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Perkins 2000 Series WORKSHOP MANUAL 6 cylinder diesel engines for industrial applications

Publication TPD 3245, Issue 2. © Proprietary information of Perkins Group Limited, all rights reserved. The information is correct at the time of print. Published in September 1999 by Technical Publications, Perkins Engines Company Limited, Lancaster Road, Shrewsbury, Shropshire, SY1 3NX, England 1

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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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12 Cylinder head assembly Rocker cover 12-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25 Rocker assembly 12-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26 Tappet clearances 12-3 To check and to adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27 Cylinder head 12-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12-5 Procedure for retightening of the cylinder head bolts ... ... ... ... ... ... ... ... ... ... ... 12-6 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12-7 To clean and to inspect the cylinder head . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12-8 To renew a valve spring with the cylinder head installed ... ... ... ... ... ... ... ... ... ... 12-9 To correct a valve seat .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12-10 To remove a valve seat insert .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12-11 To fit a valve seat insert ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12-12 To inspect the valve guides . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12-13 To renew a valve guide ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...

28 31 32 34 34 35 36 36 37 37

Valves, valve springs and valve rotators 12-14 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38 12-15 To clean and to inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38 Fuel injector sleeves 12-16 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39 Push rods 12-17 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41 12-18 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41 Fits and clearances - Rocker assemblies ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42 Fits and clearances - Cylinder heads and valve assemblies ... ... ... ... ... ... ... ... ... 43

13 Piston and connecting rod assembly General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45 Piston and connecting rod assembly 13-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47 13-2 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 49

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Piston and rings 13-3 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 50 Connecting rod 13-4 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 50 Small end bushes 13-5 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 51 Fits and clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 52

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

15 Wheelcase and drive assembly General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 67 Wheelcase 15-1 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 68 Backplate 15-2 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 68

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Camshaft gear - bolt-on type 15-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 71 Camshaft gear - integral type 15-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 72 15-5 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 73 Idler gear 15-6 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 74 15-7 To set the gear backlash ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 75 Fits and clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 77

16 Cylinder block assembly General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79 Crankcase 16-1 To fit to and to remove from a build stand . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 80 16-2 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 81 16-3 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 90 Cylinder liners 16-4 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 91 16-5 To clean and to inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 92 Cam followers 16-6 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 93 Camshaft 16-7 To remove and to fit - bolt-on type . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 94 16-8 To remove and to fit - integral type ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 95 16-9 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 96 Fits and clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 97

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

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Oil pressure relief valve 19-7 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 126 19-8 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 126

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

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Fan drive belts 21-3 How to check the fan belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 148 21-4 How to adjust the tension of the fan belts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 148 Coolant pump 21-5 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 149 21-6 To dismantle and to assemble .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 150 21-7 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 153 Thermostat 21-8 How to check the operating temperatures ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 154 21-9 How to check the operating speed ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 155 Oil cooler 21-10 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 156 21-11 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 157

22 Flywheel and flywheel housing General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 159 Flywheel 22-1 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 161 22-2 To inspect .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 161 Flywheel housing 22-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 162

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

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Engine stop solenoid 23-10 How to adjust the linkage . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 173

24 Auxiliary equipment Compressor 24-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 175 24-2 Compressor gear alignment .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 177

25 Running-in and test General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 179 Running-in and test 25-1 To run the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 180 25-2 To check the consumption rate of the engine lubricating oil .. ... ... ... ... ... ... ... .. 181

26 List of special tools Special tools .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 184

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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 User’s 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.

If the specification of your engine is in doubt, contact your Perkins distributor. In this publication engines manufactured to the later specification will be referred to as New 2000 series engines.

Cylinder bore identification The left and right sides of the engine are as seen from the rear (flywheel) end. The numbers of the cylinders start from the front of the crankcase.

Danger is indicated in the text by two methods: Warning! This indicates that there is a possible danger to the person. Caution: This indicates that there is a possible danger to the engine. Note: Is used where the information is important, but there is not a danger.

New 2000 Series engines A number of specification changes were made to engines produced after July 1996. The changes were introduced on generator set engines from the following engine specification numbers: 2006TG1A

SCG060223

2006TG2A

SGH060224

2006TWG2

SGK060225

2006TAG2

SGB060226

2006TTAG

SGJ060227

These engines can be identified by the type of sump fitted. Engines manufactured to the later specification are fitted with a sump made from a composite material. The sumps of earlier engines are made from aluminium. The specification changes were not applied to industrial engines until August 1998 (specification number: SPD060427) and then to only certain engines. Additionally, industrial engines may be manufactured to the new specification, but retain the aluminium sump.

