Cukurova Backhoe Loaders: Service Manual

CUKUROVA
BACKHOE LOADERS
885
SERVICE MANUAL
CUKUROVA BACKHOE LOADER
885
SERVICE MANUAL
PARÇA NO: C60A17R03
CONTENTS
10.01 GENERAL INFORMATION
20.01 LUBRICATION & MAINTENANCE
30 HYDRAULIC
30.01 HYDRAULIC SYSTEM
30.02 HYDRAULIC SHEMA
40.01 ELECTRICAL SYSYEM
50 AXLE GROUPS
50.01 FRONT AXLE GROUP
50.05 REAR AXLE GROUP
60.01 TRANSMISSION
70.01 ENGINE
80.01 TOOLS
10.01
GENERAL
INFORMATION
CONTENTS
Machine information……………………………….……………………………………..………………………..1
Technical properties…..……………………….…………………………………….……………..…….…..…...1
Main components……………………………...…………………………………………………………………..5
Position of the machine……………………………………..…………..…..…………………………….……....7
Safety information…………..………………………………………………………..………..………………......8
Crushing and burn prevention…………………………………………………………………………..………10
Engine start up and operating safety …………………………………………………………………………..11
Machine transporting safety……………………………………………………………………………………..13
Machine towing safety……………………………………………………………………………………………14
Machine maintenance safety…………………………………………………………………………………….14
Storage……………..………………………………………………………..………..……………………….…..17
CUKUROVA Model 885

Technical Data
Backhoe – Loader
and Maintenance
Date Page I Section 10.01
MACHINE INFORMATION
This is a backhoe loader that is designed with operating weight of 8,2 ton, rijit frame, dipper capacity of 0.19
3 3
m and shovel capacity of 1,1 m .This machine is designed to dig and load in closed and open terrain.
WARNING: Because of exhaust gas, use the machine only in good ventilated areas.
TECHNICAL PROPERTIES
885
ENGINE
Make Perkins/1104C-44T
Rated power 100(74,6)hp/kW
Rated speed 2200 rpm
Displacement 4,4 lt
Bore and stroke 105x127mm
No of cylinders 4
Max. torque 412Nm
Electrical system
Battery 12/120V/Ah
Starter 3 kW
HYDRAULIC SYSTEM
System type unload/open center
Hydraulic pump Tandem gear
Max. flow 90+64 l/min
Max. press. 220 bar
Hydraulic oil filter Full flow filter in return line with integrated fine filter area
Hydraulic oil cooler Hydraulic and transmission oil cooler
Backhoe control Hydraulic joystick controls
Loader control Hydraulic joystick control
BRAKES
2 Wheel /4 Wheel 2 Wheel
Service type Hydraulic wet multi-disc
Parking type Mechanical control on rear axle
AXLES
Front axle Rear axle
Make ZF ZF
Axle oscillations ±8 degree
Rear axle Electro hydraulic operated differential lock
TRANSMISSION
Make ZF
Type Powershift
Torque converter ratio 2.121:1
Transmission disconnect With push button
Travel speed
1 st(forward/reverse) 6.5/7 km/h
2 nd(forward/reverse) 11/12 km/h
3 rd(forward/reverse) 26/30 km/h
4 th(forward/-) 40 km/h
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
Date Page 1 Section 10.01
LOADER
Shovel capacity 1,1m³
Lift to full height 3273kg
Breakout force-lift 51,58kN
Breakout force shovel max. 77,2kN
Shovel width 2280mm
BACKHOE
Max. bucket tear-out retract 59,4kN
Dipper tear-out
Retracted 30,8kN
Extended 21,7kN
Lift at max. reach
Retracted 1116 kg
Extended 1076 kg
CAB
Cab ROPS(ISO 3741) and FOPS(ISO 3449) type
tinted safety glass giving total visibility, two doors
full opening rear-side windows, front and rear
windscreen wipers
Seat Adjustable to operator’s weight.
Heating and ventilation Fresh air heater/blower unit, full heating control
system even in storage compartment, defroster
control with only one switch.
WEIGHTS
Operating weight 8200kg
TIRES
Front 4WD-standard 12.5.80–18 12 PR
Rear 4WD-standard 16,9–28 12 PR
CAPACITIES (lt)
Engine oil (with filters) 8,4
Cooling system 25
Fuel tank 100
Hydraulic tank 100
Hydraulic system 140
Axle oil
Front 7,8
Rear 16
Brake oil 0,4
STEERING
Steering type 2 wheel
Outer tire clearance diameter 8,4m

Without brakes
Outer bucket clearance diameter 11,1m
Without brakes
Outer tire clearance diameter 7,3m
With brakes
Outer bucket clearance diameter 10,5m
With brakes
Outer bucket clearence diameter 10,5 m
With brakes
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
Backhoe Dimensions Retracted Extended
A- Max. digging depth: 4600 mm 5800 mm
B- Max. reach from rear axle centre 7000 mm 8100 mm
C- Max. reach from swing centre 5700 mm 6800 mm
D- Max. digging height 5600 mm 6450 mm
E- Max. dumping height 3850 mm 4700 mm
F- Loading reach 1800 mm 2650 mm
G-Bucket rotation angle 200,4° 200,4°
H- Max. bucket hinge pin height 4750 mm 5550 mm
Loader Dimensions
I- Distance between hinge pin and front axle centre 1200 mm
J- Max. rollback angle, fully raised 59,2°
K- Dump height 2740 mm
L- Load-over height 3200 mm
M- Height to hinge pin 3500 mm
N- Max. reach at full height 1070 mm
O- Dumping reach 630 mm
P- Digging depth 113 mm
R- Dump angle 45°
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
ATTACHMENTS
Fork attachment
part number C06A06
Mass 135 kg/piece
Clamshell attachment
Mass 700kg
Part number fixed part C02B31
Active part C02B22
Bucket attachment (standard)

Mass 380 kg
Part number C02B51
Bucket width 400 mm 600 mm 800 mm

Mass 140 kg 165 kg 190 kg
Part number C41A64 C41A35 C41A45
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
MAIN COMPONENTS
9
7
6 4
5
10
15
8
13
14
12
11
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
1. OPERATOR’S COMPARTMENT (WITH ROPS / FOPS)
2. LOADER BUCKET
3. LOADER BOOM
4. FRONT AXLE
5. REAR AXLE
6. FUEL TANK
7. TOOL BOX
8. BACKHOE BUCKET
9. BACKHOE EXTENDIBLE DIPPER
10. BACKHOE BOOM
11. BACKHOE ATTACHMENT SIDESHIFT CARRIAGE
12. STABILIZERS
13. HYDRAULIC OIL TANK
14. BATTERY BOX
15. ENGINE BONNET
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
POSITIONS OF THE MACHINE
The terms right, left, front and rear are used referring to the operator seated on the driver seat for the loader
and backhoe attachment position.
LOADER ATTACHMENT POSITION
RIGHT-HAND SIDE
F
O
R R
W E
A A
R R
D
LEFT-HAND SIDE
BACKHOE ATTACHMENT POSITION
LEFT-HAND SIDE
F
R O
E R
A W
R A
R
D
RIGHT-HAND SIDE
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
SAFETY INFORMATION
The information given in this manual provides safe operation and maintenance of the machine and should be
fully understood in order to prevent serious injury or death while working with the machine. Don’t forget that
your safety and the people around you depends on you. Therefore to develope your skill for the correct
operation, inspection, lubrication and maintenance:
• You should read this manual carefully and familiarize yourself with the position of controls and of the
operations that their movement causes.
• You should understand the warnings and operating procedures used in this manual and on the machine.
• You should understand the capabilities and limitations of the machine.
In this manual safety signs are classified according to the relative seriousness of the hazard situation by the
use of the signal word. Two signal words are used: DANGER and WARNING. The signal word alerts you to
the existence and relative seriousness of a hazard and it is essential that you understand these signal words
fully.
DANGER: Used for the situations presenting the most serious hazards and if not avoided, will result
in death or serious injury.
WARNING: used for the situations presenting a lesser degree of risk of injury or death than those
identified by the signal word DANGER and if not avoided could result in death or serious injury.
In addition to these instructions you must follow the safety regulations applicable to your work environment
and job site and any federal, state and local safety requirements.
Keep this manual in good condition and store it in a compartment where you can easily reach.
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
GENERAL SAFETY INFORMATION
• Study the Operation and Maintenance Manual before operating or working on the backhoe loader, make
sure that you have additional information for special attachements of your machine, read it and understand it!
• Allow only authorized personnel informed about the safety rules to operate, service or repair the backhoe
loader, make sure to observe any minimum applicable age requirement.
• Allow only properly trained personnel to operate or work on the backhoe loader, make sure to clearly
specify the person who is responsible for set up, maintenance and repairs.
• Make sure the operator knows his responsibility regarding the observance of traffic regulations and
permit him to refuse any unsafe instructions given by a third person.
• Any person still in training should only operate or work on the machine under the supervision and
guidance of an experienced person.
• Check and observe any person working or operating the backhoe loader periodically and regularly, if
they observe safety instructions and guidelines given in the Operation and Maintenance Manual.
• Wear proper work clothing when operating or working on the backhoe loader. Ring, watches, bracelets
and loose clothings such as ties, scarves, unbuttoned or unzipped shirts and jackets are dangerous and
could cause injury! Wear proper safety equipment, such as safety glasses, safety shoes, hard hats, work
gloves, reflector vests and ear protection.
• Consult your employer or supervisor for specific safety equipment requirements and safety regulations
on the job site.
• Do not carry tools, replacements parts or other supplies while climbing on or off the backhoe loader.
Never use the steering column, control levers or joysticks as handholds.
• Never jump off the backhoe loader, climb on and off the backhoe loader using only the steps, rails and
handles provided.
When climbing on or off the backhoe loader, use both hands for support and face the machine.
• If needed, use the rear window or right door as an escape hatch.
• If no other guidelines are given, perform maintenance and repairs utilizing the following precautions:
- Park backhoe loader on firm and level ground. Rest the attachments on the ground.
- Place all control in neutral position and engage park brake switch.
- Turn the engine off and remove the ignition key.
• Before working on the hydraulic circuit, move all joysticks and pedals with the ignition key in contact
position to release the hydraulic accumulator pressure and the remaining pressures in the different main
circuits. In addition, relieve the pressure in the hydraulic tank as described in the Operation and Maintenance
Manual.
• Secure all loose parts on the backhoe loader.
• Never operate the backhoe loader without a complete walk around inspection. Check if all warning
decals are on the machine and if they are legible.
• Observe all danger and safety guidelines.
• For certain applications, the backhoe loader must be equipped with specific safety equipment. Use the
backhoe loader only, if they are installed and functioning properly.
• Never perform any changes, additions or modifications on the machine, which could influence the safety,
without obtaining the written permission from the manufacturer. This also applies to the installation and
adjustment of safety devices and safety valves as well as to any welding on load carrying parts.
• Do not install any equipment or attachments made by other manufacturers or any which are not
specifically authorized by CUKUROVA for installation without first obtaining the written permission from
CUKUROVA. CUKUROVA will issue any required technical documentation for approved installations.
• Should the electrical circuit be modified or additional components be installed, so the modification must
be performed according to the national standards and safety regulations. The installation must be certificated
by an approved organization and a copy of the certification has to be sent to the CUKUROVA company.
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
CRUSHING AND BURN PREVENTION
• Never work underneath the backhoe loader unless it is safely resting on the ground and / or is properly
blocked and supported.
• Never use damaged or insufficent wire ropes, slings or chains. Always wear gloves when handling wire
ropes.
• Never reach into bores during attachment installation or removal. Never align bores with fingers or
hands. Use proper alignment tools when installing, changing or servicing attachments.
• Keep objects away from the radiator fan. Rotating fans will swirl and throw out objects, which can
become very dangerous and cause severe to yourself and others.
• Avoid contact with any components containing coolant. At or near operating temperature, the engine
coolant is hot and under pressure and could cause severe burns.
• Check the coolant level only after the radiator cap is cool enough to touch. Remove the radiator cap
slowly to relieve pressure.
• Do not allow your skin to come in contact with hot oil or components containing hot oil. At or near
operating temperature, engine and hydraulic oil is still hot and can be under pressure.
• Always wear safety glasses and protective gloves when handling batteries. Keep sparks or open flames
away!
• Never permit anyone to hand guide the bucket or grapple into position.
• When working in the engine area, make sure safety strut is installed.
FIRE AND EXPLOSION PREVENTION
• Always turn off the machine while refueling the backhoe loader.
• Never smoke or allow an open flame in refueling areas or where batteries are being charged, or where
batteries or flammable materials are stored.
• Always start the engine as described in the Operation and Maintenance Manual.
• Check the electrical system regularly and frequently. All defects, such as loose connections, burnt out
fuses and bulbs, burnt or damaged cables must be repaired immediately by an electrician or especially
trained personnel.
• Never store flammable fluids on the machine except in storage tanks intended for the backhoe loader’s
operation.
• Inspect all component, lines, tubes and hoses for oil and fuel leaks and / or damage. Replace or repair
any damaged components immediately. Any oil, which escapes from leaks, can easily cause fire.
• Be certain that all clamps , guards and heat shields are installed. These components prevent vibration,
rubbing, chafing and heat build-up. Install tie wraps to fasten hoses and wires, as required.
• Cold start ether is extremely flammable. Use ether only in ventilated areas and as directed. Never use it
near heat sources or open flames, do not permit anybody to smoke.
• Know the location of the backhoe loader’s fire extinguisher and be familiar with its operation. Make sure
you know your local fire regulations and fire reporting procedures.
MACHINE START UP SAFETY
• Before backhoe loader start up, perform a thorough walk around inspection.
• Visually inspect the backhoe loader, look for loose bolts, cracks, wear, any leaks and any evidence of
vandalism.
• Never start or operate an unsafe backhoe loader.
• Make sure all covers and doors are closed and locked and all warning decals are on the machine.
• Make sure all windows, as well as inside and outside mirrors are clean, and secure all doors and
windows to prevent any unintentional movement.
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
• Be certain that the area surrounding the backhoe loader is free of other personnel, and that no one is
working on or under the backhoe loader before starting the engine.
• After entering the cab, adjust the operator’s seat and controls, the inside and outside mirror and the arm
rests. Be certain that all controls can be reached comfortably.
• All noise protection devices on the machine must be functional during operation.
ENGINE START UP AND OPERATING SAFETY
• Before start up, check if all indicator lights and instruments are functioning properly, place all controls in
neutral position.
• Before starting the engine, alert any nearby personnel that the backhoe loader being started by sounding
the horn.
• Start machine only when seated in the operator’s seat, and with the seat belt fastened.
• If you have no other instructions, start the engine as outlined in the Operation and Maintenance Manual.
• Check all indicators, gauges, warning devices and controls for their proper indication.
• Start and operate the engine only in a well ventilated area. If necessary, open doors and windows. Warm
up the engine and hydraulic system to operating temperatures. Low engine and hydraulic oil temperatures
can cause the backhoe loader unresponsive.
• Check that all attachment functions are operating properly.
• Move the backhoe loader slowly into an open area and check all travel functions for their proper
operation, check travel brakes, the steering function as well as the turn signals and lights.
MACHINE OPERATING SAFETY
• Familiarize yourself with jobsite rules. Be informed about traffic and hand signals and safety signs. Ask
who is responsible for signaling.
• Check your surrounding for any obstacles in the working and movement range, check the load carrying
capacity of the terrain, and secure the job site to shield it from any public higway traffic.
• Always keep a safe distance from overhangs, walls, drop offs, and unstable ground.
• Be alert of changing weather conditions, bad or insufficient visibility and of changing ground conditions.
• Be alert for utility lines, check the location of underground cables, gas and water lines, and work
especially careful in that vicinity. If necessary and / or if required, call local authorities to mark the location.
• Keep sufficient distance to electrical lines. When working in the vicinity of high voltage electrical lines,
keep proper distance to assure that the attachment does not come close to the lines.
DANGER! You must inform yourself about safe distances.
• In case you do touch a high voltage line by accident, proceed as follows:
- Do not leave the machine!
- Move the machine, if possible, from the danger zone until you obtain sufficient distance,
- Warn any personnel in the vicinity not to come close to the backhoe loader and not to touch it,
- Instruct or initiate that someone turns off the voltage.
- Do not leave the machine until you are absolutely sure that voltage in the line, which had been touched
or damaged, has been turned off!
• Before moving the machine, make sure that the attachments and equipment is secured properly to avoid
accidents.
• Do not run the machine without backhoe attachment. this can effect the brake system and may cause
serious accidents.
• Do not install front weight balancer unless necessary.
• When travelling on public roads or highways, make sure to observe traffic regulations, and make sure
that the machine meets federal and local public highway standards.
• Always turn on the lights if visibility is bad or if you are still working during dusk.
• Never allow other personnel on the backhoe loader.
CUKUROVA Model 885
Technical Data
Backhoe - Loader
and Maintenance
• Operate the backhoe loader only while seated and with the seat belt fastened.
• Report any problems or needed repairs to your foreman or supervisor and make sure they are corrected
immediately.
• Do not move the backhoe loader until you are certain that no one is endangered by moving the backhoe
loader.
• Check the brake system before starting to work, as outlined in the Operation and Maintenance Manual.
• Make sure that brake pedals are locked before any road travel.
• Never leave the operator's seat while the machine is still moving.
• Never leave the machine unattended (within view of machine), with the engine running.
• Prevent any working movements, which could tip the machine over. If the backhoe loader begins to tip
or slip on a grade, immediately lower the attachments. If possible, always operate the backhoe loader with
the attachment positioned uphill.
• Always travel slowly on rough or slippery ground and on slopes, and on loose soils.
• Activate 4 wheel drive switch when travelling on icy or slippery road.
• Always travel downhill at permissible speed, so you don't loose control over the machine. The engine
must run at nominal speed, use only the foot pedals to brake and slow down the machine.
• Never shift during down hill travel, always shift to a lower gear before traveling downhill.
• If the road is icy or slippery when travelling uphill or downhill, engage differential lock to prevent
accidents.
• Before travelling on public highway, adjust steering column to the most straight up position and slide
operator's seat to the most forward position. Otherwise operator's field of view become restricted and an
accident may occur.
• Engine RPM is adjusted and sealed up in the factory. Do not try to readjust the engine RPM. This can
cause a serious accidents. Should this happen, consult CUKUROVA service personnel.
• Never load over. an occupied truck. Request that the driver leave the cab, even if a rock protection is
installed.
• If operating in visually obstructed terrain or whenever necessary, have another person guide you.
Always have only one person signal you.
• Allow only experienced persons to attach loads or to guide operators. The guide must be visible by the
operator and / or must be in voice contact with him.
• In case of a thunderstorm :
- Lower the attachment to the ground and if possible anchor the digging tool into the soil.
- Leave the cab and move away from the machine before the storm breaks out. Otherwise, you must stop
the backhoe loader and keep inside the closed cab Until the end of the storm.
• Auxiliary control units can have various functions. Always check their functions when starting up the
machine.
• Inspect the machine for damage if the attachment has been swung into a wall or any other obstacles.
• Applications in which the attachment is to be used to strike the material being extracted are not
permitted, even when working in a longitudinal direction.
• Repeated strikes against an object leads to damage to the steel structures and machine components.
• Please refer to your CUKUROVA dealer if special teeth for heavy-duty or special applications are
required.
• Do not attach too large bucket or bucket with side cutters or that are during operations with rocky
material. This would prolong the work cycles and may lead to damage to the bucket as well as further
machine components.
• Do not lift the machine during operation. Should this happen, lower the machine slowly back to the
ground.
• Do not let the machine fall heavily on the ground and do not hold it back with the hydraulics. This would
damage the machine.
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
• The hydraulic hammer must be selected with particular care. When using a hydraulic hammer not
permitted by CUKUROVA, steel structures or the other machine components can become damaged.
• Before beginning breaking tasks, position the machine on firm and level ground.
• Use a hydraulic hammer designed exclusively for breaking stone, concrete and other breakable
materials.
• Only operate the hydraulic hammer in the longitudinal direction of the machine and with the windshield
closed or with a front protective grid.
• Ensure during hammer operation that no cylinder is entirely extended or retracted and that the stick is
not in the vertical position.
• In order to avoid damages to the machine, try not to break stone or concrete while performing retraction
and extension motions of the hydraulic hammer.
• Do not apply the hydraulic hammer uninterrupted for more than 15 secs. at a time to the same place.
Change the breaking point. Too long uninterrupted operation of the hydraulic hammer leads to an
unnecessary overheating of the hydraulic oil.
• Do not use the drop force of the hydraulic hammer to break stone or other materials. Do not move
obstacles with the hydraulic hammer. Misuse of this nature would damage both the hammer and the
machine.
• Do not use the hydraulic hammer to lift objects.
MACHINE PARKING SAFETY
• Park the backhoe loader only on firm and level ground.

If it becomes necessary to park the machine on a grade, properly block and secure it with wedges.
• Lower the attachments to the ground and anchor the bucket lightly in the ground.
• Bring all operating levers in neutral position and engage the parking brake.
• Turn the engine off as outlined in the Operation and Maintenance Manual before you leave the
operator's seat.
• Lock the machine, remove all keys and secure the backhoe loader against vandalism, unauthorized
use, and any attractive nuisance.
MACHINE TRANSPORTING SAFETY
• Use only suitable transporting and lifting devices with sufficient capacity.
• Park the machine on firm and level ground and block the wheels.
• If necessary, remove part of the attachments during transport.
• When loading the machine on a flatbed trailer or railroad car, be sure that the loading ramp incline is
less than 30° and covered with wooden planks to prevent skidding.
• Remove all mud, snow or ice from track components before moving up the ramp.
• Align the machine with the loading ramp.
• Have another person guide and signal the operator.
• Have blocks or wedges ready to block the machine, if necessary, to prevent the machine from rolling
backwards. Be careful to crushing risks when handling and applying these wedges. Keep clear of wheels
and do not attempt to ckocke or block the machine before its complete standstill.
• Release the hydraulic pressure, remove the ignition key, engage parking brake, close and lock the cab
and close and secure all other doors and leave the machine.
• Carefully check out the transport route. Make sure that width, height and weight allowances are within
the permitted limits.
• Check that there is enough clearance underneath all bridges, underpasses, utility lines, and intunnels.
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
• During the unloading procedure, proceed with the same care and caution as during the loading
procedure. Remove all chains and wedges. Start the engine as outlined in the Operation and Maintenance
Manual. Carefully drive off the loading platform. Keep the attachment as close as possible to the ground
level. Have another person guide and signal you.
MACHINE TOWING SAFETY
• Observe the correct procedure: check the index in your Operation and Maintenance manual and refer to
the appropriate section : "Towing the Backhoe loader".
• Only tow the backhoe loader if absolutely necessary, for example to remove it for repairs from a
dangerous job site.
• Be sure all towing and pulling devices such as cables, hooks, and couplers are safe and adequate.
• Make sure that the cable or the towing rod are strong enough. Be aware that any damage to the
machine caused by towing is never covered by the manufacturer's warranty.
• Never allow anyone to stand near the cable when pulling or towing the backhoe loader.Keep the cable
tight and free of kinks.
• Engage travel slowly, and do not jerk. With a slack cable, the sudden impact of the load being towed
couId snap and break.
• Keep personnel out of area. If cable breaks while under stress, it could cause severe injury.
• During the towing procedure, keep within the required transport position, permissible, speed and
distance.
• After the towing procedure is completed, return the machine to its previous state.
• Proceed as outlined in the Operation and Maintenance Manual when putting the backhoe loader back in
service.
MACHINE MAINTENANCE SAFETY
• The machine may not be made unsafe when performing maintenance work. Never attempt maintenance
procedures or repairs you do not understand.
• Check the Operator's and Maintenance Manual for service and maintenance intervals. Make sure you
use only appropriate tools for all
maintenance work.
• Refer to your Operator's and Maintenance Manual to see, who is authorized to perform certain repairs.
The operator should only perform the daily / weekly maintenance procedures.
The remaining work may only be performed by especially trained personnel.
• Use only replacement parts corresponding to the technical requirements specified by the
manufacturer. This is assured by using only original CUKUROVA replacement parts.
• Always wear proper work clothing when maintaining the backhoe loader. Certain work .may only be
performed with a hard hat, safety shoes, safety glasses and gloves.
• During maintenance, do not allow unauthorized personnel to enter the maintenance area.
• Secure the maintenance area, as necessary.
• Inform the operator before any special or maintenance work. Make sure he knows the person, who is in
charge of the work.
• If not otherwise noted in the Operation and Maintenance Manual, always make sure the backhoe loader
is parked on firm an level ground and the engine is turned off and parking brake is engaged.
• During maintenance and service work, make sure you always retighten any loosened screw
connections!
• If it is necessary to disconnect or remove any safety devices during set up, maintenance or repair, make
sure that after completion of repairs, the safety devices are reinstalled and checked for proper function.
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
• Before any maintenance work and especially when working under the machine, make sure a "Do not
operate' tag is attached to the starter switch. Remove the ignition key.
After end of maintenance works or repair, restart the machine according to the instructions "Machine start
up", in this manual.
• Before any repairs or maintenance work, clean any oil, fuel and / or cleaning substances from any fittings
and connections. Don't use any harsh cleaners and use only lint free cloths.
• Use only nonflammable cleaning fluids to clean the machine.
• Any welding, torch or grinding work on the machine must be explicitly authorized. Written authorization
is necessary for welding on carrying structures. Before any using a welder, torch or grinder, clean off any
dust and dirt and remove any flammable materials from . the surrounding area. Make sure the area is
sufficiently ventilated. Danger of Fire and Explosion!
• Before cleaning the machine with water or steam (high pressure cleaning) or other cleaning fluids, make
sure that all openings, which , for safety and/ or functioning reasons should not be exposed to water /
steam/ cleaners, are covered and / or masked off. Especially sensitive are electrical motors, control boxes
and plug connectors.
Remove all coverings and masking material after completing the cleaning procedure. Then check all fuel
lines, engine oil lines and hydraulic oil lines for leaks, loose connections, chafing and / or damage. Fix any
problems immediately.
• If you use a high pressure cleaner with steam or hot water to clean the machine, observe following
recommendations:
− the distance between the nozzle and the surface to be cleaned must be no lower than 20 (50 cm) inches
− the water temperature should not exceed 60°C(140°F)
− limit the water pressure to 80 bar maximum (1160PSI)
− if you employ cleaning fluid, only use neutral cleaning agents such as customary car shampoos diluted
to 2 or 3 percent maximum
• Never employ high pressure cleaning apparatus during the two first months following machine delivery
or repainting.
• Observe all product safety guidelines when handling oils, grease, and other chemical substances.
• Make sure service fluids and replacement parts are disposed of properly and in an environmentally
sound manner.
• When using hot service fluids, be very careful. (They can cause severe burns and injury!).
• Operate combustion motors and fuel operated heaters only in well ventilated areas. Before operating
these units, check ventilation. In addition, always follow applicable local regulations.
• Never try to lift heavy parts. Use appropriate lifting devices with sufficient load carrying capacity. When
replacing or repairing parts or components.make sure they are mounted very carefully on lifting devices, to
prevent any possible danger. Use only suitable and technically sound lifting devices, make sure that lifting
tackle, wire cables, etc. has adequate load carrying capacity.
Never position yourself, walk or work underneath suspended loads.
• Never use damaged lifting devices, or devices which are not sufficient to carry, the load. Always wear
gloves when handling wire cables.
• Ask only experienced personnel to attach loads and guide and signal the crane operator. The guide must
be within the visibility range of the operator and /or must be in direct voice contact with the operator.
• When working overhead, use appropriate and safe ladders, scaffolding or other working platforms
designated for that purpose. Never step on parts or components on the machine when maintaining or
repairing items overhead.
When working high above ground, make sure you are fitted with ropes and appropriate safety devices which
will prevent a possible fall. Always keep handles, steps, platforms and ladders free of dirt, snow and ice!
• When working on the attachments, for example when replacing the bucket teeth, makes sure the
attachment is supported properly. Never use metal on metal support!
• Never work underneath the machine if it is raised or propped up with the attachment.
• Always use safety strut when loader boom is raised.
• Only qualified, especially trained personnel may work on travel gear, brake and steering systems.
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
• Only qualified, especially trained personnel may work on the hydraulic system.
• Never check for leaks with your bare hands, always wear gloves. Fluid escaping from a small hole can
have enough force to penetrate the skin.
• Never loosen or remove lines or fittings before the attachments has been lowered to the ground and the
engine has been turned off. Then turn the ignition key to contact position, move all servo controls (joysticks
and foot pedals) in both direction to release pressures. Then release the tank pressure as outlined in this
Operation and Maintenance Manual.
• Always disconnect the battery cable before working on the electrical system or before any arc welding
on the machine. Always disconnect the negative (-) cable first and reconnect it last.
• Check the electrical system regularly.
Make sure that any problems, such as loose connections, burnt out fuses and bulbs, scorched or chafed
cables are fixed immediately by an electrician or qualified personnel.
• Use only Original fuses with the specified amperage. Never use a different size or stronger fuse than the
original fuse.
• On machines with electrical medium or high voltage systems:
- If there is any problem with the electrical energy supply, turn the machine off immediately.
- Follow established lockout / tagout procedures where applicable.
- Any work on the electrical system may only be performed by a qualified electrician or qualified personnel
under the guidance and supervision of an electrician, according to electro-technical regulations.
• If any work is required on any parts which carry current, use a second person to turn off the main battery
switch, if necessary. Rope the work area off with a safety rope or chain, and set up warning signs. Use only
insulated tools.
• When working on medium and high voltage components, shut off the voltage and connect the supply
cable to the ground and ground the components.
• Check all disconnected parts if they are truly free of current, ground them and close them off quickly.
Insulate any close-by, current carrying parts.
HYDRAULIC LINES AND HOSES
• Hydraulic lines and hoses may never be repaired!

• All hoses, lines and fittings must be checked daily, but at least every 2 weeks for leaks and any
externally visible damage! Any damaged sections must be replaced immediately! Escaping oil can cause
injuries and fires!
• Even if hoses and lines are stored and used properly, they undergo a natural aging process. For that
reason, their service life is limited. Improper storage, mechanical damage and improper use are the most
frequent causes of hose failures.
The service life of a hose may not exceed six years, including a storage period of not more than two years
(always check the manufacturer's date on the hoses).
Using hoses and lines close to the limit ranges of permitted use can shorten the service life (for example at
high temperatures, frequent working cycles, extremely high impulse frequencies, multi shift or around the
clock operations).
• Hoses and lines must be replaced if any of the following points are found during an inspection:
− Damage on the external layer into the inner layer (such as chaff ings, cuts and rips);
− Brittleness of the outer layer (crack formation of the hose material);
− Changes in shape, which differ from the natural shape of the hose or line, when under pressure or when
not under pressure, or in bends or curves, such as separation of layers, blister or bubble formation.
− Leaks;
− Non observance of installation requirements;
− Damage or deformation of hose fittings, which might reduce the strength of the fitting or the connection
between hose and fitting;
− Any movement of hose away from the fitting;
− Corrosion on fittings, which might reduce the function or the strength of the fitting;
− Storage or service life has been exceeded.
When replacing hoses or lines, always use Original replacement parts.
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
• Route or install the hoses and lines properly. Do not mix up the connections!
• Always take care to avoid torsionaI strain when installing a new hose. On high pressure hydraulic hoses,
the mounting screws must be first mounted on both hose ends (full flange or half clamp) and tightened only
thereafter.
On high pressure hoses having one curved end, always tighten first the screws on the curved hose end and
only then the screws on the straight hose end.
Install and tighten the hose clips that may be mounted on the hose middle only when the both hose ends are
already tightened.
• Always install hoses so to avoid any friction with other hoses and parts.
We recommend to keep a distance between hose and other parts of at least one half of the hose outer
diameter. Keep a minimum gap of 1/2 inch (1.2 cm) in any case.
After mounting a hose connecting two parts that are movable to each other, check during the return to
service that the hose is not rubbing in the whole moving range.
STORAGE
PREPARING THE MACHINE FOR STORAGE
If the machine is not going to be used for a long period, it is useful to store the machine under a cover and
take the following precautions:
• Clean the machine completely and paint the damaged parts of the machine.
• Grease all greasing points.
• Drain the fuel tank and add approximately 10 lt of special washing fuel. Run the engine for about 10
minutes until the residual normal fuel is eliminated. Fill the fuel tank with diesel fuel.
• Check the air filter, clean or replace if necessary.
• Drain the engine oil and replace the filter.
• Drain the cooling system and do not close the drain plugs. Put a label onto the control panel showing
that "the cooling system is empty".
• Check the electrolyte level. Make sure that the battery is charged. Remove the battery and place it in dry
place at room temperature.
• Place blocks under the axles to prevent tyre deformation.
• Lubricate shafts.
• Cover the exhaust with a cloth.
• Engage the parking brake.
PREPARING THE MACHINE FOR WORK AFTER A LONG PERIOD OF STORAGE
• Fill the cooling system with engine coolant.

• Fll the engine with oil and check the oil level.
• Replace the fuel filter, fill the fuel tank and bleed the fuel system.
• Replace the battery and make sure that it is charged.
• Check the hydraulic oil level.
• Check the transmission oil level.
• Check the front drive axle and reduction gears oil level.
• Check the rear axle oil level.
• Check the brake oil level.
• Use a speciel solvent to clean the hydraulic cylinder rods.
• Check the tyre pressures and tightness of wheel nuts.
• Check that the indicator and warning lights on the control panels work properly.
• Start the engine after removing the cloth on the exhaust.Run to the engine 20 minutes.
CUKUROVA Model 885

Technical Data
Backhoe - Loader
and Maintenance
20.01
LUBRICATION
&
MAINTENANCE
CONTENTS
General safety information…………………………..…………………………………..………………………...1
Lubricant and operating materials specifications…………...…………………….……………..…….…..…...2
Diesel engine lubricants……………………………………………………………………………………………2
Diesel fuel……………………………………………………………………………………………………………2
Engine coolant………………………………………………………………………………………………………3
Hydraulic oil………………………………………………………………………………………………………….4
Brake oil……………………………………………………………………………………………………………...5
Transmission oil……………………………………………………………………………………………………..6
Axle oil………………………………………………………………………………………………………………..6
Lubrication schedule…………………………………………………………………………………………….….7
CUKUROVA Model 885

Lubrication &
Backhoe – Loader
Maintenance
LUBRICATION
GENERAL SAFETY INFORMATION
It is very important that ail guidelines describing lubrication, checking the oil level, replacing the oil are strictly
adhered to!
This maintenance increases the life of the backhoe loader and improves its dependability.
It is especially important to change the oil regularly and in the intervals noted on the maintenance schedule!
Only use specified lubricants and oils!
When checking or replacing the oil, observe the following :
- Park the machine on level ground, if not otherwise stated, and turn the engine off.
- When working in the engine area, make sure the covers and side doors are secured.
- Only add fuel when the engine is turned off.
- Never smoke or allow an open flame in refueling areas.
- Cleanliness is especially important when changing engine, gear or hydraulic oil. Before removing fittings or
plugs, make sure the surrounding areas are cleaned. When changing the oil, clean the fill or drain plugs.
IMPORTANT !
Be sure to drain oil into a suitable container, dispose of oil, and filter cartridges properly.
CUKUROVA Model 885

Lubrication &
Backhoe – Loader
Maintenance
LUBRICANT and OPERATING MATERIALS SPECIFICATIONS
NOTES ON LUBRICANT AND OPERATING MATERIALS CHART AND ON LUBRICATION SCHEDULE
The amounts indicated on the lubricant and operating materials chart and on the lubrication schedule are
guidelines.
Check level in appropriate aggregate after every oil change or refill.
1) DIESEL ENGINE LUBRICANTS:
Lubricant regulation for diesel engines is based on the following specifications and regulations:
API Classification : CI-4, CH-4,CG-4, CF-4 (American Petroleum Institute)
ACEA (CCMC) Classification: E5,E4,E3,E2
(Association desConstrticteurs Europeensde l'Automobile)
Intervals for Oil Change
- Oil and filter changes at 250 operating hours when using running in oil.
- Oil change depending on climate zone, sulphur content in fuel and oil quality according to sulphur chart
below.
- If indicated operating hours are not reached, change engine oil and filter at least once a year.
Oil change intervals in operating hours :
Turbo engine
Oil Quality
Sulphur content
Working conditions
in fuel CG-4, CF-4, E3-96, D5,
E2-96, D4 E4-98
< 0,5% 250 h 500 h
>-10°C
> 0,5% 125 h 250 h
< 0,5% 125 h 250 h
<-10°C > 0,5% 125 h
2) DIESEL FUEL:
Authorized Diesel fuel specifications
Use only Diesel fuel with a sulfur content of less than 0,5 % and complying with one of the following
standards: DIN EN 590, ASTMD975-89a: 1-Dand2
The sulfur content in Diesel fuel should be less than 0.5%.

Higher sulphur contents influence oil change intervals and engine life.
Lubricity
By reducing sulphur content, the question of engine fuel lubricity arose. It has been clearly shown that
engine fuels with the maximum allowable sulphur content (in Europe 0.05% by volume) can cause damage
to the injector systems (especially in the case of distributor injection pumps).
CUKUROVA Model 885

Lubrication &
Backhoe – Loader
Maintenance
Improving Diesel fuel fluidity in cold climates
Addition of regular gasoline or kerosene
When ambient temperature are below 0°C (32 °F), Diesel fuels normally used during the summer may suffer
a decline in fluidity due to paraffin separation. The same occurs if Diesel fuels normally used during the
winter are used at temperature below -15 °C (5 °F).
Often, additive diesel fuel is on offer with operating temperatures down to -20°C (-4 °F).
In order to prevent operating problems at these low temperatures, the Diesel fuel must be mixed with regular
gasoline or kerosene.
Mixing regular gasoline should be considered at last resort, under no circumstances should the ratio of
gasoline exceed 30%.
Never use super grade gas for mixing.
* If an additive of 50% is necessary, only use kerosene (no normal gasoline).
Depending on the ratio of Diesel fuel to gasoline or kerosene, engine output may some that decline.
Depending on the ambient temperature, add as little gasoline or kerosene as possible to the Diesel fuel.
Other Fuel additives (flow improvers):

Widely available flow improvers also enhance Diesel fuel ability to perform reliably in cold climate conditions.
When using such flow improvers, follow the manufacture’s recommendations closely.
3) ENGINE COOLANT
- Specifications for anticorrosion and antifreeze protection
Using a mixture of antifreeze and anticorrosion with "DCA4" anticorrosion additive.
To assure the protection from corrosion of the cooling system, the coolant must contain at least 50%
corrosion / antifreeze mixture all year round. This protects the cooling system to about - 35° C (- 33° F).
When fluid is added to the coolant mixture, it must be assured that the mixture maintains a 50% antifreeze
content.
Caution : The percentage of antifreeze should not exceed 60 % . A higher concentration would lead to
reduced antifreeze and cooling properties.
In addition, the cooling system must contain DCA4 (DCA = Diesel Coolant Additive) from FLEETGUARD.
The prescribed concentration is from 0.3 to 0.8 DCA units per liter of coolant (1.2 to 3.0 units per US
Gallon).
The coolant must be changed every 2 years. Before adding new coolant, check the circuit for cleanness
and if necessary flush it with water.
CUKUROVA Model 885

Lubrication &
Backhoe – Loader
Maintenance
Using a mixture of water and DCA4 (without antifreeze and anticorrosion)
In certain circumstances, and if ambient temperatures are constantly above the freezing point, for
instances in tropical regions, and if there are no corrosion or antifreeze fluids available, then a mixture of
water and DCA4 additives may be used.
To maintain sufficient anticorrosion properties however, the DCA4 concentration of the coolant must in this
case be about doubled in comparison with the one prescribed when using a mixture also containing
antifreeze and anticorrosion, it equals a concentration from 0.6 to 1.6 DCA units per liter of coolant (2.4 to
6.0 units per US Gallon).
Important:
if employing a mixture consisting only of water and DCA4 additives :

- The use of coolant refiners (corrosion protective oils) is not authorized,
- The coolant change interval must be reduced to once a year.
Fresh water guidelines:
To mix the coolant fluid, only clean, preferably soft water should be used. Often, but not always, regular
drinking water can be used. Sea water, brackish waters, sole water or industrial waste water may not be
used.
4) HYDRAULIC OIL
Hydraulic oil specifications
1. Mineral oils
For single viscosity oils: For multi viscosity oil:
Recommended and approved are engine oils, which conform to the following specifications and regulations :
For single viscosity oils : Vickers I-286 S, M-2950-S, Denison HF-0, HF-1,2
2. Environmentally friendly hydraulic fluids (also called "BIO oils" -bio degradable oils-)
The "environmentally friendly hydraulic fluids" recommended by CUKUROVA are limited to synthetic ester
based hydraulic fluids with a viscosity according to ISO VG 46.
Initial filling is performed ex works according to customer desires. The use of environmentally-friendly
hydraulic fluids must be arranged with the CUKUROVA beforehand.
Organic oils should not be used due to their poor temperature consistency.
Note: It is absolutely necessary never to mix different brands of environmentally friendly hydraulic fluids or
to mix fluids with mineral oils.
CUKUROVA Model 885

Lubrication &
Backhoe – Loader
Maintenance
Hydraulic oil change intervals
1. Oil changes in preset intervals
Note: Oil changes in preset intervals are only permitted for mineral oils. When using
environmentally friendly hydraulic fluids, oil sample analysis reports must be used determine the
time of the oil change.
a) In standard applications
o p e r a t in g
h o u rs
5 0 0 1 0 0 0 1 5 0 0 2 0 0 0
b) In dust intensive applications
o p e r a t in g
h o u rs
5 0 0 1 0 0 0 1 5 0 0 2 0 0 0
To limit the hydraulic oil contamination when working under extreme dusty conditions
On backhoe loaders working under very dusty conditions or with a hydraulic hammer attachment, the
contamination of the hydraulic oil may be significantly increased.
In order to avoid any premature wear and failure of hydraulic components in consequence of this
contamination reduce the oil change intervals as described above and, in addition, observe following
recommendations:
• The tank return filter element(s) must be replaced every 1000 operating hours.
• The breather filter on the hydraulic tank must be replaced with a 75 µm fine breather filter.
• This 75 µm breather filter must be replaced every time the hydraulic oil is changed (every 1000
operating hours).
BRAKE OIL
Intervals for oil change:
• Brake oil changes every 1000 hours.

• Brake oils must meet the specifications SAE 0W-40, API SL,CF
CUKUROVA Model 885

Lubrication &
Backhoe – Loader
Maintenance
TRANSMISSION OIL
Lubricant regulations for transmission oils is based on the following specifications and regulations:
SAE30, API CF / SF
• First oil change at: 100 operating hours

• First filter changes at: 100 operating hours.
• Further filter changes every 1000 hours and oil change depending on climate zone and oil quality.
FRONT AXLE OIL
Front axle oils must meet the specifications API GL-4.
• First oil change at: 500 operating hours.

• Further oil changes every 1000 hours.
REAR AXLE OIL
Rear axle oils must meet the specifications API GL-4.
• First oil change at: 500 operating hours.

• Further oil changes every 1000 hours.
CUKUROVA Model 885

Lubrication &
Backhoe – Loader
Maintenance
LUBRICATION SCHEDULE
CUKUROVA Model 885

Lubrication &
Backhoe – Loader
Maintenance
30
HYDRAULIC
30.01
HYDRAULIC
SYSTEM
CONTENTS
Tests and hydraulic pressures test……….………..…………………………………..………………………...1
Hydraulic tank and return filter…………...……………………………………….……………..…….…..….....2
Blocks………..…………………………………………………….………………………………………………..4
The function of the loader control valve and unloader valve……………………………………………….…7
Steering priority valve……………………………………………………………………………………………..8
The function of the backhoe control valve……………………………………………………………………....9
Pressure relief valve (PRV) test…………..…………………………………………………………………….10
Secondary pressure relief valves (SPRV)……………………………………………………………………...11
Unloading valve test………………………………..…………………………………………………………….12
Steering pressure test………………………………………………………………………………….………...13
Pilot pressure test…………………………………………………………………………………………..…….14
HYDRAULIC CYLINDERS
Basic type cylinder assembly……………………………………………………………………………..……..15
Nut type cylinder montage……………………………………………………………………………………….24
Loader lift cylinder………………………………………………………………………………………………...29
Loader bucket tilt cylinder……………………………………………………………………………………..…32
Clampshell cylinder…………………………………………………………………………………………….…35
Backhoe boom cylinder…………………………………………………………………………………………..38
Backhoe dipperstick cylinder………………………………………………………….…………………………41
Backhoe bucket cylinder…………………………………………………………………………………………44
Backhoe extendible dipperstick cylinder……………………………………………………………………….47
Backhoe swing cylinder……………………………………………………………………………………….…50
Backhoe stabilizer cylinder………………………………………………………………………………………53
CUKUROVA Model 885

Backhoe – Loader Hydraulic System

Tests and Hydraulic pressures Test Nominal Notes
point Value
Engine RPM Low 800 min-1
Engine RPM High 2200 min-1
±10
Oil Temperature 50 °C
3
Transmission system pressure Trans 16+ bar
Adjusted Hydraulic main system P1 210±5 bar All pressure

pressure adjustment due to
engine’s 1500 rpm
5
Hydraulic support pump system pressure P2 180± bar
Loader Valve
Boom cylinder retract P1 210±5 bar System pressure
Boom cylinder extend P1 210±5 bar System pressure
Bucket cylinder retract P1 225±5 bar

Bucket cylinder extend P1 160±5 bar
Clamp cylinder retract P1 210±5 bar System pressure

Clamp cylinder extend P1 240±5 bar
Backhoe Valve
Boom cylinder retract P1 225±5 bar
Boom cylinder extend P1 275±5 bar
5
Stick cylinder retract P1 275± bar
Stick cylinder extend P1 225±5 bar
5
Bucket cylinder retract P1 225± bar
5
Bucket cylinder extend P1 225± bar
Swing cylinder - Left P1 160±5 bar

Swing cylinder - Right P1 160±5 bar
Stabilizer - Left leg P1 210±5 bar System pressure

Stabilizer - Right leg P1 210±5 bar System pressure
Steering system
Steering unit CF 175±5 bar
Turn Right CF 175±5 bar
Turn Left CF 175±5 bar
Pilot System Pressure Pilot 27+3
CUKUROVA Model 885

Backhoe - Loader Hydraulic System

Hydraulic Tank and Return Filter
Hydraulic tank contains the hydraulic oil for the

hydraulic system.
Hydraulic tank has three separate sections;
1- Filter chamber A, all leak oil is collected.
2- Return oil side B, all return oil from the

hydraulic valves is collected.
3- Suction side C where the oil is drawn by the

hydraulic pumps.
Section B and C are divided by means of the

Figure 1 perforated steel sheet.
Filtered oil flows through the section C which is

free from the foam.
Figure 2
The tank is equipped by a breather filter so that the

oil is subjected to the atmospheric pressure. This
filter must be cleaned at least for every 500 hours
depending to the working conditions
2.1- Plug
2.2- Plug
2.3- Strainer
2.4- Housing
Figure 3
CUKUROVA Model 885


Fixed Displacement Tandem Pump
The working pump is designed as a gear

pump. It is driven by the diesel engine and
installed on the transmission unit.
Hydraulic pump converts mechanical energy to

hydraulic energy.
The double pump consists of two input units

P1 and P2 and designed as a fixed
displacement gear pump.
The pump is driven by the transmission with

the same speed of the engine.
The second pump P1 supplies oil to the

P2 Pump P1 Pump hydraulic steering system via the priority valve.
The priority valve diverts excess flow to the
loader valve.
This flow summation increases the attachment

speed.
CUKUROVA Model 885


Collector Block
The return oil from the users is collected
in the loader valve block (100) and the
backhoe valve block (200) and returns to
the tank via collector block (2).
The oil returns to the tank, either via the

pretension check valve 2.2, connections
and oil cooler (3).
To avoid the pressure peaks in the oil

cooler when the hydraulic oil is cold (high
viscosity), the pretension check valve
(2.1), which is adjusted to 7 bar, pens and
allows the return oil from the control valve
blocks to flow directly to the hydraulic tank
(1).
Function of Pretension Check Valve
The pretension check valve is pre-

adjusted in the factory.
The counter pressure is adjusted by the

spring (2) force which holds the piston (9)
in its seat. When the counter pressure is
reached to the adjusted value, the piston
leaves its seat, allowing oil to flow through
port T. The pressure at port A is
maintained to the pre-adjusted value.
The orifice on the piston allows oil on the

spring side to flow through the tank ( to
avoid the piston from blockage).
1- Cover 2- Spring 3- O-ring
4- Housing 5- O-ring 6- Seal
7- Support 8- O-ring 9- Piston
A- Inlet Port T - Tank port
CUKUROVA Model 885


Servo Valve Block
Servo valve is a collector and distributor

block.
Servo valve supply oils to the joysticks

and the backhoe boom locking valve. The
return lines of these components are
connected to the tank via the servo valve.
The valve is supplied with hydraulic oil via

connection (9) from the distributor block
which is also supplied with hydraulic oil
via the axial piston pump.
The cartridge type pressure reducing

valve is mounted to the block. The
purpose of this is to limit the servo
pressure to a certain value.
An accumulator is mounted to the block

which maintains the servo pressure
makes it possible to apply a limited times
when the engine is turned off or the
hydraulic pump has a failure.
CUKUROVA Model 885


ON-OFF Solenoid Valve
Function
The spool of the solenoid valve closes the

ports of A and B in neutral by means of
the spring force.
When the solenoid energized, the pin

inside the magnet is forced towards to the
spool. The spool moves in the same
direction of the pin allowing the oil to flow
from Port A to Port B.
All the joysticks are supplied with oil when

the solenoid valve is energized.
Adjustment
Remove cap and install the pressure

gauge to the test point SERVO for the
servo pressure of the hydraulic system.
Run the diesel engine at approx. 1000

RPM.
Load the pump slowly by means of

actuating one of the cylinders all the way.
Check the servo pressure.
CUKUROVA Model 885


If the servo pressure is lower than the
predefined value, loosen lock nut and turn
the adjustment screw clockwise to set the
pressure.
If the servo pressure is higher than the

predefined value, loosen lock nut and turn
the adjustment screw counter-clockwise
to set the pressure.
The Function of the Loader Control

Valve and Unloader Valve
The loader control valve is monoblock

P2 adjustment relief valve and open centered. The control valve is
combined of the different elements.
P2 Unloader solenoid
The control valve is mechanically
actuated and controls the working
movements of the backhoe depending on
the mechanical joystick position.
The loader control valve is combined with

the unloader valve which is activated by
hydraulically or by a solenoid valve. The
solenoid valve is energized by a button
inside the cab.
Oil from P2 enters the valve, flows

through the Check Valve and combines
with the flow from P1.
A drilling in the block feeds oil from the

main passage to the end of the unloader
spool, through the orifice to the relief
valve and solenoid valve. When pressure
in the main passage exceeds 180 Bar, the
relief valve opens and oil begins to flow
from the main passage through the orifice
P1 pump connection and the relief valve to the tank. The
pressure drop created across the orifice
P1 pump adjustment relief valve which is acting on the end of the spool
exceeds the spring force, allowing the
P2 pump connection spool to shift, opening P2 to the tank.
When pressure in the main passage falls
below the setting of the relief valve, it
closes. The flow through the orifice stops,
pressure equalizes at each end of the
spool, the spool is then shifted to its
original position by the spring. Oil from P2
passes through the check valve again to
combine with the flow from P1 to give full
flow to the Loader Control Valve.
CUKUROVA Model 885


P1 adjustment relief point Similarly, when the solenoid valve is
energized the oil flows along the same path,
cause pressure drop across the orifice and
the spool shifts and opens P2 to the tank.
Oil flow from the loader control valve enters
via connection the backhoe control valve.
Primary pressure relief valve which is

installed loader valve protect the hydraulic
system against pressure peaks above the
adjusted maximum pump working pressure
between pump and control valves.
Some of user of the control valve is fitted

either with a secondary pressure relief valve
integrated suction function to avoid from
cavitations except clamp (left and right).
Secondary pressure relief valve and protect

the working circuits by limiting the pressure
which could appear between the control
valve and the users to a preadjusted value.
The purpose of the suction valve which is

combined with the relief valve is to prevent
the cavitations which could occur during
Float valve section certain working movements, while allowing
the oil at the tank pressure to flow to the low
pressure side of the users.
Steering Priority Valve
Oil from P1 enters the steer priority valve

and is diverted to the controlled flow port
CF. Pressure in CF is sensed through a
small drillings in the spool and is directed to
the end of the Spool through an orifice.
When sufficient oil is delivered to the

steering unit to satisfy the steering
requirement, pressure in CF rises. When it
exceeds the setting of the spring, the spool
begins to shift. The excess flow is diverted
to EF to combine with the flow from P2 to
the loader control valve.
A Load Sense hose directs pressure from

the steering unit back in to LS.
CUKUROVA Model 885


The Function of the Backhoe Control
Valve
The backhoe control valve is monoblock

and open centered. The control valve is
combined of the different elements.
Oil flow from the loader control valve

enters via connection N the backhoe
control valve.
The control valve is mechanically

actuated and control the working
movements of the backhoe depending
on the mechanical joystick position.
Each user of the control valve is fitted

either with a secondary pressure relief
valve integrated suction function to avoid
from cavitations except stabilizers (left
and right).
Secondary pressure relief valve protect

the working circuits by limiting the
pressure which could appear between
the control valve and the users to a
preadjusted value.
The purpose of the suction valve which is

combined with the relief valve is to
prevent the cavitations which could occur
during certain working movements, while
allowing the oil at the tank pressure to
flow to the low pressure side of the
users.
CUKUROVA Model 885


PRESSURE RELIEF VALVE (PRV)
TEST
Park the machine on level ground. Make

sure that the attachments are in the road
travel position. Lower the loader bucket.
- Heat the hydraulic oil temperature until

it reaches to 50°C.
- Raise the loader and install the safety

strut.
- Stop the engine and release the

pressure in the hydraulic system.
- Attach the manometer (0-400 bar) to

the test point P1.
P2 test point - Make sure that there is anyone around

P1 test point the machine
- Start up the machine
- Raise the boom and control the

pressure via manometer.
NOTE: If the pressure is above or under

the determined value, adjust the main
pressure relief valve(P1).
Remove the manometer.
Manometer
P1 adjustment relief point

Adjustment bolt
CUKUROVA Model 885


SECONDARY PRESSURE RELIEF
VALVES(SPRV)
- Park the machine on flat, level ground.

Make sure that the attachments are in
the road travel position.
- Lower the loader bucket.
- Make sure that there is anyone around

the machine.
- Heat the machine until the hydraulic oil

temperature reaches to 50°C.

strut.
SPRV - Stop the engine and release the

- Attach the manometer (0-400 bar) to

the test point M1.
- Turn in the primary pressure relief valve

adjusting bolt one turns clockwise.
- Start up the engine.
- Activate the related attachment to make

the controls and see the secondary
pressure from the test point P1.
NOTE: If the pressure is lower or higher

than the determined value, park the
machine, stop the engine, release the
pressure in the hydraulic system and
remove the secondary pressure relief
valve
- Define the SPRV correctly
- Remove the secondary pressure relief

valve as shown in the pictures
- Adjust the SPRV
CUKUROVA Model 885


UNLOADING VALVE TEST
Park the machine on flat, level ground.

the road travel position. Lower the loader
bucket.

the machine.
- Heat the engine until the hydraulic oil


strut.
- Stop the machine and release the

P2 test point - Attach the manometers (0-400 bar) to

the test point P1 and P2.
- Be sure that the unloader solenoid is

not energized.
- Raise the boom and control the

pressure in the manometer.
- Make sure that the pressure in two test

points (P1 and P2) rises to 180 bar
simultaneously.
- When the pressure in test point P2

Manometer reaches to 180 bar, discharge valve
decreases the pressure of pump P2 to 0
bar.

than the determined value, the
adjustment of the discharge valve should
be done by the adjustment bolt.
- Control and adjust the pressure and

park the machine.
- Stop the engine and remove the

manometers.
P2 adjustment bolt
CUKUROVA Model 885


STEERING PRESSURE TEST

bucket.

the machine.


strut.

Steering pressure test point (CF)
- Attach the manometers (0-400 bar) to
the test point CF.
- Turn the steering one side end .
- Check the steering pressure (175 bar)

than the determined value (175 bar) , the
adjustment of the steering pressure
should be done by the adjustment bolt.
- Demount the steering control unit.
- Remove the plug
- Adjust steering pressure by adjustment

Plug (over adjustment bolt) Steering control unit bolt
Adjustment bolt
CUKUROVA Model 885


PILOT PRESSURE TEST

bucket.

the machine.


strut.

Pilot pressure test point pressure in the hydraulic system.
- Attach the manometers (0-50 bar) to

the test point Pilot.
- Check the pilot pressure (27 bar)
Pliot valve Pilot adjustment bolt NOTE: If the pressure is lower or higher
than the determined value (27 bar) , the
adjustment of the pilot pressure should
be done by the adjustment bolt.
- Untighten the nut
- Adjust pilot pressure by adjustment bolt
- Tighten the nut
Hydraulic accumulator (13 bar)
CUKUROVA Model 885


HYDRAULIC CYLINDERS
Basic type cylinder assembly
Firstly clean the piston guide with solvent or

a chemical cleaner.
Figure 1
After cleaning, dry the piston guide.
Figure 2
You can use air for drying the guide
Figure 3
CUKUROVA Model 885


Seal parts:
1) Back-up ring
2) O-ring
3) O-ring
4) Omegat
5) Dust seal
6) O-ring
7) Dust seal
8) Nutring
9) O-ring
10) Guide ring
11) Guide ring
12) Guide ring
Figure 4
Prepare the guide and piston end for

mounting
Figure 5
New seal kit montage to guide
Firstly, mount back-up ring and O-ring into

the guide surface grove. See Figure 6!
Figure 6
CUKUROVA Model 885


Firstly insert the O-ring into the groove
then mount the omagat into groove over
the O-ring (figure 8 and figure 7- same
groove)
Figure 7
Mounting of omegat
Figure 8
Use bottom of a screw driver for assist

mounting of a Omegat.
Figure 9
CUKUROVA Model 885


Prepare the guide ring for montage.
Figure 10
Mount the guide ring
Figure 11
Mount the nutring shown as figure 12
Figure 12
CUKUROVA Model 885


Mount the guide ring
Figure 13
Align the dust seal on the guide– figure 14
Figure 14
Mount the dust seal with pressure

apparatus – see figure 15.
Figure 15
CUKUROVA Model 885


Piston Montage
Seat the O-ring into the piston surface

groove.
Figure 16
Insert the O-ring inner side of piston.
Figure 17
Seat the O-ring into the piston surface

groove.
Figure 18
CUKUROVA Model 885


Use apparatus shown figure 19 for
placing the omegat.
Figure 19
Place the omegat and align on the guide

apparatus shown figure 20
Figure 20
Push the omegat through the piston with

the insert apparatus(figure 21)
Figure 21
CUKUROVA Model 885


Use a plastic hammer move the omegat
to groove.
Figure 22
Place the omegat into groove.
Figure 23
Use the circular pressure apparatus on

the omegat.
Figure 24
CUKUROVA Model 885


Fit the omegat.
Mount the piston on rod
Figure 25
Mount the guide rings

Mount the setscrew.
Figure 26
Piston is ready
Mount the piston into cylinder shell.
Figure 27
CUKUROVA Model 885


Nut type cylinder montage
In figure 1 some of the guide seals shown

nut type cylinder montage
Şekil 29 da görüldüğü gibi Somun tipli

silindir montajında kullandığımız kılavuz
görülmektedir. Kılavuzun iç kısmına Düz
tip silindir montajında görüldüğü gibi O-
ring, omegat, yataklama ringi ve keçeler
yerleştirilir.
Figure 1
Mount the O-ring,guide ring, seal and

omegat inner side of the guide groove
Figure 2
Figure 3
CUKUROVA Model 885


Mount backup ring and O-ring
Figure 4
Mount the O-ring inner side of piston
Figure 5
Mount the piston on rod
Figure 6
CUKUROVA Model 885


Use Loctite on treads
Figure 7
Mount the nut end of the rod
Figure 8
Place the guide rings on piston
Figure 9
CUKUROVA Model 885


Select the suitable torque on nut.
Tighten the nut.
Figure 10
Mount the teflon rings .
Figure 11
Align and replace the piston into the

cylinder shell.
Figure 12
CUKUROVA Model 885


Use loctite on bolts
Figure 13
Tighten the guide bolts
Cylinder is ready…
Figure 14
CUKUROVA Model 885


LOADER LIFT CYLINDER
1 CYLINDER PIPE LEFT 14 O-RING

2 TEFLON RING 15 OMEGAT
3 O-RING 16 ROD
4 BACK-UP RING 17 GREASER
5 NUTRING 18 DUST SEAL
6 TEFLON RING 19 BUSHING
7 DUST SEAL 20 DUST SEAL
8 GUIDE 21 BUSHING
9 BOLT 22 GREASER
10 NUT 23 PLUG
11 PISTON 24 LIFT CYLINDER RIGHT
12 TEFLON RING 25 LIFT CYLINDE LEFT
13 TEFLON RING 26 REPAIR KIT
CUKUROVA Model 885


10
11 8
14 1 16
7
12
22 2 6 17
12 13
15 3
13 9
4
5
18
21 19
20
1 CYLINDER PIPE LEFT 14 O-RING

3 O-RING 16 ROD
4 BACK-UP RING 17 GREASER
8 GUIDE 21 BUSHING
9 BOLT 22 GREASER
10 NUT
11 PISTON
12 TEFLON RING
13 TEFLON RING
CUKUROVA Model 885


DISASSEMBLY
Clean the cylinder.

