New Holland TK65-TK75-TK76-TK85-TK95 TRACTORS. SERVICE MANUAL

SECTION 00 -- GENERAL -- CHAPTER 1

GENERAL INSTRUCTIONS

IMPORTANT NOTICE

All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND

service technicians, in strict accordance with the instructions given and using any specific tools necessary.

Anyone performing the operations described herein without strictly following the instructions is personally re-

sponsible for any eventual injury or damage to property.

BATTERY

Before carrying out any kind of service operations, disconnect and isolate the battery negative lead, unless other-

wise requested for specific operations (e.g.: operations that require the engine running). Once the specific oper-

ation has been completed, disconnect the lead in order to complete the operation.

SHIMMING

For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add

up the recorder values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated

value indicated for each on shim.

ROTATING SHAFT SEALS

For correct rotating shaft seal installation, proceed as follows:

before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes;

thoroughly clean the shaft and check that the working surface on the shaft is not damaged;

position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direc-

tion and position 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 the it is perpendicular to the seat; once settled, make sure that it makes

contact with the thrust element, if required;

to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.

O--RING ìSEALSî

Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twist-

ing, which would jeopardise sealing efficiency.

SEALING COMPOUNDS

Apply one of the following sealing compounds on the mating surfaces marked with an X: RTV SILMATE, RHO-

DORSIL CAF 1 or LOCTITE 510 or SILASTIC AP black.

Before applying the sealing compound, prepare the surfaces as follows:

remove any incrustations using a wire brush;

thoroughly de--grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a

water and soda solution.

BEARINGS

When installing bearings it is advised to:

heat the bearings to 80 to 90⁰C (176 to 194⁰F) before fitting on the shafts;

allow the bearings to cool before installing them from the outside.

SPRING PINS

When fitting split socket elastic pins, ensure that the pin notch is positioned in the direction of the force required

to stress the pin.

Spiral spring pins do not require special positioning.

603.54.381.00 -- 05 -- 2001

SECTION 00 -- GENERAL -- CHAPTER 1

FRONT SEALS

Carefully check the metal rings, making sure that the

sealing surfaces show no signs of scoring, dents or

wear caused by ring pair misalignment or surface

flatness errors.

Even if only one of the rings is faulty, change the en-

tire seal.

Never pair a used ring with a new one or use different

pairs of rings.

To fit the seals, proceed as follows.

1. Eliminate any sharp edges or burr and carefully

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.

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), manually positioning the rubber ring

(as shown in figure

6. Before terminating assembly operations, clean

the sealing surfaces (1) with a clean (not frayed)

cloth and pour a thin covering of fluid oil over the

surfaces.

603.54.381.00 -- 05 -- 2001

SECTION 00 -- GENERAL -- CHAPTER 1

SPARE PARTS

Only use original NEW HOLLAND spare parts bearing the logo shown below.

Only original spare parts guarantee the same quality, duration and safety as they are the same parts that are

assembled during production.

Only original NEW HOLLAND parts can offer this guarantee.

When ordering spare parts, always provide the following information:

vehicle model (commercial name) and frame number;

engine type and number;

part number of the ordered part, which can be found in the ìMicrofichesî or the ìSpare Parts Catalogueî, used

for order processing.

TOOLS

The tools that NEW HOLLAND propose and illustrate in this manual are:

specifically researched and designed for use with NEW HOLLAND vehicles;

essential for reliable repair operations;

accurately built and rigorously tested so as to offer 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 ìfrontî, ìrearî, ìright--

handî and ìleft--handî (when referred to different parts) are intended as seen from the driving position with the

vehicle in the normal direction of movement.

MOVING THE TRACTOR WITH THE BATTERY REMOVED

External power supply cables should only be connected to the respective positive and negative cable terminals,

using efficient clamps that guarantee adequate and secure contact.

Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle.

If the vehicle electrical system requires checking, carry out operations with the power supply connected; once

checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.

603.54.381.00 -- 05 -- 2001

SECTION 00 -- GENERAL -- CHAPTER 1

SAFETY REGULATIONS

WARNING AND DANGER SYMBOL

This warning symbol points out important messages

concerning your safety.

Carefully read the following safety regulations and

observe advised precautions in order to avoid poten-

tial hazards and safeguard your health and safety.

In this manual the symbol is accompanied by the fol-

lowing key--words:

CAUTION -- Warnings concerning unsuitable repair

operations that may jeopardise the safety of Service

personnel.

DANGER Specific warnings concerning potential

hazards for operator safety or for other persons di-

rectly or indirectly involved.

Do not carry out repair operations with someone

sitting in the driverís seat, unless the person is a

trained technician who is assisting with the oper-

ACCIDENT PREVENTION

ation in question.

Most accidents or injuries that occur in workshops

Do not operate the vehicle or use any of the im-

are the result of non--observance of simple and fun-

plements from different positions, other than the

damental safety regulations. For this reason, IN

driverís seat.

MOST CASES THESE ACCIDENTS CAN BE

Do not carry out operations on the vehicle with

AVOIDED by foreseeing possible causes and conse-

the engine running, unless specifically indicated.

quently acting with the necessary caution and care.

Stop the engine and check that the hydraulic cir-

Accidents may occur with all types of vehicles, re-

cuits are pressure--free before removing caps,

gardless of how well it was designed and built.

covers, valves, etc.

A careful and judicious service technician is the best

All repair and maintenance operations must be

guarantee against accidents.

carried out using extreme care and attention.

Precise observance of the most basic safety rule is

Service steps and platforms used in the work-

normally sufficient to avoid many serious accidents.

shop or elsewhere should be built according to

DANGER. Never carry out any cleaning, lubrication

standard accident prevention regulations.

or maintenance operations when the engine is run-

Disconnect the batteries and label all controls to

ning.

indicate that the vehicle is being serviced. Any

parts that are to be raised must be locked in posi-

tion.

SAFETY REGULATIONS

Do not check or fill fuel tanks, accumulator bat-

teries, nor use starting liquid when smoking or

near naked flames, as these fluids are inflam-

GENERAL GUIDELINES

mable.

Carefully follow specified repair and mainten-

Brakes are inoperative when manually released

ance procedures.

for repair or maintenance purposes. Use blocks

or similar devices to control the machine in these

Do not wear rings, wristwatches, jewellery, un-

conditions.

buttoned or loose articles of clothing such as:

ties, torn clothing, scarves, open jackets or shirts

The fuel nozzle should always be in contact with

with open zips that may remain entangled in

the filling aperture. Maintain this position until fill-

moving parts. It is advised to wear approved

ing operations are completed in order to avoid

safety clothing, e.g.: non--slip footwear, gloves,

possible sparks caused by the accumulation of

safety goggles, helmets, etc.

static electricity.

603.54.381.00 -- 05 -- 2001

SECTION 00 -- GENERAL -- CHAPTER 1

Only use specified towing points for towing the

driverís seat. The operator must maintain visual

tractor. Connect parts carefully. Make sure that

contact with the service technician at all times.

all pins and/or locks are secured in position be-

If operating outside the workshop, position the

fore applying traction. Never remain near the

vehicle on a flat surface and lock in position. If

towing bars, cables or chains that are operating

working on a slope, lock the vehicle in position.

under load.

Move to a flat area as soon as is safely possible.

Transport vehicles that cannot be driven using a

Damaged or bent chains or cables are unreliable.

trailer or a low--loading platform trolley, if avail-

Do not use them for lifting or towing. Always use

able.

suitable protective gloves when handling chains

When loading or unloading the vehicle from the

or cables.

trailer (or other means of transport), select a flat

area capable of sustaining the trailer or truck

Chains should always be safely secured. Make

wheels. Firmly secure the tractor to the truck or

sure that the hitch--up point is capable of sustain-

trailer and lock the wheels in the position used by

ing the load in question. Keep the area near the

the carrier.

hitch--up point, chains or cables free of all by-

standers.

Electric heaters, battery--chargers and similar

equipment must only be powered by auxiliary

Maintenance and repair operations must be car-

power supplies with efficient ground insulation to

ried out in a CLEAN and DRY area. Eliminate any

avoid electrical shock hazards.

water or oil spillage immediately.

Always use suitable hoisting or lifting devices

Do not create piles of oil or grease--soaked rags

when raising or moving heavy parts.

as they represent a serious fire hazard. Always

Take extra care if bystanders are present.

store rags in a closed metal container.