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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

U

Country of manufacture

66381

Build line number

T

Year of manufacture

Engines made after August 1994, have a new engine number system. For these engines, a typical number is: SGK 06 0024 U 2238 B, which consists of these codes: SG

Engine application

K

Engine type

06

Number of engine cylinders

0024

Engine specification number

U

The country of manufacture

2238

Build line number

B

Year of manufacture

Units such as the fuel injection pump and turbochargers have their own data plates. If you need parts, service or information for your engine, you must give the complete engine number to your Perkins distributor.

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General safety precautions These safety precautions are important. Reference must also be made to the local regulations in the country of operation.

10

z

Read and use the instructions relevant to lift equipment which are given on page 14.

z

Always use a safety cage to protect the operator when a component is to be pressure tested in a tank of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to be pressure tested.

z

Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help immediately.

z

Turbochargers operate at a high speed and at high temperatures. Keep fingers, tools and other items away from the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.

z

Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons. Protect your hands with gloves or a special solution to protect the skin.

z

Only use these engines in the type of application for which they have been designed.

z

Do not change the specification of the engine.

z

Do not smoke when you put fuel in the tank.

z

Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a safe place.

z

Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).

z

Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training; even then extreme caution must be used to prevent injury).

z

Do not make adjustments that you do not understand.

z

z

Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.

Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated with oil into the pockets.

z

Discard used lubricating oil in a safe place to prevent contamination.

z

Other persons must be kept at a safe distance while the engine or equipment is in operation.

z

z

Do not permit loose clothing or long hair near moving parts.

Ensure that the control lever of the transmission drive is in the ‘out-of-drive’ position before the engine is started.

z

z

Keep away from moving parts during engine operation. Warning! The fan cannot be seen clearly while the engine runs.

z

Do not operate the engine if a safety guard has been removed.

The combustible material of some components of the engine (for example certain seals) can become extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with the eyes.

z

Fit only genuine Perkins parts.

z

Do not remove the filler cap of the cooling system while the engine is hot and while the coolant is under pressure as dangerous hot coolant can be discharged.

z

Fuel and oil pipes MUST be inspected for cracks or damage before they are fitted to the engine.

z

Do not allow sparks or fire near the batteries (especially when the batteries are on charge), because the gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially to the eyes.

z

Disconnect the battery terminals before a repair is made to the electrical system.

z

Only one person must control the engine.

z

Ensure that the engine is operated only from the control panel or from the operator’s position.

z

Be extremely careful if emergency repairs must be made in adverse conditions.

z

If your skin comes into contact with high pressure fuel, obtain medical assistance immediately.

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10

Safety

.

Engine lift equipment Use only the lift equipment which is designed for the engine. The part number for the lift adaptor to use for the engine is: 21825 821. Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder head, flywheel housing, crankshaft and flywheel. Check the engine lift brackets for security before the engine is lifted.

A

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

Work in an area with good ventilation.

z

Do NOT smoke.

z

Use a hand scraper to remove the joints - do NOT use a rotary wire brush.

z

Ensure that the joint to be removed is wet with oil or water to contain any loose particles.

z

Spray all asbestos debris with water and place it in a closed container which can be sealed for safe disposal.

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10

Dangers from used engine oils

Viton seals

Prolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. The oil also contains potentially harmful contaminants which may result in skin cancer.

Some seals used in engines and in components fitted to engines are made from Viton.

Adequate means of skin protection and washing facilities should be readily available. The following is a list of ‘Health Protection Precautions’, suggested to minimise the risk of contamination. 1 Avoid prolonged and repeated contact with used engine oils 2 Wear protective clothing, including impervious gloves where applicable. 3 Do not put oily rags into pockets. 4 Avoid contaminating clothes, particularly underwear, with oil. 5 Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear. 6 First aid treatment should be obtained immediately for open cuts and wounds. 7 Apply barrier creams before each period of work to aid the removal of mineral oil from the skin.

Viton is used by many manufacturers and is a safe material under normal conditions of operation. If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes. If it is necessary to come into contact with components which have been burnt, ensure that the precautions which follow are used: z

Ensure that the components have cooled.

z

Use Neoprene gloves and discard the gloves safely after use.

z

Wash the area with a calcium hydroxide solution and then with clean water.

z

Disposal of gloves and components which are contaminated, must be in accordance with local regulations.

If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or with a calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.

8 Wash with soap and hot water, or alternatively use a skin cleanser and a nail brush, to ensure that all oil is removed from the skin. Preparations containing lanolin will help replace the natural skin oils which have been removed. 9 Do NOT use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing the skin. 10 If a skin disorder appears, medical advice must be taken. 11 Degrease components before handling if practicable. 12 Where there is the possibility of a risk to the eyes, goggles or a face shield should be worn. An eye wash facility should be readily available.

