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WORKSHOP MANUAL
Specifications
Publication SENR9742-00
Proprietary information of Perkins Engines Company Limited 2004, all rights reserved.
The information is correct at the time of print.
Published by Technical Publications.
Perkins Engines Company Limited, Peterborough, PE1 5NA, England
3
Table of Contents
Table of Contents
Specifications Section
Engine Design .....................................................
Fuel Injection Lines ..............................................
Fuel Injection Pump .............................................
Fuel Injection Nozzles ..........................................
Fuel Lines .............................................................
Fuel Filter Base ....................................................
Fuel Priming Pump ..............................................
Lifter Group ...........................................................
Rocker Shaft ........................................................
Valve Mechanism Cover ......................................
Cylinder Head Valves ............................................
Cylinder Head ......................................................
Turbocharger ........................................................
Inlet Manifold .......................................................
Exhaust Manifold .................................................
Camshaft .............................................................
Camshaft Bearings ..............................................
Engine Oil Filter Base ..........................................
Engine Oil Filter Bypass Valve ..............................
Engine Oil Cooler .................................................
Engine Oil Pump ..................................................
Engine Oil Pressure .............................................
Engine Oil Bypass Valve ......................................
Engine Oil Pan .....................................................
Crankcase Breather .............................................
Water Temperature Regulator Housing ................
Water Temperature Regulator ..............................
Water Pump .........................................................
Cylinder Block ......................................................
Cylinder Liner .......................................................
Crankshaft ...........................................................
Crankshaft Seals .................................................
Vibration Damper and Pulley ...............................
Connecting Rod Bearing Journal .........................
Main Bearing Journal ............................................
Connecting Rod ...................................................
Piston and Rings ..................................................
Piston Cooling Jet .................................................
Front Housing and Covers ...................................
Gear Group (Front) ...............................................
Flywheel ...............................................................
Flywheel Housing ................................................
Engine Lifting Bracket ...........................................
Alternator (12 volt and 24 volt alternator) .............
Starter Motor ........................................................
Coolant Temperature Sensor ...............................
Boost Pressure Sensor .........................................
Inlet Manifold Temperature Sensor .......................
Speed and Timing Sensor ...................................
Electronic Control Module .....................................
Air Inlet Heater ......................................................
4
4
4
5
6
7
8
8
8
10
10
13
14
14
15
15
16
17
17
17
18
19
19
19
20
21
21
21
21
23
23
25
26
27
27
27
28
29
29
30
31
31
31
32
33
34
35
35
36
36
36
Index Section
Index ..................................................................... 38
4
Specifications Section
Specifications Section
i01843807
Engine Design
Illustration 1
g00939480
Illustration 2
Typical example
g00885325
i01714139
Illustration 3
g00889064
5
Specifications Section
Illustration 4
g00894396
NOTICE
Ensure that the new fuel injection nozzles have the
same identification code as the previous fuel injection
nozzles in the cylinder head. If the fuel injection nozzles have an incorrect identification code, damage to
the engine may occur.
NOTICE
Do not use dirty test fluids when you test fuel injection
nozzles. Also, do not test fuel injection nozzles unless
you have the correct service tools.The use of dirty test
fluids and the use of incorrect service tools will result
in damage to fuel injection nozzles.
6
Specifications Section
i01855626
Fuel Lines
Illustration 5
g00959607
7
Specifications Section
g00977252
Illustration 6
The high mounted fuel system
Illustration 7
g00888095
8
Specifications Section
i01843933
i01714153
Lifter Group
Illustration 9
g00629433
Illustration 8
g00628370
(1) Bolt
Apply 1861108 POWERPART Silicon rubber
sealant to the first three threads of the bolts.
