FRONTSEALS
Carefullycheckthemetalrings,makingsurethatthe sealingsurfacesshownosignsofscoring,dentsor wearcausedbyringpairmisalignmentorsurface flatnesserrors.
Evenifonlyoneoftheringsisfaulty,changetheentireseal.
Neverpairausedringwithanewoneorusedifferent pairsofrings.
Tofittheseals,proceedasfollows.
1.Eliminateanysharpedgesorburrandcarefully cleantheseatsfortherubberrings.
2.Thoroughlycleantheringsontheseals.
3.Inserteachmetalring(2)ontherespective rubberring(1),asshowninthedrawing,acting onthepointsindicatedbythearrows.
4.Makesurethatthemetalringisfittedcorrectly, checkingthatmeasurement(A)isconstantonall ofthecircumference.
5.Assembleeachpairofringsintheirrespective seats(1),manuallypositioningtherubberring (asshowninfigure
6.Beforeterminatingassemblyoperations,clean thesealingsurfaces(1)withaclean(notfrayed) clothandpourathincoveringoffluidoiloverthe surfaces.
2 SECTION00--GENERAL--CHAPTER1
603.54.381.00 --05--2001
1
2
3
SPAREPARTS
OnlyuseoriginalNEWHOLLANDsparepartsbearingthelogoshownbelow.
Onlyoriginalsparepartsguaranteethesamequality,durationandsafetyastheyarethesamepartsthatare assembledduringproduction.
Only originalNEWHOLLANDparts canofferthisguarantee. Whenorderingspareparts,alwaysprovidethefollowinginformation:
--vehiclemodel(commercialname)andframenumber;
--enginetypeandnumber;
--partnumberoftheorderedpart,whichcanbefoundintheìMicrofichesîortheìSparePartsCatalogueî,used fororderprocessing.
TOOLS
ThetoolsthatNEWHOLLANDproposeandillustrateinthismanualare:
--specificallyresearchedanddesignedforusewithNEWHOLLANDvehicles;
--essentialforreliablerepairoperations;
--accuratelybuiltandrigorouslytestedsoastoofferefficientandlong--lastingoperation.
Byusingthesetools,repairpersonnelwillbenefitfrom:
--operatinginoptimaltechnicalconditions;
--obtainingthebestresults;
--savingtimeandeffort;
--workinginsafeconditions.
CAUTION
Wearlimitvaluesindicatedforcertainpartsarerecommended,butnotbinding.Thetermsìfrontî,ìrearî,ìright-handîandìleft--handî(whenreferredtodifferentparts)areintendedasseenfromthedrivingpositionwiththe vehicleinthenormaldirectionofmovement.
MOVINGTHETRACTORWITHTHEBATTERYREMOVED
Externalpowersupplycablesshouldonlybeconnectedtotherespectivepositiveandnegativecableterminals, usingefficientclampsthatguaranteeadequateandsecurecontact.
Disconnectallservices(lights,windshieldwipers,etc.)beforestartingthevehicle.
Ifthevehicleelectricalsystemrequireschecking,carryoutoperationswiththepowersupplyconnected;once checkingiscompleted,disconnectallservicesandswitchoffthepowersupplybeforedisconnectingthecables.
SECTION00--GENERAL--CHAPTER1 3
--05--2001
603.54.381.00
4
SAFETYREGULATIONS
WARNINGANDDANGERSYMBOL
Thiswarningsymbolpointsoutimportantmessages concerningyoursafety.
Carefullyreadthefollowingsafetyregulationsand observeadvisedprecautionsinordertoavoidpotentialhazardsandsafeguardyourhealthandsafety.
Inthismanualthesymbolisaccompaniedbythefollowingkey--words:
CAUTION --Warningsconcerningunsuitablerepair operationsthatmayjeopardisethesafetyofService personnel.
DANGER Specificwarningsconcerningpotential hazardsforoperatorsafetyorforotherpersonsdirectlyorindirectlyinvolved.
ACCIDENTPREVENTION
Mostaccidentsorinjuriesthatoccurinworkshops aretheresultofnon--observanceofsimpleandfundamentalsafetyregulations.Forthisreason,IN MOSTCASESTHESEACCIDENTSCANBE AVOIDEDbyforeseeingpossiblecausesandconsequentlyactingwiththenecessarycautionandcare.
Accidentsmayoccurwithalltypesofvehicles,regardlessofhowwellitwasdesignedandbuilt.
Acarefulandjudiciousservicetechnicianisthebest guaranteeagainstaccidents.
Preciseobservanceofthemostbasicsafetyruleis normallysufficienttoavoidmanyseriousaccidents.
DANGER. Nevercarryoutanycleaning,lubrication ormaintenanceoperationswhentheengineisrunning.
SAFETYREGULATIONS
GENERALGUIDELINES
--Carefullyfollowspecifiedrepairandmaintenanceprocedures.
--Donotwearrings,wristwatches,jewellery,unbuttonedorloosearticlesofclothingsuchas: ties,tornclothing,scarves,openjacketsorshirts withopenzipsthatmayremainentangledin movingparts.Itisadvisedtowearapproved safetyclothing,e.g.:non--slipfootwear,gloves, safetygoggles,helmets,etc.
--Donotcarryoutrepairoperationswithsomeone sittinginthedriverísseat,unlessthepersonisa trainedtechnicianwhoisassistingwiththeoperationinquestion.
--Donotoperatethevehicleoruseanyoftheimplementsfromdifferentpositions,otherthanthe driverísseat.
--Donotcarryoutoperationsonthevehiclewith theenginerunning,unlessspecificallyindicated.
--Stoptheengineandcheckthatthehydrauliccircuitsarepressure--freebeforeremovingcaps, covers,valves,etc.
--Allrepairandmaintenanceoperationsmustbe carriedoutusingextremecareandattention.
--Servicestepsandplatformsusedintheworkshoporelsewhereshouldbebuiltaccordingto standardaccidentpreventionregulations.
--Disconnectthebatteriesandlabelallcontrolsto indicatethatthevehicleisbeingserviced.Any partsthataretoberaisedmustbelockedinposition.
--Donotcheckorfillfueltanks,accumulatorbatteries,norusestartingliquidwhensmokingor nearnakedflames,asthesefluidsareinflammable.
--Brakesareinoperativewhenmanuallyreleased forrepairormaintenancepurposes.Useblocks orsimilardevicestocontrolthemachineinthese conditions.
--Thefuelnozzleshouldalwaysbeincontactwith thefillingaperture.Maintainthispositionuntilfillingoperationsarecompletedinordertoavoid possiblesparkscausedbytheaccumulationof staticelectricity.
603.54.381.00 --05--2001
4 SECTION00--GENERAL--CHAPTER1
5
--Onlyusespecifiedtowingpointsfortowingthe tractor.Connectpartscarefully.Makesurethat allpinsand/orlocksaresecuredinpositionbeforeapplyingtraction.Neverremainnearthe towingbars,cablesorchainsthatareoperating underload.
--Transportvehiclesthatcannotbedrivenusinga traileroralow--loadingplatformtrolley,ifavailable.
--Whenloadingorunloadingthevehiclefromthe trailer(orothermeansoftransport),selectaflat areacapableofsustainingthetrailerortruck wheels.Firmlysecurethetractortothetruckor trailerandlockthewheelsinthepositionusedby thecarrier.
--Electricheaters,battery--chargersandsimilar equipmentmustonlybepoweredbyauxiliary powersupplieswithefficientgroundinsulationto avoidelectricalshockhazards.
--Alwaysusesuitablehoistingorliftingdevices whenraisingormovingheavyparts.
--Takeextracareifbystandersarepresent.
--Neverpourgasolineordieseloilintoopen,wide orlowcontainers.
--Neverusegasoline,dieseloilorotherinflammableliquidsascleaningagents.Usenon--inflammable,nontoxiccommerciallyavailablesolvents.
--Wearsafetygoggleswithsideguardswhen cleaningpartswithcompressedair.
--Limittheairpressuretoamaximumof2.1bar (30.46psi),accordingtolocalregulations.
--Donotruntheengineinconfinedspaceswithout suitableventilation.
--Donotsmoke,usenakedflames,orcause sparksintheareawhenfuelfillingorhandling highlyinflammableliquids.
--Neverusenakedflamesforlightingwhenworkingonthemachineorcheckingforìleaks.
