Documente Academic
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WORKSHOP MANUAL
6 cylinder diesel engines
for industrial applications
This document has been printed from SPI. Not for Resale
This document has been printed from SPI. Not for Resale
Contents
10 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
New 2000 Series engines . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
Cylinder bore identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12
General safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 13
Safety . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 14
Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 14
Asbestos joints . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 14
Dangers from used engine oils ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 15
Environmental protection ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 15
Viton seals . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 15
Practical information ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 16
11 Specifications
Basic engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 19
Recommended specific applied torques ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 22
Recommended nominal applied torques ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 24
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28
31
32
34
34
35
36
36
37
37
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14 Crankshaft assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 57
Damper and pulley - early engines
14-1 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 58
Damper and pulley - new engines
14-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 59
Crankshaft hub and front oil seal
14-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 60
14-4 To fit a new oil seal to a wheelcase removed from the engine . ... ... ... ... ... ... ... . 61
Rear oil seal
14-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 62
Crankshaft
14-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 63
14-7 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 64
Fits and clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 65
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17 Engine timing
Valve timing
17-1 To check ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 99
Fuel injection pump timing
17-2 To check and to adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 100
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18 Aspiration system
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 103
Aspiration system maintenance .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 103
Turbocharger
18-1 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 105
18-2 How to check the waste-gate ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 105
Turbochargers: OE49342, OE50642, OE51140, and OE51430
18-3 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 106
18-4 To clean and to inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 108
Turbocharger: OE50674
18-5 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 109
18-6 To clean and to inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 111
Turbochargers: OE52534 and OE52535
18-7 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 112
18-8 To clean and to inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 114
Inlet manifold
18-9 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 115
Exhaust manifold
18-10 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 115
19 Lubrication system
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 117
Lubricating oil filter
19-1 To renew the canister ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 120
By-pass filter/separator
19-2 To renew the canisters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 121
Sump
19-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 122
Sump drain plugs .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 123
Lubricating oil pump
19-4 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 124
19-5 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 125
19-6 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 125
Perkins Engines Company Limited
This document has been printed from SPI. Not for Resale
20 Fuel system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 128
Overhaul instructions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 128
Fuel injectors
20-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 129
20-2 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 131
20-3 To clean and to inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 131
20-4 To set and to test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 133
Fuel lift pumps ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 135
Single acting type
20-5 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 135
20-6 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 135
Double acting type
20-7 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 136
20-8 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 136
20-9 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 137
Fuel injection pump
20-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 138
20-11 How to eliminate air from the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 141
Air stop cylinder
20-12 How to set the air-operated stop cylinder ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 142
21 Cooling system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 143
Radiator
21-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 146
Fan
21-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 147
This document has been printed from SPI. Not for Resale
23 Electrical equipment
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 163
Alternator drive belts
23-1 To check and to adjust the tension ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 165
Alternator
23-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 166
Starter motor . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 167
23-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 167
23-4 To dismantle and to assemble the solenoid switch ... ... ... ... ... ... ... ... ... ... ... ... 167
23-5 To dismantle and to assemble the starter motor ... ... ... ... ... ... ... ... ... ... ... ... ... 169
23-6 To clean ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 171
23-7 To inspect and to correct ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 171
23-8 To test ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 172
23-9 To fit the main starter cables . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 172
Perkins Engines Company Limited
This document has been printed from SPI. Not for Resale
24 Auxiliary equipment
Compressor
24-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 175
24-2 Compressor gear alignment .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 177
10
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10
General information
10
Introduction
This workshop manual has been designed to provide
assistance in the service and the overhaul of 2000
Series engines. Most of the general information,
which is included in the Users Handbook (sections 1
to 9), has not been repeated in this Workshop Manual
and the two publications should be used together.
Read the Safety precautions and remember them.
They are given for your protection and must be
applied at all times.
To ensure that you use the correct information for
your specific engine type, refer to Engine
identification on page 12.
SCG060223
2006TG2A
SGH060224
2006TWG2
SGK060225
2006TAG2
SGB060226
2006TTAG
SGJ060227
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10
Engine identification
The engine number is stamped on the data plate
which is fastened to the left side of the crankcase.
For early engines, a typical engine number is:
8B13718U 66381T, which consists of these codes:
8B
Engine family
13718
Engine number
Country of manufacture
66381
Year of manufacture
Engine application
Engine type
06
0024
2238
Year of manufacture
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Safety
Asbestos joints
Some joints and gaskets contain compressed
asbestos fibres in a rubber compound or in a metal
outer cover. The white asbestos (Chrysotile) which is
used is a safer type of asbestos and the danger of
damage to health is extremely small.
Contact with asbestos particles normally occurs at
joint edges or where a joint is damaged during
removal, or where a joint is removed by an abrasive
method.
To ensure that the risk is kept to a minimum, the
procedures given below must be followed when an
engine which has asbestos joints is dismantled or
assembled.
z
Do NOT smoke.
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10
Viton seals
Environmental protection
There is legislation to protect the environment from
the incorrect disposal of used lubricating oil. To
ensure that the environment is protected, consult your
Local Authority who can give advice.
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10
Practical information
To clean components
It is important that the work area is kept clean and that
the components are protected from dirt and other
debris. Ensure that dirt does not contaminate the fuel
system.
Before a component is removed from the engine,
clean around the component and ensure that all
openings, disconnected hoses and pipes are sealed.
Remove, clean and inspect each component
carefully. If it is usable, put it in a clean dry place until
needed. Ball and roller bearings must be cleaned
thoroughly and inspected. If the bearings are usable,
they must be flushed in low viscosity oil and protected
with clean paper until needed.
Before the components are assembled, ensure that
the area is as free from dust and dirt as possible.
Inspect each component immediately before it is
fitted, wash all pipes and ports and pass dry
compressed air through them before connections are
made.
Use suitable gloves for protection when components
are degreased or cleaned with trichloroethylene,
white spirit, etc. Degreasing solutions which are
basically trichloroethane are not recommended.
Suitable fluids to clean and to protect
components
Warning! Full information for the use of all the
products listed below and for their safe disposal, and
especially for the health and safety of the personnel
who use them, will be found in the Manufacturers
data.
Ardrox 667: Ardrox Limited, Brentford,
Middlesex.
Maxan 774:
16
Method of use
The components to be degreased must be lowered
completely into the degreasing solution. Allow
enough time to elapse for the components to be
thoroughly cleaned. Subsequently, the components
must be thoroughly flushed in clean water. In use,
maintain a layer of water at least 76 mm (3 inches)
deep above the cleaning fluid to ensure that vapour
and toxic gases are not released.
Warning! Do NOT smoke near the container.
Protection for the eyes and for the skin must be used
always during the use of these fluids, and the
container must be in a place with good ventilation.
Oil seals
Apply petroleum jelly to oil seals before they are fitted,
and do not damage the lip of the seal on sharp edges.
Unless other specifications apply, fit the seal with the
edge of the lip toward the bearing.
Hose connections
Do not use a screwdriver to remove hoses by force
because adaptors or pipe connections can be
damaged. Cut through the hose and then cut the ends
of the hose from the adaptor or pipe connection.
When a new hose is fitted, a suitable rubber lubricant
can be used instead of antifreeze, water or french
chalk. Never lubricate a hose with oil or grease.
Gaskets, joints and O rings
Discard all used items if an engine or a component is
dismantled and fit only new and correct parts.
If a jointing compound is needed, Hylomar PL 32
jointing compound is recommended for use, but on
metal joints ONLY. Only a thin application is needed,
an excessive quantity of compound can restrict the
flow of fluids in pipes and passages.
Caution: Hylomar jointing compound must NOT be
used in contact with any fibre joints as the solvent
contained in Hylomar can damage the joint material.
Apply a small amount of a suitable lubricant to O ring
seals to prevent damage during assembly.
This document has been printed from SPI. Not for Resale
10
Locking devices
MIL-STD 271-E
MIL-L 25135
B.S. 5750
D.T.D. 929
Exchange units
It is recommended that unserviceable units are
returned, as complete as the new exchange unit, with
covers fitted to all openings and the joint faces
protected. When necessary, protect the unit, both
inside and outside, from corrosion.
Special tools
Parts
Applied torques
The specifications for applied torques, which are
given in section 11, apply to certain bolts and nuts
where damage or failure can occur if they are
incorrectly tightened.
Part number
8 to 54 Nm (6 to 40 lbf ft)
21825 846
21825 991
21825 992
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This document has been printed from SPI. Not for Resale
11
Specifications
11
Typical electropak:
19
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11
Cooling system
Capacity of coolant system (engine only)
(does not include radiator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,4 litres (4.5 UK gallons)
Coolant system pressure . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum 70 kN/m (10 lbf/in) to suit installation
Coolant pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal, gear driven unit
Temperature (normal)
(At sea level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 to 95C (172 to 203F)
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Triple element, wax capsule type with radiator by-pass
Fuel system
Type. . . . . . . . . . . . . . . . . . . . . . . . . Low pressure supply to injection pump with return of spill fuel to the tank
Fuel injection pump
165 kW (221 bhp) to . . . . . . . . . . . . . . . . . S3000 with 12mm lower helix elements (damper plates fitted to
257 kW (345 bhp) gross . . . . . . . . . . . . . variable speed engines over 300 bhp only). Boost control device
fitted to 300 bhp engines only. Automatic selection of excess fuel
and retarded timing for starting. The engine is retarded by 6.
229 kW (307 bhp) to . . . . . . . . . . . . . . . . . . . S7100 with 12mm lower helix elements and snubber valves.