Never pour gasoline or diesel oil into open, wide

Before starting the vehicle or implements, make

sure that the driverís seat is locked in position.

or low containers.

Also check that there are no persons within the

Never use gasoline, diesel oil or other inflam-

tractor or implement range of action.

mable liquids as cleaning agents. Use non--in-

flammable, non toxic commercially available sol-

Empty pockets of all objects that may fall unob-

vents.

served into the vehicle parts.

Wear safety goggles with side guards when

In the presence of protruding metal parts, use

cleaning parts with compressed air.

protective goggles or goggles with side guards,

Limit the air pressure to a maximum of 2.1 bar

helmets, special footwear and gloves.

(30.46 psi), according to local regulations.

When welding, use protective safety devices:

Do not run the engine in confined spaces without

tinted safety goggles, helmets, special overalls,

suitable ventilation.

gloves and footwear. All persons present in the

Do not smoke, use naked flames, or cause

area where welding is taking place must wear

sparks in the area when fuel filling or handling

tinted goggles. NEVER LOOK DIRECTLY AT

highly inflammable liquids.

THE WELDING ARC WITHOUT SUITABLE

EYE PROTECTION.

Never use naked flames for lighting when work-

ing on the machine or checking forìleaks.

Metal cables tend to fray with repeated use. Al-

All movements must be carried out carefully

ways use suitable protective devices (gloves,

when working under, on or near the vehicle.

goggles, etc.) when handling cables.

Wear protective equipment: helmets, goggles

Handle all parts carefully. Do not put your hands

and special footwear.

or fingers between moving parts. Wear suitable

When carrying out checks with the engine run-

safety clothing

-- safety goggles, gloves and

ning, request the assistance of an operator in the

shoes.

603.54.381.00 -- 05 -- 2001

SECTION 00 -- GENERAL -- CHAPTER 1

START UP

enough to penetrate the skin; Therefore, NEVER

USE HANDS TO CHECK FOR LEAKS. Use a

Never run the engine in confined spaces that are

piece of cardboard or wood for this purpose. If

not equipped with adequate ventilation for ex-

any liquid penetrates skin tissue, call for medical

haust gas extraction.

aid immediately. Failure to treat this condition

Never place the head, body, limbs, feet, hands or

with correct medical procedure may result in seri-

fingers near fans or rotating belts.

ous infection or dermatosis.

ENGINE

In order to check the pressure in the system use

suitable instruments.

Always loosen the radiator cap slowly before re-

moving it to allow any remaining pressure in the

system to be discharged. Filling up with coolant

WHEELS AND TYRES

should only be carried out with the engine

Make sure that the tyres are correctly inflated at

stopped or idling (if hot).

the pressure specified by the manufacturer.

Never fill up with fuel when the engine is running,

Periodically check the rims and tyres for dam-

especially if hot, in order to prevent the outbreak

age.

of fire as a result of fuel spillage.

Stand away from (at the side of) the tyre when

Never check or adjust fan belt tension when the

checking inflation pressure.

engine is running.

Only check pressure when the tractor is un-

Never adjust the fuel injection pump when the ve-

loaded and the tyres are cold, to avoid incorrect

hicle is moving.

readings as a result of over--pressure. Do not use

Never lubricate the vehicle when the engine is

parts of recovered wheels as incorrect welding

running.

brazing or heating may weaken and eventually

cause damage to the wheel.

ELECTRICAL SYSTEMS

Never cut or weld a rim mounted with an inflated

If it is necessary to use auxiliary batteries, re-

tyre.

member that both ends of the cables must be

To remove the wheels, lock both the front and

connected as follows: (+) with (+) and (--) with (--).

rear vehicle wheels. After having raised the ve-

Avoid short--circuiting the terminals. GAS RE-

hicle, position supports underneath, according to

LEASED FROM BATTERIES IS HIGHLY IN-

regulations in force.

FLAMMABLE. During charging, leave the bat-

tery compartment uncovered to improve

Deflate the tyre before removing any objects that

ventilation. Never check the battery charge using

may be jammed in the tyre tread.

ìjumpersî

(metal objects placed on the ter-

Never inflate tyres using inflammable gases; as

minals). Avoid sparks or flames near the battery

this may result in explosions and injury to by-

zone. Do not smoke to prevent explosion haz-

standers.

ards.

Before servicing operations, check for fuel or

REMOVAL AND RE--FITTING

current leaks. Eliminate any eventual leaks be-

fore proceeding with work.

Lift and handle all heavy parts using suitable ho-

Never charge batteries in confined spaces. Make

isting equipment. Make sure that parts are sus-

sure that there is adequate ventilation in order to

tained by appropriate hooks and slings. Use the

prevent accidental explosion hazards as a result

hoisting eyebolts for lifting operations. Extra care

of the accumulation of gases released during

should be taken if persons are present near the

charging operations.

load to be lifted.

Always disconnect the batteries before perform-

Handle all parts carefully. Do not put your hands

ing any kind of servicing on the electrical system.

or fingers between parts. Wear suitable safety

clothing -- safety goggles, gloves and shoes.

HYDRAULIC SYSTEMS

Avoid twisting chains or metal cables. Always

A liquid leaking from a tiny hole may be almost

wear safety gloves when handling cables or

invisible but, at the same time, be powerful

chains.

603.54.381.00 -- 05 -- 2001

SECTION 00 -- GENERAL -- CHAPTER 1

CONSUMABLES

QUANTITY

RECOMMENDED

COMPONENT TO BE FILLED

NEW HOLLAND

INTERNATIONAL

NEW HOLLAND

OR TOPPED UP

SPECIFICATIONS

(gallons)

PRODUCTS

Cooling system:

Water & liquid

AMBRA

models TK65, TK75

10.5

(2.31)

NH 900 A

AGRIFLU

models TK76, TK85, TK95

13.0

(2.86)

50% + 50%

Fuel tank:

Decanted and fil-

models TK65, TK75

(17.6)

tered diesel fuel

models TK76, TK85, TK95

129

(28.38)

Engine sump:

without filter:

NH 330G

models TK65, TK75

6.7

(1.47)

AMBRA

(SAE 15W--40)

API CF--4/SG

SUPER GOLD

models TK76, TK85, TK95

10.5

(2.31)

CCMC D4

15W -- 40 oil or

NH 24G

MIL--L--2104E

with filter:

10W -- 30

(SAE 10W--30)

models TK65, TK75

7.3

(1.61)

models TK76, TK85, TK95

11.2

(2.46)

API CE CCMC D4

AMBRA

Steering clutches

1.4

(0.31)

NH 301 C

MIL--L--2104C

SUPER oil 10W

SAE 10W

Transmission:

(gears, bevel drive,

brakes and hydraulic

lift)

API GL4

33.3

(7.32)

AMBRA MULTI F

models TK65, TK75

NH 420 A

ISO 46/68

oil

models TK76, TK85, TK95

39.0

(7.92)

SAE 20W--30

Track tension wheel,

carriage rollers, track support

rollers

API GL5

Final drives

AMBRA

NH 520 A

MIL--L--2105D

(each)

2.0

(0.44)

HYPOIDE 90 oil

SAE 80W--90

Grease fittings

AMBRA GR9

NH 710 A

NLGI 2

grease

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

SECTION 10 -- ENGINE

Chapter 1 -- Engine

CONTENTS

Section

Description

Page

10 000

General specifications

Main data

Torque settings

Tools

Sections

Lubrication and cooling system diagrams

Troubleshooting

10 001

Engine. Removal--Installation

10 001

Engine. Compression test

10 001

Engine. Disassembly--Assembly

10 101

Valve guides. Replacement

10 101

Injector sleeve. Replacement

10 102

Front engine oil seal. Removal--Installation

10 106

Valve/rocker arm clearance

10 216

Rear fuel tank -- models TK 65 and TK 75. Removal--Installation

10 216

Rear fuel tank -- models TK 76, TK 85 and TK 95. Removal--Installation

10 216

Front fuel tank -- models TK 65 and TK 75. Removal--Installation

100

10 216

Front fuel tank -- models TK 76, TK 85 and TK 95. Removal--Installation

102

10 218

Engine injectors. Removal--Installation

104

10 246

Bosch injection pump. Removal--Installation timing and air bleeding check

106

10 254

Exhaust pipe. Removal--Installation

113

10 402

Coolant pump. Removal--Installation with radiator removed

114

10 402

Coolant pump. Overhaul

115

10 402

Thermostat. Removal--Installation

116

10 406

Radiator. Removal--Installation

117

10 414

Coolant pump and generator drive belt. Adjustment

120

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

GENERAL SPECIFICATIONS

3 cylinders

4 cylinders

Engine, technical type:

model TK 65 -- type 8035.05.421 (BOSCH pump)