--Allmovementsmustbecarriedoutcarefully whenworkingunder,onornearthevehicle. Wearprotectiveequipment:helmets,goggles andspecialfootwear.
--Whencarryingoutcheckswiththeenginerunning,requesttheassistanceofanoperatorinthe
driverísseat.Theoperatormustmaintainvisual contactwiththeservicetechnicianatalltimes.
--Ifoperatingoutsidetheworkshop,positionthe vehicleonaflatsurfaceandlockinposition.If workingonaslope,lockthevehicleinposition. Movetoaflatareaassoonasissafelypossible.
--Damagedorbentchainsorcablesareunreliable. Donotusethemforliftingortowing.Alwaysuse suitableprotectivegloveswhenhandlingchains orcables.
--Chainsshouldalwaysbesafelysecured.Make surethatthehitch--uppointiscapableofsustainingtheloadinquestion.Keeptheareanearthe hitch--uppoint,chainsorcablesfreeofallbystanders.
--MaintenanceandrepairoperationsmustbecarriedoutinaCLEANandDRYarea.Eliminateany wateroroilspillageimmediately.
--Donotcreatepilesofoilorgrease--soakedrags astheyrepresentaseriousfirehazard.Always storeragsinaclosedmetalcontainer. Beforestartingthevehicleorimplements,make surethatthedriverísseatislockedinposition. Alsocheckthattherearenopersonswithinthe tractororimplementrangeofaction.
--Emptypocketsofallobjectsthatmayfallunobservedintothevehicleparts.
--Inthepresenceofprotrudingmetalparts,use protectivegogglesorgoggleswithsideguards, helmets,specialfootwearandgloves.
--Whenwelding,useprotectivesafetydevices: tintedsafetygoggles,helmets,specialoveralls, glovesandfootwear.Allpersonspresentinthe areawhereweldingistakingplacemustwear tintedgoggles.NEVERLOOKDIRECTLYAT THEWELDINGARCWITHOUTSUITABLE EYEPROTECTION.
--Metalcablestendtofraywithrepeateduse.Alwaysusesuitableprotectivedevices(gloves, goggles,etc.)whenhandlingcables.
--Handleallpartscarefully.Donotputyourhands orfingersbetweenmovingparts.Wearsuitable safetyclothing--safetygoggles,glovesand shoes.
SECTION00--GENERAL--CHAPTER1 5 603.54.381.00 --05--2001
STARTUP
--Neverruntheengineinconfinedspacesthatare notequippedwithadequateventilationforexhaustgasextraction.
--Neverplacethehead,body,limbs,feet,handsor fingersnearfansorrotatingbelts.
ENGINE
--Alwaysloosentheradiatorcapslowlybeforeremovingittoallowanyremainingpressureinthe systemtobedischarged.Fillingupwithcoolant shouldonlybecarriedoutwiththeengine stoppedoridling(ifhot).
--Neverfillupwithfuelwhentheengineisrunning, especiallyifhot,inordertopreventtheoutbreak offireasaresultoffuelspillage.
--Nevercheckoradjustfanbelttensionwhenthe engineisrunning.
Neveradjustthefuelinjectionpumpwhenthevehicleismoving.
--Neverlubricatethevehiclewhentheengineis running.
ELECTRICALSYSTEMS
--Ifitisnecessarytouseauxiliarybatteries,rememberthatbothendsofthecablesmustbe connectedasfollows:(+)with(+)and(--)with(--). Avoidshort--circuitingtheterminals.GASRELEASEDFROMBATTERIESISHIGHLYINFLAMMABLE.Duringcharging,leavethebatterycompartmentuncoveredtoimprove ventilation.Nevercheckthebatterychargeusing ìjumpersî(metalobjectsplacedontheterminals).Avoidsparksorflamesnearthebattery zone.Donotsmoketopreventexplosionhazards.
--Beforeservicingoperations,checkforfuelor currentleaks.Eliminateanyeventualleaksbeforeproceedingwithwork.
--Neverchargebatteriesinconfinedspaces.Make surethatthereisadequateventilationinorderto preventaccidentalexplosionhazardsasaresult oftheaccumulationofgasesreleasedduring chargingoperations.
--Alwaysdisconnectthebatteriesbeforeperforminganykindofservicingontheelectricalsystem.
HYDRAULIC SYSTEMS
--Aliquidleakingfromatinyholemaybealmost invisiblebut,atthesametime,bepowerful
enoughtopenetratetheskin;Therefore,NEVER USEHANDSTOCHECKFORLEAKS.Usea pieceofcardboardorwoodforthispurpose.If anyliquidpenetratesskintissue,callformedical aidimmediately.Failuretotreatthiscondition withcorrectmedicalproceduremayresultinseriousinfectionordermatosis.
--Inordertocheckthepressureinthesystemuse suitableinstruments.
WHEELSANDTYRES
--Makesurethatthetyresarecorrectlyinflatedat thepressurespecifiedbythemanufacturer. Periodicallychecktherimsandtyresfordamage.
--Standawayfrom(atthesideof)thetyrewhen checkinginflationpressure.
--Onlycheckpressurewhenthetractorisunloadedandthetyresarecold,toavoidincorrect readingsasaresultofover--pressure.Donotuse partsofrecoveredwheelsasincorrectwelding brazingorheatingmayweakenandeventually causedamagetothewheel.
--Nevercutorweldarimmountedwithaninflated tyre.
--Toremovethewheels,lockboththefrontand rearvehiclewheels.Afterhavingraisedthevehicle,positionsupportsunderneath,accordingto regulationsinforce.
--Deflatethetyrebeforeremovinganyobjectsthat maybejammedinthetyretread.
--Neverinflatetyresusinginflammablegases;as thismayresultinexplosionsandinjurytobystanders.
REMOVALANDRE--FITTING
--Liftandhandleallheavypartsusingsuitablehoistingequipment.Makesurethatpartsaresustainedbyappropriatehooksandslings.Usethe hoistingeyeboltsforliftingoperations.Extracare shouldbetakenifpersonsarepresentnearthe loadtobelifted.
--Handleallpartscarefully.Donotputyourhands orfingersbetweenparts.Wearsuitablesafety clothing--safetygoggles,glovesandshoes.
--Avoidtwistingchainsormetalcables.Always wearsafetygloveswhenhandlingcablesor chains.
