming 2 RotatingShaftSeals2 ........................................................ O-Rings 2 Sealers 2 .................................................................... Bearings 2 SpringPins 2 ................................................................ PrecautionaryNotice3 EquipmentNotice3 ........................................................... SparePartsNotice3 GeneralNotices3 ............................................................ HealthandSafety4 HealthandSafetyPrecautions4 GeneralWorkshopToolsandEquipment10 LegalAspects10 LubricantsandGreases10 PrecautionaryStatements11 PersonalSafety 11 MachineSafety 11 Safety 12 ...................................................................... TheTractor 12 DrivingtheTractor12 ........................................................ OperatingtheTractor12 OperatingthePTO13 ........................................................ ServicingtheTractor13 DieselFuel 14 .............................................................. ROPS 14 EcologyandtheEnvironment15 .................................................. TighteningTorques16 FederalEmissionsWarranty18 ................................................... CaliforniaEmissionControlWarrantyStatement19 Lubricants 21 ...............................................................

GENERALINSTRUCTIONS

WARNING

Allmaintenanceandrepairworkdescribedin thismanualmustbeperformedexclusivelyby NEWHOLLANDservicetechniciansinstrict accordancewiththeinstructionsgivenand usinganyspecifictoolsnecessary.

WARNING

Anyonewhoperformstheoperationsdescribed hereinwithoutstrictlyfollowingtheinstructions ispersonallyresponsibleforresultinginjuryor damagetoproperty.

WARNING

TheManufacturerandallorganizationsbelongingtotheManufacturerísdistributionnetwork, includingbutnotrestrictedtonational,regional orlocaldistributors,willacceptnoresponsibility forpersonalinjuryordamagetopropertycaused byabnormalfunctionofpartsand/orcomponentsnotapprovedbytheManufacturer, includingthoseusedformaintenanceand/or repairoftheproductmanufacturedormarketed bytheManufacturer.Inanycase,theproduct manufacturedormarketedbytheManufacturer iscoveredbynoguaranteeofanykindagainst personalinjuryordamagetopropertycausedby abnormalfunctionofpartsand/orcomponents notapprovedbytheManufacturer.

IMPORTANTNOTICE

Allmaintenanceandrepairoperationsdescribedin thismanualshouldbecarriedoutexclusivelybythe authorizedworkshops.Allinstructionsdetailed shouldbecarefullyobservedandspecialequipment indicatedshouldbeusedifnecessary.

Everyonewhocarriesoutserviceoperationsdescribed withoutcarefullyobservingtheseprescriptionswillbe directlyresponsibleofderivingdamages.

SHIMMING

Ateachadjustment,selectadjustingshims,measure themindividuallyusingamicrometerandthensum uprecordedvalues.Donotrelyonmeasuringthe wholeshimmingset,whichmaybeincorrect,oron theratedvalueindicatedforeachshim.

ROTATINGSHAFTSEALS

Tocorrectlyinstallrotatingshaftseals,observethe followinginstructions:

• Letthesealsoakintothesameoilasitwillseal foratleasthalfanhourbeforemounting.

• Thoroughlycleantheshaftandensurethatthe shaftworkingsurfaceisnotdamaged.

• Placethesealingliptowardsthefluid.Incaseof ahydrodynamiclip,considertheshaftrotation directionandorientgroovesinorderthatthey deviatethefluidtowardstheinnersideofthe seal.

• Coatthesealinglipwithathinlayeroflubricant (oilratherthangrease)andfillthegapbetween thesealinglipandthedustlipofdoublelipseals withgrease.

• Insertthesealintoitsseatandpressitdown usingaflatpunch.Donottapthesealwitha hammeroradrift.

• Takecaretoinsertthesealperpendicularlytoits seatwhileyouarepressingit.Oncethesealis settled,ensurethatitcontactsthethrustelement, ifrequired.

• Topreventdamagingthesealinglipagainstthe shaft,placeasuitableprotectionduring installation.

O-RINGS

LubricatetheO-ringsbeforeinsertingthemintotheir seats.ThiswillpreventtheO-ringsfromrolloverand twistingduringmounting,whichwilljeopardize sealing.