Fix the cylinder very carefully (1).
Remove the bolts(9) and take the guide(8)
Remove the rod (16) carefully.
Fix the rod (16) from the pin side. Remove the nut (10) by means of a key.
Remove the piston(11) from the rod(16)
Remove the ring (15),the bearing (12,13)and O-ring(14)
Remove the guide(8) from the rod(16)
Remove the teflon ring(2,6),O-ring(3),back-up ring(4),nutring (5),dust seal(7) from the guide(8).
Check the greasers (17,22) and if they don’t work, change them.
CHECK
Clean all parts of the cylinder.

Check inside the cylinder (1).
If there is damage in the pipe, renew it.
Check the surface of the rod (16), renew it if there is a damage.
Check the linearity of the rod (16).
Check the bushings (19, 21).Change it if necessary.
Check the guide (8).Change it if necessary.
Check the piston (11).Change it if necessary.
ASSEMBLY
After the assembly of the teflon rings(2,6) to the guide, place the dust seal(7) and nutring(5).
Then, place O-ring(3) and back-up ring(4).
Grease the guide (8).Pass the O- ring (16) from the head of the guide (8).
Pass the Omegat (15) on the piston (11).
Grease the O-ring (14) and pass it on the piston (11).
Grease the teflon ring(12,13)and pass it on the piston(11)
Assemble the piston(11) to the rod(16)
Tighten the nut(10) and fix the piston(11)
Install the rod to the cylinder which is greased by hydraulic oil.
Fix the guide(8) with bolts(9)
CUKUROVA Model 885


LOADER BUCKET (TILT) CYLINDER
1 CYLINDER PIPE LEFT 13 TEFLON RING

2 TEFLON RING 14 O-RING
3 OMEGAT 15 OMEGAT
4 O-RING 16 TEFLON RING
5 BACK-UP RING 17 ROD
8 DUST SEAL 20 GREASER
9 GUIDE 21 BUSHING
10 BOLT 22 TILT CYLINDER
11 NUT 23 REPAIR KIT
12 PISTON
CUKUROVA Model 885


3 OMEGAT 15 OMEGAT
9 GUIDE 21 BUSHING
10 BOLT 22 TILT CYLINDER
11 NUT
12 PISTON
CUKUROVA Model 885


DISASSEMBLY
Clean the cylinder.

Fix the cylinder (1)
Remove the bolts(10) and the head of the cylinder.(9)
Remove the rod (17).
Fix the rod (17) from the pin side. Remove the nut (11) with a key.
Remove the Omegat (15), teflon ring (13, 16) and O-ring (14) from the piston.
Remove the teflon ring(2,7),Omegat(3),O-ring(4),back-up ring(5), nutring(6) and dust seal(8).
CHECK
Clean all parts.

Check inside the cylinder (1)
Change the cylinder (1) if necessary.
Check the surface of the rod (17).Change it if necessary.
Check the linearity of the rod (17).
Check the bushings (19, 21).Change it if necessary.
Check the guide (9).If a problem is seen, renew it.
Check the piston (12). If a problem is seen, renew it.
ASSEMBLY
Then, place Omegat(3),O-ring(4) and Back-up ring(5).
Grease the guide (9) and pass the rod (17) from the head of the guide (9).
Pass the Omegat(15) on the piston(12)
Grease the O-ring(14) and pass the piston(12)
Grease the teflon rings(13,16) and pass on the piston(12)
Make the assembly of the piston(12) to the rod(17)
Pass the rod from the cylinder (1) which is greased by hydraulic oil.
CUKUROVA Model 885


CLAMPSHELL CYLINDER
1 CYLINDER PIPE 13 OMEGAT

5 OMEGAT 17 SEGMENT
6 NUTRING 18 JOINT
9 GUIDE 21 GREASER
10 NUT 22 CLAMP CYLINDER
11 PISTON 23 REPAIR KIT
12 TEFLON RING
CUKUROVA Model 885


5 OMEGAT 17 SEGMENT
6 NUTRING 18 JOINT
9 GUIDE 21 GREASER
10 NUT
11 PISTON
12 TEFLON RING
CUKUROVA Model 885


DISASSEMBLY
Clean the cylinder.

Fix the cylinder .(1)
Remove the cylinder head (9).
Remove the rod (16) carefully.
Fix the rod (16) from the pin side. Remove the nut by mean of a key(10)
Remove the Teflon rings (12, 15), Omegat (14) and O-ring (13) from the piston.
Remove the guide (9) from the rod (16).
Remove the teflon ring(2,7),Omegat(5),O-ring(3),back-up ring(4),nutring(6) and dust seal(8).
CHECK
Clean all parts.

If there is damage inside the cylinder (1), renew it.
Check the surface of the rod (16), if there is damage on the surface, renew it.
Check the linearity of the rod(16).If there is a problem, renew it
Check the bushings (18, 19).Change them if necessary.
Check the piston (11).If a problem is seen, renew it.
ASSEMBLY
Place the Teflon rings (2, 7) to the guide after the assembly of dust seal (8) and nutring (6).
Then, place Omegat (5), O-ring (3) and back-up ring (4).
Grease the guide (9) and pass the rod (16) from the head of the guide (9) very carefully.
Grease the O-ring (13) and pass on the piston.
Grease the Teflon rings (12, 15) and pass on the piston (11).
Make the assembly of the piston (11) to the rod (16).
Tighten the nut(10)and fix the piston(11)
Pass the rod (16) from the cylinder (1) which is greased by hydraulic oil.
Fix the guide(9)
CUKUROVA Model 885


BACKHOE BOOM CYLINDER
1 CYLINDER PIPE 15 TEFLON RING

3 O-RING 17 OMEGAT
4 BACK-UP RING 18 TEFLON RING
5 OMEGAT 19 TEFLON RING
6 NUTRING 20 ROD
7 TEFLON RING 21 DUST SEAL
8 DUST SEAL 22 BUSHING
9 GUIDE 23 GREASER
10 BOLT 24 BUSHING
11 SEGMENT 25 REPAIR KIT
12 WASHER 26 BACKHOE BOOM CYL.
13 WASHER 27 SCREW
14 PISTON
CUKUROVA Model 885


3 O-RING 17 OMEGAT
6 NUTRING 20 ROD
9 GUIDE 23 GREASER
10 BOLT 24 BUSHING
11 SEGMENT 25 SCREW
12 WASHER
13 WASHER
14 PISTON
CUKUROVA Model 885


DISASSEMBLY
Clean the cylinder.

Remove the bolts(10) and take the cylinder head(9)
Remove the rod(20) carefully
Fix the rod(20)
Remove the Omegat (17), Teflon rings (15, 18, and 19) ,O-ring (16), washers(12,13) and segment (11)
on the piston.
Remove the guide(9)from the rod(20)
Remove the teflon rings(2,7), Omegat(5),O-ring(3), back-up ring(4) ,nutring(6)and dust seal(8) from the
guide(9).
CHECK
Clean all parts.

Check inside the cylinder(1)
If there is damage inside the cylinder, renew it.
Check the surface of the rod (20).If there is damage on the surface, change it.
Check the linearity of the rod (20).If there is a problem, renew it.
Check the guide. If a problem is seen, change it.
Check the piston (14).If a problem is seen, renew it.
ASSEMBLY
After the assembly of the teflon rings(2,7) to the guide, place the dust seal (8) and nutring(6).
Then, place Omegat(5),O-ring(3) and back-up ring(4).
Grease the guide(9)Pass the rod(20) from the head of the guide(9)
Place the Omegat(17) on the piston(14)
Grease the O-ring (16) and then pass it on the piston(14).
Grease the teflon rings(15,18,19) and then pass on the piston(14)
Make the assembly of the piston (14) to the rod (20).
Place the washer (12,13) and segment (11) and fix the piston(14)
CUKUROVA Model 885


BACKHOE DIPPERSTICK CYLINDER

2 O-RING 14 OMEGAT
3 FIBER RING 15 GREASER
4 NUTRING 16 ROD
7 GUIDE 19 DUST SEAL
8 BOLT 20 BUSHING
9 NUT 21 DIPPERSTICK CYLINDER
10 PISTON
11 TEFLON RING
12 O-RING
CUKUROVA Model 885


2 O-RING 14 OMEGAT
3 FIBER RING 15 GREASER
4 NUTRING 16 ROD
7 GUIDE 19 DUST SEAL
8 BOLT 20 BUSHING
9 NUT
10 PISTON
11 TEFLON RING
12 O-RING
CUKUROVA Model 885


DISASSEMBLY
Clean the cylinder.

Fix the cylinder (1) very carefully.
Remove the bolts(8) and take the cylinder head(7)
Remove the rod(16) carefully
Fix the rod(16) from the pin side and remove the nut(9) with a key.
Remove the Omegat(14), teflon ring(11,13) and O-ring(12)
Remove the fiber-ring(3),O-ring(2),teflon ring(5),nutring(4) and dust seal(6)from the guide(7).
CHECK
Clean all parts.

If there is damage inside the cylinder, renew it.
Check the surface of the rod (16).If there is damage, renew the cylinder.
Check the linearity of the rod (16).Change it if necessary.
Check the bushings (18, 20). Change them if necessary.
Check the guide (7).If there is a problem, renew it.
Check the piston (10).If a problem is found, change it.
ASSEMBLY
After the assembly of the Teflon ring (5) to the guide (7), place the dust seal (6) and nutring (4).
Then, place the fiber ring (3) and O-ring (2).
Grease the O-ring(12) and then pass on the piston(10)
Grease the teflon rings(11,13) and then pass on the piston(10)
Fix the guide (7) with bolts (8).
CUKUROVA Model 885


BACKHOE BUCKET CYLINDER
1 CYLINDER PIPE 13 O-RING

4 O-RING 16 ROD
8 GUIDE 20 BUSHING
9 BOLT 21 DUST SEAL
10 NUT 22 BACKHOE BUCKET CYL.
11 PISTON
12 TEFLON RING
CUKUROVA Model 885


1 CYLINDER PIPE 13 O-RING
4 O-RING 16 ROD
8 GUIDE 20 BUSHING
9 BOLT 21 DUST SEAL
10 NUT
11 PISTON
12 TEFLON RING
CUKUROVA Model 885


DISASSEMBLY
Clean the cylinder.

Remove the bolts (9) and take the cylinder head (8).
Remove the rod (16) very carefully.
Fix the rod (16) from the pin side and remove the nut (10) with a key.
Remove the Omegat (15),teflon rings(12,14) and O-ring(13) on the piston(11)
Remove the guide from the rod(16)
Remove the teflon rings(3,6),O-ring(4),back-up ring(2),nutring(5) and dust seal(7) from the guide(8).
CHECK
Clean all parts.

Check the inside the cylinder (1)
If there is a damage in the cylinder , renew it
Check the surface of the rod (16), if there is damage, renew it.
Check the linearity of the rod (16).If there is a problem, change it.
Check the piston (11) Renew it if necessary.
ASSEMBLY
After the assembly of the teflon rings(3,6)to the guide, place the dust seal(7) and nutring(5).
Then, place the o-ring(4) and back-up ring(2)
Grease the O-ring(14) and then pass on the piston(11)
Grease the teflon rings(12,14)and then pass on the piston(11)
Assemble the piston(11) to the rod(16)
Tighten the nut(10) and then fix the piston(11)
Fix the guide (8) with bolts (9).
CUKUROVA Model 885


BACKHOE EXTENDIBLE DIPPERSTICK CYLINDER

2 TEFLON RING 14 ROD
3 O-RING 15 DUST SEAL
4 BACK-UP RING 16 BUSHING
5 NUTRING 17 GREASER
6 TEFLON RING 18 RUBBER BUMPER
7 DUST SEAL 19 EXTENDIBLE DIPPERSTICK CYLINDER
8 GUIDE 20 REPAIR KIT
9 NUT
10 PISTON
11 TEFLON RING
12 O-RING
CUKUROVA Model 885


2 TEFLON RING 14 ROD
3 O-RING 15 DUST SEAL
4 BACK-UP RING 16 BUSHING
6 TEFLON RING 18 RUBBER BUMPER
7 DUST SEAL
8 GUIDE
9 NUT
10 PISTON
11 TEFLON RING
12 O-RING
CUKUROVA Model 885


DISASSEMBLY
Clean the cylinder.

Remove the cylinder head(8)
Remove the rod(14) from the cylinder (1)
Remove the piston(10)from the rod(14)
Remove the Teflon ring (11), Omegat (13) and O-ring (12) from the piston.
Remove the teflon rings(2,6),O-ring(3),Back-up ring(4),nutring(5) and dust seal(7)
CHECK
Clean all parts.

Check the surface of the rod (14), If there is a damage inside it, change it.
Check the guide(8).Change it if necessary
Check the piston(10).If there is a problem, change the piston.
Check the greaser (17). If it doesn’t work, change it.
ASSEMBLY
Then place the O-ring(3) and back-up ring(4)
Grease the guide(8) and pass the rod(14) from the head of the guide(8)
Grease the O-ring(12) and pass on the piston(10)
Grease the teflon ring(11) and pass on the piston(10)
Make the assembly of the piston(10) to the to the rod(14)
Pass the rod from the cylinder (1) which is greased by hydraulic oil.
Fix the guide(9)
CUKUROVA Model 885


BACKHOE SWING CYLINDER
1 CYLINDER PIPE RIGHT 13 PISTON

3 BACK-UP RING 16 O-RING
5 OMEGAT 18 ROD
9 GUIDE 22 SWING CYL.RIGHT
10 SEGMENT 23 SWING CYL.-LEFT
11 WASHER 24 REPAIR KIT
12 WASHER 25 SCREW
CUKUROVA Model 885


1 CYLINDER PIPE RIGHT 13 PISTON
2 TEFLON RING 14 TEFLON RING
3 BACK-UP RING 15 OMEGAT
4 O-RING 16 O-RING
6 NUTRING 18 ROD
7 TEFLON RING 19 GREASER
9 GUIDE 21 BUSHING
10 SEGMENT 22 SCREW
11 WASHER
12 WASHER
CUKUROVA Model 885


DISASSEMBLY
Clean the cylinder.

Remove the cylinder head (9)
Remove the rod (16) very carefully.
Fix the rod (18) from the pin side.
Remove the piston (13) from the rod (18).
Remove the teflon rings(14,17), Omegat(15), O-ring(16), washer (11,12) and segment (10) from the piston
Remove the guide (9) from the rod (18).
Remove the teflon rings(2,7), Omegat(5),O-ring(4), back-up ring(3), nutring(6) and dust seal(8) from the
guide(9).
CHECK
Clean all parts.

Check inside the cylinder (1) if it is worn out or not.
If there is damage in the cylinder (1), renew it.
Check the surface of the rod (18).Renew it if necessary.
Check the bushing (21).Change it if necessary.
Check the guide (9).If a problem is seen, change the guide.
Check the piston(13).If a problem is seen, renew the piston.
ASSEMBLY
Then, place the Omegat(5),O-ring(4) and back-up ring(3).
Grease the guide(9) and pass the rod(18) from the head of the guide(9)
Grease the teflon-ring(14,17), washers(11,12) and segment (10). And pass on the piston(13)
Make the assembly of the piston(13)to the rod(18)
Fix the piston(13)
Pass the rod (18) from the cylinder which is greased by hydraulic oil.
Fix the guide(9)
CUKUROVA Model 885


BACKHOE STABILIZER CYLINDER

3 OMEGAT 15 O-RING
5 O-RING 17 SEGMENT
6 NUTRING 18 JOINT
8 DUST SEAL 20 BOLT
9 GUIDE 21 LOCK WASHER
10 NUT 22 WASHER
11 PISTON 23 STABILIZER CYLINDER
12 TEFLON RING 24 REPAIR KIT
CUKUROVA Model 885


3 OMEGAT 15 O-RING
5 O-RING 17 SEGMENT
6 NUTRING 18 JOINT
8 DUST SEAL 20 BOLT
9 GUIDE 21 LOCK WASHER
10 NUT 22 WASHER
11 PISTON
12 TEFLON RING
CUKUROVA Model 885


DISASSEMBLY
Clean the cylinder.

Remove the cylinder head (9).
Remove the rod (16) from the cylinder (1) very carefully.
Remove the Teflon rings (12, 13), Omegat (14) and O-ring (15) from the piston.
Remove the guide(9),teflon-rings(2,7),Omegat(3),O-ring(5),back-up ring43),nutring(6) and dust seal(8)
CHECK
Clean all parts.

Check inside the cylinder(1)
Check the surface of the rod(16),if is damaged, renew it.
Check the linearity of the rod(16), change it if necessary.
Check the guide (9).If there is a problem, change it.
Check the piston(11).If a problem is seen, change it.
Check the joint (18). If a problem is seen, change it.
Check the greaser (19). If it doesn’t work, change it.
ASSEMBLY
Then place the Omegat(3),O-ring(5) and Back-up ring(4)
Grease the guide (9).Pass the rod (16) from the head of the guide (9).
Grease the teflon rings(12,13) and pass on the piston(11)
Fix the guide(9)
CUKUROVA Model 885


30.02
HYDRAULIC
SCHEMA
40.01
ELECTRICAL
SYSTEM
CONTENTS
Electrical circuit diagrams……………………………………….…………………………………………..…….2
Electrical circuit diagram explanations.…………………………………………………………………………..7
Gear selector………………………………………………………………………………………………………10
Encoding transmission……………………………………………………………………………………………11
Encoding gear selector……………………………………………………………………………………………11
CUKUROVA Model 885

Backhoe – Loader Electrical System

BACKHOE – LOADER RC5
Device Design Device
15 Plus(+) Downstream of Battery
30 Input from (+) Battery Terminal Direct
31 (-) Battery Terminal or Ground, Direct
B1 Oil Pressure Warning Sensor
B2 Engine Temperature Sensor
B3 Transmission Temperature Sensor
B4 Fuel Level Sensor
B5 Warning Horn
B6 Transmission Pressure Sensor
B7 Rear Horn
B8 Front Horn
B9 Backup Alarm
B10 Tape Recorder
B11 Left Speaker
B12 Right Speaker
B13 Antenna
D1….D25 Diodes
E1 Alternator Charge-Indicator Lamp
E2 Heater Indicator Lamp
E3 Oil Pressure Indicator Lamp
E4 Engine Temperature Indicator Lamp
E5 Transmission Temperature Indicator Lamp
E6 Air Filter Indicator Lamp
E7 Fuel Indicator Lamp
E8 Brake Hydraulic Oil Level Indicator Lamp
E9 General Warning Lamp
E10 Transmission Pressure Indicator Lamp
E11 Pump Valve Indicator Lamp
E12 Beacon Indicator Lamp
E13 Transport Locking Indicator Lamp
E14 Hazard Warning Signal Indicator Lamp
E15 High Beam Indicator Lamp
E16 Differential Lock Indicator Lamp
E17* Ride Control Indicator Lamp(EHSS)
E18 4x4 Indicator Lamp
E19 Parking Brake Indicator Lamp
E20 Joystick Locking Indicator Lamp
E21 Joystick Unlocking Indicator Lamp
F1…F28 Fuses
G1 Battery
G2 Alternator
H1 Beacon Lamp
H2 Turn Signal Lamp FL
H3 Turn Signal Lamp RL
H4 Turn Signal Lamp FR
H5 Turn Signal Lamp BR
H6 Right Front Parking Lamp
H7 Left Front Parking Lamp
H8 Right Rear Parking Lamp
H9 Left Rear Parking Lamp
H10 License Tag Lamp
H11 Left Low Beam Headlamp
H12 Right Low Beam Headlamp
H13 Left High Beam Lamp
H14 Right High Beam Lamp
CUKUROVA Model 885


H15 Left Brake Lamp
H16 Right Brake Lamp
H17 Right Front Working Lamp
H18 Left Front Working Lamp
H19 Right Rear Working Lamp
H20 Right Rear Working Lamp
H21 Left Rear Working Lamp
H22 Left Rear Working Lamp
H23 Cab Light
K1 Heater Relay
K2 Starter Main Electric Relay
K3 Starter Relay
K4 Timer Relay
K5 High Beam Headlamp Relay
K6 Low Beam Headlamp Relay
K7 Brake Lamp Relay
K8 Gear Relay - I
K9 Gear Relay - II
K10 Unloader When The Brake Is Applied Relay
K11 Parking Brake Warning Horn Relay
K12 Forward Relay
K13 Backward
K14 Parking Brake Relay
K15 4X4 Relay
K16 Joystick Locking Relay
K17 Transmission Pressure Indicator R.
K18 Pump Valve Relay
K19 Tilt Automatic Relay
K20 Hazard Warning Signal Flasher
K21 3 and 4 Gear Pump Unloader Relay
K22 Starter Warning Relay
K23 Rear Working Light Relay
K24 Front Working Light Relay
K25 Transmission Unloader Relay
M1 Starter Motor
M2 Front Wiper Motor
M3 Front Windshield Washer Motor
M4 Rear Windshield Washer Motor
M5 Rear Wiper Motor
P1 Tachometer with LCD Hourmeter
P2 Engine Temperature Indicator
P3 Fuel level Indicator
R1 Resistant
S1 Starter Switch
S2 Battery Switch
S3a Motor Stop Switch
S3b Motor Stop Switch(Fuel Pump sensor)
S3c Motor Stop Switch(Engine Advance sensor)
S4 Air Filter Switch
S5 Brake Hydraulic Oil Level Sensor
S6 Test Switch
S7 Pump Unloader Valve switch
S8 Beacon Switch
S9 Transport Locking switch
S10 Magnetic Switch
S11 Left Rear Joystick
S12 Right Rear Joystick
CUKUROVA Model 885


S13 Tilt Automatic Sensor
S14 Front Joystick
S15 Hazard Warning Switch
S16 Parking Lamb Switch
S17 Horn, Windshield, Signal Switch
S18 Windshield and Wiper Switch
S19 Cab Light Switch
S20 Differential Lock Switch
S21 Ride Control System Switch
S22 Brake Switch - 1
S23 Brake Switch - 2
S24 4x4 Switch
S25 Hand Brake Switch
S26 Joystick Locking switch
S27 Front Working Light Switch
S28 Rear Working Light Switch
V1 Pump Unloader Valve
V2 Transport Lock Valve
V3 Smoot Ride Control System Valve
V4 Smoot Ride Control System Valve
V7 Joystick Locking Valve
X1 Immobilizer
X2 Gear Lever
X3 Cigarette lighter
X4 Heater + AC
Y1 Connector(forward solenoid)
Y2 Connector(rear solenoid)
Y3 Connector (Shift Control solenoid)
Y7 Connector (Differential Locking solenoid)
Y8 Connector (4x4 solenoid)
Y9 Connector (Parking Brake solenoid)
* Optional
CUKUROVA Model 885


NOTE: Place the F-N-R lever in -N- and set the park brake before leaving seat our using backhoe-loader
CUKUROVA Model 885


Encoding transmission
■ Solenoid under current

Forward Reverse Natural
Gear 1 2 3 4 1 2 3 N
Y1(AD4) ■ ■ ■ ■
Y2(AD5) ■ ■ ■
Y5(AD3) ■ ■ ■
Y4(AD2) ■ ■ ■ ■
Y6(AD7) ■
Y3(AD1) ■ ■ ■ ■
Engaged KV KV K4 K4 KR KR KR
Clutches K1 K2 K1 K2 K1 K2 K3
Encoding gear selector
Output
Digital Selection of Speed range
Digital inputs
Outputs Direction Gear
PIN PİN F N R 1 2 3 4
ED1 (VP) 1 AD4 F 5 ■
AD5 R 6 ■
AD6 N 4 ■
ED2 (VP) 9 AD1 B3 7 ■ ■
AD2 B2 3 ■ ■
AD3 B1 2 ■ ■
AD7 B4 8 ■
Legend
VP = Supply Voltage
F = Forward
N = Neutral
R = Reverse
B = Gear range signal
Y = Solenoid valves Y1…Y6
Note
Y6 = Not available for version 4 WG-90

(4 forward / 2 reverse)
CUKUROVA Model 885


50
AXLES
50.01
FRONT AXLE
ZF - Multisteer steering axle
MS-B 3025
CUKUROVA Model 885

Backhoe – Loader Front Axle

CONTENTS
DISASSEMBLY
Disassembly output……………………………………..………………………………………………………....1
Disassembly steering………………………………………………………………………………………………8
Disassembly input…………………………………………………………………………………………………11
Disassembly limited slip differential DZ-250 / differential D-250 ……………………………………………15
REASSEMBLY……………………………………………………………………………………………………17
Reassembly differential D-250…………………………………………………………………………………..21
Reassembly input ………………………………………………………………………………………………..24
Reassembly output Mount the knuckle housing………………………………………………………………33
Basic track setting………………………………………………………………………………………………..46
Setting of steering angle…………………………………………………………………………………………47
CUKUROVA Model 885

Backhoe – Loader Front Axle
Date Page II Section 50.01

ZF - Multisteer steering axle MS-B 3025
DISASSEMBLY
Disassembly output
Fix the axle to the assembly truck.
(S) Assembly truck C77AS34

(S) Fixtures C77AS35
(S) Fixing bracket C77AS36
Figure 1
Loosen the screw plug and drain oil from the axle.
Figure 2
Loosen the screw plug and drain oil from the planetary
carrier.
Figure 3
Loosen the cylindrical screws and pull the planetary

carrier from the hub.
Figure 4
CUKUROVA Model 885

Backhoe - Loader Front Axle

Disengage the retaining ring.
Figure 5
Pull off the planetary gear with the cylindrical roller

bearing.
Figure 6
Loosen the locking screws.
Figure 7
Pull the ring gear with a three-armed puller from

the knuckle housing/from the bushes.
(S) Pressure piece C77AT28
Figure 8
CUKUROVA Model 885


Pull the hub with a two-armed puller from the
knuckle housing.
Pay attention to the releasing bearing inner

ring!
Figure 9
Force the cassette type sealing out of the hub.
Figure 10
Force both bearing outer rings out of the hub and

remove the O-ring (see arrow).
Figure 11
Pull the bearing inner ring from the knuckle

housing.
(S) Rapid grip C77AT29

Figure 12
CUKUROVA Model 885


Loosen the hexagon nut.
Figure 13
Press the tie rod with a forcing device (S) out of the
knuckle housing.
(S) Forcing device C77AT30
Figure 14
Loosen the hexagon screws on both bearing bolts.
Figure 15
Use a lever to remove both bearing bolts from the

knuckle housing.
Figure 16
CUKUROVA Model 885


Press the bearing inner ring and the shaft seal ring
with the cut-off device (S) from the bearing bolt.
(S) Cut-off device C77AT31
Figure 17
Separate the knuckle housing with the double u-joint

shaft from the axle housing.
Figure 18
Force the retaining ring apart and pull the sun gear
shaft from the double u-joint shaft.
(S) Pliers C77AT32
Figure 19
Disengage the retaining ring out of the annular groove

of the double u-joint shaft.
Figure 20
CUKUROVA Model 885


Press the double U- joint shaft out of the knuckle
housing.
(S) Extracting tool C77AT33
Figure 21
Pull the shaft seal out of the housing hole.

(S) Internal extractor C77AT34
(S) Counter support C77AT35
Figure 22
Disengage the retaining ring and press the releasing

ball bearing out of the knuckle housing.
Figure 23
If necessary provide the bushes with threads (M12)

and use a striker (S) to pull them out of the housing.
(S) Striker C77AT36
Figure 24
CUKUROVA Model 885


Pull both bearing outer rings out of the pivot bearing
holes.

Figure 25
Pull shaft seal and bush out of the axle housing.

Figure 26
CUKUROVA Model 885


Disassembly steering
Heat the piston rod with a hot air blower.
The axial joint is mounted with Loctite

(type no.: 243)!
Figure 1
Separate the tie rod from the piston rod.
Figure 2
Loosen the hexagon screws.
Figure 3
Force the complete steering cylinder out of the axle

housing holes.
Figure 4
CUKUROVA Model 885


Unsnap the ring and remove the releasing flange.
(S) Pliers C77AT32
Figure 5
Unsnap the retaining ring.
Figure 6
Push or force the plug into the cylindrical tube, until it

is possible to unsnap the retaining ring (see sketch
below).
Figure 7
Comment on sketch
1 = Cylindrical tube
2 = Retaining ring
3 = Plug
4 = Piston rod
Figure 8
CUKUROVA Model 885


Unsnap the retaining ring.
Figure 9
Force the piston rod with the plug out of the cylindrical
tube.
Then remove all sealing elements from piston rod,

plug and cylindrical tube.
Figure 10
CUKUROVA Model 885


Disassembly input
Secure the axle housing with the lifting device and
loosen the screw joint.
Then separate the axle housings.
Figure 1
Pull the bearing outer ring with a striker out of the

bearing hole and remove the shim lying behind.
Remove the O-ring (see arrow).
Figure 2
Lift the differential out of the axle housing.
Figure 3
Pull the bearing outer ring with a striker out of the

bearing hole and remove the shim lying behind.
Figure 4
CUKUROVA Model 885


Loosen the hexagon nut and remove the shim lying
behind.
(S) Clamping fork C77AS49
Figure 5
Pull the yoke from the input pinion.
Figure 6
Press the screen sheet with the cut-off device (S) from
the yoke.
(S) Cut-off device C77AT31
Figure 7
Force the input pinion out of the axle housing.
If the pinion bearing should not be replaced,

special care must be taken that the outer bearing
inner ring is always in contact position with the
bearing outer ring when forcing the input pinion
out!
Figure 8
CUKUROVA Model 885


Remove spacer ring and bush.
Figure 9
Pull the roller bearing from the input pinion and

remove the releasing shim.
(S) Grab sleeve C77AT37

(S) Basic device C77AS51
Figure 10
Use a lever to remove the shaft seal ring from the axle
housing and remove the releasing roller bearing.
Figure 11
Pull the bearing outer ring out of the outer bearing

hole.
(S) Internal extractor C77AS42

(S) Counter support C77AS43
Figure 12
CUKUROVA Model 885


Force the bearing outer ring out of the inner bearing
hole.
Figure 13
If necessary, pull both bushes out of the axle housing.

Figure 14
CUKUROVA Model 885


Disassembly limited slip differential
DZ-250 / differential D-250
Pull both roller bearings from the differential carrier.

(S) Basic device C77AS51
Figure 1
Use a press to fix the differential and loosen the

cylindrical screws.
Cylindrical screws are mounted with Loctite (type

no.: 243)!
Figure 2
Press crown wheel from differential carrier and cover.
Figure 3
Version: DZ-250
Lift the axle bevel gear with pressure disk and disk
package out of the differential carrier.
Version: D-250
Lift the axle bevel gear with thrust washer and
constant spacer out of the differential carrier.
Figure 4
CUKUROVA Model 885


Insert the slotted pin into the differential shaft until
contact is obtained.
Figure 5
Pull the differential shaft out of the housing and

remove the releasing single parts.
Then force the slotted pin out of the differential shaft.
Figure 6
CUKUROVA Model 885


REASSEMBLY
Reassembly differentials ( DZ-250 and D-250
Reassembly limited slip differential DZ-250
Setting of the axial play of both axle bevel gears =

0.00 - 0.15 mm (Figure 1 ... 5)
In order to achieve a correct measuring result, the

single parts must first be mounted without
lubricant!
Preassemble the single parts as described on the

sketch left.
1 = Axle bevel gear

2 = Pressure disk
3 = Outer disks
4 = Inner disks
Mount the pressure disk with the coated face

showing to the outer disk!
Figure 1
Insert the preassembled axle bevel gear into the

differential carrier.
Figure 2
Insert both axle bevel gears with thrust washers into

the differential carrier and fix them with a differential
shaft.
Pay attention to the radial installation position of

the thrust washers!
Figure 3
CUKUROVA Model 885


Check the axial play of the axle bevel gear.
In case of deviations from the necessary axial play

correct with the corresponding outer disks
(s=1.4 mm or s=1.5 mm)!
Figure 4
Separate the single parts again after setting has been

completed.
Then oil all single parts as specified in the lubrication
and maintenance instruction and reassemble them.

the differential shaft!
Thickness and coating of the disk package may no

more be changed!
Figure 5
Use a slotted pin to fix the differential shaft.
Pay attention that the installation depth of

differential carrier and differential shaft is the
same (see sketch below) !
Figure 6
Comment on sketch:
1 = Differential carrier
2 = Slotted pin
3 = Differential shaft
Figure 7
CUKUROVA Model 885


Preassemble the second axle bevel gear with identical
coating and thickness.
1 = Axle bevel gear

2 = Pressure disk
3 = Outer disks
4 = Inner disks
Mount the pressure disk with the coated face

showing to the outer disk!
Figure 8 Thickness and coating of the disk package must be

identical on both sides of the differential assy!

Figure 9
Mount two adjusting screws (S) and install the cover.
(S) Adjusting screws C77AT13
Figure 10
Heat the crown wheel and mount until contact position

with the differential carrier is obtained.
Figure 11
CUKUROVA Model 885


Use a press to fix the differential and fix the crown wheel
with cylindrical screws.
Tightening torque (M10/10.9) . . . . . . . . . MA = 68 Nm
Wet the thread of the cylindrical screws with Loctite

(type no.: 243)!
Figure12
Heat both roller bearings and mount until contact is

obtained.
Adjust bearing after cooling down!

Figure 13
CUKUROVA Model 885


Reassembly differential D-250
Preassemble the single parts as shown on the left

sketch.
1 = Axle bevel gear

2 = Thrust washer
3 = Constant spacer
Oil all single parts as specified in the

corresponding lubrication and maintenance
instruction)!
Figure 14

Figure 15
Insert both axle bevel gears with thrust washers into

the differential carrier and fix them with the differential
shaft.

thrust washers and differential shaft!
Figure 16
Fix the differential shaft with a slotted pin.
Pay attention that the installation depth of

differential carrier and differential shaft (see
sketch below) is the same!
Figure 17
CUKUROVA Model 885


Comment on sketch:
2 = Slotted pin
3 = Differential shaft
Figure 18
Preassemble the second axle bevel gear.
1 = Axle bevel gear

2 = Thrust washer
3 = Constant spacer
Figure 19

Figure 20
Mount two adjusting screws (S) and install the cover.
(S) Adjusting screws C77AT13
Figure 21
CUKUROVA Model 885


Heat the crown wheel and mount until contact position
with the differential carrier is obtained.
Figure 22
Use a press to fix the differential and fix the crown

wheel with cylindrical screws.
Wet the thread of the cylindrical screws with

Loctite (type no.: 243)!
Figure 23
Heat both roller bearings and mount them until contact

is obtained.
Adjust the bearing after cooling down!
Figure 24
CUKUROVA Model 885


Reassembly input
If crown wheel or input pinion are damaged, both

parts must be replaced together! When reinstalling
a complete bevel gear set, pay attention that input
pinion and crown wheel have identical mating
numbers!
Installation of input pinion
Undercool the outer bearing outer ring (see arrow) and

use the assembly fixture (S) to bring it into contact
position with the bearing hole.
(S) Assembly fixture C77AT40

(S) Pressure rings C77AT41
Figure 1
Undercool the bearing outer ring and insert until

contact position with the bearing hole is obtained.
(S) Driver tool C77AS52

(S) Handle C77AS53
Figure 2
Determine the thickness of the shim to obtain a

correct contact pattern
Perform the following measuring operations with

utmost accuracy!
Inaccurate measurements result in a defective
contact pattern and require to disassemble and
reassemble the input pinion one more time!
Read dimension I on the axle housing.

Dimension I e.g. . . . . . . . . . . . . . . . . . . . 130.55 mm
Figure 3
CUKUROVA Model 885


Read dimension II (pinion dimension).
Dimension II e.g. . . . . . . . . . . . . . . . . 97.00 mm
Figure 4
Determine dimension III (bearing width).
Dimension III e.g. . . . . . . . . . . . . . . . . . . 30.35 mm

CALCULATION EXAMPLE „A“:
Dimension II . . . . . . . . . . . . . . . . . . . .. . 97.00 mm
Dimension III . . . . . . . . . . . . . . . . . . .. + 30.35 mm
Leads to X = 127.35 mm
CALCULATION EXAMPLE „B“:
Dimension I . . . . . . . . . . . . . . . . . . . 130.55 mm
Figure 5 Dimension X . . . . . . . . . . . . . . . . . - 127.35 mm

Difference = shim s = 3.20 mm
Insert the determined shim e.g. s = 3.20 mm.
Figure 6
Heat the roller bearing and mount until contact is

obtained.
Adjust the bearing after cooling down!
Figure 7
CUKUROVA Model 885


Setting of the rolling torque of the input
pinion bearing 1.0 ... 3.0 Nm (without
shaft seal ring)
Mount bush (1) and spacer (2), e.g. s = 6.40 mm).
Experience has shown that the required rolling

torque is reached when reusing the shims being
removed during disassembly ( e.g. s = 6.40 mm)!
A later check of the rolling torque, however, is
absolutely necessary!
Figure 8
Insert the preassembled input pinion into the axle

housing and mount the heated roller bearing until
Figure 9
Press the screen sheet (see arrow) onto the yoke until
The shaft seal ring is only mounted after

acceptance of the contact pattern
Figure 10
Mount the yoke and fix it with disk and hexagon nut.
Tightening torque . . . . . . . . . . . . . . . . . . . MA = 450

Nm
First use the old hexagon nut (self securing),

which has been removed during disassembly!
While tightening, rotate the input pinion several

times in both directions!
Figure 11
CUKUROVA Model 885


Check the rolling torque (1.0 ... 3.0 Nm without shaft
seal ring).
With new bearings try to achieve the upper value

of the rolling torque!
In case of deviations from the necessary rolling

torque correct with a corresponding spacer ring
(Figure 8), as specified below!
Insufficient rolling torque - mount a thinner spacer
ring
Excessive rolling torque - mount a thicker spacer
ring
Figure 12
SETTING OF THE BACKLASH OF CROWN WHEEL

SET AND BEARING PRELOAD OF THE
DIFFERENTIAL
Backlash = 0.12 ... 0.24 mm
Bearing preload = 0.10 ... 0.15 mm (corresponds to a

bearing rolling torque of 3 ... 4 Nm)
Pivot the axle housing 90°!
Insert the shim e.g. s = 0.90 mm (recommended

value) into the bearing hole and adjust the bearing
outer ring until contact is obtained.
Figure 13
Cover some drive and coast flanks with marking ink.
Figure 14
CUKUROVA Model 885


Insert the preassembled differential into the axle
housing.
Figure 15
Mount the bearing outer ring.
Rotate differential and bearing outer ring in both

directions, in order to assure that the rollers are
positioned correctly.
Figure 16
Align the differential centrically and determine

dimension I, between the mounting face of the axle
housing and the front face of the bearing outer ring.
Dimension I e.g. . . . . . . . . . . . . . . . . 9.50 mm
(S) Straightedge C77AS56
Take several measuring points to find the average

value!
Figure 17
Determine dimension II, between the mounting face of

the axle housing (part II) and the contact face of the
bearing outer ring.
Dimension II e.g. . . . . . . . . . . . . . . 8.80 mm

CALCULATION EXAMPLE „C“:
Dimension I . . . . . . . . . . . . . . . . . . . 9.50 mm
Dimension II . . . . . . . . . . . . . . . . . . - 8.80 mm
Difference = 0.70 mm
Figure 18 Required bearing preload e.g. + 0.10 mm

Leads to shim s = 0.80 mm
CUKUROVA Model 885


Insert the determined shim e.g. s = 0.80 into the
bearing hole and adjust the bearing outer ring until
Figure 19
Mount the axle housing (part II) with the lifting device.
Provisionally mount the axle housing without

O-ring!
Figure 20
Check the gap between the two axle housings with a

feeler gauge.
If the shim (according to calculation example C, s

= 0.80 mm) has been determined correctly, the gap
width is approx. 0.10 mm!
Take several measuring points to find the average

value!
Figure 21
Tighten the axle housing parts with hexagon screws

until contact is obtained.
Tightening torque (M16/10.9) . . . . . . . MA = 280 Nm
Figure 22
CUKUROVA Model 885


Pivot the axle housing 90° and fix the torsion bar (S)
with the cone connection (S) in the hole of the cover
(differential).
(S) Torsion bar C77AT67

(S) Cone connection C77AT68
Figure 23
Place the dial indicator right-angled through the oil

drain hole at a tooth flank of the crown wheel and
check the backlash.
In case of deviations from the necessary backlash

(0.12 … 0.24 mm) correct with the corresponding
shims! (Figure 13)
1.Insufficient backlash – mount a thicker shim
.The shim to determine the bearing preload ,
(Figure 19) must be accordingly thinner.
Figure 24 2.Excessive backlash – mount a thinner

shim(Figure 13)
. The shim to determine the bearing preload
(Figure 19) must be accordingly thicker.
Check the contact pattern:
Rotate the yoke to roll the crown wheel several times

in both directions over the input pinion.
Then separate the axle housings and remove the

differential again.
Compare the received contact pattern with contact
pattern examples
In case of a contact pattern deviation it is

imperative to correct the measuring failures which
occurred when determining the shim!
CUKUROVA Model 885


Insert the differential again into the axle housing after
checking the contact pattern.
Figure 25
Grease the O-ring (see arrow) and mount it to the axle

housing (part II).
Then mount the axle housing (part II) until contact is

obtained.
Figure 26
Finally tighten the axle housing with hexagon screws.
Tightening torque (M16/10.9) . . . . . . . .MA = 280 Nm
Figure 27
Mount the shaft seal ring (yoke)
Loosen the hexagon nut and pull the yoke from the
input pinion.
Figure 28
CUKUROVA Model 885


Mount the shaft seal ring with the seal lip showing to
the oil chamber.
(S) Driver tool C77AT44
Use the specified driver (S) to obtain the exact

installation position of the shaft seal ring!
Just before the assembly wet the outer diameter

of the shaft seal ring with spirit and fill the space
between seal and dust lip with grease!
Figure 29
Mount the yoke and finally tighten with disk and „new“
hexagon nut (self securing).
Tightening torque . . . . . . . . . . . . . . MA = 450 Nm
Figure 30
CUKUROVA Model 885


Reassembly output
Mount the knuckle housing
Flush-mount the bush into the axle housing.

(S) Handle C77AS53
Pay attention to the radial installation position, the

latching/ cross joint of the bush must be showing
upwards (12 o’clock) in installed condition!
Figure 1
Flush mount the shaft seal ring into the axle housing
with the seal lip showing to the oil chamber.

Right before the assembly wet the outer diameter

of the shaft seal ring with spirit and fill the space
between the seal lips with grease!
Figure 2
Mount both bearing outer rings until contact position

with the pivot bearing holes is obtained.

(S) Driver tool C77AS52
(S) Handle C77AS53
Figure 3
Insert the bushes until contact position with the holes

of the knuckle housing is obtained.
(S) Mandrel C77AT49
Figure 4
CUKUROVA Model 885


Insert the ball bearing into the knuckle housing until
contact position is obtained.
Figure 5
Fix the ball bearing with a retaining ring.
Figure 6
Insert the cassette type seal ring into the knuckle

housing.
The use of the specified driver tool (S) ensures

that the installation position of the cassette type
ring is correct!
Right before the assembly wet the outer diameter

of the cassette type seal ring with spirit!
Figure 7
Mount the double u-joint shaft
Insert the double u-joint shaft into the knuckle housing.
Right before the assembly wet the cassette type

seal ring with spirit !
Figure 8
CUKUROVA Model 885


Pull the double u-joint shaft into the knuckle housing

Place the internal extractor (S) into the groove of

the double u-joint shaft!
Figure 9
Fix the double u-joint shaft with a retaining ring.
Figure 10
Insert the retaining ring into the groove of the double

u-joint shaft.
Figure 11
Insert the sun gear shaft into the double u-joint shaft,
until the retaining ring engages into the annular groove
(see arrow).
Figure 12
CUKUROVA Model 885


Mount the pivot bearing
Press the shaft seal ring over the collar of the bearing
bolt.


that the installation position of the shaft seal ring
is correct!
Figure 13
Press the roller bearing onto the bearing bolts until

contact position is obtained.
Then wet the collar of the bearing bolts (see arrow)

with anti-corrosive agent (Weicon Anti-Seize).
Figure 14
Bring the knuckle housing into correct position at the

axle housing.
Thereby mount the double u-joint shaft into the

axle housing until the teeth of the joint fork are
mounted to the differential (axle bevel gear)!
Figure 15
Fix the knuckle housing with preassembled bearing

bolts (Figure 16 and 17).
Insert the roller bearing with long-term lubricant

(e.g. grease Renolit 283 EP 2)!
Just before the assembly wet the shaft seal ring

with spirit!
Figure 16
CUKUROVA Model 885


Figure 17
Fix both bearing bolts with hexagon screws.
Tightening torque (M12/10.9) . . . . . . . . MA = 117 Nm
Figure 18
Mount the hub
Press the wheel bolts into the hub until contact position
is obtained.
(S) Wheel bolt puller – basic tool C77AT54

(S) Insert (M22x1.5) C77AT55
The special tool (S) is only intended for repair

solutions when replacing single wheel bolts with
mounted hub!
Figure 19
Press both bearing outer rings in until contact position

is obtained.
Figure 20
CUKUROVA Model 885


Press the cassette type seal with the label „OUT
SIDE“ showing outwards (upwards) into flush position
with the hub.

that the installation position of the cassette type
seal ring is correct!
Just before the assembly wet the outer diameter

of the cassette type seal ring with spirit!
Figure 21
Heat the roller bearing and mount until contact position

with the knuckle housing is obtained.
Figure 22
Mount the preassembled hub.
Right before the assembly wet the seal lips of the

shaft seal ring with spirit!
Figure 23
Heat the roller bearing and mount until contact position

is obtained.
Figure 24
CUKUROVA Model 885


Mount the ring gear and pre- tighten with the old
retaining screws (which have been removed during
disassembly) until contact position is obtained.
Then loosen the retaining screws again and finally

tighten the ring gear with „new“ retaining screws.
Tightening torque . . . . . . . . . . . . . . . . . MA = 90 Nm
Figure 25
Insert the O-ring (see arrow) into the annular groove of

the hub and grease.
Figure 26
Mount the planetary carrier
Insert the cylindrical roller bearing into the planetary

gear – for this purpose press the cylindrical roller
bearing through the packaging sleeve until the snap
ring engages into the annular groove of the planetary
gear.
The packaging sleeve is used as assembly aid!

1 = Cylindrical roller bearing
2 = Packaging sleeve
3 = Snap ring
4 = Planetary gear
Figure 27
Heat the bearing inner ring and mount the planetary

gear until contact position is obtained.
Mount the bearing inner ring with the large radius

showing to the planetary carrier (downwards)!
Figure 28
CUKUROVA Model 885


Fix the planetary gear with a retaining ring.
Figure 29
Mount the planetary carrier and fix it with cylindrical

screws.
Prior to putting the axle into operation, fill it with

oil: For this purpose stick to the ZF lubrication
and maintenance instructions!
Figure 30
CUKUROVA Model 885


Reassembly steering
Pre-assemble the cylindrical tube as shown on the
sketch.
2 = Rod seal
3 = Scraper
Figure 1
Pre-assemble the piston rod as shown on the sketch.
1 = Piston rod
2 = Guide ring
3 = Piston seal
4 = Spacer part
Figure 2
Pre-assemble the plug as shown on the sketch.
1 = Plug
2 = Dual ring
3 = Rod seal
4 = Scraper
Figure 3
Push the preassembled piston rod into the cylindrical

tube until contact position is obtained.
Slightly oil all seal elements before inserting the

piston rod!
Figure 4
CUKUROVA Model 885


Push the preassembled plug into the cylindrical tube,
until the retaining ring (see sketch below) can be
mounted.
Slightly oil all seal elements before inserting the

plugs!
Figure 5
Engage the retaining ring into the groove of the

cylindrical roller.
Installation position, see also sketch 8!
Figure 6
Use the piston rod to bring the plug in contact position

with the retaining ring.
Figure 7
Fill the space (X) between plug and cylindrical tube

with grease.
Comment on sketch:
1 = Retaining ring
2 = Plug
3 = Piston rod
X = Space grease filling
Figure 8
CUKUROVA Model 885


Use a retaining ring to fix the plug.
Figure 9
Mount the flange and fix with a ring.
(S) Pliers C77AT32
Figure 10
Mount the steering
Wet the contact faces (cylindrical tube/axle housing,

see arrows) with anti-corrosion agent (Weicon Anti-
Seize).
Figure 11
Mount the pre-assembled steering cylinder into the

holes of the axle housing.
Then fix the steering cylinder with hexagon screws.
Tightening torque . . . . . . . . . .. . . . . . MA = 240 Nm
Figure 12
CUKUROVA Model 885


Screw hexagon nut and ball joint to the axial joint.
Operation must be implemented on both

tie rods.
Figure 13
Fix the preassembled tie rod to the piston rod.
Tightening torque . . . . . . . . . . . . . . . . . . MA = 300

Nm
Wet the thread of the axial joint with Loctite (Type

no.: 243)!
Figure 14
Mount the tie rod to the joint housing and fix with „new“
hexagon nut (self-securing).
Output torque . . . . . . . . . . . . . . . . . . . . MA = 100 Nm

+45°
Tightening rotation angle . . . . . . . . . . . α = 180°
First tighten the hexagon nut with a tightening

torque of 100 Nm ±15%.
Then mark the position of the hexagon nut and
+45°
retighten with a rotation angle of 180° .
Figure 15
Flush mount the bushes on both sides into the axle

housing.

(S) Handle C77AS53
Figure 16
CUKUROVA Model 885


Figure 17
Basic track setting
Bring the piston rod into central position.
Setting of dimension X = 121.75 mm (measured between front face/steering cylinder and front face/axial
joint).
CAUTION:
The axial position of the piston rod may no more be changed during track setting!
Mount the straightedges (1) in horizontal and central axis position.

Fix the measuring device (2) to the yoke.
Loosen the hexagon nut (3) and set the length of the tie rod (axial joint), until
„ 0° “ (= track setting of „zero“ mm) can be read on the measuring device (2).
NOTE:
For a toe-in and toe-out setting, which might be required, stick to the vehicle manufacturer’s specification!
CAUTION:
Carry out setting on both output sides!
Comment on sketch:
1 = (S) Straightedges C77AT58

2 = (S) Measuring device C77AT59
3 = Hexagon nut
X = Setting dimension 121.75 mm
Check track setting (0°) :
Determine dimension A1.

Turn both outputs by 180° – Dimension A2 must be identical with dimension A1.
Dimension „Y“ = distance between wheel center and rim flange.
Then fix both tie rods (axial joint) with hexagon nut (3).
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . MA = 300 Nm
CUKUROVA Model 885


Setting of steering angle
CAUTION:
If track setting should be carried out, the setting of the steering angle should only be carried out after
completion of the track setting!
3
3
3
3
Figure 18
Mount the straightedge (1) in horizontal and central axis position.

Fix the measuring device (2) to the yoke.
Pivot the output until the steering angle (e.g. 52°) can be read on the measuring device (2).
Then bring the stop screws (3) into contact position with the axle housing and lock them with hexagon nuts.
Tightening torque (M14X1.5) . . . . . . . . . . . . . . . MA = 150 Nm
NOTE:
The value of the required steering value can be taken from the vehicle manufacturer’s specifications!
CAUTION:
Carry out the setting on both output sides!
Comment on sketch:
1 = (S) Straightedge C77AT58

2 = (S) Measuring device C77AT59
3 = Stop screws
Leakage test of the steering
Use a HP pump to check the steering for leakage in both steering directions.
Build up test pressure p = 200 bar (thereby bleed the pressure chamber).
Then close the connection to the HP pump with a shut-off valve.
During a 20 second testing time a pressure decrease of max. 5 bar is permitted.
Test medium: Engine oils SAE 10W

MIL-L 2104 C / MIL-L 46152
(S) HP pump C77AS59

(S) Threaded coupling C77AS66
CUKUROVA Model 885


50.05
REAR AXLE
ZF –REAR AXLE
MT – B 3070
CUKUROVA Model 885

Backhoe – Loader Rear Axle

CONTENTS
Lubrication and maintenance instructions…………………….…………………………………………..…….2
Service brake – brake wear measurement……………………………………………………………………...3
Instructions for the displacement resp. emergency towing of the vehicle …………………………………..5
Technical data……………………………………………………………………………………………………...6
Disassembly output unit.………………………………..…………………………………………………………9
Service brake…….………………………………………………………………………………………………..14
Differential……..…………………………………………………………………………………………………..15
Disassembly – input……….……………………………………………………………………………………..22
Disassembly parking brake “MULTI-DISC BRAKE”…………………………………………………………..25
Disassembly parking brake “DISC BRAKE”…………………………………………………………………...28
Reassembly – input………………………………………………………………………………………………29
Reassembly – differential……………………………………………………………………………………..…34
Assembly service brake (multi-disc brake)…………………………………………………………………….44
Reassembly – output unit…………………………………………………………………………………….….51
Reassembly parking brake version “MULTI-DISC BRAKE”………………………………………………….56
Reassembly parking brake version “DISC BRAKE”…………………………………………………………..61
CUKUROVA Model 885

Backhoe – Loader Rear Axle

ZF – AXLE
MT – B 3070
Preface
This documentation has been developed for specialized staff trained by ZF Passau for repair and
maintenance work to be made on ZF-units.
Due to the continuous technical improvement of the product, however, the maintenance of the unit at your
disposal might require both deviating work steps and differing setting and testing data.
These lubrication and maintenance instructions are based on the unit’s state-of-the-art at the time of
printing. They were prepared with utmost care in order to avoid errors.
ZF Passau GmbH, however, shall not be liable for any possible errors in figures or descriptions.
ZF Passau GmbH reserves the right to replace these lubrication and maintenance instructions by a
successive edition at any time without advance notice. Upon request, ZF Passau GmbH will advise, which
edition is the latest one.
The owner and the user shall be responsible for complying with the safety instructions and for implementing
the maintenance work according to the specified guidelines.
ZF Passau GmbH shall not be liable for any incorrect installation, improper handling, insufficient
maintenance, improperly and incompetently performed work and any consequential damage resulting
thereof.
CUKUROVA Model 885

Backhoe - Loader Rear Axle

LUBRICATION and MAINTENANCE INSTRUCTIONS
Oil grade
Approved oils for ZF axles MT-B 3070 see ZF List of Lubricants TE-ML 05.
The ZF list of lubricants is being continuously updated and can be obtained or viewed as follows
Oil change
Precondition for a prescribed oil change is a horizontal axle installation position in each direction!
Place vehicle in horizontal position!
Carefully clean drain plug, filler plug and level check plug prior to opening!
Only drain the oil immediately after a longer vehicle operation (axle/oil at operating temperature)!
Legend
1 = Oil drain hole (7/8“-14 UNF 2B) ............... MA = 30 Nm

2 = Oil drain hole (7/8“-14 UNF 2B) ............... MA = 30 Nm
3 = Oil filler hole/oil level check hole (7/8“-14 UNF 2B) ............... MA = 30 Nm
Oil drain from axle
Loosen drain plugs (1) and drain the oil from the axle.
Oil drain from output units
To prevent any injury due to a possible pressure build-up in the oil circuit of the planetary carrier when
opening the oil drain plug and the oil filler plug (2) –Bring drain hole to the upper position (12 o’clock position)
and turn out oil drain plug and oil filler plug (2),carefully. Then bring drain hole to lower position (6 o’clock
position) – drain oil from both outputs.
Waste oil to be disposed of ecologically and according to legal requirements!
Oil filling of axle

Provide drain plugs (1 and 2) with new O-ring and install it. Fill in oil to overflow on the filler hole (3).
Tightening torque (7/8“-14 UNF 2B) ............... MA = 30 Nm
Oil quantity
app. 16.0 ltr
Check
Check oil level after some minutes and refill until the prescribed level has been achieved and remains
constant. Provide filler plugs and level check plug (3) with new O ring and install them.
Tightening torque (7/8“-14 UNF 2B) ............... MA = 30 Nm.
CUKUROVA Model 885


Oil change interval
In this connection refer to specification in the ZF list of lubricants TE-ML 05
Oil level check
Check oil level every month, in particular, however, when a vehicle has been put into service with new or
repaired axles or axle parts.
Brake
The following oils are approved for the pneumatic-hydraulic brake actuation or for brake operation through an
accumulator system
- Motor oils SAE 10 W acc. to specification MIL-L 2104 C, MIL-L 46152, API-CC, CD, SC, SD, SE
- ATF – oils type A, Suffic A, Dexron of II D
SERVICE BRAKE – BRAKE WEAR MEASUREMENT

on the ZF-AXLE MT-B 3070
ATTENTION
The lining wear measurement on the service brake (multi-disc brake) provides only limited information about
the total state of the disc package – without disassembly of the output unit.
Carry out lining wear measurement at least once per year, in particular, however, if braking behavior has
changed, like
- Brake noises
- Reduced braking power
- Changed deceleration
- Changed brake oil level
- Changed braking pressure
Wear measurement – service brake (multi-disc brake)

The wear measurement must be carried out on both
output sides!
For this purpose remove the screw plug, actuate the brake
and determine dimension „X“ using a feeler gauge.
Feeler gauge 5870 200 113
Dimension „X“ = Thickness of lined /inner disc
Figure 1
If dimension „X“ < 4.5 mm, replace

the lined /inner discs on both output
sides
Then install screw plug (check hole)– fitted with new O-ring.
Tightening torque (7/8“-14 UNF 2B) ……….. MA = 30 Nm
Figure 2
CUKUROVA Model 885


Just for the axle type with PARKING BRAKE VERSION “MULTI DISC BRAKE“:
Notes on vehicle dislocation and emergency towing
The parking brake (multi-disc brake) is spring actuated.

If the pressure cannot be built up by the vehicle (e.g. motor standstill) for hydraulically breathing the
parking brake, it is necessary to activate the mechanical emergency breathing as follows for towing or
dislocating the vehicle
Loosen lock nut of adjusting screws (arrows/figure 1) and turn in hex. screws evenly until preload of the cup
spring is compensated and the disc pack is released.
NOTE
Evenly turning in the two hex. screws prevents the brake piston from twisting.
Figure 1
Important
Any time the parking brake has been actuated due to an emergency braking (e.g. caused
by a hydraulic system failure on the vehicle), replace the discs of the parking brake!
Ensure operability of the parking brake after dislocating the vehicle or after repair work. For
this purpose turn both hex. screws (arrows) evenly back to their initial position and lock by
hexagon nuts.
Adjust installation dimension „Y“ = 29 + 2.0 mm - see figure 2 - on both adjusting screws!
Tightening torque M 10x1 ……….. MA = 46 Nm
Figure 2
Attention
The vehicle manufacturer’s specifications are binding for the maximum towing speed and the
permitted towing distance, also taking the legal directions into account!
CUKUROVA Model 885


INSTRUCTIONS FOR THE DISPLACEMENT RESP.
EMERGENCY TOWING OF THE VEHICLE
The parking brake will be preloaded (closed) by means of spring force. If a pressure build up from the engine
side (e.g. engine standstill) for the release of the hydraulic parking brake is not possible, the mechanical
emergency release for the towing, resp. the displacement of the vehicle must be activated as follows.
Loosen both lock nuts of the adjusting screws

(Arrow/Fig. 1) and screw hex. head screws evenly in
until the preload force of the compression springs will
be neutralized, resp. the plate pack is released.
NOTE
The even application of the two hex. head screws
prevents a misalignment of the brake piston
Figure 1
Important
After the realized displacement of the vehicle, the
functionality of the parking brake has to be restored.
For this purpose, turn both hex. head screws (Arrows)
evenly back again into the start position, and lock
them by means of hex. nuts.
NOTE
+
Pay attention to the installation dimension = 29 mm,
see Figure 2!
ATTENTION
As far as the permitted towing speed as well as the
towing distance is concerned, the Specifications of the
Vehicle Manufacturer are binding, under consideration
Figure 2 of the legal conditions!
CUKUROVA Model 885


TECHNICAL DATA
Axle arrangement…………………..……………: Rear axle
Final drive…………………………………………: Planetary gear drive
Service brake……………: Hydr. Controlled multi-disk brake with automatic Adjuster, Type HLB 232 x 154/3
Parking brake……………………………………..: Multi-disk brake (release through hydr. pressure)
Differential Type………………………………...: DHK-750, with hydr. controlled 100%-Lock
ADJUSTMENT VALUES
FINAL DRIVE
Rolling moment - Output shaft bearing……….….: T L a =l ? 5...3Nm *)

End play- Sun-gear shaft…………………………: 0,5 ... 1,7 mm
End play - Planetary carrier………………………..: 0,1... 0,4 mm
DRIVE – DIFFERENTIAL
Bearing rolling moment - Drive pinion…………….: T = 0,5 ... 1,0 Nm (without sealing ring)
Bearing rolling moment - Differential………………: T = 3 ... 4 Nm (corresponds to a bearing

. preload of 0,10... 0,15 mm)
Torque limit of the hex. Nut on the drive flange…..: 600 Nm

Backlash - Crown-wheel set……………………….: 0,15 ... 0,25 mm
Note Ref.* : At the reassembly, determine the total rolling moment of the output shaft (inclusive of .
shaft seal). Tges = Twdr + TLa.
CUKUROVA Model 885


EXAMPLES OF GEAR-TOOTH-CONTACT PATTERNS FOR THE GLEASON GEAR-TOOTH SYSTEM
Ideal tooth-contact pattern i.e. pinion distance is correct
Figure 2/4/6
Figure 1/3/5 Drive side (convex)
Coast side (concave)
CUKUROVA Model 885


Pinion distance must be increased Pinion distance must be decreased
CUKUROVA Model 885


DISASSEMBLY – OUTPUT UNIT
ZF-Axle MT-B 3070
Parking brake-version „Disc brake“
1 = Input
2 = Axle drive housing
3 = Bearing housing
4 = Axle housing
5 = Output unit
6 = Parking brake
Figure 1
Parking brake-version „multi-disc brake“
Legend to figure no. 1

1 = Input
3 = Bearing housing
4 = Axle housing
5 = Output unit
6 = Parking brake
Figure 2
Mount axle on assembly truck.