603.54.381.00 --05--2001
6 SECTION00--GENERAL--CHAPTER1
Transmission: (gears,beveldrive, brakesandhydraulic lift)
--modelsTK65,TK75
--modelsTK76,TK85,TK95
carriagerollers,tracksupport
SECTION00--GENERAL--CHAPTER1 7 603.54.381.00 --05--2001
COMPONENTTOBEFILLED ORTOPPEDUP QUANTITY dm3 (gallons) RECOMMENDED NEWHOLLAND PRODUCTS NEWHOLLAND SPECIFICATIONS INTERNATIONAL SPECIFICATIONS Coolingsystem: --modelsTK65,TK75 --modelsTK76,TK85,TK95 10.5(2.31) 13.0(2.86) Water&liquid AMBRA AGRIFLU 50%+50% NH900A Fueltank: --modelsTK65,TK75 ...... --modelsTK76,TK85,TK95 80(17.6) 129(28.38) Decantedandfiltereddieselfuel Enginesump: withoutfilter: --modelsTK65,TK75 --modelsTK76,TK85,TK95 withfilter: --modelsTK65,TK75 ...... --modelsTK76,TK85,TK95 6.7(1.47) 10.5(2.31) 7.3(1.61) 11.2(2.46) AMBRA SUPERGOLD 15W--40 oilor 10W--30 NH330G (SAE15W--40) NH24G (SAE10W--30) APICF--4/SG CCMCD4 MIL--L--2104E Steeringclutches............ 1.4(0.31) AMBRA SUPER oil 10W NH301C APICECCMCD4 MIL--L--2104C SAE10W
CONSUMABLES
rollers...................... 33.3(7.32) 39.0(7.92) AMBRAMULTIF oil NH420A APIGL4 ISO46/68 SAE20W--30 Finaldrives (each)..................... 2.0(0.44) AMBRA HYPOIDE90 oil NH520A APIGL5 MIL--L--2105D SAE80W--90 Greasefittings.............. AMBRAGR9 grease NH710A NLGI2
Tracktensionwheel,
SECTION10--ENGINE--CHAPTER1 1 603.54.381.00 --05--2001
CONTENTS SectionDescription Page 10000 Generalspecifications2 ......................................................... Maindata 5 Torquesettings 24 Tools 25 ....................................................................... Sections 27 Lubricationandcoolingsystemdiagrams31 Troubleshooting34 1000110 Engine.Removal--Installation38 1000130 Engine.Compressiontest42 1000154 Engine.Disassembly--Assembly43 1010153 Valveguides.Replacement78 1010160 Injectorsleeve.Replacement82 1010270 Frontengineoilseal.Removal--Installation87 1010612 Valve/rockerarmclearance91 .................................................... 1021610 Rearfueltank--modelsTK65andTK75.Removal--Installation94 .................... 1021610 Rearfueltank--modelsTK76,TK85andTK95.Removal--Installation97 ............. 1021640 Frontfueltank--modelsTK65andTK75.Removal--Installation100 .................. 1021640 Frontfueltank--modelsTK76,TK85andTK95.Removal--Installation102 ............ 1021830 Engineinjectors.Removal--Installation104 ......................................... 1024614 Boschinjectionpump.Removal--Installationtimingandairbleedingcheck106 1025444 Exhaustpipe.Removal--Installation113 1040211 Coolantpump.Removal--Installationwithradiatorremoved114 1040228 Coolantpump.Overhaul115 1040230 Thermostat.Removal--Installation116 1040610 Radiator.Removal--Installation117 1041410 Coolantpumpandgeneratordrivebelt.Adjustment120
SECTION10--ENGINE Chapter1--Engine
GENERALSPECIFICATIONS
Engine,technicaltype:
3cylinders 4cylinders
--modelTK65--type8035.05.421(BOSCHpump) ..... Seedataonpage6--7
--modelTK75--type8035.25.421(BOSCHpump) Seedataonpage8--9
--modelTK76--type8045.06.421/521(BOSCHpump). Seedataonpage10--11
--modelTK85--type8045.05.421/521(BOSCHpump). Seedataonpage12--13
--modelTK95--type8045.25L.421(BOSCHpump) Seedataonpage14--15
Cycle............................................... diesel,4--stroke
Injection............................................. direct Numberofon--linecylinders ........................... 3 4 Cylinderliners dryforce--fittedincylinderblock
--modelTK76
603.54.381.00 --05--2001
2 SECTION10--ENGINE--CHAPTER1
.............................. 104mm(4.0945in.)
Pistondiameter --modelsTK65,TK75
100mm(3.937in.)
104mm(4.0945in.) Pistonstroke........................................ 115mm(4.37in.)
--modelTK65 ..................................... 2931cm3 (0.6447gal.) --modelTK75 2931cm3 (0.6447gal.) --modelTK76 3613cm3 (0.7947gal.) --modelTK85 ..................................... 3908cm3 (0.8596gal.) --modelTK95 3908cm3 (0.8596gal.) CompressionratioformodelsTK65,TK76andTK85 17to1normallyaspirated CompressionratioformodelsTK75andTK95 .......... 16.5to1turbocharged Maximumpower: --modelTK65 44.5kW(60Hp) --modelTK75 54kW(72Hp) --modelTK76 ..................................... 53kW(71Hp) --modelTK85 58.8kW(80Hp) --modelTK95 66.5kW(90Hp) Maximumpowerspeed--modelsTK65,TK75 .......... 2300rpm Maximumpowerspeed--TK76,TK85,TK95 2500rpm Maximumtorquespeed--modelTK65 1400rpm Maximumtorquespeed--modelTK75 1400rpm Maximumtorquespeed--modelTK76 .................. 1500rpm Maximumtorquespeed--modelTK85 1500rpm Maximumtorquespeed--modelTK95 1500rpm Numberofmainbearings .............................. 4 5 Sumppan........................................... structural,castiron (continued)
--modelsTK85,TK95
Totaldisplacement:
GENERALSPECIFICATIONS
(continued)
3cylinders 4cylinders
Lubrication system .................................... forced,withgearpump
Pumpdrive............................................ camshaft
Enginespeed/oilpumpspeedratio 2:1
Oilcleaning ............................................ meshfilteronoilintakeandfilteringcartridgeondeliveryline
Normaloilpressurewithmotorwarmed--upandrunningat maximumspeed:
FormodelsTK65,TK76,TK85 2.9to3.9bar(42.1to56.6psi)
FormodelsTK75,TK95(startingpressure) .............. 6bar(87psi)
Pressurereliefvalve.................................... incorporatedinoilpumphousing
Valveinitialopeningpressure 3.5bar(50.8psi)
Forfurtherlubricationtechnicaldata...................... Seepage23
Coolingsystem ....................................... coolantcirculation
RadiatoronmodelsTK65,TK75 3linesofverticalpipeswithcopperfins
RadiatoronmodelsTK76,TK85,TK95 .................. 4linesofverticalcopperpipes
Fan,attachedtocoolantpumppulley..................... intake,4--bladeinsheet--metal
Coolantpump.......................................... centrifugalvane--type
Enginespeed/coolantpumpspeedratio 1:1.403
Temperaturecontrol.................................... thermostat
Coolantthermometer................................... colouredscaledividedinto3sections
Temperaturerangescorrespondingtoeachsection:
--initialwhitesection.................................. 30to65 oC(86to149 oF)
--middlegreensection(normalworkingconditions) ........ 65to105 oC(149to221 oF)
--finalredsection..................................... 105to115 oC(221to239 oF)
Forfurthercoolingsystemtechnicaldata Seepage23
Revcounter incorporatedincontrolpanel
Operatingsystem fromgearoncamshaft
Hourcountercalibratedforenginespeedof ................ 1800rpm
(continued)
603.54.381.00 --05--2001
SECTION10--ENGINE--CHAPTER1 3
GENERALSPECIFICATIONS 3cylinders 4cylinders
Timingsystem ........................................ overheadvalvesoperatedbytappets,rods androckerarmsviathecamshaftlocated intheengineblock;thecamshaftisdriven bythecrankshaftusinghelicalgears
Inlet:
--start:beforeTDC.................................... 12o
--end:afterBDC. 31o
Exhaust:
--start:beforeBDC.................................... 50o
--end:afterTDC. ..................................... 16o
valve--rockerarmclearancefortimingcheck............... 0.45mm(0.248in.)
valve--rockerarmclearance(withenginecold):
--intake............................................. 0.30 0.05mm(0.1654 0.0276in.)
--exhaust 0.30 0.05mm(0.1654 0.0276in.)
Forfurthertimingsystemtechnicaldata ................... Seepage20
Fuelsystem
Aircleaning dualcartridgedryairfilter,withclogged filterindicatorwithcentrifugalpre--filter andautomaticdustejector
Fuelpump............................................. doublediaphragm
Fuelfiltering........................................... throughwirefilterinfuelsupplypump,and replaceablecartridgeondeliverylineto injectionpump
Minimumfuelflowratewithpumpshaftrotatingat1600rpm. 100litres/hour(22gal./hour)
Camoperated enginetiming
BOSCHinjectionpump.................................. rotatingdistributortype
All--speedgovernor,incorporatedinpump:
BOSCH............................................... centrifugalcounterweights
Automaticadvanceregulator,incorporatedinpump: BOSCH............................................... hydraulic
Forfurtherfuelsystemtechnicaldata:
Fixedadvance(pumpsettingforstartofdeliverybeforeTDC)
--Pressuresetting--Injectionorder,andotherinformation regardingtheBOSCHpump refertothedatafortherelevantengine typeinthetableonpage2
603.54.381.00 --05--2001
4 SECTION10--ENGINE--CHAPTER1
(continued)
Turbocharger(modelsTK75,TK95):
FUELSYSTEMDATA
SECTION10--ENGINE--CHAPTER1 5 603.54.381.00 --05--2001
--GARRETTtype..................................... TA3118--0.82A/R--57 Injectionpump......................................... rotatingdistributorwithspeedgovernor andadvancevariatorincorporated BOSCHpump: --modelTK65 ....................................... VE3/11F1150L766--99441586 --modelTK75 ....................................... VE3/11F1150L764--99441587 --modelTK76 ....................................... VE4/11F1250L794--99472104 --modelTK76 VE4/11F1250L810--500324959 --modelTK85 VE4/11F1250L773--99472102 --modelTK85 VE4/11F1250L787--500324962 --modelTK95 VE4/11F1250L850--500358111 Directionofrotation..................................... counter--clockwise Injectionorder......................................... 1--2--3(TK65,TK75)1--3--4--2(TK76, TK85,TK95) TK65 TK75 TK85 TK95 TK76 Injectors: BOSCHtype....................... 500307714 500317389 --Nozzleholdertype.............. 4791124(KBEL83S35) --Nozzletype.................... 99469341(DLLA132S1320) 500317390 (DLLA132S 1335) Numberofnozzleholes............. 5 5 Nozzleholediametermm(in.) 0.23(0.0091) 0.21 (0.0083) Calibrationpressurebar(psi) 260to272(3771to3945) 260to272 (3771to 3945) DeliverylinesforBOSCHpump --type........................... 99441952 99449006 --Linedimensionmm(in.) 6x1.75x540 (0.2362x0.0689x21.260) 6x1.75x530 (0.2362x 0.0689x 20.866) 6x1.75x530 (0.2362x 0.0689x 20.866)
MODELTK65--CALIBRATIONDATAFORBOSCHINJECTIONPUMP
TYPEVE3/11F1150L766--99441586
ASSEMBLYDATA
Pumptimingonengine:deliverystart9o 0.5o before TDCofcylinder1compressionstroke.