See data on page 6--7

model TK 75 -- type 8035.25.421 (BOSCH pump)

See data on page 8--9

model TK 76 -- type 8045.06.421/521 (BOSCH pump)

See data on page 10--11

model TK 85 -- type 8045.05.421/521 (BOSCH pump)

See data on page 12--13

model TK 95 -- type 8045.25L.421 (BOSCH pump)

See data on page 14--15

Cycle

diesel, 4--stroke

Injection

direct

Number of on--line cylinders

Cylinder liners

dry force--fitted in cylinder block

Piston diameter

models TK 65, TK 75

104 mm (4.0945 in.)

model TK 76

100 mm (3.937 in.)

models TK 85, TK 95

104 mm (4.0945 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)

model TK 75

54 kW (72 Hp)

model TK 76

53 kW (71 Hp)

model TK 85

58.8 kW (80 Hp)

model TK 95

66.5 kW (90 Hp)

Maximum power speed -- models TK 65, TK 75

2300 rpm

Maximum power speed -- TK 76, TK 85, TK 95

2500 rpm

Maximum torque speed -- model TK 65

1400 rpm

Maximum torque speed -- model TK 75

1400 rpm

Maximum torque speed -- model TK 76

1500 rpm

Maximum torque speed -- model TK 85

1500 rpm

Maximum torque speed -- model TK 95

1500 rpm

Number of main bearings

Sump pan

structural, cast iron

(continued)

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

(continued)

GENERAL SPECIFICATIONS

3 cylinders

4 cylinders

Lubrication system

forced, with gear pump

Pump drive

camshaft

Engine speed/oil pump speed ratio

2:1

Oil cleaning

mesh filter on oil intake and filtering car-

tridge on delivery line

Normal oil pressure with motor warmed--up and running at

maximum speed:

For models TK 65, TK 76, TK 85

2.9 to 3.9 bar (42.1 to 56.6 psi)

For models TK 75, TK 95 (starting pressure)

6 bar (87 psi)

Pressure relief valve

incorporated in oil pump housing

Valve initial opening pressure

3.5 bar (50.8 psi)

For further lubrication technical data

See page 23

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 into 3 sections

Temperature ranges corresponding to each section:

initial white section

30 to 65^oC (86 to 149^oF)

middle green section (normal working conditions)

65 to 105^oC (149 to 221^oF)

final red section

105 to 115^oC (221 to 239^oF)

For further cooling system technical data

See page 23

Rev counter

incorporated in control panel

Operating system

from gear on camshaft

Hour counter calibrated for engine speed of

1800 rpm

(continued)

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

(continued)

GENERAL SPECIFICATIONS

3 cylinders

4 cylinders

Timing system

overhead valves operated by tappets, rods

and rocker arms via the camshaft located

in the engine block; the camshaft is driven

by the crankshaft using helical gears

Inlet:

start: before TDC

12^o

end: after BDC

31^o

Exhaust:

start: before BDC

50^o

end: after TDC

16^o

valve--rocker arm clearance for timing check

0.45 mm (0.248 in.)

valve--rocker arm clearance (with engine cold):

intake

0.30

0.05 mm (0.1654

0.0276 in.)

exhaust

0.30

0.05 mm (0.1654

0.0276 in.)

For further timing system technical data

See page 20

Fuel system

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 injection pump

rotating distributor type

All--speed governor, incorporated in pump:

BOSCH

centrifugal counterweights

Automatic advance regulator, incorporated in pump:

BOSCH

hydraulic

For further fuel system technical data:

Fixed advance (pump setting for start of delivery before TDC)

-- Pressure setting -- Injection order, and other information

regarding the BOSCH pump

refer to the data for the relevant engine

type in the table on page 2

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

FUEL SYSTEM DATA

Turbocharger (models TK 75, TK 95):

GARRETT type

TA 3118--0.82 A/R--57

Injection pump

rotating distributor with speed governor

and advance variator incorporated

BOSCH pump:

model TK 65

VE 3/11 F 1150 L 766 -- 99441586

model TK 75

VE 3/11 F 1150 L 764 -- 99441587

model TK 76

VE 4/11 F 1250 L 794 -- 99472104

model TK 76

VE 4/11 F 1250 L 810 -- 500324959

model TK 85

VE 4/11 F 1250 L 773 -- 99472102

model TK 85

VE 4/11 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

Nozzle hole diameter

mm (in.)

0.23

(0.0091)

0.21

(0.0083)

Calibration pressure

bar (psi)

260 to 272 (3771 to 3945)

260 to 272

(3771 to

3945)

Delivery lines for BOSCH pump

type

99441952

99449006

Line dimension

mm (in.)

6x1.75x540

6x1.75x530

(0.2362x0.0689x21.260)

(0.2362x

0.0689x

20.866)

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

MODEL TK 65 -- CALIBRATION DATA FOR BOSCH INJECTION PUMP

TYPE VE 3/11 F 1150 L 766 -- 99441586

ASSEMBLY DATA

CALIBRATION TEST CONDITIONS

Pump timing on engine: delivery start 9^o

0.5^o before

Test bench conforming to ISO 4008/1 .../2

TDC of cylinder 1 compression stroke.

Injectors conforming to ISO

7440--A61

Plunger pre--lift for timing on engine: 1 mm (0.0394

(1.688.901.020 with calibrated pad

0.6 mm --

in.) from BDC (with tools 291754 -- 291755).

0.0236 in.).

Cylinder No.1 delivery line union on pump: marked

Injector pressure setting 172 to 175 bar (2495 to

with letter A.

2538 psi).

Fuel supply pressure:

ASSEMBLY DIMENSIONS

0.35 + 0.05 bar (5.1 + 0.7 psi).

Pipes (conforming to ISO 4093.2):

SYMBOL

VHA

6x2x840mm(0.2362x0.0787x33.071in.).

30.1

36.5 to 38.5

40.4 to 45.6

Graduate drain time

: 30î.

(in.)

(1.185)

(1.437 to

(1.5905 to

1.5157)

1.7953)

Test liquid: ISO 4113 at a temperature of 45^o

1oC

(113^o

33.8^oF) at outlet.

1. START OF DELIVERY

Plunger pre--lift from TDC:

Pump rotation (viewed from drive side):

Injection order:1--2--3

mm --

counter--clockwise

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 GOVERNOR AT IDLE SPEED

rpm: 325

Delivery per 1000 shots: 16.3 to 17.3 cm³ (0.0036 to 0.0038 gal.)

Spread:

5.5 cm³ (0.0012 gal.)

6. SPREAD GOVERNOR AT MAXIMUM SPEED

rpm: 1200

Delivery per 1000 shots: 48.5 to 49.5 cm³ (0.0107 to 0.0109 gal.)

Spread: cm³ --

7. DELIVERY AT STARTING SPEED

rpm: 100

Delivery per 1000 shots: 60 to 100 cm³ (0.0132 to 0.022 gal.)

8. TRANSFER PRESSURE PROGRESSION

rpm

1220

400

Internal pressure

bar (psi)

7.9 to 8.5 (114.6 to 123.3)

3.4 to 4.4 (49.3 to 63.8)

9. INJECTION ADVANCE PROGRESSION

rpm

1220

1260

Advance stroke

mm (in.)

0.7 to 1.1 (0.276 to 0.0433)

1.3 to 1.9 (0.0512 to 0.0748)

10. BACKFLOW

rpm

400

1150

Backflow

cm³ (gal.)/10 sec

16 to 28 (0.0035 to 0.0062)

20 to 36 (0.0044 to 0.0079)

(continued)

Note: the values shown above in brackets must be used for checking purposes only.

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

(continued)

11. DELIVERY PROGRESSION

rpm

Delivery per 1000 shots: cm³ (gal.)

1270

0 to 3 (0 to 0.0007)

1200

48.5 to 49.5 (0.0107 to 0.0109)

700

66.7 to 67.7 (0.0147 to 0.0149)

1150

64.4 to 68.4 (0.0142 to 0.0150)

12. DELIVERY CHECK AT IDLE SPEED

rpm

325

275

Delivery per 1000

shots:

cm³ (gal.)