368 kW (494 bhp) gross . . . . . . . . . . . . . . . Boost control device fitted. Automatic selection of excess fuel
and retarded timing for starting. The engine is retarded by 6.
Governor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . All speed, integral with fuel injection pump or electric
(depending on requirements)
Lift pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single acting, with integral preliminary fuel filter
Fuel supply pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103 to 207 kN/m (15 to 30 lbf/in)
Stop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electrical, 24 volt
Fuel injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low spring type, opening pressure 240 bar
Main fuel filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single screw-on type canister
Lubrication system
Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wet sump
Capacity of lubricating oil sump
Max. mark on dipstick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 litres (5.5 UK gallons)
Max. mark on dipstick - composite sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 litres (7.9 UK gallons)
Lubricating oil pressure
Normal load conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350 to 480 kN/m (50 to 70 lbf/in)
Minimum at rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *207 kN/m (30 lbf/in)
Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . Spring loaded plunger in body of oil pump, not adjustable
Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414 kN/m (60 lbf/in)
Oil filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two, screw-on type canisters with integral by-pass valves.
And a lubricating oil by-pass filter
Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single unit, tube stack type with partial by-pass for coolant
* Important for the protection of turbocharger bearings
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Induction/exhaust system
11
Aspiration
2006 TTAG. . . . . . . . . . . . . . . . . . . . . . Pressure charged by twin turbochargers: OE50642 and OE50674
Other 2000 series. . . . . . . . . . . . . . . . . . Pressure charged by a single turbocharger OE49342, OE50642,
OE51140, OE51430, OE52534 or OE52535
Air inlet depression limits
Clean filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 mm (10 in) W.g. nominal
Dirty filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559 mm (22 in) W.g. maximum
Air charge cooler
TG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not fitted
TA, TAG and TTAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air-to-air type, integral with radiator
TW, TWG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air-to-coolant type, integral with induction manifold
Cold start aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Optional - Start Pilot or Fleetguard
Electrical equipment
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt driven unit, 24 volt, 40 amp
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single, 24 volt - flange-mounted
Auxiliary equipment
Air compressor (if fitted). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single or twin cylinder, flange mounted
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11
lbf ft
Prestolite
95
7-
CAV 5
54
40
CAV 7
88
65
Thrustplate setbolts/capscrews
54
40
61
45
176
13
200 to 250
148 to 184
217
160
24
18
136
100
204
Camshafts
150
+40 degrees
41
30
41
30
16.3
12
10.8
33
24
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11
Nm
lbf ft
217
160
353
260
95
70
949
700
41
30
45
33
24
18
Crankcase
Crankshaft
Hub retaining nut
Note: If a torque wrench is not available, tighten by hand
and then use the special tool, 21825 807, to tighten by a
further two flats
Damper setbolts
Exhaust manifolds
Bolts
Flywheel
Friction face bolts 5/16 inch UNC
Friction face bolts
3/
45
33
122
90
95
70
300
220
61
45
10,8
45
33
47
35
Hub nut
163
120
45
33
25
18
11
61
45
41
30
61
45
11
inch UNF
Fuel injectors
Cap screws, injector clamp
Cap nut, nozzle
Fuel injection pump
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11
24
Bolt size
Nm
lbf ft
M5
4.5
M6
9.5
M8
23
17
M10
46
34
M12
80
59
M14
127
94
M16
198
146
M18
273
201
M20
387
285
M22
526
388
M24
669
493
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12
Cylinder head assembly
12
Rocker cover
To remove and to fit
12-1
To remove
1 Remove the three cap nuts (A) from the top of the
cover.
2 The cover and joint can now be removed. For
certain engines it may be necessary to first remove
the air ducting between the turbocharger and the inlet
manifold.
To fit
1 Remove the joint from the rocker cover and clean
the two corresponding faces of the cover and cylinder
head.
275
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12
Rocker assembly
1
12-2
To remove
1 Remove the rocker cover as previously described.
2 Unscrew the bolts (A1) which secure the rocker
pedestals to the cylinder head.
3 Remove the rocker assembly complete and
carefully lift out the push rods. Ensure that the tappets
remain in position in the crankcase.
To fit
273
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12
Tappet clearances
To check and to adjust
12-3
Check tappets on
cylinder No
151
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12
Cylinder head
To remove and to fit
12-4
Special tools:
Lifting bar, 21825 816
Bobbin removal tool, 21825 800
Torque angle gauge, 21825 924
To remove
1 Drain the cooling system.
2 Remove the air inlet ducting between the
turbocharger and the induction manifold.
3 Remove the rocker cover(s), operation 12-1.
4 Remove rocker assembly and push rods, operation
12-2.
5 Unscrew and remove the set of high-pressure fuel
pipes. Do not remove the pipes individually, they
MUST be removed as a full set. Do NOT bend the
pipes.
Warning! If a high-pressure fuel pipe becomes bent,
its structure will be damaged and it may become split
during use.
6 Remove the coolant rail/thermostat housing and
the fuel filter assembly.
7 Unscrew and remove the turbocharger(s). Remove
the inlet and exhaust manifolds.
8 Remove the fuel spill return pipes from the
injectors. Unscrew the injector clamping bolts and
withdraw the injectors.
Caution: Ensure that dirt does not enter the fuel
injectors.
9 Fit suitable caps or plugs to the injector nozzles,
fuel pump delivery valve holders and other open
apertures.
10 Unscrew and remove the cylinder head securing
bolts and washers together with the nut from the
oilway stud (later engines are fitted with a special bolt
in place of the stud and nut), working inwards from
each end.
11 Using the lifting bar, 21825 816, remove the
cylinder head and place it on a clean surface. Protect
the face of the head from damage.
12 Remove the cylinder head gasket and the coolant
transfer bobbins using bobbin removal tool, 21825
800.
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To fit
1 Clean the face of the cylinder head and the top
surface of the crankcase. Check that the cylinder
bores are clean and free from debris.
2 Fit a new cylinder head gasket over the roll pins in
the crankcase top face, ensuring the side stamped
TOP is fitted uppermost.
3 Fit the transfer bobbins with new sealing rings and
place in position.
4 Ensure that the face of the head is clean and, using
lifting bar, 21825 816, carefully lower the head into
position on the crankcase.
5 A light application of oil must be applied under the
head of each cylinder head bolt and also to the
threaded area. Do NOT use an excess amount of oil.
Where relevant, fit a washer to each bolt. Recent
engines use a different type of bolt which must not be
fitted with a washer.
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274
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12-5
Special tools:
Torque angle gauge, 21825 924
Note: For engines from build line number 91880, this
procedure is NOT necessary due to new procedures
used when the engine is assembled.
The cylinder head bolts of engines built before build
line number 91880 must be retightened after the first
12 months of operation. Additionally, if a cylinder
head from one of these engines has been removed,
its bolts and nut must be retightened to the correct
torque figures and the tappet clearances checked
after the first 500 to 1 000 km. Use the procedure
which follows.
Caution: A drilled bolt, which is identified by the word
"OIL" stamped on its head for early engines and by a
recess in its head for later engines, is fitted at position
22 shown on the illustration (A). This special bolt
MUST be used at the correct position.
56
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12-6
Special tools:
Cup plug removal tool, 21825 855
Slide hammer, 21825 849
Replacer kit for cup plugs, 21825 865
Drive handle, 21825 861
Valve spring compressor, 21825 739
Adaptor, 21825 742
Insertion tool, 21825 764
To dismantle
215
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To assemble
1 Clean all components and renew all seals.
269
270
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12-8
Special tools:
Valve spring compressor, 21825 739
Adaptor, 21825 742
If necessary, it is possible to renew a valve spring
without removing the cylinder head. Proceed as
follows:
1 Remove the relevant rocker cover, operation 12-1,
and turn the engine in the normal direction of rotation
until the inlet valve of the cylinder concerned just
commences to open. The piston of that cylinder will
then be at TDC position.
2 Slacken the tappet screws of this cylinder, remove
the rocker assembly and lift out the push rods.
3 Cover the push rod holes to ensure that no
components can drop in and fit the valve spring
compressor, 21825 739, and adaptor, 21825 742, to
an adjacent hole.
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12-9
Special tools:
Valve seat tool, 21825 841
Replacement tips, 21825 842
It is recommended that all the valve guides are
inspected, and renewed as necessary, before the
work is begun on the valve seat inserts. Ensure that
the bores of the guides are within the limits given at
the end of this section.
1 Inspect the inserts for erosion and cracks. If it is
necessary to correct the inserts, lightly lap the faces
of the valve seats and their relevant valves. To correct
the faces of more badly damaged valve seats, use the
valve seat tool, 21825 841, together with the relevant
pilot. To use the tool, fit the guide (A) and proceed as
shown (B). Ensure that the cutter is correct for the
angle of the valve seat, which is given on page 43.
The surface finish of the valve seat will be improved if
a compressed air supply is used to remove debris
during this operation.
222
223
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12-10
1
34
12-11
Special tools:
Valve seat insertion tool, 21825 869
To fit
1 Replacement inserts are available in either
standard or 0,050 mm (0.002 in) oversize diameters.
Always check that you have the required size.
2 Ensure that the counter bores in the cylinder head
are clean. The insert should be frozen in liquid
nitrogen immediately before insertion.
3 Fit the insert immediately, using the special tool
21825 869.
4 Check, using a 0,04 mm (0.0015 in) feeler gauge,
that the insert is fully seated.
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12-12
1
12-13
Special tools:
Valve guide remover, 21825 752
Valve guide replacer, 21825 763
272
231
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12-14
To remove
1 Remove the cylinder heads, operation 12-4.
2 Remove the valves, the valve springs and the valve
rotators, operation 12-6.