SEALERS

Applysilicone/gasketeliminatoroverthemating surfacesmarkedwithanX.

Beforeapplyingthesealer,preparethesurfaceas follows:

• Removepossiblescalesusingametalbrush.

• Thoroughlydegreasethesurfacesusingoneof thefollowingcleaningagents:trichlorethylene, dieselfuelorawaterandsodasolution.

BEARINGS

Itisadvisabletoheatthebearingsto80° to90°C (176° to194°F)beforemountingthemontheirshafts andcoolthemdownbeforeinsertingthemintotheir seatswithexternaltapping.

SPRINGPINS

Whenmountingsplitsocketspringpins,ensurethat thepinnotchisorientedinthedirectionoftheeffort tostressthepin.

Spiralspringpinsshouldnotbeorientedduring installation.

SECTION00--GENERAL--CHAPTER1 00-2

Manyoftheproceduresassociatedwithvehicle maintenanceandrepairinvolvephysicalhazardsor otherriskstohealth.Thissectionlists,alphabetically, someofthesehazardousoperationsandthe materialsandequipmentassociatedwiththem.The precautionsnecessarytoavoidthesehazardsare identified.

SECTION00--GENERAL--CHAPTER1 00-4 HEALTHANDSAFETY CONTENTS Description Page HEALTHANDSAFETYPRECAUTIONS5 ACIDSANDALKALIS 6 ......................................................................... ADHESIVESANDSEALERS--seeFire6 ANTIFREEZE--seeFire,Solventse.g.Isopropanol,EthyleneGlycol,Methanol6 ....................... ARCWELDING--seeWelding 7 BATTERYACIDS--seeAcidsandAlkalis7 ........................................................ BRAKEANDCLUTCHFLUIDS(PolyalkyleneGlycols)--seeFire7 BRAZING--seeWelding 7 ...................................................................... CHEMICALMATERIALS--GENERAL--seeLegalAspects7 DOíS 7 DONOTS 8 ................................................................................... CORROSIONPROTECTIONMATERIALS--seeSolvents,Fire8 DUSTS 8 ..................................................................................... ELECTRICSHOCK 8 EXHAUSTFUMES 9 ........................................................................... FIBERINSULATION--seeDusts 9 FIRE--seeWelding,Foams,LegalAspects9 ...................................................... FIRSTAID 9 FOAMS--Polyurethane--seeFire9 .............................................................. FUELS--seeFire,LegalAspects,Chemicals--General,Solvents10 GASCYLINDERS--seeFire 10 ................................................................. GENERALWORKSHOPTOOLSANDEQUIPMENT11 LEGALASPECTS 11 LUBRICANTSANDGREASES 11 HEALTHANDSAFETYPRECAUTIONS

Thelistisnotexhaustiveandalloperationsand proceduresandthehandlingofmaterials,shouldbe carriedoutwithhealthandsafetyinmind.

ACIDSANDALKALIS seeBatteryacids,e.g. causticsoda,sulfuricacid.

Usedinbatteriesandcleaningmaterials.

Irritantandcorrosivetotheskin,eyes,noseand throat.Causesburns.

Avoidsplashestotheskin,eyesandclothing.Wear suitableprotectiveglovesandgoggles.Candestroy ordinaryprotectiveclothing.Donotbreathemists.

Ensureaccesstowaterandsoapisreadilyavailable forsplashingaccidents.

ADHESIVESANDSEALERS seeFire

HighlyFlammable,Flammable,combustible.

GenerallyshouldbestoredinìNoSmokingîareas; cleanlinessandtidinessinuseshouldbeobserved, e.g.disposablepapercoveringbenches;shouldbe dispensedfromapplicatorswherepossible;containers,includingsecondarycontainers,shouldbe labelled.

SolventbasedAdhesives/Sealers --SeeSolvents.

Followmanufacturersinstructions.