Plungerpre--liftfortimingonengine:1mm(0.0394 in.)fromBDC(withtools 291754 291755). CylinderNo.1deliverylineuniononpump:marked withletterA.
ASSEMBLYDIMENSIONS
CALIBRATIONTESTCONDITIONS
TestbenchconformingtoISO4008/1 .../2
InjectorsconformingtoISO7440--A61-(1.688.901.020withcalibratedpad 0.6mm-0.0236in.).
Injectorpressuresetting172to175bar(2495to 2538psi).
Fuelsupplypressure: 0.35+0.05bar(5.1+0.7psi).
Pipes(conformingtoISO4093.2): 6x2x840mm(0.2362x0.0787x33.071in.). Graduatedraintime:30î.
Testliquid:ISO4113atatemperatureof45o 1oC (113o 33.8oF)atoutlet.
1.STARTOFDELIVERY
Plungerpre--liftfromTDC: mm-Pumprotation(viewedfromdriveside): counter--clockwise Injectionorder:1--2--3
2.ADVANCEREGULATORSTROKE
Note:thevaluesshownaboveinbracketsmustbeusedforcheckingpurposesonly.
603.54.381.00 --05--2001
6 SECTION10--ENGINE--CHAPTER1
SYMBOL VHA MS ya yb mm (in.) 30.1 (1.185) 36.5to38.5 (1.437to 1.5157) 40.4to45.6 (1.5905to 1.7953)
rpm:1220 Advancestroke:0.7to1.1mm(0.0276to0.0433in.)
rpm:1220 Internalpressure:7.9to8.5bar(114.5to123.3psi) 4.FULLLOADDELIVERY rpm:700 Deliveryper1000shots:66.7to67.7cm3 (0.0147to0.0149gal.) Spread: 3.5cm3 (0.0008gal.)
rpm:325 Deliveryper1000shots:16.3to17.3cm3 (0.0036to0.0038gal.) Spread: 5.5cm3 (0.0012gal.)
rpm:1200 Deliveryper1000shots:48.5to49.5cm3 (0.0107to0.0109gal.) Spread:cm3
rpm:100 Deliveryper1000shots:60to100cm3 (0.0132to0.022gal.)
rpm 1220 400 Internalpressurebar(psi) 7.9to8.5(114.6to123.3) 3.4to4.4(49.3to63.8) 9.INJECTIONADVANCEPROGRESSION rpm 1220 1260 Advancestrokemm(in.) 0.7to1.1(0.276to0.0433) 1.3to1.9(0.0512to0.0748) 10.BACKFLOW rpm 400 1150 Backflowcm3 (gal.)/10sec 16to28(0.0035to0.0062) 20to36(0.0044to0.0079) (continued)
3.FUELSUPPLYPUMPPRESSURE
5.SPREADGOVERNORATIDLESPEED
6.SPREADGOVERNORATMAXIMUMSPEED
7.DELIVERYATSTARTINGSPEED
8.TRANSFERPRESSUREPROGRESSION
11.DELIVERYPROGRESSION
12.DELIVERYCHECKATIDLESPEED
13.ZEROCAPACITY(STOP)
14.AUTOMATICSTARTSUPPLEMENT
Note:thevaluesshownaboveinbracketsmustbeusedforcheckingpurposesonly.
SECTION10--ENGINE--CHAPTER1 7 603.54.381.00 --05--2001 (continued)
rpm Deliveryper1000shots:cm3 (gal.) 1270 0to3(0to0.0007) 1200 48.5to49.5(0.0107to0.0109) 700 66.7to67.7(0.0147to0.0149) 1150 64.4to68.4(0.0142to0.0150)
rpm 325 275 Deliveryper1000shots:cm3 (gal.) 16.3to17.3(0.0036to0.0038) 46to47(0.0101to0.0103)
rpm Voltage(volts) Deliveryper1000shots:cm3 (gal.) 325 0 0to3(0to0.0070)
rpm Deliveryper1000shots:cm3 (gal.) 100 60to100(0.0132to0.022) 270 59to69(0.0130to0.0152)
Relativehumidity70o/o 5. Enginewithoutfan,airfilterandexhaustsilencer. Ambienttemperature20 3 oC(68 37.4 oF). Atmosphericpressure740 5mm(29.1339 0.1968in.) mercury. Specificgravityofdieselfuel840g/latatemperatureof15 oC(59 oF). Throttle l B k i l d li d Enginespeed Poweroutputwithenginerun--inforatotalof: Fuelconsumption lever position Brakingloadapplied rpm Productionspeed kW(Hp) 50hours(total) kW(Hp) kg(lbs.)/h Maximum Formaximumpower output 2300 42(57.1) 43to45.6 (58.5to62) 9.9to10.5 (21.83to 23.15) Maximum Formaximumtorque 1400 29.4(40) 30to31.8 (40.8to43.2) 6.4to6.8 (14.11to 23.15) Maximum None(no--load) 2450to 2500 Minimum None(no--load) 625to675
BENCHTESTPERFORMANCEDATA Testconditions FixedadvancebeforeTDCcylinderNo.1incompression stroke:(seepreviouspage)
MODELSTK75--CALIBRATIONDATAFORBOSCHINJECTIONPUMP TYPEVE3/11F1150L764--99441587
ASSEMBLYDATA
Pumptimingonengine:deliverystart6o 0.5o beforeTDCofcylinder1compressionstroke.
Plungerpre--liftfortimingonengine:1mm (0.0394in.)fromBDC(withtools 291754 291755). CylinderNo.1deliverylineuniononpump:marked withletterA.
ASSEMBLYDIMENSIONS
CALIBRATIONTESTCONDITIONS
TestbenchconformingtoISO4008/1 .../2
InjectorsconformingtoISO7440--A61-(1.688.901.027withcalibratedpad 0.5mm-0.0197in.).
Injectorpressuresetting250to253bar(3626to 3669psi).
Fuelsupplypressure: 0.35+0.05bar(5.1+0.7psi).
Deliverypipes(conformingtoISO4093.2): 6x2x450mm(0.2362x0.0787x17.716in.).
Graduatedraintime:30î.
Testliquid:ISO4113atatemperatureof45o 1oC (113o 33.8oF)atoutlet.
1.STARTOFDELIVERY
Plungerpre--liftfromTDC: mm-Pumprotation(viewedfromdriveside): counter--clockwise Injectionorder:1--2--3
2.ADVANCEREGULATORSTROKE rpm:850 LDApressure:kPa100
3.FUELSUPPLYPUMPPRESSURE
4.FULL--LOADDELIVERYWITHBOOSTERPRESSURE
Note:thevaluesshownaboveinbracketsmustbeusedforcheckingpurposesonly.