To fit
1 Fit the valves, the valve springs and the valve
rotators, operation 12-6.
2 Fit the cylinder heads, operation 12-4.
12-15
Special tools:
Gauge, 21825 754
1 Clean the valves thoroughly and inspect the head
of each valve for cracks or other damage. Check the
valve stems, the collet grooves and the tips of the
valves for wear. On valves which appear serviceable,
test, for cracks using a dye penetrant process such as
Ardrox 996. See page 16.
271
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12-16
Special tools:
Fuel injector remover, 21825 914
Injector sleeve remover, 21825 922
Injector sleeve wrench, 21825 908
2
To remove
1 Remove the high-pressure fuel pipes: For new
2000 series engines remove the set of high-pressure
fuel pipes. For these engines, do not remove the
pipes individually, they MUST be removed as a
complete set. Do NOT bend the pipes.
Warning! If a high-pressure fuel pipe becomes bent,
its structure will be damaged and it may become split
during use.
2 Remove the relevant low pressure fuel pipes and
remove the injector assembly. To remove a tight fuel
injector use the special tool, 21825 914, as follows:
place the cylindrical portion of the tool (A1) over the
fuel injector to be removed. Unscrew the nut (A2).
Rotate the central part of the tool (A3) until the thread
fully engages with the thread on the injector. Turn the
hexagon nut (A2) with a suitable spanner; this action
will lift the injector from its sleeve, without damaging
the sleeve. Other, harsher methods, may damage the
sleeve or the cylinder head.
179
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To fit
40
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Push rods
To remove and to fit
12-17
To inspect
12-18
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2
3
4
5
6
7
8
289
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2
3
4
5
6
7
8
289
Valve in seat
Clearance below flame face (A8)
Inlet valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025 to 0,33 mm (0.001 to 0.013 in)
Permissible worn dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,633 mm (0.025 in)
Exhaust valves (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025 to 0,33 mm (0.001 to 0.013 in)
Permissible worn dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,633 mm (0.025 in)
Valve seat inserts
Angle of valve seat
Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 degrees
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 degrees
Inserts in cylinder head
Cylinder head bore inlet valves (A7) . . . . . . . . . . . . . . . . . . . . . . . . . . . 58,06 to 58.09 mm (2.286 to 2.287 in)
Insert diameter inlet valves (A7) (standard). . . . . . . . . . . . . . . . . . 58,141 to 58,166 mm (2.2890 to 2.2900 in)
Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,051 to 0,106 mm (0.002 to 0.004 in)
Cylinder head bore exhaust valves (A7) . . . . . . . . . . . . . . . . . . . . 52,999 to 53,002 mm (2.0866 to 2.0867 in)
Insert diameter exhaust valves (A7)(standard) . . . . . . . . . . . . . . . 53,099 to 53,101 mm (2.0905 to 2.0906 in)
Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,097 to 0,102 mm (0.0038 to 0.004 in)
Service inserts 0,05 mm (0.002 in) oversize are available.
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1
2
3
4
5
6
7
8
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Valve springs
Inlet and exhaust valve springs:
Outer spring (A4):
Free length: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77,9 mm (3.07 in)
Length under 125 6 lbf load:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37,0 mm (1.457 in)
Inner spring (A5):
Free length: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73,4 mm (2.89 in)
Length under 65 3.5 lbf load: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,8 mm (1.292 in)
Valve guides
Valve guide bore in cylinder head (A6) . . . . . . . . . . . . . . . . . . . . . . . . 19,05 to 19,06 mm (0.750 to 0.7505 in)
Valve guide diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,101 to 19,114 mm (0.7520 to 0.7525 in)
Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,041 to 0,064 mm (0.0015 to 0.0025 in)
Valves in guides
Inlet valve stem diameter (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,649 to 12,662 mm (0.4980 to 0.4985 in)
Inlet valve guide bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,687 to 12,700 mm (0.4995 to 0.500 in)
Clearance (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025 to 0,051 mm (0.001 to 0.002 in)
Permissible worn clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,142 mm (0.006 in)
Exhaust valve stem diameter (A3) . . . . . . . . . . . . . . . . . . . . . . . . . 12,637 to 12,649 mm (0.4975 to 0,4980 in)
Exhaust valve guide bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,687 to 12,700 mm (0.4995 to 0.500 in)
Clearance (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,038 to 0,063 mm (0.0015 to 0.0025 in)
Permissible worn clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,203 mm (0.008 in)
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Piston and connecting rod
assembly
13
General description
Pistons
1 The pistons (A) are cast in a low expansion type
aluminium alloy with an inserted cast iron top ring
groove (A1). The piston crown (B) is machined to form
two valve recesses (B1) and an open combustion
chamber (B2).
335
1
2
Compression ratio:
TAG1, 2, 3 and TWG
15.9:1
TTAG
15:1
2006-12TA1, 2 and 3
Compression height:
17.8:1
277
98,81 to 98,93 mm
(3.890 to 3.895 in)
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Piston rings
Top ring (A1)
278
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2
1
280
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13-1
Special tools:
Piston ring sleeve, 21825 784
Dial gauge, 21825 782
To remove
1 Drain the coolant and lubricating oil.
2 Remove the cylinder head, operation 12-4.
281
283
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284
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13-2
Special tools:
13
To assemble
1 Fit the rings to the piston ensuring that the nonreversible rings are fitted correctly.
2 Heat the piston to approximately 20C (68F). Oil
the small end bushes and assemble the rod to the
piston with the FRONT marking on the piston crown
in correct relationship to the correlation marks.
Ensure that the gudgeon pin circlips are correctly
located in their grooves.
3 Set the gaps of the piston rings at equidistant
intervals as shown (A) before the assembly is fitted to
the engine.
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Connecting rod
13-3 To inspect
13-4
3 Crack test the gudgeon pin and check for a push fit
in the piston at 20C (68F). If the pin is slack in the
piston the assembly should be discarded.
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13-5
Special tools:
Con-rod bush remover/replacer, 21825 814
For use only on early engines.
Early engines
1 Press out the unserviceable bushes. Remove any
burrs from the eye of the connecting rod and ensure
that the oilway is clear.
282
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2
3
1
291
Pistons
Gudgeon pin in piston
Bore of piston (A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,8000 to 50,8025 mm (2.0000 to 2.0001 in)
Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,8000 to 50,8064 mm (2.00000 to 2.00025 in)
Gudgeon pin in piston - clearance (new) . . . . . . . . . . . . . . . . -0,0063 to +0,0025 mm (-0.00025 to +0.0001 in)
Top groove in piston
(Wedge shaped for top ring OE 48644)
Diameter over 2,779 mm (0.1094 in) rollers . . . . . . . . . . . . . . . . . 128,981 to 129,184 mm (5.078 to 5.086 in)
Piston clearance at top dead centre
Piston crown (A2) below top face of crankcase . . . . . . . . . . . . . . . . . . . . . 0,28 to 0,38 mm (0.011 to 0.015 in)
(Machine the piston crown to obtain the correct clearance)
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2
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291
Piston rings
Depending on the application, different piston and piston ring combinations are used on the range of 2000
series engines. Use the part number of the piston rings to determine the correct clearances for the piston rings.
Clearances of piston rings in grooves (A3)
Top ring OE 48644 (wedge shaped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to ring gap dimensions
Second ring OE 48645 (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,076 to 0,114 mm (0.003 to 0.0045 in)
Maximum permissible worn clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,152 mm (0.006 in)
Oil control ring OE 48646 (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,025 to 0,063 mm (0.001 to 0.0025 in)
Maximum permissible worn clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,102 mm (0.004 in)
Clearances of piston rings in grooves (A3)
Top ring OE 50977 (wedge shaped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to ring gap dimensions
Second ring OE 52517 (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,076 to 0,113 mm (0.003 to 0.0044 in)
Maximum permissible worn clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,152 mm (0.006 in)
Oil control ring OE 52518 (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,023 to 0,060 mm (0.0009 to 0.0024 in)
Maximum permissible worn clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,010 mm (0.004 in)
Second ring OE 50978 (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,076 to 0,113 mm (0.003 to 0.0044 in)
Maximum permissible worn clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,152 mm (0.006 in)
Oil control ring OE 50979 (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,023 to 0,060 mm (0.0009 to 0.0024 in)
Maximum permissible worn clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,010 mm (0.004 in)
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291
Piston ring gaps (A4) measured with the ring fitted in a new liner
Top ring OE 48644 (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40 to 0,60 mm (0.016 to 0.024 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,52 mm (0.060 in)
Second ring OE 48645 (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40 to 0,60 mm (0.016 to 0.024 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,52 mm (0.060 in)
Oil control ring OE 48646 (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40 to 0,65 mm (0.016 to 0.0256 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,02 mm (0.040 in)
Top ring OE 50977 (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40 to 0,60 mm (0.016 to 0.024 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,52 mm (0.060 in)
Second ring OE 52517 (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,80 to 1,00 mm (0.031 to 0.039 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,52 mm (0.060 in)
Oil control ring OE 52518 (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40 to 0,65 mm (0.016 to 0.0256 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,02 mm (0.040 in)
Second ring OE 50978 (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40 to 0,60 mm (0.016 to 0.024 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,52 mm (0.060 in)
Oil control ring OE 50979 (new). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,40 to 0,65 mm (0.016 to 0.026 in)
Maximum permissible worn gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,02 mm (0.040 in)
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290
Connecting rods
Gudgeon pin in bush (A1)
Bore of bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,813 to 50,838 mm (2.0005 to 2.0015 in)
(Bush pressed into position and bored to size)
Diameter of gudgeon pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50,8000 to 50,8064 mm (2.00000 to 2.00025 in)
Clearance (new) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,0064 to 0,038 mm (0.00025 to 0.0015 in)
Permissible worn clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,067 mm (0.0026 in)
Bush in small end (A2)
Bore in connecting rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57,137 to 57,15 mm (2.2495 to 2.250 in)
Diameter of bush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57,277 to 57,328 mm (2.255 to 2.257 in)
Interference fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,127 to 0,19 mm (0.005 to 0.0075 in)
Alignment of connecting rod (A3)
Parallel alignment between centres. . . . . . . . . . . . . . . . . . . . . . . To be no more than 0,025 mm (0.002 in) out
of parallel over a length of 254 mm (10 inches)
Distance between centres . . . . . . . . . . . . . . . . . . . . . . . . . . . 274,307 to 274,333 mm (10.7995 to 10.8005 in)
End-float of big end (A4)
End-float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,076 to 0,20 mm (0.003 to 0.008 in)
Permissible worn end-float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,305 mm (0.012 in)
Clearance on diameter of big end (A5)
Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,063 to 0,10 mm (0.0025 to 0.004 in)
(Check that crank pin is within the limits of ovality)
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This document has been printed from SPI. Not for Resale
This document has been printed from SPI. Not for Resale
14
Crankshaft assembly
14
General description
The crankshaft is forged from chrome-molybdenum
steel. It is dynamically balanced, and all bearing
surfaces are nitride-hardened and lapped to size. The
rear flange is machined to form a spigot location for
the flywheel and is drilled to accept the flywheel bolts.