16.3 to 17.3 (0.0036 to 0.0038)

46 to 47 (0.0101 to 0.0103)

13. ZERO CAPACITY (STOP)

rpm

Voltage (volts)

Delivery per 1000 shots: cm³ (gal.)

325

0 to 3 (0 to 0.0070)

14. AUTOMATIC START SUPPLEMENT

rpm

Delivery per 1000 shots: cm³ (gal.)

100

60 to 100 (0.0132 to 0.022)

270

59 to 69 (0.0130 to 0.0152)

Note: the values shown above in brackets must be used for checking purposes only.

BENCH TEST PERFORMANCE DATA

Test conditions

Fixed advance before TDC cylinder No.1 in compression

Relative humidity 70^o/_o

stroke: (see previous page)

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.)

Specific gravity of diesel fuel 840 g/l at a tem-

mercury.

perature of 15^oC (59^oF).

Fuel consum-

Engine speed

Power output with engine run--in for a total of:

Throttle

ption

lever

Braking load

applied

Production speed

50 hours (total)

position

rpm

kW (Hp)

kg (lbs.)/h

9.9 to 10.5

For maximum power

43 to 45.6

Maximum

2300

(57.1)

(21.83 to

output

(58.5 to 62)

23.15)

6.4 to 6.8

30 to 31.8

Maximum

For maximum torque

1400

29.4

(40)

(14.11 to

(40.8 to 43.2)

23.15)

2450 to

Maximum

None (no--load)

2500

Minimum

None (no--load)

625 to 675

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

MODELS TK 75 -- CALIBRATION DATA FOR BOSCH INJECTION PUMP

TYPE VE 3/11 F 1150 L 764 -- 99441587

ASSEMBLY DATA

CALIBRATION TEST CONDITIONS

Pump timing on engine: delivery start 6^o

0.5^o be-

Test bench conforming to ISO 4008/1 .../2

fore TDC of cylinder 1 compression stroke.

Injectors conforming to ISO

7440--A61

Plunger pre--lift for timing on engine:

(1.688.901.027 with calibrated pad

0.5 mm --

(0.0394 in.) from BDC (with tools 291754 -- 291755).

0.0197 in.).

Cylinder No.1 delivery line union on pump: marked

Injector pressure setting 250 to 253 bar (3626 to

with letter A.

3669 psi).

ASSEMBLY DIMENSIONS

Fuel supply pressure:

0.35 + 0.05 bar (5.1 + 0.7 psi).

SYMBOL

Delivery pipes (conforming to ISO 4093.2):

38.6 to 40.6

40.4 to 45.6

6x2x450mm(0.2362x0.0787x17.716in.).

(in.)

(1.5197 to

(1.5905 to

Graduate drain time

: 30î.

1.5984)

1.7953)

Test liquid: ISO 4113 at a temperature of 45^o

1oC

(113^o

33.8^oF) at outlet.

1. START OF DELIVERY

Plunger pre--lift from TDC:

Pump rotation (viewed from drive side):

Injection order:1--2--3

mm --

counter--clockwise

2. ADVANCE REGULATOR STROKE

rpm: 850

LDA pressure: kPa 100

Advance stroke: 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 cm³ (0.0155 to 0.0166 gal.)

Spread: -- cm³

6. SPREAD GOVERNOR AT IDLE SPEED

rpm: 325

LDA pressure: kPa 0

Delivery per 1000 shots: 6.3 to 17.3 cm³ (0.0014 to 0.0038 gal.)

Spread:

-- cm³

7. SPREAD GOVERNOR AT MAXIMUM SPEED

rpm: 1210

LDA pressure: kPa 100

Delivery per 1000 shots: 37 to 53 cm³ (0.0081 to 0.0117 gal.)

Spread: -- cm³

8. DELIVERY AT STARTING SPEED

rpm: 100

Delivery per 1000 shots: 85 to 125 cm³ (0.0187 to 0.0275 gal.)

9. INJECTION ADVANCE PROGRESSION

LDA pressure:

kPa

100

rpm

850

950

Advance stroke

mm (in.)

0.2 to 1.2 (0.0079 to 0.0473)

1.3 to 1.9 (0.0512 to 0.0748)

10. TRANSFER PRESSURE PROGRESSION

LDA pressure:

kPa

100

rpm

500

1220

1180

Internal pressure supply:

bar (psi)

3.8 to 5.0

8.3 to 9.5

7.9 to 9.1

(55.1 to 72.5)

(120.4 to 137.8)

(114.6 to 132)

11. BACKFLOW

rpm

600

1150

LDA pressure:

kPa

100

Backflow for 10 sec.

l (gal.)/h

17 to 31 (3.7395 to 6.819)

21 to 39 (4.6193 to 8.5788)

(continued)

Note: the values shown above in brackets must be used for checking purposes only.

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

(continued)

12. DELIVERY PROGRESSION

rpm

LDA pressure kPa

Delivery per 1000 shots: cm³ (gal.)

1270

100

0 to 3 (0 to 0.0007)

1210

100

37 to 53 (0.0081 to 0.0117)

700

100

88.4 to 93.4 (0.0194 to 0.0205)

600

80 to 87 (0.0176 to 0.0191)

600

70.5 to 75.5 (0.0155 to 0.0166)

1150

100

76 to 82 (0.0167 to 0.0180)

13. ZERO CAPACITY (STOP)

rpm:

325

Voltage (volts): 0

Delivery per 1000 shots: cm³:

0 to 3

14. DELIVERY CHECK AT IDLE SPEED

rpm

325

410

Delivery per 1000 shots:

cm³ (gal.)

6.3 to 17.3 (0.0014 to 0.0038)

0 to 3 (0 to 0.0007)

Note: the values shown above in brackets must be used for checking purposes only.

15. AUTOMATIC START SUPPLEMENT

rpm

Delivery per 1000 shots: cm³ (gal.)

100

85 to 125 (0.0187 to 0.0275)

250

74.6 to 86.6 (0.0164 to 0.0190)

160

100 to 130 (0.220 to 0.0286)

BENCH TEST PERFORMANCE DATA

Test conditions

Fixed advance before TDC cylinder No.1 in compression

Relative humidity 70^o/_o

stroke: (see previous page)

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).

Engine

Fuel

Power output with engine run--in for a total of:

Throttle

speed

consumption

lever

Braking load

applied

Production speed

50 hours (total)

position

rpm

kW (Hp)

kg (lbs.)/h

11.6 to 12.3

For maximum

51.4 to 54.5 (1)

Maximum

2300

50.4

(68.5)

(25.57 to

power output

(69.9 to 74.1)

27.12)

9.1 to 9.6

For maximum

40.1 to 42.6 (2)

Maximum

1400

39.3

(53.4)

(20.06 to

torque

(54.5 to 57.9)

21.16)

2475 to

Maximum

None (no--load)

2525

Minimum

None (no--load)

625 to 675

Note: Air delivery pressure (1) 0.875 to 1.025 bar (12.6908 to 14.8664 psi) -- (2) 0.55 to 0.65 bar (7.9771 to 9.4275 psi).

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

MODELTK 76 -- CALIBRATION DATA FOR BOSCH INJECTION PUMP

TYPE VE 4/11 F 1250 L 794 -- 99472104 / VE 4/11 F 1250 L 810 -- 500324959

ASSEMBLY DATA

CALIBRATION TEST CONDITIONS

Pump timing on engine: delivery start 9^o

0.5^o before

Test bench conforming to ISO 4008/1 .../2

TDC of cylinder 1 compression stroke.

Injectors conforming to ISO

7440--A61

Plunger pre--lift for timing on engine: 1 mm (0.0394

(1.688.901.027 with calibrated pad

0.5 mm --

in.) from BDC (with tools 291754 -- 291755).

0.0197 in.).

Cylinder No.1 delivery line union on pump: marked

Injector pressure setting 247 to 253 bar (3582 to

with letter A.

3669 psi).

ASSEMBLY DIMENSIONS

Fuel supply pressure:

SYMBOL

SVS

0.35 + 0.05 bar (5.1 + 0.7 psi).

Delivery pipes (conforming to ISO 4093.2):

3.1 to 3.5

0.9 to 1.3

36.5 to

38.8 to 44

(in.)

(0.1220 to

(0..0354 to

38.5

(1.5276 to

6x2x450mm(0.2362x0.0787x17.716in.).

