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26

SECTION 10 -- ENGINE -- CHAPTER 1

603.54.381.00

-- 05 -- 2001

26102

1

Splining tool to be manufactured for assembling the crankshaft front seal

(print No. 50138 on the tool -- Values in mm).

Make in UNI C40 material.

26103

3.8 to 4

2

Splining tool to be manufactured for assembling the crankshaft rear seal

(print No. 50139 on the tool -- Values in mm).

Make in UNI C40 material.

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Summary of Contents for TK65

Page 1: ...NUAL SECTIONS GENERAL GUIDELINES 00 ENGINE 10 CLUTCH 18 TRANSMISSIONS 21 REAR MECHANICAL TRANSMISSION 27 POWER TAKE OFF 31 BRAKES 33 HYDRAULIC SYSTEMS 35 STEERING CLUTCHES 46 SUSPENSION AND TRACKS 48 ELECTRICAL SYSTEM 55 S E R V I C E 6035438100 ...

Page 2: ...Find manuals at https best manuals com ...

Page 3: ...on the grooves so that they will deviate the fluid towards the inner side of the seal coat the sealing lip with a thin layer of lubricant use oil rather than grease and fill the gap between the sealing lip and the dust lip on double lip seals with grease insert the seal in its seat and press down using a flat punch do not tap the seal with a hammer or mallet whilst inserting the seal check that th...

Page 4: ...efully clean the seats for the rubber rings 2 Thoroughly clean the rings on the seals 3 Insert each metal ring 2 on the respective rubber ring 1 as shown in the drawing acting on the points indicated by the arrows 1 4 Make sure that the metal ring is fitted correctly checking that measurement A is constant on all of the circumference 5 Assemble each pair of rings in their respective seats 1 manual...

Page 5: ... efficient and long lasting operation By using these tools repair personnel will benefit from operating in optimal technical conditions obtaining the best results saving time and effort working in safe conditions CAUTION Wear limit values indicated for certain parts are recommended but not binding The terms front rear right hand and left hand when referred to different parts are intended as seen f...

Page 6: ... or loose articles of clothing such as ties torn clothing scarves open jackets or shirts with open zips that may remain entangled in moving parts It is advised to wear approved safety clothing e g non slip footwear gloves safety goggles helmets etc 5 Do not carry out repair operations with someone sitting in the driver s seat unless the person is a trained technician who is assisting with the oper...

Page 7: ...n carrying out checks with the engine run ning request the assistance of an operator in the driver s seat The operator must maintain visual contact with the service technician at all times If operating outside the workshop position the vehicle on a flat surface and lock in position If working on a slope lock the vehicle in position Move to a flat area as soon as is safely possible Damaged or bent ...

Page 8: ...DRAULIC SYSTEMS A liquid leaking from a tiny hole may be almost invisible but at the same time be powerful enough to penetrate the skin Therefore NEVER USE HANDS TO CHECK FOR LEAKS Use a piece of cardboard or wood for this purpose If any liquid penetrates skin tissue call for medical aid immediately Failure to treat this condition with correct medical procedure may result inseri ous infection or d...

Page 9: ...5 with filter models TK65 TK75 models TK76 TK85 TK95 6 7 1 47 10 5 2 31 7 3 1 61 11 2 2 46 AMBRA SUPER GOLD 15W 40 oil or 10W 30 NH 330G SAE 15W 40 NH 24G SAE 10W 30 API CF 4 SG CCMC D4 MIL L 2104E Steering clutches 1 4 0 31 AMBRA SUPER oil 10W NH 301 C API CE CCMC D4 MIL L 2104C SAE 10W Transmission gears bevel drive brakes and hydraulic lift models TK65 TK75 models TK76 TK85 TK95 Track tension w...

Page 10: ...8 SECTION 00 GENERAL CHAPTER 1 603 54 381 00 05 2001 Find manuals at https best manuals com ...

Page 11: ...nce 91 10 216 10 Rear fuel tank models TK 65 and TK 75 Removal Installation 94 10 216 10 Rear fuel tank models TK 76 TK 85 and TK 95 Removal Installation 97 10 216 40 Front fuel tank models TK 65 and TK 75 Removal Installation 100 10 216 40 Front fuel tank models TK 76 TK 85 and TK 95 Removal Installation 102 10 218 30 Engine injectors Removal Installation 104 10 246 14 Bosch injection pump Remova...

Page 12: ...945 in Piston stroke 115 mm 4 37 in Total displacement model TK 65 2931 cm3 0 6447 gal model TK 75 2931 cm3 0 6447 gal model TK 76 3613 cm3 0 7947 gal model TK 85 3908 cm3 0 8596 gal model TK 95 3908 cm3 0 8596 gal Compression ratio for models TK 65 TK 76 and TK 85 17 to 1 normally aspirated Compression ratio for models TK 75 and TK 95 16 5 to 1 turbocharged Maximum power model TK 65 44 5 kW 60 Hp...