Drillings in the crankshaft permit oil transfer to the
seven main bearings.
A drilling from each journal conveys oil to an adjacent
crankpin, which incorporates an oil reservoir with a
detachable plug. This plug is fitted with an O ring and
is secured by a spring clip.
Crankshafts fitted after July 1995, have a new
arrangement of oil passageways which removes the
need for oil reservoirs. These new crankshafts are
therefore not fitted with oil reservoir plugs.
If, during overhaul, the oil reservoir plugs are removed
from the earlier crankshaft, the plugs MUST be
refitted before the engine is run.
Crankshaft end float is controlled by steel-backed
lead bronze thrust washers, fitted either side of the
centre main bearing. The lower half of the washer has
a tang which locates in a slot machined in the bearing
cap.
The nose of the crankshaft carries the oil pump drive
gear and the main pinion, and is splined to receive the
hub to which the damper and pulley are attached.
The main crankshaft oil seals are of lip type design.
The rear oil seal is fitted directly into the flywheel
housing and forms a seal around the rear flange of the
crankshaft. For earlier engines the oil seal is carried
in a housing which is bolted to the rear of the
crankcase. The front oil seal is fitted in the wheelcase
and forms a seal around the crankshaft hub. Both
seals are supplied with a plastic insert for fitting
purposes.
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14-1
To remove
1 Slacken the belt tensioner pulley and remove the
drive belts.
2 Slacken and remove the bolts which secure the
pulley and damper to the hub.
3 Withdraw the pulley, the hub nut locking plate, the
spacer and the damper, noting the sequence for
refitting.
To fit
1 Assemble the damper, the spacer, the hub nut
locking plate and the pulley to the crankshaft, in the
correct sequence.
2 Fit the sixteen setbolts and spring washers. Tighten
the setbolts evenly to a torque of 41 Nm (30 lbf ft).
3 Refit the drive belts, adjust to the correct tension,
and tighten the belt tensioner pulley.
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14-2
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14
14-3
Special tools:
Spanner, 21825 807
To remove
1 Remove the pulley and damper as previously
instructed in this section.
2 Using the spanner, 21825 807, and a suitable
hammer, unscrew and remove the hub securing nut.
152
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14-5
1
Special tools:
To remove
1 Drain the engine oil and remove the flywheel,
operation 22-1.
2 Use a centre punch to make two holes in the edge
of the seal at diametrically opposite positions (A1 and
A2). Drill two holes, of 5 mm (3/16 in) diameter, in the
seal at the positions shown (A1 and A2).
3 Select two suitable self-tapping screws, complete
with plain washers, and fit the screws to the drilled
holes. Leave a small space between the face of the
seal and the plain washers. Use two screwdrivers, as
levers, between the plain washers and the flywheel
housing (oil seal housing on early engines) to remove
the oil seal.
4 Clean the bore of the flywheel housing, or oil seal
housing, which was in contact with the old seal.
35
To fit
Ensure that the crankshaft and the bore of the
flywheel housing are clean and free from grease.
Caution: Check that the part number of the new seal
is the correct one for the engine.
1 Ensure that the flywheel location dowel is fitted to
the crankshaft. Fit the guide part of the special tool,
27610 007, onto the end of the crankshaft and secure
it with the four bolts. Take care not to damage the fine
edge of the guide during fitting.
2 Before the oil seal is fitted, check the guide and the
crankshaft again for dirt or for a rough surface finish
which could damage the lip of the oil seal. Remove
and discard the yellow inner sleeve from the new oil
seal and fit the seal onto the guide. The lip of the seal
must be toward the crankcase.
Caution: Do NOT apply oil or grease to the oil seal
to assist the operation. There is a dry lubricant on the
contact face of a new seal for this purpose.
3 Slide the collar part of the tool onto the guide until
the face of the collar is against the outer face of the oil
seal. Lubricate lightly the thread of the stud and also
the thrust washer. Fit the nut and washer to retain the
collar. Rotate the nut until the seal is pressed fully into
the flywheel housing or oil seal housing for earlier
engines.
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Crankshaft
To remove and to fit
Special tools:
To fit
To remove
1 Drain the engine lubricating oil and coolant whilst
the engine is still installed.
2 Remove the unit and fit it to the engine build stand,
21825 993. See operation 16-1.
3 Remove the sump and oil pump, operation 19-3
and operation 19-4.
4 Remove the coolant pump, operation 21-5 and the
thermostat housing/coolant rail assembly.
5 If fitted, remove the compressor, operation 24-1.
6 Remove the fuel injection pump, operation 20-10.
7 Remove the starter motor, operation 23-3.
8 Remove the alternator, operation 23-2.
9 Remove the flywheel housing, operation 22-3.
10 If fitted, remove the crankshaft rear seal housing.
11 Remove the crankshaft hub and damper
assembly, operation 14-3 and operation 14-1 or
operation 14-2.
12 Remove the wheelcase, operation 15-1.
13 Unscrew the idler gear retaining bolt and withdraw
the gear and thrust plate.
14 Remove the camshaft gear or, for engines with an
integral gear, remove the camshaft, operation 16-8.
15 If fitted, remove the fuel pump adapter plate and
discard the O rings. Remove the wheelcase
backplate and discard the gasket.
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To inspect
14-7
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15
Wheelcase and drive assembly
15
General description
The wheelcase assembly of the new 2000 series
engine consists of an aluminium wheelcase and a
cast iron backplate. For earlier engines, the backplate
is manufactured from aluminium. The assembly is
situated at the front end of the crankcase and houses
the engine gear train. The backplate is located on the
crankcase by dowels and is secured by close fitting
bolts. This ensures the correct positioning of the front
seal in relation to the crankshaft.
A steel oil transfer tube is fitted between the backplate
and the front end of the main oil gallery in the
crankcase. Lubricating oil is supplied through this
tube and through drillings in the backplate to the fuel
injection pump.
The wheelcase provides mounting points for the
coolant pump, alternator and belt tensioner bracket.
The backplate houses the radiator by-pass tube and
provides mounting points for the compressor and fuel
injection pump.
The gears of new 2000 series engines have a
different gear tooth design and are not
interchangeable with those fitted to earlier engines.
The idler axle fitted to new 2000 engines does not
require adjustment.
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Wheelcase
To remove and to fit
Backplate
15-1 To remove and to fit
To remove
To remove
15-2
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To fit
1 Fit the oil transfer tube (A1) to the backplate,
complete with a new O ring (A2).
285
6 Fit the idler gear thrust plate (B3) and securing bolt
(B4). Ensure that the slot in the plate (D1) is correctly
located on the roll pin (D2), then tighten the bolt to a
torque of 61 Nm (45 lbf ft).
7 Tighten the camshaft gear retaining bolts to a
torque of 61 Nm (45 lbf ft), and bend over the locking
plate tabs to secure. Ensure that the tabs are bent
fully against the flats of the bolts heads.
Continued
3
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15-3
To remove
1 Remove the wheelcase, operation 15-1.
2 Turn the engine until No.1 piston is at TDC with the
relevant mark on the flywheel aligned with the timing
pointer in the flywheel housing. The timing marks on
the camshaft and crankshaft gears should now be
facing the idler gear axle as shown (A), and the mark
on the front end of the crankshaft at the 12 oclock
position.
2
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15-4
To remove
To remove the camshaft gear from this type of
camshaft, the camshaft must first be removed from
the engine.
1 Remove the cam followers, operation 16-6.
2 Remove the idler gear, operation 15-6.
3 Remove the camshaft, operation 16-8.
4 Place the camshaft in a hydraulic press with the
camshaft gear uppermost. Support the gear under the
thrust plate with suitable packing, such as vee blocks.
Carefully press the camshaft from the gear and
remove the thrust plate and the key.
Caution: Do not damage the camshaft during this
operation.
To fit
1 Support the camshaft in a suitable press. Fit the
thrust plate to the camshaft. Ensure that the plate is
fitted with the words FRONT (A1) uppermost, away
from the cams.