0.1378)

0.0512)

(1.437 to

1.7323)

Graduate drain time

: 30î.

1.5157)

Test liquid: ISO 4113 at a temperature of 45^o

1oC

(113^o

33.8^oF) at outlet.

1. START OF DELIVERY

Plunger pre--lift from TDC: mm --

Pump rotation (viewed from drive side):

Injection order:1--3--4--2

counter--clockwise

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 (0.0143 to 0.0145 gal.)

Spread:-- 3.5 cm³ (-- 0.0008 gal.)

5. SPREAD GOVERNOR AT IDLE SPEED

rpm: 325

Delivery per 1000 shots: 7.5 to 8.5 cm³ (0.0016 to 0.0019 gal.)

Spread:

3.5 cm³ (0.0008 gal.)

6. SPREAD GOVERNOR AT MAXIMUM SPEED

rpm: 1270

Delivery per 1000 shots: 43.5 to 44.5 cm³ (0.0096 to 0.0098 gal.)

Spread: -- cm³

7. DELIVERY AT STARTING SPEED

rpm: 100

Delivery per 1000 shots: 75 to 105 cm³ (0.0165 to 0.0231 gal.)

8. TRANSFER PRESSURE PROGRESSION

rpm

800

400

Internal pressure

bar (psi)

5.9 to 6.5 (85.6 to 94.3 psi)

3.8 to 4.4 (55.1 to 63.8 psi)

9. INJECTION ADVANCE PROGRESSION

rpm

800

Advance stroke

mm (in.)

0.7 to 1.1 (0.0276 to 0.0433)

10. BACKFLOW

rpm

400

1200

Backflow

cm³ (gal.)

44.1 to 77.2 (0.0097 to 0.017)

60.7 to 104.8 (0.0134 to

0.0231)

(continued)

Note: the values shown above in brackets must be used for checking purposes only.

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

(continued)

11. DELIVERY PROGRESSION

rpm

Delivery per 1000 shots: cm³ (gal.)

1340

0 to 3 (0 to 0.0007)

1270

43.5 to 44.5 (0.0096 to 0.0098)

1200

58.4 to 61.3 (0.0128 to 0.0135)

800

65.1 to 66.1 (0.0143 to 0.0145)

400

59.6 to 67.6 (0.0131 to 0.0149)

12. DELIVERY CHECK AT IDLE SPEED

rpm

325

290

370

Delivery per 1000 shots:

cm³ (gal.)

7.5 to 8.5

15.5 to 23.5

0 to 3

(0.0016 to 0.0019)

(0.00345 to 0.0052)

(0 to 0.0007)

Note: the values shown above in brackets must be used for checking purposes only.

13. ZERO CAPACITY (STOP)

rpm

Voltage (volts)

Delivery per 1000 shots: cm³ (gal.)

325

0 to 3 (0 to 0.0007)

14. AUTOMATIC START SUPPLEMENT

rpm

Delivery per 1000 shots: cm³ (gal.)

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

Relative humidity 70^o/_o

stroke: (see previous page)

Engine without fan, air filter and exhaust silencer.

Ambient temperature 25^oC (77^oF).

Atmospheric pressure 740

5 mm (29.1339

0.1968 in.)

Specific gravity of diesel fuel 840 g/l at a tem-

mercury.

perature of 15^oC (59^oF).

Fuel consum-

Engine speed

Power output with engine run--in for a total of:

Throttle

ption

lever

Braking load applied

Production speed

50 hours (total)

position

rpm

kW (Hp)

kg (lbs.)/h

11.8 to 12.4

For maximum power

51.1 to 54

Maximum

2500

(68)

(26.01 to

output

(69.5 to 73.4)

27.34)

8.0 to 8.4

36.8 to 39

Maximum

For maximum torque

1500

(48.9)

(17.66 to

(51.1 to 54.2)

18.52)

2700 to

Maximum

None (no--load)

2750

Minimum

None (no--load)

625 to 675

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

MODELTK 85 -- CALIBRATION DATA FOR BOSCH INJECTION PUMP

TYPE VE 4/11 F 1250 L 773 -- 99472102 / VE 4/11 F 1250 L 787 -- 500324962

ASSEMBLY DATA

CALIBRATION TEST CONDITIONS

Pump timing on engine: delivery start 9^o

0.5^o before

Test bench conforming to ISO 4008/1 .../2

TDC of cylinder 1 compression stroke.

Injectors conforming to ISO

7440--A61

Plunger pre--lift for timing on engine: 1 mm (0.0394

(1.688.901.027 with calibrated pad

0.5 mm --

in.) from BDC (with tools 291754 -- 291755).

0.0197 in.).

Cylinder No.1 delivery line union on pump: marked

with letter A.

Injector pressure setting 250 to 253 bar (3626 to

3669 psi).

ASSEMBLY DIMENSIONS

Fuel supply pressure:

0.35 + 0.05 bar (5.1 + 0.7 psi).

SYMBOL

Delivery pipes (conforming to ISO 4093.2):

30.1

36.5 to 38.5

37.4 to 42.6

6x2x450mm(0.2362x0.0787x17.716in.).

(in.)

(1.185)

(1.437 to

(1.4724 to

Graduate drain time

: 30î.

1.5157)

1.6772)

Test liquid: ISO 4113 at a temperature of 45^o

1oC

(113^o

33.8^oF) at outlet.

1. START OF DELIVERY

Plunger pre--lift from TDC:

Pump rotation (viewed from drive side): coun-

Injection order:1--3--4--2

mm --

ter--clockwise

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 gal.)

5. SPREAD GOVERNOR AT IDLE SPEED

rpm: 300

Delivery per 1000 shots: 9.2 to 10.2 cm³ (0.002 to 0.0022 gal.)

Spread:

-- cm³

6. SPREAD GOVERNOR AT MAXIMUM SPEED

rpm: 1300

Delivery per 1000 shots: 41.1 to 42.1 cm³ (0.0090 to 0.0092 gal.)

Spread:

3.5 cm³ (0.0008 gal.)

7. DELIVERY AT STARTING SPEED

rpm: 100

Delivery per 1000 shots: 33 to 73 cm³ (0.0073 to 0.0161 gal.)

8. TRANSFER PRESSURE PROGRESSION

rpm

900

450

Internal pressure supply:

bar (psi)

6.7 to 7.3 (97.2 to 105.9 psi)

4.3 to 5.3 (62.4 to 76.9 psi)

9. INJECTION ADVANCE PROGRESSION

rpm

900

1020

Advance stroke

mm (in.)

0.7 to 1.1 mm (0.0276 to 0.0433)

1.3 to 1.9 (0.0512 to 0.0748)

10. BACKFLOW

rpm

450

1250

Backflow for 10 s

cm³ (gal.)

18 to 30 (0.0040 to 0.0066)

24 to 40 (0.0053 to 0.0088)

(continued)

Note: the values shown above in brackets must be used for checking purposes only.

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

(continued)

11. DELIVERY PROGRESSION

rpm

Delivery per 1000 shots: cm³ (gal.)

1400

0 to 3 (0 to 0.0007)

1300

41.1 to 42.1 (0.0090 to 0.0092)

1250

52.5 to 57.5 (0.0115 to 0.0126)

1200

53.5 to 58.5 (0.0118 to 0.0129)

800

61.2 to 62.2 (0.0135 to 0.0137)

12. DELIVERY CHECK AT IDLE SPEED

rpm

300

Delivery per 1000 shots:

cm³ (gal.)

9.2 to 10.2 (0.0020 to 0.0022)

Note: the values shown above in brackets must be used for checking purposes only.

13. ZERO CAPACITY (STOP)

rpm

Voltage (volts)

Delivery per 1000 shots: cm³

(gal.)

300

0 to 3 (0 to 0.0007)

14. AUTOMATIC START SUPPLEMENT

rpm

Delivery per 1000 shots: cm³ (gal.)

100

33 to 73 (0.0073 to 0.0161)

250

34 to 44 (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

Relative humidity 70^o/_o

stroke: (see previous page)

Engine without fan, air filter and exhaust silencer.

Ambient temperature 25^oC (77^oF).

Atmospheric pressure 740

5 mm (29.1339

0.1968 in.)

Specific gravity of diesel fuel 840 g/l at a tem-

mercury.

perature of 15^oC (59^oF).