(Illustration shows axle version „A“)
Assembly truck C77AS34

Fixtures C77AS35
Fixing bracket C77AS36
Figure 3
Remove screw plug (arrow) and drain oil from the

axle
Figure 4
CUKUROVA Model 885


Just for axle version „A“ (parking brake = multi-disc
brake) :
To rotate the output (oil drain hole in 6 o’clock

position – see figure-no. 6) equalize the brake fixing
on the axle which was removed from the vehicle by
turning in the two emergency breathing screws
(arrows).
Turn in both emergency breathing screws evenly!

Figure 5
Remove screw plug (arrow) and drain oil from both

output units
Figure 6
Loosen both hex screws (arrows) of planetary carrier

fixing.
Figure 7
Take up planetary carrier by means of a lifting strap

and pull it off the hub.
Figure 8
CUKUROVA Model 885


Snap out retaining ring.
Figure 9
Pull off planetary gear.
Disassemble the remaining planetary gears in the

same way.
Figure 10
Pull out sun gear shaft and remove O-ring (arrow).
Figure 11
Loosen locking screws of internal gear bolting.
Figure 12
CUKUROVA Model 885


Insert two adjusting screws (M 14 – see arrows) and
press internal gear evenly off the axle housing by
means of puller screws.
Adjusting screws (M 14) C77AS37
Figure 13
If required – remove bushings from internal gear.

For this purpose fit bushings with thread and pull them
out by means of a striker.
Figure 14
To ensure functioning replace shaft seal (cassette-

type sealing) after any disassembly of hub - see
figure-no. 16!
Pull hub off the axle housing using a pressure piece

and a two-armed puller.
Pay attention that releasing bearing inner ring

does not drop !
Figure 15
Lift off shaft seal (arrow) with lever and remove both
bearing outer rings from hub.
Figure 16
CUKUROVA Model 885


Pull bearing inner ring off the axle housing.
Grab sleeve C77AS39
Figure 17
CUKUROVA Model 885


SERVICE BRAKE (multi disc brake)
1 = Service brake (multi disc brake)

1a = Crown wheel side
1b = Side opposite of crown wheel
2 = Differential
3 = Differential lock (100% lock)
5 = Bearing housing (crown wheel side)
6 = Axle housing (crown wheel side)
7 = Bearing housing (side opposite of crown wheel)
Figure 1 8 = Axle housing (side opposite of crown wheel)
The description below shows the disassembly of

the service brake on the axle housing (crown
wheel side). The service brake on the other axle
housing (side opposite of crown wheel) must be
disassembled in the same way to a large extent.
Secure axle by means of a support, see arrow!
Loosen screws (axle housing/bearing housing/axle

drive housing – crown wheel side).
Figure 2
Take up axle housing by means of a lifting strap, insert

two adjusting screws (M 16) – see arrows – and
separate axle housing from bearing housing.
Pay attention that releasing O-rings do not drop!

Adjusting screws C77AS40
Assembly lever C77AS41
Figure 3
Remove cpl. stub shaft (with inner disc carrier) from

axle housing.
Figure 4
CUKUROVA Model 885


Unsnap retaining ring and pull inner disc carrier from
the stub shaft.
Figure 5
Take disc package out of axle housing
Figure 6
Remove O-rings (arrows 1+2).
Figure 7
Loosen screws and remove cpl. ring.
Figure 8
CUKUROVA Model 885


Equalize cup spring preload by a press, unsnap
retaining ring and remove washer.
Figure 9
Press off piston by means of compressed air, remove

washer and cup spring behind.
Figure 10
Remove sealing elements from axle housing and

piston – see arrows.
Figure 11
Figure 12
CUKUROVA Model 885


DIFFERENTIAL with 100 % lock
If it is necessary to dismantle the differential

and/or the input pinion, separate the axle housing
assy (crown wheel side) from bearing
housing/axle drive housing.
1 = Differential
Figure 1 6 = Axle housing (crown wheel side)
7 =Axle housing (side opposite of crown wheel)
Secure axle by means of a support, see arrow!
Loosen screws (axle housing/bearing housing/axle

drive housing – crown wheel side).
Figure 2
Take up axle housing by means of lifting strap, insert

two adjusting screws (M 16) – see arrows – and
separate axle housing from bearing housing.

Adjusting screws C77AS40
Assembly lever C77AS41
Figure 3
Remove bearing housing.
Figure 4
CUKUROVA Model 885


Press off piston by means of compressed air and
remove O-ring (arrow).
Figure 5
Remove bearing outer ring and shim (Differential

bearing preload)
Figure 6
Remove sealing elements (arrows) from bearing

housing.
Figure 7
Take cpl. locking slide out of differential.

Remove O-rings (arrows).
Figure 8
CUKUROVA Model 885


Single parts of locking slide
1 = Locking slide
2 = Compression spring
3 = Axial needle cage
Figure 9
Remove both hex. screws (arrows) of planetary carrier

fixing (output on side opposite of crown wheel).
Figure 10
Take up planetary carrier by means of lifting strap and

pull it off the hub.
Figure 11
Pull off sun gear shaft and stub shaft.
Pay attention that releasing differential does not

drop!
Figure 12
CUKUROVA Model 885


Bring axle in upright position and lift differential out of
the axle.
Internal extractor C77AS42

Eye nut C77AS44
Figure 13
Pull off bearing inner ring.
Grab sleeve C77AS45

Basic tool C77AS46
Figure 14
Pull off bearing inner ring.
Grab sleeve C77AS47

Basic tool C77AS48
Figure 15
CUKUROVA Model 885


Loosen screws
Figure 16
Separate differential carrier halves and remove single

parts.
Figure 17
Separate crown wheel from differential carrier.
Figure 18
Remove bearing outer ring and the shim behind

(backlash).
Mark shim (position/bearing allocation)!
Figure 19
CUKUROVA Model 885


DISASSEMBLY - INPUT
The below description shows the disassembly of
the input on the axle with parking brake version
„multi-disc brake“ – disassembly procedure of the
input on the axle with parking brake version „disc
brake“ is largely the same, however, the cpl.
brake caliper with brake disc must be removed
first – for this purpose refer to chapter „6.
Disassembly parking brake version – disc brake “.
Secure axle by means of a support - see arrow!

Figure 1
Fix input flange using a clamping fork, loosen hex. nut

and pull off input flange.
Difficult disassembly! Hex. nut has been located

with locking compound (Loctite), if required, heat up
hex. nut with hot air blower.
Clamping fork C77AS49
If required – lift off shaft seal with lever.
Figure 2
Work steps figure-no. 3 …. figure-no. 6

Only applicable for parking brake version „multi-disc
brake“
Remove hex screws of brake housing bolted

connection and loosen the two hex. nuts evenly
(brake housing is subject to compression spring
preload).
Figure 3
Take off the cpl. brake housing cover.
Figure 4
CUKUROVA Model 885


Remove disc carrier.
Figure 5
Remove compression springs.
Figure 6
Press off input pinion by means of two-armed puller –

pay attention that releasing bearing inner ring does
not drop!
The input pinion can also be dismantled on the

disassembled brake housing!
Figure 7
Remove spacer ring (arrow) from input pinion and pull

off bearing inner ring
Grab sleeve C77AS50

Basic tool C77AS51
Figure 8
CUKUROVA Model 885


Drive internal bearing outer ring off the housing hole
- pay attention that releasing shim (contact pattern/
bevel gear set) does not drop!
Mark shim (strength/position and bearing

allocation) !
Figure 9
Pull out external bearing outer ring.

Counter support C77AS43
Figure 10
Only applicable for parking brake version „multi-disc

brake“
Loosen cyl. screws, turn in two adjusting screws (M

16) –see arrows – and separate brake housing by
means of slight hits with a plastic hammer.
Figure 11
Only applicable for parking brake version „disc brake “
Loosen cyl. screws, turn in two adjusting screws

(M16) and separate brake housing (arrow) by means
of slight hits with a plastic hammer.
Figure 12
CUKUROVA Model 885


DISASSEMBLY
PARKING BRAKE “MULTI-DISC BRAKE”
Disassembly of parking brake version „multi-disc

brake“ was shown as part of the whole
disassembly of the axle – disassembly, however,
can also be made on the fully mounted axle.
Secure axle by means of a support - see arrow!
Fix input flange using a clamping fork, loosen hex. nut

and pull off input flange.
Difficult disassembly! Hex. nut has been located

with locking compound (Loctite), if required, heat up
hex nut with hot air blower
Figure 1 Clamping fork C77AS49
If required – lift off shaft seal with lever.
Figure 2
Remove hex. screws of brake housing bolted
connection and loosen the two hex. nuts evenly
(brake housing is subject to compression spring
preload).
Figure 3
Take off the cpl. brake housing cover.
Figure 4
CUKUROVA Model 885


Remove disc carrier.
Figure 5
Remove compression springs.
Figure 6
Press piston out of brake housing cover by means of

compressed air.
Figure 7
Take disc package out of brake housing cover.
Figure 8
CUKUROVA Model 885


Remove sealing elements –see arrows – from the
grooves of the brake housing cover.
Figure 9
Pull off both bolts (with O-ring).

Remove O-ring (arrow).
Figure 10
If required, disassemble brake housing
For this purpose, the cpl. differential must be

dismounted first –in this connection see parts of
section „ 3. Disassembly differential“
Press-off input pinion using a two-armed puller – pay

attention that releasing bearing inner ring does not
drop!
Figure 11
Loosen cyl. screws, turn in two adjusting screws (M

16) –see arrows – and separate brake housing by
means of slight hits with a plastic hammer.
Figure 12
CUKUROVA Model 885


DISASSEMBLY
PARKING BRAKE “DISC BRAKE”
Loosen both hex. screws (1) and remove

brake caliper assy (2).
For further work steps regarding disassembly of

brake linings as well as the brake caliper refer to
“original by Knott“ !
Figure 1
Remove brake disc (1).
Fix input flange (2) by means of clamping fork and

loosen hex. nut (3)
Difficult disassembly!
Hex. nut has been located with locking compound
(Loctite), If required, heat up hex nut with hot air
blower.
Figure 2
Pull off input flange (1).
Remove shaft seal (2).
Disassembly of brake housing is shown in

“DISASSEMBLY – INPUT“!
Figure 3
CUKUROVA Model 885


REASSEMBLY – INPUT
The adjacent figure shows the INPUT
in the axle with parking brake version „multi-disc
brake“.
Legend to figure no.1

1 = Input pinion
2 = Crown wheel
3 = Inner roller bearing 9 = Washer
4 = Shim (contact 10 = Hex. nut
pattern)
5 =Adjust. ring 11 = Flange
(rolling torque)
6 = Outer roller bearing 12 = Axle drive housing
7 = Disc carrier 13 = Brake housing
8 = Shaft seal 14 = Brake housing cover
Figure 5
The adjacent figure shows the INPUT

in the axle type with parking brake version „Disc
brake“.

1 = Pinion
2 = Crown wheel
3 = Inner roller bearing 9 = Washer
4 = Shim (contact pattern) 10 = Hex. nut
5 = Adjust. ring (rolling 11 = Brake disc
torque)
6 = Outer roller bearing 12 = Axle drive housing
7 = Shaft seal 13 = Brake housing
8 = Flange 14 = Brake caliper
Figure 6
The description below shows the reassembly of

the input on the axle with parking brake version
„multi-disc brake“ – reassembly of the input on
axle with parking brake version „disc brake“ is
largely the same.
CUKUROVA Model 885


Determine shim for pinion position required to
obtain an optimum contact pattern on the bevel
gear set (crown wheel/pinion)
Insert shim (e.g. „S“ = 1.60 mm) into hole of brake

housing.
We would recommend to reinstall the shim found

during disassembly (e.g. „S“ = 1.60 mm – refer to
disassembly instructions, figure no. 9) into the inner
bearing hole /pinion bearing.
As an alternative, e.g. when assembling new parts
(pinion or roller bearing) – a basic setting of the
Figure 3 required pinion position can be made as described

below (figure-no. 9 … figure no. 12).
The contact pattern required on the bevel gear set,

however, is decisive. Any deviation – see contact
pattern check on figure-no. 22, demands a
correction of the pinion position by a
corresponding shim!
Insert bearing outer ring until contact is obtained.
Driver C77AT65
Grip C77AS53
Figure 4
Insert bearing outer ring until contact is obtained.
Driver C77AT65
Grip C77AS53
Figure 5
Apply sealing agent (Loctite-no. 574) to contact face of

brake housing /axle drive housing
Area around oil return hole (arrow) must fully be

wet!
Figure 6
CUKUROVA Model 885


Figure no. 7 – axle with parking brake version „multi
disc brake“
Mount pre-assembled brake housing and fix with

cylinder screws.
Ensure a correct installation position regarding oil return

hole location!
Tightening torque (M 16/8.8) ........... MA = 195 Nm
Figure 7
Figure no. 8 - axle with parking brake version „disc

brake“
Mount pre-assembled brake housing and fix with

cylinder screws.
Ensure a correct installation position of brake housing!
Tightening torque (M 16/8.8) ........... MA = 195 Nm
Figure 8
Basic setting of pinion position

(figure-no. 9 ….. figure-no. 12)
Read dimension "I" = dimension for production/axle

drive housing (from axle center line to bearing
contact/inner bearing hole) from brake housing (position
– see arrow).
Dimension „I“ e.g. .............................165.04 mm
Figure 9
Just for assembly of a „new“ brake housing
(figure no. 9+10):
Determine dimension „X“ (contact face/brake housing to

locating face tapered roller bearing) of brake housing
„OLD“ and brake housing „NEW“.
Any difference caused by production must be taken into

consideration accordingly in dimension “I“ (see figure-
no. 9)!
Figure 10
CUKUROVA Model 885


Read pinion dimension (distance standard dimension =
127.0) from pinion, in case of a + or – deviation of the
distance standard dimension caused by production, the
actual value is indicated on the pinion
e.g.:
Pinion dimension → without + or – deviation = 127.0mm

+ 0.1
Pinion dimension → with a deviation = 127.1mm
Pinion dimension → with a – 0.1 deviation = 126.9mm
Dimension „II“ (pinion dimension) e.g…..126.90mm

Figure 11
Determine dimension „III“ bearing width, making sure

that the rollers are located without clearance (rotate
bearing inner ring in both directions several times –
roller setting)!Since the installed roller bearing is subject
to a preload in installation position, deduct an
experience value of – 0.05 mm !
Dimension„III“ = e.g….36.60 mm–0.05 mm → 36.55mm
CALCULATION EXAMPLE e.g.:

Dimension „I“ ………………………..........165.04 mm
Dimension „II + III“ (126.90 + 36.55) … – 163.45 mm
Result ..................................................= 1.59 mm
Required shim “S”………………………….1.60 mm
Figure 12
Rolling torque setting of input pinion

bearing
Mount heated bearing inner ring until contact is obtained

and re-adjust after cooling-down.
Install spacer ring (s = optional).
We recommend to reinstall the spacer ring found during

disassembly (e.g. s = 16.8 mm).
If the originally mounted shim (contact pattern/bevel

gear set) –see figure-no. 3 – was replaced, also install a
spacer ring adjusted by the same correction value.
Figure 13
However, the required bearing rolling torque is

decisive, for assembly of
“New” rolling bearing → 1.5 ... 3.0 Nm
(without shaft seal)
“Old” rolling bearing → 0.5 … 1.0 Nm
(without shaft seal)
Try to achieve upper value.
(“Old” = reinstalled rolling bearing).
Any deviation from the required rolling bearing –
see bearing rolling torque check (figure-no. 18) –
demands a correction of the bearing rolling torque
by a corresponding spacer ring!
Figure 14
CUKUROVA Model 885


Insert pre-assembled input pinion,
mount heated bearing inner ring until contact is
obtained.
Figure 15
Mount disc carrier (arrow – just for axle version with

parking brake version „multi-disc brake“) – Pay
attention to installation position!
Install flange.
Figure 16
Fix flange with washer and hex. nut.
During tightening rotate pinion in both directions

several times (roller setting)!
Tightening torque (M30x1.5) ................. MA = 600 Nm
Check rolling torque of pinion bearing!

Required bearing rolling torque when using
Figure 17
New“ rolling bearing → 1.5 . 3.0 Nm(without shaft seal)

„Old“ rolling bearing → 0.5 1.0 Nm (without shaft seal)
Try to achieve upper value.

(„old“ = reused roller bearing).
Any deviation from the required rolling torque requires a

correction by a corresponding spacer ring!
If results of contact pattern check are positive,

mount shaft seal and input flange according to the
descriptions in
- axle with parking brake version - „multi-disc brake“.

Figure 18
CUKUROVA Model 885


REASSEMBLY – DIFFERENTIAL
1 = Differential
2 = Shim (backlash)
3 = Shim (diff. bearing rolling torque)
7 = Multi-disc brake - service brake (crown wheel side)
8 = Multi-disc brake - service brake
(side opposite of crown wheel)
9 = Axle housing
11 = Axle housing
Figure 1
Install slotted pins (arrows) into differential carrier half

– observing the assembly instructions, see figure no.
21.
Figure 2
Assembly instructions:
Locate slotted pin(s) with slot in direction of force

(arrow)!
In case of double slotted pins - bring the slots in a 180°

degrees offset position to each other!
To figure
2 = Slotted pin
3 = Slotted pin (just for version with double slotted pins)
X = direction of force
Figure 3
CUKUROVA Model 885


Insert thrust washer and axle bevel gear into differential
carrier half I.
Figure 4
Legend to figure-no.5
1 = Differential spider
2 = Spider gear
3 = Thrust washer
Figure 5
Mount spider gears and thrust washers on differential

spider and insert in differential carrier half.
Ensure radial installation position of thrust

washers!
Tab to show straight upwards (see arrows)!
Figure 6
Position axle bevel gear (arrow) on differential spider.
Fix thrust washer with grease (assembly aid), in

differential carrier half II.
Figure 7
CUKUROVA Model 885


Position pre-assembled differential carrier half II on
differential carrier half I.
Ensure radial installation of both differential

carrier halves – punch-marked ZF-no. (see arrow)
corresponds to radial position marking !
Figure 8
Position crown wheel on slotted pins and press onto

differential carrier until contact is obtained.
Figure 9
Fix differential by means of a press and connect

differential carrier halves with cylinder screws.
Tightening torque (M 12/12.9) ……… MA = 135 Nm
Figure 10
Install both bearing inner rings
Use suitable support (arrow) – differential must not be

supported on bearing cage!
Figure 11
CUKUROVA Model 885


Cover some tooth flanks of crown wheel with marking
ink (for contact pattern check – see figure no. 22)
Figure 12
Bring axle into vertical position.
Insert shim (backlash) into hole of axle housing and

locate bearing outer ring until contact.
We would recommend to reinstall the shim found

during disassembly – refer to disassembly
instructions, figure-no. 19 - (e.g. s = 1.70 mm) !
The required backlash, however, is decisive for

the shim(s), to be used.
Figure 13
Insert preassembled differential.

Eye nut C77AT66
Position bearing outer ring on bearing inner ring, until

all rollers are located without clearance.
Figure 14 For the following determination of dimension pay

attention to an exact contact of the bearing outer
ring and a correct positioning of the differential!
Determine dimension „A“ - from mounting face/axle

drive housing to front face/bearing outer ring (take
measurements at several points and find out mean
value).
Dimension „I“ e.g. ……………………. 6.64 mm
Straightedge C77AS56
Figure 15
CUKUROVA Model 885


Determine dimension „II“ – from mounting face
/bearing housing to bearing hole/bearing outer ring
contact
Dimension „Z“ e.g. ……………………. 5.35 mm
CALCULATION EXAMPLE
Dimension „I“ e.g. …………….………..….6.64 mm

Dimension “II“ e.g. ……….…………..….– 5.35 mm
Difference …………………..……………...1.29 mm
Bearing preload …………………………+ 0.10 mm
Figure 16 Result ………………………………..…..= 1.39 mm
Required shim (s)…………….………..= 1.40 mm
A bearing preload of 0.10 mm corresponds to a

bearing rolling torque of appr. 1.0 … 4.0 Nm, if
new bevel roller bearings are used !
Insert determined shim (e.g. s = 1.40 mm) into hole of

bearing housing and locate bearing outer ring until
contact.
Figure 17
Mount preassembled bearing housing (without O

rings). Bring it to contact position and fix provisionally
with hex. screws (3x with washer, L = 70 mm).
Rotate differential in both directions several times –

roller setting (also see figure-no. 19!)
Tightening torque (M 16/8.8) …………M A = 195 Nm
Figure 18
CUKUROVA Model 885


Check of backlash and of bevel gear set contact
pattern
Insert cylinder screw (2) into internal extractor (1) and

fix straightedge (3) and internal extractor in the hole of
the differential carrier.
Internal extractor must not be positioned in the

axle bevel gear!

Cylinder screw (M20) C77AS58
Straightedge C77AS57
Figure 19
Place dial indicator (3) at right angles to the straight

edge (1) within a distance corresponding to the outer
diameter of the crown wheel (r = app. 126 mm) –and
check backlash.
Backlash 0.15 …. 0.25
Any deviation from the required backlash requires

its correction with corresponding shim(s) – see
figure-no. 31,
A correction of the shim/backlash also requires a

counter-correction of shim / diff. bearing rolling
torque.
Figure 20
For contact pattern check, roll input pinion against
crown wheel in both directions (drive and coast side
engagement).
.
Figure 21
Mount preassembled bearing housing (without O

rings). Bring it to contact position and fix provisionally
with hex. screws (3x with washer, L = 70 mm).

roller setting (also see figure-no. 19!)
Tightening torque (M 16/8.8) ………… M A = 195 Nm
Figure 22
CUKUROVA Model 885


Place sun gear shaft and stub shaft into the planetary
carrier (output opposite to crown wheel)
Figure 23
Mount planetary carrier, and insert stub shaft into the

planetary carrier (service brake).
Pay attention to mounted O ring (arrow)!
Figure 24
Fix planetary carrier with hex. screws.
Insert hex. screws with locking compound (Loctite

no. 243)!
Tightening torque (M12/8.8) ……….. MA = 55 Nm
Figure 25
Relocate differential, and insert stub shaft into the axle

bevel gear.

Eye nut C77AT66
Figure 26
CUKUROVA Model 885


Install adjusting screws (1) and fix both O-rings (2)
with grease (assembly aid) into the countersinks of the
axle drive housing.
Adjusting screws/M16 (1 set = 2 pcs.) C77AS40
Figure 27
Insert locking slide with mounted compression spring.
Figure 28
Mount axial needle cage on locking slide.
Fix axial needle cage with grease – assembly aid!

Figure 29
Oil both grooved rings (1 + 2) and place into annular

grooves of the bearing housing – paying attention to
the installation position (see detailed figure).
Install O-ring (3).
Legend to detailed
figure
1 = Grooved ring
2 = Grooved ring
3 = O-ring
4 = bearing housing
Figure 30
CUKUROVA Model 885


Oil sealing surface and insert piston.
Figure 31
Press piston to contact position.
Figure 32
Mount preassembled bearing housing.
Figure 33
-Check leakage of 100% lock.
CUKUROVA Model 885


ASSEMBLY SERVICE BRAKE (multi-disc brake)
Figure 1
1 = Service brake (multi-disc brake) 12 = Disc carrier

1a = crown wheel side (CS) 12a = Disc carrier (CS)
1b = side opposite of crown wheel (SOC) 12b = Disc carrier (SOC)
2 = Axle housing (CS) 13 = Retaining ring
3 = Bearing housing (CS) 13a = Retaining ring (CS)
4 = Differential assy 13b = Retaining rings (SOC)
4a = Differential 14 = Retaining ring
4b = Crown wheel 15 = Slotted pin
4c = 100% lock 16 = Cup spring
5 = Axle drive housing 17 = Washer
6 = Bearing housing (SOC) 18 = Washer
7 = Axle housing (SOC) 19 = Cup spring
8 = Grooved ring 20 = Piston
9 = Back-up ring 21 = Disc package
10 = Cylinder screw 21a = Disc package (CS)
11 = Ring 21b = Disc package (SOC)
Below, the reassembly of the service brake on the

axle housing (CS = crown wheel side) is shown.
For reassembly of the service brake on the other

axle housing (SOC = side opposite of crown
wheel) proceed in the same way.
CUKUROVA Model 885


Insert sealing elements (2 +3 – see figure no.3) into
annular groove (arrow) of the axle housing.
Pay attention to installation position of the sealing

elements!
Figure 2
Legend to figure no.3, figure no.2 and figure no.4
1 = Axle housing
2 = Back-up ring
3 = Grooved ring
4 = Grooved ring
5 = Back-up ring
6 = Piston
7 = Slotted pins
Figure 3
Insert sealing elements (4 +5 – see figure no. 3) into

annular groove (arrow) of piston (6).
Pay attention to installation position of sealing

elements!
Flush-mount slotted pins (7) (front face) into piston (6),

or relocate – if not dismantled.
Figure 4
Legend to figure no.5 and figure no.6
1 = Axle housing
2 = Cup spring
3 = Washer
4 = Piston
5 = Ring
6 = Cup spring
7 = Washer
8 = Retaining ring
Figure 5
CUKUROVA Model 885


Locate cup spring (2) – paying attention to correct
installation position (see figure no. 56) - and
washer (3) into axle housing (1).
Figure 6
Oil grooved rings and sealing surfaces of axle housing

and piston.
Mount pre-assembled piston (1)
Figure 7
Push piston to contact position using a two-armed

puller and a pressure plate.
Pay attention to the slotted pins placed in the

piston!
Ensure that position of located slotted pins does

not change –pressure plate may only touch piston
front face!
Figure 8
Mount cup spring (6) – paying attention to correct

installation position (see figure no. 5) - and washer
(7) on ring (5).
Figure 9
CUKUROVA Model 885


Press down cup spring preload using a press, and
snap in retaining ring (8).
Figure 10
Insert preassembled ring and fix with cylinder screws.
Install cylinder screws with locking compound

(Loctite no. 262)!

Figure 11
Legend to figure no.12 and figure-no.13
1 = Outer discs
2 = Inner discs (lined discs)
Figure 12
Locate disc package – taking the disc arrangement
into consideration (see figure no. 12) !
Fix outside disc with grease – assembly aid!
Figure 13
CUKUROVA Model 885


Mount disc carrier – paying attention to correct
installation position (see figure-no. 14) –and snap
in retaining ring.
Figure 14
Insert pre-assembled stub shaft until all inner discs are

mounted.
Figure 15
Mount sun gear shaft to inserted stub shaft –

assembly aid (for central position of stub shaft).
Figure 16
Fix both O rings (1) with grease (assembly aid) into

countersinks of the axle housing.
Oil O-ring (2) and install on the axle housing.
Figure 17
CUKUROVA Model 885


Take up cpl. axle half by means of a lifting strap and
position it on bearing housing/axle drive housing – and
insert stub shaft into gearing of the axle bevel gear
(differential).
Pay attention to O-rings installed in the axle drive

housing and in the axle housing!
Figure 18
Bring axle housing equally to contact position and fix it

by means of hex. screws.

roller setting!
Tightening torque (M 16/8.8) …………M A = 195 Nm
Figure 19
Leakage test of multi-disc brake
Mount breather valve (arrow) and connect HP-pump.

HP pump 5870 287 007
Threaded coupling (9/16”-18UNF) 5870 950 115
Oil collector bottle 5870 286 072
Completely breathe brake prior to test start!
Leakage test
Build up test pressure p = 60 bar – 10 bar and close
shut-off valve of HP pump (maintain pressure).
A pressure drop of max. 3 bar is allowed during a 2
minute testing time.
Figure 20
Test media
Motor oils SAE-10W ;MIL-L 2104 C; MIL-L 46152;
API-CC, CD, SC, SD, SE,
ATF-oils: type A; Suffic A; Dexron of II D
CUKUROVA Model 885


Disc clearance test of service brake
The brake must fully be breathed for obtaining an

objective test result of the disc clearance!
Pressurize brake by HP pump with p = 60 bar ,– 10 bar

then release brake and check disc clearance “X“ using
a feeler gauge – also refer to figure no. 22!
Disc clearance „X“ nom. = 0.4 …. 0.75 mm
If the required disc clearance „X“ is not obtained,

assembly was
Figure 21 not carried out properly, and another disassembly and
reassembly is imperative!
Bring axle housing equally to contact position and fix it

by means of hex. screws.
roller setting!
Tightening torque (M 16/8.8) …………. M A = 195 Nm
Legend to figure no. 22 and figure no. 21:

1 = Piston
2 = Outer disc
3 = Inner disc (lined disc)
X = Disc clearance (0.4 … 0.75 mm)
Figure 22
Leakage test of differential lock (100% lock)
Prior to starting the test, bleed pressure chamber and

then check 100% lock!
Test:
Build up test pressure p = 13 bar and close shut-off
valve of HP pump.
No pressure drop is allowed during a 2 minute

testing time!
(S) HP pump C77AS59

(S) Threaded coupling (7/16-20 UNF) C77AS60
Figure 23
Test media
Motor oils SAE-10W ;MIL-L 2104 C; MIL-L 46152;
API-CC, CD, SC, SD, SE,
ATF-oils: type A; Suffic A; Dexron of II D
CUKUROVA Model 885


REASSEMBLY - OUTPUT UNIT
Legend to figure no.1
1 = Axle housing
2 = Hub
3 = Shaft seal
4 = Roller bearing (hub bearing)
5 = Internal gear
6 = Planetary gears
7 = Planetary carrier
8 = Sun gear shaft
Figure 1
Mount wheel bolt.
Figure 2
Install both bearing outer rings of hub bearing until

Hub must not be supported on wheel bolts!
Driver tool C77AS62

Handle C77AS63
To ensure functioning, always use a „new“ shaft

seal when reassembling the hub – also refer to
disassembly figure no. 15!
Figure 3 Apply sealing agent to contact face shaft seal/hub

(Loctite no. 574).
Mount shaft seal observing the correct installation
position.
labeling OUT-SIDE showing upwards / outwards and
the correct offset „X“ –see detailed figure.

and detailed figure:
1 = Hub
2 = shaft seal
X = installation dimension 5 + 1 mm
Figure 4 Driver tool C77AS64
CUKUROVA Model 885


Mount heated bearing inner ring until contact.
Figure 5
Just before fitting, wet the contact face shaft

seal/axle housing with spirit – assembly aid.
Mount preassembled hub until contact and fix it with

heated external bearing inner ring.
Lifting bracket C77AS38
Figure 6
If disassembled – insert bushings into the internal gear

Figure 7
Mount preassembled internal gear and equally bring to

contact position using the „old“ locking screws (from
disassembly).
Rotate hub in both directions several times – roller

setting!
Figure 8
CUKUROVA Model 885


Finally fix internal gear with „new“ locking screws.
Locking screws are permitted for one-time use

only!
Tightening torque (M14/12.9) ……… MA = 250 Nm
Figure 9
Just for new parts assembly:
Insert cylinder roller bearing into the planetary gear –

by pressing the roller bearing into the planetary gear
by the assembly sleeve (arrow) until the snap ring
engages into the annular groove of the planetary
gear.

1 = Planetary gear
2 = Roller bearing (with bearing inner ring /cylinder
rollers/axial washers and snap ring)
3 = Assembly sleeve
Figure 10
Heat preassembled planetary gear (bearing inner ring)

and install until contact, with large radius /bearing
inner ring showing downwards (arrow).
Adjust bearing inner ring/planetary gear after

cooling down!
Figure 11
Snap in retaining ring.
Check contact position of retaining ring on

groove base and readjust!
For assembly of the other planetary gears proceed in

the same way.
Figure 12
CUKUROVA Model 885


If disassembled – install stop pin (arrow)
Figure 13
Oil o-ring (arrow-1) and install on collar of hub.
Figure 14
Take sun gear shaft (see arrow -2 / figure-no. 14) out

of axle housing and insert in the preassembled
planetary carrier – assembly aid.
Figure 15
Take up preassembled planetary carrier by means of

lifting strap and mount it on the hub –installing stub
shaft into sun gear shaft.
Figure 16
CUKUROVA Model 885


Fix planetary carrier with hex. screws.
Insert hex. screws with locking compound (Loctite-no.

243)!
Figure 17
Prior to putting into operation fill the axle with oil

– for this purpose stick to the ZF-lubrication and
maintenance instructions
(ZF-order no.: 5871 519 902) !

In general, observe the vehicle manufacturer’s
regulations and instructions !
CUKUROVA Model 885


REASSEMBLY
PARKING BRAKE version “MULTI-DISC BRAKE”
For reassembly of the brake housing (1) see

reassembly description of the input pinion
Insert all compression springs (2+3) into the holes of

the brake housing (1).
Just for assembly of new parts, or if dismantled:

Install slotted pins (4) – with slots of slotted pins in a
180° offset position – and stud bolts (5).
Figure 1 Insert stud bolts with locking agent
(Loctite-no. 262)!
Legend to figure no. 2 and figure no. 4
1 = Brake housing cover

2 = Grooved ring
3 = Grooved ring
4 = Piston
5 = Bolt
6 = O-ring
7 = Hex. screw
8 = Hex. nut
9 = O-ring
Figure 2
Oil both grooved rings (arrow) and insert them into the
brake housing cover – observing the installation
position, see figure-no. 3.
Figure 3
Insert both bolts (arrows) with O-ring into the brake

housing cover – observing the installation position, see
figure no. 2.
Figure 4
CUKUROVA Model 885


Legend to figure no.5 ,figure-no.6
1 = Outer discs (steel discs)

2 = Inner discs (lined discs)
Figure 5
Insert disc package into the brake housing cover –

observing the disc arrangement (see figure no.5)
starting with an outer disc.
Figure 6
Oil sealing surface of piston and of brake housing

cover and press piston into the brake housing cover to
contact position.
Press in piston without tilting – risk of damage to

grooved rings and piston!
Figure 7
Mount preassembled brake housing cover and fix with

hex. nuts (arrows).
Figure 8
CUKUROVA Model 885


Insert disc carrier so that all discs (inner discs) are
mounted.
Ensure a correct installation position of the disc carrier

– countersink/input flange contact to show outwards
(arrow)!
Figure 9
Bring brake housing cover to contact position evenly
by hex nuts and hex. screws, then fix it finally.
Hereby install disc carrier accordingly, to ensure all

inner discs remain mounted!
Tightening torque (M10/8.8) ………..….. MA = 46 Nm
Figure 10
Shaft seal/input flange
Legend to figure no. 11 …. figure-no. 15:
1 = Brake housing cover 5 = Washer
2 = Shaft seal 6 = Hex nut
3 = Screen sheet 7 = Input pinion
4 = Input flange
„Z“ = detailed figure – installation dimension/shaft
seal
+ 0.5
Figure 11 X = install. dim. 3.5 mm
Insert shaft seal (2) – observing installation

dimension X (see detailed figure “Z“).
Contact surface (outer diameter) of shaft seal:

- if rubber-coated, wet with spirit (assembly aid)
- if made of metal, apply sealing agent (Loctite no.
574)
Grease shaft seal around the sealing and dust lip!
(grease e.g. "PETAMO GHY 133 N" ZF-order no.
0671 190 099)
Pay attention to a plane installation position of the
shaft seal – use the specified driver tool to ensure
an exact installation position of the shaft seal!
CUKUROVA Model 885


Just for new parts assembly:
Mount screen sheet (3)on input flange (4) and bring to

contact position.
Ensure correct installation position of screen sheet–

also see figure no 11 and detailed figure „Z“!
Install screen sheet without deforming it – use
suitable driver tool!
Figure 13
Mount preassembled input flange.
Figure 14
Secure axle by using a support (arrow) – risk of

accident!
Fix flange with washer (5) and hex. nut (6).
While tightening rotate pinion in both directions

several times (roller setting)!
Install hex. nut with locking compound (Loctite-

no. 262)!
Tightening torque (M30x1.5) .............. MA = 600 Nm

Figure 15
Check break-away torque of multi-disc brake

Secure axle by using a support (see figure no. 15)
– risk of accident!
Fix locating piece (arrow) on input flange and check

break-away torque of parking brake (do not place
torque wrench on hex. nut of input flange fixing)!
Break-away torque of parking brake = min. 1000

Nm
In case of a proper parking brake functioning, a

break-away (slipping) of < 1000 Nm is not allowed!
Figure 16
CUKUROVA Model 885


Setting of emergency breathing of multi-disc brake
Legend to figure no. 17 and figure no.18:
1 = Brake housing cover

2 = Hex. screw
3 = Hex. nut
+2
Y = Installation dimension → 29 mm
Figure 17
Install both emergency breather screws, observing
the installation dimension „Y“ – see figure no. 17.
Tightening torque (M10x1) .............. MA = 46 Nm
Figure 18
Leakage test of multi disc brake
Mount breather (1) and screw plug (2).
Install screw plug with sealing agent – Loctite-Nr. 574!
Tightening torque (1-breather) ................. MA = 6 Nm

Tightening torque (2-screw plug) ……… MA = 25 Nm
Check
Prior to staring the test, bleed pressure chamber and
then pressurize multi-disc brake several times !
Figure 19
Build up test pressure p = 13 bar and close shut-off
valve of HP-pump.
A pressure drop of max < 1 bar is permissible
during a 4-minute test duration!
Test media
Motor oils SAE-10 W corresponds,

MIL-L 2104 C, MIL-L 46152,
API-CC, CD, SC, SD, SE.
ATF-oils type A, Suffic A Dexron of II D.
HP pump C77AS59
Reducing adapter (7/8” to G 1/4”) C77AS68
Threaded coupling (G ¼”) C77AS67
Figure 20 Prior to putting into operation fill the axle with oil
(ZF-order no.: 5871 519 902)!
regulations and instructions!
CUKUROVA Model 885


REASSEMBLY
PARKING BRAKE version “DISC BRAKE”
For reassembly of brake housing (1) refer to

reassembly procedure of input pinion described in
INPUT reassembly,
Mount breather (2) into the brake housing.
Tightening torque (breather) ..................... MA = 6 Nm
Figure 1
Legend to figure no.2 to figure no. 7
1 = Brake housing „Z“ = detailed figure

2 = Shaft seal (installation dimension/shaft seal)
3 = Screen sheet
4 = Input flange
5 = Hex. screws
6 = Input pinion
7 = Washer
8 = Hex. nut
9 = Brake disc
10 = Brake cpl.
11 = Washer
12 = Hex.screw
+ 0.2
X = Install. dimension 13.5 mm
Figure 2
Insert shaft seal (2) – observing installation

dimension X (see detailed figure “Z“) .
Contact face (outer diameter) of shaft seal:

- if rubber-coated: wet with spirit (assembly aid)
- if made of metal: apply sealing (Loctite no. 574)
Grease shaft seal around the sealing and dust lip!
Observe a plane installation position of the shaft

seal – using the specified driver tool (A) ensures
an exact installation position of the shaft seal!
Just for assembly of new parts, or if disassembled:
Insert hex. screws (5) into the input flange (4). Mount
screen sheet (3)on input flange (4) and bring to
contact position.
Observe installation position of screen sheet!
During assembly, screen sheet must not be

deformed – use suitable driver tool!
Figure 4
CUKUROVA Model 885


Secure axle by means of a support (arrow) – risk
of accident!
Mount preassembled input flange (4), fix with washer

(7) and hex. nut (8).
Fix input flange using a clamping fork, and rotate in

both directions several times while tightening the hex.
nut - (roller setting/pinion bearing)!
Install hex. nut with locking compound (Loctite-

no. 262)!
Tightening torque (M30x1.5) .............. MA = 600 Nm
Figure 5
Mount brake disc (9) – observe installation position -

and fix with tube and hex nut (arrows) – transportation
lock.
Figure 6
Fix brake assy (10) with washer (11) and hex. screw
(12).
Tightening torque (M16x1.5/10.9) ......... MA = 300 Nm
Regarding assembly, functional characteristics,

maintenance und setting instructions for the brake
assy (10) - see original documents of component
manufacturer (Knott)
Figure 7
Prior to putting into operation, fill the axle with oil

– for this purpose stick to the ZF lubrication and
(ZF order no.: 5871 519 902) !
regulations and specifications!
CUKUROVA Model 885


Completion of axle
1 = Oil drain plug
2 = Oil filler-/level check plug
3 = Brake control plug
4 = Identification plate
Fit all screw plugs with new O ring and install them.
Tightening torque (7/8“ – 14 UN) …… MA = 30 Nm
Just for assembly of new parts or if disassembled:
Fix identification plate with grooved pins.

Figure 1
Fit screw plugs (arrow) of both output units with new

O-ring and mount them.
Check axle regarding leakage
Max. test pressure = 0.5 bar must not be exceeded

here – risk of damage!
Mount air connection into brake control hole of axle

housing.
Pressurize axle with a test pressure of = 0.5 bar – and
Figure 2 close shut-off valve.
No pressure drop is allowed during a 3-minute

testing time!
Air connection C77AS69

Connection plug C77AS70
Reducing adapter (7/8“ to G ¼“) C77AS68
Remove air connection, then fit screw plug with new

O-ring and install it.
Figure 3
Prior to putting into operation fill the axle with oil

maintenance instructions !
In general observe the vehicle manufacturer’s

regulations and instructions!
CUKUROVA Model 885


60.01
TRANSMISSION
ZF – TRANSMISSION
4WG-90/94
WORKSHOP MANUEL
CUKUROVA Model 885

Backhoe - Loader Transmission

CONTENTS
SCHEMATICS
Configuration 4 WG-94 without front wheel drive……………………………………..………………………..3
Configuration 4 WG-94 with front wheel drive…………………………………….……………..…….…..…...4
Transmission schematics- Gear schematics.…………………………………………………………………..5
Measuring points for pressure oil and temperature……..…………..…..…………………………….…….....7
DISASSEMBLY ……………………………………………………………………………………………………9
Solenoid valves, inductive sensor, screw plugs and nozzles (orifices).……………………………..…......11
Disassembly of engine connection, main pressure valve and converter safety valve.………….....……..12
Main pressure valve and converter safety valve ………………………………………………....…………..13
Removal of clutches, central shaft and disassembly of transmission pump:………………………………15
Disassembly of transmission pump…………..………………………………………………………………...19
Disassembly clutches.……………………………………………………………………………………….…...21
KR clutch/input………………………………………………………………………………….21
KV clutch.………………………………………………………………….…………….……...25
K1 clutch.………………………………………………………………….……………….……29
K2 clutch.………………………………………………………………….………………….…33
K3 clutch.………………………………………………………….……….…………………...37
K4 clutch.……………………………………………………….…………….…………….…..41
Front wheel drive (VA)………………………………………………………………………...45
REASSEMBLY
KR clutch/input………………………………………………………………………......…….48
KV clutch.………………………………………………………………….…………….……...54
K1 clutch.………………………………………………………………….………….…………60
K2 clutch.………………………………………………………………….…………….………66
K3 clutch.………………………………………………………….……….…………………...72
K4 clutch.……………………………………………………….…………….…………….…..78
Front wheel drive (VA)………………………………………………………………………...84
CUKUROVA Model 885


Reinstallation and reassembly of transmission pump, oil suction tube and oil filler tube,
control pressure and converter safety valve, coarse filter and clutches…………….………….…….….....89
Reassembly of transmission pump………………….…………………………………...…..89
Reinstallation of converter safety valve……………………………………………….……..91
Reassembly of main pressure valve (control pressure valve)…………………………….91
Reinstallation of transmission pump………………………………….…………….…….….92
Reinstallation of clutches.………………………………………………..……………….…..93
Reinstallation of K2 and K3 (Version without front wheel drive)……..…….……..……...94
Reinstallation of K2, K3 and front wheel drive (Version with front wheel drive)………..95
Reinstallation of K1…………….……………………………………………………………...96
Reinstallation of KV and KR…………….…………………………………………………....96
Reinstallation of K4………………….…………………………………………………….…..96
Reassembly of rear axle output flange and screw plug at measuring point „63“ after
the converter, and sealing of version with and without front Wheel drive………………………………….99
Reassembly of rear axle output flange…………………………………..……….…………99
Reinstallation of nozzles (orifices),screw plugs, solenoid valves,inductive sensor and

Mounting provision for oil filler tube…………………………………………………………………...…..….102
Reinstallation of nozzles (orifices).…………………………………………………………102
Reinstallation of nozzles (orifices)…..…………………………..……………………….…102
Reinstallation of solenoid valves……………………………………………………………103
Reinstallation of inductive sensor (option).…………………………………………..……………………....104
Mounting provision for oil filler tube (option)……………….………………………………………………...104
Reassembly of PTO……………………..…………………………………………………………………..….105
Reassembly of engine connection.…………………………………………………………………………....106
Reassembly of filter and oil drain plug……………………..……………………………………………….…107
CUKUROVA Model 885

Date Page III Section 60.01

PREFACE
This documentation has been developed for specialized staff trained by ZF Passau for repair and
maintenance work to be made on ZF units.
This documentation describes a ZF series product with a design level valid at the date of edition.
Due to the continuous technical upgrading of the product, however, the repair of the unit at your disposal
may require both deviating work steps and differing setting and testing data.
We would therefore recommend you to entrust masters and servicemen with the work on your ZF
productwhose practical and theoretical training is constantly updated in our training school.
The Service Stations established by ZF Friedrichshafen all over the world offer you:
1. Permanently trained staff

2. Specified equipment, e.g. special tools
3. State-of-the-art genuine ZF spare parts
All work is done there with utmost care and reliability.
In addition, repair work carried out by ZF Service Stations is covered by the ZF warranty within the
terms of the currently applicable contractual conditions.
Any damage resulting from work which is done in an improper and unprofessional manner by third parties
and any consequential costs incurred shall be excluded from this contractual liability.
This shall also be applicable if other than genuine ZF spare parts are used.
CUKUROVA Model 885


GENERAL
The Service Manual covers all work required for disassembly and the relating reassembly.
When repairing the transmission, ensure utmost cleanliness and that the work is done in a professional
manner.
Dismantle the unit only if any damaged parts must be replaced. After removing screws or nuts, loosen lids
and housing parts, which were installed with seals, by slight hammer blows with a plastic hammer. Use
suitable pulling devices for removing parts being tightly installed on the shafts, such as bearings, bearing
rings and similar.
Carry out disassembly and reassembly work on a clean working place. Use special tools which have been
developed for this purpose. Prior to reinstallation of the parts, clean contact faces of housings and lids
from residues of seals. Remove any burrs or similar irregularities with an oil stone. Clean housings and
end covers, in particular corners and angles, with a suitable detergent. Damaged or heavily worn parts
must be replaced, with an expert assessing whether parts subject to normal wear during operation, such
as bearings,thrust washers etc. will be reinstalled.
Parts such as seal rings, locking plates, split pins etc. must generally be replaced. Radial seal rings
withworn or broken sealing lip must also be replaced. In particular, ensure that no chips or other foreign
bodies remain in the housing. Check the lube oil holes and grooves regarding unhindered passage.
Oil according to the relating List of Lubricants shall be applied to all bearings prior to their installation.
NOTE : Only a heating furnace or an electric drier is permitted to be used for heating up parts such
as bearings, housings, etc.!
Parts fitted in heated state must be readjusted after cooling down to ensure a perfect
contact.
CAUTION
When assembling the unit, exactly observe the tightening torques and setting data indicated in the
manual.
Tighten screws and nuts according to the enclosed standard table, unless otherwise specified.
The use of fluid seals or Molykote is not permitted for the control part in transmissions – due to a possible
malfunction.
Never wash disks having organic friction linings (e.g. paper disks - adverse effect on lining adhesion).
Only dry cleaning is permitted (leather cloth).
CUKUROVA Model 885


Configuration 4 WG-94 without front wheel drive
1 = Converter
2 = Flexplate for direct mount
3 = Transmission pump
4 = Converter bell
5 = Clutch shaft „K2“
6 = Way of installation font wheel drive
8 = Output flange
11 = PTO; coaxial, engine-dependent (Central shaft) „PTO“
12 = Input shaft / clutch shaft Clutch shaft „KR“
13 = Clutch shaft „KV“
13
1
12
2
11
10
8
5
6
7
Figure 1
CUKUROVA Model 885


Configuration 4 WG-94 with front wheel drive
1 = Converter
2 = Flexplate for direct mount
3 = Transmission pump
4 = Converter bell
6 = Font wheel drive
8 = Output flange
11 = PTO; coaxial, engine-dependent (Central shaft) „PTO“
12 = Input shaft / clutch shaft Clutch shaft „KR“
13 = Clutch shaft „KV“
13
1
12
2
11
10
9
4
8
5
6
7
Figure 2
CUKUROVA Model 885


Transmission schematics Gear schematics
KV
KV
AN/KR PTO
K4
AN/KR
K4
K1
K1
K2/AB
K3
AN/K2
VA
K3
VA
Legend:
AN/KR = Input / KV clutch - directional clutch
KV = KV clutch - directional clutch
K1 = K1 clutch - gear clutch
K2/AB = K2 clutch / output - gear clutch
K3 = K3 clutch - gear clutch
K4 = K4 clutch - directional clutch
VA = Front wheel drive
PTO = Power take-off;coaxial, engine-dependent
CUKUROVA Model 885


CUKUROVA Model 885

Measuring points for pressure oil and temperature:
51 = Before the converter – opening pressure 11+2 bar M10x1

53 = Clutch - Forward KV 16+3 bar M10x1
55 = Clutch - Reverse KR 16+3 bar M10x1
56 = Clutch K1 16+3 bar M10x1
63 = Temperature after the converter 100° C; short-term 120° C M14x1,5
67 = System pressure 16+3 bar M10x1
68 = Parking brake PB 16+3 bar 9/16“ - 18 UNF
69 = Differential lock DL 16+3 bar 3/4“ - 18 UNF
70 = Front wheel drive WD 16+3 bar M10x1
Connections:
13 = Connection Parking brake (rear axle) 9/16“ - 18 UNF
14 = Connection towards return line into transmissions sump 9/16“ - 18 UNF
15 = Connection towards heat exchanger 7/8“ 14 UNF
16 = Connection from heat exchanger 7/8“ 14 UNF
Inductive transmitter:
35 = Inductive transmitter n speedometer (Option) M18x1,5
Valve:
Y1 … = Valves
Y6
YWD = Front wheel drive
YDL = Differential lock (rear axle)
YPB = Parking brake (rear axle)
CUKUROVA Model 885


CUKUROVA Model 885

DISASSEMBLY:
1 Transmission 4 WG-94
Attach transmission to the assembly truck by

means of holding fixtures (1) and clamping angles
(2).
(S) Assembly truck C77AS34

(S) Holding fixtures C77AT10
(S) CLAMPING ANGLES C77AT11
1 1
Figure 1
Drain oil prior to starting disassembly!
Remove screw plug (1).
1
Disposal of oil according to legal requirements!
Figure 2
The figure shows the mounting provision for oil

filler tube with oil dipstick (option)!
Loosen hexagon screw (1) and remove cover (2)

and seal (3).
2 3
1
If an oil filler tube with oil dipstick is installed
instead of the cover (2), these two parts must
be removed.
Figure 3
CUKUROVA Model 885


Separate ZF fine filter (1) from the filter head by
means of a belt wrench.
(S) Belt wrench C77AT12
Figure 4
Loosen cylindrical screws (2) and separate filter

head (1) from the transmission housing.
Figure 5
Remove both O-rings (1) out of the annular groove

1
of the filter head.
Figure 6
CUKUROVA Model 885


1 2
3 DISASSEMBLY:
4
Solenoid valves, inductive sensor,
screw plugs and nozzles (orifices)
Loosen cylindrical screws, remove bracket and pull

solenoid valves off the holes.
5 Mark solenoid valves (different versions).
1 = Y1 (control valve)
2 = YPB (parking brake - rear axle)
3 = YDL (differential lock - rear axle)
6
7 9 = YWD (front wheel drive)
8
Figure 1
Version with inductive sensor (option)!

Loosen inductive sensor (1).
1
Remove O-ring !
Figure 2
Pull output flange (1) off the output shaft.
1 Remove all screw plugs and nozzles (orifices)!
Figure 3
CUKUROVA Model 885


2 1 Disassembly of engine connection,
main pressure valve and converter
safety valve
Engine connection
Loosen hexagon screws (1) and separate flexplate

(2) from converter (3).
3
Figure 1
Pull off converter (1) by hand.

1
Figure 2
Loosen bolted connection between converter

bellhousing/housing (1) and transmission
1 2 pump/housing (2) .
Figure 3
Loosen screw plug „measuring point 63“ (1).

1
Remove O-ring!
Figure 4
CUKUROVA Model 885


Separate converter bellhousing from the mounting
face of the transmission housing by means of slight
hits with a plastic hammer.
Figure 5
Remove converter bellhousing by means of
assembly lever.
Difficult disassembly
cylindrical pins!
due to fixing by
Figure 6
2 If required, remove both cylindrical pins (1).

S 1
Remove filter (2).
1
Transmission pump cannot be separated from
the housing until the 4 cylindrical screws of the
housing inner side have been loosened.
Fit adjusting screws to ensure that the

transmission pump is centred at the housing
after the 4 cylindrical screws have been
loosened.
Figure 7 (S) Adjusting screws (M10) C77AT13
1 2
Main pressure valve and converter
safety valve
3
4 Loosen screw plug (1) and remove main pressure
5 valve (control pressure valve) :
Main pressure valve consists of:
1 = screw plug
2 = O-ring
3 = piston
4 = spacer ring
5 = compression spring
Figure 8
CUKUROVA Model 885


Functional check of converter safety valve (1).
Use a screwdriver to check the movability
of the ball in the valve.
1
If the valve is o.k., it does not need to be
removed.
Valve assy is installed in the housing - not

visible !
Figure 9
CUKUROVA Model 885


Removal of clutches, central shaft and
disassembly of transmission pump
Removal Of clutches
Force out cylindrical pins (1).
Loosen bolted connection (2) of housing front and

rear part.
Figure 1
Separate housing front part from transmission

housing rear part by means of lifting device
(approx. 1 cm).
Use the plastic hammer to reset the output shaft

(1) of the front wheel drive to its initial position, thus
separating the screen sheet (2) from the shaft of
the clutch.
(S) Eye bolts assortment C77AT14
Figure 2
CUKUROVA Model 885


Remove screen sheet (1) and separate
transmission housing front part by means of lifting
device.
Figure 3
Designation of clutches:
KV = forward clutch (directional clutch)

KR = reverse clutch (directional clutch)
K1 = K1 clutch (gear clutch)
K4 = K4 clutch (directional clutch)
VA = front wheel drive clutch
Figure 4
Remove K4 clutch.
Figure 5
CUKUROVA Model 885


Slightly lift clutch (K2) and remove clutch (K1).
Figure 6
Lift KV and KR clutch off the bearing outer rings

jointly and then remove them one after the other.
Figure 7
Jointly remove VA, K2 and K3 clutch together with

screen sheet (1).
Use the lifting device to jointly lift VA and K3 clutch

together with K2 clutch, and then remove the
components one after the other.
(S) Eyebolts C77AT15
Figure 8
CUKUROVA Model 885


Snap out retaining ring (1) and remove central
shaft (2).
1 2
Figure 9
Snap out rectangular ring (1).

2
Press ball bearing (2) off the central shaft (3).
3 1
Figure 10
Remove O-rings (1).

1 2
Remove all bearing outer rings (2) from the
housing rear part.
If, contrary to the ZF recommendation, the

tapered roller bearings of clutches are not
replaced, it is imperative to ensure the previous
pairing (bearing outer ring / bearing inner ring).
Bearing outer ring and bearing inner ring must

be marked!
Figure 11
Loosen the cylindrical screws (1) and remove

suction tube (2).
1 Remove all bearing outer rings (3) from the
housing front part.
2
3
tapered roller bearings of clutches and input
are not replaced, it is imperative to ensure the
previous pairing (bearing outer ring / bearing
inner ring).
Bearing outer ring and bearing inner ring must

be marked!
Figure 12
CUKUROVA Model 885


Disassembly of transmission pump
2 Loosen cylindrical screws (3 and 4) and remove
1 transmission pump.
Pay attention so that the transmission pump

does not drop!
Figure 13
Remove transmission pump (1).
Figure 14
Remove O-ring (1).
1 2 Loosen cylindrical screws (2).
Figure 15
Check transmission pump:

1 In case of wear marks in the pump housing,
2
stator hollow shaft or on the inner and outer
rotor, the complete transmission pump must be
replaced.
3
1 = stator hollow shaft
2 = inner rotor
4 3 = outer rotor
4 = pump housing
Figure 16
CUKUROVA Model 885


Remove shaft seal ring (1) from the pump housing
(2).
1
Figure 17
CUKUROVA Model 885


Disassembly clutches
KR clutch/input

1
Figure 1
Pull off bearing inner ring with inner disk carrier (1).
Figure 2
Remove bearing inner ring (1), axial bearing assy

1 (2) and inner disk carrier (3).
2
Figure 3
Remove needle cage (1).
1
Figure 4
CUKUROVA Model 885


Remove axial bearing assy (1).
1
Figure 5
Remove snap ring (1).
Figure 6
Remove end plate (1), disk package (2) and plate

assy with cup springs (3) from the disk carrier.
2
1
Figure 7
Remove retaining ring (1) at axial bearing contact.

1
Figure 8
CUKUROVA Model 885


Preload compression spring and remove snap ring
(1).
1
(S) Assembly aid C77AT16
Figure 9
Remove spring cup (1) and compression spring

1
(2).
2
Figure 10
By means of compressed air (see arrow), press

1 piston (1) off the shaft/disk carrier and remove it.
Figure 11
Remove both O-rings (1 and 2).
1
Figure 12
CUKUROVA Model 885


Snap out rectangular rings (1).
1
Figure 13
Pull tapered roller bearing (inner ring) off the shaft.

(S) Basic tool C77AS51
Figure 14
The input shaft (1) cannot be disassembled!

1A
It is supplied by the spare parts service only as
a complete assy which consists of:
1B
1A = Ball
1C 1B = Helical gear
1
1C = Disk carrier
1D = Input shaft
1D
Figure 15
CUKUROVA Model 885


KV Clutch
1
Figure 1
Figure 2

2
Figure 3

1
Figure 4
CUKUROVA Model 885


1
Figure 5
1
Figure 6
2
1
Figure 7

1
Figure 8
CUKUROVA Model 885


(1).
1 (S) Assembly aid C77AT16
Figure 9

1
(2).
2
Figure 10

Figure 11
Figure 12
CUKUROVA Model 885


1
Figure 13

(S) Basic tool C77AT19
Figure 14
1A The clutch (1) cannot be disassembled!

1B
1C 1A = Retaining ring
1 1B = Helical gear
1C = Helical gear
1D
1D = Disk carrier
1E = Shaft
1E
Figure 15
CUKUROVA Model 885


K1 Clutch
Figure 1
Figure 2

2
Figure 3

1
Figure 4
CUKUROVA Model 885


1
Figure 5

1
Figure 6
Remove end plate (1), disk package (2) and cup

springs (3) from the disk carrier.
2
1
Figure 7

1
Figure 8
CUKUROVA Model 885


(1).
Figure 9

1 (2).
Figure 10

Figure 11
Figure 12
CUKUROVA Model 885


1
Figure 13

Figure 14
The clutch (1) cannot be disassembled!

1A
1A = Helical gear
1 1B = Disk carrier
1C = Shaft
1B
1C
Figure 15
CUKUROVA Model 885


K2 Clutch
1
Figure 1
Figure 2

2
Figure 3
Remove needle cage (1) and bushing (2).

2 1
Figure 4
CUKUROVA Model 885


1
Figure 5

1
Figure 6

2
1
Figure 7

1
Figure 8
CUKUROVA Model 885


Preload cup springs and remove snap ring (1).

1
Figure 9
1 Remove axial washer (1) and cup springs (2).
Figure 10

Figure 11
Figure 12
CUKUROVA Model 885


Snap out rectangular rings (1).
Figure 13

Figure 14

1A It is supplied by the spare parts service only as
1B 1A = Ball
1 1B = Helical gear
1C 1C = Shaft
1D = Disk carrier
1D
Figure 15
CUKUROVA Model 885


K3 Clutch
1
Figure 1
Figure 2

2
Figure 3
Remove needle cage (1) and bushing (2).

2 1
Figure 4
CUKUROVA Model 885


1
Figure 5

1
Figure 6

Figure 7

(1).

1
Figure 8
CUKUROVA Model 885


1 (2).
2
Figure 9

Figure 10
Figure 11

1
Figure 12
CUKUROVA Model 885



Figure 13

1A
1A = Helical gear
1 1B = Shaft
1B 1C = Disk carrier
1C
Figure 14
CUKUROVA Model 885


K4 Clutch
1
Figure 1
Figure 2

2
Figure 3

1
Figure 4
CUKUROVA Model 885


1
Figure 5

1
Figure 6

Figure 7

1
Figure 8
CUKUROVA Model 885


(1).
Figure 9

1
(2).
2
Figure 10

Figure 11
Figure 12
CUKUROVA Model 885


1
Figure 13

Figure 14

1A It is supplied by the spare parts service only as
1B 1A = Retaining ring
1 1B = Helical gear
1C = Disk carrier
1C
1D = Shaft
1D
Figure 15
CUKUROVA Model 885


Front wheel drive (VA)
1
Figure 1

Figure 2
Remove running disk (1).

1
Figure 3
Pull off inner disk carrier (1).

1
Figure 4
CUKUROVA Model 885


Figure 5
Remove end plate (1) and disk package (2) from

the disk carrier.
Figure 6
Preload cup springs and remove snap ring (1).