WaterbasedAdhesives/Sealers

Thosebasedonpolymeremulsionsandrubber latticesmaycontainsmallamountsofvolatiletoxic andharmfulchemicals.Skinandeyecontactshould beavoidedandadequateventilationprovidedduring use.

Followmanufacturersinstructions.

ResinbasedAdhesives/Sealers --e.g.epoxide andformaldehyderesinbased.

Mixingshouldonlybecarriedoutinwellventilated areasasharmfulortoxicvolatilechemicalsmaybe released.

Skincontactwithuncuredresinsandhardenerscan resultinirritation;dermatitisandabsorptionoftoxic orharmfulchemicalsthroughtheskin.Splashescan damagetheeyes.

Provideadequateventilationandavoidskinandeye contact.Followmanufacturersinstructions.

Anaerobic,CyanoacrylateandotherAcrylic Adhesives

Manyareirritant,sensitizingorharmfultotheskin. Someareeyeirritants.

Skinandeyecontactshouldbeavoidedandthe manufacturersinstructionsfollowed.

Cyanoacrylateadhesives(superglues)mustnot contacttheskinoreyes.Ifskinoreyetissueis bonded,coverwithacleanmoistpadandget medicalattention.Donotattempttopulltissueapart. Useinwellventilatedareasasvaporscancause irritationofthenoseandeyes.

Fortwo-packsystems,seeResinbased adhesives/ sealers.

Isocyanate(Polyurethane)Adhesives/ Sealers -- seeResinbasedAdhesives.

Individualssufferingfromasthmaorrespiratory allergiesshouldnotworkwithornearthesematerials assensitivityreactionscanoccur.

Anysprayingshouldpreferablybecarriedoutin exhaustventilatedbooths,removingvaporsand spraydropletsfromthebreathingzone.Individuals workingwithsprayapplicationsshouldwear suppliedairrespirators.

ANTIFREEZE -- seeFire,Solventse.g. Isopropanol,EthyleneGlycol,Methanol.

HighlyFlammable,Flammable,Combustible.

Usedinvehiclecoolantsystems,brakeairpressure systems,screenwashsolutions.

Vaporsgivenofffromcoolantantifreeze(glycol)arise onlywhenheated.

Antifreezemaybeabsorbedthroughtheskinintoxic orharmfulquantities.Antifreezeifswallowedisfatal andmedicalattentionmustbefoundimmediately.

SECTION00--GENERAL--CHAPTER1 00-5

ARCWELDING seeWelding.

BATTERYACIDS seeAcidsandAlkalis. Gasesreleasedduringchargingareexplosive. Neverusenakedflamesorallowsparksnear chargingorrecentlychargedbatteries.

BRAKEANDCLUTCHFLUIDS (PolyalkyleneGlycols) seeFire. Combustible.

Splashestotheskinandeyesareslightlyirritating. Avoidskinandeyecontactasfaraspossible. Inhalationofvaporshazardsdonotariseatambient temperaturesbecauseoftheverylowvapors pressure.

BRAZING seeWelding.

CHEMICALMATERIALS--GENERAL see LegalAspects.

Chemicalmaterialssuchassolvents,sealers, adhesives,paints,resinfoams,batteryacids, antifreeze,brakefluids,oilsandgreaseshould alwaysbeusedwithcautionandstoredandhandled withcare.Theymaybetoxic,harmful,corrosive, irritantorhighlyinflammableandgiveriseto hazardousfumesanddusts.

Theeffectsofexcessiveexposuretochemicalsmay beimmediateordelayed;brieflyexperiencedor permanent;cumulative;superficial;lifethreatening; ormayreducelife-expectancy.

DOíS

Do removechemicalmaterialsfromtheskinand clothingassoonaspracticableaftersoiling.Change heavilysoiledclothingandhaveitcleaned.

Do carefullyreadandobservehazardand precautionwarningsgivenonmaterialcontainers (labels)andinanyaccompanyingleaflets,posteror otherinstructions.Materialhealthandsafetydata sheetscanbeobtainedfromManufacturers.

Do organizeworkpracticesandwearprotective clothingtoavoidirritationoftheskinandeyes; breathingvapors/aerosols/dusts/fumes;inadequate containerlabelling;fireandexplosionhazards.