Fuel consum-

Engine speed

Power output with engine run--in for a total of:

Throttle

ption

lever

Braking load applied

Production speed

50 hours (total)

position

rpm

kW (Hp)

kg (lbs.)/h

12.9 to 13.7

For maximum power

56.2 to 59.6

Maximum

2500

(74.8)

(28.44 to

output

(76.4 to 81)

30.2)

8.8 to 9.4

40.2 to 42.7

Maximum

For maximum torque

1500

39.3

(53.4)

(19.4 to

(54.7 to 58.1)

20.72)

2700 to

Maximum

None (no--load)

2750

Minimum

None (no--load)

625 to 675

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

MODELTK 95 -- CALIBRATION DATA FOR BOSCH INJECTION PUMP

TYPE VE 4/11 F 1250 L 850 -- 500358111

ASSEMBLY DATA

CALIBRATION TEST CONDITIONS

Pump timing on engine: delivery start 5^o

0.5^o before

Test bench conforming to ISO 4008/1 .../2

TDC of cylinder 1 compression stroke.

Injectors conforming to ISO

7440--A61

Plunger pre--lift for timing on engine: 1 mm (0.0394

(1.688.901.027 with calibrated pad

0.5 mm --

in.) from BDC (with tools 291754 -- 291755).

0.0197 in.).

Cylinder No.1 delivery line union on pump: marked

Injector pressure setting 250 to 253 bar (3626 to

with letter A.

3669 psi).

ASSEMBLY DIMENSIONS

Fuel supply pressure:

0.35 + 0.05 bar (5.1 + 0.7 psi).

SYMBOL

Delivery pipes (conforming to ISO 4093.2):

30.1

36.5 to 38.5

40 to 46

6x2x450mm(0.2362x0.0787x17.716in.).

(in.)

(1.185)

(1.437 to

1.5157)

Graduate drain time

: 30î.

Test liquid: ISO 4113 at a temperature of 45^o

1oC

(113^o

33.8^oF) at outlet.

1. START OF DELIVERY

Plunger pre--lift from TDC: mm --

Pump rotation (viewed from drive side): coun-

Injection order:1--3--4--2

ter--clockwise

2. ADVANCE REGULATOR 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

Spread:

3.5 cm³ (0.0008 gal.)

to 0.0169 gal.)

5. FULL--LOAD DELIVERY WITHOUT BOOSTER PRESSURE

rpm: 600

Delivery per 1000 shots: 54.2 to 55.2 cm³ (0.0119 to 0.0121 gal.)

6. SPREAD GOVERNOR AT IDLE SPEED

rpm: 325

Delivery per 1000 shots: 11.5 to 12.5 cm³ (0.0025 to 0.0027 gal.)

Spread:

4.0 cm³ (0.0009 gal.)

7. SPREAD GOVERNOR AT MAXIMUM SPEED

rpm: 1300

LDA pressure: kPa 100

Delivery per 1000 shots: 42.7 to 43.7 cm³ (0.0094 to 0.0096 gal.)

8. DELIVERY AT STARTING SPEED

rpm: 100

Delivery per 1000 shots: 85 to 125 cm³ (0.0187 to 0.0275 gal.)

9. TRANSFER PRESSURE PROGRESSION

LDA pressure:

kPa

100

rpm

400

900

Internal pressure supply:

bar (psi)

2.9 to 3.9 (42.1 to 56.6)

6.2 to 6.8 (89.9 to 98.6)

10. INJECTION ADVANCE PROGRESSION

LDA pressure

kPa

100

rpm

900

1050

Advance stroke

mm (in.)

0.8 to 1.2 (0.0315 to 0.0472)

1.4 to 2.0 (0.0551 to 0.0787)

11. BACKFLOW

rpm

600

1250

LDA pressure

kPa

100

Backflow

cm³ (gal.)

18 to 30 (0.0039 to 0.0066)

22 to 38 (0.0048 to 0.0083)

(continued)

Note: the values shown above in brackets must be used for checking purposes only.

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

(continued)

12. DELIVERY PROGRESSION

rpm

Pressure LDA kPa

Delivery per 1000 shots: cm³ (gal.)

600

70.5 to 71.5 (0.0155 to 0.0157)

1380

100

0 to 3 (0 to 0.0007)

1300

100

42.7 to 43.7 (0.0094 to 0.0096)

1250

100

66.1 to 70.1 (0.0145 to 0.0154)

750

100

76 to 77 (0.0167 to 0.0169)

600

54.2 to 55.2 (0.0119 to 0.0121)

13. DELIVERY CHECK AT IDLE SPEED

rpm

325

275

Delivery per 1000 shots

cm³ (gal.)

11.5 to 12.5 (0.0025 to 0.0027)

28.4 to 40.4 (0.0062 to 0.0089)

Note: the values shown above in brackets must be used for checking purposes only.

14. ZERO CAPACITY (STOP)

rpm

Voltage (volts)

Delivery per 1000 shots: cm³ (gal.)

325

0 to 3 (0 to 0.0007)

15. AUTOMATIC START SUPPLEMENT

rpm

Pressure LDA kPa

Delivery 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

Relative humidity 70^o/_o

stroke: (see previous page)

Engine without fan, air filter and exhaust silencer.

Ambient temperature 25^oC (77^oF).

Atmospheric pressure 740

5 mm (29.1339

0.1968 in.)

Specific gravity of diesel fuel 840 g/l at a tem-

mercury.

perature of 15^oC (59^oF).

Engine speed

Power output with engine run--in for a total of:

Fuel consumption

Throttle

lever

Braking load applied

Production speed

50 hours (total)

position

rpm

kW (Hp)

kg (lbs.)/h

For maximum power

64.5 to 68.5

15.2 to 16.2

Maximum

2500

63.2

(85.9)

output

(87.7 to 93.1)

(33.51 to 35.71)

50.5 to 53.5

10.8 to 11.4

Maximum

For maximum torque

1500

49.5

(67.3)

(68.7 to 72.8)

(23.81 to 25.13)

2700 to

Maximum

None (no--load)

2750

Minimum

None (no--load)

625 to 675

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

FUEL SUPPLY PUMP DATA

mm (in.)

Eccentricity of drive shaft

(0.1181)

Diameter of drive shaft at bushings

31.975 to 32.000 (1.2588 to 1.2598)

Internal diameter of installed and reamed bushings

32.050 to 32.075 (1.2618 to 1.2628)

Interference between bushings and seats

0.063 to 0.140 (0.0025 to 0.0055)

Clearance between axle shafts and bushes

0.050 to 0.100 (0.0020 to 0.0039)

Thickness of internal washer

1.45 to 1.50 (0.0571 to 0.0591)

Thickness of external washer

2.93 to 3.00 (0.1154 to 0.1181)

mm (in.)

CRANKCASE/CYLINDER BLOCK DATA

Bore 100

Bore 104

Cylinder block

cast--iron monobloc with replaceable

dry--fitted cylinder liners, incorporating

seatings for crankshaft bearings, cam-

shaft and tappet assemblies

Internal diameter of cylinder liners

100 to 100.024 (¹)

104 to 104.024 (¹)

(3.937 to 3.9379)

(4.0945 to 4.0954)

External diameter of cylinder liners

103.02 to 103.05

107.02 to 107.05

(4.0559 to 4.0571)

(4.2134 to 4.2146)

Diameter of cylinder liner bores on block

102.85 to 102.9

106.85 to 106.9

(4.0492 to 4.0512)

(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

0.4 to 0.8 (0.0157 to 0.0315)

Liner external diameter oversizes

0.2

(0.0079)

Maximum permissible liner ovality or taper due to wear (²)

0.12

(0.0047)

Main journal half bearing seat diameter

84.200 to 84.230 (3.3150 to 3.3161)

Camshaft bushing seat diameter:

-- front

54.780 to 54.805 (2.1567 to 2.1577)

-- intermediate

54.280 to 54.305 (2.1370 to 2.1380)

-- rear

53.780 to 53.805 (2.1173 to 2.1183)

Diameter of standard tappet bores in crankcase

15.000 to 15.018 (0.5905 to 0.5912)

Tappet oversizes

0.1 -- 0.2 -- 0.3

(0.0039 -- 0.0079 -- 0.0118)

(1) Measured after press--fitting and reaming.

(²) Measure in the area swept by piston rings, both parallel and perpendicular to the crankshaft axis.

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

mm (in.)