1
Figure 7
1 Remove washer (1) and cup springs (2).
Figure 8
CUKUROVA Model 885


Figure 9

Figure 10

1A
1A = Shaft
1 1B = Disk carrier
1B
Figure 11
CUKUROVA Model 885


1A Reassembly of clutches:
1B KR clutch/input
1C
1
The input shaft (1) is supplied by the spare
parts service only as a complete assy which
consists of:
1D 1A = Ball
1B = Helical gear
1C = Disk carrier
1D = Input shaft
Figure 1
Heat up bearing inner ring (approx. 120° C).
Figure 2
Mount bearing inner ring (1) until contact is

2
1 obtained.
Fit rectangular rings 50x2.5 (2).
Wear protective gloves!
Adjust bearing inner ring after cooling-down.
Figure 3
Insert both O-rings (1 and 2) into the piston

1 grooves and oil them.
1 = 40x3
2 = 104.5x3
2
Figure 4
CUKUROVA Model 885


Insert piston (1) into the disk carrier.
1
Pay attention to the installation position, see

Figure!
Figure 5
Use a hand-operated press to place piston into the

disk carrier by means of the assembly aid.
Figure 6
Mount compression spring (1) and spring cup (2).

2
1
Figure 7
By means of the assembly aid, preload

compression spring under a hand-operated press
until the retaining ring 40x1.75 (1) can be snapped
in.
1
Figure 8
CUKUROVA Model 885


Mount plate assy with cup springs (1), with the
1 open side showing towards the piston.
Installation position of plate see also Figure 10!
Figure 9
2 1 Fit plate (1) according to sketch (see arrow).
Legend:
1 = Plate assy with cup springs

3 2 = Compression spring with spring cup and
retaining ring
3 = Piston with O-rings
4 4 = Input shaft assy
Figure 10
Install outer and inner disks alternately into the disk
carrier (3) as shown in Figure 11,
starting with an outer disk and ending with an inner

disk.
2 1 Legend:
3
1 = Outer disks (10 pcs)
2 = Inner disks (10 pcs)
3 = Input shaft assy
Figure 11
Mount end plate (1) with the flat side showing
2 towards the disk package and fix it by means of
snap ring (2) (e.g. thickness = 2.5 mm /
recommended value).
1
Pay attention to the installation position of the

end plate!
Figure 12
CUKUROVA Model 885


Equally press on end plate with F (approx.18 N to
20 N = 1.8 kg to 2.0 kg) and set dial indicator to
"zero".
F
Figure 13
Then press end plate against the snap ring

F (upwards) and read the disk clearance.
Disk clearance: 2.0 to 2.3 mm!
In case of deviations, the disk clearance must

be corrected with an appropriate snap ring
(optional thickness = 2.0 …... 3.5 mm/available
in steps of 0.25 mm)!
Figure 14
Snap retaining ring 40x1.75 (1) into the groove.
1 Contact for axial bearing - see Figure 16!
Figure 15
3 Mount running disk 40x60x3.5 (1), axial needle

2 cage 40x60x3 (2) and axial washer 40x60x1 (3)
1 and oil them.
Mount running disk (1), with the chamfer

showing towards the retaining ring!
Figure 16
CUKUROVA Model 885


Mount needle cage 40x45x17 (1) and oil it.
1
Figure 17
Mount inner disk carrier until contact is obtained.
Install inner disks by short ccw/cw rotations of the

inner disk carrier (1).
L R
Figure 18
Mount axial washer 40x60x1 (1), axial needle cage

3
2 40x60x3 (2) and running disk (3) 40x60x3.5 and oil
them.
1

showing towards the tapered roller bearing!
Figure 19
Figure 20
CUKUROVA Model 885


obtained.
Fit rectangular ring 30x2 (2).

2
1
Figure 21
Check closing and opening of the clutch by

means of compressed air at the hole (see
arrow).
Closing and opening of the clutch must be

clearly audible.
Figure 22
CUKUROVA Model 885


KV clutch
1A
1B The clutch (1) is supplied by the spare parts

service only as a complete assy which consists
1C of:
1
1D 1A = Retaining ring
1B = Helical gear
1C = Helical gear
1E 1D = Disk carrier
1E = Shaft
Figure 1
Figure 2

2 1 obtained.
Figure 3

grooves and oil them.
1
1 = 40x3
2 = 104.5x3
2
Figure 4
CUKUROVA Model 885


1

Figure!
Figure 5

Figure 6

2
Figure 7

in.
1
Figure 8
CUKUROVA Model 885


Figure 9
Legend:

retaining ring
Figure 10


disk.
2 1 Legend:
3 1 = Outer disks (10 pcs)

3 = Clutch assy
Figure 11

1 recommended value).

end plate!
Figure 12
CUKUROVA Model 885


"zero".
F
Figure 13
(upwards) and read the disk clearance.
F

Figure 14
1
Contact for axial bearing - see Figure 37!
Figure 15

and oil them.
1

Figure 16
CUKUROVA Model 885


1
Figure 17
L R Install inner disks by short ccw/cw rotations of the

1
Figure 18

3
40x60x3 (2) and running disk (3) 40x60x3.5 and oil
2 them.
1

Figure 19
Figure 20
CUKUROVA Model 885


2
1 obtained.
Figure 21

arrow).

clearly audible.
Figure 22
CUKUROVA Model 885


K1 clutch
1A The clutch (1) is supplied by the spare parts

of:
1 1A = Helical gear
1B
1B = Disk carrier
1C = Shaft
1C
Figure 1
Figure 2

2
obtained.
1 Fit rectangular ring 30x2 (2).
Figure 3

1
1 = 40x3
2 = 104.5x3
2
Figure 4
CUKUROVA Model 885


1

Figure!
Figure 5

Figure 6

2
Figure 7

in.
1
Figure 8
CUKUROVA Model 885


Mount cup spring 112x75x2.55 (1) with the convex
1 side showing towards the piston.
Installation position of cup spring see also

Figure 10!
Figure 9
Install cup spring (1) according to the sketch.

2 1
Legend:
1 = Cup spring 112x75x2.55 (convex side

towards the piston)
3
2 = Compression spring with spring cup and
retaining ring
4
4 = Clutch assy
Figure 10


disk.
2
1 Legend:

3 = Clutch assy
Figure 11


end plate!
Figure 12
CUKUROVA Model 885


"zero".
F
Figure 13
F

Figure 14
Contact for axial bearing – see Figure 16!
Figure 15
Mount running disk 40x60x3.5 (1), axial needle

3
and oil them.
1
Mount running disk (1) with the chamfer

Figure 16
CUKUROVA Model 885


1
Figure 17

L R
1
Figure 18

3
2 them.
1

Figure 19
Figure 20
CUKUROVA Model 885


2 1 obtained.
Adjust bearing inner ring after cooling-down!
Figure 21

arrow).

clearly audible.
Figure 22
CUKUROVA Model 885


1A K2 clutch
1B The clutch (1) is supplied by the spare parts

1C of:
1
1A = Ball
1B = Shaft
1D 1C = Helical gear
1D = Disk carrier
Figure 1
Figure 2

obtained.
1 2
Fit rectangular rings 50x2.5 (2).
Figure 3

1 1 = 40x3
2 = 115x3
2
Figure 4
CUKUROVA Model 885


1

Figure!
Figure 5

Figure 6
1 Mount cup spring package (1) and axial washer

(2).
2
Installation position of cup springs see Figure
73!
Figure 7
Fit cup springs according to the sketch.

4 3 2
5 Legend:
1 = Clutch
1 2 = Piston with O-rings
3 = Cup springs (7 pcs)
4 = Axial washer (40x60x1)
5 = Retaining ring (40x1.75)
Figure 8
CUKUROVA Model 885


By means of the assembly aid, preload cup springs
under a hand-operated press until the retaining ring
40x1.75 (1) can be snapped in.
1
Figure 9
Mount cup spring 122.7x87x2.55 (1) with the

1 convex side showing towards the piston.

Figure 11!
Figure 10

2 1
Legend:
1 = Cup spring 122.7x87x2.55 (convex side

showing towards the piston)
retaining ring
4 4 = Clutch assy
Figure 11


disk.
2
1 Legend:
3
3 = Clutch assy
Figure 12
CUKUROVA Model 885


2
snap ring (2) (e.g. thickness = 2.5 mm/
recommended value).

end plate!
Figure 13

F 20 N = 1.8 kg to 2.0 kg) and set dial indicator to
"zero".
Figure 14
F Then press end plate against the snap ring


(optional thickness = 2.0 ... 3.5 mm/available in
steps of 0.25 mm)!
Figure 15

1
Figure 16
CUKUROVA Model 885


1 and oil them.

Figure 17
Mount needle cage 40x45x17 (1) and bushing (2)

2 1 and oil them.
Figure 18

L R
1
Figure 19

2 them.
1

Figure 20
CUKUROVA Model 885


Figure 21

2 1 obtained.
Figure 22

arrow).

clearly audible.
Figure 23
CUKUROVA Model 885


K3 clutch

of:
1 1A = Helical gear
1B
1B = Disk carrier
1C = Shaft
1C
Figure 1
Figure 2

2 obtained.
1

2
1
Figure 3

1
1 = 40x3
2 = 104.5x3
2
Figure 4
CUKUROVA Model 885


1

Figure!
Figure 5

Figure 6

2
1
Figure 7

in.
Figure 8
CUKUROVA Model 885


Mount cup spring 112x75x2.55 (1) with the convex
1 side showing towards the piston.

Figure 10!
Figure 9

2 1
Legend:
1 = Cup spring 112x75x2.55 (convex side

showing towards the piston)
3
2 = Compression spring with spring cup and
retaining ring
4
4 = Clutch assy
Figure 10


disk.
2 1
Legend:

3 = Clutch assy
Figure 11

towards the disk package and fix it by means of
2
recommended value).
1

end plate!
Figure 12
CUKUROVA Model 885


"zero".
F
Figure 13

F

steps of 0.25 mm)!
Figure 14

1 and oil them.

Figure 15
Mount needle cage 35x42x18 (1) and bushing (2)

and oil them.
2 1
Figure 16
CUKUROVA Model 885



Figure 17

3
2 them.
1

Figure 18
Figure 19

2 1 obtained.
Figure 20
CUKUROVA Model 885


means of compressed air at the hole
(see arrow).

clearly audible.
Figure 21
CUKUROVA Model 885


K4 clutch
1A
1B
The clutch (1) is supplied by the spare parts
of:
1 1A = Retaining ring
1C 1B = Helical gear
1C = Disk carrier
1D 1D = Shaft
Figure 1
Figure 2

2 1 obtained.
Figure 3

1
1 = 40x3
2 = 104.5x3
2
Figure 4
CUKUROVA Model 885


1

Figure!
Figure 5

Figure 6
2 Mount compression spring (1) and spring cup (2).
Figure 7

in.

1
Figure 8
CUKUROVA Model 885


Figure 9
Legend:

retaining ring
Figure 10


disk.
3 2 1
Legend:

3 = Clutch assy
Figure 11

towards the disk package and fix it by means of
2 snap ring (2) (e.g. thickness = 2.5 mm /

end plate!
Figure 12
CUKUROVA Model 885


"zero".
F
Figure 13

F (upwards) and read the disk clearance.

steps of 0.25 mm)!
Figure 14
1
Figure 15
Mount running disk 40x60x3.5 (1), axial needle

2
and oil them.
1

Figure 16
CUKUROVA Model 885


1
Figure 17

Figure 18

2 them.
1

Figure 19
Figure 20
CUKUROVA Model 885


2 1 obtained.
Figure 21

arrow).

clearly audible.
Figure 22
CUKUROVA Model 885


Front wheel drive (VA)

of:
1
1A = Shaft
1B 1B = Disk carrier
Figure 1
Figure 2

obtained.

1
Figure 3

1
Oil both sealing lips!

Figure!
Figure 4
CUKUROVA Model 885


Figure 5
Mount cup spring package (1) and washer (2).

1
2 Installation position of cup springs see Figure

7!
Figure 6
Fit cup springs according to the sketch.

2
3 2 Legend:
1
1 = Clutch
2 = Piston
3 = Cup springs (7 pcs)
1 4 = Washer
5 = Retaining ring (50x2)
Figure 7
By means of the assembly aid, preload cup springs

1 under a hand-operated press until the retaining ring
50x2 (1) can be snapped in.
Figure 8
CUKUROVA Model 885



disk.
2
1 Legend:
3
3 = Clutch assy
Figure 9

1 snap ring (2) (e.g. thickness = 2.5 mm /
recommended value).

end plate!
Figure 10

F 20 N = 1.8 kg to 2.0 kg) and set dial indicator to
"zero".
Figure 11
F Then press end plate against the snap ring


(optional thickness = 2.0 … 4.0 mm/available in
steps of 0.25 mm)!
Figure 12
CUKUROVA Model 885



Figure 13
Mount running disk 40x60x3.5 (1).
Figure 14
Figure 15

2 1 obtained.
Figure 16
CUKUROVA Model 885


arrow).

clearly audible.
Figure 17
CUKUROVA Model 885


Reinstallation and reassembly of trans-
mission pump, oil suction tube and oil
filler tube, control pressure and
converter safety valve, coarse filter and
clutches
Reassembly of transmission pump

1
In case of wear marks in the pump housing,
stator hollow shaft, inner rotor, outer rotor and
2 on the sliding bearing, the pump assy must be
replaced.
3
Legend:
1 = Stator hollow shaft
4 2 = Inner rotor
3 = Outer rotor
4 = Pump housing with sliding bearing
Figure 1
With the sealing lip showing downwards, carefully

insert the shaft seal 55x75x8 (1) into the pump
S housing (2) until contact is obtained.
1 Fill space between sealing lip and dust lip with

grease!
2 Outer diameter:
• if rubber-coated: wet with spirit
• if made of metal: apply sealing agent
Loctite No. 574!
Figure 2
Fit outer rotor (1) and inner rotor (2).
2 The driver pins of the inner rotor (see arrows)

are to be fitted in upward direction.
Figure 3
CUKUROVA Model 885


Fit stator hollow shaft (1).
Figure 4
Fix stator hollow shaft radially with two cylindrical

1 screws (1).
Do not tighten the cylindrical screws – just turn

them in until contact is obtained and then turn
them back by approx. ½ rotation!
2 Place O-ring (2) 135x3 into the annular groove and

grease it.
Figure 5
Oil suction tube and oil filler tube
1
Mount O-ring 30x3 (1) onto the suction tube (2) and
grease it.
Figure 6
Fix suction tube (1) with cylindrical screws M8x16

(2).
2
Tightening torque M8/8.8x16.......... MA = 23 Nm
Figure 7
CUKUROVA Model 885


Insert tube (1) into the transmission housing by
means of driver tool (S).
S
A
Use the driver tool to obtain the correct offset!
1
Apply Loctite (type No. 574) onto the surface
(A)!
Figure 8
Coarse filter
1
Insert filter (1).
Figure 9
Reinstallation of converter safety valve

S
Insert valve (1) with drift (S) into the housing until
1
(S) Drift C77AT24
Figure 10
2 Reassembly of main pressure valve (control

pressure valve)
1
3 Insert main pressure valve (1).
4 Main pressure valve consists of:
2 = Piston
3 = Spacer ring (2 pcs)
recommended value 5 mm
4 = Compression spring
The main pressure 16 + 3 bar is determined by

means of the spacer rings!
Figure 11 Gradation of available spacer rings see spare

parts list.
CUKUROVA Model 885


Fit screw plug M22x1.5 (1) with O-ring 19x2.
1
Tightening torque ..............................MA = 50 Nm
Figure 12
Reinstallation of transmission pump
S Fit two adjusting screws (S) and position converter

bellhousing (1) equally until contact is obtained.
1 Pay attention to the hole pattern!
Wet mounting face with Loctite (type No. 574)!

(S) Adjusting screws (M10) C77AT13
Figure 13
Force the cylindrical pins 12x24 (1) into the holes

1 (blind holes) until contact is obtained.
Figure 14
Fix converter bellhousing (1) with cylindrical screws

1 M10x30 (2).
2
Tightening torque (M10/8.8x30) ........ MA = 46 Nm
Figure 15
CUKUROVA Model 885


Fit two adjusting screws (S) and mount
preassembled pump (1).
1 S
Pay attention to the hole pattern!

(S) Adjusting screws (M8) C77AT25
Figure 16
Position transmission pump with 3 cylindrical

1 screws (1) M8x60 (3x120° offset position) equally
ATTENTION: Do not damage (shear off) the O-

ring!
Fix transmission pump with cylindrical screws

M8x60 (1).
Tightening torque (M8/8.8x60) ...................MA = 23

Nm
Figure 17
Fix pump with cylindrical screws (1 and 2).

1 = M 8x16
1 2 = M 8x35
Tightening torque M 8/8.8x16........... MA = 23 Nm

2
Tightening torque M 8/8.8x35........... MA = 23 Nm
Figure 18
Reinstallation of clutches
Insert all bearing outer rings (1) into the bearing

holes of both housing parts (see Figures 19 and
20).
Place bearing outer rings into the bearing holes

using assembly grease.
Figure 19
CUKUROVA Model 885


tapered roller bearings of clutches and input
are not replaced, it is imperative to ensure the
previous pairing (bearing inner ring/bearing
1 outer ring) - see Chapter 4, Figures 11 and 12!
Figure 20
Reinstallation of K2 and K3
(Version without front wheel drive)
Align rectangular rings 50x2,5 (6) and rectangular

ring 30x2 (7) and grease them.
Hold K3 clutch (3) by means of the lifting device,

position K2 clutch (2) and screen sheet (1) at K3
clutch (3), and then jointly insert the assembly.
Bolts (4) of the screen sheet must be fixed into

the pilot holes (5)!
Figure 21
CUKUROVA Model 885


Reinstallation of K2, K3 and front wheel drive
(Version with front wheel drive)
Align and grease rectangular rings 50x2,5 (4) and

rectangular rings 30x2 (6), as well as those of the
front wheel drive.
Hold K3 clutch (5) and front wheel drive (1) by

means of the lifting device, position K2 clutch (2)
and screen sheet (3) at K3 clutch (5), and then
jointly insert the assembly.

the pilot holes (7)!
Figure 22
CUKUROVA Model 885


Reinstallation of K1
1 Align and grease rectangular ring 30x2 (2).
Position K1 clutch (1).

2
Figure 23
Reinstallation of KV and KR
1 Align and grease rectangular rings 50x2,5 (4) and
2 rectangular ring 30x2 (3).
Jointly position KV clutch (1) and KR clutch (2).
4
3
Figure 24
Reinstallation of K4
2
Align and grease rectangular ring 30x2 (1).
Position K4 clutch (2).

1
Figure 25
Version without front wheel drive:
3 4 Place O-rings (5 and 7) into the hole and grease

them.
2 5 6
7 Align and grease rectangular rings (1,2,3,4 and 6 ).
1
1 = Rectangular ring 30x2 (KV clutch)
2 = Rectangular ring 30x2 (K4 clutch)
3 = Rectangular ring 35x2 (KR clutch)
5 = O-Ring 15x2
7 = O-Ring 21.89x2.62
Figure 26 8 = Rectangular ring 30x2 (K3 clutch)
CUKUROVA Model 885


Version with front wheel drive:
6 Place O-rings (5 and 8) into the hole and grease

3 them.
4
2 5 7
Align and grease rectangular rings (1,2,3, 4 and 7).
1 8
1 = Rectangular ring 30x2 (KV clutch)
3 = Rectangular ring 35x2 (KR clutch)
5 = O-ring 15x2
6 = O-Ring 21.89x2.62
7 = ----------------------- (front wheel drives)
Figure 27 8 = Rectangular ring 30x2 (K2 clutch)
Use the lifting device to carefully bring the

transmission housing front part into contact
position.

the pilot holes!
Wet mounting face with Loctite (type N. 574)!
Figure 28
Hand-tighten the transmission housings crosswise

1 with 2 cylindrical screws (1).
2
Fit cylindrical pins 12x24 (2) centrically to the

2 mounting face.
Figure 29
CUKUROVA Model 885


Fix transmission housing front and rear part by
2 means of cylindrical screws (1 and 2).
3 1
Fit bracket (3).
Cylindrical screw (1) M10x30 (14x)

Cylindrical screw (2) M10x50 (10x)
Tightening torque M10/8.8x30.........MA = 46 Nm
Tightening torque M10/8.8x50 ........MA = 46 Nm
Figure 30
CUKUROVA Model 885


Reassembly of rear axle output flange
and screw plug at measuring point
„63“ after the converter, and sealing of
version with and without front wheel
drive
Reassembly of rear axle output flange

Use driver tool (S) to fit the shaft seal 60x90x8 (1)
until contact position, with the sealing lip showing
S towards the oil sump (see Figure 2).
Fill space between sealing lip and dust lip with

grease!
Wet rubber-coated outer diameter with spirit!
Figure 1
1 2 Installation situation - rear axle output
1 = Shaft seal 60x90x8

2 = Screen sheet
5 3 = Closing cover
3 4 = Output flange
5 = K2 clutch shaft
6 = Transmission housing
6
4
Figure 2
Press closing cover (3) into the flange (4) until

contact is obtained (see Figure 2).
Apply Loctite (type No. 518) to the closing

cover!
4
Use suitable pressure piece; closing cover
must not be deformed!
Figure 3
CUKUROVA Model 885


Press screen sheet (2) onto the flange (4) until
contact is obtained (see Figure 2).
Use suitable pressure piece; screen sheet must

not be deformed!
2
4
Figure 4
Mount output flange (4) until contact position

(see Figure 2).
Figure 5 Sealing of version with front-wheel-drive
Use driver tool (S) to fit the shaft seal 40x62x7 (1)
S until contact position, with the sealing lip showing
towards the oil sump (see Figure 7).
Fill space between sealing lip and dust lip with

grease!
Wet rubber-coated outer diameter with spirit!

Figure 6
Installation situation - sealing of version with

4 front-wheel-drive
2
3
1 = Shaft seal 40x62x7
2 = Screen sheet
3 = VA clutch shaft
Figure 7
CUKUROVA Model 885


Use the driver tool (S) to install screen sheet (2)
S onto the VA clutch shaft (3) until contact position
(see Figure 7).
2 (S) Driver tool C77AT27

3
Figure 8 Sealing of version without front-wheel-drive
Use the driver tool (S) to place screen sheet (1)

S into the transmission housing (2) until contact is
obtained (see Figure 10).
Figure 9
Installation situation - sealing of version

2
without front-wheel-drive
1 = Screen sheet
1
Figure 10
Reassembly of screw plug at measuring point

"63"
1
2 Fit screw plug M14x1.5 (1) with new O-ring 11x2
(2).
Tightening torque ………................ MA = 25 Nm
Figure 11
CUKUROVA Model 885


Reinstallation of nozzles (orifices),
screw plugs, solenoid valves,
inductive sensor and mounting
provision for oil filler tube
Reinstallation of nozzles (orifices)
Fit nozzle M10x1 Ø 1.55 (1) for the directional

clutches KV, KR and K4.
1
Tightening torque ................ MA = 10 Nm
Figure 1
Fit nozzles for the gear clutches K1, K2 and K3.

2
1 = Nozzle (K1) M10x1 Ø1.4

2 = Nozzle (K2) M8 Ø1.7
3 = Nozzle (K3) M8 Ø1.4
Tightening torque M8 ................ MA = 10 Nm

Tightening torque M10x1........... MA = 10 Nm
1 3
Figure 2
Reinstallation of screw plugs
Install all screw plugs with O-rings.

1
1 = Screw plug 3/4 -16 UNF; O-ring 16.36x2.21
(2x)
2 = Screw plug M10x1; O-ring 8x1.5 (36x)
3 3 = Screw plug 9/16 -18 UNF; O-ring 11.89x1.98
(3x)
2
Tightening torque 3/4 -16 UNF .......... MA = 28 Nm
Tightening torque M10x1 ................... MA = 6 Nm
Tightening torque 9/16 -18 UNF .... ... MA = 15 Nm
Figure 3
CUKUROVA Model 885


Reinstallation of solenoid valves
3 1
Insert solenoid valves (1 and 2) into the
transmission housing and fix them by means of
3
2 bracket and cylindrical screw M6x12 (3).
1 = Solenoid valve - parking brake - rear axle

2 = Solenoid valve - differential lock – rear axle
Tightening torque M6/8.8 ............. MA = 9.5 Nm
Figure 4
Insert solenoid valve Y2 (1) into the transmission

1 housing and fix it by means of bracket and
cylindrical screw
M6x12 (2).
2
Figure 5
Insert solenoid valves Y1 (1) and Y3 (2) into the

3 1 transmission housing and fix them by means of
bracket and cylindrical screw M6x12 (3).
2
3
Figure 6
Insert solenoid valve YWD (1) into the transmission

housing and fix it by means of bracket and
cylindrical screw M6x12 (2).
Figure 7
CUKUROVA Model 885


Insert solenoid valve Y5 (1) into the transmission
housing and fix it by means of bracket and
cylindrical screw M 6x12 (2).
Tightening torque M 6/8.8 ............. MA = 9.5 Nm
Figure 8
Insert solenoid valves Y6 (1) and Y4 (2) into the

transmission housing and fix them by means of
bracket and cylindrical screw M 6x12 (3).
Tightening torque M 6/8.8 ............. MA = 9.5 Nm
3 2
3 1
Figure 9
Reinstallation of inductive sensor (option)
Install inductive sensor (1) with O-ring 15x2 (2).
Tightening torque ............. MA = 30 Nm

2 1
Figure 10
Mounting provision for oil filler tube (option)
Fix closing cover (2) and seal (3) with hexagon

screws (1).
2 3
1
Tightening torque (M8/8.8x18)........... MA = 34 Nm
Figure 11
CUKUROVA Model 885


Reassembly of PTO
1
Press ball bearing 45x75x16 (1) onto the pump
shaft (2) until contact is obtained.
3
Fit rectangular ring 50x2.5 (3).

2
Grease and centrically align rectangular ring.
Figure 12
Mount pump shaft (2) until contact is obtained and

fix it by means of retaining ring 75x2.5 (1).
Figure 13
CUKUROVA Model 885


Reassembly of engine connection
1
Mount converter (1) until contact is obtained.
Figure 1
4 Position 1 washer/each / thickness=1.0 mm (4x)

(1) onto the flexplate mounting webs (4x).
3
2
Place flexplates (2).
Pay attention to the installation position! Spot-

welded reinforcing disks of the flexplate to be
1 arranged towards the outside - see arrows !
Mount washer (3) onto the hexagon screw M10x16

(4) and fix flexplates.
Figure 2
Tighten hexagon screws (1).

1
Tightening torque (M10/8.8x16) ...... MA = 46 Nm
Fix converter axially!

Risk of injury!
Figure 3
CUKUROVA Model 885


Reassembly of filter and oil drain plug
Place O-rings 34.2x3 (1) into the holes and grease

1 them.
Figure 1
Attach filter head (1) with cylindrical screws M8x30

(2).
2
Tightening torque (M8/8.8X30) ............MA = 23 Nm
Figure 2
The ZF filter (1) has to be fitted as follows:

- Slightly oil the seal
- Turn in the filter until contact with the sealing

1 surface is obtained, and then tighten it by hand
with approx. 1/3 to 1/2 rotation.
Figure 3
CUKUROVA Model 885


Fit oil drain plug 7/8-14 UN 2A (1).
Tightening torque (7/8-14 UN 2A).......MA = 30 Nm
Fix identification plate (2) by means of 4 grooved

pins 3x5.
2
Figure 4
Before putting the transmission into operation,

fill it with oil according to Operation Manual !
Figure 5
CUKUROVA Model 885


70.01
ENGINE
Perkins 1100 Series
Models RE, RF, RG, RH, RJ and RK
WORKSHOP MANUAL
4 cylinder diesel engines for industrial, agriculture and construction applications
CUKUROVA Model 885

Backhoe - Loader Engine

Chapters
1 General information
2 Specifications
3 Cylinder head assembly
4 Piston and connecting rod assemblies
5 Crankshaft assembly
6 Timing case and drive assembly
7 Cylinder block assembly
8 Engine timing
9 Aspiration system
10 Lubrication system
11 Fuel system
12 Cooling system
13 Flywheel and housing
14 Electrical equipment
15 Auxiliary equipment
16 Special tools
CUKUROVA Model 885


Contents
General information
Introduction …………………………………………………………………………………………………………1
Engine views…………………………………………………………………………………………………..……2
Engine identification…………………………………………………………………………………………..……3
Safety precautions………………………..……………………………………………………… ...………..……5
Engine lift equipment…………………………………………………………………………………………. …..6
Viton seals…………………………………………………………………………………………………..………7
POWERPART recommended consumable products……………………………………………………..……8
Specifications
Basic engine data……………………………………………………………………………………………..….10

Data and dimensions……………………………………………………………………………………………..11
Thread sealant……………………………………………………………………………………………..……..28
Standard torque values…………………………………………………………………………………………..29
Specific torque values……………………………………………………………………………………………30
Compression test data………………………………………………………………………………………......33
Cylinder head assembly
General description………………………………………………………………………………………….……34
Atomiser cover
Operation 3-1 To remove and to fit……………………………………………………………………35
Rocker cover
Operation 3-2 To remove……………………………………………………………………………….35
Operation 3-3 To fit……………………………………………………………………………………...36
Rocker assembly
Operation 3-5 To dismantle and to assemble………………………………………………………..38
Operation 3-6 To inspect and to correct………………………………………………………..…….38
Valve tip clearances

Operation 3-7 To check and to adjust………………………………………………………..……….39
Valve springs
Operation 3-8 To change the valve springs (with cylinder head fitted)……………………………40

Operation 3-9 To remove………………………………………………………………………………42
Operation 3-10 To fit……………………………………………………………………………………44
Valves and valve springs

Operation 3-11 To remove……………………………………………………………………………..47
Operation 3-12 To fit……………………………………………………………………………………48
Operation 3-13 To inspect and to correct…………………………………………………………….49
Valve guides
Operation 3-14 To inspect………………………….…………………………………………………..50
Operation 3-16 To fit……………………………………………………………………………………52
CUKUROVA Model 885

Date Page III Section 70.01

Cylinder head
Operation 3-17 To inspect and to correct…………………………………………………………….54
Operation 3-18 To correct a valve seat with a valve seat cutter…………………………………...55
Operation 3-19 To fit valve seat inserts……………………………………………………………....57
Piston and connecting rod assemblies
General description……………………………………………………………………………………………….58
Big end bearing

Operation 4-1 To remove……………………………………………………………………………....60
Operation 4-2 To fit…………………………………………………………………………………......61
Operation 4-3 To inspect……………………………………………………………………………….61
Piston and connecting rod

Operation 4-4 To remove………………………………………………………… …………..............62
Operation 4-5 To fit…………………………………………………………………………………......63
Operation 4-6 To check the piston height above the cylinder block……………………………….64
Piston rings
Operation 4-8 To fit……………………………………………………………………………………..65
Piston and connecting rod assembly

Operation 4-9 To dismantle.........................................................................................................66
Operation 4-10 To assemble………………………………………………………………………......66
Operation 4-11 To check the length of a connecting rod…………………………………………...67
Piston and piston rings

Operation 4-12 To inspect……………………………………………………………………………...68
Connecting rod
Partially finished small end bush

Operation 4-14 To remove and to fit…………………………………………………………………..69
Piston cooling jets

Operation 4-15 To remove and to fit……………………………………………………………….....70
Operation 4-16 To check the jet alignment…………………………………………………………..70
Crankshaft assembly
Crankshaft pulley
Rear end oil seal assembly

Operation 5-2 To remove and to fit the rear end oil seal assembly………………………............73
Operation 5-3 To remove and to fit a wear sleeve…………………………………………………..77
Thrust washers
Operation 5-4 To check crankshaft end-float………………………………………………………..78
Operation 5-6 To fit……………………………………………………………………………………..80
Main bearings
Operation 5-7 To remove (with the crankshaft in position)…………………………………….......81
Operation 5-8 To fit (with the crankshaft in position)………………………………………………..82
Operation 5-9 To inspect……………………………………………………………………………….82
CUKUROVA Model 885

Date Page IV Section 70.01

Crankshaft
Operation 5-11 To fit……………………………………………………………………….……………84
Operation 5-12 To inspect……………………………………………………………….……………..85
Operation 5-14 To fit…………………………………………………………………………….………87
Balancer unit
Operation 5-15 To remove and to fit……………………………………………………….………….88
Operation 5-16 To dismantle (oil pump)……………………………………...………………………89
Operation 5-17 To assemble (oil pump) ……………………………………………………………..90
Timing case and drive assembly
Timing case cover

Operation 6-2 To fit……………………………………………………………………………………...93
Mechanical fuel pump gear

Operation 6-4 To fit…………………………………………………………………………………......95
Electronic fuel pump gear

Operation 6-6 To fit……………………………………………………………………………………..98
Idler gear and hub

Operation 6-7 To remove…………………………………………………………………………...….99
Operation 6-8 To fit……………………………………………………………………………………100
Operation 6-9 To remove and fit idler gear bushes………………………………………………..101
Heavy duty idler gear assembly

Operation 6-10 To dismantle…………………………………………………………………………102
Operation 6-11 To assemble…………………………………………………………………………102
Camshaft gear
Operation 6-12 To remove and to fit…………………………………………………………………103
Front oil seal

Operation 6-13 To remove……………………………………………………………………………104
Operation 6-14 To fit…………………………………………………………………………………..105
Operation 6-15 To fit a wear sleeve………………………………………………………………….106
Timing case
Operation 6-17 To fit…………………………………………………………………………………..108
Crankshaft gear
Camshaft and tappets

Operation 6-20 To fit…………………………………………………………………………………..111
CUKUROVA Model 885

Date Page V Section 70.01

Cylinder block assembly
General description……………………………………………………………………………………………..112
Cylinder block
Operation 7-1 To dismantle…………………………………………………………………………..112
Operation 7-2 To assemble…………………………………………………………………………..113
Operation 7-3 To inspect……………………………………………………………………….……..113
Cylinder bore
Engine timing
General description………………………………………………………………………………………….….115
Engine timing
Operation 8-1 To set number 1 piston to TDC on the compression stroke………………….….116
Operation 8-2 To check the timing of the Bosch VP30 fuel injection pump………………….....117
Operation 8-3 To check the timing of the Bosch EPVE fuel injection pump………………….…118
Operation 8-4 To adjust the timing of the Bosch EPVE fuel injection pump………………….…119
Operation 8-5 To check the timing of the Delphi DP210 fuel injection pump……………..........120
Operation 8-6 To check the valve timing……………………………………………………….…...121
Aspiration system
Aspiration system
Operation 9-1 To remove and to fit an exhaust elbow.……………………………………………123
Turbocharger side mounted

Operation 9-3 To fit……………………………………………………………………………………125
Operation 9-4 To check the operation of the waste-gate.………………………………………...126
Turbocharger faults…………………………………………………………………………..........…………127
Open engine breather

Operation 9-5 To remove and to fit the breather pipe……………………………………………..129
Naturally aspirated engine breather

Operation 9-6 To remove and fit the breather pipe……………………………………………......130
Closed engine breather

Operation 9-7 To clean and to renew………………………………………………………………..131
Lubrication system
General description……………………………………………………………………………………….........131
Lubrication system flow diagram………………………………………………………………………………132
Filter canister
Operation 10-1 To renew (canister type oil filter)…………………………………………………..133
Operation 10-2 To renew (element type oil filter)…………………………………………………..134
Filter head
CUKUROVA Model 885

Date Page VI Section 70.01

Sump
Operation 10-5 To fit…………………………………………………………………………………..136
Dipstick tube
Oil strainer and suction pipe

Operation 10-8 To inspect and to correct…………………………………………………………...139
Lubricating oil pump assembly

Operation 10-10 To fit…………………………………………………………………………………140
Operation 10-11 To inspect………………………………………………………………….………..141
Relief valve
Operation 10-12 To remove and to fit the relief valve of the balancer…………………………...141
Operation 10-13 To remove and to fit the relief valve of the lubricating oil pump………………142
Operation 10-14 To inspect the relief valve of the lubricating oil pump/balancer…………........142
Fuel system
Cold start advance unit (KSB)…………………………………………………………………………………145
Typical fuel system……………………………………………………………………………………………...146
Fuel filter assembly

Operation 11-1 To renew……………………………………………………………………………..147
Atomisers
Operation 11-2 To identify a faulty atomiser………………………………………………………..148
Operation 11-4 To fit…………………………………………………………………………………..150
Fuel lift pump and filter assembly

Operation 11-6 To test………………………………………………………………………………...152
Operation 11-7 To test pressure regulator……………………………………………………….....152
Air in the fuel system

Operation 11-8 To eliminate air from the fuel system…………………………………………......153
.
Bosch VP30 fuel injection pump……………………………………………………………………………154
Operation 11-1 0 To fit………………………………………………………………………………...157
Bosch EVPE fuel injection pump……………………………………………………………………………159

Operation 11-11 To remove……………………………………………………………………….….160
Operation 11-12 To fit…………………………………………………………………………………161
Delphi DP210 fuel injection pump…………………………………………………………………………..162

Operation 11-13 To remove…………………………………………………………………………..163
Operation 11-14 To fit…………………………………………………………………………………164
CUKUROVA Model 885

Date Page VII Section 70.01

Cooling system
Coolant flow diagram………………………………………………………………………………………..….166
Thermostat
Operation 12-2 To fit…………………………………………………………………………………..168
Operation 12-3 To test……………………………………………………………………………......169
Coolant pump
Operation 12-5 To fit…………………………………………………………………………….…….170
Fan
Fan drive
Lubricating oil cooler

Operation 12-10 To remove………………………………………………………………………..…174
Operation 12-11 To fit…………………………………………………………………………………175
Operation 12-12 To dismantle and to assemble……………………………………………………175
Operation 12 -13 To remove and to fit a coolant by-pass pipe…………………………………...176
Flywheel and housing
General description…………………………………………………………………………………………......177
Flywheel
Ring gear
Flywheel housing
Electrical equipment
Alternators
Operation 14-1 To check the drive belts………………………………………………………….…179
Operation 14-2 To adjust drive belt tension…………………………………………………………180
Operation 14-3 To remove and to fit the drive belts………………………………………………..180
Operation 14-4 To remove and to fit the alternator………………………………………………...181
Operation 14-5 To maintain…………………………………………………………………………..181
Operation 14-6 Fault diagnosis for the alternator…………………………………………………..181
Starter motors
Operation 14-8 To maintain the brush gear and the commutator ………………………………..183
Operation 14-9 To test on the engine………………………………………………………………..184
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Date Page VIII Section 70.01

Starting aid
Operation 14-10 To remove and to fit a glow plug…………………………………………………184
Operation 14-11 To check the glow plugs power supply continuity………………………………185
Operation 14-12 To check the operation of the glow plug………………………………………...185
Electronic components……………………………………………………………………………………….186
Operation 14-13 To remove and to fit the Engine Control Module (ECM)………………………188
Operation 14-14 To remove and to fit the Voltage Load Protection Module (VLPM)……….....190
Operation 14-15 To program a new ECM………………………………………………………..…191
Operation 14-16 To remove and to fit the speed and timing sensor……………………………..192
Operation 14-17 To remove and to fit a pressure sensor…………………………………...........193
Operation 14-18 To remove and to fit a temperature sensor…………………………….............195
Wiring harness………………………………………………………………………………………………….196
Operation 14-19 To repair a sensor connector……………………………………………….........198
Operation 14-20 To repair a Diagnostic, a ECM, or a MIC connector…………………………...199
Operation 14-21 To connect a new wire or connector to the wiring harness…………………...201
Auxiliary equipment
Power steering pump

Operation 15-1 To remove and to fit………………………………………………………………...202
Adaptor for a hydraulic pump or a steering pump

Exhauster
Special tools
List of special tools……………………………………………………………………………………………...205
CUKUROVA Model 885

Date Page IX Section 70.01

General Information
Introduction
This Workshop Manual has been written to provide assistance in the service and overhaul of Perkins 1100
Series 4 cylinder engines. It should be used in conjunction with normal workshop practice and information
contained in current service bulletins. Mention of certain accepted practices therefore, has been purposely
omitted in order to avoid repetition. For overhaul procedures the assumption is made that the engine is
removed from application.
The engine conforms with USA (EPA/CARB) stage 2 and EEC stage 2 emissions legislation for agriculture,
construction and industrial applications.
Most of the general information which is included in the relevant has not been repeated in this workshop
manual and the two publications should be used together.
Where the information applies only to certain engine types, this is indicated in the text.
The details of some operations will be different according to the type of fuel injection pump which is fitted.
The specific pump type used can be found by reference to the manufacturer’s identification plate on the
pump body but, generally, the type of pump fitted is as shown below:
• Delphi- DP210 Series

• Bosch- VP30
• Bosch- EPVE
When reference is made to the ‘’ left’’ or ‘’ right’’ side of the engine, this is as seen from the flywheel end of
the engine.
Special tools have been made available and a list of these is given in Special tools. Reference to the
relevant special tools is also made at the beginning of each operation.
POWERPART recommended consumable products are listed under ‘’ POWERPART recommended

consumable products ‘’. Reference to the relevant consumable products is also made at the beginning of
each operation.
Data and dimensions are included in Specifications.
Read and remember the ‘’ Safety precautions ‘’. They are given for your protection and must be used at all
times.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Not: Is used where the information is important, but there is not a danger.
CUKUROVA Model 885


ENGINE VIEWS :
CUKUROVA Model 885


Engine Identification:
The Perkins 1100 series 4 cylinder engines have been designed for industrial, construction and agricultural
applications. There are a range of four cylinder engines with or without electronics, available in naturally
aspirated, turbocharged and air to air charge cooled models.
In this Workshop Manual, the different models are indicated by their code letters. The first two letters of the
engine number are indicated below:
RE Naturally aspirated
RF Naturally aspirated, electronic
RG Turbocharged
RH Turbocharged, electronic
RJ Turbocharged, charge cooled
RK Turbocharged, charge cooled, electronic
CUKUROVA Model 885


The Perkins 1100 Series 4 cylinder engines have been designed for agricultural, industrial and
construction applications.
The correct identification of the engine is by the full engine number.
The engine number is stamped on a label which is fastened to the left side (A2) of the cylinder block. An
example of an engine number is:
RE......*U.......*
If you need parts, service or information for your engine, you must give the complete engine number to your
Perkins Deale / Distributor. If there is a number in the area of the label marked TPL No, then this number
must also be given to your Perkins Dealer / Distributor.
Other identification labels fitted to the engineer include:
- A label (A1) with the fuel injection pump part numbers.

- An emissions legislation label (A3), (A6), (A7) and (C1) can be fitted in four different positions on the
engine.
- A ‘’ Ether ’’ warning label (A5) is fitted on the intake manifold.
- A “Caution please read label ‘’ (A4) is screen printed into the atomizer cover.
If a short engine has been fitted in service, two engine serial numbers and a TPL number are stamped on
the engine serial number label (B3).
The engine serial number plate (B) contains the following information:
- TPL number (1).

- Type (2).
- Serial number (3).
- List number (4).
CUKUROVA Model 885


Safety Precautions
These safety precautions are important. You must refer also to the local regulations in the country of
use.
Some items only refer to specific applications.
• Only use these engines in the type of application for which they have been designed.
• Don not change the specification of the engine.
• Do not smoke when you put fuel in the tank.
• Clean away fuel which has been split. Material which has been contaminated by fuel must be moved
to a safe place.
• Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
• Do not clean, and lubricating oil, or adjust the engine while it runs (unless you have had the correct
training; even then extreme care must be used to prevent injury).
• Do not make adjustments that you do not understand.
• Ensure that the engine does not run in a location where it can cause a concentration of toxic
emissions.
• Other persons must be kept at a safe distance while the engine or auxiliary equipment is in
operation.
• Do not permit loose clothing or long hair near moving parts.
• Keep away from moving parts during engine operation.
Warning! Some moving parts cannot be seen clearly while the engine runs.
• Do not operate the engine if a safety guard has been removed.

• Do not remove the filler cap, or any component of the cooling system while the engine is hot and
while the coolant is under pressure because dangerous hot coolant can be discharged.
• Do not allow sparks or fire near the batteries (especially when the batteries are on charge) because
the gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and
especially to the eyes.
• Disconnect the battery terminals before a repair is made to the electrical system.
• Only one person must control the engine.
• Ensure that the engine is operated only from the control panel or from the operator’s position.
• If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
• Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain
persons. Protect your hands with gloves or a special solution to protect the skin.
• The combustible material of some components of the engine ( for example certain seals) can
become extremely dangerous if it is burned. Never allow this burnt material to come into contact with
the skin or with the eyes, see ‘’Viton seals’’ for safety precautions.
• Do not wear clothing which is contaminated by lubricating oil. Do not put material which is
contaminated with oil into the pockets of clothing.
• Discard used lubricating oil in a safe place to prevent contamination.
• Ensure that the control lever of the transmission drive is in the ‘’ out-of-drive’’ position before the
engine is started.
• Use extreme care if emergency repairs must be made in adverse conditions.
• Read and use the instructions relevant to ‘’ Engine lift equipment’’.
• Always use a safety cage to protect the operator when a component is to be pressure tested in a
container of water. Fit safety wires to secure the plugs, which seal the hose connections of a
component which is to be pressure tested.
• Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical
help immediately.
• Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and items away
from the inlet and outlet ports of the turbocharger and prevent contact with the hot surfaces.
• Do not clean an engine while it runs. If cols cleaning fluids are applied to a hot engine, certain
components on the engine may be damaged.
• Fit only genuine Perkins parts.
CUKUROVA Model 885


Engine Lift Equipment
The maximum weight of the engine without coolant, lubricant or a gearbox fitted will vary for different
applications. It is recommended that lift equipment of the maximum capacity listed below is used:
Four cylinder engines 600 kg (1320 lbs)
Note: Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block,
cylinder head, balancer unit, flywheel housing, crankshaft and flywheel.
Before the engine is lifted:
• Always use lift equipment of the approved type and of the correct capacity to lift the engine. It is
recommended that lift equipment of the type shown in (A) is used, to provide a vertical lift directly
above the engine lift brackets (A1). Never use a single lift bracket to raise an engine.
• Check the engine lift brackets for damage and that they are secure before the engine is lifted. The
torque for the setscrews for the engine lift brackets is 44 Nm (33 lbf ft) 4,5 kgf m.
• To prevent damage to the rocker cover, ensure that there is clearance between the hooks and the
rocker cover.
CUKUROVA Model 885


Viton Seals
Some seals used in engines, and in components fitted to engines, are made of Viton. Viton is used by many
manufacturers and is a safe material under normal conditions of operation.
If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this
burnt material to come into contact with the skin or with the eyes.
If it is necessary to come into contact with components which have been burnt, ensure that the precautions
which follow are used:
• Ensure that the components have cooled.

• Use neoprene gloves and discard the gloves safely after use.
• Wash the area with calcium hydroxide solution and then with clean water.
• Disposal of components and gloves which are contaminated must be in accordance with local
regulations.
If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water
or with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.
Safety cautions when an engine is cleaned
Care should be taken, when an engine is cleaned with a high pressure cleaning system.
Cautions:
• Do not wash an engine while it runs or while it is hot. If cold cleaning fluids are applied to a hot
engine, certain components on the engine could be damaged.
• Leave the engine to cool for at least one hour and disconnect the battery connections before
cleaning.
• Do not wash any part of the fuel injection pump (FIP), cold start device, electrical shut off solenoid
(ESOS) or electrical connectors.
• Ensure that the alternator, starter motor and any other electrical components are shielded and not
directly cleaned by the high pressure cleaning system.
If theses cautions are ignored, the engine or certain components could be damaged, fail to operate and also
make the manufacturer’s warranty invalid.
CUKUROVA Model 885


POWERPART recommended consumable products
Perkins have made available the products recommended below in order to assist in the correct operation,
service and maintenance of your engine and your machine. The instructions for the use of each product are
given on the outside of each container. These products are available from your Perkins Dealer/ Distributor.
POWERPART Antifreeze
Protect the cooling system against frost and corrosion. Part number 21825166.
POWERPART Atomizer thread sealant
To seal the threads of the atomizer into the cylinder head. Part number 21825474.
.
POWERPART Easy Flush
Cleans the cooling system. Part number 21825166.
POWERPART Gasket and flange sealant
To seal flat faces of components where no joint is used. Especially suitable for aluminum components. Part
number 21820518.
POWERPART Gasket remover
An aerosol for the removal of sealants and adhesives. Part number 21820116.
POWERPART Graphite
To improve the grip of worn tools and fasteners. Part number 21820129.
POWERPART Hydraulic thread seal
To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic
systems. Part number 21820121.
POWERPART Industrial grade super glue
Instant adhesive designed for metals, plastics and rubbers. Part number 21820125.
POWERPART Lay-Up 1
A diesel fuel additive for protection against corrosion. Part number 1772204.
POWERPART Lay-Up 2
Protect the inside of the engine and of other closed systems. Part number 162811.
POWERPART Lay-Up 3
Protects outside metal parts. Part number 1734115.
CUKUROVA Model 885


POWERPART Metal repair putty
Designed for external repair of metal and plastic. Part number 21820126.
POWERPART Pipe sealant and sealant primer
To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately. Part
number 21820122.
POWERPART Radiator stop leak
For the repair of radiator leaks. Part number 21820127.
POWERPART Red rubber grease
Providers lubrication for the fitting of ‘’O’’ rings. Part number 21820221.
POWERPART Retainer (high strength)
To retain components that have an interference fit. Part number 21820638.
POWERPART Retainer (oil tolerant)
To retain components that have an interference fit, but is in contact with oil. Part number 21820603.
POWERPART Safety cleaner
General cleaner in an aerosol container. Part number 21820128.
POWERPART Silicone adhesive
An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets. Used for
sealing flange where oil resistance is needed and movement of the joint occurs. Part number 21826038.
POWERPART Silicone RTV sealing and jointing compound
Silicone rubber sealant that prevents leakage through gaps. Part number 1861108.
POWERPART Stud and bearing lock
To provide a heavy duty seal to components that have a light interference fit. Part number 21820119 or
21820120.
POWERPART Threadlock and nutlock
To retain small fasteners where easy removal is necessary. Part number 21820117 or 21820118.
POWERPART Universal jointing compound
Universal jointing compound that seals joints. Part number 1861117.
CUKUROVA Model 885


SPECIFICATIONS
Basic Engine Data
Number of cylinders:
RE,RF,RG,RH,RJ,RK ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 4
Cylinder arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ..In line
Cycle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... Four stroke
Direction of rotation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..... Clockwise from the front
Induction system:
RE,RF ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … . . Naturally aspirated
RG,RH ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . ... ... ... ... ..Turbocharged
RJ,RK . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Turbocharged, charge cooled
Combustion system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …. . Direct injection
Nominal bore:
RE,RF,RG,RH,RJ,RK .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 105 mm (4.133 in)
Stroke ... ... ... ... ... ..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 105 mm (5.00 in)
Compression ratio:
RE,RF ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19.3:1
RG,RH,RJ,RK .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18.2:1
Cubic capacity:
3
RE,RF,RG,RH,RJ,RK .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4,4 liters (268 in )
Firing order:
RE,RF,RG,RH,RJ,RK .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,3,4,2
Valve tip clearances (Cold):

Inlet … ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,20 mm (0.008 in)
Exhaust ... ... ... ... ... ... ..... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,45 mm (0.018 in)
(1)
Lubrication oil pressure
2 2
RE,RF,RG,RH,RJ,RK .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 300 kPa (43 lbf/in ) 3,0 kgf/cm
(1) Minimum at maximum engine speed and normal engine temperature
CUKUROVA Model 885


Data and dimensions
Note: This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all engines,
unless an engine type code is shown.
Cylinder head
Angle of valve seat :

-Intake ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 30° (120° included angle)
-Exhaust... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30° (120° included angle)
2 2
Leak test pressure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …. … 200 kPa (29 lbf/in ) 2,04 kgf/cm
Head thickness ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … … 117,95/118,05 mm (4.643/4.647 in)
RZ and Rmax to be measured to DIN EN ISO 4287
Surface finish of head face for cylinder head joint … … … … … … … … … … … Rz < 15um Rmax < 20um
Permissible wave depth:

W t <2,0 mm with a wave distance W d ≤ 4 um
Diameter of parent bore for valve guide :

- Intake ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 13,000/13,027 mm (0.5118/0.5129 in)
- Exhaust... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 13,000/13,027 mm (0.5118/0.5128 in)
Minimum permissible thickness after head face has been machined ... ... ... ... ... 117,20 mm (4.614 in)
Maximum permissible distortion of cylinder head face
A1 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,03 mm (0.0012 in)
A2 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,05 mm (0.0019 in)
A3 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,05 mm (0.0019 in)
A4 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,03 mm (0.0012 in)
CUKUROVA Model 885


Intake and exhaust valves
Intake valves
Diameter of valve stem ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 8,953/8,975 mm (0.3525/0.3533 in)
Clearance in valve guide ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,025/0,069 mm (0.001/0.0027 in)
Maximum permissible clearance in valve guide :

-Production limit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..... ............. ... 0,069 mm (0.0027 in)
-Service limit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …. ………... ... ... 0,13 mm (0.005 in)
Diameter of valve head ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …. 46,20/46,45 mm (1.819/1.829 in)
Angle of valve face ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...... … ... ... .... ... ... ... ... ... ... ... ... ... ... ... ... 30°
Full length ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ……………. 128,92/129,37 mm (5.076/5.093 in)
Seal arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Stem seal with integral seating washer
Depth of valve head below the face of cylinder head:

Production limit, RE and RF ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...... …. 0,58/0,84 mm (0.023/0.033 in)
Service limit, RE and RF ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . ... ... ... … …. 1,09 mm (0.043 in)
Production limit, RG,RH,RJ,RK ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..… . 1,58/1,84 mm (0.062/0.072 in)
Service limit, RG,RH,RJ,RK ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ... … … … 2,09 mm (0.082 in)
Exhaust valves
Diameter of valve stem... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ….. ... ... 8,938/8,960 mm (0.3519/0.3528 in)
Clearance in valve guide ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ... ... ... 0,040/0,84 mm (0.0016/0.033 in)
Maximum permissible clearance in valve guide:

- Production limit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . ... ... ... ... ... ... … … 0,84 mm (0.003 in)
- Service limit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . ... ... ... ... ... … … … 0,15 mm (0.006 in)
Diameter of valve head ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . ... ... ... 41,51/41,75 mm (1.634/1.644 in)
Angle of valve face ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ... ... ... ... ... ... ... ... ... ... ... ... … .. 30°
Full length... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … … ... 128,92/129,37 mm (5.075/5.093 in)
Seal arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ...Stem seal with integral seating washer
Depth of valve head below the face of cylinder head:

Production limit, RE and RF ... ... ... ... ... ... ... ... ... ... ... ... ... .. ... ... … … 0,53/0,81 mm (0.021/0.032 in)
Service limit, RE and RF ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … … … 1,06 mm (0.042 in)
Production limit, RG,RH,RJ,RK ... ... ... ... ... ... ... ... ... ... ... ...... ... … … … 1,53/1,81 mm (0.060/0.071 in)
Service limit, RG,RH,RJ,RK ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … … … . 2,06 mm (0.081 in)
CUKUROVA Model 885


Dimensions of recesses for valve seat inserts
Models RE and RF
Intake
A1 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9,910/10,040 mm (0.3902/0.3953 in)
A2 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … 47,820/47,845 mm (1.8827/1.8837 in)
A3 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … ….Radius 0,38 mm (0.015 in) maximum
Exhaust
A1 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...9,910/10,040 mm (0.3901/0.3951 in)
A2 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … 42,420/42,445 mm (1.6701/1.6711 in)
A3 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … … Radius 0,38 mm (0.015 in) maximum
Models RG , RH , RJ and RK
Intake
A1 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 10,910/11,040 mm (0.4295/0.4346 in)
A2 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47,820/47,845 mm (1.8827/1.8837 in)
A3 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Radius 0,38 mm (0.015 in) maximum
Exhaust
A1 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … 10,910/11,040 mm (0.4295/0.4346 in)
A2 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … 42,420/42,445 mm (1.6701/1.6711 in)
A3 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … …Radius 0,38 mm (0.015 in) maximum
CUKUROVA Model 885


Valve seat insert tool
Intake
A1 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 1,5 mm (0.06 in)
A2 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20 mm (0.80 in)
A3 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6,8/7,1 mm (0.267/0.279 in)
A4 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 100 mm (3.94 in)
A5 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38,10/38,30 mm (1.500/1.507 in)
A6 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46,25/46,50 mm (1.820/1.830 in)
A7 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Radius 1,4 mm (0.055 in) maximum
A8 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ... Radius 1,5 mm (0.06 in)
A9 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..... ... ... ... ... Radius 1,5 mm (0.06 in)
A10 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 8,77/8.80 mm (0.345/0.346 in)
Exhaust
A1 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 1,5 mm (0.06 in)
A2 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20 mm (0.80 in)
A3 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7,2/7,5 mm (0.283/0.295 in)
A4 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 100 mm (3.94 in)
A5 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34,38/34,38 mm (1.353/1.361 in)
A6 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41,75/42,00 mm (1.643/1.653 in)
A7 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Radius 1,4 mm (0.055 in) maximum
A8 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ... ... ... ... Radius 1,5 mm (0.06 in)
A9 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …. ... ... ... ... ... Radius 1,5 mm (0.06 in)
A10 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 8,77/8.80 mm (0.345/0.346 in)
CUKUROVA Model 885


Valve guides and valve springs
Valve guides
Inside diameter of partially finished guide... ... ... ... ... ... ... ... ... ... 8,250/8,350 mm (0.3248/0.3287 in)
Inside diameter of finished guide ... ... ... ... ... ... ... ... ... ... ... .... .. 9,000/9,022 mm (0.3543/0.3552 in)
Outside diameter:
-Intake ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 13,034/13,047 mm (0.5131/0.5137 in)
-Exhaust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 13,034/13,047 mm (0.5131/0.5137 in)
Interference fit of valve guide in cylinder head … ... ... ... ... ... ... 0,007/0,047 mm (0.0003/0.0019 in)
Full length …... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51,00/51,50 mm (2.008/2.028 in)
Protrusion from bottom of recess for valve spring ... ... ... ... ... ... ... 12,35/12,65 mm (0.486/0.498 in)
Valve springs
Fitted length:
Models RE and RF ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … 33,5 mm (1.319 in)
Models RG,RH,RJ and RK .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34,5 mm (1.358 in)
Load at fitted length:

Models RE and RF ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 254 n (57 lbf) 26,0 kgf
Models RG,RH,RJ and RK .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 229 n (51 lbf) 23,0 kgf
Number of active coils ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3.8
Number of damper coils ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0
Direction of coils ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Right hand
Tappets, rocker shaft, rocker levers
Tappets
Diameter of tappet stem ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18,987/19,012 mm (0.7480/0.7485 in)
Diameter of tappet bore in cylinder block … … ... ... ... ... ... ... ... ... 19,050/19,082 mm (0.7500/0.7513 in)
Clearance of tappet in cylinder block … ... ... ... ... ... ... ... ... ... … 19,050/19,082 mm (0.7500/0.7513 in)
Rocker shaft
Outside diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24,962/24,987 mm (0.9828/0.9837 in)
Rocker levers and bushes
Diameter of parent bore for rocker lever ... ... ... ... ... ... ... .... …... 25,013/25,051 mm (0.9848/0.9863 in)
Clearance between rocker lever bore and rocker shaft ... ... .... .... ..... 0,026/0,89 mm (0.0010/0.0035 in)
Maximum permissible clearance between rocker lever bore and rocker shaft ... ... … 0,17 mm (0.007 in)
CUKUROVA Model 885


Pistons and piston cooling jets
Pistons
Type ... . “Fastram” combustion bowl, re-entrant angle 80° (turbocharged), 70° (naturally aspirated)
Diameter of bore for gudgeon pin . ... ... ... ... ... ... ... ... ... ... ... 39,703/39,709 mm (1.5631/1.5633 in)
Height of piston above top face of cylinder block … … ... ... ... ... ... 0,21/0,35 mm (0.008/0.0137 in)
Width of groove for top ring:

Engine types RE and RF ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,58/2,60 mm (0.1015/0.1023 in)
Engine types RG, RH, RJ and RK ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Tapered
Width of groove for second ring . ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2,54/2,56 mm (0.0999/0.1007 in)
Width of groove for third ring ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 3,52/3,54 mm (0.1385/0.1393 in)
Piston cooling jets

2 2
Valve open pressure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 150/250 kPa (22/36 Ibf/in ) 1,5/2,5 kgf/cm
Piston rings
Top compression ring:

Engine types RE and RF ... ... ... ... ... ... ... ... ... ... ... ... Barrel face, molybdenum insert, rectangular
Engine types RG, RH, RJ and RK ... ... ... ... ... ... ... ... ... Barrel face, molybdenum insert, keystone
Second compression ring ... ... ... ... ... ... ... ... ... ... ... ... Taper face, cast iron , internal bottom chamfer
Oil scraper ring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Two piece coil spring loaded, chromium faced
Width of top ring:

Engine types RE and RF ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...... 2,47/2,49 mm (0.097/0.098 in)
Engine types RG, RH, RJ and RK ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ... ... ... ... ... ... Tapered
Width of second ring... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..2,47/2,49 mm (0.097/0.098 in)
Width of third ring … ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... 3,47/3,49 mm (0.1366/0.1374 in)
Clearance of top ring in groove:
Engine types RE and RF ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..... 0,09/0,13 mm (0.035/0.0051 in)
Engine types RG, RH, RJ and RK ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ….........Wedge
Clearance of second ring in groove... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,05/0,09 mm (0.002/0.003 in)
Clearance of third ring in groove... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,03/0,07 mm (0.0011/0.0027 in)
Gap of top ring.... ... ... ... .. . .. .. ... ... .. . ... . . ... ... . .... ... ... ... ……….0,30/0,55 mm (0.0118/0.0216 in)
Gap of second ring... ... ... ... ... ... ... ... ... ... .... ... ... .... ... ... ... ..........0,70/0,95 mm (0.0275/0.0374 in)
Gap of third ring ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ………. 0,30/0,55 mm (0.0118/0.0216 in)
CUKUROVA Model 885