603.54.381.00 --05--2001
8 SECTION10--ENGINE--CHAPTER1
SYMBOL K MS ya yb mm (in.) 38.6to40.6 (1.5197to 1.5984) 40.4to45.6 (1.5905to 1.7953)
Advancestroke:0.2to1.2mm(0.0079to0.0472in.)
rpm:1220 LDApressure:kPa100 Internalpressure:8.3to9.5bar(129.1to137.8psi)
rpm:700 LDApressure:kPa100 Deliveryper1000shots:88.4to93.4cm3 (0.0194to0.0205gal.) Spread: --cm3 5.FULL--LOADDELIVERYWITHOUTBOOSTERPRESSURE rpm:600 LDApressure:kPa0 Deliveryper1000shots:70.5to75.5cm3 (0.0155to0.0166gal.) Spread:--cm3 6.SPREADGOVERNORATIDLESPEED rpm:325 LDApressure:kPa0 Deliveryper1000shots:6.3to17.3cm3 (0.0014to0.0038gal.) Spread: --cm3 7.SPREADGOVERNORATMAXIMUMSPEED rpm:1210 LDApressure:kPa100 Deliveryper1000shots:37to53cm3 (0.0081to0.0117gal.) Spread:--cm3 8.DELIVERYATSTARTINGSPEED rpm:100 Deliveryper1000shots:85to125cm3 (0.0187to0.0275gal.) 9.INJECTIONADVANCEPROGRESSION LDApressure:kPa 100 rpm 850 950 Advancestrokemm(in.) 0.2to1.2(0.0079to0.0473) 1.3to1.9(0.0512to0.0748) 10.TRANSFERPRESSUREPROGRESSION LDApressure:kPa 100 rpm 500 1220 1180 Internalpressuresupply:bar(psi) 3.8to5.0 (55.1to72.5) 8.3to9.5 (120.4to137.8) 7.9to9.1 (114.6to132)
rpm 600 1150 LDApressure:kPa 0 100 Backflowfor10sec.l(gal.)/h 17to31(3.7395to6.819) 21to39(4.6193to8.5788) (continued)
11.BACKFLOW
12.DELIVERYPROGRESSION
Note:thevaluesshownaboveinbracketsmustbeusedforcheckingpurposesonly.
Testconditions
BENCHTESTPERFORMANCEDATA
FixedadvancebeforeTDCcylinderNo.1incompression stroke:(seepreviouspage)
SECTION10--ENGINE--CHAPTER1 9 603.54.381.00 --05--2001 (continued)
rpm LDApressurekPa Deliveryper1000shots:cm3 (gal.) 1270 100 0to3(0to0.0007) 1210 100 37to53(0.0081to0.0117) 700 100 88.4to93.4(0.0194to0.0205) 600 40 80to87(0.0176to0.0191) 600 0 70.5to75.5(0.0155to0.0166) 1150 100 76to82(0.0167to0.0180)
rpm:325 Voltage(volts):0 Deliveryper1000shots:cm3:0to3 14.DELIVERYCHECKATIDLESPEED rpm 325 410 Deliveryper1000shots:cm3 (gal.) 6.3to17.3(0.0014to0.0038) 0to3(0to0.0007)
13.ZEROCAPACITY(STOP)
15.AUTOMATICSTARTSUPPLEMENT rpm Deliveryper1000shots:cm3 (gal.) 100 85to125(0.0187to0.0275) 250 74.6to86.6(0.0164to0.0190) 160 100to130(0.220to0.0286)
Relativehumidity70o/o 5. Enginewithoutfan,airfilterandexhaustsilencer. Ambienttemperature20 3 oC(68 37.4 oF). Atmosphericpressure990 10mbar(1.8855psi). Specificgravityofdieselfuel840g/lata temperatureof15 oC(59 oF). Throttle l B k i l d li d Engine speed Poweroutputwithenginerun--inforatotalof: Fuel consumption lever position Brakingloadapplied rpm Productionspeed kW(Hp) 50hours(total) kW(Hp) kg(lbs.)/h Maximum Formaximum poweroutput 2300 50.4(68.5) 51.4to54.5(1) (69.9to74.1) 11.6to12.3 (25.57to 27.12) Maximum Formaximum torque 1400 39.3(53.4) 40.1to42.6(2) (54.5to57.9) 9.1to9.6 (20.06to 21.16) Maximum None(no--load) 2475to 2525 Minimum None(no--load) 625to675 Note:Airdeliverypressure(1)0.875to1.025bar(12.6908to14.8664psi)--(2)0.55to0.65bar(7.9771to9.4275psi).
MODELTK76--CALIBRATIONDATAFORBOSCHINJECTIONPUMP
TYPEVE4/11F1250L794--99472104/VE4/11F1250L810--500324959
ASSEMBLYDATA
Pumptimingonengine:deliverystart9o 0.5o before TDCofcylinder1compressionstroke.
Plungerpre--liftfortimingonengine:1mm(0.0394 in.)fromBDC(withtools 291754 291755). CylinderNo.1deliverylineuniononpump:marked withletterA.
ASSEMBLYDIMENSIONS
CALIBRATIONTESTCONDITIONS
TestbenchconformingtoISO4008/1 .../2
InjectorsconformingtoISO7440--A61-(1.688.901.027withcalibratedpad 0.5mm-0.0197in.).
Injectorpressuresetting247to253bar(3582to 3669psi).
Fuelsupplypressure: 0.35+0.05bar(5.1+0.7psi). ......
Deliverypipes(conformingtoISO4093.2): 6x2x450mm(0.2362x0.0787x17.716in.).
Graduatedraintime:30î.
Testliquid:ISO4113atatemperatureof45o 1oC (113o 33.8oF)atoutlet.
1.STARTOFDELIVERY
Plungerpre--liftfromTDC:mm--
Pumprotation(viewedfromdriveside): counter--clockwise
Injectionorder:1--3--4--2
2.ADVANCEREGULATORSTROKE rpm:800 Advancestroke:0.7to1.1mm(0.0276to0.0433in.)
3.FUELSUPPLYPUMPPRESSURE rpm:800 Internalpressure:5.9to6.5bar(85.6to94.3psi)
4.FULLLOADDELIVERY rpm:800 Deliveryper1000shots:65.1to66.1cm3 (0.0143to0.0145gal.) Spread:--3.5cm3 (--0.0008gal.)
5.SPREADGOVERNORATIDLESPEED
Deliveryper1000shots:7.5to8.5cm3 (0.0016to0.0019gal.) Spread: 3.5cm3 (0.0008gal.)
6.SPREADGOVERNORATMAXIMUMSPEED
(0.0096to0.0098gal.) Spread:--cm3
7.DELIVERYATSTARTINGSPEED rpm:100 Deliveryper1000shots:75to105cm3 (0.0165to0.0231gal.)
8.TRANSFERPRESSUREPROGRESSION
Note:thevaluesshownaboveinbracketsmustbeusedforcheckingpurposesonly.
603.54.381.00 --05--2001
10 SECTION10--ENGINE--CHAPTER1
SYMBOL SVS K MS ya yb mm (in.) 3.1to3.5 (0.1220to 0.1378) 0.9to1.3 (0..0354to 0.0512) 36.5to 38.5 (1.437to 1.5157) 38.8to44 (1.5276to 1.7323)
rpm:325
rpm:1270 Deliveryper1000shots:43.5to44.5cm3
rpm 800 400 Internalpressurebar(psi) 5.9to6.5(85.6to94.3psi) 3.8to4.4(55.1to63.8psi)
rpm 800 Advancestrokemm(in.) 0.7to1.1(0.0276to0.0433) 10.BACKFLOW rpm 400 1200 Backflowcm3 (gal.) 44.1to77.2(0.0097to0.017) 60.7to104.8(0.0134to 0.0231) (continued)
9.INJECTIONADVANCEPROGRESSION
11.DELIVERYPROGRESSION
Note:thevaluesshownaboveinbracketsmustbeusedforcheckingpurposesonly.