Page 13: ...Cooling system coolant circulation Radiator on models TK 65 TK 75 3 lines of vertical pipes with copper fins Radiator on models TK 76 TK 85 TK 95 4 lines of vertical copper pipes Fan attached to coolant pump pulley intake 4 blade in sheet metal Coolant pump centrifugal vane type Engine speed coolant pump speed ratio 1 1 403 Temperature control thermostat Coolant thermometer coloured scale divided ...

Page 14: ...em Air cleaning dual cartridge dry air filter with clogged filter indicator with centrifugal pre filter and automatic dust ejector Fuel pump double diaphragm Fuel filtering through wire filter in fuel supply pump and replaceable cartridge on delivery line to injection pump Minimum fuel flow rate with pump shaft rotating at 1600 rpm 100 litres hour 22 gal hour Cam operated engine timing BOSCH injec...

Page 15: ... 11 F 1250 L 787 500324962 model TK 95 VE 4 11 F 1250 L 850 500358111 Direction of rotation counter clockwise Injection order 1 2 3 TK 65 TK 75 1 3 4 2 TK 76 TK 85 TK 95 TK 65 TK 75 TK 85 TK 95 TK 76 Injectors BOSCH type 500307714 500317389 Nozzle holder type 4791124 KBEL83S35 Nozzle type 99469341 DLLA132S1320 500317390 DLLA132S 1335 Number of nozzle holes 5 5 Nozzle hole diameter mm in 0 23 0 009...

Page 16: ...r pre lift from TDC mm Pump rotation viewed from drive side counter clockwise Injection order 1 2 3 2 ADVANCE REGULATOR STROKE rpm 1220 Advance stroke 0 7 to 1 1 mm 0 0276 to 0 0433 in 3 FUEL SUPPLY PUMP PRESSURE rpm 1220 Internal pressure 7 9 to 8 5 bar 114 5 to 123 3 psi 4 FULL LOAD DELIVERY rpm 700 Delivery per 1000 shots 66 7 to 67 7 cm3 0 0147 to 0 0149 gal Spread 3 5 cm3 0 0008 gal 5 SPREAD ...

Page 17: ... be used for checking purposes only BENCH TEST PERFORMANCE DATA Test conditions Fixed advance before TDC cylinder No 1 in compression stroke see previous page Relative humidity 70o o 5 Engine without fan air filter and exhaust silencer Ambient temperature 20 3 oC 68 37 4 oF Atmospheric pressure 740 5 mm 29 1339 0 1968 in mercury Specific gravity of diesel fuel 840 g l at a tem perature of 15 oC 59...

Page 18: ... 0 2 to 1 2 mm 0 0079 to 0 0472 in 3 FUEL SUPPLY PUMP PRESSURE rpm 1220 LDA pressure kPa 100 Internal pressure 8 3 to 9 5 bar 129 1 to 137 8 psi 4 FULL LOAD DELIVERY WITH BOOSTER PRESSURE rpm 700 LDA pressure kPa 100 Delivery per 1000 shots 88 4 to 93 4 cm3 0 0194 to 0 0205 gal Spread cm3 5 FULL LOAD DELIVERY WITHOUT BOOSTER PRESSURE rpm 600 LDA pressure kPa 0 Delivery per 1000 shots 70 5 to 75 5 ...

Page 19: ...0 160 100 to 130 0 220 to 0 0286 BENCH TEST PERFORMANCE DATA Test conditions Fixed advance before TDC cylinder No 1 in compression stroke see previous page Relative humidity 70o o 5 Engine without fan air filter and exhaust silencer Ambient temperature 20 3 oC 68 37 4 oF Atmospheric pressure 990 10 mbar 1 8855 psi Specific gravity of diesel fuel 840 g l at a temperature of 15 oC 59 oF Throttle l B...

Page 20: ...f 45o 1oC 113o 33 8oF at outlet 1 START OF DELIVERY Plunger pre lift from TDC mm Pump rotation viewed from drive side counter clockwise Injection order 1 3 4 2 2 ADVANCE REGULATOR STROKE rpm 800 Advance stroke 0 7 to 1 1 mm 0 0276 to 0 0433 in 3 FUEL SUPPLY PUMP PRESSURE rpm 800 Internal pressure 5 9 to 6 5 bar 85 6 to 94 3 psi 4 FULL LOAD DELIVERY rpm 800 Delivery per 1000 shots 65 1 to 66 1cm3 0...