Do washbeforejobbreaks;beforeeating,smoking, drinkingorusingtoiletfacilitieswhenhandling chemicalmaterials.

Do keepworkareasclean,unclutteredandfreeof spills.

Do storeaccordingtonationalandlocalregulations. Do keepchemicalmaterialsoutofreachofchildren.

SECTION00--GENERAL--CHAPTER1 00-6

MountingtheBalancingDevicewithCounter-rotatingWeights54 ...............

MountingtheTappetsandDriveShaftWithMainBearingCaps, BearingsandThrustRings55

MountingtheRearCoverWithSealandEngineFlywheel57

SealInstallation59

MountingthePistonsCompleteWithRings,Pins,Connecting Rods,BigEndCapsandBearings--CheckingProtrusionIn RelationToCylinderBlockFace60 .........................................

SynchronizingtheTimingGears61

InstallingtheCounter-rotatingWeightBoxtotheOilSump62 ..................

InstallingtheBoschInjectionPump63

InstallingtheCylinderHeadGasket64 ......................................

InstallingandTighteningtheCylinderHead64

Valve/RockerArmClearanceAdjustment65 ................................

InstallingFuelInjectors65

CoolingSystemBeltTensionAdjustment65

Checks,MeasurementsandRepairsofComponents66

CylinderBlock66

SECTION10--ENGINE--CHAPTER1 10-1 SECTION10--ENGINE Chapter1--Engine CONTENTS SectionDescription Page Specifications 4 TighteningTorques24 SpecialTools 26 EngineCoolingSystemDiagram30 Troubleshooting 31 .............................................................. EngineOverhaul35 Engine 35 .................................................................. Removal35 Installation38 ............................................................ CompressionTest39 Disassembly40 .......................................................... Assembly54

SECTION10--ENGINE--CHAPTER1 10-2 SectionDescription Page Crankshaft,MainBearingsandFlywheel68 Crankshaft68 Bearings70 Flywheel71 ConnectingRods72 ......................................................... Pistons 73 Camshaft,TappetsandValves76 .............................................. Valves 76 Tappets 76 .............................................................. Camshaft77 CylinderHead79 ............................................................ ValveGuides80 ValveSeatsInCylinderHead83 ............................................... InjectorSleeves84 CylinderHeadBolts85 .................................................... CounterweightBalancer86 LubricationSystemMaintenance87 ............................................ EngineOilPumpServicing87 LowOilPressureIndicator88 CoolingSystemMaintenance88 RadiatorServicing88 TestingCoolingSystemThermometer89 ReplacingtheThermostat89 DriveBeltsTensionAdjustment89 .......................................... Radiator 90 Removal90 ............................................................. Installation92 CrankshaftFrontOilSeal93 .................................................. Removal93 Installation96 ............................................................ Valve--RockerArmClearance97 RearFuelTank100 .......................................................... Removal100 Installation102 ........................................................... FrontFuelTank103 Removal103 Installation104

SECTION10--ENGINE--CHAPTER1 10-3 SectionDescription Page Injectors 105 Removal105 Installation106 BoschInjectionPump107 Removal107 ............................................................ Installation111 Timing 112 .............................................................. AirBleeding114 TimingInjectionPumpOfftheTractor115 ................................... InstallingtheInjectionPumpOntotheEngine120 TurbochargedDieselEngine-TK75VA,TK90A,TK90MA,TK100AModels121 ExhaustPipe124 ............................................................ Removal124 Installation124 ........................................................... CoolantPump125 Removal125 Installation126 ........................................................... Disassembly127 Assembly127 ........................................................... ThermostaticValve128 Removal128 ............................................................ Installation129 CoolantPumpandAlternatorDriveBelt130 ..................................... TensionAdjustment130

SPECIFICATIONS

Engine,type:

--ModelsTK75VA 8035.25.921

--ModelsTK80A,TK80MA .............................. 8045.05R.921

--ModelsTK90A,TK90MA .............................. 8045.25.921

--ModelsTK100A ...................................... 8045.25L.921

Cycle.................................................. diesel,4-stroke

Fuelinjection........................................... direct

Numberofcylindersinline

--ModelsTK75VA ...................................... 3

--ModelsTK80A,TK80MA,TK90A,TK90MA,TK100A ...... 4

Pistondiameter......................................... 104mm(4.0944in)

Pistonstroke............................................ 115mm(4.5275in)

Totaldisplacement:

--ModelsTK75VA 2931cm3 (179cuin)

--ModelsTK80A,TK80MA .............................. 3908cm3 (238cuin)

--ModelsTK90A,TK90MA .............................. 3908cm3 (238cuin)

--ModelsTK100A ...................................... 3908cm3 (238cuin)

Compressionratio:

--ModelsTK80A,TK80MA .............................. 17:1naturallyaspirated

--ModelsTK75VA,TK90A,TK90MA,TK100A

--ModelsTK80A,TK80MA

--ModelsTK100A

--ModelsTK75VA

--ModelsTK80A,TK80MA

--ModelsTK90A,TK90MA

--ModelsTK100A

Maximumtorquespeed

--ModelsTK80A,TK80MA

--ModelsTK90A,TK90MA

SECTION10--ENGINE--CHAPTER1 10-4

............. 16.5:1turbocharged

...................................... 55.5kw(net76hp)

Maximumpower: --ModelsTK75VA

.............................. 58.5kw(net80hp)

.............................. 65.5kw(net90hp)

--ModelsTK90A,TK90MA

...................................... 69kw(net94hp)

Maximumpowerspeed

...................................... 2300rpm

.............................. 2500rpm

2500rpm

1400rpm

--ModelsTK75VA ......................................

.............................. 1500rpm

1500rpm

................................. 5 Sumppan.............................................. structural,castiron

--ModelsTK100A

Numberofmainbearings

Lubricationsystem forced,withgearpump

1st50hr(Break-inEngineOil)........................... 10W-40--APISE/CC10W-40

After50hr(AMBRASUPERGOLDEngineOil)............. 15W-40--PremiumMulti-gradeNH330G

Pumpdrive............................................ camshaft

Enginespeed/oilpumpspeedratio 2:1

Oilcleaning meshscreenonoilpick--upandfilter cartridgeindeliveryline

Normaloilpressure,warmenginerunningatmaxspeed

TK75VA............................................... ≥ 2bar(29psi)

TK80A,TK80MA....................................... 2.9to3.9bar(42to56psi)

TK90A,TK90MA....................................... ≥ 2bar(29psi)

TK100A ≥ 4bar(58psi)

Pressurereliefvalve.................................... builtintopumphousing

Valveopeningpressure 3.5bar(50.8psi)

Coolingsystem ....................................... watercirculation

Radiator............................................... 4-rowverticalpipeswithcopperfins

Fan,attachedtocoolantpumppulley...................... 4-bladeinsheetmetal

Coolantpump.......................................... centrifugalvane-type

Enginespeed/coolantpumpspeedratio 1:1.403

Temperaturecontrol.................................... thermostat

Coolantthermometer................................... coloredscaledividedinto3sections

Temperaturerangescorrespondingtoeachsection:

--initialwhitesection.................................. 30o to65oC(86o to149oF)

--middlegreensection(normalworkingconditions) 65o to105oC(149o to221oF)

--finalredsection.................................... 105o to115oC(221o to239oF)

Revcounter/hourmeter ................................ incorporatedincontrolpanel

Operatingsystem ....................................... fromgearoncamshaft

Hourcountercalibratedforenginespeedof 1800rpm (continued)

SECTION10--ENGINE--CHAPTER1 10-5

ENGINE

Removal

DANGER

Liftandhandleallheavypartsusingsuitable liftingequipment.

Makesurethatassembliesorpartsare supportedbymeansofsuitableslingsand hooks.Makesurethatnooneisstandinginthe vicinityoftheloadtobelifted.

CAUTION

Alwaysuseappropriatetoolstoalignfixing holes.NEVERUSEYOURFINGERSORHANDS.