Connecting rods and big end bearings
Connecting rods
Type ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …. .‘H’ shape section, wedge shape small end
Location of cap to connecting rod.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Fracture split
Diameter of parent bore for big end. ... ... ... ... ... ... ... ... ... ... ... ... .. 67,21/67,22 mm (2.6460/2.6465 in)
Diameter of parent bore for small end . ... ... ... ... ... ... ... ... ... ... ... ... ... 43,01/43,03 mm (1.693/1.694 in)
Length grades … … ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... F , G , H , J , K , L
Length between centers (parent bores) ... ... ... ... ... ... ... ... ... ... ... ... 219,05/219,10 mm (8.624/8.626 in)
Big end bearings
Type:
- Naturally aspirated engines ... ... ... ... ... ... ... ... ... ... ... 8x Steel back ,tin / aluminum bearing material
-Turbocharged engines bearing cap .. ... ... ... ... ... ... ... ... 4x Steel back ,tin / aluminum bearing material
-Turbocharged engines bearing rod. ... ... ... ... ... ... ... ... ... 4x Steel back ,loaded bronze bearing material
Width ... ... ... ... ... ... ... ... ... …. … … .... ... ... ... ... ... ... ... ... ... ... ... ... 31,55/31,88 mm (1.240/1.255 in)
Thickness at center of bearings. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1,835/1,842 mm (0.0723/0.0725 in)
Bearing clearance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,030/0,081 mm (0.0012/0.0032 in)
Available undersize bearings... ... ... ... ... ... 0,25 mm (-0.010 in); -0,50 mm (-0.020 in); 0,75 mm (-0.030 in)
Gudgeon pins and small end bushes
Gudgeon pins
Production:
Type ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … … … … Fully floating
Outside diameter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39,694/39,700 mm (1.5628/1.5630 in)
Clearance fit in piston boss... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...0,003/0,015 mm (0,0001/0,0006 in)
Small end bushes
Type ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … Steel back, lead bronze
Outside diameter … … … ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43,66/43,84 mm (1.7190/1.7259 in)
Inside diameter … … … … ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...39,723/39,738 mm (1.5638/1.5645 in)
Surface finish grade ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … … … .Ra 0,8 micrometer
Clearance between bush in small end and gudgeon pin... ... ... ... ... ... ...0,023/0,044 mm (0.0009/0.0017 in)
CUKUROVA Model 885


Crankshaft
Diameter of main journals. ... ... ... ... ... ... ... ... ... ... ... ... ... ... …… ... 76,159/76,180 mm (2.9984/2.9992 in)
Maximum wear and ovality on journals and crank pins... ... ... ... ... ... ……….. ... ... ... .. 0,04 mm (0.0016 in)
Width of center journal. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ……... 44,15/44,22 mm (1.738/1.741 in)
Width of all other journals.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. … … 39,24/39,34 mm (1.545/1.549 in)
Diameter of crank pins.. ... ... ... ... ... ... . .. ... ... ... ... ... ... ... ... ... ... ……… 63,47/63,49 mm (2.499/2.500 in)
Width of crank pins ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ………. 40,35/40,42 mm (1.589/1.591 in)
Diameter of flange.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ………. 135,27/135,32 mm (5.3257/5.3277 in)
Depth of recess for spigot bearing... ... ... ... ... ... ... ... ... ... ... ... .. ……… 20,40/20,60 mm (0.8031/0.8112 in)
Bore of recess for spigot bearing. ... ... ... ... ... ... ... ... ... ... ... ... ... …. …. 46,96/46,99 mm (1.8488/1.8488 in)
Crankshaft end-float... ... .. . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … … . 0,05/0,38 mm (0.002/0.015 in)
Maximum permissible end-float. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … … 0,51 mm (0.020 in)
Fillet radii of journals and crank pins… ... ... ... ... ... ... ... ... ... ... ... ... ... … … 3,68/3,96 mm (0.145/0.156 in)
Undersize journals and crank pins. ... … … - 0,25 mm (-0.010 in); -0,51 mm (-0.020 in); 0,76 mm (-0.030 in)
Crankshaft heat treatment
Induction hardened... ... ... ... ... ... ... ... ... .... .... ..... .. ... ... ... ... ... ... ... Part number 3131D074, 4114A006
Nitrocarburised... ... ... ... ... ... ... ... ... ... ... .... … … .... .. ... ... ... ... ... ... Part number 3131D072, 4114A005
Crankshaft overhaul
Notes:
- Nitrocarburised crankshafts must be hardened again each time they are machined. These crankshafts must
be Nitrocarburised or, if this process is not available, they can be nitrided for 20 hours. If neither process is
available a new crankshaft, or a ‘’ new for old’’ crankshaft, must be fitted.
- Check the crankshaft for cracks before and after it is ground. Demagnetize the crankshaft after it has been
checked for cracks.
- After the crankshaft for cracks before and after it is ground. Demagnetize the crankshaft after it has been
checked for cracks.
- After the crankshaft has been machined remove any sharp corners from the lubricating oil holes.
- Surface finish and fillet radii must be maintained and require Ra 0.4 um.
CUKUROVA Model 885


The finished sizes for crankshaft journals (A) which have been ground undersize are given in the table
below:
Item 0,25 mm 0,51 mm 0,76 mm

(0.010 in) (0.020 in) (0.030 in)
1 75,909/75,930 mm (2.9884/2.9892 in) 75,649/75,670 mm 75,399/75,420 mm
(2.9784/2.9792 in) (2.9684/2.9692 in)
2 63,220/63,240 mm (2.488/2.4896 in) 62,960/62,982 mm 62,708/62,728 mm
(2.4788/2.4796 in) (2.4688/2.4696 in)
3 39,47 mm (1.554 in) max. --- ---
4 37,44 mm (1.474 in) max. --- ---
5 44,68 mm (1.759 in) max. --- ---
6 40,55 mm (1.594 in) max. --- ---
7 Do not machine --- ---
8 Do not machine --- ---
9 3,68/3,69 mm (0.1448/0.1452 in) --- ---
Surface finish for journals, crank pins and fillet radii must be 0,4 microns ( 16 micro inches). Surface finish for
the seal area of the crankshaft palm must be 0,4/1,1 microns (16/43 micro inches).
CUKUROVA Model 885


With the crankshaft on mountings at he front and rear journals, the maximum run-out (total indicator reading)
at the journals must not be more than shown below:
Journal Maximum run-out

1 Mounting
2 0,08 mm (0.0031 in)
3 0,15 mm (0.0059 in)
4 0,08 mm (0.0031 in)
5 Mounting
Run-out must not be opposite. The difference in run-out between one journal and the next must not be
more than 0, 10 mm (0,004 in).
Run-out on the crankshaft pulley diameter, rear oil seal diameter and the rear flange diameter must not
be more than 0,05 mm (0,002 in) total indicator reading.
Main bearings
Type ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Steel back with, tin / aluminum bearing material
Bearing width
All bearings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31,62/31,88 mm (1.244/1.255 in)
Bearing thickness at center. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,083/2,089 mm (0.0820/0.823 in)
Bearing clearance
All bearings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,057/0,117 mm (0.0022/0.0046 in)
Available undersize bearings… … ... ..- 0,25 mm (-0.010 in); -0,51 mm (-0.020 in); 0,76 mm (-0.030 in)
Crankshaft thrust washers
Type ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … … Steel back bearing material
Position ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Each side of center main bearing
Thickness :
-Standard ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,26/2,31 mm (0,089/0,091 in)
-Oversize… … … … … … ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2,45/2,50 mm (0,096/0,098 in)
Balancer unit
Number of teeth on gear of drive shaft ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 17
Backlash from gear of drive shaft to idler gear … ..... ... ... ... ... ... ... 0,097/0,17 mm (0.0038/0.0066 in)
Diameter of bore for idler gear. ... ... ... ... ... ... ... ... ... ... ... ... ... 37,197/37,212 mm (1.5431/1.5437 in)
Diameter of hub of idler gear ... ... ... ... ... ... ... ... ... ... ... ... ... 37,152/37,162 mm (1.4626/1.4630 in)
End-float of idler gear ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,12/0,27 mm (0.0047/0.0106 in)
Number of teeth on idler gear... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44
Lubricating oil pump on the balancer
Type ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Differential rotor, gear driven
Number of lobes:
Inner rotor … ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4
Outer rotor… .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4
Clearance of outer rotor to body… ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,13/0,23 mm (0.005/0.009 in)
Clearance of inner rotor to outer rotor.. ... ... ... ... ... ... ... ... ... ... ... ... 0,05/0,20 mm (0.0020/0.0079 in)
End clearance
Inner rotor … … .. ... ... ... ... ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... 0,032/0,125 mm (0.0013/0.0049 in)
Outer rotor .... …. … . ... ... ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... 0,032/0,125 mm (0.0013/0.0049 in)
CUKUROVA Model 885


Timing case and drive assembly:
Camshaft
Diameter of number 1 journal ... ... ... ... ... ... ... ... ... ... ... .. ... ..... ... 50,711/50,737 mm (1.9965/1.9975 in)
Diameter of number 2 journal ... ... ... ... ... ... ... ... ... ... ... .. ..... ... ... 50,457/50,485 mm (1.9865/1.9875 in)
Diameter of number 3 journal. ... ... ... ... ... ... ... ... ... ... ... .. ..... ... ... 49,949/49,975 mm (1.9865/1.9675 in)
Cam lift:
Intake for models RE , RF ... ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... 7,382/7,482 mm (0.2906/0.2946 in)
Intake for models RG , RH , RJ , RK ... ... ... ... ... ... .. ... ... ... ... ... ... ... 7,031/7,13 mm (0.2768/0.2807 in)
Exhaust for models RE , RF ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... ... 7,404/7,504 mm (0.2914/0.2954 in)
Exhaust for models RG , RH , RJ , RK. .. ... ... ... ... ... .. ... ... ... ... ... ... 7,963/8,063 mm (0.3135/0.3174 in)
Maximum permissible ovality and wear on journals.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,05 mm (0,21 in)
End-float:
-Production limits ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,10/0,55 mm (0,004/0,022 in)
-Service limits … . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,60 mm (0,023 in)
Width of spigot for thrust washer... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5,64/5,89 mm (0,222/0,232 in)
Camshaft thrust washer
Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 360°
Depth of recess in cylinder block for thrust washer. ... ... ... ... ... …. ... ... ... 5,54/5,64 mm (0,218/0,222 in)
Thickness of thrust washer. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ….. .. ... 5,486/5,537 mm (0,216/0,218 in)
Relationship of thrust washer to front face of cylinder block... … ... .-0,154/-0,003 mm (-0,0006/-0,0001 in)
Camshaft gear
Number of teeth ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 68
Diameter of bore ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …... ... 34,92/34,95 mm (1,3750/1,3760 in)
Outside diameter of the camshaft hub... ... ... ... ... ... ... ... ... ... …... ... 34,90/34,92 mm (1,3741/1,3747 in)
Fuel pump gear electronic engines
Number of teeth... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 68
Bore ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …….. ... ... 29,995/30,021 mm (1,417/1,419 in)
Fuel pump gear mechanical engines
Number of teeth. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … 68
Bore ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …... ... ... 36,00/36,06 mm (1,1809/1,1819 in)
Crankshaft gear
Number of teeth... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 34
Diameter of bore... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …... .. 47,625/47,650 mm (1,8750/1,8760 in)
Diameter of hub for gear on crankshaft . ... ... ... …….... ... …... .... 47,625/47,645 mm (1,8750/1,8758 in)
Transition fit of gear on crankshaft... ... ... ... ... ... ... ... ... …... ….-0,020/+0,020 mm (-0,0008/+0,0008 in)
CUKUROVA Model 885


Idler gear and hub
Number of teeth... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ....73
Diameter of bore of gear... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …. ...57,14/57,18 mm (2.2495/2.2512 in)
- with roller bearings... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... 72,35/72,36 mm (2.8482/2.8489 in)
Width of gear and split bush assembly (fitted in position)... .. ... .... ... .30,14/30,16 mm (1.186/1.187 in)
Inside diameter of flanged bushes (fitted in position) ..........................50,78/50,80 mm (1.9999/2.000 in)
Outside diameter of hub..... ... ... ... ...................................................50,70/50,74 mm (1.9990/1.9999 in)
- with needle roller bearings... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …49,975/49,988 mm (1.967/1.968 in)
Clearance of bushes on hub... ... ... ... ... ... ... ... ............. ... ... .. ......... 0,04/0,1 mm (0.0016/0.0039 in)
Timing gear backlash values :
- Production limits... ... ... ... ... ... ... ... ... ... ... ... .. ... ... ... ... ... ... .. ... ....0,10/0,20 mm (0.004/0.008 in)
- with needle roller bearings... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0,10/0,75 mm (0.0039/0.295 in)
- Service limit.... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …..0,38 mm (0,015 in)
Timing gear backlash values
Oil pump gear (with oil pump idler)……….. ... ... ... ... ... .... ... …. ... . 0,046/0,106 mm (0.0018/0.0041 in)
Oil pump idler gear (with crankshaft gear) ………………………..………,095/0,160 mm (0.0037/0.0063 in)
Crankshaft gear (with idler gear)………………………………….……...0,064/0,124 mm (0.0025/0.0049 in)
Camshaft gear (with idler gear)……………………………………..……0,052/0,1 07 mm (0.0020/0.0042 in)
Power take off LHS (PTO) gear (with idler gear)………………..……...0,112/0,172 mm (0.0044/0.0068 in)
Fuel injection pump gear (with idler gear) ………………………..……..0,054/0,109 mm (0.0021/0.0043 in)
Coolant pump gear (with fuel injection pump gear)…………….………0,073/0,133 mm (0.0028/0.0052 in)
Cylinder block
Height between top and bottom faces………………………….441,073/441,374 mm (17.3657/17.3769 in)

Diameter of cylinder bore…………………………………………...105,000/105,025 mm (4.1338/4.1348 in)
Diameter of first oversize cylinder bore…………………………...105,500/105,525 mm (4.1535/4.1545 in)
Diameter of second oversize cylinder bore ……………………...106,000/106,025 mm (4.173214.1742 in)
Maximum permissible cylinder bore wear ………………………………………………. 0,15 mm (0.0059 in)
Diameter of parent bore for main bearing …………………………...80,416/80,442 mm (3.1660/3.1670 in)
Camshaft bore diameter
Number 1 (for bush) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 55,563/55,593 mm (2.188/2.189 in)
Number 2 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 50,546/50,597 mm (1.990/1.992 in)
Number 3 ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... … 50,038/50,089 4mm (1.969/1.972 in)
CUKUROVA Model 885


Turbocharger
The make and type and part number of turbocharger fitted is marked on the turbocharger identification plate.
that is fitted to the turbocharger body.
As a general guide, the make and type of turbocharger fitted is : Garrett GT25
Waste-gate test pressure for rod movement of 1.00 mm (O.039 in)
Turbocharger Waste-gate pressure

(kPa) (Ibf/in²) (kgf/cm²)
part number
(+/- 5) (+/- 0.72) (+/- 0.05)
2674A200 100 14.5 1,01
2674A201 110 15.9 1,12
2674A202 128 18.5 1,30
2674A209 100 14.5 1,01
2674A211 128 18.5 1,30
2674A215 128 18.5 1,30
2674A223 136 19.7 1,38
2674A224 136 19.7 1,30
2674A225 136 19.7 1,38
2674A226 100 14.5 1,01
2674A227 128 18.5 1,30
CUKUROVA Model 885


Lubrication system
Canister type oil filter
Type………………………………………………………………………………Full flow, screw-on type canister

2
Pressure to open by-pass valve in filter ………………………………………………80/120 kPa (16/24Ibffin )
Element type oil filter
Type …………………………………………………………………………………Full flow, replaceable element

2
Pressure to open by-pass valve in filter………………………………………………130/170 kPa (26/12Ibf/in )
Lubricating oil pump
Type…………………………………………………………………………………...Differential rotor, gear driven
Number of lobes:
- Inner rotor …………………………………………………………………………………………………………..5

- Outer rotor…………………………………………………………………………………………………………..6
Clearance of outer rotor to body…………………………………………...0,152/0,330 mm (0.0059/0.0129 in)

End clearance
- Inner rotor …………………………………………………………………..0,038/0,089 mm (0.0014/0.0035 in)
- Outer rotor…………………………………………………………………..0,025/0,076 mm (0.0010/0.0029 in)
Idler gear for lubricating oil pump
End float………………………………………………………………………0,050/0,275 mm (0.0019/0.0108 in)

Inside diameter of bush (fitted)………………………………………….16,012/16,038 mm (0.6303/0.6314 in)
Outside diameter of idler shaft…………………………………………..15,966/15,984 mm (0.6285/0.6292 in)
Clearance of bush of idler gear on shaft…………………………………..0,028/0,072 mm (0.0011/0.0028 in)
Oil pressure relief valve (oil pump)
Diameter of bore for plunger……………………………………………19,250/19,300 mm (0.7578/0.7598 in)

Outside diameter of plunger ………………………………………….19,186/19j211 mm (0.75553/0.7563 in)
Clearance of plunger in bore …………………………………………….0,0;39/0, 114mm (0.0015/0.0044 in)
Length of spring (fitted) ……………………………………………………………………..59,8 mm (2.3543 in)
Load on spring (fitted) turbocharged with lubricating oil cooler…………………….121 N (27.1 Ibf) 12,0 kgf
Load on spring (fitted) naturally aspirated without lubricating oil cooler …………..90,9 N (20.1 Ibf) 9.2 kgf
Oil pressure relief valve (balancer)
Diameter of bore for ……………………………………………………….14,52/14,54 mm.(0.5716/0.5724 in)

Outside diameter of plunger……………………………………………….14,46/14,48 mm (0.5692/0.5700 in)
Clearance of plunger in bore…………………………………………………0,04/0,08 mm (0.0015/0.0031 in)
Length of spring (fitted) …………………………………………………………………………..45 mm (1.77 in)
Load on spring (fitted) Turbocharged………………………………………77/84 N (17.3118.9Ibf) 7,8/8,5 kgf
Load on spring (fitted) Naturally aspirated oil cooled…………………….70/77 N (15.7/17.3 Ibf) 7,1/7,8 kgf
Load on spring (fitted) Naturally aspirated non oil cooled …………………59/65 N (13.3/14.6Ibf) 6.0/6,6 kg
CUKUROVA Model 885


Cooling system
Coolant pump
Type .........................................................................................................................Centrifugal gear driven

Outside diameter of shaft ................................................................21,425/21,438 mm (0.8435/0.8440 in)
Diameter of bore of drive gear .........................................................21,375/21,400 mm (0.8415/0.8425 in)
Interference fit of drive gear on shaft ...................................................0,025/0,063 mm (0.0009/0.0024 in)
Diameter of bore of impeller ............................................................11,943/11,971 mm (0.4701/0.4712 in)
Outside diameter of shaft for impeller .............................................11,997/12,008 mm (0.4723/0.4727 in)
Interference fit of impeller on shaft ......................................................0,026/0,065 mm (0.0010/0.0025 in)
Diameter of bore for bearing ...........................................................39,989/40,014 mm (1.5743/1.5753 in)
Diameter of bearing .........................................................................39,989/40,000 mm (1.5743/1.5747 in)
Interference fit of bearing in pump body (transition fit) ................... +0,025/-0,011 mm (0.0009/-0.0005 in)
Dimension of impeller boss to front face of pump body (fitted) ................. 7,030/7,33 mm (0.276/0.288 in)
Dimension of gear from rear flat face of pump body (fitted) ....................31,60/32,10 mm (1.244/1.263 in)
Fan drive housing
Bore of housing for bearing .............................................................61,986/62,005 mm (2.4403/2.4411 in)
Outside diameter of bearing ............................................................61,987/62,000 mm (2.4404/2.4409 in)
Interference fit of bearing in housing ................................................ 0,014/-0,018 mm (0.0006/-0.0007 in)
Outside diameter of shaft ................................................................25,002/25,011 mm (0.9843/0.9846 in)
Maximum permissible end-float of shaft .................................................................... 0,200 mm (0.0079 in)
Thermostat
Type:
- Single ........................................................................................................ Wax element, by-pass blanking
Nominal temperature stamped "Start to open" "Fully open" Minimum valve

Part number
on thermostat by- pass valve temperature temperature lift fully open
2485C034 82 ᑻC 79/84 ᑻC 93 ᑻC 10mm
CUKUROVA Model 885


Fuel system
Bosch fuel injection pump

Type ......................................................................... Bosch VP30 electronic, pin timed, with a locking screw
Direction of rotation from drive end ....................................... .............................. Clockwise from drive end
Type ................... ….. ....................................................................................... EPVE, with a locking screw
Direction of rotation from drive end ..................................................................... Clockwise from drive end
Delphi fuel injection pump
Type .................................................................................................................DP210, with a locking screw
Direction of rotation from drive end ..................................................................... Clockwise from drive end
Fuel lift pump
Type ............................................................................................................................. Electrically operated
Method of drive ....................................................................................................... Electric motor 12v / 24v
Blue fuel filter
Type ...................................................................................................................................... Single element
Green fuel filter
Type ...................................................................................................................Replaceable paper element
Atomiser service settings
Set and reset pressure

Colour code Holder Nozzle
atm (Ibf/in²) MP
Yellow 2645A321 2645A611 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Blue 2645A321 2645A612 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Red 2645A322 2645A613 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Black 2645A322 2645A614 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
White 2645A322 2645A612 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Limits for flywheel housing run-out and alignment (total indicator reading)
Diameter of housing flange bore Maximum limit (total indicator reading)

mm in mm in
410 16.14 0,25 0.010
CUKUROVA Model 885


Alternators
Note: The information which follows is general and can change with specific applications.
Make and type . ................... , ................................……………. ................................................... .……Denso
Rating:
Denso A115i 12V ............................ ...... ………………………………………….…12V/65A, 12V/75A,12V/ 85A
Denso A127i 24V ............................ ...... ……………………………..12V/100A, 12V/120A, 24V/55A, 24V/ 80A
Rotation …………………………………………………………………………Clockwise from the drive end
Starter motors
Note: The information which follows is general and can change with specific applications.
Make and type ………………………………………………………………………………………………..Denso
Voltage:
Denso P95RL ………………………………………………………………………………………..12V 3.0 kW rhs
Denso R4.5 ………………………………………………………………………………………..24V 4,5 kW rhs
Number of teeth on pinion …………………………………………………………………………………………..10
Maximum starter cable resistance at 200 DC (680 ᑻF):
- 12V………………………………………………………………………………………………………0.0017 ohms
- 24V………………………………………………………………………………………………………0.0034 ohms
Starting aids
The information which follows is general and can change with specific applications.
Type…………………………………………………………………………………………………………Glow plugs
Voltage………………………………………………………………………………………………………12V or 24V
CUKUROVA Model 885


Thread sealant
When setscrews or studs are fitted into holes which are tapped through the cylinder block, a suitable sealant
must be used to prevent leakage.
Micro encapsulated anaerobic sealant (M.E.A.S.) fasteners have been introduced instead of jointing
compounds or other sealants when the fasteners are fitted in through holes into oil or coolant passages. The
identification of these fasteners. as supplied, is by a red, blue, or other color sealant around the fastener
threads.
With M.E.A.S. sealed studs, the sealed end must be fitted into the cylinder head I cylinder block etc. Ensure
that the threaded holes have a 1,59 mm (0.0625 in) 45° chamfer, to ensure that when the new fasteners are
fitted the M.E.A.S. sealant is not removed. If the fasteners have to be removed and fitted again. the threads
must be cleaned and a suitable sealant used.
Note: New setscrews have sealant applied by the manufacturer to the first 13,0 mm (0.50 in) of the threads.
If the setscrews are to be used again, clean the old sealant from the male and female threads and apply new
sealant, (POWERPART Threadlock and Nutlock) to the setscrews
CUKUROVA Model 885


Standard torque values
Most of the torque values on the engine are standard. Special torque values are listed in the separate
special torque tables. The standard torque values listed in the tables below can be used when a special
torque is not necessary.
The torque values below apply to components lubricated with a little clean engine oil before they are fitted.
Standard torques for setscrews and nuts
Torque
Thread size
Nm Ibf ft Kgf m
M6 x 1,00 9 7 0,9
M8 x 1,25 22 16 2,2
M10 x 1,50 44 32 4,5
M12 x 1,25 78 58 8,0
M14 x 2,00 124 92 13,0
M16 x 2,00 190 140 19,3
Standard torques for studs (metal end)
Torque
Thread size
Nm Ibf ft Kgf m
M6 x 1,00 5 4 4
M8 x 1,25 11 8 1,1
M10x 1,50 18 13 1,8
M12x 1,75 25 18 2,5
Standard torques for pipe unions, plugs, and adaptors
Torque
Thread size inches
Nm Ibf ft Kgf m
1/8 PTF 9,5 7 0,9
1/4 PTF 17 12 1,7
3/8 & 1/2 PTF 30 22 3,0
3/4 PTF 45 33 4,6
CUKUROVA Model 885


Specific torque values
The torque values below apply to components lubricated with a little clean engine oil before they are fitted.
Special torques for setscrews and nuts
Torque
Description Thread size
Nm Ibf ft Kgf m
Setscrew cylinder head See Operation 3-10
Torx screw, rocker shaft M8 35 26 3,5
Lock nut, rocker lever adjustment 3/8 UNF 27 20 2,7
Fastener, rocker cover M6 9 7 0,9
Setscrew, heatshield to cover M6 9 7 0,9
Setscrew, exhaust manifold to cylinder head M10 33 24 3,3
Setscrew, fracture split connecting rod See Operation 4-2
Crankshaft assembly
Setscrews, main bearings 5/8 UNF 245 180 25
Setscrew, crankshaft pulley 7/16 UNF 115 85 12
Allen screws, bridge piece to cylinder block M6 16 12 1,6
Torx screw, rear end oil seal housing M8 22 16 2,2
Setscrews, balancer to cylinder block M10 54 39 5,5
Setscrew, camshaft gear M12 95 70 9,7
Setscrew, PTO blanking plate plastic M10 22 16 2,2
Setscrew, plastic oil filler M8 22 16 2,2
CUKUROVA Model 885


Thread Torque
Description
size Nm Ibf ft Kgf m
Cylinder block
Plug, compressor oil feed M10 22 16 2,2
Plug, oil rail rear face 7/8 UNF 68 50 7,0
Plug, front feet M12 46 34 4,6
Plug, turbocharger feed M10x1 19 14 1,9
Plug, coolant drain 1/4 NSPM 40 29 4,0
Fuel system
Nuts, high-pressure fuel pipes M12 30 22 3,0
Setscrew, atomiser clamp M8 35 26 3,5
Nut, fuel injection pump 10 gear (mechanical) M14 88 65 9,0
Setscrews, gear 10 fuel injection pump electronic M8 22 16 2,2
Setscrew, timing case to fuel injection pump M8 25 18 2,5
Locking screw on shaft of Bosch fuel injection
M10 31 23 3,1
pump
Locking screw in run position of Bosch fuel
M10 12 9 1,2
injection pump
Locking screw on shaft of DP 210 fuel injection
M12 17 12 1,7
pump
Locking screw in run position of DP 210 fuel
M12 12 9 1,2
injection pump
Lubrication system
Plug, lubricating oil sump G 3/4 34 25 3,4
Oil inspection valve M10 x 1 12 9 1,2
Oil inspection valve plug M10 x 1 12 9 1,2
Nut, dipstick tube M16 18 13 1,8
Element oil filter 31/2ACME 25 18 2,5
Cooling system
Setscrews, fan drive housing to cylinder head M10 44 32 4,5
Setscrews, fan drive pulley 10 hub M8 12 9 1,2
Setscrews, fan M8 12 9 1,2
Engine types RE, RF, RG, RJ and RH
1/2 UNF 105 77 10,7
Setscrews. flywheel to crankshaft
Engine type RK
1/2 UNF 115 85 11,7
Setscrews, flywheel to crankshaft
Setscrews, cast iron flywheel housing to cylinder
M10 44 32 4,5
block.
- Head stamped 8.8 M12 7 55 7,6
- Head stamped 10.9 M10 63 46 6,4
- Head stamped 10.9 M12 115 85 11,7
Setscrews, flywheel housing to cylinder block
M10 70 52 7,1
(paper joint)
Aspiration system
Nuts, turbocharger to manifold M10 47 35 4,8
Banjo bolt, turbo feed M10x1 22 16 2,2
Fastener, breather pipe to cylinder head M6 9 7 0,9
CUKUROVA Model 885


Thread Torque
Description
size Nm Ibf ft Kgf m
Sensor, engine oil pressure M12x 1,5 10 7 1,0
Plug, engine oil pressure M12 x 1,5 12 9 1,2
Sensor, inlet manifold temperature M18 20 15 2,0
Plug, inlet manifold temperature M18 20 15 2,0
Sensor, inlet manifold pressure M12 10 7 1,0
Plug, inlet manifold pressure M12 10 7 1,0
Sensor, coolant temperature M18 20 15 2,0
Plug, coolant temperature M18 20 15 2,0
Setscrew, ECM plug to ECM. M5 6 4 0,6
KSB 1/2 PTF 30 22 3,0
Glow plug to cylinder head M10 18 13 1,8
Nut, bus-bar to grow plug M4 2 1 0,2
Nut, alternator pulley:
- CAV AC5RA and AC5RS
- Thin nut A127, and Motorola pulley, 22 mm A/F
- Thick nut A127, and Motorola pulley, 24 mm A/F M16 80 59 8,1
- Bosch 55A
- Bosch 55A
- Butec 5524
Nut, starter motor M10 44 32 4,5
CUKUROVA Model 885


Compression test data
Tests have shown that many factors affect compression pressures. Battery and starter motor condition,
ambient conditions and the type of gauge used can give a wide variation of results for a given engine.
It is not possible to give accurate data for compression pressure, but tests have shown that the results
should be within 2000/3500 kPa (300/500 Ibf/in²) 21,0/35,0 kgf/cm² for diesel engines.
Compression tests should only be used to compare between the cylinders of an engine. If one or more
cylinders vary by more than 350 kPa (50 IbfJin2) 3,5 kgf/cm² then those cylinders may be faulty.
Compression tests should not be the only method used to show the condition of an engine, but they should
be used together with other symptoms and tests.
How to do a compression test
Caution: Before the compression test, ensure that the battery is in good condition and that it is fully charged.
Also ensure that the starter motor is in good condition.
1 Ensure that the valve tip clearances are set correctly, see Operation 3-7.
2 Remove the atomisers, see Operation 11-3.
3 Fit a suitable gauge into the atomiser hole of the cylinder to be tested.
Warning! Ensure that the engine cannot start.
4 Operate the starter motor and record the pressure indicated on the gauge for each cylinder.
CUKUROVA Model 885


General description
In a diesel engine there is little carbon deposit and for this reason the number of hours run is no indication of
when to overhaul a cylinder head assembly. The factors which indicate when an overhaul is necessary are
how easily the engine starts and its general performance.
The cast iron cylinder head is fastened to the cylinder block by flanged head setscrews. The cylinder head
gasket is a multi-layer construction. The individual inlet and exhaust ports are designed to assist air swirl and
improve air flow.
The intake manifold is integral within the cylinder head, and the rocker cover also contains the engine
breather pipe.
The cylinder head assembly has two overhead valves fitted for each cylinder. Each overhead valve is held in
place by a single coil spring, cap, and two collets. The face angle of the intake and the exhaust valves are
both 30°. The cylinder head has steel valve seat inserts fitted for both the intake and the exhaust valves, and
these can be renewed. The angles of the valve seats in the-cylinder head for the intake and the exhaust
valves are both 30°. The valves move in sintered steel valve guides which can also be renewed. The
exhaust valve guides have a counterbore to prevent seizure of the valve stem caused by a build up of
carbon under the head of the valve. Each valve stem is fitted with a synthetic rubber oil seal.
The overhead valves are operated by a rocker shaft assembly fitted to the top of the cylinder head and under
a composite rocker cover. The forged steel rocker levers are operated by cold drawn push rods with
hardened heads. The rocker shaft is secured to the cylinder head by sintered steel brackets between each
pair of valves. The rockers and valve gear are lubricated by an oil now from the hollow rocker shaft that
receives a reduced oil flow from the camshaft oil feed.
Tappet adjustment is achieved by adjustment screws and locknuts at the Push rod end of each rocker lever.
CUKUROVA Model 885


Atomiser cover
To remove and to fit Operation 3 - 1
To remove
1- Remove the atomiser cover setscrews (A1) and remove the atomiser cover (A2).
To fit
1- Fit the atomiser cover (A2) and tighten the setscrews (A1) to 9 Nm (7 Ibf ft) 0,9 kgf m.
Rocker cover
To remove Operation 3 - 2
Note: If a top mounted turbocharger is fitted, the heat shield must be removed first.
1 Remove the atomiser cover, see Operation 3-1

2 Remove the breather pipe, see Operation 9-5 or Operation 9-6.
3 Release the fasteners (A), remove the rocker cover and discard the joint.
CUKUROVA Model 885


To fit Operation 3 - 3
Note: Reflective heat shields fitted to the rocker covers must be kept clean and free from dust, all or paint. If
the surface of the heat shield is not shiny, the component that is protected by the heat shield could be
damaged.
1 If the rocker cover has an oil filler, check the condition of the 0-ring, renew as required.
2 Ensure that the rocker cover and the groove for the joint are clean and free from oil and grease.
3 Fit a new joint (A1) to the rocker cover.
4 Check the condition of the fasteners (B), renew as required.
5 Clean the seal face of the cylinder head and fit the rocker cover.
6 Secure the rocker cover to the cylinder head with the fasteners and tighten in sequence (C) to 9 Nm (7Ibfft)
0.9 kgf m.
7 Fit the breather pipe, see Operation 9-5 or Operation 9-6 .
CUKUROVA Model 885


Rocker assembly
Special requirements
Special tools
Description Part number
Rocker assembly tools 27610227
To remove
1 Remove the atomiser cover, see Operation 3-1.

2 Remove the rocker cover, see Operation 3-2.
3 Fit the rocker assembly tools between each pair of rocker levers (A1).
4 Release evenly and gradually the Torx screws of the rocker shaft; begin with the end Torx screws and
move toward the centre. Remove the Torx screws and lift off the rocker assembly.
To fit
Note: Ensure that the machined square is facing upwards before the rocker assembly is fitted and that the
longest Torx screw is fitted in (A2).
1 Check that the push rods fit correctly in the sockets of the tappets and ensure that the rocker assembly
tools are correctly fitted between each pair of rocker levers (A1). Fit the rocker assembly. Check that the
ends of the adjustment screws fit correctly in the sockets of the push rods.
2 Fit the Torx screws for the rocker shaft and tighten the Torx screws 35 Nm (26 Ibf ft) 3,6 kgf m; begin with
the inner Torx screws and work outwards.
3 Set valve tip clearance. see Operation 3-7.
4 Fit the rocker cover, see Operation 3-3.
5 Fit the atomiser cover, see Operation 3-1 .
CUKUROVA Model 885


To dismantle and to assemble Operation 3 - 5
To dismantle
1 Remove the circlips from both ends of the rocker shaft. Ensure that the ends of the rocker shaft are not
damaged.
2 Dismantle the assembly and make a note of the position of each component to ensure that they can be
assembled in the same position.
To assemble
1 Ensure that the oil holes in the rocker shaft and in the rocker levers are not restricted.
2 Lubricate the components with clean engine lubricating oil before assembly. Assemble the components in
the correct order. Fit the circlips to the ends of the rocker shaft.
To inspect and to correct Operation 3 - 6
To inspect
1 Clean and inspect all the components for wear and any other damage.
2 Check the clearance of the rocker levers on the rocker shaft. If the clearance is greater than 0.13 mm
(0.005 in), renew the rocker lever and/or the rocker shaft.
CUKUROVA Model 885


Valve tip clearances
To check and to adjust Operation 3 - 7
The valve tip clearances are checked between the top of the valve stem and the rocker lever (A), with the
engine cold. The correct clearance for intake valves is 0.20 mm (0.008 in) and 0,45 mm (0.018 in) for
exhaust valves. The valve positions are shown at (B).
The sequence of valves from number 1 cylinder is shown in the table below.
Note: Number 1 cylinder is the furthest cylinder from the flywheel end of the engine.
1 Rotate the crankshaft in the normal direction of rotation until the intake valve (B7) of number 4 cylinder has
just opened and the exhaust valve (B8) of the same cylinder has not closed completely. Check the
clearances of the valves (B1 and B2) of number 1 cylinder and adjust them, if necessary.
Note: The correct torque for the locknut on the adjusting screws is 27 Nm (20 lbf ft) 2,8 kgf m.
2 Set the valves (B3 and 84) of number 2 cylinder as indicated above for number 4 cylinder. Then check/
adjust the clearances of the valves (B5 and B6) of number 3 cylinder.
3 Set the valves (B1 and B2) of number 1 cylinder. Then check/adjust the clearances of the valves
(B7 and B8) of number 4 cylinder.
4 Set the valves (B5 and B6) of number 3 cylinder. Then check/adjust the clearances of the valves
(B3 and B4) of number 2 cylinder.
Note: After the valve tip clearances have been adjusted, lubricate the rocker assembly with clean engine oil.
Apply particular attention to the rocker shaft bearing surfaces, valve tips; push rod sockets and the
push rods so that the oil will drain to lubricate the cam followers.
Cylinder 1 2 3 4
and
Valve number 1 2 3 5 6 7 8
4
Valve
I = Intake I E I E I E I E
E = Exhaust
CUKUROVA Model 885


Valve springs
To change the valve springs (with cylinder head fitted) Operation 3 - 8
Special tools
Description Part number Description Part number
Valve spring compressor 21825666 Setscrew adaptor used with 27610235
21825666
Note: Steps 1 to 11 refer to a change of valve spring for a single cylinder.
Warning! Wear eye protection during this operation.

3 Rotate the crankshaft in the normal direction of rotation until the intake valve of the relevant cylinder has
just opened and the exhaust valve has not fully closed. In this position the piston will be at approximately
top dead centre (TDG).
4 Remove the rocker assembly, see Operation 3-4.
5 Fit the valve spring compressor (A1) and the adaptor (A2).
Caution: Ensure that the valve spring is compressed squarely or damage can occur to the valve stem.
Note: Do not over compress the valve springs so that coils are touching.
6 Compress the valve spring and remove the collets. Ensure that the valve spring is compressed squarely or
damage to the valve stem can occur.
Caution: Do not rotate the crankshaft while the valve spring is removed.
7 Release the valve spring compressor and remove the valve spring, cap and valve seal. Note: The valve
stem seal must only be used once.
8 Ensure that the new valve stem seal is clean, not damaged and that the spring is present and correctly
located on the seal.
9 Lubricate the valve 'stem with clean engine oil. Fit the valve stem seal onto the valve guide and ensure
that, the seal and the seating washer are correctly located.
10 Put the new valve spring in position, ensure that the larger diameter is against the cylinder head.
CUKUROVA Model 885


11 Fit the valve spring cap
Note: Do not over compress the valve springs so that coils are touching.
12 Fit the valve spring compressor, compress the valve spring and fit the collets. Remove the valve spring
compressor.
13 Fit the rocker assembly, see Operation 3-4.
14 Check the valve tip clearances, see Operation 3-7.
Note: If other or all of the valve springs are to be changed, they can be changed two cylinders at a time. The
sets of cylinders are 1 and 4, 2 and 3.
If the rocker assembly has been removed, piston TOC can be found as follows:
1 Fit the valve spring compressor and compress the valve springs to open the valve.
2 Rotate the crankshaft. by hand. in the normal direction of rotation until the piston touches the valve.
Note: Ensure that the collets are fully located before the pressure is released on the valve spring
compressor.
3 Continue to rotate the crankshaft, and at the same time, release pressure on the valve spring compressor
until the piston is at TOC (B).
CUKUROVA Model 885


1 Drain the cooling system.

2 Disconnect the battery terminals.
3 Remove the air filter I cleaner hose at the intake manifold.
4 For engines fitted with a boost control device, remove the boost control pipe that is fitted between the
intake manifold and the top of the fuel injection pump.
5 For engines fitted with a turbocharger, disconnect all connections to the turbocharger and remove the
turbocharger, see Operation 9-2.
6 Release the exhaust manifold fasteners in the reverse sequence to that shown in (A).
7 Remove the low-pressure fuel pipes which are fitted between the fuel injection pump and the fuel lift pump
with integral fuel filter.
8 Remove the fuel lift pump with integral fuel filter.
Caution: Where access to the fuel injection pump outlet unions is possible, ensure that a separate spanner
is used to prevent movement of the fuel injection pump outlets when the connections of the high-
pressure pipes are released. Fit suitable covers to all open connections on the fuel injection pump.

10 Remove the high-pressure fuel pipes.
11 Remove the atomiser leak-off hoses.
12 Remove the atomisers, see Operation 11-3. Fit suitable covers to the nozzles and the open connections.
13 Remove the bus-bar and glow plugs.
14 Release the setscrews of the coolant by-pass pipe at the timing case. Remove the coolant by-pass pipe
from the cylinder head.
15 Disconnect the coolant temperature sensor/sender unit
17 Remove the rocker assembly, see Operation 3-4
18 Remove the push rods.
CUKUROVA Model 885


19 Release the cylinder head setscrews evenly and gradually in the reverse sequence to that shown in (B).
20 Check the setscrews for distortion with a straight edge (C1) held along the setscrew (C2). If there is a
visual reduction in the diameter of the thread that has not been in engagement with the cylinder block,
the setscrew must be discarded.
Caution: Do not use a lever to separate the cylinder head from the cylinder block, as this may damage the
face of either the cylinder head or the cylinder block.
21 Remove the cylinder head and put it on a surface that will not damage the bottom face of the cylinder
head.
22 Remove the cylinder head gasket.
CUKUROVA Model 885


To fit Operation 3-10
Special tools
Angle gauge (to tighten cylinder head setscrews) 21825607
1 With a suitable cleaner, clean thoroughly the bottom face of the cylinder head and the top face of the
cylinder block. Hard carbon and corrosion can be removed with a hard plastic or hard wood scraper.
Ensure that the top face of the cylinder block and the bottom face of the cylinder head are free from
scratches or other damage and there is no debris in the cylinder bores, see "Cylinder head" .
Note: The engines have two location pins (A2), one at each end of the cylinder head, pressed into the
cylinder block to hold the cylinder head and cylinder head gasket in the correct position when the
cylinder head is fitted.
Cautions:
- To prevent damage to the cylinder head gasket, ensure that the location pins are pressed in the cylinder
block before the cylinder head is fitted.
- The cylinder head gasket must be fitted without jointing compound.
2 Fit a new cylinder head gasket in the correct position.

3 To ensure the cylinder head is fitted into the correct position, fit two suitable M15 guide studs (A1). Put the
cylinder head in position. Ensure that the two location pins are fully engaged in the cylinder head.
4 Apply a small amount of lubricant to the threads and the thrust faces of the cylinder head setscrews.
Engage the seven short setscrews in positions 2, 5, 6, 7, 8. 9, 10, then remove the guide studs(A1). Fit the
three long setscrews in positions 1, 3, 4.
5 Tighten the setscrews to 50 Nm (37 Ibf ft) 5,1 kgf m in the sequence shown in (B).
6 Tighten the setscrews to 100 Nm (74Ibf ft) 10,0 kgf m in the sequence shown in (B).
CUKUROVA Model 885


7 Tighten the setscrews, in the correct sequence, a further part of a turn according to the length of the
setscrews. Short setscrews (S) must be turned a further 225°. Long setscrews (L) must be turned a further
270°. A special tool (C) can be used for this operation.
Fit the tool between the socket and the handle. Position the stop (C1) against a suitable protrusion on the
cylinder head to prevent movement of the degree dial in a clockwise direction. Rotate the pointer to align
with the relevant angle on the degree dial for the length of setscrew. Tighten the setscrew until the pointer on
the tool is aligned with the zero position on the degree dial.
If no tool is available, make a suitable mark on the cylinder head in line with a corner of each setscrew (D).
Make another mark, at the correct angle (counter-clockwise). on the edge of the flange of each fastener
according to the length of the setscrew. Tighten each setscrew in the correct sequence until the marks on
the flange are next to, and in line with, the marks on the cylinder head.
8 Put the push rods in position. Ensure that the end of each push rod fits correctly in the tappet socket.
10 Set the valve tip clearances, see Operation 3-7.
11 Fit the atomisers, see Operation 114.
12 Fit the atomiser leak-off hoses.
13 Fit the glow plugs and bus-bar, see Operation 14-10.
14 Fit the high-pressure fuel pipes; tighten the connection nuts to 22 Nm (16 Ibf-ft)2,2 kgf m.
Caution: Where access to the fuel injecti9n pump out/et unions is possible; ensure that a separate spanner
is', used to prevent movement of the fuel injection pump outlets when the connections of the high
"pressure pipes" are tightened.
15 Fit the fuel lift pump with integral fuel filter and the bracket. Fit the low-pressure fuel pipes between
the-fuel-injection pump and the fuel lift pump with integral fuel filter.
16 Fit the coolant by-pass pipe ,see operation 12-13
CUKUROVA Model 885


17 Fit two suitable temporary studs (E1) then fit the exhaust manifold joint (E2).
Caution: Damage to the exhaust manifold can occur if not aligned and tightened correctly.
18 Fit the exhaust manifold and the fasteners, lightly tighten the fasteners 1 and 2 (F).
19 Remove the two temporary studs, fit the remaining fasteners and lightly tighten.
20 Evenly and gradually tighten the exhaust manifold fasteners to 33 Nm (24 Ibf ft) 3,4 kgf m in the
sequence shown (F).
21 For engines fitted with turbochargers, fit the turbocharger. see Operation 9-3.
22 Connect the electrical connection to the cold start device.
23 For engines fitted with a boost control device, fit the boost control pipe between the intake manifold and
the top of the fuel injection pump.
24 Fit the electrical connection to the coolant temperature sensor/sender unit.
25 Connect the coolant outlet and the hoses for the cab heater. Tighten the clips.
26 Fin the cooling system.
27 Connect the air filter/cleaner.
28 Connect the battery.
29 Eliminate air from the fuel system. see Operation 11-8.
30 Start the engine and run it at low speed. Check that oil flows from the holes in the rocker lavers. If the oil
flow is correct, fit the rocker cover, see Operation 3-3.
Note: It is not necessary to tighten the cylinder head setscrews again with the engine hot or after a limited
period in service.
CUKUROVA Model 885


Valves and valve springs
Special tools
Valve spring compressor 21825666 Setscrew adaptor used with 21825666 27610235
Warning: Wear eye protection during this operation
1 Remove the cylinder head, see Operation 3-9.
2 Clean the bottom face of the cylinder head and check the depth of the heads of the valves below the face
of the cylinder head, see Operation 3-13.
3 Make a suitable mark on the heads of the valves to ensure that the valves can be fitted in their original
positions, if they are to be used again.
Caution: Ensure that the valve springs are compressed squarely or the valve stem can be damaged. Note:
Do not over compress the valve springs so that coils are touching.
4 Use the valve spring compressor and the relevant adaptor to compress the valve spring (A3) and remove
the collets (A1).
5 Release the valve spring compressor and remove the valve spring cap (A2), valve spring and valve stem
seal (A4).
6 Repeat steps 4 and 5 for the other valves.
CUKUROVA Model 885


Special tools
Valve spring compressor 21825666 Setscrew adaptor used with 21825666 27610235
Warning: Wear eye protection during this operation
Cautions:
- Valves must not be lapped, as the special heat resistant layer on the face of the valve will be destroyed.
- If inlet valves are badly worn or damaged they must be replaced.
Note: The intake valve has a larger diameter head than the exhaust valve.
1 Lubricate the valve stem (A5) with clean engine oil and fit the valves in their respective guides.
Note: The valve stem seal must only be used once.
2 Fit new valve stem seals (A4) on the valve guides.
3 Put the valve springs in position, ensure that the larger diameter is against the cylinder head. Fit the valve
spring cap (A2).
4 Use the valve spring compressor and the relevant adaptor to compress the valve spring (A3) and fit the
collets (A1).
CUKUROVA Model 885


Special tools
Gauge, valve depth 21825496 Dial gauge for use with 21825496 21825617
1 Ensure that the heads of the valves and the bottom face of the cylinder head are clean.
2 Put the valve depth gauge on the face of the cylinder head and zero the dial gauge.
3 Carefully put the valve depth gauge in position over the head of each valve (A) and make a note of the
measurement. The maximum depth, in service, is given in the relevant Data and dimensions for the
"intake and exhaust valves”.
4 If a valve is below the depth limit, check the valve depth with a new valve in position. If the valve depth is
still below the limit the valve seat insert must be renewed, see Operation 3-19.
5 Check the valves for cracks. Check the stems of the valves for wear and for correct fit in their valve guides.
Cautions:
Valves must not be lapped, as the special heat resistant layer on the face of the valve will be destroyed.
If inlet valves are badly worn or damaged they must be replaced.
6 Check that the seat faces of the valves are not badly burnt or damaged. Seat faces of valves which are
damaged can be ground on a special machine. When new valves are fitted, the valve depths must be
checked after the valve springs are fitted.
7 Check that the load on the valve springs is correct at their fitted length, refer to the relevant Data and
dimensions for the 'Valve guides and valve springs". Fit new valve springs at every complete engine
overhaul.
CUKUROVA Model 885


Valve guides
To inspect Operation 3 - 14
To check the valve guides for wear. The maximum permissible clearance (A5) with a valve lift of 15,0 mm
(0.6in), between the valve stem and the bore of the guide is 0,22 mm (0.009 in) for intake valves and 0.25
mm (0.010 in) for exhaust valves. If the clearance, with a new valve fitted, is more than the limit, then a new
valve guide (A4) must be fitted.
It is recommended that the procedure given below is used to check the valve guide clearance:
1 Put a new valve in the valve guide.
2 Put a dial test indicator with a magnetic base (A1) onto the face of the cylinder head.
3 With the valve lifted 15,0 mm (0.6 in) and the gauge (A2) in contact with the edge of the valve head (A3),
move the valve radially away from the gauge. With the valve held in this position. set the gauge to zero.
4 Move the valve radially across the axis of the cylinder head towards the gauge. Make a note of the reading
on the gauge. If the reading is equal to or greater than the data given above, a new valve guide (A4) must
be fitted.
CUKUROVA Model 885


Special tools
Remover/replacer for valve guides 21825478 Adaptor used with 21825478 21825479
1 Fit the adaptor (A4) into the remover/replacer tool (A3).
2 With the adaptor fitted to the tool, put the spacer (A5) in position on the tool. Pass the adaptor (A4) through
the valve guide (A6) and put the spacer and tool in position on the valve seat.
3 Fit the attachment (A7) to secure the adaptor to the valve guide.
4 Hold the top handle (A1) and turn the bottom handle (A2) clockwise to pull the valve guide out of the
cylinder head.
CUKUROVA Model 885


Special tools
Remover/replacer for valve guides 21825478 Adaptor used with
27610234
Adaptor used with 21825478 21825479 21825478 and 21825479
Note: The partially finished valve guides are reamed and the valve seats are cut in one operation with a
special tool. The valve seat and the guide are cut in one operation to ensure the concentricity of the
valve seat to the valve guide. This will ensure a good seal between the guide and its seat. New valves
and new valve seat inserts must be fitted each time a new valve guide is fitted. Valves must not be
lapped. If all or most of the original valve guides need to be renewed it may be cost effective to
overhaul or exchange the cylinder head.
1 Clean the parent bore in the cylinder head for the valve guide.
2 Lubricate the outer surface of the new valve guide (A6) with clean engine lubricating oil.
3 Fit the adaptor (A5) into the remover/replacer tool (A3).
4 With the adaptor fitted to the tool, put the spacer (A4) in position on the tool. Pass the adaptor through the
cylinder head and put the spacer and tool assembly in position on the valve seat.
CUKUROVA Model 885


5 Put the valve guide in position on the adaptor and fit the adaptor (B7). Fit the attachment (B8) to secure the
valve guide to the adaptor.
6 Hold the top handle (B1) and turn the bottom handle (B2) clockwise to pull the valve guide until the
distance piece contacts the cylinder head.
7 When the valve guide is fitted correctly, the top of the valve 'guide will have a protrusion (B9) of
12,35/12,65 mm (0.486/0.498 in) above the valve spring seat.
8 Ream the valve guide to the finished size, see Operation 3-18.
CUKUROVA Model 885


Cylinder head
Inspection and to correct Operation 3 - 17
1 Remove the cylinder head assembly, see Operation 3-9.
2 Remove the thermostat housing, see Operation 12-1.
3 Inspect the cylinder head for signs of gas or coolant leakage.
4 Remove the valve springs and the valves, see Operation 3-11.
5 Clean the face of the cylinder head and the passages for coot ant and for lubricating oil. The coolant jacket
can be cleaned with a special solvent which must be used in accordance with the manufacturer's
instructions.
6 Test the cylinder head for leaks at the pressure given in the relevant Data and dimensions for the
"Cylinder head".
7 When the cylinder head is thoroughly clean, check it for cracks. Inspect carefully the areas around the
valve seats and around the holes for the atomiser nozzles.
Caution: Remove only the minimum material and ensure that the thickness of the cylinder head will not be
less than 117.20mm (4.614 in) after the cylinder head has been machined.
8 The bottom face of the cylinder head can be machined if there is distortion, or deep scratches, see step 9.
9 Use a straight edge and feeler gauges to check the cylinder head for distortion. Refer to the relevant Data
and dimensions for the "Cylinder head".
If the distortion is more than the given limit, the bottom face can be machined. Refer to the relevant Data and
dimensions for the "Cylinder head" the surface grade finish of the cylinder head face.
Cautions: After the cylinder head has been machined the valve seats must be corrected to give the correct
valve head depth. Work to the minimum limit to allow for later wear.
10 Check the valve seats for wear and for damage.
11 Before any work is done on the valve seats, new valve guides must be fitted, see Operation 3->16.
12 Badly damaged valve seats can be corrected by use of the cutter tool, see Operation 3-18, or new inserts
can be fitted, see Operation 3-19.
CUKUROVA Model 885


To correct a valve seat with a valve seat cutter Operation 3 - 18
Special tools
Cutter (30°) for Inlet and exhaust valve
27610030
seats and valve guide reamer
Caution: Valves must not be lapped.

Note: The partially finished valve guides are reamed and the valve seats are cut in one operation with a
special tool. The valve seat and the guide are cut in one operation to ensure the concentricity of the
valve seat to the valve guide. This will ensure a good seal between the guide and its seat. New valves
and new valve seat inserts must be fitted each time a new valve guide is fitted. Valves must not be
lapped. If all or most of the original valve guides need to be renewed it may be cost effective to
overhaul or exchange the cylinder head.
1 Before any work is done on the valve seats, new valve guides must be fitted, see Operation 3-16.
Cautions:
- Ensure that the correct cutter is fitted, for 30° valve seats.
- Ensure that the valve seat cutter is not allowed to fall onto the seat as this can damage the blades.
Note: The intake valve has a larger diameter head than the exhaust valve
2 Select the relevant valve seat cutter, 30° (A2) and the valve guide reamer (A1). Set the blades of the
cutters to the diameter of the valve seat to be cut, see "Intake and exhaust valves".
CUKUROVA Model 885


Note: The blades of the reamer must not cut the valve guide when the seat is cut.
3 Fit the cutter onto the reamer and push the handle fully onto the reamer. Ensure that the flat part of the
reamer shank is towards the Allen screw. Tighten the Allen screw to secure the reamer to the handle.
4 Fit the reamer/cutter assembly into the valve guide. Ensure that the valve seat cutter is not allowed to fall
onto the seat as this can damage the blades. Carefully turn the handle in a clockwise direction (B3) and
gradually move the reamer into the valve guide until the valve guide is reamed to the finished size. A
lubricant is not necessary.
5 Continue to turn the handle in a clockwise direction to cut the valve seat. Remove only the minimum
material to ensure a good valve seat. Keep the seat as narrow as possible.
6 When the seat is cut, remove the reamer/cutter assembly. Remove any debris from the area of the valve
guide, valve seat and the port.
7 Fit the valve, see Operation 3-12.
8 Check that the valve depth is within limits. refer to the relevant Data and dimensions for the "Intake and
exhaust valves".
Note: If a valve seat has become too damaged or too worn to correct, a valve seat insert can be fitted, see
Operation 3-19. If all or most of the original valve seat inserts need to be renewed, it may be cost
effective to overhaul or exchange the cylinder head.
CUKUROVA Model 885


To fit valve seat inserts Operation 3 - 19
1 Remove the valve guide, see Operation 3-15. and clean the. bare into which the guide is to be fitted.
2 Fit new partially finished valve guides, see Operation 3-16.
3 With the bore of the new partially finished valve guide used as a pilot, machine the recess in the cylinder
head to the dimensions shown in "Dimensions of recesses for valve seat inserts", or machine out the old
insert. Remove all debris and clean the insert recess.
4 If the bottom face of the cylinder head has been machined, the insert will have to be surface ground on the
back face to ensure that there is no protrusion of the insert above the bottom face of the cylinder head.
After the back of the insert has been ground, ensure that the outer edge of the back face has a 0.9/1,3 mm
(0.035/0.051 in) chamfer at 30° to the vertical.
5 With the bore of the new, partially finished, valve guide used as a pilot, and with the rear face of the insert
towards the cylinder head, press in the insert with the valve seat insert tool, see "Valve seat insert tool".
Caution: Do not use a hammer on the insert and do not use lubrication.
Use a hydraulic press or a hand press in one continuous movement. Ensure that the bottom of the insert is in
contact with the bottom of the recess.
6 Ream the valve guide and cut the valve seat at an included angle of 120° for 30° valve seats,
see Operation 3-18.
Ensure that the depth of the valve head below the face of the cylinder head is within the production limits,
refer to the relevant Data and dimensions for the "Intake and exhaust valves".
Note: Work as near as possible to the minimum value to allow for future wear on the valve seal
CUKUROVA Model 885


General description
The pistons used in the 1100 Series 4 cylinder engines have a combustion chamber in the top of the piston.
Piston (A) is for models RE. RF. and piston (B) is for models RG, RH, RJ, and RK. The combustion chamber
is designed to give an efficient mix of fuel and air.
The pistons and connecting rods are matched to the relevant cylinder.
The pistons have two compression rings and an oil control ring. 'The groove for the top ring has a hard metal
insert to reduce wear of the groove. The piston skirt has a layer of graphite to improve the wear
characteristics.
Axial location of the fully floating gudgeon pin is by circlips, The gudgeon pin is off-centre to reduce the
noise level.
Piston cooling jets are fitted in the cylinder block to spray lubricating oil onto the inner surface of the pistons.
The correct piston height is important to ensure that the piston does not contact the cylinder head and to
ensure the efficient combustion of fuel.
The piston height is controlled by the length of the connecting rod. There are six length grades of connecting
rods used to obtain the correct piston height.
To obtain the different grades, the small-end bush is machined oft-centre. The amount that the bush is
off centre gives the different length grades.
CUKUROVA Model 885


In service, a partially finished small-end bush is available, which can be fitted to the original connecting rod
and machined to obtain the correct length grade, see Operation 4-14. Specialist equipment and personnel
with the correct training are needed to machine the partially finished small-end bush. Connecting rod kits are
also available with the small end bush fitted and machined to obtain the correct connecting rod grade.
Notes:
- If the crankshaft or the cylinder block is to be renewed, it may be necessary to change the grade of the
connecting rods, see Operation 4-11. This will occur if the correct piston height above the cylinder block
face cannot be maintained with the original connecting rod assemblies, see Operation 4-6.
- Always use the engine identification number to order new parts.
The connecting rod is a one-piece forging that is fractured hydraulically to split the big end cap from the
connecting rod. This process produces rough but accurately matched surfaces (C1).
CUKUROVA Model 885


Big end bearing
1 Drain the engine lubricating on.