Tighten the 4 bolts that fasten the fuel transfer
pump to the cylinder block to the following
torque. ..................................... 22 Nm (16 lb ft)
i01843982
Rocker Shaft
Illustration 10
g00876530
9
Specifications Section
Illustration 11
The tightening sequence for the rocker shaft
g00954315
10
Specifications Section
i01714274
Illustration 12
i01855498
g00882246
Illustration 14
g00294082
g00882273
to 8.700 mm
0.3425 inch)
to 9.022 mm
0.3552 inch)
11
Specifications Section
g00840529
Illustration 15
Inlet valve
to 8.975 mm
0.3533 inch)
to 0.069 mm
0.0027 inch)
12
Specifications Section
Illustration 16
g00840530
13
Specifications Section
i01855449
Cylinder Head
g00876966
Illustration 17
Cylinder head tightening sequence
g00295372
Illustration 18
Checking the distortion of the cylinder head
Dimension
Width A
Length B
Diagonal C
14
Specifications Section
i01844373
Turbocharger
Illustration 19
i01846903
Inlet Manifold
g00883118
Typical example
Illustration 20
g00876646
Typical example
Illustration 21
g00876652
Typical example
15
Specifications Section
i01844590
Exhaust Manifold
Illustration 22
i01853426
Camshaft
g00943878
Illustration 24
g00976240
Illustration 23
g00944336
Illustration 25
g00976195
(2) Bolt
Tighten the bolt to the following torque. .. 95 Nm
(70 lb ft)
(3) Camshaft thrust washer
Thickness of the thrust washer .. 5.49 to 5.54 mm
(0.216 to 0.218 inch)
Depth of the recess in the cylinder block for the
thrust washer ............................ 5.46 to 5.54 mm
(0.215 to 0.218 inch)
Tolerance of the thrust washer in cylinder block
front face ............................. 0.05 to +0.08 mm
(0.002 to +0.003 inch)
16
Specifications Section
Table 2
(1)
Camshaft
Journals
Standard Diameter
Service Limit
Diameter(1)
50.710 to 50.740 mm
(1.9965 to 1.9975
inch)
50.660 mm
(1.9945 inch)
50.460 to 50.480 mm
(1.9865 to 1.9875
inch)
50.410 mm
(1.9845 inch)
50.200 to 50.230 mm
(1.9764 to 1.9775
inch)
50.150 mm
(1.9745 inch)
49.950 to 49.980 mm
(1.9665 to 1.9675
inch)
49.900 mm
(1.9645 inch)
i01602266
Camshaft Bearings
Illustration 27
g00584302
g00629702
to 7.69 mm
0.303 inch)
to 7.79 mm
0.307 inch)
17
Specifications Section
i01853455
Illustration 28
g00887068
Typical example
Illustration 30
g00879440
Illustration 31
g00887098
i01853469
g00907545
(1) Torque the bolt for the oil filter bypass valve to
the following torque. ................ 60 Nm (44 lb ft)
Illustration 29
18
Specifications Section
(2) Tighten the bolts for the cover on the engine oil
pump to the following torque. ............. 28.5 Nm
(21.02 lb ft)
i01854853
Illustration 32
g00887110
Illustration 34
g00888637
Illustration 35
g00876990
Illustration 33
g00876984
19
Specifications Section
Illustration 36
to 0.118 mm
0.0046 inch)
to 0.106 mm
0.0042 inch)
i01855409
g00767653
Illustration 37
g00888110
Illustration 39
g00984376
20
Specifications Section
i01885714
Crankcase Breather
Illustration 40
g00888603
Illustration 41
g00945263
21
Specifications Section
i01600716
Water Pump
Illustration 42
g00629806
Typical example
Illustration 44
g00885051
Cylinder Block
Illustration 43
g00877006
Illustration 45
The cylinder block
g00888427
22
Specifications Section
Illustration 46
g00887142
g00887815
23
Specifications Section
i01885751
Crankshaft
Cylinder Liner
Illustration 49
g00979485
The crankshaft
(1) Crankshaft
The end play of the crankshaft ...... 0.05 to 0.38 mm
(0.002 to 0.015 inch)
Illustration 48
g00790690
24
Specifications Section
g00886525
Illustration 50
Timing ring
39.47 mm
(1.5539 inch)maximum
N/A
N/A
37.82 mm
(1.4890 inch)maximum
N/A
N/A
44.68 mm
(1.7591 inch)maximum
N/A
N/A
40.55 mm
(1.5965 inch)maximum
N/A
N/A
133.17 mm
(5.2429 inch)maximum
N/A
N/A
N/A
N/A
N/A
N/A
25
Specifications Section
g00979724
Illustration 51
The crankshaft
i01882388
Crankshaft Seals
Crankshaft Front Seal
Depth of the crankshaft front seal from the front face
of the oil seal housing ................ 10.20 to 10.70 mm
(0.402 to 0.421 inch)
g00955880
26
Specifications Section
g00975010
Illustration 53
The alignment tool
Wear Sleeve
Illustration 54
i01884984
g00886912
Illustration 55
g00953667
(4) Crankshaft
(1) Crankshaft
27
Specifications Section
i01721833
(5) bolts
Tighten the rear mounted M8 bolts that fasten
the crankshaft pulley to the vibration damper to
the following torque. ................ 35 Nm (26 lb ft)
Tighten the rear mounted M10 bolts that fasten
the crankshaft pulley to the vibration damper to
the following torque. ................ 65 Nm (48 lb ft)
Table 5
76.16 to 76.18 mm
(2.998 to 2.999 inch)
Undersize Journal
0.25 mm (0.010 inch)
75.91 to 75.93 mm
(2.988 to 2.989 inch)
Undersize Journal
0.51 mm (0.020 inch)
75.65 to 75.67 mm
(2.978 to 2.979 inch)
Undersize Journal
0.76 mm (0.030 inch)
75.40 to 75.42 mm
(2.968 to 2.969 inch)
Illustration 56
Front mounted vibration damper
i01708286
Connecting Rod
63.47 to 63.49 mm
(2.499 to 2.500 inch)
Undersize Journal
0.25 mm (0.010 inch)
63.22 to 63.24 mm
(2.489 to 2.490 inch)
Undersize Journal
0.51 mm (0.020 inch)
62.96 to 62.98 mm
(2.479 to 2.480 inch)
Undersize Journal
0.76 mm (0.030 inch)
62.71 to 62.73 mm
(2.469 to 2.470 inch)
g00889532
28
Specifications Section
i01859737
Illustration 58
g00888215
29
Specifications Section
(2) Rod
Use the following procedure in order to check the
alignment of the piston cooling jet:
1. Insert rod (2) into the end of the piston cooling jet.
Rod (2) has a diameter of 1.70 mm (0.067 inch).