CRANKSHAFT AND BEARINGS DATA

Bore 100

Bore 104

Crankshaft

balanced with integral counterweights

Standard journal diameter

79.791 to 79.810 (¹) (3.1414 to 3.1421)

Journal undersizes

0.254 -- 0.508 -- 0.762 -- 1.016

(0.01 -- 0.02 -- 0.03 -- 0.04)

Main journal half bearing thickness

2.168 to 2.178 (0.0853 to 0.0857)

Main half bearing undersizes (internal diameter)

0.254 -- 0.508 -- 0.762 -- 1.016

(0.01 -- 0.02 -- 0.03 -- 0.04)

Bearing shell to journal clearance

0.034 to 0.103 (0.0013 to 0.0040)

Maximum permitted wear clearance

0.180

(0.0071)

Standard crankpin diameter

63.725 to 63.744 (¹) (2.5086 to 2.5096)

Crankpin undersizes

0.254 -- 0.508 -- 0.762 -- 1.016

(0.01 -- 0.02 -- 0.03 -- 0.04)

Standard connecting rod half bearing thickness

1.805 to 1.815 (0.0711 to 0.0714)

Connecting rod half bearing undersizes (internal diameter)

0.254 -- 0.508 -- 0.762 -- 1.016

(0.01 -- 0.02 -- 0.03 -- 0.04)

Bearing to crankpin clearance

0.033 to 0.087 (0.0013 to 0.0034)

Maximum permitted 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 0.0131)

Maximum permitted axial wear clearance

0.40

(0.0157)

Maximum ovality or taper of journals and crankpin after regrind-

ing

0.01

(0.0039)

Maximum ovality or taper of journals and crankpin

0.05

(0.0020)

Maximum tolerance for alignment of crankshaft journals with

crankshaft supported on the two outer journals

0.1

(0.0039)

Maximum permitted tolerance, in both directions, on crankpin

alignment (3--cylinder engine), or of each pair of crankpins rela-

tive to crankshaft journals (4--cylinder engine)

0.25

(0.0098)

Maximum tolerance for run--out between the outer surfaces of

the crankshaft journals and the crankshaft centreline

0.1

(0.0039)

(continued)

(1) Crankshafts with 0.1 mm (0.0039 in.) undersize journals, crankpins and, consequently, undersize bearing shells may

be fitted in factory production.

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

(continued)

mm (in.)

CRANKSHAFT AND BEARINGS DATA

Bore 100

Bore 104

Maximum permitted tolerance on run--out of flywheel mounting

flange surface relative to the crankshaft centreline, measured with

1/100 mm scale dial gauge resting on front flange surface (A,

fig. 96) on a 108 mm (4.252 in.) diameter (total dial gauge reading)

0.025

(0.001)

Maximum permitted tolerance on co--axial alignment of flywheel

centering (B, fig. 96 ) in relation to crankshaft journals (total dial

gauge reading)

0.04

(0.0016)

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 bushing (measured after fitting) . . .

38.004 to 38.014 (1.4962 to 1.4966)

Diameter of big end bearing seats

67.407 to 67.422 (2.6538 to 2.6544)

Max. tolerance for parallelism between the small end and the big

end axes measured at 125 mm (4.9213 in.)

0.07

(0.0027)

Maximum weight difference between con rods in same engine . .

25 g. (0.055 lbs.)

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

mm (in.)

PISTON DATA

Bore 100

Bore 104

Pistons

light alloy with three compression rings,

including two seal rings and one

scraper ring

Standard piston diameter, measured at 57 mm from skirt base

and perpendicularly to the gudgeon pin axis

99.827 to 99.841

103.812 to

(3.9302 to 3.9307)

103.826

(4.0871 to 4.0876)

Piston clearance in cylinder liner

0.159 to 0.197

0.174 to 0.212

(0.0062 to 0.0077)

(0.0068 to 0.0083)

Maximum permitted wear clearance

0.30

(0.0118)

Piston oversizes

0.4 -- 0.8 (0.0157 -- 0.0315)

Piston protrusion at TDC from cylinder block face

0.355 to 0.761 (0.014 to 0.03)

Gudgeon pin diameter

37.983 to 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 vertically):

-- 1^st ring

0.090 to 0.122 (0.0035 to 0.0048)

-- 2^nd ring

0.060 to 0.092 (0.0024 to 0.0036)

-- 3^rd ring

0.040 to 0.075 (0.0016 to 0.0029)

Maximum permitted wear clearance:

-- 1^st ring

0.50

(0.0197)

-- 2^nd and 3^rd ring

0.20

(0.0079)

Assembly clearance between piston ring ends in cylinder

sleeves:

-- 1^st ring

0.35 to 0.55

0.40 to 0.65

(0.0138 to 0.0216)

(0.0157 to 0.0256)

-- 2^nd ring

0.30 to 0.45

0.30 to 0.55

(0.0118 to 0.0177)

(0.0118 to 0.0216)

-- 3^rd ring

0.30 to 0.60 (0.0118 to 0.0024)

Maximum permissible gap (wear limit)

1.20

(0.0472)

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

mm (in.)

VALVE TIMING GEAR DATA

Bore 100

Bore 104

Clearance between sides of timing gear pair teeth

0.160

(0.0063)

Inside diameter of intermediate gear bushings (fitted and

reamed)

37.050 to 37.075 (1.4587 to 1.4596)

Diameter of intermediate gear journal

36.975 to 37.000 (1.4557 to 1.4567)

Clearance between pin and relative bushings

0.050 to 0.100 (0.002 to 0.0039)

Maximum permitted wear clearance

0.15

(0.0059)

Bushing interference fit in seat in intermediate gear

0.063 to 0.140 (0.0025 to 0.0055)

Outside diameter of camshaft bearings:

-- front

54.875 to 54.930 (2.1604 to 2.1626)

-- intermediate

54.375 to 54.430 (2.1407 to 2.1429)

-- rear

53.875 to 53.930 (2.1211 to 2.1232)

Interference between bearings and seats in cylinder 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 camshaft journals and bushings

0.080 to 0.160 (0.0031 to 0.0063)

Maximum permitted wear clearance

0.20

(0.0079)

Camshaft endfloat between thrust plate and seat on camshaft . .

0.070 to 0.220 (0.0027 to 0.0087)

For further timing system technical data

see page 4

mm (in.)

TAPPET DATA

Bore 100

Bore 104

Tappet bore in crankcase

15.000 to 15.018 (0.5905 to 0.5912)

Outside diameter of standard tappet

14.950 to 14.970 (0.5886 to 0.5894)

Tappet running clearance

0.030 to 0.068 (0.0012 to 0.0027)

Maximum permitted wear clearance

0.15

(0.0059)

Tappet oversizes

0.1 -- 0.2 -- 0.3

(0.0039 -- 0.0079 -- 0.0118)

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

mm (in.)

ROCKER ARM - VALVE DATA

Bore 100

Bore 104

Diameter of shaft bores in rocker arms

18.016 to 18.034 (0.7093 to 0.71)

Diameter of rocker arm shaft

17.982 to 18.000 (0.7079 to 0.7087)

Rocker shaft to rocker arm bore clearance

0.016 to 0.052 (0.0006 to 0.002)

Maximum permitted wear endfloat

0.15

(0.0059)

Rocker arm spacing springs:

-- free length

59.5

(2.3425)

-- length under load of 46 to 52 N

(1.7323)

(4.7 to 5.3 kg, 10.36 to 11.68 lbs.)

Valve clearance for timing check

0.45

(0.0177)

Valve clearance for normal running (engine cold):

-- inlet valve

0.30

0.05

(0.0118

0.002)

-- exhaust valve

0.30

0.05

(0.0118

0.002)

Cam lift:

-- inlet valve

5.67

(0.2232)

-- exhaust valve

5.95

(0.2342)

(*) Only fitted on

MAIN DATA FOR EQUALIZER

4--cylinder models

WITH COUNTER ROTATION MASSES (fig. 60) (*)

mm (in.)

Bushing (28) interference fit in seat on gear unit (26)

0.063 to 0.140 (0.0025 to 0.0055)

Clearance between intermediate gear journal (27) and 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 seat on casing (12) . .