2 Remove the lubricating oil sump, see Operation 10-4.
3 Remove the lubricating oil pump, see Operation 10-9 or remove the balancer unit, see Operation 5-15.
4 Release the fasteners (A4) and remove the bearing cap (A3).
Caution: Do not stamp or punch the connecting rod assembly, as this could cause a fracture.
5 Mark the bearing cap and the connecting rod with the cylinder number to ensure correct assembly.
Caution: Engine models RG, RH, RJ and RK have a different shell bearing fitted to the cap and connecting
rod. Ensure that the relevant shell bearing is kept with the correct cap or connecting rod.
6 Rotate the crankshaft until the relevant connecting rod is at its lowest position.
7 Remove the shell bearing (A5) from the cap (A3). Keep the bearing with the cap.
8 Carefully push the connecting rod up the cylinder bore just enough to allow access to the upper half of the
shell bearing. Remove the shell bearing (A6) from the connecting rod (A1). Keep the bearing with the
connecting rod.
Caution: Do not allow the connecting rod to hit the piston cooling jet, if fitted.
CUKUROVA Model 885


1 Clean the bearing faces of the connecting rod and the crank pin.
Cautions:
- Engine models RG, RH, RJ and RK have a different shell bearing fitted to the cap and connecting rod.
Ensure that the relevant shell bearing is kept with the correct cap or connecting rod.
- Do not stamp or punch the connecting rod assembly, as this could cause a fracture.
2 Clean the complete bearing and lubricate the bearing surface and the crank pin with clean engine
lubricating oil.
3 Fit the upper half of the shell bearing to the connecting rod; ensure that the bearing shell is fitted centrally
(A1). Fit the connecting rod to the crank pin. Ensure that the forged marks (B1) face to the front of the
engine.
Note: The fasteners used with these connecting rods must only be used once.
4 Clean, lubricate and fit the lower half of the shell bearing into the cap; ensure that the bearing shell is fitted
centrally (A1). Fit the connecting rod fasteners. Fit the cap to the connecting rod. Ensure that the assembly
has both of the forged marks on the same side (B1).
5 Tighten the new fasteners to an initial torque of 18 Nm (13 Ibf ft) 1,9 kgf m.
6 Tighten the new fasteners to 70 Nm (52 Ibf It) 7,1 kgf m. The fasteners must then be tightened a further
1200
7 Ensure that the crankshaft rotates freely.
8 Fit the lubricating oil pump, see Operation 10-10, or fit the balancer unit, see Operation 5-15.
9 Fit the lubricating oil sump, see Operation 10-5 and fill the sump to the correct level with lubricating oil of
an approved grade.
1 Check the bearings and the crank pin for wear or other damage.
CUKUROVA Model 885


Piston and connecting rod
1 Drain the lubricating all and the cooling system.
2 Remove the cylinder head assembly, see Operation 3-9.
3 Remove all carbon from the top of the bores of the cylinders.
4 Remove the lubricating oil sump, see Operation 104.
5 Remove the lubricating oil pump, see Operation 10-9 or remove the balancer unit, see Operation 5-15.
Cautions:
Do not stamp or punch the connecting rod assembly, as this could cause a fracture
The pistons and connecting rods are matched to the relevant cylinder. Mark each connecting rod and piston
with the cylinder number to ensure correct assembly.
6 Remove the big end caps and the big end bearings from the connecting rods, see Operation 4-1.
Caution: Do not allow the connecting rods to hit the piston cooling jets. If a cooling jet is hit, renew it if
necessary.
7 Rotate the connecting rods 90° to prevent contact with the piston cooling jets. Push the pistons and the
connecting rods out through the top of the cylinder liners. Keep the bearings and caps together to ensure
that they can be fitted in their original positions.
8 Inspect the crank pins for damage.
CUKUROVA Model 885


To fit Operation 4- 5
Special tools
Piston replacer tool 21825491
1 Ensure that the piston, the cylinder bore, the crank pin and the big end of the connecting rod are clean.
Lubricate the piston and the cylinder bore with clean engine lubricating oil.
2 Rotate the crankshaft until the relevant crank pin is at its lowest position. Lubricate the crank pin with clean
engine lubricating oil.
3 Fit the upper half of the shell bearings to the connecting rod. Ensure that the bearing shell is fitted
correctly, see Operation 4-2. Lubricate the bearing with clean engine lubricating oil.
4 Put the piston replacer tool in position at the top of the relevant cylinder. The tool has a tapered bore to
compress the piston rings when the piston and connecting rod assembly is fitted. Ensure that the smaller
end of the tapered bore is towards the face of the cylinder block.
5 Put the piston ring gaps 120ᑻ apart. Pass the connecting rod through the piston replacer tool and allow the
piston to enter the tool. The arrow mark on the top of the piston (B) must be towards the front of the
engine.
Caution: Ensure that the connecting rod will not hit the piston cooling jet (if fitted) as the connecting rod
assembly is fitted.
6 Push the piston and connecting rod assembly through the piston replacer tool (A) and onto the crank pin.
The piston and connecting rod assembly must be rotated to ensure that the connecting rod will not hit the
piston cooling jet as the assembly is fitted. When the connecting rod has passed the piston cooling jet,
rotate the connecting rod until the arrow mark on top of the piston is towards the front of the engine
CUKUROVA Model 885


7 Clean the connecting rod cap and the lower half of the bearing. Fit the bearing to the cap; ensure that the
bearing is fitted correctly, see Operation 4-2. Lubricate the bearing with clean engine lubricating oil. Fit the
cap and ensure that the assembly number is the same as that on the connecting rod and that the numbers
are on the same side. Tighten the fasteners gradually and evenly, see Operation 4-2.
8 Check that the crankshaft will rotate freely.
9 Check the piston height above the top face of the cylinder block, see Operation 4-6.
10 Fit the lubricating oil pump. see Operation 10-10 or fit the balancer unit, see Operation 5-15. 11 Fit the
lubricating oil sump, see Operation 10-5
12 Fit the cylinder head assembly, see Operation 3-10.
13 Fill the sump to the correct level with lubricating oil of an approved grade.
14 Fill the cooling system.
To check the piston height above the cylinder block Operation 4- 6
Special tools
Piston height tool 21825496 Dial gauge for use with 21825496 21825617
Caution: if the correct piston height above the cylinder block is not obtained, damage to the engine can
occur and the engine may not be emissions compliant.
Put the piston height tool (A) on the face of the cylinder block and rotate the gauge dial to the zero position.
Rotate the crankshaft until the piston crown is approximately at top dead centre (TOG). Carefully put the tool
over the top of the piston with the plunger of the gauge in contact with the piston above the axis of the
gudgeon pin. Rotate the crankshaft to ensure that the piston is at the highest position and make a note of the
gauge indication.
The piston height above the top face of the cylinder block should be 0,21/0,35 mm (0.008/0.014 in).
Notes:
- The top of the piston should not be machined.
- If the original piston is used, ensure that it is assembled to the correct connecting rod and is used in the
original cylinder.
If any of the components listed below are renewed. refer to the relevant operation:
- The connecting rod, see Operation 4-11
- The small end bush, see Operation 4-14
CUKUROVA Model 885


Piston rings
Note: The pistons have two compression rings and an oil control ring. All the piston rings are above the
gudgeon pin. To ensure that the correct type is obtained always use the engine identification number
to order new parts.
Caution: Only expand the ring gaps enough to ensure that the ends of the rings do not damage the piston
when the ring is removed or put into position.
1 Remove the piston rings with a suitable ring expander. Keep the rings with their relevant piston.
Use a suitable piston ring expander to fit the piston rings.
Caution: Only expand the ring gaps enough to ensure that the ends of the rings do not damage the piston
when the ring is removed or put into position.
1 Fit the spring of the oil control ring in the bottom groove with the latch pin (A1) inside both ends of the
spring (A). Fit the oil control ring over the spring. Ensure that the ring gap is at 180° to the latch pin.
2 Fit the cast iron ring with the taper face into the second groove .
3 The second ring has a green identification mark which must be on the left of the ring gap when the ring is
fitted and the piston is upright. with the word ''TOP'' towards the top of the piston.
4 The first ring has a red identification mark which must be on the left of the ring gap when the ring is fitted
and the piston is upright.
5 Ensure that the ring gaps are 120° apart.
CUKUROVA Model 885


Piston and connecting rod assembly
To dismantle Operation 4 - 9
Caution: The pistons and connecting rods are matched to the relevant cylinder. Note the position of each
connecting rod and piston for correct assembly.
1 Remove the piston rings, see Operation 4-7.

2 Remove the circlips which retain the gudgeon pin.
Caution: Do not scratch, etch or stamp the piston surface.
3 Put a temporary mark on the piston to indicate the cylinder number as shown on the connecting rod. Put
the temporary mark on the piston on the same side as the mark on the big end to ensure that they are
assembled correctly (A).
4 Push the gudgeon pin out by hand. If the gudgeon pin is tight, heat the piston to 40/50 °C (100/120 °F) for
easy removal of the gudgeon pin.
5 Inspect the piston and connecting rod assembly, see Operation 4-12 and Operation 4-13.
To assemble Operation 4 - 10
1 Clean the bore of the small end bush and lubricate it with clean engine lubricating oil.
2 Fit a new circlip in the circlip groove of one of the gudgeon pin bosses. Ensure that it fits correctly in the
groove.
3 With the piston upside down, put the connecting rod in position with the forged mark (A1) on the same side
as the recess in the gudgeon pin boss (A2). If the original piston is used, ensure that it is assembled to the
correct connecting rod and is used in the original cylinder.
Note: 1100 Series 4 cylinder engines have six connecting rod length grades controlled by the small end
bush machining. If a new connecting rod is fitted, ensure that it is of the correct length grade, see
Operation 4-11.
4 Lubricate the gudgeon pin bosses with clean engine lubricating oil and push in the gudgeon pin towards
the circlip. If the gudgeon pin is a tight fit in the piston, heat the piston to 40/50 °C (100/120 °F) before the
gudgeon pin is fitted.
5 Fit a new circlip in the groove in the other gudgeon pin boss. Ensure that it fits correctly in the groove.
6 Fit the piston rings, see Operation 4-8.
CUKUROVA Model 885


To check the length of a connecting rod Operation 4 - 11
A partially finished small end bush, which can be fitted to the original connecting rod and machined to obtain
the correct length grade is available, see Operation 4-14. Specialist equipment and personnel with the
correct training are needed to machine the partially finished small end bush.
Connecting rod kits are also available with the small end bush fitted and machined to obtain the correct
connecting rod grade.
Cautions:
- It is important that the piston does not contact the cylinder head. Ensure that the piston height above the
cylinder block is correct.
- Ensure that the connecting rods are fitted in the correct cylinder. Record the position of the connecting rod
and its relevant cylinder when it is removed from the engine.
To ensure that the piston height above the cylinder block is correct, the engine may have up to six length
grades (F to L) of connecting rods fitted.
Identification of the length grade is by a letter or colour which is marked on the side of each connecting rod
(A1). The letter F is the longest grade of connecting rod and letter L is the shortest grade. The difference
between grades is 0,046 mm (0.0018 in).
If the grade letter or colour on the side of the connecting rod cannot be seen, the length can be checked by
the measurement of the dimension (X) shown in (A). Before the length of the connecting rod is measured,
ensure that the bores of the big end and the small end are square and parallel, see Operation 4-13. The
length is checked with the big end bearing removed and the original small end bush fitted. The dimensions
for each grade are listed in the table below:
Grade letter Colour code Length (mm)

F Red 165,728/165,761
G Orange 165,682/165,715
H White 165,637/165,670
J Green 165,591/165,624
K Purple 165,545/165,578
L Blue 165,499/165,532
CUKUROVA Model 885


Piston and piston rings
inspect Operation 4 - 12
1 Check the piston for wear and other damage.
2 Check that the piston rings are free to move in their grooves and that the rings are not broken.
3 Remove the piston rings, see Operation 4-7, and dean the piston ring grooves and the piston rings.
Note: Engine models RG, RH, RJ, and RK, have pistons that have a tapered top groove and the piston ring
is wedge shaped. The top piston ring clearance cannot be checked by this method.
4 Fit new piston rings in the grooves and check for wear of the grooves with feeler gauges (A). Compare the
piston ring clearance in the groove to that given for new components in the relevant Data and dimensions
for the "Pistons and piston cooling jets", and renew the piston if necessary.
5 Clean all carbon from the top of the cylinder bore. Fit each piston ring in the top part of the cylinder bore
and measure the ring gap with feeler gauges (B). The coil spring must be removed from the oil control ring
when the gap of this piston ring is measured.
The piston ring gaps for new components are given in the relevant Data and dimensions for the "Piston
rings" .
CUKUROVA Model 885


Connecting rod
1 Check the small end bush for wear or for other damage and renew it, if necessary.
Note: Connecting rod kits are available with a new small-end bush fitted and finished to the correct grade,
see Operation 4-11 to identify the correct connecting rod grade.
A partially finished small end bush, which can be fitted to the original connecting rod and machined to obtain
the correct length grade is also available, see Operation 4-14.
2 Check the connecting rod for distortion. Refer to the relevant Data and dimensions for the "Connecting
rods and big end bearings to identify the correct mandrel size.
Note: The large and small end bores must be square and parallel with each other within the limits of +/- 0,25
mm (0.010 in) measured 127 mm (5.0 in) each side of the connecting rod axis on a test
mandrel. With the small end bush fitted, the limits are reduced to +/- 0,06 mm (0.0025 in).
3 Check the fit of the gudgeon pin in the small end bush and check the gudgeon pin for wear, refer to the
relevant Data and dimensions for the "Gudgeon pins and small end bushes".
Partially finished small end bush

Note: For details on how to change the partially finished small end bush, contact your nearest Perkins
Dealer Distributor for advice.
CUKUROVA Model 885


Piston cooling jets
To remove
Release the setscrew (A1) and remove the piston cooling jet assembly. Note; The crankshaft is removed in
(A) to show clearly the piston cooling jet. To 'fit
1 Check that the spring loaded valve moves freely against spring pressure in the valve assembly and that
the jet tube is not damaged. Renew piston cooling jets as necessary.
2 Fit the piston cooling jet; ensure that the valve is fitted correctly in the locating hole in the cylinder block.
3 Fit the setscrew (A1) and tighten to 9 Nm (7 Ibf ft.) 0,9 kgf m.
To check the jet alignment Operation 4 - 16
Note: Ensure that the end of a 1,70 mm (0.067 in) diameter rod is round, to prevent damage to the piston
cooling jet bore.
Carefully insert a 1.70 mm (0.067 in) diameter tad. of 300 mm (11.8 in) in length, into the jet. If a suitable rod
is not available, reduce the end of a thicker rod to 1,70 mm (0.067 in) diameter for a length of 16.00 mm
(0.630 in).
When the rod is inserted into the jet it must extend out of the top of the cylinder within the area shown in (A).
Replace the piston cooling jet, as necessary.
CUKUROVA Model 885


Crankshaft assembly
General description
The crankshaft is forged from chromium molybdenum steel and has five main journals, There is a large
flange at the rear of the crankshaft to which the flywheel is fitted.
End-float and thrust movements are controlled by two split 360ᑻ thrust washers on both sides of the centre
main bearing.
The main bearings have steel backs with an aluminum/tin bearing material, and main bearing caps are made
of cast iron or spheroidal graphite iron.
The timing ring is an interference fit onto the machined surface of the web, The timing ring is fitted behind the
crankshaft palm and is located by a dowel.
The rear end oil seal is made from a PTFE material and is an integral part of the pressed steel housing,
which is fitted to the cylinder block.
The crankshaft pulley (A2) is held in position by a plain thrust block (A3) and three setscrews (A4). The nose
(A1) of the crankshaft and the pulley is serrated for location.
CUKUROVA Model 885


Crankshaft pulley
To remove
1 Remove the fan drive belt(s), see Operation 14-3.
2 Remove the three setscrews (A4) which hold the pulley and remove the setscrews, the thrust block (A3)
and the pulley (A2).
3 Clean the components and check for damage. Renew damaged components as required.
4 Check the area of the seal contact on the pulley for wear. If there is excessive wear a wear sleeve can be
fitted. see Operation 5-3.
To fit
1 Put the pulley (A2) in position on the crankshaft nose (A1). Lubricate lightly the threads of the setscrews
(A4) with clean engine lubricating oil. Fit the thrust block (A3) and the setscrews (A4) and tighten the
screws to 115 Nm (85 Ibf ft) 11,8 kgf m.
2 Check each setscrew again to ensure that they are still to the correct torque.
3 Fit the drive belt(s), see Operation 14-3.
CUKUROVA Model 885


Rear end oil seal assembly
To remove and to fit the rear end oil seal assembly Operation 5 - 2
Caution: The new rear end oil seal assembly includes a plastic protection sleeve (A2) that is fitted to the
inside of the seal. This sleeve is to protect the oil seal from damage when it is fitted to the
crankshaft palm (A1). The plastic sleeve must remain inside the seal until the assembly is fitted.
When the assembly is fitted, the plastic sleeve will be pushed out of the oil seal and the assembly.
The plastic sleeve must be discarded after the assembly is fitted. The seal of the new rear end oil
seal assembly is pre-wexed, there is no need to lubricate the palm or the seal before it is fitted.
Notes:
- The oil seal for the rear end oil seal assembly cannot be renewed, if the seal is faulty, the complete
assembly must be renewed.
- If the crankshaft palm has a wear groove caused by the old oil seal assembly, a wear sleeve must be fitted
to the crankshaft palm before the new assembly is fitted, see Operation 5-3.
- An alignment tool is needed to fit the rear end oil seal assembly.
- The rear end oil seal cannot be used again and must be replaced if removed.
To remove
1 Remove the drive components from the rear end of the engine.
2 Remove the flywheel, see Operation 13~1 and the flywheel housing, see Operation 13-3.
3 Remove the Torx screws from the rear end oil seal housing and remove the assembly.
CUKUROVA Model 885


To fit
Caution: To prevent contamination of the oil seal surface, keep the new assembly packed until required for
use.
Note: The rear end oil seal cannot be used again and must be replaced if removed.
1 Ensure that the crankshaft pal m (A1), the rear face of the cylinder block and the bridge piece are dry. free
from dirt, and that there are no rough metal edges. Do not use a lubricant on either the crankshaft palm. or
on the rear end oil seal. as the seal is pre-waxed.
2 Remove the new rear end oil seal assembly (A3) from its pack. Ensure that the plastic sleeve (A2) supplied
with the rear end oil seal is square within the rear end oil seal. The plastic protection sleeve must be in
place when the seal is fitted to the crankshaft palm, this will prevent the seal being damaged when fitted.
3 Place the rear end oil seal over the crankshaft palm and engage the plastic protection sleeve (B1) onto the
crankshaft palm (A1).
4 With the plastic protection sleeve engaged on the crankshaft palm, push the rear end oil seal assembly
evenly and smoothly onto the crankshaft palm until it is against the cylinder block. The plastic protection
sleeve will be pushed out of the assembly (C).
CUKUROVA Model 885


5 Discard the plastic sleeve.
6 Rotate the rear end oil seal (D3) to align the holes in the rear end oil seal assembly with the holes in the
cylinder block rear face and the cylinder block bridge piece.
7 Loosely fit the Torx screws (D5). .
8 Place the seal alignment tool (D4), onto the crankshaft palm and over the rear end oil seal housing to align
the rear end oil seal to the crankshaft palm.
Notes:
- Ensure that the two rubber locating pins are correctly located into the cylinder block.
- Ensure that there is no distortion of the rubber dust lip and that is in full contact with crankshaft palm. If
there is distortion, discard the seal and replace with a new seal.
9 Tighten setscrews 1, 2,3,4,5,6.7, and 10 in the sequence shown in (E) to 22 Nm (16 Ibf ft) 2,2 kgf m.
10 Remove the alignment tool and tighten the remaining Torx screws 8 and 9 in sequence (E) to 22 Nm
(16 lbf It) 2,2 kgf m.
11 Fit the flywheel, see Operation 13-1 and the flywheel housing, see Operation 13-3.
12 Fit the drive components to the rear end of the engine.
CUKUROVA Model 885


Alignment tool
The alignment tool (F) must be manufactured locally to the following specifications:
1 Outer surface (F1) to be knurled
2 Remove all sharp edges
3 To be made from material EN 32, harden 0.5 mm deep.
Note: All dimensions are in millimeters.
CUKUROVA Model 885


To remove and to fit a wear sleeve Operation 5 - 3
Special tools
POWERPART Liquid gasket 21820518
To remove
1 Remove the rear end oil seal, see Operation 5-2.

2 With a sharp tool mark a deep line along the length of the sleeve.
3 Insert a suitable thin blade between the crankshaft palm and the sleeve next to the marked line. The wear
sleeve will separate along the marked line.
4 Remove the wear sleeve. Use a suitable cleaner to remove any sealant from the crankshaft palm.
To fit
1 Ensure that the crankshaft palm is dry and free from oil, dirt and sealant.
2 Remove any rough areas from the crankshaft palm surface.
3 Apply a small continuous bead of sealant (Al), that does not harden, to the inner surface of the wear sleeve
5,0 mm (0.197 in) from the flange end of 'the sleeve (A1).
Caution: The wear sleeve must be fitted within five minutes of applying the sealant.
4 Ensure that the crankshaft is fully forward in the engine.
5 Place the wear sleeve onto the crankshaft palm (B3), use the tool (B1) that is supplied with the new wear
sleeve and a suitable hammer, to force the wear sleeve (B2) over the crankshaft palm leaving a gap (B5)
of 0.4/0,6 mm (0.016/0.024 in).
6 Remove the tool and measure the gap (B5) between the wear sleeve flange and the cylinder block in two
places 180 apart. The correct gap is 0,4/0,6 mm (0.016/0.024 in).
7 After the wear sleeve has been fitted, check and remove any rough metal edges from the crankshaft palm
and the wear sleeve.
8 Fit a new rear end oil seal, see Operation 5-2.
CUKUROVA Model 885


Thrust washers
To check crankshaft end-float Operation 5 - 4
The axial movement of the crankshaft is controlled by thrust washers fitted both sides of the centre main
bearing (A).
The end-float can be checked with a feeler gauge between a thrust washer and the crankshaft (B), or with a
dial test indicator on one end of the crankshaft to check the movement (C).
If the end-float is more than the tolerance given in the relevant Data and dimensions for the "Crankshaft",
thrust washers which are 0,019 mm (0.0075 in) oversize can be fitted.
The oversize thrust washers can be fitted to one or to both sides of the main bearing. They are fitted instead
of the standard size washer, to reduce the end-float to the factory tolerances.
CUKUROVA Model 885


1 Drain the lubricating oil and remove the lubricating oil sump., see Operation 10-4.
2 If necessary, remove the lubricating oil pump. see Operation 10-9, or remove the balancer unit. see
Operation 5-15.
3 Release the setscrews of the centre main bearing and remove the main bearing cap complete with the
lower halves of the thrust washers.
4 Use a suitable tool (A1) made of a soft material to push each of the upper halves of the thrust washers
from their recesses. Where necessary, move the crankshaft to the front or to the rear to loosen a tight
washer.
CUKUROVA Model 885


To fit
Operation 5 - 6
1 Lubricate the thrust washers with clean engine lubricating oil.
Caution: Factory built engines have an upper shell bearing that has an lubricating oil slot (C1) that is fitted to
the number one crankshaft journal. The remaining upper shell bearings have a lubricating oil holes
(C2). For service all upper shell bearings will be replaced with bearings that have the lubricating oil
slot (C1).
2 Slide each of the upper halves of the thrust washers into their recesses in the cylinder block. Ensure that
the sides of the thrust washers that have the grooves (A1) are against the crankshaft.
3 Fit the lower half thrust washers to the main bearing cap with the location tags in their recesses.
4 Ensure that the location thimbles (B2) are fitted correctly in the main bearing cap or in the cylinder block.
5 Ensure that the bearing is fitted correctly in the cap and that the bearing and the crankshaft journal are
clean. Lubricate the bearing with clean engine lubricating oil.
6 Fit the cap with the location tags of both halves of the shell bearings to the same side (B1), ensure that the
plain bearing shell is fitted to the lower bearing cap (B).
7 Tighten the main bearing setscrews to 245 Nm (181Ibfft) 25,0 kgf m.
8 Ensure that the crankshaft turns freely. If the thrust washers have been removed and fitted, check the
crankshaft end-float, see Operation 5-4.
9 If necessary, fit the lubricating oil pump, see Operation 10-10, or fit the balancer unit, see Operation 5-15.
10 Fit the lubricating oil sump, see Operation 10-5, and fill the sump to the correct level with lubricating oil of
an approved grade.
CUKUROVA Model 885


Main bearings
To remove (with the crankshaft in position) Operation 5 - 7
Caution: Ensure that the tops of the main bearing caps are stamped with their relevant position number.
Keep the bearings with their relevant caps.
Notes:
- If more than one set of main bearings are to removed then identify, and keep each pair as a set
- If the rear main bearing cap is to be removed with the crankshaft in position, the flywheel, the flywheel
housing, the rear end oil seal assembly and the bridge piece will have to be removed.
1 Drain the lubricating oil and remove the sump, see Operation 10-4.
2 Remove all necessary components to get access to the specific bearing cap.
3 Release the setscrews of the bearing cap and remove the bearing cap. Remove the lower half of the shell
bearing from the cap.
4 With a suitable tool (A1), push the upper half of the shell bearing from the side opposite to the location tag
(A2) to remove the bearing tag from its recess (A3) in the bearing housing. Carefully rotate the crankshaft
to release the bearing from its housing.
CUKUROVA Model 885


To fit (with the crankshaft in position) Operation 5 - 8
1 Clean the upper half of the shell bearing and lubricate the bearing surface with clean engine lubricating oil.
Caution: Only the upper half of the bearing has lubrication holes and must be fitted to the cylinder block.
2 Fit the plain end of the upper half of the bearing between the crankshaft journal and the side of the bearing
housing which has the recess for the location tag. Slide the bearing into its housing until the tag on the
bearing is fitted correctly in its recess in the housing.
3 Clean the lower half of the bearing and the cap, lubricate the bearing surface with clean engine lubricating
oil.
4 Fit the bearing into the cap with the tag of the bearing fitted correctly in the recess in the cap.
5 Ensure that the location thimbles (A2) are fitted correctly to the cap or to the cylinder block. Fit the bearing
cap with the location tags of both bearings on the same side (A1).
6 Inspect the setscrews for damage and for distortion and renew them if necessary. Lightly lubricate the
setscrew threads with clean engine lubricating oil. Fit the setscrews and tighten the setscrews to 245 Nm
(181Ibf ft) 25,0 kgf m.
7 Ensure that the crankshaft turns freely. If the thrust washers have been removed and fitted, check the
crankshaft end-float. see Operation 5-4.
8 Fit all the components which were removed for access to the main bearing cap.
9 Fit the lubricating oil sump, see Operation 10-5 J and fill the sump to the correct level with lubricating oil of
an approved grade.
1 Inspect the bearings for wear and for other damage. If a bearing is worn or damaged, renew both halves of
the shell bearings and check the condition of the other bearings.
CUKUROVA Model 885


Crankshaft
Note: If the crankshaft is to be renewed, it may be necessary to change the grade of the connecting rods.
see Operation 4-11. This will occur if the correct piston height above the block face cannot be
maintained with the original piston and connecting rod assemblies, see Operation 4-6.
Warning! Use lift equipment or obtain assistance to lift heavy engine components such as the flywheel,
flywheel housing and the crankshaft.
1 Before the engine is removed from the vehicle or from the machine, drain the lubricating oil and the
coolant.
3 Remove the fan, see Operation 12-8, the drive belts, see Operation 14-3, the fan drive pulley and housing,
see Operation 12-9 and the coolant pump, see Operation 12-4.
4 Remove the fuel injection pump:

- For Bosch VP30 fuel injection pumps, see Operation 11-9.
- For Bosch EPVE fuel injection pumps, see Operation 11-11,
- For Delphi DP210 fuel injection pumps, see Operation 11-13.
5 Remove the crankshaft pulley, see Operation 5-1.
6 Remove the alternator and its mounting bracket, see Operation 14-4.
7 Remove the exhauster if fitted, see Operation 15-5.
8 Remove the timing case cover, see Operation 6-1.
9 Remove the timing gears and the timing case. Timing case and drive assembly.
10 Remove the flywheel, see Operation 13-1, and the flywheel housing, see Operation 13-3.
11 Remove the rear end oil seal housing, see Operation 5-2.
12 Remove the lubricating oil pump, see Operation 10-9, or remove the balancer unit, see Operation 5-15.
13 Remove the bridge piece.
Warning! The engine should be upside down before the fasteners for the crankshaft are removed. If the
engine cannot be turned upside down support the crankshaft before the fasteners are removed.
14 Remove the caps of the connecting rods. Keep the bearings and caps together. Remove the bolts of the
connecting rods and carefully push the pistons towards the top their bores, see Operation 4-4.
15 Ensure that the tops of the main bearing caps are stamped with their relevant position number. Remove
the main bearing caps- the lower half of the shell bearings and the upper and lower thrust washers. Keep
the bearings with their relevant caps, see Operation 5-5 and Operation 5-7.
16- Lift out the crankshaft. Remove the upper half of the bearings and keep each, bearing with its relevant
lower half and cap.
Caution: If a timing ring is fitted to the crankshaft ensure that is protected from damage and is correctly
stored.
CUKUROVA Model 885


Special tools
POWERPART Silicone adhesive 21826038
1 Ensure that all lubricating oil passages are clean and free from restriction.
2 Clean the main bearing housings and the upper half of the bearings. Fit the shell bearings with the location
tags fitted correctly in their recesses. Lubricate the bearings with dean engine lubricating oil.
3 Ensure that the main journals of the crankshaft are clean. Put the crankshaft in position on the upper
bearings.
4 Clean and lubricate the upper halves of the thrust washers and slide them into their recesses on both sides
of the bearing housing. Ensure that the slotted sides of the thrust washers are towards the crankshaft, see
Operation 5-6.
5 Clean the bearing caps and the lower half of the bearings. Fit the bearings to the caps with the location
tags fitted correctly in their recesses. Lubricate the bearings with clean engine lubricating oil.
6 Clean the lower halves of the thrust washers and lubricate them with clean engine lubricating oil. Fit the
thrust washers on both sides of the bearing cap for the centre main bearing.
7 Check that the location thimbles for the main bearing caps are fitted correctly in the caps or in the cylinder
block. Fit the bearing caps in their correct positions with the location tags of the bearings on the same side.
8 Fit the setscrews to the main bearing caps and tighten them to 265 Nm (196 Ibf ft) 27,0 kgf m.
9 Clean the bridge piece and the location areas for the bridge piece in the cylinder block. Use a straight edge
(A2) to ensure that the bridge piece is in line with the rear face of the cylinder block.. Tighten the bridge
piece cap screws (A1) to 16 Nm (12 Ibf ft) 1,6 kgf m.
Note: The maximum protrusion for the bridge piece (C2) to the cylinder block (C1) is 0/-0,075 mm
(0/-0.0029 in) (C3).
10 When the bridge piece is in position, inject POWER PART Silicone adhesive into the groove (B2) at each
end of the bridge piece. Continue to inject adhesive until the groove is completely full and the adhesive
leaves the lower groove (B1) at the front and rear of the bridge piece.
CUKUROVA Model 885


11 Fit the connecting rod caps, see Operation 4-2. Rotate the crankshaft two turns to ensure free movement
12 At the lubricating oil pump, see Operation 10-10, or fit the balancer unit, see Operation 5-15.
13 Fit the rear end oil seal housing, see Operation 5-2.
14 Fit the flywheel housing, see Operation 13-3, and the flywheel, se~ Operation 13-1.
15 Fit the timing case and the timing gears. Timing case and drive assembly.
16 Fit the timing case cover, see Operation 6-2.
17 Fit the exhauster if removed, see Operation 15-5.
18 Fit the alternator and its mounting bracket, see Operation 14-4.
19 Fit the crankshaft pulley, see Operation 5-1.
20 Fit the fuel injection pump:

- For Bosch VP30 fuel injection pumps, see Operation 11-10.
- For Bosch EPVE fuel injection pumps, see Operation 11-12.
- For Delphi DP210 fuel injection pumps, see Operation 11-14.
21 Fit the coolant pump, see Operation 12-5, the fan drive pulley and housing, see Operation 12-9, the drive
belts, see Operation 14-3, and the fan, see Operation 12-8.
22 Fit the lubricating oil sump, see Operation 10-5.
23 After the engine has been installed, fill the lubricating oil sump to the correct level with an approved oil
Check the crankshaft for wear and other damage. The maximum permissible wear and ovality on the
crankshaft journals and crank pins is 0,04 mm (0.0016 in).
The main journals and the crank pins of standard size crankshafts can be machined to 0,25 mm (0.010 in),
0,50 mm (0.020 in) or 0,75 mm (0.030 in) undersize on diameter, see "Crankshaft overhaul".
Special undersize bearings are available.
CUKUROVA Model 885


Crankshaft timing ring
Warning! Ensure that suitable protective clothing is worn.
Cautions:
- Apply heat to the timing ring only to reduce the risk of damage to the crankshaft
- Carefully remove the timing ring, do not damage the crankshaft palm oil seal face.
1 Remove the crankshaft from the cylinder block, see Operation 5-10.
Note: If a "speed sleeve" (wear sleeve) has been fitted to service the crankshaft palm seal diameter, the
shoulder of this sleeve must be removed to give clearance for the timing ring.
2 Support the crankshaft in a vertical position with the crankshaft palm at the bottom.
3 Apply heat to the timing ring (A1) with a flame. The temperature of the timing ring must not exceed 2700 C
(518° F). When heat is applied to the timing ring, the ring will fall off the crankshaft web.
4 Discard the old timing ring after it has been allowed to cool safely.
5 Do not remove the timing ring locating dowel (A2) from the crankshaft web unless the locating dowel is
damaged.
CUKUROVA Model 885


Waming! Ensure that suitable protective clothing is worn.
Cautions:
- Apply heat to the timing ring evenly to reduce the risk of damage and distortion to the timing ring (A1)
- Carefully fit the timing ring, do not damage the crankshaft palm oil seal face.
1 Ensure that the timing ring bore, and the crankshaft timing ring location shoulder, are both clean and free
from any rough metal edges.
2 If the locating dowel (A2) was removed press a new locating dowel into the hole in the crankshaft web.
Ensure that the locating dowel is at the bottom of the hole.
3 Support the crankshaft in a vertical position with the crankshaft palm at the top.
4 Heat the timing ring (A1) in an oven to a temperature of between 20r/2S0°C (40so/482° F). With the timing
ring bore chamfer and relief groove towards the crankshaft web, and the dowel hole aligned with the
dowel, immediately fit the timing ring. Ensure that the timing ring is fitted fully against the crankshaft web
shoulder.
5 Allow the timing ring to cool safely.
6 Fit the crankshaft to the cylinder block, see Operation 5-11.
CUKUROVA Model 885


Balancer unit
Special tools
Timing pin 27610225
To remove
1 Drain the lubricating oil from the sump and remove the sump, see Operation 10-4.
2 Set the piston of the number 1 cylinder to TOG, see Operation 8-1.
3 Insert the timing pin (C1) into the balancer, ensure that the timing pin is fully located in the drive shaft.
Warning! The weight of the unit is approximately 25 kg (55 Ib).
4 Provide a support for the balancer unit before release of the setscrews from the engine.
5 Release the setscrews and carefully remove the balancer unit
To fit
1 Ensure that the contact faces of the cylinder block and of the balancer unit are clean and that the thimble
(A1) and the dowel (A2) are fitted correctly to the cylinder block or to the balancer unit.
2 Set the piston of the number 1 cylinder to TOG, see Operation 8-1.
3 Fit two suitable M10 guide studs into positions (B1).
CUKUROVA Model 885


4 Insert the timing pin (D1) into balancer, ensure that the timing pin is fully located in the drive shaft and that
the balancer weights are pointing away from the cylinder block.
5 Carefully fit the balancer unit onto the two M10 guide studs in the cylinder block, check that the balancer
unit is fitted correctly on the thimble and the dowel. Ensure that the idler and crankshaft gears are in mesh.
Fit two setscrews in the centre positions of the balancer frame, then tighten the setscrews to 54 Nm
(40 lbf ft) 5,5 kgf m.
6 Remove the two M10 guide studs and fit the four remaining setscrews in their correct position. Tighten the
setscrews to 54 Nm (40 Ibf ft) 5,5 kgf m.
7 Rotate the crankshaft through two turns to ensure that it is free to rotate.
8 Fit the lubricating oil sump, see Operation 10-5, and fill the sump to the correct level with lubricating oil of
an approved grade.
To dismantle (oil pump) Operation 5 - 16
1 Remove the balancer from the engine, see Operation 5-15.

2 To prevent movement of the drive shaft. Put a suitable flat distance piece in position between the balancer
weights.
3 Release the setscrew and remove the idler gear assembly (A).
Note: Keep the components together as an assembly.
4 Release the nut of the lubricating oil pump gear and remove the nut. Using a suitable 2 legged puller locate
the puller arms on the back of the gear (B1) and remove the lubricating oil pump gear from the shaft.
5 Release the four setscrews (C1) from the lubricating oil pump cover plate and remove the cover.
6 Inspect the lubricating oil pump, see Operation 5-18.
7 Dismantle the lubricating oil relief valve, see Operation 10-12.
CUKUROVA Model 885


To assemble (oil pump) Operation 5 - 17
Special tools
POWERPART Threadlock and nutlock 21820117
1 Assemble1he lubricating oil relief valve, see Operation 10-12.
2 Fit the four setscrews (A1) to the lubricating oil pump cover plate and tighten to 26 Nm (19 Ibf ft) 2,6 kgf m.
3 Fit the lubricating oil pump gear and nut, gradually tighten to 95 Nm (70 Ibf ft) 9,7 kgf m.
Note: Ensure that the flats on the thrust washer (B2) are aligned.
4 If necessary, renew the idler gear. Lubricate the bush with clean engine lubricating oil. Fit the hub into the
bush and fit the thrust washer onto the rear of the hub. Ensure that the threads of the setscrew are clean
and dry. Fit the setscrew through the assembly and apply a small amount of POWER PART Threadlock
and nutlock to the thread.Fit the assembly to the front of the balancer unit. Tighten the setscrew to 26 Nm
(19 Ibf ft) 2,6 kgf m.
5 Check the end-float of the idler gear with a feeler gauge between the front face of the idler gear and the
hub. Check the backlash between the idler gear and the drive shaft gear.
Refer to the Data and dimensions for "Balancer unit" .
6 Fit the suction tube and the joint and tighten the setscrews, if removed.
7 Remove the distance piece from the balancer weights.
8 Fit the balancer to the engine, see Operation 5-15.
CUKUROVA Model 885


Note: If any part is worn enough to have an effect on the performance of the oil pump, the complete oil pump
must be renewed.
1 Remove the setscrews and remove the cover of the oil pump.
2 Remove the outer rotor and clean thoroughly all the parts. Check for cracks and any other damage.
3 Fit the outer rotor and check the outer rotor to body clearance (A), refer to the Data and dimensions for the
Lubricating oil pump".
4 Check the inner rotor to outer rotor clearance (B), refer to the Data and dimensions for the "Lubricating oil
pump".
5 Check the rotor end-float with a straight edge and a feeler gauge. For all the above clearances, refer to the
Data and dimensions for the "Lubricating oil pump".
6 Lubricate the inner and outer rotor with clean engine lubricating oil. Clean the top face of the oil pump and
the inner face of the cover. Fit the cover. Tighten the setscrews to 28 Nm (21 Ibf ft) 2,9 kgf m.
CUKUROVA Model 885


General description
The timing case is made of either aluminum or cast iron.
The cast iron timing case is used to mount two power take-off units.
The timing gears are made of steel. There are two different types of steel camshaft gear and upper idler
gear. One for heavy duty and one for light duty. A power take-off is available on either the left hand side. or
the right hand side or on both sides of the timing case. Some engines have an idler gear with a roller
bearing.
The drive from the crankshaft gear passes through an idler gear to the camshaft gear and to the gear of the
fuel injection pump. The drive from the crankshaft gear also passes through a lower idler gear to the gear of
the lubricating oil pump. The coolant pump is driven by the gear of the fuel injection pump. The camshaft and
the fuel injection pump run at half the speed of the crankshaft.
In (A) the electronic fuel pump gear is fitted. In (B) the mechanical fuel pump gear is fitted.
The timing case contains the front oil seal.
CUKUROVA Model 885


Timing case cover
Notes:
To assist with access to the timing case cover, the fan drive can be removed, see Operation 12-9.
The timing case cover can be removed with the crankshaft pulley fitted.
1 Remove the coolant pump. see Operation 12-4.

2 Remove the setscrews and the cover (A1), together with the joint. 3 Remove the joint from the cover and
discard the joint.
1 Clean the joint faces of the timing case and cover.

2 The new joint must be aligned by the three joint dowels (A1). The joint dowels are a push fit into the cover
(A2).
3 Fit two temporary studs (B1) through the timing case and into the cylinder block.
4 Remove the timing pins, if fitted.
5 Fit the cover to timing case and loosely fit the setscrews.
6 Loosely fit the coolant pump, see Operation 12-5.
7 Tighten the cover setscrews (C2) and coolant pump fasteners (C1) together to 22 Nm (16 Ibf ft) 2,2 kgf m
9 If removed fit the crankshaft pulley, see Operation 5-1.
10 Fit the fan drive, see Operation 12-9.
CUKUROVA Model 885


Mechanical fuel pump gear
Special tools
Crankshaft timing pin 27610211
Camshaft timing pin 27610212
Rocker assembly tools 27610227
Cautions:
- These procedures must only be carried out by a person with the correct training.
- If the Delphi DP210 fuel injection pump nut (A1) is loosened before the fuel pump timing is set and the
pump locked, the fuel injection pump timing will be lost and the fuel injection pump will have to be removed
and sent to your nearest Perkins Dealer/Distributor to be reset.
- The Delphi DP21 0 fuel injection pump must remain locked if the fuel pump gear is removed. The fuel
injection pump timing will be lost and the fuel injection pump will have to be removed and sent to your
nearest Perkins Dealer Distributor to be reset.
- If the Bosch EPVE fuel injection pump timing is lost, the pump timing can be reset on the engine, see
Operation 8-4.
- The timing pins are a push fit. Do not use excessive force to fit the pins.
- The engine is pin timed at TDC, do not use the pins as a locking device when repairs are carried out on the
engine.
Notes:
The fuel pump gear can be removed with the crankshaft pulley fitted.
It is recommend to help rotate the crankshaft, that the glow plugs are removed, see Operation 14-10.
1 Rotate the crankshaft to TDG, see Operation 8-1.
Caution: The backlash must be removed from all the gears before the fuel injection pump is locked. Failure
to do so will make the fuel pump timing incorrect.
3 Apply pressure counter clockwise by hand to the fuel pump gear (A2), to remove back lash from the gears
(B1), then lock the fuel injection pump.
4 There are two types of mechanical injection pump the Bosch EPVE and Delphi DP210. Both have different
locking screws and require a different method to lock the pump.
CUKUROVA Model 885


- To lock the Bosch EPVE pump shaft, ensure the backlash is removed. Loosen the locking screw (C2) and
remove the washer (C1). Tighten the locking screw (C2) to 31 Nm (23 Ibf ft) 3,1 kgf m.
- To lock the Delphi DP21 0 pump shaft, ensure the backlash is removed. Loosen the locking screw (D1) and
move the washer (D2). Tighten the locking screw (D1) to 17 Nm (12 Ibf ft) 1,7 kgf m. The washer (D2) can
now rotate around the locking screw (D1) with the pump shaft locked.
5 Release the nut (E2) and fit a suitable two legged puller (E3). Tighten the puller until the gear is released.
6 Remove the puller (E3) and the nut (E2). Remove the gear (E1 ).
Special tools
Crankshaft timing pin 27610211 Camshaft timing pin 27610212
Cautions:
- These procedures must only be carried out my a person with the correct training.
- The drive shaft of the pump must not be turned without the locking screw released, as this will damage be
the drive shaft.
- The engine is pin timed at TOG, do not use the pins as a locking device when repairs are carried out on the
engine.
1 Clean and check the fuel pump gear and renew if damaged. Clean the fuel injection pump tapered shaft
(A1)
2 Check the engine is set to TDC, see Operation 8-1.
3 Fit the gear (A2) onto the tapered shaft (A1). Check that the fuel pump gear is correctly in mesh with the
idler gear.
4 Fit the washer and nut (B1) and tighten by hand.
Caution: The backlash must be removed before the fuel injection pump is released. Failure to do so will
make the fuel pump timing incorrect.
5 Apply pressure counter clockwise by hand (B2) to the fuel pump gear to remove the backlash from all the
gears (C1). Tighten the nut (B1) to 24 Nm (18 Ibf ft) 2,4 kgf m.
CUKUROVA Model 885


6 Release the locked fuel pump shaft.
- To release the Bosch EPVE pump shaft, ensure the backlash is removed. Loosen the locking screw (D2)
and fit the washer (D1). Tighten the locking screw (D2) to 12 Nm (9 Ibf ft) 1,2 kgf m .
- To release the Delphi DP210 pump shaft, ensure the backlash is removed. Loosen the locking screw (E1)
and move the washer (E2). Tighten the locking screw (E 1) onto the washer to 12 Nm (9 Ibf ft) 1,2 kgf m.
7 Tighten the nut (B1) to 88 Nm (65 Ibf ft) 9,0 kgf m.
8 Remove the two timing pins.
9 Check the fuel injection pump gear end-float (F1) and the backlash (G1), see ''Timing case and drive
assembly".
10 Lightly lubricate each gear with clean engine lubricating oil.
12 Fit the glow plugs, see Operation 14-10.
14 Fit the rocker cover, see Operation 3-3 .
CUKUROVA Model 885


Electronic fuel pump gear
Special tools
Fuel pump timing pin 27610032
Cautions:
- If the hub nut (A3) is loosened the fuel injection pump timing will be lost and the fuel injection pump will
have to be removed and sent to your nearest Perkins Dealer/Distributor to be reset.
- The timing pins are a push fit and must not be forced into place.
- The engine is pin timed at TOC, do not use the pins as a locking device when repairs are carried out on the
engine.
Note: The fuel pump gear can be removed with the crankshaft pulley fitted.
1 Rotate the crankshaft to obtain TOG see, Operation 8-1.
2 Set the Bosch VP30 fuel injection pump timing, see Operation 8-2.
3 With all three timing pins fitted (A1), remove the setscrews (A2) and the hardened washers from the gear.
4 Remove the gear (B 1) from the hub (B2).
CUKUROVA Model 885


Cautions:
- The engine is pin timed at TDC, do not use the pins as a locking device when repairs are carried out on the
engine.
Note: The fuel pump gear will only fit correctly in one position.
1 Clean and check the fuel pump gear (A1) for damage and renew if necessary. Clean the fuel injection
pump hub (A3).
2 If the timing pin (A2) has been removed. rotate the hub (A3) until the slot in the hub is aligned with the hole
in the pump body. Insert the timing pin through the slot into the hub (A3) and fully into the body of the fuel
injection pump.
3 With all three timing pins fitted. fit the fuel pump gear (A1) over the timing pin (A2) and onto the hub (A3).
4 Loosely fit the flat hardened washers and setscrews (B3).
Caution: To ensure that the engine is correctly timed, backlash must be removed from all the gears.
5 Apply pressure counter clockwise by hand (B1) to the fuel pump gear (B2), to remove the backlash.
6 Tighten the setscrews (B3) to 22 Nm (161bf ft) 2,2 kgf m.
7 Remove the timing pins.
8 Check the fuel pump gear end-float and backlash, see ''Timing case and drive assembly".
9 Lightly lubricate each gear with clean engine lubricating oil.
CUKUROVA Model 885


Idler gear and hub
Notes:
- There are two types of idler gear and hub. One gear is bushed and the other is fitted with roller bearings.
This gear is the heavy duty idler gear. To remove the heavy duty idler gear assembly, the plate (A2) is
removed and fitted as part of the gear assembly. To dismantle the assembly, see Operation 6-10.
- When the idler gear is to be removed, it is good practice to mark the plate (A2) and the idler gear, to help
align the parts when they are to be assembled.
1 Remove the fuel pump gear; for the mechanical fuel pump gear, see Operation 6-3, and for the electronic
fuel pump gear, see Operation 6·5.
3 Remove the three setscrews (A1) and the plate (A2) from the idler gear. Remove the gear and the hub
assembly (B1) from the recess (D1) in the cylinder block. The hub assembly (B1) must be moved forward
and lifted over the front oil seal housing (B2).
4 Slide the hub (C2) out of the gear (C1).
CUKUROVA Model 885


Special tools
Cautions:
- The hub assembly must be aligned correctly to the plate (B2) and the cylinder block to allow the gear to be
lubricated.
- The marked teeth (A2) on the idler gear must be assembled to the hub so that they face to the front.
- The marked teeth (A2) on the idler gear must not be used as timing marks.
- The engine is pin timed at TOG, do not use the pins as a locking device when repairs are carried out on the
engine.
Note: To fit the heavy duty idler gear assembly the plate (B2) is fitted as part of the gear assembly. The plate
will be marked with the word TOP, ensure this is facing the front of the engine this is to allow the gear
assembly to be fitted correctly. To assemble the heavy duty idler gear, see Operation 6-11.
1 Clean and check the hub and gear for damage, renew if necessary.
2 Check the engine timing, see Operation 8-1.
3 Lubricate the hub with clean lubricating engine oil and fit the gear to the hub. Rotate the hub in the gear to
align the oil way to the top.
4 Fit the hub assembly (C1) over the front oil seal housing (C2) and into mesh with crankshaft gear and
camshaft gear. Check that the hole (D1) is towards the cylinder head.
5 Align the plate (E2) to the three holes in the hub. Fit the setscrew (E3).
6 With the hub assembly fitted, tighten evenly the three setscrews (E3) to 44 Nm (32 lbf) 4,5 kgf m.
7 Check the end float (E1) and back lash, see "Timing case and drive assembly".
8 Fit the mechanical fuel pump gear, see Operation 6-4, or the electronic fuel pump gear, see Operation 6-6.
CUKUROVA Model 885


To remove and fit idler gear bushes Operation 6 - 9
Caution: If the bushes in the idler gear are to be renewed, the backlash between the camshaft gear and the
idler gear, and between the idler gear and the fuel pump gear must be accurate.
If the bushes are to be changed, remove them with a suitable puller. If a puller is not available, machine off
the face of one of the bushes and press them out Press in new bushes and machine the bores to get the
correct clearance on the hub. The gear must have the correct backlash. Machine the faces to get the correct
end clearance.
When assembled, the idler gear backlash between the crank gear and idler gear must be checked in four
positions. Rotate the crankshaft clockwise viewed from the front, and check the backlash between the two
gears every 90°, see "Timing case and drive assembly".
CUKUROVA Model 885


Heavy duty idler gear assembly
1 Remove the setscrew (A2), and the plate (A3) from the assembly.
2 Press the hub (All) out of the bearing housing (A8).
3 Remove the circlip (A4) and the thrust washer (A5) from the gear (A6). Slide the bearing housing (A8) with
the rollers (A7) out of the gear (A6).
Note: With the removal of the bearing from the gear, the rollers (A7) will become loose.
4 Remove the circlip (A 10) and the thrust washer (A9).
Consumable products
POWERPART Threadlock and 21820117
nutlock
Cautions:
- The bearing and the hub must be fitted so that the marked teeth of the heavy duty idler gear are to the
front.
- The new bearing assembly has a sleeve fitted, to hold the needle roller bearing securely. The sleeve must
not be removed before the bearing assembly is fitted into the gear. If the sleeve is removed from the
bearing assembly before the bearing is fitted, the bearing rollers will become loose.
- The hub assembly must be aligned correctly to the plate (A3) and the cylinder block to allow the gear to be
lubricated.
- If a used bearing assembly is dismantled and the rollers become loose, a new bearing assembly must be
fitted.
1 Clean all parts and check for wear and damage, renew as necessary.
2 Fit the circlip (A 10) into the back face of the gear (A6). slide the thrust washer (A9) into the front face of
the gear bore (A1).
3 Align the new bearing assembly with the sleeve to the front face (A1) of the gear bore. push the bearing
assembly out of the sleeve and into the gear bore.
4 Fit the thrust washer (A5) and the circlip (A4). Lightly lubricate the bearing with clean engine lubricating oil.
CUKUROVA Model 885


5 Press the gear assembly onto the hub (A 11).
Note: If the old setscrew (A2) is to be used. apply POWERPART Threadlock and nutlock.
6 Fit the plate (A3) and the setscrew (A2) to the gear assembly .. Rotate the plate (A3) until the three holes
in the plate are aligned correctly to the three holes in the hub (A 11). The plate (A3) will be marked with the
word TOP, ensure this is facing the front of the engine. Tighten the setscrew (A2) to 9 Nm(7 Ibf ft) 0,9kgfm.
Camshaft gear
To remove
Caution: The engine is pin timed at TOC, do not use the pins as a locking device when repairs are carried
out on the engine.
1 Remove the idler gear, see Operation 6-7.
2 Remove the camshaft timing pin.
3 Remove the setscrew (A1 ), with its washer, and remove the gear from the camshaft. Ensure that the key
in the camshaft is not lost.
CUKUROVA Model 885


To fit
Note: The camshaft timing pin is a push fit into the timing case. The camshaft-gear will rotate a small amount
when the pin is fitted. This is to allow the assembly of the gears and removal of the backlash from the
gears when needed, with the timing pin fitted.
1 Clean and check the camshaft gear and camshaft key for wear and damage, renew if necessary .
2 Ensure that the camshaft key is fitted correctly.
3 Fit the camshaft gear to the camshaft with the marked teeth towards the front and the keyway correctly
aligned with the key. If necessary, lightly hit the gear with a soft-face hammer to engage the key into the
keyway. Fit the camshaft timing pin. If the camshaft needs to be rotated, remove the rocker assembly, see
Operation 3-4.
4 Fit the washer an-d setscrew (A1) to the gear and tighten the setscrew to 95 Nm (70 Ibf ft) 9,7 kgf m.
5 Fit the idler gear, see Operation 6-8
Front oil seal

Special tools
Three legged puller 27610230
To remove the oil seal from the timing case fitted to the engine
Warning! The oil seal is made of "Viton", see the safety precautions for "Viton seals".
Caution: The oil seal housing must not be damaged when the oil seal is removed.

2 Thoroughly clean the area around the oil seal housing.
3 Fit the legs (A2) of the puller under the oil seal and lock into position.
4 Fit a suitable distance piece (A1) between the crankshaft and the puller.
5 Remove the oil seal from the housing.
6 Discard the oil seal.
Note: If the timing case is removed from the engine. the seal can be removed from the timing case. Use a
suitable adaptor to press the seal out of the timing case. Ensure that the timing case is supported
correctly, and that excessive pressure is not used to remove the seal, this can damage or distort the
case.
CUKUROVA Model 885


Special tools
Crankshaft front oil seal replacer 21825577 Pressure plate for use with 21825577 21825578
Fastener plate for use with 21825580 Adaptor for use with 21825577 27610217
21825577
To fit the oil seal with the timing case fitted
Warning! The oil seal (A6) is made of "viton", see the safety precautions for 'Viton seals".
Cautions:
- New timing case oil seals have a sleeve (A5) fitted to protect the oil seal. Do not remove the sleeve until the
crankshaft pulley is to be fitted. Discard the new oil seal if the sleeve (A5) is not fitted.
- Damage may be done to the seal if the correct tool is not used.
- It is important that only genuine Perkins parts are used. The use of a seal that is not a genuine Perkins part
may damage the engine and will affect the warranty.
- Do not lubricate the oil seal or the oil seal housing.
1 Clean the oil seal housing and check for damage, renew if necessary.
2 Check the crankshaft pulley seal face for wear. To repair the pulley, see Operation 6-15.
3 Assemble the oil seal tool. Fit the fastener plate (A7) to the front of the crankshaft.
4 Assemble the nut (A1) and the pressure plate (A2) onto the threaded bar (A3).
5 Align the seal (A6) and the sleeve (A5) to the front of the oil seal housing (A8).
6 Fit the adaptor (A4) onto the sleeve (A5).
7 Put the pressure plate assembly onto the adaptor (A4) and tighten the threaded bar (A3) onto the fastener
plate (A7). Check the alignment of the assembly and the oil seal to the oil seal housing.
8 Fit a rod through the hole in the end of the threaded bar to prevent .movement of the bar when the nut is
tightened. Tighten the nut (A1) to push the seal into the housing. Tighten until contact is made with the
bottom face of the oil seal housing.
9 Remove the replacer tool.
10 Turn and pull the sleeve (A5) counter clockwise. to remove the sleeve from the oil seal.
11 Fit the crankshaft pulley immediately see, see Operation 5-1.
CUKUROVA Model 885


To fit the oil seal with the timing case removed
1 Clean the oil seal housing and check for damage, renew if necessary.
2 Check the crankshaft pulley for damaged. To repair the pulley, see Operation 6-15.
3 Check that the new oil seal has the sleeve protector fitted.
4 Align the oil seal to the oil seal housing. Do not lubricate the oil seal or the housing.
5 With a suitable tool, press the oil seal into the housing until contact is made with the bottom face of the
housing.
6 Fit the timing case, see Operation 6-17.
7 When the front timing case cover is fitted, turn and pull the sleeve protector counter clockwise, to remove
the sleeve from the seal.
8 Fit the crankshaft pulley immediately, see Operation 5-1.
To fit a wear sleeve Operation 6 - 15
To renew a worn or damaged crankshaft pulley. a wear sleeve (A2) is fitted over the spigot (A1).
Note: Full instructions and a special tool to fit the wear sleeve are in each service kit.
2 Fit the wear sleeve, in accordance with the manufacturer's instructions. It is not necessary to remove the
flange (A3) of the wear sleeve after it has been fitted. A new front oil seal (A4) must be used when a wear
sleeve is fitted.
3 Fit the crankshaft pulley, see Operation 5-1
CUKUROVA Model 885


Timing case
Special tools
Note: It is not necessary to remove the alternator, jf the belts and the link setscrew are removed. The
alternator can be rotated away from the timing case.
1 Drain the lubricating oil and coolant.

2 Remove the fan drive, see Operation 12-9.
3 If not previously removed. remove the crankshaft pulley, see Operation 5-1.
4 If required remove the alternator, see Operation 14-4.
6 Remove the fuel injection pump:

- For Bosch fuel injection pumps, see Operation 11-9 or Operation 11-11 .
- For the Delphi DP210 fuel injection pump, see Operation 11-13.
7 Remove the coolant by-pass, see Operation 12-13.

8 Remove the PTO, if fitted see Operation 15-2.
9 Remove the crankshaft timing pin and the camshaft timing pin.
10 Remove the camshaft gear, see Operation 6-12.
11 Remove the timing case oil seal if a new oil seal is to be fitted. see Operation 6-13.
12 Remove the internal setscrews (A1) and the outer setscrews (A2) of the timing case.
13 Remove the timing case from the cylinder block. Remove the upper joint (B1) from the timing case, and
the lower joint from the cylinder block.
14 Discard all old joints.
CUKUROVA Model 885


Special tools
POWERPART Retainer 21820608
Alignment tool 27610216
Note: If a new timing case is to be fitted, it may be necessary to fit blanking plugs. Apply POWERPART
retainer, part number 21820608, to the blanking plug bore. This plug must be fitted into the timing case
before the case is fitted to the engine.
1 Clean and check the timing case for damage, renew if necessary.
2 Check that the camshaft thrust washer is fitted correctly. Fit the lower timing case joint (A1) onto the
cylinder block.
3 Fit two temporary studs (A2) to the cylinder block.
4 Fit the upper timing case joint (B1) to the timing case (B2).
CUKUROVA Model 885


5 Fit the alignment tool (C2) into the block, and secure in place.
6 Fit the timing case (C1) over the alignment tool (C2) and onto the cylinder block. Fit the setscrews into the
timing case and tighten by hand.
7 Align the timing case (D2) to the cylinder block (D1).
Note: To seal the lubricating oil sump joint. ensure that the bottom of the timing case is correctly aligned with
the bottom of the cylinder block before the setscrews are tightened. The alignment of the bottom face
of the timing case (D2) and the cylinder block (D1) must not exceed ± 0,05 mm (0,002 in).
8 Tighten the setscrews to 22 Nm (16 Ibf ft) 2,2 kgf m, and check the alignment (C3) of the timing case face
to the cylinder block face, adjust if necessary.
9 Fit the coolant by-pass, see Operation 12-13.
11 Fit the camshaft gear, see Operation 6-12.
12 Fit the idler gear, see Operation 6-8.
13 Fit the fuel injection pump:
- For Bosch fuel injection pumps, see Operation 11-10 or, see Operation 11-12 .
- For the Delphi DP210 fuel injection pump, see Operation 11-14.
15 Fit the coolant pump, see Operation 12-5.
Note: The coolant pump setscrews should be tightened together with the timing case cover setscrews.
16 Fit a new oil seal to the timing case, see Operation 6-14.
17 Fit the crankshaft pulley, see Operation 5-1.
18 If removed fit the alternator, see Operation 14-4.
19 Fit the fan drive, see Operation 12-9.
20 When the engine is fitted into the application, fill the lubricating oil sump to the correct level and with the
correct grade of engine lubricating oil, see Operation 10-5. Fill the cooling system to the correct level, and
with the recommended POWERPART Antifreeze.
CUKUROVA Model 885


Crankshaft gear
To remove
1 Remove the timing case, see Operation 6-16.