Page 21: ...l 100 70 to 105 0 0154 to 0 0231 250 47 5 to 55 5 0 0104 to 0 0122 BENCH TEST PERFORMANCE DATA TEST Conditions Fixed advance before TDC cylinder No 1 in compression stroke see previous page Relative humidity 70o o 5 Engine without fan air filter and exhaust silencer Ambient temperature 25 oC 77 oF Atmospheric pressure 740 5 mm 29 1339 0 1968 in mercury Specific gravity of diesel fuel 840 g l at a ...

Page 22: ...IVERY Plunger pre lift from TDC mm Pump rotation viewed from drive side coun ter clockwise Injection order 1 3 4 2 2 ADVANCE REGULATOR STROKE rpm 900 Advance stroke 0 7 to 1 1 mm 0 0276 to 0 0433 in 3 FUEL SUPPLY PUMP PRESSURE rpm 900 Internal pressure 6 7 to 7 3 bar 97 2 to 105 9 psi 4 FULL LOAD DELIVERY rpm 800 Delivery per 1000 shots 61 2 to 62 2 cm3 0 0135 to 0 0137 gal Spread 3 5 cm3 0 0008 g...

Page 23: ...4 0 0075 to 0 0097 140 40 to 70 0 0088 to 0 0154 BENCH TEST PERFORMANCE DATA Test conditions Fixed advance before TDC cylinder No 1 in compression stroke see previous page Relative humidity 70o o 5 Engine without fan air filter and exhaust silencer Ambient temperature 25 oC 77 oF Atmospheric pressure 740 5 mm 29 1339 0 1968 in mercury Specific gravity of diesel fuel 840 g l at a tem perature of 15...

Page 24: ...R STROKE rpm 900 Advance stroke 0 8 to 1 2 mm 0 0315 to 0 0472 in 3 FUEL SUPPLY PUMP PRESSURE rpm 900 Internal pressure 6 2 to 6 8 bar 89 9 to 98 6 psi 4 FULL LOAD DELIVERY WITH BOOSTER PRESSURE rpm 750 LDA pressure kPa 100 Delivery per 1000 shots 76 to 77 cm3 0 0167 to 0 0169 gal Spread 3 5 cm3 0 0008 gal 5 FULL LOAD DELIVERY WITHOUT BOOSTER PRESSURE rpm 600 Delivery per 1000 shots 54 2 to 55 2 c...

Page 25: ...per 1000 shots cm3 gal 100 85 to 125 0 0187 to 0 0275 250 60 to 70 0 0132 to 0 0154 150 100 to 130 0 0220 to 0 0286 BENCH TEST PERFORMANCE DATA Test conditions Fixed advance before TDC cylinder No 1 in compression stroke see previous page Relative humidity 70o o 5 Engine without fan air filter and exhaust silencer Ambient temperature 25 oC 77 oF Atmospheric pressure 740 5 mm 29 1339 0 1968 in merc...

Page 26: ...379 104 to 104 024 1 4 0945 to 4 0954 External diameter of cylinder liners 103 02 to 103 05 4 0559 to 4 0571 107 02 to 107 05 4 2134 to 4 2146 Diameter of cylinder liner bores on block 102 85 to 102 9 4 0492 to 4 0512 106 85 to 106 9 4 2067 to 4 2087 Interference fit between cylinder liners and bores on the cylinder block 0 120 to 0 200 0 0047 to 0 0079 Cylinder liners internal diameter oversizes ...

Page 27: ... wear clearance 0 180 0 0071 Standard crankshaft thrust washer thickness 3 378 to 3 429 0 1330 to 0 135 Thrust washer oversizes thickness 0 127 0 254 0 381 0 508 0 005 0 01 0 015 0 02 Width of main bearing including thrust washers 31 766 to 31 918 1 2506 to 1 2566 Width of corresponding crankshaft journal 32 000 to 32 100 1 2598 to 1 2602 Crankshaft assembly endfloat 0 082 to 0 334 0 0032 to 0 013...

Page 28: ...ournals total dial gauge reading 0 04 0 0016 CONNECTING ROD DATA mm in CONNECTING ROD DATA Bore 100 Bore 104 Connecting rods cast iron with oil way Diameter of small end bushing seat 41 846 to 41 884 1 6475 to 1 649 Outside diameter of small end bushing 41 979 to 42 017 1 6527 to 1 6542 Interference between small end bushing and seat 0 095 to 0 171 0 0037 to 0 0067 Inside diameter of small end bus...