2 Insert a new key in the camshaft keyway.
3 Heat the gear in a pre-heated oven at
minimum of 15 minutes.
300oC
142
for a
B
72
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To inspect
15-5
15
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Idler gear
To remove and to fit
15-6
To remove
1 Remove the wheelcase, operation 15-1.
2 Turn the engine until No.1 piston is at TDC with the
relevant mark on the flywheel aligned with the timing
pointer in the flywheel housing. The timing marks on
the camshaft and crankshaft gears (A3 and A2)
should now be facing the axle of the idler gear (A1),
and the mark on the front end of the crankshaft at the
12 oclock position.
2
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15-7
15
Special tools:
Reaming jig, idler gear axle, 21825 999
Note: This operation is NOT applicable to New 2000
series engines.
The backlash of the timing gears is set by the position
of the idler gear axle. If, during an overhaul, a new
idler gear, a new idler gear axle or a new crankcase is
used, the correct position for the idler gear can
change and effect the backlash setting of the gears.
To obtain the position that will give the correct
backlash settings for the idler gear, the position of the
dowel holes may have to change. To do this, the
dowel holes must be reamed to a larger size by 0,38
mm (0.015 in), this will give them a diameter of 8,33
mm (0.328 in). If this operation has been done before,
they may have to be reamed by a further 0,38 mm
(0.015 in) to a finished size of 8,73 mm (0.3437 in).
According to the size of the dowels which are to be
fitted, a selection of these location pins and reamers
will be necessary:
Dowel size 8,33mm (0.32in) oversize
Dowel part number:
Location pin:
Reamer:
Location pin:
OE51709/1
21825 830
21825 833
21825 831
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Between the idler gear and the drive gear for the fuel
injection pump (FIP):
0,05 to 0,15 mm (0.002 to 0.006 in).
Between the idler gear and the camshaft gear:
0,05 to 0,15 mm (0.002 to 0.006 in).
Between the idler gear and the crankshaft gear:
0,15 to 0,40 mm (0.006 to 0.010 in).
02
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16
Cylinder block assembly
16
General description
The crankcase is a single unit cast in high grade
nickel-chrome iron and comprises the crank chamber
and the cylinder block. The crank chamber extends
below the crankshaft line to ensure rigidity. Lateral
bolts to the front, centre and rear main bearing caps
provide additional stiffness.
Five transverse webs within the crankcase provide
support for the crankshaft and camshaft. The
crankshaft is carried in seven bearings, secured by
removable caps and fitted with thrust washers at the
centre bearing.
The camshaft has seven journals. On all engines prior
to build line number 79339 the camshaft runs in
bearing surfaces machined in the crankcase parent
metal. Industrial engines, from build line number
79339, have a bush fitted to the front journal with the
six remaining journals running in bearing surfaces
machined in the crankcase parent metal.
The low-mounted camshaft is gear driven from the
front of the crankshaft through an idler gear. It is
drilled through its complete length to form an oil
gallery and runs in bearings or bearing surfaces
machined in the crankcase.
Oil is transferred from the centre bearing to lubricate
the remaining six camshaft journals and certain other
components.
The drive gear is located on the shaft by a single
dowel and retained by five setbolts/capscrews and a
locking plate. For certain early engines, the drive gear
is pressed onto the camshaft and is located by a
woodruff key.
Slip-fit wet-type cylinder liners manufactured from
cast iron and which have been induction hardened
are used. The liner bore is honed and carbide
finished, which results in a matt surface.
Caution: If a used liner is to be refitted to an engine,
it is vital that NO re-honing or de-glazing of the bore is
undertaken.
The top of the liner is flanged and forms a coolant seal
with the counterbore seat in the crankcase top face.
Three grooves are machined into the skirt of the liner
to accept three composition sealing rings.
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Crankcase
To fit to and to remove from a
build stand
Special tools:
Strap wrench, 21825 825
Lift adaptor for engine, 21825 821
Build stand - engine, 21825 993
To fit to a build stand
To obtain access to the crankcase and further main
components, the engine must be disconnected from
its driven unit and fitted in a build stand. Instructions
to disconnect the driven unit are to be found in the
publication of the relevant manufacturer. To fit the
engine to a build stand proceed as follows:
1 Disconnect the batteries.
2 Close the valves and disconnect the pipes for the
fuel supply and the fuel return.
3 Drain the coolant system (refer to the Users
Handbook TSD 3215), remove the radiator, operation
21-1, and the relevant coolant pipes and air ducts.
Warning! Remove carefully the radiator filler cap as
the system may be under pressure.
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16-2
Special tools:
Cylinder head lifting bar, 21825 816
Bobbin removal tool, 21825 800
Flywheel lifting bracket, 21825 817
Bearing cap removal tool, 21825 806
Engine build stand, 21825 993
Lapping tool. 21825 902
Piston replacer sleeve, 21825 784
Dial gauge, 21825 782
Torque angle gauge, 21825 924
Sump guide studs, 21825 812
16
To dismantle
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To assemble
82
Continued
13 15
11
17 19
16 14
10
12
20 18
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0.114
0.127
0.102
0.114
0.089
0.102
0.076
0.089
0.076
0.076
0.076
0.076
0.089
0.076
0.076
0.076
0.114
0.102
0.102
0.127
0.127
0.127
0.089
0.127
0.127
0.114
Acceptable
0.127
0.127
0.076
0.102
0.102
0.076
0.127
0.102
0.127
0.076
0.076
0.114
0.076
0.076
0.076
0.076
0.127
0.127
0.127
0.127
0.076
0.102
Unacceptable
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Perkins Engines Company Limited
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2
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Adjust tappets on
cylinder number
No.6
No.1
No.3
No.4
No.5
No.2
No.1
No.6
No.4
No.3
No.2
No.5
Exhaust valves:
151
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300
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To inspect
16-3
Special tools:
Remover tool for cup plugs, 21825 855
Slide hammer, 21825 849
Replacer kit for cup plugs, 21825 865
Drive handle, 21825 861
Cutting tool, 21825 791
Cutter, 21825 792
Crankcase
Remove all blanking plugs and clean the crankcase
thoroughly giving special attention to oilways. Refit
the coolant plugs to the cylinder block, apply Loctite
225 to the threads and use new sealing washers
where necessary. Remove any suspect core plugs
using the core plug remover, 21825 855, and slide
hammer, 21825 849. To fit new core plugs use the
replacer kit, 21825 865, and drive handle, 21825 861.
303
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Cylinder liners
1
16-4
Special tools:
Remover/replacer tool, 21825 790
Cylinder liner clamp, 21825 844
To remove
1 Drain cooling and engine lubrication systems.
2 Remove the cylinder head/s, operation 12-4.
141
298
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296
297
16-5
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Cam followers
To remove and to fit
To fit
16
To remove
1 If a compressor is fitted to the engine, drain the
coolant system to below the level of the coolant inlet
pipe of the compressor.
2 Remove the rocker covers and the rocker
assemblies, operation 12-1 and operation 12-2.
Withdraw the push rods and store them in the correct
sequence to ensure that they can be refitted to their
original positions.
3 Where fitted, disconnect and remove the oil feed
and coolant pipes from the compressor, and remove
the compressor air supply pipe.
4 Slacken the hose clip and remove the breather pipe
from the cam follower cover.
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Camshaft
To remove and to fit - bolt-on type
16-7
To remove
1 Remove the cam followers, operation 16-6.
2 Remove the alternator, operation 23-2.
3 Remove the coolant pump, operation 21-5.
4 Remove the crankshaft pulley assembly, operation
14-1 or operation 14-2, and the wheelcase, operation
15-1.
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305
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Camshaft
To remove and to fit - integral type
16-8
To remove
1 Remove the cam followers, operation 16-6.
2 Remove the alternator, operation 23-2.
3 Remove the coolant pump, operation 21-5.
4 Remove the crankshaft pulley assembly, operation
14-1 or operation 14-2, and the wheelcase, operation
15-1.
306
2
304
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To inspect
16-9
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1
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Engine timing
17
Valve timing
To check
17-1
2
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17-2
307
308
Continued
309
D
100
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18
Aspiration system
18
General description
The induction system of the engine is supplied with air
under pressure by means of a turbocharger driven by
the energy of the waste exhaust gases. The part
number of the turbocharger can be found on the
turbocharger data plate. Early engines are fitted with
one of these: OE49342, OE51140 or OE51430. New
2000 series engines are fitted with OE52534 or
OE52535. TTAG engines are fitted with two
turbochargers: OE50642 and OE50674.
Turbochargers OE51430 and OE52535 are each
fitted with a waste-gate.
The exhaust manifolds direct the exhaust gases to the
turbine wheel of the turbocharger rotor, causing the
rotor to spin. The turbocharger compressor impeller,
which forms part of the rotor assembly, draws air in
through the air cleaner and delivers it to the induction
manifold, under pressure, to be distributed to each
cylinder as the inlet valves open. A waste-gate, fitted
to certain turbochargers, monitors the boost delivery
pressure in the turbocharger compressor and, once
this reaches a pre-set figure, opens and allows the
excess pressure to escape.
TWG engines are fitted with an air-to-coolant charge
cooler, interposed between the turbocharger and the
induction manifold. This serves to lower the
temperature of the compressed induction charge
before it passes into the engine. The charge cooler is
supplied by coolant from the engine. The coolant
flows through a matrix of tubes within the charge
cooler before recirculating through the engine coolant
system.
All TA, TAG, and TTAG engines are fitted with an airto-air charge cooler, an intercooler. It is mounted at
the front face of the coolant radiator. The
turbocharger compressor directs air through the
intercooler before it passes through large bore
pipework into the induction manifold.