2 The crankshaft gear is a transition fit on the crankshaft. It may slide off easily or, if it is a tight fit and the
gear is to be renewed, it may be necessary to remove the crankshaft, to remove the gear safely, see
Operation 510.
To fit
Caution: Do not use a flame to heat the gear, as this can cause local damage.
1 The gear (A1) can fit easily, or it may be necessary to heat the gear before it will fit onto the crankshaft.. If
the gear is to be heated, heat the gear in an oven to not more than 200 ºC (392 ºF). If an oven is not
available, heat the gear in coolant which is at its boiling point.
2 Align the keyway in the gear to the key in the crankshaft.
3 Fit the gear (A1) with the shoulder (A2) facing outwards.
Camshaft and tappets

1 Remove the timing case, see Operation 6-16. 2 Remove the rocker cover, see Operation 3-2.
3 Remove the rocker assembly and the push rods, see Operation 3-4.
4 With the engine upside down, remove the camshaft thrust washer (A1) and carefully remove the camshaft
(B).
5 Remove the tappets.
6 Inspect the camshaft and the tappets for wear and other damage, also inspect the camshaft bush. Renew
the components as necessary.
CUKUROVA Model 885


1 Ensure that an components are clean and are lubricated with clean engine lubricating oil.
2 With the engine upside down, fit the tappets into position.
3 Carefully fit the camshaft.
4 Fit the camshaft thrust washer (A2). Ensure that it is fitted correctly onto the hollow dowel (A1).
5 Turn the engine the right way up.
7 Check that the camshaft end-float is within the limits. see "Camshaft".
8 Fit the push rods.
10 Adjust the valve tip clearance, see Operation 3-7.
CUKUROVA Model 885


General description
The cylinder block is made of high duty cast iron with an integral crankcase. The sides of the cylinder block
extend below the crankshaft centre line to give added strength. The cylinder block provides full length
support for the cylinder bores.
All bores are honed with silicon carbide tools to a controlled finish to ensure long life and low oil
consumption. A bush is fitted in the cylinder block for the front camshaft journal and the other camshaft
journals run directly in the block.
Note: Your Perkins Dealer/Distributor has specialist equipment and personnel with the correct training to
repair worn cylinder bores.
Cylinder block
Notes:
- If the cylinder block is to be renewed, it may be necessary to change the grade of the connecting rods, see
the table in Operation 4-11. This will occur if the correct piston height above the block face cannot be
maintained with the original piston and connecting rod assemblies, see Operation 4-6.
- All of the components that need to be removed for access to the cylinder block are referred to in the
procedure below. As a result some of the stages within operations may be repeated.
1 Ensure that all engine fluids are drained.
2 Remove the ECM, if fitted, see Operation 14-13, the wiring harness, and the speed and timing sensor, if
fitted, see Operation 14-16.
3 Remove the VLPM, if fitted, see Operation 14-14.
4 Remove the lubricating oil cooler, see Operation 12-10.
5 Remove the lubricating oil filter head, see Operation 10-3.
6 Remove the cylinder head, see Operation 3-9.
7 Remove the crankshaft, see Operation 5-10.
8 Remove the piston and the connecting rod assemblies, see Operation 4-4.
9 Remove the camshaft, see Operation 6-19.
10 Remove the piston coating jets, if fitted, see Operation 4-15.
CUKUROVA Model 885


Special Requirements
Consumable products
I
I
1 Clean thoroughly the new cylinder block. Ensure that all the oil passages are clean and free from debris.
2 Remove the threaded plugs from the old cylinder block and clean the threads. Seal the threads with
POWER PART Threadlock and nutlock, and fit the threaded plugs into the new cylinder block.
3 Fit the piston cooling jets, see Operation 4-15.
4 Fit the crankshaft, see Operation 5-11. Do not fit the lubrication oil sump at this time.
5 Fit the piston and connecting rod assemblies, see Operation 4-5.
6 Fit the camshaft, see Operation 6-20.
7 Fit the lubricating oil filter housing, see Operation 10-3.
8 Fit the lubricating oil cooler, see Operation 12-11.
9 Fit the ECM, if removed, see Operation 14-13, the wiring harness, and the speed and timing sensor, if
removed, see Operation 14-16.
10 Fit the VLPM, if removed, see Operation 14-14.
11 Install the engine into the vehicle or machine.
13 Fill the lubricating oil sump to the correct level with an approved lubricating oil.
14 Eliminate air from the fuel system, see Operation 11-8.
To Inspect Operation 7 - 3
1 Clean the internal passages for the coolant and the oil.
2 Check the cylinder block for cracks and for other damage.
3 Check the camshaft bush for wear. If the bush is to be renewed, use a suitable adaptor to press it out of
the bore. Ensure that the lubricating oil hole in the new bush (A1) will be towards the front of the engine
when fitted. Press in the new bush with the oil hole on the same side and aligned with the oil hole in the
block until the front end of the bush is aligned with the face of the recess.
CUKUROVA Model 885


Cylinder bore
To ensure the best performance during the life of the engine it is important that worn or damaged cylinder
bores are re-bored and re-honed.
The condition of a cylinder bore is decided by:
- The amount and location of any polished areas
- Wear
- Damage to the bore wall.
Note: It will not be necessary to re-bore/re-hone if:
- The honed finish can still be clearly seen.
- The engine performance and oil consumption are acceptable.
To check the condition of a cylinder bore
1 Inspect the bore surface for cracks and deep scratches.
2 Check the bore wall for areas where the honed finish has been polished away. Check especially the area
around the top of the bore just below the carbon ring. In this area, thrust from the top piston ring is at its
maximum.
Cautions:
- Do not use "Flex-hone" to repair cylinder bores.
- New oversized piston and rings must be fitted when the cylinder bore is re-bored/re-honed.
- An engine can have high oil consumption with very little wear of the bores, if the surfaces of the bores are
glazed.
- Specialist training and equipment are needed to machine the finish of a cylinder bore.
CUKUROVA Model 885


Engine timing
General description
To ensure that the 1100 Series 4 cylinder engines have an accurate system of timing, the engines are pin
timed.
This system will set the engine so that number one piston is at top dead centre (TOG) on the compression
stroke.
To reach the accurate fuel injection needed for engines to conform to emissions legislation, the latest fuel
injection pumps operate at a static timing of TDC.
It is important that fuel injection timing is accurate to conform to emissions legislation. Always use Operation
8-1 to obtain TOG on the compression stroke of number one cylinder.
Cautions:
- If the hub nut (A1) is loosened the Bosch VP30 fuel injection pump timing will be lost and the fuel injection
pump will have to be removed and sent to your nearest Perkins Dealer/Distributor to be reset.
- The Delphi DP210 nut (B1) must not be released until TOG on the compression stroke is set, the backlash
is removed from the fuel injection pump gear and the fuel pump shaft is locked. If the nut (B1) is loosened
before TDG on the compression stroke is set and the fuel pump shaft is locked the fuel pump timing will be
lost. The pump will have to be removed and sent to your nearest Perkins Dealer/Distributor to be reset.
- The Bosch EPVE nut (B1) must not be released until TDC on the compression stroke is set, the backlash is
removed from the fuel injection pump gear and the fuel pump shaft is locked. If the nut (B1) is loosened
before TOG on the compression stroke is set and the fuel pump shaft is locked, the fuel pump timing will
be lost. To adjust the fuel pump timing see, Operation 8-4 .
CUKUROVA Model 885


Engine timing
To set number 1 piston to TDC on the compression stroke Operation 8 - 1
Special tools
Crankshaft timing pin 27610211 Fuel pump timing pin 27610212
Cautions:
- This procedure must only be carried out by a person with the correct training.
- The timing pins are a push fit. Do not use excessive force to fit the pins.
- Do not use the pins as a locking device when repairs are carried out on the engine.
- The timing pins must be removed before the timing case cover is fitted. Failure to do so will damage the
engine.
- The marks on the timing gears are not to be use as timing marks. The marks indicate the front of the gear
only.

2 Remove the glow plugs, see Operation 14-10.
3 Remove the timing case cover see, Operation 6-1.
Note: The crankshaft timing pin can be inserted with the crankshaft pulley still fitted.
4 To set the No 1 piston to TOC on the correct stroke. rotate the crankshaft in the normal direction of rotation
until the intake valve (A 7) of number 4 cylinder has just opened and the exhaust valve (A8) of the same
cylinder has not closed completely.
5 Carefully rotate the crankshaft in the normal direction of rotation. Align the hole in the crankshaft with the
hole in the cylinder block and the timing case (B1). Insert the crankshaft timing pin through the timing case
and the cylinder block. Push the pin fully into the hole in the crankshaft web.
6 Insert the camshaft timing pin, through the hole in the camshaft gear (B2) and into the body of the timing
case. With the two timing pins fitted the engine is set at TOC number one on the compression stroke.
Note: The camshaft timing pin is a push fit into the timing case. The camshaft-gear can rotate a small
amount when the pin is fitted. This is to allow the assembly of the gears and removal of the backlash
from the gears, with the timing pins fitted.
7 Remove the timing pin from each gear.

CUKUROVA Model 885


To check the timing of the Bosch VP30 fuel injection pump Operation 8 - 2
Special tools
Cautions:
- If the hub nut (C1) is loosened the fuel injection pump timing will be lost and the fuel injection pump will
have to be removed and sent to your nearest Perkins Dealer/Distributor to be reset.
- Do not use the pins as a locking device when repairs are carried out on the engine.
- The fuel pump timing pin is a push fit. Do not use excessive force to fit the pin.
1 Rotate the crankshaft to obtain TDC, see Operation 8-1.
Note: Do not remove the timing pins from the engine after TDC is set.
2 Insert the fuel pump timing pin through the gear (A1) and through the slot in the hub (B1). Push the pin fully
into the hole (B2) in the body of the fuel injection pump.
3 With all three timing pins fitted, the engine is set at TDC No 1 piston and the fuel injection pump timing is
correct
4 If the timing pin cannot be pushed into the fuel injection pump body, and the engine is correctly set at TDC,
see Operation 8-1, the fuel injection pump must be removed, see Operation 11-9, and sent to your nearest
Perkins Dealer/Distributor to be reset.
5 Remove all timing pins from the engine.
CUKUROVA Model 885


To check the timing of the Bosch EPVE fuel injection pump Operation 8 - 3
Special tools
Bosch EPVE fuel pump timing adaptor 27610248
Caution: This procedure must only be carried out by a person with the correct training.
2 Remove the high pressure fuel pipes from the fuel injection pump.
3 Remove the plug (A1) and washer from the rear of the fuel pump and fit the Bosch EPVE fuel pump timing
adaptor (B1), and a suitable dial gauge (B2). Set the dial gauge to indicate approximately 3,0 mm.
4 Slowly rotate the crankshaft, counter-clockwise from the front of the engine, until the dial gauge indicates
that the plunger of the fuel injection pump is at the bottom of its stroke. Set the dial to zero.
5 Slowly rotate the crankshaft clockwise, until the crankshaft timing pin can be pushed into the crankshaft
web. With the engine set at TDC, check the reading on the dial gauge. Fuel injection pump with the code
ER has a plunger lift of 1,55 mm (0.061in).
6 If the fuel pump timing is correct, remove the dial gauge and the Bosch EPVE fuel pump timing adaptor. Fit
a new washer and the plug. Tighten the plug to 29 Nm (21 Lbft) 2,9 kgf m.
7 If the fuel injection pump timing is to be adjusted, see Operation 8-4.
8 Fit the high pressure fuel pipes to the fuel injection pump.
9 Eliminate the air from the fuel system, see Operation 11-8.
CUKUROVA Model 885


To adjust the timing of the Bosch EPVE fuel injection pump Operation 8 - 4
Special tools
Bosch EPVE fuel pump timing 27610248
adaptor
Cautions:
- Do not turn the fuel injection pump with the pump shaft locked.
3 Remove the high-pressure fuel pipes from the fuel injection pump.
4 Remove the plug and washer from the rear of the fuel pump and fit the Bosch EPVE fuel pump timing
adaptor (A1) and a suitable dial gauge (A2). Set the dial gauge to indicate approximately 3,0 mm.
5 Remove the timing pins.
6 Rotate the crankshaft slowly counter-clockwise and then clockwise, until the needle of the dial gauge
indicates that the plunger of the fuel injection pump is at the bottom of its stroke. Set the dial to zero.
7 Rotate the crankshaft slowly clockwise, until the needle of the dial gauge indicates the required plunger lift,
see Operation 8-3.
8 To lock the Bosch EPVE pump shaft, loosen the locking screw (B2) and remove the washer (B1). Tighten
the locking screw (B2) to 31 Nm (23 Ibf ft) 3,1 kgf m. Ensure that the needle of the dial gauge has not
moved.
9 Remove the Bosch mechanical fuel pump gear, see Operation 6-3.
Notes:
- There no key fitted into the keyway (C1).

- If the fuel injection pump is on the correct stroke, the keyway (C1) is towards the outlet (D1).
CUKUROVA Model 885


11 Fit the fuel pump gear, see Operation 6-4.
12 Ensure that the needle of the dial gauge has not moved. Remove the dial gauge and the Bosch EPVE
fuel pump timing adaptor (A1). Fit a new washer and tighten the plug (E1) to 29 Nm (21 Ibf ft) 2,9 kgf m.
14 Fit the high pressure fuel pipes.
To check the timing of the Delphi DP210 fuel injection pump Operation 8-5
Caution: The fuel pump timing of the Delphi DP210 fuel injection pump most not be checked or adjusted. If
the fuel pump timing is lost, the pump must be removed and sent to your nearest Perkins
Dealer/Distributor to be reset.
Note: To remove the Delphi DP210 fuel injection pump, see Operation 11-13.
CUKUROVA Model 885


To check the valve liming Operation 8 - 6
Note: Do not fit the timing case cover, the glow plugs or the rocker cover at this stage.
1 Set the piston of number 1 cylinder to TDC on the compression stroke, see Operation 8-1.
2 Mark the pulley at TDC. Set a temporary pointer to the mark.
3 For naturally aspirated engines:

- Set the valve tip clearance of number 1 cylinder intake valve to 0,589 mm (0,023 in) and No 1 exhaust
valve to 0,698 mm (0.027 in).
4 For turbocharged engines:

- Set the valve tip clearance of number 1 cylinder intake valve to 1,220 mm (0.048 in) and No 1 exhaust
valve to 1,302 mm (0.051 in).
5 Rotate the crankshaft, clockwise from the front, until the push rod of number 1 cylinder intake valve is just
loose and the push rod for number 1 exhaust valve is equally loose. In this position, check if the mark on
the crankshaft pulley or damper is within +/- 2.5º of the temporary pointer. Use the formula below to find
the measurement which is equal to 2.5º on the pulley or damper.
CxP
360
C = circumference of pulley or damper
P = 2.5 degrees
6 If the timing is more than 2.5º out of position, the timing gears are likely not to be in correct mesh.
Notes:
- One tooth on the camshaft gear is equivalent to 18 mm (0.62in) at the circumference of a pulley of 200 mm
(7.87 in) diameter.
- One tooth on the camshaft gear is equivalent to 16 mm (0.70 in) at the circumference of a pulley of 170 mm
(6.69 in) diameter.
7 Rotate the crankshaft, clockwise from the front, until the intake valve of the rear cylinder has just opened,
and the exhaust valve has just closed. Set the valve tip clearance of the intake valve of No 1 cylinder to
0,20 mm (0.008 in). Set the valve tip clearance of the exhaust valve of No 1 cylinder to 0,45 mm (0.018 in).
8 Fit the timing case front cover, see Operation 6-2.
11 Remove the temporary pointer from the timing case and the timing mark from the pulley.
CUKUROVA Model 885


Aspiration system
General description
Warning! Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris
away from the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
The turbocharger is fitted between the exhaust and intake manifold and is driven by exhaust gas. The
turbocharger passes air to the engine at more than atmospheric pressure. It is lubricated by oil from the main
gallery. The oil enters through the bearing housing of the turbocharger and returns to the cylinder block.
From there it is returned to the lubricating oil sump.
All turbochargers that are fitted with a waste-gate unit (B1). The waste-gate, which is controlled by boost
pressure from the inlet manifold, will allow some of the exhaust gases to by-pass the turbine rotor at higher
engine speeds. With this arrangement the turbocharger can be designed to be more effective at lower
engine speeds.
CUKUROVA Model 885


Aspiration system
To remove and to fit an exhaust elbow Operation 9 - 1
To remove
1 Remove the two setscrews (A3) from the exhaust elbow (A1).
2 Pull the exhaust elbow (A1) away from the adaptor (A4).
To fit
1 Ensure that all the component faces are clean and free from damage, renew if necessary.
2 Push the exhaust elbow (A1) onto the adaptor (A4).
3 Align the exhaust elbow (A1) to the support bracket (B 1) and the exhaust pipe of the application.
4 Fit the setscrews (A3) and tighten to 44 Nm (33 Ibf ft) 4,5 kgf m.
Note: If the support bracket (B1) is to be removed and fitted, remove the exhaust elbow, and remove the
three setscrews that hold the support bracket. To fit the bracket, align the support bracket to the
cylinder block. Fit the top setscrew (A2) to align the bracket, then fit the two remaining setscrews.
Tighten to 44 Nm (33 Ibf ft) 4,5 kgf m.
5 Connect the exhaust elbow to the application.
CUKUROVA Model 885


Turbocharger side mounted
Warnings!
- The sealing washers used on the lubricating oil pipe (B1) contain Viton. Read the safety precautions.
- Discard old lubricating oil in a safe place and in accordance with local regulations.
Caution: Ensure that the turbocharger waste-gate and the actuator rod of the waste-gate are not used to lift
or move the turbocharger. This could damage the waste-gate and affect the calibration.
1 Thoroughly clean the turbocharger.
2 Remove the air cleaner hose at the compressor inlet.
3 Put a suitable container under the oil drain pipe.
4 Disconnect the exhaust pipe for the application and remove the exhaust elbow from the turbocharger, see
Operation 9-1.
5 Remove the three nuts (A2) of the adaptor plate and remove the adaptor plate (A3).
6 Release the hose clip of the compressor outlet. Remove the setscrews of the crossover pipe. Remove the
crossover pipe complete with the old gasket and hose. Discard the gasket.
7 Remove the banjo bolts (A5) and the sealing washers. Remove the pipe and discard the old sealing
washers.
8 Remove the setscrews (A4) from the bottom flange of the oil drain pipe.
9 Remove the nuts (A1) at the turbocharger to exhaust manifold flange. Remove the turbocharger and the
gasket with the drain pipe. Remove the bottom joint of the drain pipe.
10 Remove the setscrews from the top of the oil drain pipe and remove the pipe and joint from the
turbocharger. Discard all old joints and gaskets. Cover the open ports in the manifold, the turbocharger
and the pipes to ensure that dirt will not enter.
11 Check the air hoses and the oil drain pipe for damage, renew if necessary.
CUKUROVA Model 885


To Fit Operation 9 - 3
Warning! The sealing washers used on the lubricating oil pipe (B1) contain Viton. Read the safety
precautions.
Cautions:
- The compressor inlet hose has a heat shield material that partly covers the hose. When a new hose is
fitted, the hose must be correctly aligned to the exhaust to protect the hose from the heat.
- When a new compressor inlet hose is to be fitted, use a water and 5% soap solution to fit the hose into
position. Do not use oil or grease.
- The reflective heat shield of the inlet hose must be kept clean and free from dust, oil or paint. If the surface
of the heat shield is not shiny, the part that is protected by the heat shield could be damaged.
1 Remove the covers from the pipes, manifold and turbocharger.
2 Check that the turbocharger inlet and outlet ports are clean and free from restriction and that the
turbocharger shaft rotates freely. Also check that the open ports in the intake crossover pipe and the
exhaust pipe are clean and free from restriction.
3 Fit loosely the drain pipe (A2) and its new joint to the turbocharger (A1).
Note: The turbocharger drain pipe has different size setscrews. The top flange has 6 mm setscrews and the
bottom flange has 8 mm setscrews.
4 Fit a new gasket (A4) to the exhaust manifold flange. If the original nuts are to be used, ensure that the
threads of the studs are clean. Apply a suitable compound to the studs to prevent seizure.
Note: The threads of new nuts are phosphated to prevent seizure.
5 Fit the turbocharger (A1). Fit the nuts (B1) and tighten them to 47 Nm (34 Ibf ft) 4,8 kgf m.
6 Fit the bottom flange of the pipe (A2) together with a new joint and tighten the flange setscrews to
22 Nm (161bf ft) 2,2 kgf m. Tighten the top flange setscrews to 9 Nm (7 Ibf ft) 0,9 kgf m.
7 Lubricate the bearing housing of the turbocharger with clean engine lubricating oil. Fit loosely the pipe (A3)
and new sealing washers. Tighten both banjo bolts to 22 Nm (16 Ibf ft) 2,2 kgf m.
Note: Ensure that the lubricating oil pipe (A3) does not come in contact with other components.
8 Fit the adaptor plate (C4) to the turbocharger and fit loosely the three nuts.
9 Fit the exhaust elbow to the adaptor, see Operation 9-1.
10 With the elbow secure, tighten the nut (C1) by hand, then (C2) and (C3). Tighten the nuts in the same
sequence to 25 Nm (18 Ibf ft) 2,5 kgf m.
CUKUROVA Model 885


11 Connect the exhaust pipe for the application to the exhaust elbow.
12 Fit the crossover pipe and hose to the turbocharger. Tighten the setscrews to 22 Nm (16 Ibf ft)
2,2 kgf m. Tighten the hose clip to 5 Nm (4lbf ft) 0,5 kgf m.
13 Check that there is no restriction in the hose from the air filter to the turbocharger. Fit the hose and tighten
the clip to 5 Nm (4 Ibf ft) 0,5 kgf m .
To check the operation of the waste-gate Operation 9 - 4
If the waste-gate valve does not operate at the correct pressure, it can affect the engine performance.
If the valve opens at a low pressure, this can cause black exhaust smoke and loss of power at lower engine
speeds.
1 Disconnect the actuator hose (A2) at the actuator. Connect to the actuator an air supply which can be
adjusted accurately and is fitted with an accurate gauge.
2 Fasten a dial test indicator (A1) to the turbocharger with its plunger in contact with the end of the actuator
rod (A3) to measure the axial movement of the rod.
Caution: Do not apply an air pressure of more than 205 kPa (30 Ibflin 2 ) 2,1 kgUcm2 to the actuator.
Higher pressures may damage the actuator.
3 Slowly apply air pressure. Check that the pressure necessary to move the rod 1,00 mm (0.039 in), is within
limits, refer to the Data and dimensions for "Turbocharger". Ensure that the pointer returns to zero when
the pressure is released. Repeat the test several times to ensure that an accurate reading is obtained. It
may be necessary to lightly hit the turbine housing with a soft hammer during the test operation.
4 Consult your nearest Perkins Dealer/Distributor if the operation of the waste-gate is not correct.
5 If the air pressure is correct, release the air pressure, remove the test equipment and connect the actuator
CUKUROVA Model 885


Turbocharger faults
Caution: If the turbocharger or waste-gate is found to be damaged or faulty, a new turbocharger must be
fitted. The chart below is given to assist in the correct diagnosis of turbocharger faults.
Problems Possible causes code numbers

Not enough power 1,4,5,6,7,8,9.10,11,18,20,21,22,25,26,27,28,34.35.36
Black smoke 1,4.5,6,7.8.9,10,11,18,20,21,22,25,26,27,28.34.35,36
Blue smoke 1.2,4,6.8,9,17,19,20,21,22,30,31,32,34
High lubricating oil consumption 2,8,15,17.19,20,28,29,31,32,34
Too much lubricating oil at turbine end 2,7,8,17,19.20,22,28,30,31,32
Too much lubricating oil at compressor end 1,2,4,5.6,8.19,20,21,28,31,32
Not enough lubrication 8,12,14,15,16,23,24,29,32,33,37,38

Lubricating oil in the exhaust manifold 2,7, 17,18. 19,20,2~28,31,32
Inside of the intake manifold wet 1,2,3,4,5,6,8,10,11,17,18,19,20,21,28,32,34,
Damaged compressor impeller 3,4,6,8,12.15,16,20,21,23,24,29,32,33,37,38
Damaged turbine rotor 7,8,12. 13, 14,15,16,18,20,22,23,24,25,27,29,32,33,37,38
3,6,7,8.12,13,14,15,16,18,20.21,22,23,24,29,32,33.37,
Rotating assembly does not turn freely
38
Worn bearings, bearing bores, journals 6,7,8,12,13,14,15,16.23,24,29,33,37,38
1,3,4,5,6,7,8,9,10,11,12,13,14,15,16,18,20,21,22,23,
Noise from turbocharger
24,29,32,33,34,37,38
Sludge or carbon deposit in bearing housing 2,11.13,14.15,17,18,24,29,33,37,38
CUKUROVA Model 885


List of Possible Causes
1 Element of the air filter dirty.

2 Restricted crankcase breather.
3 Element of the air filter not fitted, or not sealing correctly. Loose connection to turbocharger.
4 Internal distortion or restriction in pipe from air filter to turbocharger.
5 Damaged/restricted crossover pipe, turbocharger to intake manifold.
6 Restriction between air filter and turbocharger.
7 Restriction in exhaust system.
8 Turbocharger loose or clamps/setscrews loose.
9 Intake manifold crossover pipe has cracks, is loose, or has flange distortion.
10 Exhaust manifold has cracks, is loose, or has flange distortion.
11 Restricted exhaust system.
12 Delay of lubricating oil to turbocharger at engine start.
13 Insufficient lubrication.
14 Dirty lubricating oil.
15 Incorrect lubricating oil.
16 Restricted lubricating oil supply pipe.
17 Restricted lubricating oil drain pipe.
18 Turbine housing damaged or restricted.
19 Leakage from turbocharger seals.
20 Worn turbocharger bearings.
21 Excessive dirt in compressor housing.
22 Excessive carbon behind turbine rotor.
23 Engine speed raised too rapidly at initial start.
24 Insufficient engine idle period.
25 Faulty fuel injection pump.
26 Worn or damaged atomizers.
27 Valves burned.
28 Worn piston rings.
29 Lubricating oil leakage from supply pipe.
30 Excessive preservation fluid (on initial engine start).
31 Excessive engine idle period.
32 Restriction in turbocharger bearing housing.
33 Restriction in lubricating oil filter.
34 Wet type air cleaner: Restricted, dirty element, viscosity of oil too low/high.
35 Waste-gate actuator faulty or damaged.
36 Waste-gate valve not free.
37 Engine stopped too soon from high load.
38 Insufficient lubricating oil.
CUKUROVA Model 885


Open engine breather
To remove and to fit the breather pipe Operation 9 - 5
To remove
1 Release the hose clip and remove the hose from the breather pipe assembly.
2 Release the two fasteners (A2) and pull the breather pipe assembly (A1) out of the rocker cover.
3 Remove the ‘’ 0 ’’ ring (A3).
4 Remove the joint (A4) and the two fasteners (A2) from the breather pipe assembly.
5 Clean all the components and discard all joints and "O" rings.
To fit
1 Fit the new joint (B4) into the breather pipe housing.
2 Push the two fasteners (B2) into the breather pipe assembly.
3 Fit a new '’ 0 " ring (B3) to the breather pipe assembly and lubricate the " 0 " ring with clean lubricating
engine oil.
4 Push the breather pipe assembly into the rocker cover and tighten the fasteners to 9 Nm(7 Ibf ft) 0,9 kgf m.
5 Fit the breather hose and tighten the clip to 5 Nm (4 Ibf ft) 0,5 kgf m .
CUKUROVA Model 885


Naturally aspirated engine breather
To remove and fit the breather pipe Operation 9 - 6
To remove
1 Release the two fasteners (A2) and pull the breather pipe assembly (A1) out of the rocker cover.
2 Remove the " 0 ’’ ring (A3).
3 Remove the joint (A4) and the two fasteners (A2) from the breather pipe assembly.
4 Clean all the components and discard all joints and ‘0’ rings.
To fit
1 Fit the new joint (B4) into the breather pipe housing.
2 Push the two fasteners (B2) into the breather pipe assembly.
3 Fit a new "0" ring (B3) to the breather pipe assembly and lubricate the "0" ring with clean lubricating engine
oil.
4 Push the breather pipe assembly into the rocker cover and tighten the fasteners to 9 Nm(7 Ibf ft) 0,9 kgf m.
5 Fit the breather hose and tighten the clip to 5 Nm (4 Ibf ft) 0.5 kgf m.
CUKUROVA Model 885


Closed engine breather
To clean and to renew Operation 9 - 7
Note: For details on how to change the closed crankcase breather and element, contact your nearest
Perkins Dealer/Distributor for advice.
Lubrication system
General description
Pressure lubrication is supplied by a rotor type pump which is driven through an idler gear from the
crankshaft gear. The pump has an inner rotor and an outer rotor which are off-set to each other. There is an
interference fit between the inner rotor and the drive shaft. When the pump rotates, the space between the
lobes which are in mesh increases to cause a suction to fill the space and the decrease to create a pressure
increase.
Lubricating oil from the sump passes through a strainer and pipe into the suction side of the pump. The
pump delivers the oil to the cylinder block. If an oil cooler is fitted the oil is transferred to and from the oil
cooler by a internal passage in the cylinder block. The oil is transferred by the oil pump frame to the oil filter
passage in the cylinder block. If an oil cooler is not fitted the oil is transferred directly to the oil filter passage.
Then relief valve is integral with the pump and re-circulates the excess oil directly back to oil pump inlet. The
lubricating oil passes through the oil filter and directly back to the main pressure rail which drilled the full
length of the left side of the cylinder block.
From the pressure rail, lubricating oil passes to the main bearings of the crankshaft and through passages in
the crankshaft to the big end bearings. The pistons and the cylinder bores by the oil jets which are attached
the main pressure rail.
Lubricating oil passes from the main bearings through passages in the cylinder block to the journals of the
camshaft. The front camshaft bearings feed oil through a drilling in the cylinder block and cylinder head to
the rocker shaft. The oil passes through the centre of the rocker shaft to the rocker levers. The rocker pads,
valve stems, cam lobes and the tappets are splash lubricated.
The hub of the idler gear is lubricated by oil from the end pressure rail and the timing gears are splash
lubricated.
The lubricating oil for turbochargers is delivered by an external pipe from a tapping on the side of the cylinder
block above the right hand side of filter face. The oil returns from the turbocharger down another extended
drain pipe into the side of the cylinder block from a connection on the right side of the cylinder block. or filter
head, through an external pipe to the turbocharger, The oil passes through the turbocharger and returns
through a pipe to the sump.
Top mounted turbochargers are fed from the filter head, or from a connection on the right hand side of the
engine.
These engines are fitted with piston cooling jets that are connected-to the oil pressure rail and spray
lubricating oil inside the pistons to keep them cool.
Key to the oil flow diagram.
1 Suction pressure to the lubrication oil pump.
2 Main engine lubrication oil pressure.
3 Reduced engine lubrication oil pressure.
CUKUROVA Model 885


Lubrication system flow diagram
CUKUROVA Model 885


Filter canister
To renew (canister type oil filter ) Operation 10 - 1
Warning! Discard the used canister, and lubricating oil in a safe place and in accordance with local
regulations.
Cautions:
- The canister contains a valve and a special tube to ensure that lubricating oil does not drain from the filter,
when the lubricating oil is changed. Ensure that the correct Perkins POWERPART canister is used.
- Ensure that the application is on a level surface to ensure an accurate reading on the dipstick.
1 Put a suitable container below the lubricating oil filter.
2 Remove the filter canister with a strap wrench. Ensure that the adaptor is secure in the filter head. Discard
the canister.
3 Clean the filter head.
4 If the filter canister is mounted vertically position (A) add clean engine lubricating oil to the new canister.
Allow the oil enough time to pass through the filter element.
5 Lubricate the top of the canister seal (A1) with clean engine lubricating oil.
6 Fit the new canister and tighten by hand only. 00 not use a strap wrench.
7 Remove the container and discard the old lubricating oil.
8 Operate the engine and check for leakage from the filter. When the engine has cooled, check the oil level
on the dipstick and add more oil into the sump, as necessary.
CUKUROVA Model 885


To renew (element type oil filter) Operation 10 - 2
Warning! Discard the used element and lubricating oil in a safe place and in accordance with local
regulations.
Caution: Ensure that the application is on a level surface to ensure an accurate reading on the dipstick.
1 Put a suitable container below the lubricating oil filter.
Note: On the horizontal filter assembly the drain plug (A2) is in the filter head and should not be removed.
2 Remove the drain plug (A2) together with the seal and drain the lubricating oil.
3 Fit a 1/2" square drive ratchet into the recess (A1) and remove the filter casing (A3). Discard the old filter
element.
4 Clean the filter casing and replace the seal (B2). Fit a new seal to the drain plug and fit the plug finger tight.
5 Fit the new filter element (B1) into the casing and rotate the element to locate it into position.
6 If the filter casing is in vertically mounted position (A), add clean engine lubricating oil to the filter casing.
Allow the oil enough time to pass through the filter element.
7 Lubricate the seal (B2) with clean engine lubricating oil. Fit the casing (A3) into the filter head (A4).
8 Tighten the casing (A3) to 25 Nm (18 Ibf ft) 2,5 kgf m.
9 Tighten the drain plug to 12 Nm (9 Ibf ft) 1,2 kgf m.
10 Remove the container and discard the old lubricating oil.
11 Operate the engine and check for leakage from the filter. When the engine has cooled, check the oil level
on the dipstick and add more oil into the sump, as necessary.
CUKUROVA Model 885


Filter Head
Consumable products
To remove
Caution: If a balancer is fitted, the oil filter head must only be mounted on the left hand of the engine.
1 Put a tray under the filter head to contain spilt lubricating oil.
2 Remove the filter canister, see Operation 10-1 or Operation 10-2.
3 Remove the setscrews and remove the filter head (A2) (B2) from the cylinder block. Discard the joint (A1)
(B1).
4 Clean the joint face (A1) (B1) of the filter head and the cylinder block.
To fit
1 Ensure that all joint surfaces are clean and free from damage.
2 Fit a new joint to the filter head the joint is fitted dry.
Note: The setscrews for securing the filter head have a sealant (MEAS) applied by the manufacturer to the
first 13,0 mm (0.50 in) of the threads. If the setscrews are used again, the sealant must be removed
from the male and female threads and POWERPART Threadlock and nutlock applied to the first
13,0mm (0.50 in) of the setscrew threads.
3 Fit the filter head to the cylinder block. Gradually and evenly tighten the setscrews
4 Fit the new filter canisters, see Operation 10-1 or Operation 10-2.
CUKUROVA Model 885


Sump
To Remove Operation 10 - 4
Warnings!
- Discard the used lubricating oil in a safe place and in accordance with local regulations.
- Before the sump is removed, especially with the cast iron version, ensure that the sump is fully supported
before the setscrews are removed.
1 Operate the engine until it is warm.
2 Stop the engine, remove the sump drain plug (A1) and its '0' ring, and drain the oil. Where necessary,
remove the dipstick and the dipstick tube, see Operation 10-6.
3 Provide a support for the sump and remove the setscrews and, if relevant, the two nuts which fasten the
sump to the timing case. Lower the sump and remove and discard the joint.
4 Wash the sump with an approved cleaning fluid, ensure all the cleaning fluid is removed. Clean the flange
face of the sump and of the cylinder block.
Consumable products
POWERPART Threadlock and nutlock 21820117 POWERPART Silicone rubber sealant 1861108
Notes:
- If either the cylinder block bridge piece, and I or the timing case, have just been fitted then fit the sump
before any bridge piece / timing case sealant has been allowed to cure.
- If the sump only is to be fitted, then any old surface sealant from either the cylinder block bridge piece,
and/or the timing case, should be removed and renewed.
1 Remove any old sealant from the cylinder block bridge piece, timing case, and cylinder block joint
surfaces.
2 Ensure that the joint faces of the cylinder block and the sump are both free from dirt and damage.
CUKUROVA Model 885


3 Insert four alignment studs into holes (A1).
4 Apply a bead of POWERPART Silicone rubber sealant to the joints between the cylinder block and the
timing case (C1), and the cylinder block and the bridge piece (B2).
Note: Handle the sump joint with care as rubber-sealing bead can be easily damaged.
5 Place the joint onto the cylinder block over the alignment studs and ensure that all of the fixing holes align
correctly.
6 Place the sump onto the cylinder block over the alignment studs.
Note: The setscrews for securing the sump have a sealant (MEAS) applied by the manufacturer to the first
13,0 mm (0.50 in) of the threads. If the setscrews are used again, the sealant must be removed from
the male and female threads and POWERPART Threadlock and nutlock applied to the first 13,0 mm
(0.50 in) of the setscrew threads.
7 Loosely fit the setscrews into all of the available holes by hand.
8 Remove the alignment studs and fit the remainder of the setscrews.
9 Tighten the four setscrews (D1) to 22 Nm (16Ibfft) 2,2 kgf m.
10 Tighten the remaining setscrews to 22 Nm (161bf ft) 2,2 kgf m.
CUKUROVA Model 885


11 Fit the drain plug, if necessary fit a new ' 0' ring, and tighten to 34 Nm (25 Ibf ft) 3,5 kgf m.
12 Fill the sump to the mark (E2) on the dipstick with new engine lubricating oil of an approved grade
Dipstick Tube
Consumable products
POWERPART Threadlock and Nutlock 21820117
1 Remove the dipstick tube M16 gland nut and remove the tube from the sump.
2 Clean the gland nut and the thread in the sump of all old sealant
3 Ensure that the rubber seal is fitted to the dipstick tube assembly.
4 Apply POWERPART Threadlock and Nutlock to the threads of the gland nut.
5 Fit the dipstick tube to the sump in the correct position, tighten the gland nut to 18 Nm (14 Ibf ft) 1,8 kgf m.
CUKUROVA Model 885


Oil strainer and suction pipe
The oil strainer is an integral part of the suction pipe. No regular service is necessary but wash the strainer
when it is removed.
To remove
1 If not already removed; remove the lubricating oil sump, see Operation 10-4.
2 Remove the setscrews from the flange of the suction pipe. Remove the suction pipe and strainer. Remove
the old joint. Clean the flange face of the oil pump and the suction pipe.
To fit
1 Fit the suction pipe to the oil pump together with a new joint. Tighten the setscrews (A1).
1 Wash the assembly in an approved cleaning fluid and dry it thoroughly.
2 Check the pipe. the strainer and the welded joints for cracks and other damage.
3 If a component is damaged, renew as necessary.
CUKUROVA Model 885


Lubricating oil pump assembly
Warning! Discard the used lubricating oil in a safe place and in accordance with local regulations.
1 If not already removed: remove the lubricating oil sump, see Operation 10-4.
2 Remove the setscrews (A1) and remove the oil pump assembly.
1 Fill the oil pump assembly with clean engine lubricating oil. Fit the oil pump assembly to the cylinder block.
ensure that the dowel (A1) and the thimble (A2) are correctly located, then tighten the setscrews to 22 Nm
2 Check the idler gear for wear and other damage. If the gear is damaged, it must only be renewed as an
assembly. The assembly consists of an idler gear, an idler shaft and a front plate.
3 Check that there is backlash between the oil pump idler gear and the crankshaft gear (B).
CUKUROVA Model 885


Note: For all the clearances, refer to the Data and dimensions for the "Lubrication system".
1 Remove the setscrews and remove the cover of the oil pump.
2 Remove the outer rotor and clean all the parts. Check for cracks and any other damage.
3 Fit the outer rotor, and check the outer rotor to body clearance (A).
4 Check the inner rotor to outer rotor clearance (B).
5 Check the rotor end-float with a straight edge and a feeler gauge.
6 Lubricate the inner and outer rotor with clean engine lubricating oil. Clean the top face of the oil pump and
the inner face of the cover. Fit the cover. Tighten the setscrews to 28 Nm (21 Ibf ft) 2,9 kgf m .
Relief valve
To remove and to fit the relief valve of the balancer Operation 10 - 12
To remove
1 Remove the plug that retains the relief valve (A1). Remove the spring and valve (B).
To fit
1 Ensure the relief valve is clean.
2 Place the relief valve and spring into the balancer.
3 Tighten the plug for the relief valve (A1) to 22 Nm (161bf ft) 2,2 kgf m.
CUKUROVA Model 885


To remove and to fit the relief valve of the lubricating oil pump Operation 10 - 13
Caution: Do not change the operation pressure of the relief valve by a method other than the installation of
new components.
To remove
1 Remove the plug which fastens the relief valve (A1). and remove the spring and valve (B).
To fit
1 Ensure the relief valve is clean.
2 Place the valve spring and relief valve into the lubricating oil pump.
3 Tighten the plug for the relief valve (A1) to 22 Nm (16 Ibf ft) 2,2 kgf m .
To inspect the relief valve of the lubricating oil pump/balancer Operation 10 - 14
Caution: Do not change the operation pressure of the relief valve by a method other than the installation of
new components.
1 Check the spring for wear and other damage and. if possible, check the load necessary to compress the
spring to its fitted length, refer to the Data and dimensions for "Oil pressure relief valve (oil pump)" or "Oil
pressure relief valve (balancer)".
2 Check the plunger for wear and other damage and ensure that it slides easily in the bore of the relief valve.
3 Check the body and the end plug for wear and other damage.
4 Renew worn or damaged components.
CUKUROVA Model 885


Fuel system
General description
Cautions:
- There are no adjustments that can be carried out on the Bosch VP30 and Delphi DP210 fuel pumps. The
fuel injection equipment must only be checked by personnel who have had the correct training.
- If a fuel injection pump is returned for repair, or under warranty, then all of the fuel ports must be closed
with a plastic blanking cap to prevent the entry of water and dirt into the pump. If these blanking caps are
not fitted then the warranty will be affected.
- A new fuel injection pump will be supplied with the pump shaft in the locked position. The drive shaft of the
pump must not be turned without the spacer (B2) in position under the locking screw (B1).
The 1100 Series four cylinder engines are used for industrial, construction and agricultural applications and
use three different types of fuel injection pump:
- Bosch VP30 (A)
- Bosch EPVE (B)
- Delphi DP210 (C).
These fuel injection pumps conform to emissions legislation.
CUKUROVA Model 885


On the Bosch VP30 the pump timing, the speed adjustment and amount of fuel supplied are all controlled
electronically by the ECM. The fuel injection pump timing is by a pin (D1) that is fitted through the fuel pump
gear, the pump flange and into the pump body,
Bosch EPVE (E) and Delphi DP210 (F) fuel injection pumps have locking screws which lock the shaft. It is
important that the locking screw is released and the pump shaft is free to turn when the pump is fitted to the
engine.
The electronic fuel lift pump and fuel filter are a single assembly.
The maximum no-load speed is shown on the emissions data plate fitted to various positions on the side of
the cylinder block, see Engine identification".
The atomizers, which are of the valve covered orifice (VCO) type, have nozzles with five-boles. The
atomizers inject fuel in a very fine spray into the combustion chamber in the top of each piston.
The atomizers are set in the factory and are not serviceable; they must be checked in accordance with the
preventive maintenance schedules.
CUKUROVA Model 885


Cold start advance unit (KSB)
Delphi DP210 and Bosch EPVE (A) fuel injection pumps have a cold start advance unit that holds the timing
of the pump in an advanced position when the engine is cold.
Caution: It is important that the electrical connections to the sender unit are connected correctly. Failure of
the KSB to operate correctly could result in damage to the engine as the timing will be fully
advanced for normal operation. The sender unit, is on the rear of the timing case on the left side of
the engine with the engine cold, the sender unit energizes to advance the pump timing for the cold
start operation of the Delphi and Bosch fuel injection pumps.
Note: The wiring diagrams on the following page show the sender unit position when the engine is cold.
To ensure that the engine conforms to emissions legislation, it is important that the electrical connections of
the engine cold start advance unit are fitted correctly before the engine is operated.
Wiring diagrams for the cold start advance unit fitted to some Delphi DP210 Series and Bosch EPVE
injection pumps are shown in the illustrations (A), and (B) respectively. For easy identification the cables are
shown in circles on the illustrations.
The amperage of each of the cables is listed in the cable identification table below. The identification
numbers for the electrical components are shown in triangles. Refer to the component identification list to
find a component.
Cable identification (1) Component identification (2)

Cable (Number) Current (Amperes) Component Description
1 3 1 Fuel injection pump
2 3 2 Engine stop solenoid
3 6 3 Sender unit
4 3 4 Start switch
5 3 5 Cold start advance unit
(1) For numbers shown in circles
(2) For numbers shown in triangles
CUKUROVA Model 885


Typical fuel system
The position of the fuel system components may vary from application to application; this information is
provided for training purposes only.
Fuel from the tank passes to the electric lift pump filter (A4). Fuel leaves the lift pump (A3) under pressure to
the fuel injection pump (A6).
The fuel injection pump has a self-vent pipe to remove air from the fuel system back into the fuel tank
through a connection on the connector block. The fuel in the injection pump also lubricates and cools the
pump. The amount of fuel and the fuel injection timing is controlled by the Engine Control Module (ECM).
The fuel injection pump increases the fuel pressure and injects high-pressure fuel at the correct time and
sequence through pipes to the atomizers (A1).
CUKUROVA Model 885


Fuel Filter Assembly
To renew Operation 11 - 1
Warnings!
- The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or
with the eyes, see ' Viton seals" for safety precautions.
- Discard the used element and fuel oil in a safe place in accordance with local regulations.
- If the fuel level in the tank is higher than the fuel lift pump, the supply and return fuel line valves must be
turned off before servicing or repairs are made. If the fuel line valves are not turned off, fuel will flow
through the system.
- Ensure that the starter switch is in the OFF position before any service or repairs are made to the fuel
system. If the lift pump has power, fuel will be released.
Cautions:
- It is important that only genuine Perkins parts are used. The use of an element that is not a genuine
Perkins part may damage the fuel injection pump.
- The pre-filter canister and main filter elements must be renewed at the same time.
- Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean the area around the
connection. After a component has been disconnected, fit a suitable cover to a/l open connections.
1 Place a suitable container below the fuel filter assembly to retain spilled fuel oil.
2 Thoroughly clean the outside surfaces of the fuel filter assembly. Open the drain tap (A1) at the bottom of
the filter casing to drain the fuel from the filter.
3 Use a strap wrench to loosen the filter casing. Remove the casing and element from the fuel filter head.
4 To remove the filter element from the casing; Press down on the filter element (B1), against the spring,
pressure, and rotate the element to the left to release it from the filter casing (B4).
5 Put the new filter element inside the casing and press the element down against the spring pressure.
Rotate the element to the right to lock the element into the casing.
6 Fit a new seal (B3) to the casing and lightly lubricate the seal face with clean fuel oil.
7 Check that the thread (B2) on the inside of the element is not damaged.
8 Fit the filter assembly to the fuel filter head and tighten by hand until the filter assembly contacts the filter
head. Tighten the assembly a further 1/8 of a turn by hand. Do not use strap wrench.
9 Close the drain tap (A) and remove the container.
CUKUROVA Model 885


Atomizers
To identify a faulty atomizer Operation 11 - 2
Regular maintenance of the atomizers is not necessary. The atomizer should be renewed and not cleaned,
and renewed only if an atomizer fault occurs. The major problems that may indicate that new atomizers are
needed are listed below:
- Engine will not start or is difficult to start

- Not enough power
- Engine misfires or runs erratically
- High fuel consumption
- Black exhaust smoke
- Engine knocks or vibration
- Excessive engine temperature.
Warnings !
- If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
- Keep away from moving parts during engine operation. Some moving parts cannot be seen clearly while
the engine runs.
To find the defective atomizer, release the atomizer cover setscrews (A1) and remove the atomizer cover
(A2), run the engine at fast idle.
Release and tighten the union nuts (B1) of the high-pressure fuel pipe at each atomizer, one at a time. Do
not loosen the union nut more than half a turn. When the union nut of the defective atomizer is released. It
has little or no effect on the engine speed.
CUKUROVA Model 885


Cautions:
- Atomizers must be removed and fitted by a person with the correct training.
- Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly the area
around the connection. After a component has been disconnected, fit a suitable cover to all open
connections.
1 Release the atomizer cover setscrews (A1) and remove the atomizer cover (A2).
2 Remove the fuel leak-off pipe from the connection (C2).
3 Remove the union nuts of the high-pressure pipe from the atomizer (C1) and from the fuel injection pump.
Do not bend the pipe. If necessary, remove the pipe clamps. Fit a plastic cap to cover the fuel inlet
connection.
4 Remove the setscrew (C3) from the clamp (C4) and remove the atomizer and its seat washer from the
recess in the cylinder head.
Caution: Remove and discard the seat washer (B1). If the original seat washer remains in the recess for the
atomizer, the nozzle protrusion will be incorrect when a new seat washer is added.
CUKUROVA Model 885


1 Put the new seat washer (A2) into the seat recess in the cylinder head.
2 Ensure that the atomizer seal (A1) is not damaged. Apply a small amount of clean engine oil to the seal.
Caution: The atomizer must be fitted so that the two leak-off connections (B2) point away from the cylinder
head towards the intake manifold.
3 Place the atomizer (B1) into the recess in the cylinder head.
4 Fit the clamp (B4), tighten the setscrew (B3) for the clamp to 27 Nm (20 Ibf ft) 2,8 kgf m.
Caution: Do not tighten the union nuts of the high-pressure pipes to more than the recommended torque
value. If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the
atomizer inlet Do not tighten the atomizer union nut more, as this can cause a restriction at the end
of the pipe. This can affect the fuel delivery.
5 Remove the plastic cap and fit the high-pressure fuel pipe. Tighten the union nuts to 27Nm (20 Ibf ft)
2,8 kgf m.
6 If removed earlier, fit the high pressure fuel pipe clamps.
7 Fit the fuel leak-off pipes to the connectors (B2).
8 Operate the engine and check for leakage of fuel and that there is no air in the system.
9 Stop the engine. Refit the atomizer cover and tighten the setscrews, see Operation 3-1.
CUKUROVA Model 885


Fuel lift pump and filter assembly
Caution: Do not allow dirt to enter the fuel system. Before a connection is disconnected, clean thoroughly
the area around the connection. After a component has been disconnected, fit a suitable cover to
all open connections.
To remove
1 Disconnect the fuel pipes from the electric fuel lift pump and filter assembly.
2 Drain the electric fuel lift pump and filter assembly, see Operation 11-1.
3 Remove the setscrew (A2) and the spacer from the support bracket (A3) for the fuel pipes.
4 Remove the setscrews (A1) and rubber washers. Remove the electric fuel lift pump and filter assembly.
To fit
Note: Ensure that new rubber washers are fitted to the setscrews and the cylinder block before the electric
fuel lift pump and filter assembly is fitted.
1 Fit the setscrews (A1) and new rubber washers to the fuel lift pump and filter assembly.
2 Fit the spacer and the setscrew (A2) to the support bracket (A3) for the fuel pipe.
3 Fit the fuel pipes to the fuel lift pump and filter assembly.
4 Eliminate any trapped air from the fuel system, see Operation 11-8.
CUKUROVA Model 885


To Test Operation 11 - 6
1 Remove the two outlet fuel pipes from the electric fuel lift pump and filter assembly, make note of the
location of the pipes to ensure that the pipes are fitted correctly.
2 Connect two suitable rubber hoses to the outlet pipes (feed to fuel infection pump and return to the fuel
tank), and place into a three liter measuring cylinder.
3 Operate the engine until a consistent flow of fuel is running from the outlet pipe of the fuel injection pump.
Note: The return pipe to the fuel tank will have a slower flow than the feed pipe from the fuel injection pump.
4 The combined flow of both pipes should be at a rate of two liters/per minute as a minimum.
5 If the flow is less than two liters/per minute, replace the electric fuel lift pump and filter assembly.
6 Connect the electric fuel lift pump outlet pipes in the correct position.
To test pressure regulator Operation 11 - 7
1 Remove the fuel lift pipe from the fuel injection pump, fit a suitable pipe with a pressure test point and
connect a 0-80 kPa {0-12 Ibf in²) 0-0,8 kgf/cm² pressure gauge.
2 Operate the engine at idle for two minutes to allow any trapped air to be removed.
3 The reading on the pressure gauge should be as below:
- Bosch EPVE = 31 kPa (4.49 Ibf/lin²) 0.31 kgf/cm² at idle. and rated speed 31 kPa (4.49 Ibf/lin²) 0.31 kgf/cm²
- Bosch VP40 = 27,5 kPa (3.98 Ibf/lin²) 0.28 kgf/cm² at idle, and rated speed 24kPa (3.48 Ibf/lin²) 0.24
kgf/cm²
- Delphi DP210 = 27,5 kPa (3.98 Ibf/lin²) 0,28 kgf/cm² at idle, and rated speed 28kPa (4.06 Ibf/lin²)
0.28 kgflcm²
4 The combined flow of both pipes should be at a rate of two liters/per minute as a minimum.
5 Connect the fuel lift pipe to the fuel injection pump. Operate the engine at idle for two minutes.
Note: If the fuel lift pump and filter assembly does not meet the above specifications check for the following;
that all the electrical, connections are fitted, there are no leaks in the pipes and connections, that the
seal on the drain tap does not leak and that the ‘’O" ring for the canister to the lift pump does not leak.
CUKUROVA Model 885


Air in the fuel system
If air enters the fuel system, it must be removed before the engine can be started.
Air can enter the system if:
- The fuel tank is drained during normal operation

- The low-pressure fuel pipes are disconnected
- A part of the low-pressure fuel system leaks during engine operation
- A fuel system component such as a filter element, or a fuel pump, has been installed during a service
- The high pressure fuel pipes have been disconnected.
To eliminate air from the fuel system Operation 11 - 8
Cautions:
- Do not operate the engine until the air is eliminated from the fuel injection pump.
- After the air is eliminated, operate the engine at low idle for two minutes.
The Delphi DP210 fuel Injection pump will eliminate air automatically when the start key is turned to the RUN
position for three minutes.
The Bosch VE and the VP30 fuel injection pumps will not eliminate air automatically.
1 Release the atomizer cover setscrews and remove the atomizer cover, see Operation 3-1.
2 Turn the start key to the RUN position for three minutes, then return the key to the OFF position.
3 Loosen the high pressure pipes (A1) at the atomizers.
4 Operate the starter motor until fuel free from air comes from the connections.
5 Tighten the connections to 30 Nm (22 Ibf ft) 3,0 kgf m.
6 Start the engine and check for leaks.
7 Fit the atomizer cover and tighten its setscrews, see Operation 3-1.
CUKUROVA Model 885


Bosch VP30 fuel injection pump
General description
Cautions:
- Do not loosen the nut (A2) from the fuel injection pump. The fuel pump hub is fitted to the shaft in the
factory to ensure that the fuel pump is in the correct position for timing. If the nut is loosened and the hub
moves, the hub will need to be accurately fitted to the pump by use of specialist equipment before the pump
can be fitted to the engine.
pump must not be turned without the spacer (B2) in position under the locking screw (B1). Before the
crankshaft is turned, or the pump is fitted, put the spacer into position under the locking screw to ensure
that the pump drive shaft is released.
The manufacturer fits the hub (A2) to the pump to ensure very accurate timing. These engines have the drive
gear fastened to the hub instead of to the shaft of the pump.
The mounting flange has holes instead of slots to prevent incorrect adjustments to the engine timing by
rotation of the fuel pump.
Accurate timing of the pump to the engine is by a pin (A1) used to align the fuel pump gear and the hub with
a hole in the body of the fuel pump. The gear is passed over the pin and fastened to the hub with four
flanged setscrews and hardened washers.
An ' 0' ring (B3) is fitted into a groove in the pump flange. This ' 0' ring is fitted instead of a joint between the
pump flange and the timing case.
CUKUROVA Model 885


Special tools
Spanner for flange nut of the Bosch
21825964 Timing pin 27610032
fuel injection pump
Caution: Do not loosen the nut (A2) from the fuel injection pump. The fuel pump hub is fitted to the shaft in
the factory to ensure that the fuel pump is in the correct position for timing. If the hub is moved, the
hub will need to be accurately fitted to the pump by use of special equipment.
1 Disconnect the battery.
2 Set the engine to TDC number 1 cylinder compression stroke, see Operation 8-1.
3 Insert the timing pin (B5) through the hole (B3) in the fuel pump gear and the slot of the hub (B2). Push the
pin fully into the hole (B1) ill the body of the fuel pump. If the pin can be fully inserted then the pump timing
is correct
There should be no resistance when the pin is inserted.
Caution: Use a second spanner to prevent movement of the high pressure outlet on the pump when the
union nut for each high pressure pipe is released.
4 Remove the low pressure and the high pressure fuel pipes from the pump.
CUKUROVA Model 885


5 Disconnect the electrical connection by pulling the locking mechanism as shown (E) from the connector.
Carefully remove the connector from the fuel pump. Do not damage the pins of the connector.
Caution: Do not rotate the crankshaft when the pump is not on the engine.
6 Remove the four setscrews and the hardened washers (D4), remove the fuel pump gear from the hub of
the fuel injection pump.
7 Remove the setscrew from the fuel pump support bracket (F1).
8 Remove the setscrews and washers from the timing case that secure the fuel pump and remove the pump.
9 Discard the fuel pump ' 0' ring (C3).
CUKUROVA Model 885


Special tools
Spanner for flange nut of the
21825964 Timing pin 27610032
Cautions:
The engine must be set to TOG number 1 cylinder compression stroke before the pump is fitted, see
Operation 8-1.
A new fuel injection pump will be supplied with the pump shaft in the locked position. The drive shaft of the
pump must not be turned without the spacer (A2) in position under the locking screw (A1). Before the
crankshaft is turned, or the pump Is fitted, put the spacer into position under the locking screw to ensure that
the pump drive 'shaft is released.
1 Fit a new ' 0' ring (A3) to the pump flange.
2 Lightly lubricate the ' 0' ring with clean engine lubricating oil. Fit the pump into position in the timing case
and fit the three washers and setscrews.
CUKUROVA Model 885


3 Loosely fit the setscrew (C1) of the support bracket Ensure that force is not applied to the fuel injection
pump.
4 Put the fuel pump gear onto the hub of the fuel pump. The setscrews (B4) for the fuel pump gear should be
in the centre of the slots to allow for the removal of backlash. Loosely fit the setscrews.
5 Insert the timing pin (B5) through the hole (B3) of the fuel pump gear and the slot of the hub (B2) until it
can be pushed fully into the hole (B1) in the body of the fuel injection pump. If the timing pin cannot be
pushed into the pump body, check that the engine is correctly set at TDC on the number 1 cylinder, see
Operation 8-1.
6 Carefully turn the gear counter-clockwise by hand to remove the backlash between the idler gear and the
fuel pump gear. Do not rotate the crankshaft or the fuel injection pump shaft. Tighten the setscrews for the
fuel injection pump gear to 28 Nm (20 Ibf ft) 2,8 kgf m.
7 Remove the timing pin.
9 Tighten the setscrew (C1) of the support bracket to 44 Nm (32 Ibf ft) 4,4 kgf m. Ensure that force is not
applied to the fuel injection pump.
CUKUROVA Model 885


Cautions:
- Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension.
If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the pump outlet. Do
not tighten the pump union nut more, as this can cause a restriction at the end of the pipe. This can affect
the fuel delivery.
- Use a second spanner to prevent movement of the high pressure outlet on the pump when the union nut for
each high pressure pipe is tightened.
10 Fit the low pressure and the high pressure fuel pipes to the pump. Tighten the high pressure pipe union
nuts to 27,5 Nm (21Ibf ft) 2,8 kgf m.
11 Fit the electrical connector to the fuel pump; to fit the electrical connector, push the connector fully into
the socket on the fuel pump, to lock the connector to the fuel pump push in the locking clamp (D). Ensure
that the connector pins are not damaged.
Bosch EVPE fuel injection pump

General description
Caution: A new fuel injection pump will be supplied with the pump shaft in the locked position. The drive
shaft of the pump must not be turned without the spacer (B2) in position under the locking screw
(B1).
Bosch EPVE fuel injection pumps have a drive gear fastened to the shaft of the pump.
An O-ring (A3) is fitted into a groove in the pump flange. This O-ring is fitted instead of a joint between the
CUKUROVA Model 885


3 Lock the pump shaft; to lock the fuel injection pump shaft loosen the locking screw (A2) and remove the
spacer (A1). Tighten the locking screw (A2) to 31 Nm (23 Ibf ft) 3.1 kgf m.
Caution: Use a second spanner to prevent movement of the high pressure out/et on the pump when the
5 Remove the fuel pump gear, see Operation 6-3.
Note: Remove the KSB electrical connections.
6 Remove the setscrew from the fuel pump support bracket (B1).
7 Remove the setscrews and washers that secure the fuel pump and remove the pump.
8 Discard the fuel pump ' 0' ring (C3).
CUKUROVA Model 885


Cautions:
- The engine must be set to TDC number 1 cylinder compression stroke before the pump is fitted, see
Operation 8-1.
- A new fuel injection pump is supplied with the pump shaft in the locked position. The drive shaft of the
pump must not be turned without the spacer (A2) in position under the locking screw (A1).
- Do not rotate the crankshaft when the pump is not on the engine.
1 Fit a new '0' ring (A3) to the pump flange. Lightly lubricate the '0' ring with clean engine lubricating oil. Put
the pump into position in the timing case and fit the three washers and setscrews, then tighten the
setscrews to 25 Nm (18Ibfft) 2,5 kgf m.
2 Loosely fit the setscrew (B1) of the support bracket. Ensure that force is not applied to the fuel injection
pump.
Caution: The fuel pump gear must be fitted to the engine before the crankshaft is rotated.