13.ZEROCAPACITY(STOP)
BENCHTESTPERFORMANCEDATA TESTConditions
FixedadvancebeforeTDCcylinderNo.1incompression stroke:(seepreviouspage)
SECTION10--ENGINE--CHAPTER1 11 603.54.381.00 --05--2001 (continued)
rpm Deliveryper1000shots:cm3 (gal.) 1340 0to3(0to0.0007) 1270 43.5to44.5(0.0096to0.0098) 1200 58.4to61.3(0.0128to0.0135) 800 65.1to66.1(0.0143to0.0145) 400 59.6to67.6(0.0131to0.0149) 12.DELIVERYCHECKATIDLESPEED rpm 325 290 370 Deliveryper1000shots:cm3 (gal.) 7.5to8.5 (0.0016to0.0019) 15.5to23.5 (0.00345to0.0052) 0to3 (0to0.0007)
rpm Voltage(volts) Deliveryper1000shots:cm3 (gal.) 325 0 0to3(0to0.0007)
rpm Deliveryper1000shots:cm3 (gal.) 100 70to105(0.0154to0.0231) 250 47.5to55.5(0.0104to0.0122)
14.AUTOMATICSTARTSUPPLEMENT
Relativehumidity70o/o 5. Enginewithoutfan,airfilterandexhaustsilencer. Ambienttemperature25 oC(77 oF). Atmosphericpressure740 5mm(29.1339
mercury. Specificgravityofdieselfuel840g/latatemperatureof15 oC(59 oF). Throttle lev er Brak ing load applied Enginespeed Poweroutputwithenginerun--inforatotalof: Fuelconsumption lever position Brakingloadapplied rpm Productionspeed kW(Hp) 50hours(total) kW(Hp) kg(lbs.)/h Maximum Formaximumpower output 2500 50(68) 51.1to54 (69.5to73.4) 11.8to12.4 (26.01to 27.34) Maximum Formaximumtorque 1500 36(48.9) 36.8to39 (51.1to54.2) 8.0to8.4 (17.66to 18.52) Maximum None(no--load) 2700to 2750 Minimum None(no--load) 625to675
0.1968in.)
MODELTK85--CALIBRATIONDATAFORBOSCHINJECTIONPUMP TYPEVE4/11F1250L773--99472102/VE4/11F1250L787--500324962
ASSEMBLYDATA
Pumptimingonengine:deliverystart9o 0.5o before TDCofcylinder1compressionstroke.
Plungerpre--liftfortimingonengine:1mm(0.0394 in.)fromBDC(withtools 291754 291755). CylinderNo.1deliverylineuniononpump:marked withletterA.
ASSEMBLYDIMENSIONS
CALIBRATIONTESTCONDITIONS
TestbenchconformingtoISO4008/1 .../2
InjectorsconformingtoISO7440--A61-(1.688.901.027withcalibratedpad 0.5mm-0.0197in.).
Injectorpressuresetting250to253bar(3626to 3669psi).
Fuelsupplypressure: 0.35+0.05bar(5.1+0.7psi).
Deliverypipes(conformingtoISO4093.2): 6x2x450mm(0.2362x0.0787x17.716in.). ......
Graduatedraintime:30î. .........
Testliquid:ISO4113atatemperatureof45o 1oC (113o 33.8oF)atoutlet.
1.STARTOFDELIVERY
Plungerpre--liftfromTDC: mm-Pumprotation(viewedfromdriveside):counter--clockwise
2.ADVANCEREGULATORSTROKE
3.FUELSUPPLYPUMPPRESSURE
4.FULLLOADDELIVERY
(0.0135to0.0137gal.)
5.SPREADGOVERNORATIDLESPEED
Injectionorder:1--3--4--2
3.5cm3 (0.0008gal.)
(0.002to0.0022gal.) Spread: --cm3
6.SPREADGOVERNORATMAXIMUMSPEED
(0.0090to0.0092gal.)
7.DELIVERYATSTARTINGSPEED
3.5cm3 (0.0008gal.)
(0.0073to0.0161gal.) 8.TRANSFERPRESSUREPROGRESSION
Note:thevaluesshownaboveinbracketsmustbeusedforcheckingpurposesonly.
12 SECTION10--ENGINE--CHAPTER1
--05--2001
603.54.381.00
K KF r ya yb mm (in.) 30.1 (1.185) 36.5to38.5 (1.437to 1.5157) 37.4to42.6 (1.4724to 1.6772)
SYMBOL
rpm:900
Advancestroke:0.7to1.1mm(0.0276to0.0433in.)
rpm:900 Internalpressure:6.7to7.3bar(97.2to105.9psi)
rpm:800 Deliveryper1000shots:61.2to62.2cm3
Spread:
rpm:300 Deliveryper1000shots:9.2to10.2cm3
rpm:1300 Deliveryper1000shots:41.1to42.1cm3
Spread:
rpm:100 Deliveryper1000shots:33to73cm3
rpm 900 450 Internalpressuresupply:bar(psi) 6.7to7.3(97.2to105.9psi) 4.3to5.3(62.4to76.9psi) 9.INJECTIONADVANCEPROGRESSION rpm 900 1020 Advancestrokemm(in.) 0.7to1.1mm(0.0276to0.0433) 1.3to1.9(0.0512to0.0748) 10.BACKFLOW rpm 450 1250 Backflowfor10scm3 (gal.) 18to30(0.0040to0.0066) 24to40(0.0053to0.0088) (continued)
11.DELIVERYPROGRESSION
12.DELIVERYCHECKATIDLESPEED
Note:thevaluesshownaboveinbracketsmustbeusedforcheckingpurposesonly.
13.ZEROCAPACITY(STOP)
14.AUTOMATICSTARTSUPPLEMENT
BENCHTESTPERFORMANCEDATA Testconditions
FixedadvancebeforeTDCcylinderNo.1incompression stroke:(seepreviouspage)
5mm(29.1339 0.1968in.) mercury.
peratureof15 oC(59 oF).
SECTION10--ENGINE--CHAPTER1 13 603.54.381.00 --05--2001 (continued)
rpm Deliveryper1000shots:cm3
1400 0to3(0to0.0007) 1300 41.1to42.1(0.0090to0.0092) 1250 52.5to57.5(0.0115to0.0126) 1200 53.5to58.5(0.0118to0.0129) 800 61.2to62.2(0.0135to0.0137)
(gal.)
rpm 300 Deliveryper1000shots:cm3
(gal.) 9.2to10.2(0.0020to0.0022)
rpm Voltage(volts) Deliveryper1000shots:cm3
300 0 0to3(0to0.0007)
(gal.)
rpm Deliveryper1000shots:cm3
100 33to73(0.0073to0.0161) 250 34to44(0.0075to0.0097) 140 40to70(0.0088to0.0154)
(gal.)
Relativehumidity70o/o 5. Enginewithoutfan,airfilterandexhaustsilencer. Ambienttemperature25
oF). Atmosphericpressure740
Specificgravityofdieselfuel840g/latatem-
Throttle lev er Brak ing load applied Enginespeed Poweroutputwithenginerun--inforatotalof: Fuelconsumption lever position Brakingloadapplied rpm Productionspeed kW(Hp) 50hours(total) kW(Hp) kg(lbs.)/h Maximum Formaximumpower output 2500 55(74.8) 56.2to59.6 (76.4to81) 12.9to13.7 (28.44to 30.2) Maximum Formaximumtorque 1500 39.3(53.4) 40.2to42.7 (54.7to58.1) 8.8to9.4 (19.4to 20.72) Maximum None(no--load) 2700to 2750 Minimum None(no--load) 625to675
oC(77
MODELTK95--CALIBRATIONDATAFORBOSCHINJECTIONPUMP TYPEVE4/11F1250L850--500358111
ASSEMBLYDATA
Pumptimingonengine:deliverystart5o 0.5o before TDCofcylinder1compressionstroke.
Plungerpre--liftfortimingonengine:1mm(0.0394 in.)fromBDC(withtools 291754 291755). CylinderNo.1deliverylineuniononpump:marked withletterA.
ASSEMBLYDIMENSIONS
CALIBRATIONTESTCONDITIONS
TestbenchconformingtoISO4008/1 .../2
InjectorsconformingtoISO7440--A61-(1.688.901.027withcalibratedpad 0.5mm-0.0197in.).
Injectorpressuresetting250to253bar(3626to 3669psi).
Fuelsupplypressure: 0.35+0.05bar(5.1+0.7psi). ......
Deliverypipes(conformingtoISO4093.2): 6x2x450mm(0.2362x0.0787x17.716in.). Graduatedraintime:30î.
Testliquid:ISO4113atatemperatureof45o 1oC (113o 33.8oF)atoutlet.
1.STARTOFDELIVERY
Plungerpre--liftfromTDC:mm--
Pumprotation(viewedfromdriveside):counter--clockwise
Injectionorder:1--3--4--2
2.ADVANCEREGULATORSTROKE rpm:900 Advancestroke:0.8to1.2mm(0.0315to0.0472in.)