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Turbocharger
To fit
Description
The turbocharger is a turbine driven compressor
which utilises the energy of the exhaust gases to
increase the mass of the induction charge.
The unit is secured to the exhaust manifold assembly
and consists of a bearing housing which contains the
rotor assembly and bearings and to which is secured
the turbine and compressor housings.
The rotor bearings are of the fully floating sleeve type.
Lateral location of the rotor and control of end float is
achieved by use of a shaft-mounted thrust ring
assembly and a thrust bearing plate. Filtered oil from
the engine is delivered under pressure to the
turbocharger to provide bearing lubrication.
18
18-2
18-1
To remove
1 Remove the turbocharger air ducts and the oil feed
and drain pipes. Do NOT damage or bend the pipes.
2 Support the turbocharger, unscrew the four
securing nuts and remove the unit.
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18-3
To dismantle
12
16
13
14
24
15
18
11
10
5
17
25
26
18
23
22
20
21
17
A
106
19
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Bolts (A4)
Bolts (A24)
Screws (A14)
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18-4
To clean
1 Use a commercially approved non-caustic cleaning
solution to soak parts until all deposits have been
loosened.
2 Clean all aluminium parts with a bristle type brush
or plastic scraper. Vapour blast may be used except
on the shaft and bearing surfaces.
3 Blow compressed air through all drilled
passageways and ensure that the surfaces adjacent
to the turbine and compressor wheels are clean,
smooth and free from deposits.
To inspect
1 Inspect the shaft bearing journals and the walls of
the seal grooves for wear and excessive scratches.
Minor scratches may be tolerated.
2 Check the turbine and compressor wheels for
cracked or damaged blades but do NOT attempt to
straighten blades.
3 Check the thrust bearing surfaces for wear or
damage. Minor scratches are acceptable. Ensure
that the feed grooves in the thrust bearing are clean.
4 Replace the bearings if excessively scratched or
worn.
5 Replace the bearing housing if the bearing or seal
bores are severely scratched or worn.
6 Have the balance of the rotor assembly checked at
an establishment which has the relevant special
equipment and knowledge.
7 Replace the O ring seal (A9).
8 Check the turbine housing for signs of rubbing,
flaking and overheating. Slight damage is acceptable
but otherwise the housing should be replaced.
9 Check the compressor housing for damage due to
contact with the rotor. Slight damage is acceptable
but otherwise the housing should be replaced.
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Turbocharger: OE50674
To dismantle
1 Use a scriber to mark the relative positions of the
turbine housing (A23), the bearing housing (A12), the
compressor housing and the V band clamp (A2).
This will ensure correct alignment during reassembly.
4
3
5
9
12
10
13
18
17
16
15
11
19
20
21
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160
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18-6
To clean
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18-7
To dismantle
Continued
10
11
12
17
4
3
15
2
6
13
16
14
24
21
20
25
23
22
26
19
A
112
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160
To assemble
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18-8
To clean
1 Use a commercially approved non-caustic cleaning
solution to soak parts until all deposits have been
loosened. Bead blasting may be used on the turbine
housing, but only if chemicals do not clean
sufficiently.
Caution: Do NOT use bead blasting on any other
turbocharger components.
2 Clean all aluminium parts with a bristle type brush
or plastic scraper. Vapour blast may be used except
on the shaft and bearing surfaces.
Caution: Do NOT use a wire brush or metal scraper
on any turbocharger component.
3 Blow compressed air through all drilled
passageways and ensure that the surfaces adjacent
to the turbine and compressor wheels are clean,
smooth and free from deposits.
To inspect
1 Inspect the shaft bearing journals and the walls of
the seal grooves for wear and excessive scratches.
Minor scratches may be tolerated.
2 Check the turbine and compressor wheels for
cracked or damaged blades but do NOT attempt to
straighten blades.
3 Check the thrust bearing surfaces for wear or
damage. Minor scratches are acceptable. Ensure that
the feed grooves in the thrust bearing are clean.
4 Replace the bearings if excessively scratched or
worn.
5 Renew the bearing housing if the bearing or seal
bores are severely scratched or worn. Ensure that the
tapped holes are clean.
6 Check the profile in the turbine housing for damage
caused by possible contact with the rotor. Inspect the
outer and inner walls for cracks or flaking caused by
overheating, also check the mounting flanges for
signs of distortion.
114
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Inlet manifold
To remove and to fit
Exhaust manifold
18-9 To remove and to fit
18
18-10
To remove
To remove
1 Drain the engine coolant.
115
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19
Lubrication system
19
General description
The engine has a wet sump type system. One of two
types of sump is fitted: a cast aluminium type or, for
recent engines, a version made from a composite
material. The capacity of the aluminium sump is 25
litres (5.5 UK gallons) to the maximum mark on the
dipstick and 18 litres (4 UK gallons) to the minimum
mark. The capacity of the composite sump is 41 litres
(9 UK gallons) to the maximum mark on the dipstick
and 34 litres (7.5 UK gallons) to the minimum mark.
The drain plug fitted to the sump depends on the type
of engine.
Continued
117
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19
1 Suction filter
2 Pressure pump
3 Oil pressure relief valve
4 Oil cooler
6 Piston cooling jets
7 Supply to turbocharger
8 Supply to injection pump (early engines)
9 Idler gear axle
A
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19
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19
19-1
Special tools:
Strap wrench, 21825 825
1 Put a tray under the canisters and use a strap
wrench, 21825 825, to remove each canister (A1).
2 Check that the sealing rings are correctly fitted to
the new canisters and clean the contact faces of the
filter head.
3 Fill the two new canisters with new engine
lubricating oil of the correct grade and lubricate the
top of each canister seal with the same oil.
1
120
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19
By-pass filter/separator
1
19-2
3
07
121
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19
Sump
To remove and to fit
19-3
To remove
1 Drain the engine lubricating oil into a suitable clean
container. Refit the sump drain plug, refer to page 123
for the correct torque figure for the sump drain plug.
2 If fitted, remove the sump noise shield.
3 Disconnect the oil filler tube and the dipstick
assembly from the sump. This is not applicable to new
2000 series engines.
167
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19
16
17
A
Perkins Engines Company Limited
18
1
159
19
123
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19
19-4
To remove
A
124
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19
19-5
Special tools:
Puller, 21825 837
Bolts, 21825 838
2
To dismantle
1 Withdraw the drive gear (A1) using puller, 21825
837 (A2), with bolts (2 off), 21825 838.
2 Unscrew and remove the pump casing bolts and
dismantle the unit.
To assemble
299
To inspect
19-6
To inspect
1 Clean all components and inspect the gears,
casings, and bearings for signs of wear or damage.
2 Carefully stone any small burrs and polish out any
slight scoring.
3 If possible, crack test all gears.
125
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19
19-7
2
3
315
To inspect
19-8
126
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20
Fuel system
20
127
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20
General description
A mechanically driven fuel feed pump draws fuel from
the supply tanks and delivers it, via the main filters, to
the injection pump gallery. The gallery pressure is
maintained at a constant pressure by a low-pressure
relief valve which is contained in the bolt which secures
the spill pipe banjo to the fuel injection pump gallery.
Fuel enters the pump elements from the gallery, and
is delivered at high pressure to the six spring type
injectors, which are set to operate at 2408 bar
(2378 atmospheres).
Excess fuel and spill from the injection pump, together
with spill from the fuel injectors, is returned to the
supply tank.
Overhaul instructions
128
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20
Fuel injectors
3
Warnings!
Ensure that the fuel does not spray onto your skin.
z
z
20-1
Special tools:
Removal tool, 21825 914
To remove
1 Clean the area around the fuel injector and around
its connections.
2 Disconnect and remove the leak-off pipe assembly
from the fuel injectors.
179
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20
To fit
125
B
130
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20
20-2
To dismantle
1 Lightly grip the injector body in a vice and unscrew
the nozzle cap nut.
To assemble
4
6
20-3
153
To clean
If the facilities are available, the injectors should be
cleaned ultrasonically. Alternatively, proceed as
follows:
1 Wash the components of each injector in paraffin or
fuel oil and dry with a jet of dry compressed air.
2 Soak the nozzle in a carbon solvent and remove
any remaining carbon using the relevant cleaning kit,
together with a cleaning wire of the correct size. Wires
are not included in the kit and must be purchased
separately.
3 It is important that the correct size of wire is used to
clean the spray holes. Fit the wire into the holder with
a maximum protrusion of 1,5 mm (0.0652 in), this will
minimise the risk of the wire breaking in the nozzle
spray holes.
4 When the spray holes are cleared, re-soak each
nozzle in carbon solvent, rinse in clean water and dry
with a jet of dry compressed air. Dip in clean test oil.
Continued
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20
132
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20
20-4
5
4
6
153
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20
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To dismantle
20
20-6
20-5
To remove
To assemble
To fit
1 Refitting is a reversal of the removal procedure; use
a new gasket.
1
2
3
8
7
6
5
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Perkins Engines Company Limited
154
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20
20-8
To dismantle
To remove
1 Before removing the lift pump from its mounting,
slacken each of the banking plugs over the three
valves, the priming pump body (A1) and the large cap
plug over the pump plunger (A2). Disconnect the fuel
pipes and remove the lift pump retaining bolts.
Remove the pump from its mounting.
To fit
1 Refitting is a reversal of the removal procedure; use
a new gasket.
Particulars of further tests for both pumps involving
special apparatus are available from the pump
manufacturer, if required.