5 Tighten the setscrew (B1) of the support bracket to 44 Nm (32Ibf ft) 4,4 kgf m. Ensure that farce is not
applied to the fuel injection pump.
CUKUROVA Model 885


Cautions:
- Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension. If
there is a leakage from the union nut, ensure that the pipe is correctly aligned with the pump outlet. Do not
tighten the pump union nut more, as this can cause a restriction at the end of the pipe. This can affect the
fuel delivery.
- Use a second spanner to prevent movement of the high pressure outlet on the, pump when the union nut
for each high pressure pipe is tightened.
nuts to 27,5 Nm (21 Ibf ft) 2,8 kgf m.
8 Fit the KSB electrical connection.
Delphi DP210 fuel injection pump
General description
Cautions:
- If the fuel injection pump is removed from the engine n will need to be returned to your nearest Perkins
Dealer/Distributor for the pump timing to be checked or reset
- Do not unlock the shaft of the fuel injection pump until the fuel pump gear is fitted.
Delphi DP210 fuel injection pumps have a drive gear fastened to the shaft of the pump.
An ' 0' ring (61) is fitted into a groove in the pump flange. This ' 0' ring is fitted instead of a joint between the
CUKUROVA Model 885


3 Lock the pump shaft: To lock the fuel injection pump shaft loosen the locking screw (A2) and rotate the
washer (A1). Tighten the locking screw (A2) to 17 Nm (12 Ibf ft) 1,7 kgf m.
Caution: Use a second spanner to prevent movement of the high pressure outlet on the pump when the
5 Remove the fuel pump gear, see Operation 6-3.
6 Remove the setscrew from the fuel pump support bracket (B1).
7 Remove the setscrews and washers that secure the fuel pump arid remove the pump.
8 Discard the fuel pump '0' ring (C1).
CUKUROVA Model 885


Cautions:
- The engine must be set to TOG number 1 cylinder, compression stroke before the pump is fitted, see
Operation 8-1.
- Do not unlock the shaft of the fuel injection pump until the fuel pump gear is fitted.
1 Fit a new ' 0' ring (B1) to the pump flange. Lightly lubricate the ' 0' ring with clean engine lubricating oil.
2 Fit the pump into position in the timing case, fit the three washers and setscrews, then tighten the
setscrews to 25 Nm (18 Ibf ft) 2,5 kgf m.
3 Loosely fit the setscrew (C1) of the support bracket Ensure that force is not applied to the fuel pump.
Caution: The fuel pump gear must be fitted to the engine before the crankshaft is rotated.
6 Tighten the setscrew (C1) of the support bracket to 44 Nm (32 Ibf ft) 4,4 kgf m. Ensure that force is not
applied to the fuel pump.
CUKUROVA Model 885


Cautions:
- Do not tighten the union nuts of the high-pressure pipes more than the recommended torque tension. If
there is a leakage from the union nut, ensure that the pipe is correctly aligned with the pump outlet. Do not
tighten the pump union nut more, as this can cause a restriction at the end of the pipe. This can affect the
fuel delivery.
- Use a second spanner to prevent movement of the high pressure outlet on the pump when the union nut for
each high pressure pipe is tightened.
nuts to 27.5 Nm (21 Ibf ft) 2,8 kgf m.
Cooling system
General description
Coolant from the bottom of the radiator passes through the centrifugal coolant pump that is fitted onto the
front of the timing case, to assist the flow of the coolant through the system.
The coolant pump is gear driven by the fuel injection pump gear.
An integral oil cooler, if fitted, has an aluminum cover with a five or seven plate element. The oil cooler has
no external pipes and is fitted to the left side of the cylinder block.
From the pump, the coolant passes through a passage in the timing case to the coolant jacket in the top left
side of the cylinder block. The coolant continues to the rear of the cylinder block where some of the coolant
passes into the lubricating oil cooler. If one is fitted. Some of the coolant passes around the element of the
integral cooler and then to the rear of the cylinder block.
The coolant then passes from the rear of the cylinder block and into the cylinder head. The coolant leaves
the cylinder head at the front and passes into the thermostat housing.
If the thermostat is closed, the coolant goes directly through a by-pass to the inlet side of the coolant pump.
If the thermostat is open, the thermostat closes the by-pass and the coolant passes to the top of the radiator.
CUKUROVA Model 885


Coolant flow diagram
CUKUROVA Model 885


Thermostat
Consumable products
POWERPART Red rubber grease 27610226
Note: Engines are fitted with a single thermostat (A). Identification of the thermostat is by the nominal
temperature which is stamped on the by-pass valve.
1 Drain the coolant in the cooling system to a level below the thermostat position and disconnect the top
hose from the coolant outlet connection.
2 Release the two setscrews (A1) and remove the thermostat housing from the cylinder head.
3 Remove the "0" ring and discard.
4 Press down on the thermostat using the thermostat tool (B1) and rotate the thermostat to release it from
the housing (B2).
5 Remove the thermostat from the housing.
CUKUROVA Model 885


Special tools Consumable products

Thermostat tool 27610226 POWERPART Red rubber grease 21820221
1 Clean the thermostat housing. Ensure that the grooves for the spring retainers and the seat for the O-ring
are free of debris.
2 Ensure that the jiggle pins (A1) in the thermostat are both free to move.
3 Lubricate a new "O" ring (B1) with POWERPART Red rubber grease before it is fitted. Fit O-ring. Place
the thermostat (C1) in position in the housing (C3).
4 Use the thermostat tool (D1) to push and rotate the thermostat to engage the spring retainers into the
grooves in the housing (C2) and (C4).
5 Fit the thermostat assembly to the cylinder head and tighten the setscrews.
6 Connect the top hose and fill the cooling system.
CUKUROVA Model 885


To Test Operation 12 - 3
Note: Do not remove the thermostat from the housing to test
1 Place the thermostat and the housing in a suitable container filled with coolant.
2 Heat the coolant gradually. Use a thermometer to check the temperature at which the valve starts to open
and at which it is fully open. For the correct operating temperatures, refer to the Data and dimensions for
"Thermostat".
Caution: If the thermostat does not operate correctly, it must be renewed. Do not try to adjust the settings.
Coolant Pump
Note: Identification of the coolant pump is by the part number that is cast onto the coolant pump body.
1 Drain the cooling system and disconnect the hose at the inlet connection of the coolant pump.
2 Remove the nine setscrews in (A) which retain the coolant pump and remove the coolant pump.
3 Remove and discard the joint.
CUKUROVA Model 885


Consumable products
1 Ensure that all joint faces are clean.

2 Check the drive gear of the coolant pump for wear or other damage. If the gear is damaged, the pump
must be renewed.
3 Fit two suitable guides (A1), fit a new joint (A2).
4 Fit the pump (B1) onto the guides and into the timing case cover with its gear in mesh with the gear of the
fuel injection pump.
Note: The setscrews that retain the coolant pump have a sealant (MEAS) applied by the manufacturer to the
first 13,0 mm (0.50 in) of the threads. If the setscrews are used again, the sealant must be removed
from the male and female threads and POWERPART Threadlock and nutlock applied to the first
13.0 mm (0.50 in) of the setscrew threads.
5 Fit and lightly tighten the seven setscrews which retain the pump to the cover of the timing case. The pump
is a tight fit in the cover, but can be pulled into position if the setscrews for the pump are gradually and
evenly lightened.
6 Remove the guides and fit the remaining setscrews.
7 Tighten all the setscrews (C) on the coolant pump to 22 Nm (16 Ibf ft) 2,2 kgf m.
8 Connect the hose to the inlet connection of the coolant pump and fill the cooling system.
9 Operate the engine and check for leakage.
1 Remove the setscrews, (A1) the cover and the joint Discard the joint.
2 To remove the impeller (B3) from the pump shaft; drill twelve 6,35 mm (0.25 in) holes between the existing
holes at equal distance around the impeller. Drilling these holes will break pieces off the impeller (B3) to
allow the 2 legged puller to be correctly fitted.
3 The impeller can be removed by using a suitable two legged puller attached to the back of the impeller
(B1). Tighten the centre setscrew (B2) of the puller until the impeller is removed. Discard the impeller.
CUKUROVA Model 885


Caution: Do not damage the sealing face of the coolant seal housing during removal of the seal.
4 To remove the coolant seal (C4), it will be necessary to break the seal and use an extractor to remove the
centre sleeve of the seal from the body of the shaft. This will loosen the grip of the seal on the shaft. To
remove the body of the seal, drill three 3,175 mm (0.125 in) holes through the top of the coolant seal 1200
apart. Fit three 25,4 mm (1.00 in) self-tapping screws. Insert a suitable lever through the coolant inlet of the
pump body and gradually and evenly apply the lever under the head of each self-tapping screw to remove
the seal. Discard the seal.
Caution: Do not damage the sealing face of the oil seal housing during removal of the seal.
5 Remove and discard the circlips (C6) (C7).

6 Put the impeller end of the pump body face down on a suitable press. Press the drive gear end of the shaft
through the gear (C10) and the pump body until the shaft (C3) and ball bearing assembly (C8) are
released from the pump. Discard the bearing and the shaft. The gear will also be released through the side
of the housing.
7 Inspect the gear for wear or other damage and renew it, if necessary.
8 Put the impeller end of the pump body face down on a press and use a suitable mandrel to engage the
outer face of the oil seal (C11). Press out the oil seal and discard it.
9 With the impeller end of the pump body face down on a press, use a suitable mandrel to engage the outer
race of the needle roller bearing (C9). Press out the bearing and discard it.
CUKUROVA Model 885


Caution: It is important that all of the components in the kit for the coolant pump are used.
1 Clean thoroughly the inside of the pump body, the bearing bores and the counterbore for the coolant seal.
These bores and their chamfers must be clean and free of corrosion.
2 Put the gear end of the pump body face down on a press. Use a suitable mandrel to engage the outer face
of the oil seal and press in until the bottom face of the oil seal is level with the face of the gear housing.
3 With the gear end of the pump body face down on a press, position the drive gear into the correct position.
Use a suitable adaptor to press the drive shaft through the oil seal and into drive gear so that there is a
1,5 mm (0.060 in) gap between the drive gear and the top face of the drive gear pocket.
4 Use a suitable adaptor to press the bearing (A8) onto the drive shaft, until it is against its shoulder.
5 Put the impeller end of the pump body face down on a press. Fit the new circlip (A6), with the bevel edge
away from the oil seal to retain the bearing assembly in the body of the pump. Fit the circlip (A7) to the
drive shaft to retain the bearing assembly to the drive shaft of the pump.
6 Turn the pump over and press the needle roller bearing (A9) into the bearing housing until the end of the
bearing is level with or 0,5 mm (0.020 in) below the top of the housing.
CUKUROVA Model 885


Caution: Do not lubricate the coolant seal (B4). The coolant seal must not be contaminated with oil or
grease. If the coolant seal is held by hand, it should be held by the edge of the outside flange.
A tool (C) can be manufactured to press the new seal into position. The tool should be made of a suitable
material to the dimensions shown below:
A 54.0 mm (2.125 in) E 44.0 mm (1.732 in)

B 6.0 mm (0.236 in) F 18.00 mm (0.708 in)
C 10.0 mm (0.393 in) G 54.00 mm (2.125 in)
D 48.0 mm (1.889 in)
7 Turn the pump over onto the gear end and with the widest end of the coolant seal towards the oil seal,
push the seal onto the shaft until it is in contact with the coolant seal counterbore. Ensure that the seal is
square with the bore and with a suitable adaptor press the seal into the counterbore, until the outer flange
is in contact with the pump body. Continue to apply force for approximately ten seconds to ensure that the
seal remains in position.
8 Press the impeller onto the shaft so that it is level with the top of the drive shaft.
9 Fit a new cover joint and fit the cover. Fit the setscrews and tighten to 22 Nm (16 Ibf ft) 2,2 kgf m.
CUKUROVA Model 885


Fan
To remove
Remove the locknuts and remove the fan from the studs. The fan extension and the pulley can now be
removed from the studs, if fitted.
To fit
Clean thoroughly the rear of the fan where the fan fits onto the fan extension. Ensure that all paint is
removed from this area. Fit the pulley onto the studs, and fit the fan extension, if removed. Clean the front
face of the fan extension. Fit the fan and the locknuts, refer to the Data and dimensions for "Special torques
for setscrews and nuts".
Fan drive
To remove
1 Loosen the pivot fasteners of the alternator and the fasteners of the alternator adjustment link. Remove the
drive belt(s), see Operation 14-3.
2 Release the locknuts and remove the fan, see Operation 12-8. Remove the fan extension, if fitted, and the
pulley.
3 Check the end-float of the drive shaft. If it is more than 0,25 mm (0.010 in), the fan drive assembly must be
renewed.
4 Release the setscrews and remove the fan drive.
To fit
1 Fit the fan drive and tighten the setscrews to 44 Nm (33 Ibf ft) .4,5 kgf m.
2 Fit the fan, see Operation 12-8.
3 Fit the belt(s) and adjust the tension, see Operation 14-3 and Operation 14-2.
Lubricating oil cooler

1 Drain the cooling system.

2 Place a suitable container under the oil cooler.
Note: Do not remove setscrews (A1), as these setscrews hold the oil cooler element to the cover.
3 Release the setscrews that retain the oil cooler to the cylinder block.
4 Remove the oil cooler and the joint.
CUKUROVA Model 885


1 Renew the joint, ensure that all the joint faces are clean.
2 Fit the oil cooler.
3 Fit all the setscrews and tighten to the correct torque.
5 Check the oil level on the dipstick (A1). Refill to the correct level with new lubricating oil of an approved
grade.
6 Operate the engine and check for leakage of coolant or oil.
To dismantle and to assemble Operation 12 - 12
To dismantle
1 Remove the oil cooler from the cylinder block, see Operation 12-10.
2 Remove the four setscrews (A1) from the oil cooler and remove the cooler element.
Warning! Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain
medical help immediately.
3 Clean the element and check for cracks. If a solution is used to clean the outside of the element, ensure
that this does not enter the element. Check that there are no restrictions to the flow of lubricating oil
through the element of the oil cooler. If the inside of the element needs to be cleaned, use a solvent which
is suitable for copper. Dry the element with low pressure air and then flush it with clean engine lubricating
oil.
To assemble
1 Renew the joints (B1) on the flanges of the element
2 Fit the element to the cover and tighten the setscrews (A1) to the correct torque.
3 Fit the oil cooler, see Operation 12-11.
CUKUROVA Model 885


To remove and to fit a coolant by-pass pipe Operation 12 - 13
Consumable products
To remove
1 Remove the two setscrews (A1).
2 Carefully pull the coolant by-pass pipe from the cylinder head. 3 Remove and discard the "0" rings.
To fit
1 Fit new "0· rings (B1) and (B2) and lubricate with POWERPART Red rubber grease.
2 Carefully fit by-pass pipe into the cylinder head, ensure that the "0" ring is correctly fitted.
3 Fit the two setscrews (A1) and tighten to the correct torque.
CUKUROVA Model 885


General description
The steel flywheel is fitted with a hardened starter ring. The starter rings have either 115 or 126 teeth.
The flywheel housing is normally made of cast iron, but certain flywheel housings are made of aluminum
alloy.
Flywheel
Warning! The flywheel is heavy. Use lift equipment or get help to assist with the lift operation before removal
of the flywheel fasteners.
To remove
1 Remove two opposite setscrews from the flywheel. Fit temporarily two guide to ensure that the flywheel
can be removed and fitted safely.
2 Remove the remainder of the setscrews and washers and remove the flywheel.
3 Check the flywheel and ring gear for damage and renew, if necessary.
To fit
1 Ensure that the location faces of the crankshaft, and the flywheel are clean and free from damage.
2 Fit a hardened steel washer to each of the ten setscrews. Fit the flywheel over the guide studs and secure
in place with eight of the setscrews. Do not fully tighten the setscrews. Tighten the setscrews, see "Specific
torque values".
3 Remove the temporary studs and fit the remaining two setscrews. Tighten the setscrews, see "Specific'
torque values".
4 Check the flywheel run-out with a dial test indicator (A). This must be less than 0,30 mm (0.012 in) total
indicator reading.
5 Check the alignment of the flywheel face (B). The error in alignment must not be more than 0,03 mm
(0.001 in) total indicator reading for every 25 mm (1.0 in) of the flywheel radius from the crankshaft axis to
the indicator plunger. During this check, keep the crankshaft pressed toward the front of the engine to
remove the effect of crankshaft end-float.
CUKUROVA Model 885


Ring gear
To remove
Warning! Wear eye protection and suitable protective clothing during this operation.
Before the ring gear is removed, check the position of the chamfer on the teeth. To remove the ring gear use
a hammer and a chisel to break the ring. Ensure that the flywheel is not damaged during this operation.
To fit
The ring gear is heated onto the flywheel. When a new gear is to be fitted, ensure that it is not heated to
more than 250°C (480 "F). Ensure that the chamfer on the teeth of the gear is in the correct direction.
Flywheel housing
Warning! The flywheel housing is heavy, use lift equipment or get help to assist with the lift operation before
removal of the flywheel housing fasteners.
To remove
1 Remove the starter, see Operation 14-7, and the flywheel, see Operation 13-1.
2 Release the housing setscrews and with a soft face hammer, hit carefully the housing to remove it from the
dowels.
To fit
1 Ensure that the rear face of the cylinder block and the faces of the housing are clean and free from
damage. Ensure that the location dowels are fitted correctly. If a felt seal is fitted to the rear flange of the
sump, renew the seal.
2 Fit the housing onto the dowels and lightly tighten the setscrews.
3 Check the housing concentricity with a dial test indicator (A). The run-out limit is given in the relevant Data
and dimensions for the "Flywheel and housing". If any adjustment is necessary, it must be made on the
housing and the concentricity checked again.
4 Tighten the setscrews to the torque recommended in "Specific torque values".
5 Check the housing alignment (B). The maximum tolerance is given in the relevant Data and dimensions for
the "Flywheel and housing". Any necessary adjustment must be made on the housing and not on the
cylinder block.
6 Fit the flywheel, see Operation 13-1 and the starter motor, see Operation 14-7.
CUKUROVA Model 885


Electrical Equipment
General
Caution: Many of the operations in this chapter should be done only by a person who has had training to
'Level 2', in '1100 Series Electronic Engine Diagnostics', or greater.
Note: It may be necessary to refer to the TIPSS EST User Manual for more details.
Alternators
General description
The Denso A 115i 12 volt and the A 127i 12 volt and 24 volt alternators are driven from the crankshaft. pulley
by double belts. The diodes, resistors and the brushes are fitted inside a cover to protect them against dirt
and moisture. Fans are included within the alternator casing to cool and protect the alternator.
These alternators have solid state regulators fitted within the rear cover. The regulators are sealed and
repair is not possible.
For any repairs to the alternator consult your nearest Perkins Dealer/Distributor.
Cautions:
- Do not disconnect the battery while the engine is in operation. This will cause a voltage surge in the
alternator charge system which will immediately cause damage to the diodes or to the transistors.
- Do not disconnect an electrical wire before the engine is stopped and all electrical switches are in the "off'
position.
- Do not cause a short circuit by the connection of electrical wires to the wrong terminals. The correct
electrical wire must be connected to the correct terminal. A short circuit or wrong connection, which gives
reverse polarity, will immediately cause permanent damage to the diodes and to the transistors.
- Do not connect a battery into the system until it has been checked for the correct polarity and voltage.
- Do not check for current flow with a spark contact as damage can be caused to the transistors.
To check the drive belts Operation 14 - 1
1 Check the belts for wear and damage and renew, if necessary, in pairs.
2 Check the belt tension. Check/adjust the tension on both belts. To ensure maximum belt life, it is
recommended that a belt tension gauge is used. Fit the gauge (A1) at the centre of the longest free length
and check the tension. If a Burroughs gauge is used, the correct tension is 535 N (120 Ibf) 54 kgf. If the
tension is equal to, or less than 250 N (56 Ibf) 25 kgf on either belt, adjust both belts to 535 N (120 Ibf) 54
kgf, see Operation 14-2.
CUKUROVA Model 885


To adjust drive belt tension Operation 14 - 2
1 Loosen the pivot fastener (A1) of the alternator and the fasteners of the adjustment link (A2) and (B1).
2 Change the position of the alternator to give the correct tension. Tighten the adjustment link fasteners, and
then tighten the pivot link fasteners. If there are two pivot fasteners, tighten the front fastener and then the
rear fastener.
3 Check the belt tension again to ensure that it is still correct, see Operation 14-1.
To remove and to fit the drive belts Operation 14 - 3
The drive belts are supplied as a set and must be renewed as a set.
1 Loosen the pivot fastener (A1) of the alternator and the adjustment link fasteners (A2) and (B1).
2 Release all of the tension from the belts and remove the belts.
3 Fit the new belts and adjust the tension, see Operation 14-2. The belt tension must be checked again after
the first 1000 km (600 miles) or 20 hours of operation.
CUKUROVA Model 885


To remove and to fit the alternator Operation 14 - 4
To remove
Warning! Ensure that the battery earth connection has been removed before any alternator connection is
removed.
1 Disconnect the electrical connection.

2 Release all the belt tension and remove the belts, see Operation 14-3.
3 Remove the adjustment link from the alternator and remove the pivot bolts. Make a note of the position of
the washers and distance pieces to ensure that they are fitted correctly. Remove the alternator.
To fit
1 Put the alternator in position and assemble loosely the pivot fasteners and the adjustment link and its
fasteners. Ensure that the washers and the distance pieces are fitted in their correct positions and that the
alternator pulley is aligned to the crankshaft pulley within ± 2,4 mm (0.094 in).
2 Fit the drive belts and adjust the drive belt tension, see Operation 14-2.
3 Connect the electrical connection.
4 If all of the work is complete, connect the battery earth connection.
To maintain Operation 14 - 5
1 Ensure that the drive belts are not worn and that the belt tension is correct, see Operation 14-1.
2 Keep the alternator clean. To clean the alternator, use a material which is damp with kerosene or a special
fluid used for this purpose. Ensure that the fluid does not enter the cover of the alternator.
3 Ensure that air can pass easily over the casing to keep it cool.
Fault diagnosis for the alternator Operation 14 - 6
The alternator is designed in such a way that a flow of current (indicated by no light at the warning lamp or a
reading shown on an ammeter) shows that the system is in correct operation. If the system is in correct
operation, no open circuit, voltage or current output checks need to be done on the installation unless:
- The warning lamp does not show when the alternator is stationary and the switch is in the ·ON" position or
it shows a light when the alternator is in operation
- No charge current is shown on the ammeter
- The battery is discharged
- The battery is hotter than normal which is an indication of loss of voltage control.
If one or more of the above symptoms occur, the procedure indicated below should be applied.
Normal operation:
1 Ensure that the engine has stopped and that the ignition switch is in the ”OFF” position.
2 Check that the battery voltage is correct, either 12V to 12.8 V (12V system), or 24V to 25.6V (24V system).
Check the condition of the battery if the voltage is not correct.
3 Turn the ignition switch to the "ON" position and check that the ignition warning lamp is illuminated.
4 Start the engine and operate it at a fast idle. Check that the ignition warning lamp is now extinguished.
5 Switch on an electrical load, such as the vehicle lights, and increase the engine to its maximum speed.
6 The battery voltage should now rise to either 13.5V (12V system), or 27V (24V system).
7 Switch off the applied electrical load and the battery voltage should rise to either 14V (12V system) or 28V
(24V system).
CUKUROVA Model 885


If the warning lamp is not illuminated when the ignition switch is in the "ON" position:
1 Check that the battery voltage is correct, (see the description for Normal operation), with the ignition switch
in the “OFF" position.
Note: Refer to the basic charging circuit illustration (A).
2 Check that the voltage at alternator terminal ’’ B+’’ (A8) to earth is the same as the battery voltage. If it is
not the cables and wires may be damaged or disconnected. Check the connections at the alternator (A7)
and at the battery (A2). Check for cable continuity. Check for earth continuity between the alternator casing
and the alternator brackets.
3 Check the ignition warning lamp bulb (A4) and renew if necessary.
4 With the ignition switch (A3) in the "On" position, check the voltage between the alternator "D+" terminal
(A5) and earth. If this voltage is greater than 2V then the alternator is faulty. Renew the alternator, see
Operation 14-4.
If the warning light continues to be illuminated when the alternator is in operation:
1 Set the ignition switch to the "On" position.
2 Start and run the engine at a fast Idle speed. Measure the voltages between the alternator terminal "B+"
(A8) and earth, and between alternator terminal ‘’D+" (A5) and earth. The voltages should be between 13V
and 15V (12V system) and between 26V and 30V (24V system). If the voltages are not within this range
then the alternator is faulty. Renew the alternator, see Operation 14-4.
3 Increase the engine to its maximum, switch on an electrical load (A1) such as the vehicle lights, and
measure the voltages between the alternator terminal "B+" (A8) and earth and the alternator terminal "0+"
(A5) and earth. The voltages should be between 13V and 15V (12V system) and 26V to 30V (24V system).
If these values are correct then the fault is within the charging system circuit. Check that the cables and
connections are all correct. If the voltages are still incorrect then the alternator is faulty. Renew the
alternator, see Operation 14-4.
Key to the basic charging circuit illustration (A).
1 Applied electrical load.

2 Battery.
3 Ignition switch.
4 Ignition warning light.
5 Alternator terminal "D+".
6 Alternator terminal “W”.
7 Alternator.
8 Alternator terminal "B+".
CUKUROVA Model 885


Starter motors
General description
The Dense P95RL (12 volt) and the R4.5 (24 volt) starter motors are operated by a solenoid and have roller
clutch drives. The solenoid engages the starter drive in two operations to ensure that the motor gets its
maximum torque only when the starter motor is engaged fully with the flywheel. The clutch prevents rotation
of the armature at high speed if the starter is held in the engaged position.
Warning! Always disconnect the battery terminals before the removal of any component of the electrical
system.
Caution: Care must be taken to avoid damage to the engine speed and timing sensor fitted to the cylinder
block (A) when a starter motor is removed from, or fitted to, the left side of the engine.
Note: The starter motor may be fastened to the flywheel housing by either setscrews or studs and nuts.
To remove
1 Disconnect the starter motor cables.

2 Remove the fasteners and remove the starter motor.
To fit
Note: The starter motors may have an ' 0' ring fitted to the starter motor flange. Check the condition of the
O-ring and renew, if necessary.
1 Check that the starter motor is free from faults, oil and grease.
2 Clean the flange face of the starter motor and the face of the flywheel housing.
3 Fit the starter motor and tighten the M10 setscrews or nuts to a torque of 44 Nm (33 Ibf ft) 4,5 kgf m.
4 Connect the starter motor cables.
To maintain the brush gear and the commutator Operation 14 - 8
Repairs to the starter motor are not recommended. Your Perkins Dealer/Distributor has specialist equipment
and personnel with the correct training to repair your starter motor.
CUKUROVA Model 885


The test on the engine Operation 14 - 9
Ensure that the battery is fully charged.
Turn on the lights and operate the starter switch. If no lights are fitted to the machine, connect a voltmeter
across the battery terminals and operate the starter switch.
If the starter does not operate but the lights keep their power, or there is no voltage drop across the battery,
check the switch and all the connections and wires. Slow action of the starter can be caused by faulty
connections.
Starting aid
General description
The starting aid for the 1100 Series four cylinder engines consists of a set of glow plugs, one on each
cylinder. The glow plugs are fitted in the cylinder head near the atomizers. The tip of the glow plugs reaches
into the combustion chamber in the piston crown.
The glow plugs are operated electrically, usually through the start switch. When the glow plugs are
energized, their tips become very hot and improve the combustion process during cold start conditions.
To remove and to fit a glow plug Operation 14 - 10
To remove
1 Disconnect the glow plugs power supply cable.

2 Remove the four nuts (A1) that fasten the bus-bar, remove the bus-bar.
3 With a suitable socket, loosen, then remove the glow plugs.
To fit
1 Ensure that the threads of the glow plugs and the cylinder head holes are clean.
2 Fit the glow plugs into the correct holes in the cylinder head, then gradually tighten to 18 Nm (13 Ibf ft)
1,8 kgf m.
3 Fit the bus-bar and the four nuts, tighten the nuts to 2 Nm (1.5 Ibf ft) 0,2 kgf m.
4 Connect the glow plugs power supply cable.
CUKUROVA Model 885


To check the glow plugs’ supply continuity Operation 14 - 11
1 Disconnect the glow plugs' power supply cable and the bus-bar.
2 Apply one probe of a multi-meter that can check continuity, to the terminal of the glow plug and apply the
other probe to a suitable earth. If the continuity is correct the multi-meter will give an audible signal. If there
is no audible signal, renew the glow plug. Repeat this check for all of the glow plugs.
Note: If a multi-meter is not available the following procedure can be used.
1 Connect a 12V test lamp between the positive terminal of the battery and earth to check that the lamp will
light.
2 Connect the test lamp between the terminal of the glow plug, that is furthest away from the power supply,
and earth.
3 Operate the control switch, the test lamp should be illuminated if the power supply is correct.
4 Disconnect the cables at each glow plug.
5 Connect the test lamp to the positive terminal of the battery and to the terminal of a glow plug. The lamp
will be illuminated if the continuity is correct. If the test lamp is not illuminated, renew the glow plug.
6 When all of the glow plugs have been checked, connect the bus-bar to the glow plugs and reconnect the
power supply cable.
To check the operation of the glow plug Operation 14 - 12
1 Disconnect the glow plugs' power supply cable and the bus-bar.
2 Connect a 50-0-50 ammeter between the power supply cable and the terminal of a glow plug.
3 Connect a voltmeter between the glow plug terminal and the earth.
4 Engage the control switch and check the readings of the ammeter and the voltmeter:
- 12 volt Beru glow plugs.
With a 12 volt supply, there is an immediate initial current of 30 amperes, that becomes approximately 21
amperes for each glow plug. This will reduce to approximately 14 amperes after 8 seconds, 10 amperes after
20 seconds and reach 9 amperes after 60 seconds.
- 24 volt Beru glow plugs.
With a 24 volt supply the initial current is approximately 12 amperes for each glow plug, that becomes
approximately 8.5 amperes after 8 seconds, 7 amperes after 20 seconds and reach 6 amperes after 60
seconds.
Note: If the ammeter reading is low, or there is no reading, renew the glow plug. If there is no voltmeter
reading, check the switch and the power supply cable.
When all of the glow plugs have been checked, remove the ammeter and the voltmeter and connect the
power supply cable. Check that the glow plugs are correctly fitted.
CUKUROVA Model 885


Electronic components
General
Some 1100 Series 4 cylinder engines have an electronic management system. The system is controlled by
an Engine Control Module (ECM). The ECM receives signals from the sensors, and the electronic fuel
injection pump, and has an output to the electronic fuel pump. The ECM controls the engine operation to
meet the operator requirements.
The electronic management system consists of the following components (A):
1 Engine Control Module (ECM)

2 Diagnostic Connector
3 Machine Interface Connector (MIG)
4 Intake Manifold Air Temperature Sensor
5 Engine Coolant Temperature Sensor
6 Engine Oil Pressure Sensor
7 Intake Manifold Pressure Sensor
8 Speed and Timing Sensor
9 Crankshaft Timing Ring
10 VP30 Electronic Fuel Injection Pump.
11 Voltage Load Protection Module (VLPM).
For engine diagnostics and fault finding; refer to the 1100 Series Diagnostic Manual or the on-line Diagnostic
Guide.
CUKUROVA Model 885


Programming configuration parameters
Many programmable configuration parameters affect engine operation. These parameters may be changed
by using the TIPSS-EST service tool. The parameters are kept in the memory of the ECM.
All parameters can be read and passwords can be used to protect them from unauthorized changes. The
parameters are divided into two groups:
System configuration parameters affect 'critical settings’ for the engine and can only be changed with factory
passwords, by TIPSS-EST. They do not normally need to be changed during the life of the engine.
A complete list of these parameters is available from the Helpdesk.
Some examples of system configuration parameters are:

- Full Load Setting (FLS) : This is a number which represents fuel system adjustments made at the factory.
- Software part number : This is the part number of the software that was programmed into the ECM.
- Engine serial number : This should match the engine serial number that is stamped on the engine
information plate. A new ECM will be supplied without the engine serial number programmed into it.
Customer configurable parameters allow the OEM to change engine parameters to match the application.
They may be changed many times, if a customer changes his requirement. These can be changed with
T1PSSEST. This may require a customer password, if one has been programmed into the ECM.
An example of these parameters is:

- Idle speed
- This is the number that sets the engine idle speed.
Passwords
Passwords are divided into two groups.

Factory passwords are required to perform each of the functions listed below:
- To program a new ECM : When an ECM is renewed, the system configuration parameters must be
programmed into the new ECM. A new ECM will allow system configuration parameters to be programmed
only once, without factory password. After this time, they are protected by factory passwords.
- To change the engine rating : This requires a change to the ECM software code, which is protected by
factory passwords.
- To read a customer password : If the owner has lost the customer password, it will not be possible to
program customer parameters. In this case, the factory passwords can be used to find the customer
password.
- To remove certain diagnostic codes from the memory of the ECM : The factory passwords are needed to
remove 'Critical event' codes from the memory of the ECM. once-they are logged:
Caution: Operating the engine with the ECM software not designed for that engine will result in engine
damage. Be sure that the ECM software is correct for your engine.
Notes:
- Some other codes require customer passwords. but most of the logged codes do not need passwords to
remove them from the memory of the ECM.·
-To obtain factory passwords, either refer to the Helpdesk or proceed as if you already have the password.
At some point if the factory passwords are needed. TIPSS-EST will also need them but it will give the
information needed to obtain them.
If a customer password has been entered, it will be needed to make changes to ANY customer parameter.
T1PS8-EST can be used to change customer parameters.
To obtain a customer password, contact the supplier of the equipment. If the owner has lost the password, it
may be found by using TIPSS-EST:
- In TIPSS-EST, go to the ' Information' menu access 'Passwords' and record the information shown.
- Go to the 'Factory Password' screen and use the factory passwords.
- Record the customer password from the 'View Customer Passwords' screen. The customer password may
then be used to change customer parameters.
CUKUROVA Model 885


To remove and to fit the Engine Control Module (ECM) Operation 14 - 13
Cautions:
- If an ECM is returned for repair, or under warranty, then the ECM connector must be covered with a plastic
blanking cap to prevent the entry of water and dirt into the unit. If this blanking cap is not fitted then the
warranty may be affected.
- The ECM is protected from vibration by rubber mountings that are fitted in the holes for the fasteners. The
fitting of the earth cable must be correct to prevent damage to the electronic components.
To remove
1 Ensure that the engine start switch is in the OFF position. Remove the battery terminals.
2 Loosen the Allen screw (A1) for the connector and remove the connector with the plastic cover from the
ECM. care must be taken to ensure that the connectors in the ECM socket are not damaged.
3 Loosen the four setscrews that secure the ECM to the cylinder block. Remove the ECM from the engine.
Note: the position of the spacers, washers and the earth cable (A2).
To fit
Caution: The ECM is programmed for the application. The Electronic Service Tool (EST) will confirm the
EOM program. If a new ECM is fitted ensure that it has been programmed correctly. Contact your
nearest Perkins Dealer/Distributor for further information.
1 Check the connectors and sockets in the ECM and the harness connector for wear or damage. If wear or
damage is found, the connectors, sockets or harness must be renewed. Refer 'to the 1100 Series
Diagnostic Manual for the test procedures.
2 Check the seal for the ECM connector, if necessary, renew the seal.
3 Check the rubber mountings (B2) for wear or cracks, if wear or cracks are found, renew the mountings.
CUKUROVA Model 885


Caution: The earth cable (C2) must be fitted correctly to prevent damage to the electronic components.
4 Fit the ECM to the engine; ensure that the rubber mountings (D3) and the earth cable (E1) are fitted in the
correct positions.
Note: The earth cable has a special washer fitted to the cable, ensure that when the setscrew for the earth
cable is tightened that the cable is not rotated and tension is not put on the cable.
5 Tighten the four setscrews (D2) to 22 Nm (16 Ibf ft) 2,2 kgf m.
Cautions:
- Do not use the connector Allen screw (C1) to pull the connector into position. This will damage the
connector.
- Ensure that the recommended Allen screw torque for the ECM connector to the ECM is not exceeded as
this will damage the connector body.
6 Fit the harness connector to the ECM; to fit the harness connector, engage the connector in the ECM,
push the connector fully into the ECM and tighten the securing screw (C1) to 6,0 Nm (4 Ibf ft) 0,6 kgf m.
7 Fit the battery terminals.
CUKUROVA Model 885


To remove and to fit the Voltage Load Protection Module (VLPM) Operation 14 - 14
To remove:
1 Disconnect the electrical connector from the VLPM.
2 Remove the setscrews (A5) that secure the connector to the ECM.
3 Carefully remove the VLPM (A6).
To fit :
1 Carefully insert the VLPM (A6) into the clips and tighten the setscrew (A5), to 22 Nm (16 Ibf ft)
2,2 kgf m.
2 Connect the VLPM cable to the connector within the wiring harness, between the ECM and the fuel
injection pump cable.
3 Lightly pull the harness connector to ensure that it is locked to the VLPM connector (A4).
CUKUROVA Model 885


To program a new ECM Operation 14 - 15
The new ECM must be programmed and configured.
- If communication with the old ECM is still possible, use the ' ECM replacement' feature in EST to get
the configuration parameters from it, see ' Using the TIPSS-EST ECM replacement feature'.
- If communication with the old ECM is not possible, see ' If the ECM replacement feature cannot be
used.
The ECM is the main component of the system. If a problem occurs, it is easy to assume that the ECM is
faulty, this is usually the wrong diagnosis.
Most failures occur at the wiring and connectors, or at a sensor input or output. Follow the diagnostic test
procedures and do not renew an ECM, unless it is faulty.
Note: If a new ECM is needed, and if the suspect ECM can communicate with TIPSS-EST, the ECM
parameters can be transferred from the suspect ECM to the new ECM unless it is faulty.
To use the TIPPS-EST ' ECM replacement feature',
Notes:
- The new ECM mayor may not be supplied with software installed at the factory,
- TIPS8-EST User Manual will provide an explanation for any errors that may occur during the
programming.
1 Go to the ' Service I Copy Configuration' menu, select the ' ECM Replacement' feature and load the
parameters from the faulty ECM onto EST.
2 Connect the new ECM to the ECM connectors.
3 Get the part number of the 'flash file' from SPI.
4 Get the ' flash file' from the TIPSS CD, if it is not on the CD go to the Perkins Secured Internet for it.
5 Load the ' flash file' software into the new ECM.
6 Use the TIPSS-EST 'ECM replacement' feature to program the new ECM.
7 Check for active codes.
8 Program any required parameters that have not been programmed.
If the 'ECM replacement' feature cannot be used.
Notes:
- The new ECM mayor may not be supplied with the software installed at the factory.
- TIPS8-EST User Manual will provide an explanation for any errors that may occur during the
programming.
1 Record the engine serial number.

2 Contact the Helpdesk or go to the Perkins Secured Internet (PTMI) to obtain the configuration parameters.
3 Connect the new ECM to the ECM connectors.
4 Get the part number for the 'flash file' from SPI.
5 Get the ' flash file' from the TIPSS CD, if it is not on the CD go to the Perkins Secured Internet for it.
6 Load the ' flash file' software into the new ECM.
7 Check the memory of the ECM for active codes.
8 Program any parameters that may be needed and have not been programmed already.
CUKUROVA Model 885


To remove and to fit the speed and timing sensor Operation 14 - 16
Warning! The '0' ring (B1) fitted to the speed and timing sensor is made of "Viton", see the safety
precautions for "Viton seals".
Note: The engine speed and timing sensor is not adjustable. The sensor and securing bracket is a single
unit and should not be dismantled. The sensor must be fitted so that the securing bracket (A2) is fully
against the machined surface of the cylinder block.
To remove
1 Disconnect the electrical connector from the sensor.

2 Remove the setscrew (A1) that secures the sensor to the cylinder block.
3 Carefully remove the sensor (A3) from the cylinder block. Do not use a lever, this can cause damage to the
sensor.
4 Discard the 0-ring (B1).
To fit
1 Ensure that the sensor body and the bore in the cylinder block are clean and free from oil and dirt.
2 Fit a new '0' ring to the sensor in the first groove (B1). Apply a small amount of clean engine oil to the
0-ring.
Note: The second groove (B2) in the sensor is not used.
3 Push the sensor fully into the bore of the cylinder block (A). Do not use the setscrew to pull the sensor
into position. Align the hole in the sensor bracket to the hole in the cylinder block and loosely fit the
setscrew (A1).
4 Tighten the setscrew to 22 Nm (16 Ibf ft) 2.2 kgf m.
5 Check that the sensor bracket is fitted fully against the machined surface of the cylinder block.
6 Check that the connector seal is in place, that it is clean and is not damaged. Renew the seal if it is
damaged.
7 Carefully fit the electrical connector to the sensor to ensure that the connector pins are not bent during
this operation.
8 Lightly pull the harness connector to ensure that it is locked to the sensor connector.
CUKUROVA Model 885


To remove and to fit a pressure sensor Operation 14 - 17
Warning! The '0' ring (C2) fitted to the oil pressure sensor is made of "Viton", see the safety precautions for
“Viton seals’’.
There are two pressure sensors fitted to the engine. One sensor is fitted to the oil filter head (A1) for the oil
pressure and one sensor is fitted to the intake manifold. The pressure sensor fitted to the intake manifold
(B2) has a cable with a connector permanently connected to the sensor.
To remove
1 For the oil pressure sensor; disconnect the electrical connector from the sensor.
For the intake manifold pressure sensor; disconnect the electrical cable from the wiring harness.
2 With a suitable spanner, loosen and then remove the sensor from the oil filter head (A1) or the intake
manifold.
3 Discard the 0-ring (C1 or C2).
CUKUROVA Model 885


To Fit
1 Ensure that the threads of the sensor and the threads in the oil filter head (D1) or the intake manifold, are
dean and free from damage.
2 Fit a new '0' ring (F1 or F2) to the sensor.
Note: The '0' ring for the intake manifold pressure sensor is yellow. The '0' ring for the oil pressure sensor is
brown. (Temperature sensor '0' rings are black).
Caution: Do not use air operated tools to fit pressure sensors as these may damage the sensor.
3 Fit the sensor to the oil filter head (D1) or the intake manifold (E2), tighten the oil pressure sensor to 10 Nm
(7 Ibf ft) 1,0 kgf m and the intake manifold pressure sensor to 20 Nm (15 Ibf ft) 2,1 kgf m.
damaged, see Operation 14-19.
5 Carefully fit the electrical connector to the sensor to ensure that the connector pins are not bent during this
operation.
CUKUROVA Model 885


To remove and to fit a temperature Operation 14 - 18
There are two temperature sensors fitted to the engine. One sensor is fitted to the cylinder head (A1) for
the coolant temperature and one sensor is fitted to the intake manifold (B1) for the air intake temperature.
To remove
Caution: Before the coolant temperature sensor is removed from the cylinder head, ensure that the
coolant is drained to a level that is below the sensor or the cylinder head.
1 Disconnect the connector from the sensor.

2 With a suitable spanner, loosen then remove the sensor from the cylinder head or the intake manifold.
3 Discard the 0-ring.
To Fit
1 Ensure that the threads of the sensor and the threads in the cylinder head or the intake manifold are clean
and free from damage.
2 Fit a new ' 0' ring (E1) to the sensor.
Note: The '0' rings for the temperature sensors are black.
3 Fit the sensor to the cylinder head (C1) and the induction manifold (D1), tighten the sensor to 20 Nm
damaged, see Operation 14-19.
5 Carefully fit the electrical connector to the sensor to ensure that the connector pins are not bent during this
operation.
CUKUROVA Model 885


Wiring Harness
Cautions:
- Repairs to the wiring harness should not be carried out unless directed by the Diagnostic Manual.
- If a wiring harness is returned under warranty, the MIC connector must be covered with a plastic blanking
cap to prevent the entry of water and dirt into the unit. If this blanking cap is not fitted then the warranty may
be affected.
Note: A repair kit is available for all wiring harness repairs.
There are three main options for wiring harness repair, these are:
1 Renew the complete wiring harness.

2 Renew the pins or sockets, complete with wires attached.
3 Renew the connector, complete with wires attached.
Repairs that are difficult, or may take a long time to repair, should not be carried out. It may be more cost
effective to renew the wiring harness.
New connector pins and sockets are supplied with a short wire attached. The end of the wire must be
crimped to the wiring harness, see Operation 14-21.
New connectors are supplied complete with pins or sockets and short wires attached. The ends of these
wires must be crimped to the wiring harness, see Operation 14-21.
The tables below show a list of repair options that are recommended for each of the connectors and the
main wiring harness:
Sensor connector
Description Repair
Remove the connector pins from the body
Damage to the connector body
and fit to a new connector body
Remove the damaged connector pin and fit
Damage to a connector pins or sockets
a new connector pin or socket
Damage to the connector body and the
Renew the complete connector
connector pins or sockets
Diagnostic connector
Note: If several connector pins are damaged, it is recommended that the .complete connector is renewed.
Description Repair
Remove the connector pins from the body
Damage to the connector body
and fit to a new connector body
Remove the damaged connector pin and
Damage to a connector pin
fit a new connector pin
Damage to the connector body and the connector
Renew the complete connector
pins
Fuel injection pump connector
Repairs to the fuel injection pump connector are not recommended because specialist equipment and
personnel with the correct training are necessary. It is more cost effective to renew the wiring harness.
CUKUROVA Model 885


ECM and MIC connectors
Note: If several connector pins or sockets are damaged, it is more cost effective to renew the connector.
Description Repair
Damage to the connector body Renew the connector body
Remove the damaged connector pin or socket
Damage to a connector pin or socket
and fit a new connector pin or socket
Wiring harness
Note: If several wires are damaged, it is more cost effective to renew the wiring harness.
Description Repair
Cut wire Use a crimp to join the wires together
Remove the damaged section of wire, replace with a
Damage to wire insulation only
new section of wire and crimp to the original wires
Remove the damaged section of wire, replace with a
Damage to wire by corrosion
new section of wire and crimp to the original wires
Damage to the harness outer cover Repair with tape
Cautions:
- Do not bend the wires directly from the rear of the connector (A1) as distortion of the rear seal will
result, and this will allow water to enter the connector.
- Ensure that all ECM and MIC connector holes, that are not used by a wire to a socket or a pin are closed
by a blanking plug (A2) to ensure a waterproof seal. The blanking plugs must be inserted into the
connector so that the head of the blanking plug is pushed against, but not into, the connector end seal
(A3).
CUKUROVA Model 885


To repair a sensor connector Operation 14 - 19
To repair a sensor connector, the body can be renewed. Individual pins and sockets can be renewed or
the connector complete with wires attached can be renewed.
The connectors (A) have locking wedges that are pushed into the connectors to lock the pins or sockets
in position.
Sensor Connector types
Male connectors (A1).

Female connectors (A2).
Connector pin (A3) with wire connected.
Connector socket (A4) with wire connected.
To remove a connector from a sensor or another connector
Cautions:
- Do not use tools to separate the two parts of a sensor connector (A), because damage to the locking
mechanism may result.
- Do not pull on the wires to separate a sensor connector.
1 Before a connector is removed from a sensor, or from another connector, ensure that the connector and
the local area are clean, free from dirt, oil and grease.
2 For a male and female sensor I harness connectors; hold the connector in two hands and press the
locking mechanism (A1) until it releases. Hold the locking mechanism down and lightly pull the two
parts of the connector until they separate.
For a pressure or temperature sensor; hold the locking mechanism (A2) or (A3) down and lightly pull on
the connector until it separates from the sensor.
CUKUROVA Model 885


To remove a pin from a male connector
1 To remove the locking wedge from a male connector, insert a small thin screwdriver blade between the
locking wedge and the connector body. Lightly lift the locking wedge off the connector body. Put the
locking wedge in a safe place so that it can be fitted later.
2 Release the connector pin locking mechanism and lightly pull the wire out of the connector.
To remove a socket from a female connector
1 To remove the locking wedge from a female connector, use thin long-nose pliers, hold the pliers firmly in
one hand and lightly pull the female connector until the locking wedge is removed. Put the locking wedge
in a safe place so that it can be fitted later.
2 Release the connector socket locking mechanism and lightly pull the wire out of the connector.
To insert a pin or socket into a sensor connector
1 Hold the wire of the pin or socket that is to be inserted into the connector approximately 25,4 mm (1.0 inch)
behind the contact crimped area.
2 Hold the connector with the rear seal towards you.
3 Push the pin or socket fully into the connector seal.
4 When all contacts are in position, insert the locking wedge and push it into place.
Note: For locking wedges that have an arrow, the arrow must be fitted towards to the connector locking
mechanism.
5 To connect a new wire or connector to the wiring harness, see Operation 14-21.
To repair a Diagnostic, a EGM, or a MIG Operation 14 - 20
It is recommended that if several pins need to be replaced, or if the connector body is damaged, it may be
cost effective to renew the harness.
To remove a pin or a socket from a connector
Notes:
- The procedure is the same for the Diagnostic, ECM and MIC connectors.
- The tool required to remove the contact pins or sockets from these connectors is supplied in the wiring
harness repair kit.
1 Before a connector pin or socket is removed from a connector, ensure that the connector and the local
area are clean, free from dirt, oil and grease.
2 Carefully fit the removal tool (A2) onto the wire (A1) that is attached to the pin (B1) or the socket to be
removed.
3 Carefully push the removal tool (C1) along the wire and into the seal of the connector.
4 Carefully push the removal tool (B2) fully into the connector to release the connector locking
mechanism (B3).
5 With the removal tool (B2) fully engaged onto the pin or the socket, carefully withdraw the pin or the
socket (B 1) with the removal tool.
Caution: After the repair of Diagnostic. ECM and MIC connectors, ensure that the seals are fitted and are
correctly in position as damage to the connector body can result if they are not.
CUKUROVA Model 885


To insert a pin or socket into a connector.
Cautions:
- Do not bend the wires directly from the rear of the connector as distortion of the rear seal will result. And
this will allow water to enter the connector.
- Ensure that all EGM and MIG connector holes that are not used by a wire to a socket or a pin, are closed
by a blanking plug to ensure a waterproof seal. The blanking plugs must be inserted into the connector so
that the head of the blanking plug is pushed against. But not into, the connector end seal.
Notes:
- The procedure is the same for Diagnostic, ECM and MIC connectors.
- New pins and sockets are supplied with a short length of wire fitted.
- Any pin or socket holes that are not used in the connector must have blanking plugs fitted.
1 Hold the wire (D1) approximately 25,4 mm (1.0 inch) behind the pin or socket.
2 Hold the connector with the rear of the connector towards you.
3 Push the pin or socket (E 1) or socket through the connector rear seal.
4 Push the pin or socket (F2) into the connector until the pin or socket is against the locking mechanism
(F1).
5 Push the pin or socket (F3) until the locking mechanism (F4) is in position behind the pin or socket.
6 Carefully pull on the wire to test that the pin or socket is locked in position. If the pin or socket pulls out
of the connector, repeat the procedure from stage 1.
Caution: After the repair of Diagnostic. EGM and MIG connectors, ensure that the seals are fitted and
are correctly in position as damage to the connector body can result if they are not.
CUKUROVA Model 885


To connect a new wire or connector to the wiring Operation 14 - 21
Caution: Do not solder the wires to the wiring harness. The wires must be correctly crimped.
Notes:
- Connector sleeves that are supplied in the wiring harness repair kit have a heat-shrink cover that has
sealant applied to the inner surface.
- The new pins, sockets, and complete connectors that are supplied in the wiring harness kit. all have
short wires connected to them.
1 Cut the original wire to give the correct length when the new wire is connected.
2 Remove the insulation from the end of the wires that are to be joined.
3 Put the wires (A2) into the connector sleeve (A) and using a crimping tool, crimp the middle area (A1).
4 Apply enough heat to the heat-shrink part of the connector (A3) to seal the wires inside the connector
sleeve.
Note: If more than one wire is to be crimped to the wiring harness the connector sleeves (B 1) must be fitted
at different lengths from the connector.
Auxiliary Equipment
General description
The power take-off (PTO) adaptor provides a means to use the engine power to operate auxiliary
equipment. The idler gear drives the splined shaft of the adaptor.
CUKUROVA Model 885


Power steering pump
To remove
1 Disconnect the pipes at the power steering pump and fit covers to the open ends of the pipes.
2 Release the setscrews and remove the pump.
To fit;
1 Renew the ' 0' ring and lubricate it with clean engine lubricating oil.
2 Check the drive coupling, or the gear, for wear and damage. Renew if necessary.
3 Fit the pump and tighten the setscrews.
4 Remove the covers from the open ends of the pipes and fit the pipes.
Adaptor for a hydraulic pump or a steering pump
To remove;
1 Remove the Allen screws (A1) and remove the adaptor assembly from the rear of the timing case.
2 Remove the setscrews (A8) and the rear cover (A 10).
3 Check the gear (A4), the spline drive and the bearings (A3 and A9) for wear and damage, renew the
components if necessary.
To fit
1 Fit a new ' 0' ring (A7) in its recess in the housing (A6) and lightly lubricate it with clean engine lubricating
oil. Lubricate the bearings (A3) and (AS) with clean engine lubricating oil. Fit the rear cover (A10) and fit
the adaptor assembly to the timing case and tighten the cap screws.
CUKUROVA Model 885


1 Remove the circlip (A5). Provide a support for the Range face of the housing (A6). Use a suitable adaptor
on the front bearing (A9) to press the gear and bearings out of the housing.
2 Remove the bearings (A3 and A9) from the gear (A4) with a suitable puller.
CUKUROVA Model 885


Consumable products
I
POWERPART Retainer (oil tolerant) 21820603
1 Apply a narrow ring of POWERPART Retainer (oil tolerant) to the outer surface of the front bearing (A9) in
the position shown (A2). Provide a support for the front face of the housing. Use a suitable adaptor on the
outer race of the bearing to press the front bearing onto the shoulder in the housing. Remove any excess
retainer.
2 Apply a narrow ring of POWERPART Retainer (oil tolerant) to the inner surface of the front bearing (A9) in
the position shown (A2). Provide a support for the bearing. With the small diameter of the gear (A4) toward
the bearing, press the gear into the bearing until the gear is against its shoulder.
3 Apply a narrow ring of POWERPART Retainer (oil tolerant) to the outer surface and to the inner surface of
the rear bearing (A3) in the positions shown (A2). Ensure that the support is under the front bearing. Use a
suitable adaptor on the outer ball race of the bearing to press the bearing into the housing and onto the
shoulder on the gear (A4). Remove any excess retainer. Fit the circlip (AS) into its groove in the housing.
4 Check the backlash between the power take-off gear and the idler gear. The backlash is 0,11/0,17 mm
(0.004/0.007 in).
Exhauster
To remove
1 Disconnect the lubricating oil and vacuum pipes from the exhauster and fit covers to the open ends of the
pipes.
2 Release the setscrews and remove the exhauster.
To fit
1 Ensure that the joint faces of the exhauster and the timing case are clean and renew the joint. Fit the
exhauster to the timing case and tighten the setscrews.
2 Remove the covers from the open ends of the pipes and connect the oil pipe and the vacuum pipe to the
exhauster.
CUKUROVA Model 885


List of special tools
CUKUROVA Model 885


CUKUROVA Model 885

CUKUROVA Model 885

CUKUROVA Model 885

80.01
TOOLS
TOOLS
Magnetic stand
C77AS73
Dial indicator
C77AS74
Gauge blocks
C77AS75 70 mm
C77AS76 100 mm
Digital depth gauge
C77AS77 200 mm
C77AS78 300 mm
Digital caliper gauge
C77AS79 150 mm
Torque wrench
C77AS80 0.6 -6.0 Nm

C77AS81 1.0 – 12 Nm
C77AS82 3.0 – 23 Nm
C77AS83 5.0 – 45 Nm
C77AS84 10 – 90 Nm
C77AS85 80 – 400 Nm
C77AS86 140 – 750 Nm
C77AS87 750 - 2000 Nm
Hot air blower
C77AS88 230 V
C77AS89 115 V
Plastic hammer
C77AS90 Ø 60 mm
Substitute nylon insert
C77AS91
CUKUROVA Model 885

Backhoe - Loader Tools

Lifting strap
C77AS92
Lifting chain
C77AT04
Pry bar
C77AT05
Striker
C77AT06
Set of internal pliers

I1-I2-I3-I4
C77AT07
Set of internal pliers

I11-I21-I31-I41 90°
C77AT08
Set of external pliers
A1-A2-A3-A4
C77AS93
Set of external pliers
A01-A02-A03-A04 90°
C77AS94
CUKUROVA Model 885


Two-armed puller
C77AS95
Jaw width 80 mm
Throat depth 100 mm
C77AS96
Jaw width 120 mm
Throat depth 125 mm
C77AS97
Jaw width 170 mm
Throat depth 125 mm
C77AS98
Jaw width 200 mm
Throat depth 175 mm
C77AS99
Jaw width 350 mm
Throat depth 250 mm
C77AT01
Jaw width 520 mm
Throat depth 300 - 500 mm
C77AT02
Jaw width 250 mm
Throat depth 200 mm
C77AT03
Jaw width 380 mm
Throat depth 200 mm
Three armed puller
C77AT09
Jaw width 85 mm
Throat depth 65 mm
C77AT60
Jaw width 130 mm
Throat depth 105 mm
C77AT61
Jaw width 230 mm
Throat depth 150 mm
C77AT62
Jaw width 295 mm
Throat depth 235 mm
C77AT63
Jaw width 390 mm
Throat depth 270 mm
C77AT64
Jaw width 640 mm
Throat depth 300 mm
Assembly truck assy

with tilting device
C77AS34
CUKUROVA Model 885


Support
C77AS35
Support bracket
C77AS36
Used with support and assembly truck.
Adjusting screws (M14)
C77AS37 (1 set = 2 pcs.)
Fixing bracket
C77AS38
Grab sleeve
C77AS39
Adjusting screws (M 16)
C77AS40 (1 set = 2 pcs.)
Assembly lever
C77AS41 (1 set = 2 pcs.)
CUKUROVA Model 885


Internal Extractor
C77AS42
Counter support
C77AS43
Eye nut
C77AS44
Grab sleeve
C77AS45
Basic tool
C77AS46
Grab sleeve
C77AS47
Basic tool
C77AS48
Clamping fork
C77AS49
CUKUROVA Model 885


Grab sleeve
C77AS50
Basic tool
C77AS51
Driver tool
C77AS52
Handle
C77AS53
Driver tool
C77AS54
Adjusting screws M 16
C77AS55 (1 set = 2 pcs.)
Straightedge
C77AS56
Straightedge
C77AS57
CUKUROVA Model 885


Cylinder screws (M 20)
C77AS58
HD-Pump
C77AS59
Threaded coupling (7/16-20 UNF)
C77AS60
Oil collector tank
C77AS61
Driver tool
C77AS62
Handle
C77AS63
Driver tool
C77AS64
Driver tool
C77AS65
CUKUROVA Model 885


Threaded coupling (9/16-18 UNF)
C77AS66
Threaded coupling (G ¼“)
C77AS67
To be used with Reducer

(7/8“ auf G ¼“) C77AS68
Reducer (7/8“ auf G ¼“)

NF
- 14 U
7/8 ”
C77AS68
4”
G 1/
Air connection Unit
C77AS69

(7/8“ auf G ¼“) C77AS68
and connector plug C77AS70
Connector plug
C77AS70

(7/8“ auf G ¼“) C77AS68
Feeler Gage
C77AS71
Driver tool
C77AS72
Pressure piece
C77AT28
CUKUROVA Model 885


Rapid grip
C77AT29
Forcing device
C77AT30
Cut-off device
C77AT31
Pliers
C77AT32
Extracting tool
C77AT33
Internal extractor
C77AT34
Counter support
C77AT35
Striker
C77AT36
Grab sleeve
C77AT37
Internal extractor
C77AT38
CUKUROVA Model 885


Grab sleeve
C77AT39
Adjusting screws
C77AT13 M10
Assembly fixture
C77AT40
Pressure rings
C77AT41
Torsion bar
C77AT42
Cone connection
C77AT43
Driver tool
C77AT44
Driver tool
C77AT45
Driver tool
C77AT46
Driver tool
C77AT47
Driver tool
C77AT48
CUKUROVA Model 885


Mandrel
C77AT49
Driver tool
C77AT50
Internal extractor
C77AT51
Driver tool
C77AT52
Driver tool
C77AT53
Wheel bolt puller - basic device
C77AT54
Insert
C77AT55 (M22x1.5)
Driver tool
C77AT56
Driver tool
C77AT57
Straightedges
C77AT58
Measuring device
C77AT59
CUKUROVA Model 885


Holding fixtures
C77AT10
Clamping angles
C77AT11
Belt wrench
C77AT12
Adjusting screws
C77AT13
Eye bolt assortment
C77AT14
Eyebolts
C77AT15
Assembly aid
C77AT16
Grab sleeve
C77AT17
Grab sleeve
C77AT18
CUKUROVA Model 885


Basic tool
C77AT19
Grab sleeve
C77AT20
Assembly aid
C77AT21
Driver tool
C77AT22
Driver tool
C77AT23
Drift
C77AT24
Adjusting screws
C77AT13 M10
Adjusting screws
C77AT25 M8
Driver tool
C77AT26
Driver tool
C77AT27
CUKUROVA Model 885


Cukurova Backhoe Loaders: Service Manual

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Cukurova Backhoe Loaders: Service Manual

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CUKUROVA

10.01 GENERAL INFORMATION

20.01 LUBRICATION & MAINTENANCE

30.01 HYDRAULIC SYSTEM

30.02 HYDRAULIC SHEMA

40.01 ELECTRICAL SYSYEM

50.01 FRONT AXLE GROUP

50.05 REAR AXLE GROUP

Position of the machine……………………………………..…………..…..…………………………….……....7

Crushing and burn prevention…………………………………………………………………………..………10

Engine start up and operating safety …………………………………………………………………………..11

Machine transporting safety……………………………………………………………………………………..13

Machine towing safety……………………………………………………………………………………………14

Machine maintenance safety…………………………………………………………………………………….14

CUKUROVA Model 885

CUKUROVA Model 885

Seat Adjustable to operator’s weight.

Outer tire clearance diameter 8,4m

CUKUROVA Model 885

CUKUROVA Model 885

Bucket attachment (standard)

Bucket width 400 mm 600 mm 800 mm

CUKUROVA Model 885

CUKUROVA Model 885

CUKUROVA Model 885

LOADER ATTACHMENT POSITION

BACKHOE ATTACHMENT POSITION

CUKUROVA Model 885

CUKUROVA Model 885

CUKUROVA Model 885

FIRE AND EXPLOSION PREVENTION

MACHINE START UP SAFETY

CUKUROVA Model 885

ENGINE START UP AND OPERATING SAFETY

MACHINE OPERATING SAFETY

CUKUROVA Model 885

MACHINE PARKING SAFETY

• Park the backhoe loader only on firm and level ground.

MACHINE TRANSPORTING SAFETY

CUKUROVA Model 885

MACHINE TOWING SAFETY

MACHINE MAINTENANCE SAFETY

CUKUROVA Model 885

CUKUROVA Model 885

HYDRAULIC LINES AND HOSES

• Hydraulic lines and hoses may never be repaired!

CUKUROVA Model 885

PREPARING THE MACHINE FOR STORAGE

PREPARING THE MACHINE FOR WORK AFTER A LONG PERIOD OF STORAGE

• Fill the cooling system with engine coolant.

CUKUROVA Model 885

Lubricant and operating materials specifications…………...…………………….……………..…….…..…...2

Diesel engine lubricants……………………………………………………………………………………………2

CUKUROVA Model 885

When checking or replacing the oil, observe the following :

- Only add fuel when the engine is turned off.

- Never smoke or allow an open flame in refueling areas.

CUKUROVA Model 885

NOTES ON LUBRICANT AND OPERATING MATERIALS CHART AND ON LUBRICATION SCHEDULE

1) DIESEL ENGINE LUBRICANTS:

Intervals for Oil Change

Authorized Diesel fuel specifications

The sulfur content in Diesel fuel should be less than 0.5%.