3.FUELSUPPLYPUMPPRESSURE rpm:900 Internalpressure:6.2to6.8bar(89.9to98.6psi)
4.FULL--LOADDELIVERYWITHBOOSTERPRESSURE rpm:750 LDApressure:kPa100 Deliveryper1000shots:76to77cm3 (0.0167 to0.0169gal.) Spread: 3.5cm3 (0.0008gal.)
5.FULL--LOADDELIVERYWITHOUTBOOSTERPRESSURE
6.SPREADGOVERNORATIDLESPEED
(0.0025to0.0027gal.)
7.SPREADGOVERNORATMAXIMUMSPEED
8.DELIVERYATSTARTINGSPEED
9.TRANSFERPRESSUREPROGRESSION
(0.0119to0.0121gal.)
4.0cm3 (0.0009gal.)
(0.0094to0.0096gal.)
(0.0187to0.0275gal.)
Note:thevaluesshownaboveinbracketsmustbeusedforcheckingpurposesonly.
603.54.381.00 --05--2001
14 SECTION10--ENGINE--CHAPTER1
SYMBOL K r ya yb mm (in.) 30.1 (1.185) 36.5to38.5 (1.437to 1.5157) 40to46
rpm:600 Deliveryper1000shots:54.2to55.2cm3
rpm:325 Deliveryper1000shots:11.5to12.5cm3
Spread:
rpm:1300
Deliveryper1000shots:42.7to43.7cm3
LDApressure:kPa100
rpm:100 Deliveryper1000shots:85to125cm3
LDApressure:kPa 100 rpm 400 900 Internalpressuresupply:bar(psi) 2.9to3.9(42.1to56.6) 6.2to6.8(89.9to98.6) 10.INJECTIONADVANCEPROGRESSION LDApressurekPa 100 rpm 900 1050 Advancestrokemm(in.) 0.8to1.2(0.0315to0.0472) 1.4to2.0(0.0551to0.0787) 11.BACKFLOW rpm 600 1250 LDApressurekPa 0 100 Backflowcm3 (gal.) 18to30(0.0039to0.0066) 22to38(0.0048to0.0083) (continued)
SECTION10--ENGINE--CHAPTER1 27 603.54.381.00 --05--2001 1 2 3 4 5 6 7 25355 3
Enginelongitudinalcrosssection--3--cylindermodelTK65.
28 SECTION10--ENGINE--CHAPTER1 603.54.381.00 --05--2001 25356 4
Enginecrosssection--3--cylindermodelTK65.
SECTION10--ENGINE--CHAPTER1 29 603.54.381.00 --05--2001 1 2 3 4 5 7 6 25357 5
Enginelongitudinalcrosssection--4--cylindermodelsTK76andTK85.
30 SECTION10--ENGINE--CHAPTER1 603.54.381.00 --05--2001 1 25358 6
Enginelongitudinalcrosssection--4--cylindermodelsTK76andTK85.
SECTION10--ENGINE--CHAPTER1 31 603.54.381.00 --05--2001 3--cylinderenginelubricationsystemdiagram
7
1.Oilfillerplug--2.Filtersafetyvalve(activatedwhentheoilinfeedpressureonthefilterexceedstheoutfeedpressure by1.5--1.7bar/cm2--3.Filter--4.Switchforindicatorlamp(ondashboard)--lowenginelubricationoilpressure--
5.Dipstick--6.Pump--7.Oilpressurereliefvalve--8.Intakemeshfilter
4--cylinderenginelubricationsystemdiagram
1.Oilfillerplug--2.Filtersafetyvalve(activatedwhentheoilinfeedpressureonthefilterexceedstheoutfeedpressure by1.5--1.7bar/cm2--3.Filter--4.Switchforindicatorlamp(ondashboard)--lowenginelubricationoilpressure-- 5.Dipstick--6.Pump--7.Oilpressurereliefvalve--8.Intakemeshfilter
32 SECTION10--ENGINE--CHAPTER1 603.54.381.00 --05--2001
8
SECTION10--ENGINE--CHAPTER1 33 603.54.381.00 --05--2001 C D 1 2 3 4 5 6 25363 25364 1 2 3 4 5 6 A B 9
Enginecoolingsystemcircuitdiagram
A. Coolantcirculationwiththermostatclosed
B. Coolantcirculationwiththermostatopen
C. 3--cylindermodels
D. 4--cylindermodels
1. Thermostat
2. Pump
3. Electricthermometerforenginecoolanttemperature
4. Temperaturetransmitter
5. Fan
6. Radiator
ENGINETROUBLESHOOTING
Possiblecauses
Remedies
1.Maximumdeliveryofinjection pumptoohigh Calibratepumpontestbenchtovaluesspecifiedincalibrationtables
2.Injectionpumpdeliveryexcessivelyretardedorautomaticadvanceregulatordamaged
Adjustinjectionpumptimingorcheck automaticadvanceregulator
3.Injectionpumpdeliveryexcessivelyadvanced Adjustinjectionpumptiming
4.Injectorspartiallyortotallyobstructedorincorrectlyadjusted
5.Airfilterclogged
6.Lossofenginecompressiondue to: --pistonringssticking; --cylinderlinerwear; --wornorincorrectlyadjustedvalves
Clean,overhaulandcalibrateinjectors;replaceifnecessary
Cleanfilterunitandreplacefilterelementifnecessary
Replacedamagedpartsor,ifnecessary,overhaultheengine
7.High--pressurefuellinesdamaged Inspectandreplaceifnecessary
Blue,grey--blueorgrey-whitesmoke
1.Injectionpumpdeliveryexcessivelyretardedorautomaticadvanceregulatordamaged
Adjustinjectionpumptimingorcheck automaticadvanceregulator
2.Injectorsobstructedordamaged Clean,overhaulandcalibrateinjectors,replaceifnecessary
3.Oilleakingpastpistonringsdue tostickingringsorcylinderliner wear
4.Oilleakingthroughtheinletvalve guides,duetoguideorvalve stemwear
5.Enginedoesnotreachcorrect operatingtemperature(thermostatfaulty)
Replacedamagedpartsor,ifnecessary,overhaultheengine
Overhaulcylinderhead
Replacethermostat
Enginerunsonafter switchingoff
1.Enginestopelectromagnetdamaged Replaceelectromagnet
2.All--speedgovernordamaged Overhaulinjectionpumpandadjust ontestbenchtovaluesspecifiedin calibrationtable
SECTION10--ENGINE--CHAPTER1 37
603.54.381.00 --05--2001
(continued)
Op.1000110
ENGINE Removal--Installation
DANGER
Liftandhandleallheavypartsusingsuitablelifting equipment.
Makesurethatassembliesorpartsaresupportedby meansofsuitableslingsandhooks.Makesurethat nooneisstandinginthevicinityoftheloadtobe lifted.
CAUTION
Alwaysuseappropriatetoolstoalignfixingholes. NEVERUSEYOURFINGERSORHANDS.
Carryoutoperations1to32relativetoclutchremoval (Op. 1811010 page11,Section18)proceedingas follows:
7.For4--cylinderengines,removetherubberheat guard(2)fromtherollbarsupport(1).
8.For4--cylinderengines,removetheretaining bolts(1)andtherollbarsupport(2).
603.54.381.00 --05--2001
38 SECTION10--ENGINE--CHAPTER1
10
11
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9.For3--cylinderengines,removetheretaining bolts,thecrosspiece(1)andtheright(2)and left--hand(3)rollbarsupports.
10.Removetheretainingboltsandtherightandleft-handenginelateralguards.
13.Detachthesleeve(1)ontheradiatorupperpiping.
14.For4--cylinderengines,removetheretaining boltsandtheradiatoruppertierod(2).
15.Removethepiping(1)andthesleeve(2)located onthelowerpartofthetank.
SECTION10--ENGINE--CHAPTER1 39 603.54.381.00 --05--2001
12
11.Placeacontainerforthecoolantunderthe sleeve(1).
13
12.Detachthesleeve(1)onthelowerpipingand drainoffthecoolant.
14
15
16.Removethepiping(1)and(2)locatedonthe upperpartofthetank.
19.Hitchthefrontsuspension(1)toahoist,remove thesuspensionretainingpin(2)onthesupport (3)andremovethefrontsuspension.