1
3
A
136
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To test
20-9
20
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20
20-10
To remove
1 Disconnect and remove all relevant pipework and
linkages. Do NOT bend the pipes.
Note: For new 2000 series engines the high pressure
fuel pipes must be removed and fitted as a complete
set.
2 Remove the front rocker cover and turn the engine
in the correct direction of rotation until No. 1 inlet valve
closes.
3 Remove the fuel injection pump access cover (A1)
from the front of the engine.
4 Remove the four bolts which retain the pump drive
gear together with the clamping plate and withdraw
the drive gear.
5 Remove the four nuts and washers from the pump
flange (B1) and the two nuts, bolts and washers (B2)
from the rear end of the fuel injection pump.
311
321
Continued
C
138
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20
322
323
308
D
Perkins Engines Company Limited
310
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20
308
140
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20
20-11
54
141
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20
20-12
31
142
2
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21
Cooling system
21
General description
The illustration (A) on page 144 shows the coolant
flow characteristics for a 2006 TW or TWG engine
which has an air-to-coolant charge cooler. The
illustration (B) on page 145 shows a 2006TA or TAG
engine.
143
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21
A
144
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21
1 Oil cooler
12 Coolant pump
6 Thermostat housing
14 Drain plugs
7 Thermostat
8 To thermostat
16 Fan
145
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21
Radiator
To remove and to fit
21-1
318
To remove
1 Drain the coolant system as given in the User's
Handbook TSD3215.
2 Disconnect and remove the pipe from between the
oil cooler and the radiator.
3 Disconnect and remove the pipe (B1) from between
the thermostat housing and the radiator.
4 Release the hose clips at the radiator end of the
turbocharger-to-radiator air duct.
5 Remove the air duct (B2), and retaining straps,
from between the connection on the inlet manifold
and the radiator.
6 Remove the nuts and bolts which secure the
radiator to the radiator stand and carefully slide the
radiator assembly away from the engine. Ensure that
the fan cowl does not touch the fan blades.
Caution: Do not damage the fan blades during
removal and fitting of the radiator. If the fan blades
become cracked or bent it will be necessary to renew
the fan.
To fit
1 Place the radiator on the radiator stand and
carefully slide it toward the engine until the fan blades
are halfway inside the fan cowl. Take care not to
damage the fan blades.
2 Loosely fit the nuts, bolts and washers which retain
the radiator on the radiator stand.
3 Rotate the fan so that two of the fan blades are
horizontal. Stand behind the engine and check the
horizontal distance between the two fan blades and
the fan cowl. Adjust the horizontal position of the
radiator until the gap is equal at both sides, then
tighten the nuts and bolts at the base of the radiator.
338
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21
1
8 Fit the coolant pipe between the oil cooler and the
radiator. Use new hoses and tighten the hose clips to
a torque of 4 Nm (3 lbf ft).
9 Using a new hose, connect the air duct from the
turbocharger to the radiator. Tighten the hose clips to
a torque of 4 Nm (3 lbf ft). If the complete air duct
assembly was removed, proceed as follows:
10 Fit the air duct assembly between the
turbocharger and the radiator, use new hoses but
do not tighten the hose clips at this stage. If
necessary, adjust the position of the turbocharger
compressor housing so that the duct assembly lies
naturally between the components. Fit the brackets
to the crankcase and secure the duct assembly with
the two U-bolts. Tighten the hose clips to a torque
of 4 Nm (3 lbf ft).
338
Fan
To remove and to fit
21-2
To remove
1 Remove the radiator, operation 21-1.
2 Remove the six retaining screws, remove the fan
and collect the spacer if fitted.
To fit
1 Where necessary, fit the spacer. Fit the fan and
retain with six bolts and spring washers. Tighten each
bolt to a torque of 47 Nm (35 lbf ft).
2 Check that the spring washers have seated correctly
and have not spread out. If any have become distorted
or have spread out from under the bolt head: remove
the relevant bolt, fit a new spring washer and tighten
the bolt to a torque of 47 Nm (35 lbf ft). Check that the
new spring washer has seated correctly.
3 Fit the radiator, operation 21-1.
147
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21
21-3
21-4
157
1
2
3
4
148
5
6
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21
Coolant pump
To remove and to fit
21-5
To remove
1 Drain the coolant system.
2 Remove the radiator, operation 21-1.
3 Remove the cooling fan, operation 21-2.
4 Remove the alternator and drive belt/s.
5 Release the belt tension and remove the coolant
pump drive belts.
6 Remove the coolant pump drive pulley. For engines
with low mounted pump, remove the crankshaft pulley
and damper.
7 Slacken the hose clips and disconnect the coolant
pipe from the coolant pump.
8 Unscrew the pump retaining bolts and remove the
pump.
To fit
1 Ensure that all joint surfaces are clean.
2 Fit the pump, complete with new joints.
3 Fit the crankshaft pulley, and damper if applicable.
4 Fit the coolant pump pulley and tighten the securing
bolts to a torque of 24 Nm (18 lbf ft).
5 Fit the coolant pump drive belts.
6 Fit the mounting bracket and, where applicable, the
alternator and its drive belt/s.
7 Adjust the tension of all belts, operation 21-4 and
operation 23-1.
8 Connect the coolant pipe between the oil cooler
and the coolant pump.
9 Fit the fan, operation 21-2.
10 Fit the radiator, operation 21-1.
11 Refill the coolant system with the correct coolant
mixture.
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21
21-6 4 Remove the hub (A14), lever out the front oil seal
(A13) and release the circlip (A12).
Special tools:
Puller, 21825 837
Bolts, 21825 838
Bearing replacer, 21825 904
Seal replacer, 21825 899
Bearing replacer, 21825 903
To dismantle
Note: Unless the special tools required for coolant
pump overhaul are readily available, users are
advised to fit a Service Exchange unit. For further
details contact your Authorised Perkins Dealer.
1 Remove the pump backplate, where applicable.
2 Withdraw the impeller (A5) from the shaft using the
puller, 21825 837, and two bolts, 21825 838.
3 Position the pump assembly on a press and
remove the shaft (A4) by pressing it out towards the
rear of the assembly.
2
3
9
10
11
12
A
150
13
14
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21
To assemble
1 Pack the bearing with Shell Retinax A grease. The
later type of bearing is double-sealed and prepacked for life.
2 Ensure that the outer diameter of the bearing and
the inner diameter of the bearing housing are
completely free from oil and grease.
3 Use a brush to apply a coat of Loctite 648 to the
shoulder inside the bearing housing (A).
4 Press the bearing into the housing using the special
tool, 21825 904, with the sealed side of the bearing
leading.
5 Apply grease to the inside of the bearing housing
and insert the two spacers.
324
325
326
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21
327
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To inspect
21
21-7
2
3
9
10
11
12
A
Perkins Engines Company Limited
13
14
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21
Thermostat
4
Description
The thermostat (A1) is a wax-type triple-element unit
fitted to a housing (A2) above the coolant pump. It is
correctly located in the housing by a roll-pin (A3),
fitted in the rim. This ensures that the valves are
correctly positioned over the by-pass ports.
To extract the thermostat, remove the thermostat
housing cover (A4) and lift out the unit. The
thermostat requires no servicing and must be
replaced if it becomes defective. Sticking valves may
be rectified by applying silicone grease to the spindles
and operating the valves by hand until they are free.
21-8
1
2
319
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21-9
21
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21
Oil cooler
Description
21-10
To dismantle
1 Drain the coolant and disconnect the coolant hoses
and lubricating oil pipes from the unit.
2 Remove the two canister type oil filters.
3 Remove the bolts which secure the unit to the
mounting and lift it away.
A
156
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21
To assemble
To inspect
21-11
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22
Flywheel and flywheel housing
22
General description
The flywheel housing (A1) is machined from
aluminium and is fitted to the rear of the crankcase. It
is located by two dowels and provides the mounting
for the starter motor. Additionally, the flywheel
housing fitted to new 2000 series engines contains
the crankcase rear oil seal.
Continued
337
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22
160
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Flywheel
To inspect
22
22-2
Special tools:
Guide studs, 21825 802
Lifting attachment, 21825 817
To remove
1 Remove the timing pointer from the flywheel
housing to prevent it from fouling the ring gear when
withdrawing the flywheel.
2 Remove two horizontally opposed flywheel
retaining bolts and replace with two guide studs,
21825 802.
3 Unscrew and remove the remaining ten bolts.
4 Carefully release the flywheel from its dowel and
slide it onto the guide studs. Fit the lifting attachment,
21825 817, and using suitable lifting equipment
remove the flywheel from the engine.
To fit
1 Ensure that the two guide studs, 21825 802, are
fitted securely.
2 Lift the flywheel onto the guide studs and align the
dowel hole with the dowel in the crankshaft.
3 Fit the securing bolts and washers and remove the
guide studs. Tighten the bolts evenly to a torque of
122 Nm (90 lbf ft).
4 Fit the timing pointer and its cover.
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22
Flywheel housing
To remove and to fit
22-3
To remove
1 Remove the flywheel, operation 22-1.
2 Remove the starter motor, operation 23-3.
3 Remove the bolts which secure the housing to the
crankcase.
300
3 Lift the housing onto the locating dowels and fit the
retaining bolts and washers. Tighten the bolts evenly
to a torque of 61 Nm (45 lbf ft).
4 Fit the flywheel, operation 22-1.
5 Fit the starter motor, operation 23-3.
162
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23
Electrical equipment
23
General description
The electrical components of the engine consist of an
alternator, a starter motor and an engine stop
solenoid. Certain engines may be fitted with warning/
shut-down switches. One of many types of alternator
may be fitted to the engine, but only one type of
starter motor is utilised.