1.Carryoutoperationforclutchremoval.

2.Removetherubberheatguard,2,fromthe support,1.

SECTION10--ENGINE--CHAPTER1 10-35

ENGINEOVERHAUL

3.Removetheretainingbolts,1,andthesupport, 2.

SECTION10--ENGINE--CHAPTER1 10-36

4.Removetheretainingboltsandtherightand left-handenginesideguards. 5.Placeacontainerforthecoolantunderthe sleeve,1.

6.Detachthesleeve,1,onthelowerpipeanddrain offthecoolant. 7.Detachthesleeve,1,ontheradiatorupper piping.

8.Removetheretainingboltsandtheradiator uppersupport,2.

9.Removethepiping,1,andthesleeve,2,located onthelowerpartofthetank.

SECTION10--ENGINE--CHAPTER1 10-37

10.Removethepiping,1,and,2,locatedonthe upperpartofthetank.

11.Detachtheoilvaporbreatherpipes,1,andthe turbochargerfeedpiping,2,asapplicable.

12.Removethetowbarhook,1,andthefront ballast,2.

13.Hitchthefrontsuspension,1,toahoist.Remove thesuspensionretainingpin,2,onthesupport, 3,andremovethefrontsuspension.

14.Hitchthefrontsuspensionsupport,3,toahoist, removethesumpretainingboltsandremovethe support.

Installation

Toinstalltheengine,proceedasfollows:

CAUTION

Alwaysuseappropriatetoolstoalignfixing holes.NEVERUSEYOURFINGERSORHANDS. 16

1.Applythetorquesettingslistedinthetorque table.

2.Hitchthefrontsuspensionsupporttoahoistand installtothesump,securinginpositionwiththe retainingbolts.

3.Hitchthefrontsuspensiontoahoist.Installon thesupportandassemblethesuspension retainingpin.

4.Installthefrontballastandtowbar.

5.Installtheoilvaporrecoverypipingandthe turbochargerfeedpiping(whereremoved).

6.Installthepipingontheupperpartofthetank.

7.Installthepipingandsleevelocatedonthelower partofthetank.

8.Installtheuppertanksupportandtightenthe retainingbolts.

9.Installtheradiatorupperpipingsleeve.

10.Installtheradiatorlowerpipingsleeve.

11.Fillupwithcoolant.

12.Installtheenginesideguardsandretainingbolts.

13.Assembletherollbarsupportandretainingbolts.

14.Installtherubberheatguardonthesupport.

15.Carryouttherelativeclutchassembly operations.

16.Bleedthefuelsystemofairasdescribedinthis section.

SECTION10--ENGINE--CHAPTER1 10-38

CompressionTest

Incaseofpoorengineperformance,inadditionto checkingthefuelinjectionsystem(injectionnozzles andinjectionpump),alsotestthecompressionon eachcylinder.

DANGER

Donotusematches,lighters,blowtorchesorany formofnakedflameasasourceoflightwhen inspectingtheengineduetothepresenceof inflammablefluidsandvapor.

Compressionratio

Thecompressionratioisameasureofthequantity ofairdrawnintothecylinder,andprovidesan indicationoftheefficiencyofthesealingelementsin thecylinder(pistonringsandvalves).

Uniformcompressioninallthecylindersensuresthat theyallperformanequalamountofwork,provided thateachcylinderisinjectedwiththesamequantity offuelattherighttime.

Lowcompressionnotonlyreducesengineperformance,italsocausesincompletefuelcombustion duetothelackofavailablecombustionair.

Theenginethereforegivespoorperformancewith excessivefuelconsumptionand,consequently, exhaustsmokeandrestrictionoftheexhaust passages.

Asthecompressionratio alsovarieswiththe temperatureoftheengine (coldenginesproduce lowercompressionvaluesthanhotengines),the compressionshouldonlybetestedwhentheengine isatnormaloperatingtemperature.