Rod (2) should protrude out of the top of the
cylinder block.
2. Dimension (A) is 33 mm (1.3 inch) and dimension
(B) is 21 mm (0.8 inch). Dimension (A) and
dimension (B) are tangent to the cylinder bore.
3. Position rod (2) within dimension (C). Dimension
(C) is 14 mm (0.6 inch).
(3) Cylinder block
i01600755
Illustration 59
g00888229
Illustration 60
g00635918
30
Specifications Section
(3) Bolt
Tighten the bolts that fasten the front housing
and the front cover to the cylinder block to the
following torque:
M8 ............................................ 22 Nm (16 lb ft)
M10 .......................................... 44 Nm (33 lb ft)
(4) Crankshaft
i01735288
Illustration 61
g00889556
31
Specifications Section
i01854866
Flywheel
i01600766
Flywheel Housing
g00631781
Illustration 63
(1) Bolt
Illustration 62
g00584712
8.8 ................................. 44
10.9 ............................... 63
8.8 ................................. 75
10.9 ............................. 115
Nm
Nm
Nm
Nm
(33
(47
(55
(85
lb
lb
lb
lb
ft)
ft)
ft)
ft)
i01721280
(2) Flywheel
(3) Bolt
Tighten the flywheel bolts to the following
torque. ................................... 120 Nm (88 lb ft)
32
Specifications Section
i01866226
Alternator
(12 volt and 24 volt alternator)
Illustration 64
g00959541
33
Specifications Section
i01866400
Starter Motor
Illustration 65
The 24 volt starter motor which shows the electrical connections
g00974968
34
Specifications Section
g00977365
Illustration 66
The 12 volt starter motor which shows the electrical connections
Illustration 68
g00884683
Illustration 67
Location of the coolant temperature sensor
g00884680
35
Specifications Section
i01746847
Illustration 69
i01746858
g00884732
Illustration 72
g00887774
Illustration 70
g00884734
Illustration 73
g00887773
Illustration 71
g00884730
Illustration 74
g00884683
36
Specifications Section
i01860273
Illustration 75
i01854832
g00884737
Illustration 77
g00884768
Illustration 76
g00884736
Speed/timing sensor
i01853830
Illustration 78
Air inlet heater for top mounted turbocharger
g00884774
37
Specifications Section
Illustration 79
g00884777
38
Index Section
Index
A
B
Boost Pressure Sensor.......................................... 35
C
L
Camshaft ...............................................................
Camshaft Bearings ................................................
Connecting Rod.....................................................
Connecting Rod Bearing Journal ..........................
Coolant Temperature Sensor.................................
Crankcase Breather...............................................
Crankshaft ............................................................
Crankshaft Seals ...................................................
Crankshaft Front Seal ........................................
Crankshaft Rear Seal.........................................
Cylinder Block........................................................
Cylinder Head........................................................
Cylinder Head Valves ............................................
Cylinder Liner ........................................................
15
16
27
27
34
20
23
25
25
25
21
13
10
23
Lifter Group............................................................ 8
M
Main Bearing Journal ............................................ 27
P
Piston and Rings ................................................... 28
Piston Cooling Jet.................................................. 29
R
E
Rocker Shaft.......................................................... 8
Electronic Control Module .....................................
Engine Design .......................................................
Engine Lifting Bracket............................................
Engine Oil Bypass Valve .......................................
Engine Oil Cooler ..................................................
Engine Oil Filter Base............................................
Engine Oil Filter Bypass Valve ..............................
Engine Oil Pan.......................................................
Engine Oil Pressure...............................................
Engine Oil Pump....................................................
Exhaust Manifold ...................................................
36
4
31
19
17
17
17
19
19
18
15
S
Specifications Section ...........................................
Speed and Timing Sensor .....................................
Starter Motor .........................................................
12 volt starter motor...........................................
24 Volt Starter Motor ..........................................
4
36
33
34
33
T
Table of Contents................................................... 3
Turbocharger ......................................................... 14
F
Flywheel ................................................................
Flywheel Housing ..................................................
Front Housing and Covers.....................................
Fuel Filter Base .....................................................
Fuel Injection Lines................................................
Fuel Injection Nozzles ...........................................
Fuel Injection Pump...............................................
Fuel Lines ..............................................................
Fuel Priming Pump................................................
31
31
29
7
4
5
4
6
8
V
Valve Mechanism Cover ........................................ 10
Vibration Damper and Pulley................................. 26
W
Water Pump........................................................... 21
Water Temperature Regulator ............................... 21
39
Index Section