20.Hitchthefrontsuspensionsupport(3)toahoist, removethesumpretainingboltsandremovethe support.
40 SECTION10--ENGINE--CHAPTER1
--05--2001
603.54.381.00
16
17
17.Detachtheoilvaporbreatherpipes(1)andthe turbochargerfeedpiping(2).
18
18.Removethetowbarhook(1)andthefrontballast (2).
19
21.Torefittheengine,proceedasfollows:
CAUTION
Alwaysuseappropriatetoolstoalignfixingholes. NEVERUSEYOURFINGERSORHANDS.
--Applythetorquesettingslistedonpage24.
--Hitchthefrontsuspensionsupporttoahoistand refittothesump,securinginpositionwiththeretainingbolts.
--Hitchthefrontsuspensiontoahoist,fitonthe supportandassemblethesuspensionretaining pin.
--Refitthefrontballastandtowbar.
--Refittheoilvapourrecoverypipingandtheturbochargerfeedpiping.
--Refitthepipingontheupperpartofthetank.
--Detachthepipingandsleevelocatedonthe lowerpartofthetank.
--For4--cylinderengines,fittheuppertankretainingtierodandtightentheretainingbolts.
--Refittheradiatorupperpipingsleeve.
--Refittheradiatorlowerpipingsleeve.
--Fillupwithcoolant.
--Assembletheenginelateralguardsandretaining bolts.
--For3--cylinderengines,fittherightandleft--hand supports,therollbarcrosspieceandtheretainingbolts.
--For4--cylinderengines,assembletherollbar supportandretainingbolts.
--For4--cylinderengines,fittherubberheatguard ontherollbarsupport.
--Carryouttherelativeclutchassemblyoperations asdescribedinoperation 1811010 page19, Section18)
--Loosentheinjectorunionsandrevtheengine withthestartermotor;whenfuelcomesoutwithoutairbubbles,tightentheinjectorunionsand carryouttheenginestart--uptest.
SECTION10--ENGINE--CHAPTER1 41 603.54.381.00 --05--2001
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Op.1000130 COMPRESSIONTEST
Incaseofpoorengineperformance,inadditionto checkingthefuelinjectionsystem(injectionnozzles andinjectionpump),alsotestthecompressionon eachcylinder.
DANGER
Donotusematches,lighters,blowtorchesorany formofnakedflameasasourceoflightwheninspectingtheengineduetothepresenceofinflammablefluidsandvapour.
Compressionratio
Thecompressionratioisameasureofthequantity ofairdrawnintothecylinder,andprovidesanindicationoftheefficiencyofthesealingelementsinthe cylinder(pistonringsandvalves).
Uniformcompressioninallthecylindersensuresthat theyallperformanequalamountofwork,provided thateachcylinderisinjectedwiththesamequantity offuelattherighttime.
Lowcompressionnotonlyreducesengineperformance,italsocausesincompletefuelcombustiondue tothelackofavailablecombustionair.
Theenginethereforegivespoorperformancewith excessivefuelconsumptionand,consequently,exhaustsmokeandrestrictionoftheexhaustpassages.
Asthecompressionratio alsovarieswiththetemperatureoftheengine (coldenginesproducelower compressionvaluesthanhotengines),thecompressionshouldonlybetestedwhentheengineisatnormaloperatingtemperature.
Compressionshouldbetestedusingthecompressiontestkit 291309, asfollows:
1)runtheengineuntilitreachesnormaloperating temperature;
2)switchofftheengine;
3)disconnecttheleadfromtheenginestopelectromagnetontheinjectionpumpinordertoclosethe valve,andblocktheflowoffueltotheinjectors;
4)removetheinjectorfromthecylindertobetested;
5)turntheengineoverafewtimeswiththestarter motorinordertoexpelanycarbonresidue;
6)fitthedummyinjector 293862 inplaceoftheinjectorremovedpreviously,interposingthecoppersealingwasher;
7)connectthecompressiontestinstrument 291309 andtakereadingswhileturningtheengineoverwith thestartermotor.
Onenginesinperfectworkingorder,withthesump oilatapprox.40 oC(104 oF)atsealevel(760mm, 29.9212in.,mercury)andatanenginespeedof200 to280rpm,thecompressionshouldbe25.5to27.5 bar(369.8to398.8psi).
8)Testthecompressionontheothercylinders,repeatingsteps4--5--6--7,bearinginmindthat:
Theminimumpermissiblecompressiononaused engineis21.6bar(313.2psi).
Themaximumpermissiblecompressiondifference betweencylindersis3bar(43.5psi).
Every100meters(109.36yards)abovesealevel correspondstoareductionincompressionbyapprox.1%.
CONSIDERATIONS: Uniformcompression
Althoughhighcompressionisimportant,itismore importantforsmoothenginerunningthatcompressionisuniforminallcylinders.
Lowcompressionreadings
Ifextremelylowpressurereadingsareobtainedon onecylinderitisadvisabletorepeatthetest.
Beforetestingthistime,pourapprox.onespoonful ofengineoilintothecylinderthroughtheinjector bore.
Turnovertheengineafewtimestodistributetheoil evenlyoverthecylinderwalls,andthenrepeatthe test.
Ifthesecondtestreadingsaresignificantlyhigher, suspectwornpistonrings,out--of--roundordamaged pistonsorliners.
Ifthesecondtestreadingsarenothigher,theproblemwillbethevalves.
Ontheotherhand,ifthesecondtestreadingshows onlyaslightimprovement,theproblemwillbedueto boththevalvesandtherings.
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42 SECTION10--ENGINE--CHAPTER1
Op.1000154 ENGINE Disassembly--Assembly CAUTION
Handleallpartscarefully. Donotputyourhandsorfingersbetweenparts. Wearsuitablesafetyclothing--safetygoggles, glovesandshoes.
Usingseries 293860 brackets,positionandsecure theengineontherotatingstand 290090, proceeding asfollows:
1.Disconnecttheturbochargerlubricationpiping (1).
2.Removetheretainingboltsandtheexhaust manifold(2)togetherwiththeturbocharger(1).
3.Removeretainingnuts(1)and(2)andthebelt tensionadjustmentbracket.
4.Removethealternatorfulcrumlowerbolt(4).
5.Recoverthealternator(3)andthebelt(5).
6.Disconnectpiping(2)and(5)onthesediment filter.
7.Removetheintakemanifold(1)andsediment filter(3).
8.Disconnectthepipingandremovethemanipulatoroiltank(4)andbracket.
9.Removetheinjectionpump/injectorsunions(6) andpiping.
10.Removethefuelfilter(7)connectionsandpiping.
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11.Disconnectpiping(1)and(2)ontheinjection pump.
12.Removetheretainingnuts(3)thatsecurethe pumptothetimingcasingandtheaccesscover (4)tothegearunit.
13.Removethepumpretainingnutsandgearunit, extractingthegearunitwithtool 295042;recover thepumpandtheWoodruffkey.
14.Disconnectthepipingandremovethefuelpump (5).
15.Removetheretainingboltsandthestartermotor (1).
16.Removetheretainingbolts,detachthefan(1) andrelativepulley(2).
17.Removetheoilfilter(3).
18.Detachthepipingandremovethecoolantpump (1).
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25
26
MDC0282B 27
19.Removetheretainingboltsandthecoolantpump support(1).
20.Removetheretainingboltsandthethermostat (1),togetherwiththesupport.
21.Detachthemanipulatorcircuitfuelpumppiping (1)and(2).
22.Removetheshaftpulley(3)andhub.
23.Disassembletheintake(1)anddeliverypipes (2),theliftpump(1)andthemanipulatorcircuit fuelpump(3).
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MDC0284B 29
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46 SECTION10--ENGINE--CHAPTER1
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24.Removetheinjectormountingnuts,theunderlyingsphericalwashers,thenthesupportsandthe injectorsthemselves.
2 1 25098 32
25.Removetheretainingbolts(1),washersand seal,thenremovetherockerhousingcover(2) andseal.
25099 1 2 33
26.Removetherockershaftretainingbolts(2),then removetheentirerockershaftassembly(1).
25100 2 1 34
27.Removethevalvecollets(1)andextractthe pushrods(2).
25101 1 35
28.Unscrewthecylinderheadretainingboltsandremovetheheadwithhoistandhook 290740 29.Removethecylinderheadgasket.