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 Manufacturer’s data. Ardrox 667: Ardrox Limited, Brentford, Middlesex. Maxan 774:

Henkel Chemicals Limited, Edgeware Road, London.

These products are basically methylene chloride and are safe to use on most metals for the removal of carbon and to remove paint. They can damage rubber and most plastic materials.

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.

Perkins Engines Company Limited

This document has been printed from SPI². Not for Resale


10

Locking devices

Checks for cracks

Split pins, locking plates and tab washers which have been used must be discarded. Stiffnuts can be used again only if they have not lost their grip and the original torque is needed to turn them.

When possible, it is recommended that components which are affected by high stresses, such as the crankshaft, the connecting rods, the gears and the cylinder liners, are tested for cracks during overhaul. They should also be checked for cracks when they have been affected by an excessive load or impact.

There must be a minimum protrusion of one full thread of the bolt or stud through the stiffnut when it is tightened fully. Application of thread locking compounds

It is recommended that ferrous components are tested by the electro-magnetic method if possible. Portable electro-magnetic test equipment is available from Radalloyd Limited, Oadby, Leicester.

Remove all oil, grease and dirt from engine parts before thread locking compounds are applied to them. Most thread locking compounds have a date by which they must be used. Do not use any compounds after their expiry date.

Non-ferrous components can be tested by the use of a dye penetrant process such as ‘Ardrox 996’, available from Ardrox Limited, Brentford, Middlesex. The dye penetrant must conform to one of the standards listed below:

Discard all stiffnuts which have nylon or fibre inserts.

Fits and clearances

MIL-STD 271-E

The dimensions given at the end of each section are acceptable limits. The components which have measurements within these limits are acceptable for a complete period of service.

MIL-L 25135

Certain components which are worn by more than these limits can be corrected in accordance with a Service Reclamation Scheme (SRS). Information about the Service Reclamation Schemes is available from the Service Department at Perkins Engines Company Limited, Shrewsbury.

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

Special tools are available for specific jobs and should be used, where recommended, to save time and prevent damage to parts. These tools are listed in section 25.

To ensure maximum reliability, fit only genuine PERKINS parts supplied by the official distributor. These parts are made to the latest specification and have a guarantee for 12 months. The use of parts, such as filter elements, which do not conform to PERKINS standards, may reduce the life of the engine and can affect the warranty.

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.

If you need parts, spares or information for your engine, give the complete engine number to the official distributor.

Where joints are fitted, for example, between the cylinder head and the crankcase, it is also important that bolts and nuts are tightened evenly and gradually, and in the correct sequence. The torque wrenches listed below are suitable for the requirements of the engine and are available from Perkins Distributors. Range

Part number

8 to 54 Nm (6 to 40 lbf ft)

21825 846

30 to 150 Nm (20 to 110 lbf ft)

21825 991

70 to 310 Nm (50 to 230 lbf ft)

21825 992

Perkins Engines Company Limited

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This document has been printed from SPI². Not for Resale


11 Specifications

11

Basic engine data Engine Number of cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cylinder arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-line Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four stroke Induction system 191 kW (256 bhp) to 272kW (365 bhp) versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged 287 kW (385 bhp) to 368 kW (494 bhp) versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turbocharged and charge cooled Combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct injection Nominal bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130,17 mm (5.125 in) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152,4 mm (6.00 in) Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12,17 litres (742.64 in3) Compression ratio TAG1, 2, 3 and TWG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.9:1 TTAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15:1 2006-12TA1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.8:1 Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 4, 2, 6, 3, 5 No.1 cylinder is at the front (fan end) Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise: view on front (fan end) Tappet clearances (cold) Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,25 mm (0.010 in) Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,50 mm (0.020 in) Injection timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As stamped on engine data plate Dry weight of engine (approximate) . . . . . . . . . . . . . . . . . . . . . . Engine only:

Typical electropak:

TG1, TG1A, TG2, TG2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1118 kg (2465 lb)

1180 kg (2601 lb)

TAG, TAG2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1231 kg (2714 lb)

1365 kg (3009 lb)

TWG, TWG2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1138 kg (2509 lb)

1216 kg (2681 lb)

TTAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1325 kg (2921 lb)

1459 kg (3217 lb)

Industrial Open Power Units: 12TA1, 12TA2, 12TA3 . . . . . . . . . . . . . . 1255 kg (2767 lb) - includes radiator, alternator and starter motor