0.063 to 0.140 (0.0025 to 0.0055)

Clearance between rotating masses shaft (13) and front bush

(16)

0.050 to 0.100 (0.002 to 0.0039)

Interference between rotating masses rear bush (13) and seat on

support (7)

0.037 to 0.101 (0.0014 to 0.0040)

Clearance between shaft (13) and rear bush

0.013 to 0.061 (0.0005 to 0.0024)

Interference between bushings and relative seats on masses (6)

0.040 to 0.100 (0.0016 to 0.0039)

Clearance between rotating masses axis (5) and relative

bushings

0.020 to 0.073 (0.0008 to 0.0029)

Interference between intermediate gear bush (10) and relative

seat on rotating masses casing (12)

0.037 to 0.101 (0.0014 to 0.00409)

Clearance between intermediate gear shaft (10) and relative

0.013 to 0.061 (0.0005 to 0.0024)

bush

Clearance between the teeth and the coupled wheels

0.080

(0.0031)

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

mm (in.)

CYLINDER HEAD DATA

Bore 100

Bore 104

Cylinder head

with valve seats cut directly in the

casting and press--fitted steel valve

guides.

Original height of cylinder head

(3.622)

Maximum face re--grinding depth that can be removed from the

cylinder head in the event of reboring

0.5

(0.0197)

Diameter of standard valve guide bores in head

13.950 to 13.983 (0.5492 to 0.5505)

Outside diameter of standard valve guides

13.993 to 14.016 (0.5509 to 0.5518)

Guide interference fit in bores

0.010 to 0.066 (0.0004 to 0.0026)

Inside diameter of valve guide (fitted in head)

8.023 to 8.043 (0.3159 to 0.3166)

Valve stem diameter

7.985 to 8.000 (0.3144 to 0.315)

Assembly clearance between valve stem and guide

0.023 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

360^o 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

60^o

5í

-- exhaust valve

45^o

5í

Valve face angle:

-- inlet valve

60^o 30í

7í

-- exhaust valve

45^o 30í

7í

Valve head diameter:

-- inlet valve

45.300 to 45.500 (1.7835 to 1.7913)

-- exhaust valve

37.500 to 37.750 (1.4764 to 1.4862)

Valve stand--in relative to cylinder head face

0.7 to 1.0 (0.0275 to 0.0394)

Maximum permissible valve stand--in

1.3

(0.0512)

Inlet and exhaust valve springs:

-- free length

44.6

(1.7559)

-- length with valve closed, under load of 256 to 284 N

(26.1 to 28.9 kg, 57.54 to 63.71 lbs.)

(1.3386)

-- length with valve open, under load of

502 to 554 N

(51.2 to 56.5 kg, 112.88 to 124.56 lbs.)

23.8

(0.937)

Injector protrusion relative to head face:

D BOSCH injector no. 500307714 and 500317389

0.3 to 1.1 (0.0118 to 0.0433)

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

mm (in.)

LUBRICATION SYSTEM DATA

TK 65, TK 76,

TK 75, TK 95

TK 85

Assembly clearance between oil pump drive shaft and bush

0.016 to 0.055

(0.0006 to 0.0022)

Clearance between shaft and driven gear

0.033 to 0.066

(0.0013 to 0.0026)

Tooth backlash between drive and driven gears

0.100

(0.0039)

Radial clearance between drive and driven gears and housing . .

0.060 to 0.170

(0.0024 to 0.0067)

Thickness of drive and driven gears

40.961 to 41.000

(1.6126 to 1.6142)

Height of gear seat in pump

41.025 to 41.087

(1.6151 to 1.6176)

Endfloat between gears and gear housing in pump

0.025 to 0.126

(0.001 to 0.005)

Pressure relief valve spring

spring free length

(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.)

(1.1417)

spring length (2, fig. 134) under load of 233.4 to 258 N

(238 to 263 kg, 524.7 to 579.8 lbs.)

23.2

(0.9134)

For further lubrication technical data

see page 3

mm (in.)

COOLING SYSTEM DATA

Bore 100

Bore 104

Interference fit between pump impeller and shaft

0.017 to 0.059 (0.0007 to 0.0023)

Interference fit between fan hub and shaft

0.024 to 0.058 (0.0009 to 0.0023)

Interference fit between front seal bushing and impeller

0.012 to 0.058 (0.0005 to 0.0023)

For further cooling system technical data

see page 3

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

TORQUE SETTINGS WITH ANGLE

Tightening torque

PARTS TO TIGHTEN

Thread

Angle

kgm

Cylinder head bolts (2, fig. 3 , or fig. 5 )

M 12 x 1.25

7.1

90^o + 90^o

Main bearing cap bolts (4)

M 14 x 1.5

8.2

90^o

Big--end cap bolts (5)

M 11 x 1.5

4.1

60^o

Flywheel mounting bolts (3)

M 12 x 1.25

4.1

60^o

TORQUE SETTINGS

Tightening torque

PARTS TO TIGHTEN

Thread

kgm

Rocker shaft pedestal bolts (1, fig. 3 , or fig. 5 )

2.5

Crankshaft hub retaining nut (7)

M 30 x 1.5

294

Fan and alternator pulley bolts (6)

10 x 1.25

5.6

Additional rotating masses retaining bolts (1, fig. 6)

for models TK 76, TK 85 and TK 95

12 x 1.25

110

11.2

Intake manifold retaining bolts (1, fig. 23)

2.6

Alternator and belt tension adjustment nut (2, fig. 22)

10 x 1.25

5.6

Coolant pump retaining bolts (1, fig. 27)

10 x 1.25

5.6

Nuts for injector mounting studs (1. fig. 90)

(*)

2.6

(*)

Tappet cover nuts (1, fig. 32)

1.5

Rocker shaft pedestal bolts (2, fig. 33)

2.5

Oil pump and cover retaining bolts (1, fig. 41)

2.6

Timing gear case and cover bolts (1, fig. 45)

2.6

Intermediate flanged journal bolts (1, fig. 48)

10 x 1.25

5.6

Camshaft thrust plate retaining bolts (2, fig. 49)

3.6

Rear crankcase cover bolts (2, fig. 69)

2.6

Tappet adjuster locknuts (1, fig. 89)

2.2

Exhaust manifold retaining bolts (2, fig. 21)

2.6

Injection pump retaining bolts (1, fig. 191)

2.6

Engine sump retaining bolts (4, fig. 38)

12 x 1.25

(*) Tighten the nuts in two stages -- see operations described in fig. 95.

603.54.381.00 -- 05 -- 2001

SECTION 10 -- ENGINE -- CHAPTER 1

TOOLS

294027

Twist bit for enlarging valve guide

bore.

Warning -- The operations described in this section

can only be carried out with ESSENTIAL tools indi-

294028

8⁰ Tapered grinder for swaging ex-

cated by an (X).

haust valve guides.

To work safely and efficiently and obtain the best re-

sults, it is also necessary to use the recommended

293231

Bush for valve guide installation (with

specific tools listed below and certain other tools,

291046).

which are to be made according to the drawings in-

cluded in this manual.

291177

Engine valve guide reamer.

291050

Engine valve spring disassembly--as-

List of specific tools required for the various

sembly compressor.

operations described in this section.

293270

Set of grinding tools for regrinding in-

290740

Engine lifting hook.

jector seat.

290090

Revolving engine service stand.

291182

Puller for coolant pump impeller.

293860

Engine mounting brackets for rotating

stand 290090.

293280

Drift for installation of coolant pump

impeller seal.

291309

Compression test kit (complete with

dummy injector 293862).

293814

Charger impeller reaction block (for

models TK 75, TK 95).

291966

Digital rev counter.

291979

Digital thermometer for temperature

293786

Wrench for injection pump delivery

control.

line unions.

292870

Engine oil pressure test kit.

293671

Injector cleaning kit.

293240

Check set, turbo charger, for models.

293761

Wrench set for injector dismantling

TK 75, TK 95).

(with 295008).

293679

Tool for cartridge filter disassembly.

293780

Hand pump for injector calibration

297029

Device for engine belt tension check.

test.

291160

Piston ring pliers.

292927

Striking mass.

291048

Piston ring clamp.

Injection pump bench test

292248

Protractor

for

angular torque

measurement.

291754

Dial gauge (1/100 mm, stroke 5 mm

(0.1968 in.),

40 mm (1.5748 in.) with

291504

Puller for crankshaft pulley hub.

291755).

291883

Wrench for valve clearance adjust-

291755

Device for BOSCH injection pump tim-

ment.

ing on engine (with 291754).

291046

Drift for valve guide extraction / in-

stallation.

295042

Puller for injection pump drive gear.

603.54.381.00 -- 05 -- 2001