Page 29: ... 37 990 1 4954 to 1 4957 Diameter of gudgeon pin seat in piston 37 993 to 38 000 1 4958 to 1 4961 Gudgeon pin to seat clearance 0 003 to 0 017 0 0001 to 0 0007 Gudgeon pin to small end bearing clearance 0 014 to 0 031 0 0005 to 0 0012 Maximum permitted wear clearance 0 06 0 0024 Maximum weight difference between pistons in same engine 20 g 0 0001 lbs Piston ring groove clearance measured verticall...

Page 30: ...der block 0 070 to 0 150 0 0027 to 0 0059 Inside diameter of camshaft bearings fitted and reamed front 51 080 to 51 130 2 011 to 2 013 intermediate 50 580 to 50 630 1 9913 to 1 9933 rear 50 080 to 50 130 1 9716 to 1 9736 Diameter of camshaft journals front 50 970 to 51 000 2 0067 to 2 0079 intermediate 50 470 to 50 500 1 9870 to 1 9882 rear 49 970 to 50 000 1 9673 to 1 9685 Clearance between camsh...

Page 31: ...nd bushing 28 0 050 to 0 100 0 002 to 0 0039 Interference between bushings and support seats 20 0 063 to 0 140 0 0025 to 0 0055 Clearance between gear unit shaft 22 and relative bushings 0 050 to 0 100 0 002 to 0 0039 Clearance between sides of sleeve grooves 17 drive gear unit connection 22 and rotating masses gear unit 13 0 038 to 0 106 0 0015 to 0 0042 Interference between front bush 16 and sea...

Page 32: ...to 0 058 0 0009 to 0 0023 Maximum permitted wear endfloat 0 13 0 0005 Maximum run out of valve guided on its stem measured through 360o with dial gauge contact point resting on valve head contact band 0 03 0 0012 Valve guide oversizes 0 2 0 0079 Valve seat angle in head inlet valve 60o 5 exhaust valve 45o 5 Valve face angle inlet valve 60o 30 7 exhaust valve 45o 30 7 Valve head diameter inlet valv...

Page 33: ...005 Pressure relief valve spring spring free length 45 1 7716 35 9 1 2165 length under load of 45 to 49 N 4 6 to 5 kg 10 14 to 11 02 lbs 37 5 1 4764 length under load of 88 to 94 N 9 to 9 6 kg 19 84 to 21 16 lbs 30 5 1 2008 spring length 2 fig 134 under load of 127 8 to 141 2 N 130 to 144 kg 286 6 to 317 46 lbs 29 1 1417 spring length 2 fig 134 under load of 233 4 to 258 N 238 to 263 kg 524 7 to 5...

Page 34: ... TK 95 M 12 x 1 25 110 11 2 Intake manifold retaining bolts 1 fig 23 M 8 25 2 6 Alternator and belt tension adjustment nut 2 fig 22 M 10 x 1 25 55 5 6 Coolant pump retaining bolts 1 fig 27 M 10 x 1 25 55 5 6 Nuts for injector mounting studs 1 fig 90 M 8 25 2 6 Tappet cover nuts 1 fig 32 M 8 15 1 5 Rocker shaft pedestal bolts 2 fig 33 M 8 25 2 5 Oil pump and cover retaining bolts 1 fig 41 M 8 25 2 ...

Page 35: ...ing pliers X 291048 Piston ring clamp X 292248 Protractor for angular torque measurement X 291504 Puller for crankshaft pulley hub X 291883 Wrench for valve clearance adjust ment X 291046 Drift for valve guide extraction in stallation X 294027 Twist bit for enlarging valve guide bore X 294028 80 Tapered grinder for swaging ex haust valve guides X 293231 Bush for valve guide installation with 29104...

Page 36: ...o be manufactured for assembling the crankshaft front seal print No 50138 on the tool Values in mm Make in UNI C40 material 26103 3 8 to 4 2 Splining tool to be manufactured for assembling the crankshaft rear seal print No 50139 on the tool Values in mm Make in UNI C40 material ...

Page 37: ...SECTION 10 ENGINE CHAPTER 1 27 603 54 381 00 05 2001 1 2 3 4 5 6 7 25355 3 Engine longitudinal cross section 3 cylinder model TK 65 ...

Page 38: ...28 SECTION 10 ENGINE CHAPTER 1 603 54 381 00 05 2001 25356 4 Engine cross section 3 cylinder model TK 65 ...

Page 39: ...SECTION 10 ENGINE CHAPTER 1 29 603 54 381 00 05 2001 1 2 3 4 5 7 6 25357 5 Engine longitudinal cross section 4 cylinder models TK 76 and TK 85 ...

Page 40: ...30 SECTION 10 ENGINE CHAPTER 1 603 54 381 00 05 2001 1 25358 6 Engine longitudinal cross section 4 cylinder models TK 76 and TK 85 ...

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