Perkins Engines Company Limited

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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/m² (10 lbf/in²) to suit installation Coolant pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Centrifugal, gear driven unit Temperature (normal) (At sea level). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 to 95°C (172 to 203°F) 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/m² (15 to 30 lbf/in²) 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/m² (50 to 70 lbf/in²) Minimum at rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . *207 kN/m² (30 lbf/in²) Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . Spring loaded plunger in body of oil pump, not adjustable Opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414 kN/m² (60 lbf/in²) 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

20

Perkins Engines Company Limited

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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

Perkins Engines Company Limited

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11

Recommended specific applied torques Caution: The torque loads listed below apply to threads in an oil wet condition, unless the use of thread locking compound is recommended. Application of a torque load specification is NOT enough to ensure that the relevant components are retained securely as an assembly. It is important to conform also to the recommendations for assembly and, if given, the sequence in which the bolts or nuts must be tightened. This information is given in the relevant section of this publication. If a bolt or nut is retained with a locking washer, locking plate or split pin, the specification for a torque load can be exceeded, if necessary, by the MINIMUM amount that is needed for correct assembly. Nm

lbf ft

Prestolite

95

7-

CAV 5

54

40

CAV 7

88

65

Thrustplate setbolts/capscrews

54

40

Drive gear setbolts

61

45

176

13

200 to 250

148 to 184

217

160

24

18

Initial tightening of all bolts and nuts

136

100

Intermediate tightening of all bolts and nuts

204

Alternator pulley nut

Camshafts

Compressor - single cylinder model Drive gear nut Compressor - twin cylinder model Drive gear nut Connecting rods Big end bearing bolts and nuts Coolant pump Pulley retaining screws (low-mounted pump) Cylinder heads

Final tightening at positions 1 to 23 in black circles ONLY

150 +40 degrees

Caution: The 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, MUST be fitted at position 22. The old and new drilled bolts are interchangeable. Certain early engines have a stud fitted at position 22 and require a nut and washer.

Rocker pedestal bolts

41

30

Tappet screw lock nuts

41

30

Rocker cover stud (apply Loctite 270 to thread before fitting to pedestal)

16.3

12

Rocker cover nuts

10.8

8

33

24

Fuel injector sleeves 22

Perkins Engines Company Limited

This document has been printed from SPI². Not for Resale


11 Nm

lbf ft

Front, centre and rear bearing cap bolts

217

160

Intermediate bearing cap bolts

353

260

Lateral bolts for main bearing caps

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

Idler gear axle bolt - New 2000 series

300

220

Idler gear axle bolts - earlier engines

61

45

10,8

8

45

33

Bolts, pump to crankcase

47

35

Hub nut

163

120

Setscrews, FIP drive gear

45

33

Nuts for high pressure fuel pipes

25

18

Pinch bolt of Econocruise actuator lever

11

8

61

45

41

30

61

45

11

6

8

inch UNF

Flywheel retaining bolts Flywheel housing Bolts, flywheel housing to crankcase Front timing gears

Fuel injectors Cap screws, injector clamp Cap nut, nozzle Fuel injection pump

Lubricating oil filters Adaptor insert Sump Sump retaining bolts (all types of sump) Sump drain plug New 2000 series only Caution: One of five different types of sump drain plug is fitted. Refer to section 19 to identify the correct torque figure for the drain plug of your engine. Turbochargers Vee band clamp

Perkins Engines Company Limited

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11

Recommended nominal applied torques Where instructions are not given for the correct torque to be applied to nuts and bolts, the figures which follow should be used.

24

Bolt size

Nm

lbf ft

M5

6

4.5

M6

9.5

7

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

Perkins Engines Company Limited

This document has been printed from SPI². Not for Resale


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.

A

275

2 Fit a new joint to the rocker cover and, ensuring that it is correctly located within the slots in the cover, secure it to the cover with a suitable adhesive. Place the cover in position on the head. 3 Secure the cover with the three cap nuts and check that the joint has not moved. Tighten the cap nuts evenly to a torque of 11 Nm (8 lbf ft). Do NOT overtighten.

Perkins Engines Company Limited

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12

Rocker assembly 1

To remove and to fit

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

A

273

1 Ensure that the tappets have remained correctly positioned in the crankcase and fit the push rods. 2 Check that the lower ends of the push rods are located inside the tappets. 3 Fit the rocker assembly with the tappet adjusting screws seating in the upper end of the push rods. 4 Screw in the pedestal securing bolts and tighten evenly, outwards from the centre, to a torque of 41 Nm (30 lbf ft). 5 Check and adjust the tappet clearances as given on page 27. 6 On completion of tappet clearance adjustment, fit the rocker covers.

26

Perkins Engines Company Limited

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