Compressionshouldbetestedusingthecompressiontestkit 380000303, asfollows:

1)runtheengineuntilitreachesnormaloperating temperature;

2)switchofftheengine;

3)disconnecttheleadfromtheenginestop electromagnetontheinjectionpumpinordertoclose thevalve,andblocktheflowoffueltotheinjectors;

4)removetheinjectorfromthecylindertobetested;

5)turntheengineoverafewtimeswiththestarter motorinordertoexpelanycarbonresidue;

6)fitthedummyinjector 380000617 inplaceofthe injectorremovedpreviously,interposingthecopper sealingwasher;

7)connectthecompressiontestinstrument 380000303 andtakereadingswhileturningthe engineoverwiththestartermotor.

Onenginesinperfectworkingorder,withthesump oilatapproximately40 oC(104 oF)atsealevel(760 mm[29.9212in,mercury])andatanenginespeedof 200to280rpm,thecompressionshouldbe25.5to 27.5bar(369.8to398.8psi).

8)Testthecompressionontheothercylinders, repeatingsteps4--5--6--7,bearinginmindthat:

Theminimumpermissiblecompressiononaused engineis21.6bar(313.2psi).

Themaximumpermissiblecompressiondifference betweencylindersis3bar(43.5psi).

Every100meters(109.36yards)abovesealevel correspondstoareductionincompressionby approximately1%.

Considerations:

Uniformcompression

Althoughhighcompressionisimportant,itismore importantforsmoothenginerunningthatcompressionisuniforminallcylinders.

Lowcompressionreadings

Ifextremelylowpressurereadingsareobtainedon onecylinderitisadvisabletorepeatthetest.

Beforetestingthistime,pourapproximatelyone spoonfulofengineoilintothecylinderthroughthe injectorbore.

Turnovertheengineafewtimestodistributetheoil evenlyoverthecylinderwalls,andthenrepeatthe test.

Ifthesecondtestreadingsaresignificantlyhigher, suspectwornpistonrings,out-of-roundordamaged pistons.

Ifthesecondtestreadingsarenothigher,the problemwillbethevalves.

Ontheotherhand,ifthesecondtestreadingshows onlyaslightimprovement,theproblemwillbedueto boththevalvesandtherings.

SECTION10--ENGINE--CHAPTER1 10-39

Disassembly

CAUTION

Handleallpartscarefully. Donotputyourhandsorfingersbetweenparts. Wearsuitablesafetyclothing--safetygoggles, glovesandshoes.

1.Positiontheengineonarotatingstand (380000301)usingbrackets(380000313).Ensuretheengineissecured.

2.Disconnecttheturbochargerlubepipe,1. Removetheturbochargeralongwiththeexhaust manifold,2.

3.Removeretainingnuts,1,and,2,andthebelt tensionadjustmentbracket.

4.Removethealternatorlowerbolt,4.

5.Removethealternator,3,andthebelt,5.

6.Disconnectpiping,2,and5,onthesediment filter.

7.Removetheintakemanifold,1,andsediment filter,3.

8.Disconnectthepipingandremovethemanipulatoroiltank,4,andbracket.

9.Removetheinjectionpump/injectorsunions,6, andpiping.

10.Removethefuelfilter,7,connectionsandpiping.

SECTION10--ENGINE--CHAPTER1 10-40

11.Disconnectpiping,1,and,2,ontheinjection pump.

12.Removetheretainingnuts,3,thatsecurethe pumptothetimingcasingandtheaccesscover, 4,tothegearunit.

13.Removethepumpretainingnutsandgearunit, extractingthegearunitwithtool 380000322; recoverthepumpandtheWoodruffkey.

14.Disconnectthepipingandremovethefuel pump,5.

15.Removetheretainingboltsandthestarter motor,1.

16.Removetheretainingbolts,detachthefan,1, andrelativepulley,2.

17.Removetheoilfilter,3.

SECTION10--ENGINE--CHAPTER1 10-41

18.Detachthepipingandremovethecoolantpump, 1.

19.Removetheretainingboltsandthecoolantpump support,1.

SECTION10--ENGINE--CHAPTER1 10-42

MDC0282B

20.Removetheretainingboltsandthethermostat, 1,togetherwiththesupport.