A typical wiring diagram for a 2000 series engine is
shown (A).
Cable Data
24 volt battery *
Section area
Size
Start relay *
in2
mm2
0.093
60.00
II
0.007
4.52
III
0.001
0.65
* SUPPLIED BY CUSTOMER
Run switch
II
Start switch *
III
I
Ammeter *
40-0-40
II
II
II
24 volt
2.8 watt
Lamp *
II
4
III
D
F
II
ALTERNATOR
STARTER MOTOR
268
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23
Alternator
The alternator fitted to current engines will be rated at
55 or 70 amps, depending on application.
Each type of alternator is fitted with an integral
regulator. The regulator requires no adjustment
during service and is a non-repairable item.
It is not advisable to attempt repairs to the alternator.
Such work requires specialist equipment and
knowledge. Should alternator failure occur, operators
are advised to take advantage of the Perkins service
exchange scheme.
Starter motor
As specialist equipment and knowledge are
necessary to overhaul the starter motor assembly, it
is recommended that an exchange unit is fitted. If the
equipment and expertise are available, the
instructions for starter motor overhaul are given in this
section.
The starter motor is a 24 volt unit, actuated by an
externally mounted solenoid switch through a lever
arm. The pinion assembly incorporates a positive
engagement device, an overload clutch and a
freewheel ratchet. It is mounted on the flywheel
housing.
Operation of the starter switch energises the pull-in
and hold-in coils and actuates the solenoid to move
the pinion into mesh with the starter ring. Should the
teeth abut, the pinion moves back against its spring
load and rotates slightly until engagement occurs.
The starting contacts then close in parallel with the
pull-in coil, which is de-energised, and full torque is
applied.
If engine resistance is excessive the pinion clutch
comes into operation.
When the engine starts, the pinion is allowed to run
free, in mesh with the starter ring, until the starter
switch is released. The hold-in coil is then deenergised, allowing the return spring in the solenoid
switch to disengage the pinion through the lever arm.
Certain engines are fitted with control switches.
These are set at the factory and cannot be adjusted.
Discard if faulty
164
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23
23-1
To check
Check all drive belts and renew a belt if it is worn or
damaged. Where more than one belt is used between
two pulleys, all of the belts must be renewed together.
See section 21 for details about the fan drive belts.
Check the alternator belt tension at the centre of the
longest free length (A1).
Use a V-belt tension gauge to check the tension of the
belt. The correct tension for all belts is 400 to 489 N
(90 to 100 lbf).
Note: When a new belt is fitted it must be checked
again after the engine has been run for 15 minutes
and, if necessary, adjusted to the correct tension.
To adjust the tension
Loosen the two bolts (A2) and rotate the alternator on
the pivot bolt to tighten the belt to the correct tension.
Tighten the two bolts.
157
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23
Alternator
2
23-2
To remove
1 Disconnect the battery.
183
To fit
1 Fit the alternator. Retain with the pivot bolt and a
spring washer. Then fit the adjustment bolt, complete
with nut and washers.
2 Reconnect the wiring loom to the alternator.
3 Fit the alternator drive belt and adjust the tension,
operation 23-1.
4 Connect the battery.
166
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Starter motor
23
23-4
23-3 To dismantle
1 Remove both jumper leads from between the
solenoid switch and the starter body.
To remove
To fit
1 Fit carefully the starter motor assembly to the
flywheel housing, fit the three retaining screws,
complete with plain and spring washers, and tighten
securely.
2 Connect the cables to the correct terminals.
3 Connect the battery.
Continued
2
1
3
4
5
8
9
7
6
A
Perkins Engines Company Limited
329
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23
To assemble
2
1
3
4
5
8
9
7
6
A
168
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To assemble
23-5 Ensure that all of the components are clean and dry
To dismantle
1 Remove the solenoid switch, operation 23-4.
Before the starter motor is dismantled, mark the
edges of each section of the starter motor to ensure
their correct relationship during assembly.
2 Remove the cover (A4), release the connections
and carefully withdraw the carbon brushes (A3).
3 Disconnect the two cables from the field windings
(A7), release the four bolts and remove the end cover
(A1). Withdraw the armature (A5).
4 Release the six cap screws and remove the pinion
housing (A8); disconnect and remove the pinion
assembly (A10).
5 Remove the screw and washer from the housing
(A8); withdraw the pivot and remove the shift lever
(A12). Separate the housing from the yoke (A6).
4
1
5
2
3
12
13
14
6
7
8
A
Perkins Engines Company Limited
10
11
332
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23
4
1
5
2
3
12
13
14
6
7
8
A
170
10
11
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To clean
23-6
23
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23
To test
23-8
330
331
55
23-9
1 Switch
2 Battery
Hold in
Pull in
D
172
4 Switch
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23
Description
334
135
23-10
3
136
4 Hold the lever at this position and adjust the lock nut
(C1) until its rear face is level with the front of the rod
(C2) as shown. Ensure that the lock nut is not
moved from this position on the thread.
5 Connect the linkage to the solenoid and rotate the
rod (C2) until it reaches the lock nut. Hold the lock nut
with a suitable spanner and tighten the rod securely
against the lock nut.
6 Energise and de-energise the solenoid to check the
operation.
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24
Auxiliary equipment
24
Compressor
Description
Certain engines may be fitted with a compressor. The
compressor will be one of two types: a single cylinder
version for early engines, or a twin cylinder version for
new 2000 series engines.
The single cylinder compressor is a 293 cc water
cooled unit flange mounted to the rear of the
wheelcase backplate. It is gear driven from the
camshaft at 1.212 times engine speed.
The twin cylinder compressor is a 440 cc water cooled
unit flange mounted to the rear of the wheelcase
backplate. It is gear driven from the camshaft at 1.212
times engine speed.
336
24-1
To remove
1 Using a 5/16 in allen key remove the hydraulic pump
and coupling, where fitted, from the rear of the
compressor.
2 Drain the engine coolant into a suitable clean
container.
3 Disconnect and remove the rubber coolant pipe
from between the compressor and the crankcase.
4 Remove the compressor air intake filter assembly,
or disconnect the air intake pipe from the induction
system (whichever is fitted).
5 Unscrew the steel coolant pipe from the front of the
compressor cylinder head. Do NOT bend the pipe.
6 Disconnect the oil feed pipe, free it from its clips,
and remove it from the engine.
7 Unscrew the three compressor securing nuts and
washers.
8 Support and carefully withdraw the compressor (A).
Discard the gasket.
175
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24
To fit
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24
24-2
BDC
175
176
177
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25
Running-in and test
25
General description
Every new or reconditioned engine which is supplied
by Perkins Engines Limited is run and tested before it
is received by the customer. There is no requirement
for the running-in of the engine when it is initially in
use, but it is recommended that the engine is
operated in accordance with the instructions which
are given in section 3 of the Users Handbook TSD
3215.
A period of running-in, which is relevant to the rating
of the engine, should be done in accordance with the
instructions given below when:
z
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25
25-1
Rev/min
Load or power
rating
Period
(minutes)
10
10
10
10
180
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25
181
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26
List of special tools
26
183
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26
Special tools
A new range of numbers have been allocated to the tools used on Perkins engines. The tables in this section
include all of the tools listed in the workshop manual. The additional number, in brackets below each special
tool number, is the number by which the tool was previously available.
Number
Description
21825 739
(GA5000)
21825 742
(GA5000-3)
21825 743
(GA5000-4)
21825 748
(GA5003)
21825 752
(GA5007)
184
Illustration
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26
Number
Description
21825 754
(GA5009)
21825 763
(GA5018)
21825 764
(GA5019)
21825 782
(GA5031)
21825 784
(GA5033)
21825 786
(GA5035)
Illustration
185
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26
Number
Description
21825 787
(GA5035-1)
21825 790
(GA5037)
21825 791
(GA5038)
21825 792
(GA5038-1)
21825 793
Ring expander
21825 800
(GA5047)
186
Illustration
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26
Number
Description
21825 802
(GA5050)
21825 805
(GA5053)
21825 806
(GA5054)
21825 807
(GA5055)
21825 812
(GA5061)
21825 814
(GA5063)
Illustration
187
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26
Number
Description
21825 816
(GA5066)
21825 817
(GA5067)
21825 821
(GA5071)
21825 823
(GA5073)
21825 825
(GA5074)
Filter wrench
21825 826
(GA5075)
188
Illustration
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26
Number
Description
21825 837
(GA5090)
Puller
21825 838
(GA5090-1)
Adaptor bolts
Use with 21825 837 (GA5090)
21825 841
(GA5091)
21825 844
21825 846
(GA5095)
21825 848
(GA5098)
Illustration
189
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26
Number
Description
21825 849
(GA5100)
Slide hammer
21825 855
21825 860
(GA5100-11)
Adaptor
Use with 21825 739 (GA5100)
21825 861
(GA5101)
Drive
21825 865
(GA5101-4)
21825 869
(GA5101-8)
190
Illustration
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26
Number
Description
21825 899
(GA5143)
21825 902
(GA5148A)
21825 903
(GA5149)
21825 904
(GA5150)
21825 908
(GA5164)
21825 909
(GA5165)
Illustration
191
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26
Number
Description
21825 914
(GA5170)
21825 922
(GA5909)
21825 924
(GA5911)
21825 991
21825 992
(GA5097)
21825 993
(GA5099)
192
Illustration
This document has been printed from SPI. Not for Resale
26
Number
Description
21825 999
Reaming jig
27610 006
27610 007
Illustration
193
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This document has been printed from SPI. Not for Resale