MDC0284B

21.Detachthemanipulatorcircuitfuelpumppiping, 1and2.

22.Removetheshaftpulley,3,andhub.

23.Disconnectthefeedandsupplypipes,2,fromthe liftpump,1.Removetheliftpumpandthe manipulatorcircuitfuelpump,3.

24.Removetheinjectormountingnuts,the underlyingsphericalwashers,thenthesupports andtheinjectorsthemselves.

25.Removetherockercoverbolts,1,washersand seals,andthentherockercover,2,andits gasket.

SECTION10--ENGINE--CHAPTER1 10-43

25098 2 1 28

380000216

SECTION10--ENGINE--CHAPTER1 10-44

25099 1 2 29

26.Removetherockershaftretainingbolts,2,then removetheentirerockershaftassembly,1.

25100 2 1 30

27.Removethevalvecollets,1,andextractthe pushrods,2. 28.Unscrewthecylinderheadbolts,1,andremove theheadusingahoistandliftinghook

25101 1 31

29.Removethecylinderheadgasket.

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SECTION10--ENGINE--CHAPTER1 10-45

25102 1 2 32

30.Turntheengineupsidedownontherotarystand. Removethesumppanbolts,thesumppan,1, anditsgasket,2. 31.Unscrewtheretainingboltsandremovetheoil pick-uppipe,1,completewiththestrainfilterand seal.

25103 1 2 3 4 33

32.Unscrewtheretainingbolts,2,anddetachthe counterweighthousing,3,bymovingitoutward, removethesleevecoupling,4,andthe housing,3. 33.Unscrewthesumppanretainingbolts,4,and removethesumppanusingahoist,liftinghook 380000216 andliftingchainwitheyeholes.

1 25104 2 3 4 34

34.Removethehalf-gaskets,1,and,3,betweenthe crankcaseandsumppanandthegasket,2, betweenthetiminggearcarrierandsumppan.

NOTE:

NOTE: ForTK75VA,TK90A,TK90MA,andTK100A

SECTION10--ENGINE--CHAPTER1 10-46

35.Removethegasket,1,betweentheflywheel carrierandthesumppan.

1 25105 35

Whenrelocatinggaskets(1,figure35and2, figure34),applyRHODORSILCAF1siliconesealing compoundtothematingsurfaces.

25106 1 36

36.Removetherotatingcounterweightoilseal O-ring,1,installedonthecrankcasemating surface. 37.Unscrewretainingbolts,1,andremovethe completeoilpump.

25107 1 37

modelsseefigure54.

SECTION10--ENGINE--CHAPTER1 10-47

25108 1 2 38

38.Unscrewtheretainingbolts,2,andremovethe crankshaftpulley,1.

25109 1 39

39.Straightenthelocktab,holdthecrankshaft againstrotationandunscrewnut.

25110 1 40

40.Pullthepulleyhuboffthecrankshaftusingtool 380000226,1,andrecovertheWoodruffkey.

SECTION10--ENGINE--CHAPTER1 10-48

25111 1 41

41.Unscrewtheretainingbolt,1,andremovethe timingcoveranditsgasket.

25112 1 42

42.Unscrewtheretainingboltsandremovethelift pumpdrivegearcarrier,1. 43.Removethecirclip,1,andrecoverthethrust washerandtheintermediategear,2.

25113 1 2 43

NOTE: Wheninstallingtheintermediategearsee enginetiminginstructions.

SECTION10--ENGINE--CHAPTER1 10-49

25114 1 44

44.Unscrewtheretainingbolts,1,andremovethe intermediategearjournal.

25115 1 4 3 2 45

45.Unscrewtheretainingbolts,2,andwithdrawthe camshaft,3,completewiththecamshaftgear,1, andtheendplate,4. 46.Removethecirclip,1,andthethrustwasher,and withdrawthegearwithfuelsupplypump camshaft,2,fromtheoppositeside.

25108 1 2 46

NOTE: Thisgeartransmitsdrivetotheinjection pump.Onre-assemblyseetiminginstructions.