Perkins companies 2TPD1361E1.pdf

ThPerkins Service Data BookletPart 2: Current products up to 8,7 litres (530 cu in)

100 Series4.41Prima/500 Series700 Series900 SeriesPhaser/1000 SeriesPeregrine/1300 Series

Publication TPD 1361E issue 1 Proprietary information of Perkins Group Limited, all rights reserved.The information is correct at the time of print.Published in February 1997 by Technical Publications.Perkins International Limited, Peterborough PE1 5NA, Englandi

is document has been printed from SPI. Not for Resale

Chapters

1 General information2 Engine data3 General dataThe following pages contain a detailed table of contents.

Perkins Approved Clear EnglishThis publication is written inii

This document has been printed from SPI. Not for Resale

ThForewordThe Perkins Service Data Booklet contains the data which is most commonly used by experienced mechanics and technicians.The booklet contains information for Perkins Peterborough engines and is available in two parts:Part 1: Mature products up to 8,85 litres (540 cu in)4.108

3.152 Series4.203 Series4.236 Series6.3544 SeriesV8.540 SeriesPart 2: Current products up to 8,7 litres (530 cu in)100 Series4.41

Prima/500 Series700 Series900 SeriesPhaser/1000 SeriesPeregrine/1300 SeriesThe booklet should be used together with the relevant Users Handbook, Workshop Manual and Service Bulletins.

Any recommendations for future issues of the booklet should be sent to Technical Publications Department.iii


iv

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ThCurrent product

Contents

1 General informationPerkins companies ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1

List of Perkins service publications ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2

POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... ... 3

Engine number guide For engines made after 1974 . ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5

Basic fault-finding guide .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7

Turbocharger fault guide . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9

General safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11

2 Engine data100 Series

Basic technical data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 13

Preventive maintenance periods . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 16

Maintenance schedules ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 16

Recommended torque tensions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 17

Cylinder head torque sequence .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 18

4.41

Basic technical data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 19Service Data Booklet, TPD 1361E, issue 1 v


Current productPreventive maintenance periods . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20

Fuel pump codes and timing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21

Recommended torque tensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22

Cylinder head torque sequence ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23

Prima/500 Series

Basic technical data .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24

Preventive maintenance periods . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25



700 Series





900 Series



Fuel pump codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34


Phaser/1000 Series



Maintenance schedule - Phaser ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39

Fuel pump codes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 40


Cylinder head torque sequence 4 cylinder engines ... ... ... ... ... ... ... ... ... ... ... ... ... 43

Cylinder head torque sequence 6 cylinder engines ... ... ... ... ... ... ... ... ... ... ... ... ... 44vi Service Data Booklet, TPD 1361E, issue 1


ThCurrent productPeregrine/1300 Series

Basic technical data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 45

Preventive maintenance periods . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 47

Fuel pump codes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 48

Static timing chart . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 48

Recommended torque tensions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 49

Cylinder head torque sequence .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 50

3 General dataSpecification of engine fluids .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 51

Standard torque settings - except Peregrine/1300 Series ... ... ... ... ... ... ... ... ... ... . 53

Standard torque settings - Peregrine/1300 Series . ... ... ... ... ... ... ... ... ... ... ... ... ... . 53

How to check the specific gravity of the coolant ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 54

Conversion tables . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 55

Atomiser information - except Peregrine/1300 Series ... ... ... ... ... ... ... ... ... ... ... ... . 57

Atomiser information - Peregrine and 1300 Series ... ... ... ... ... ... ... ... ... ... ... ... ... . 61

Turbocharger waste-gate settings .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 62

Thermostat ratings ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 62

Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 63

How to do a compression test . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 63Service Data Booklet, TPD 1361E, issue 1 vii


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Th1Current product

General information 1

Perkins companies

AustraliaPerkins Engines Australia Pty. Ltd,Suite 2, 364 Main Street,Mornington 3931, Victoria, Australia.Telephone: 0061 (0) 597 51877Telex: Perkoil AA30816Fax: 0061 (0) 597 1305France

Moteurs Perkins S.A.,9-11 Avenue Michelet,93583 Saint Ouen, Cedex, France.Telephone: 0033 (1) 40 10 42 70Telex: 642924FFax: 0033 (1) 40-10-42-45GermanyPerkins Motoren GmbH,Saalaeckerstrasse 4,63801 Kleinostheim,Germany.Telephone: 0049 6027 5010Fax: 0049 6027 501124

Hong KongPerkins International Ltd,Varity Asia/Pacific,Suite 3301Convention Plaza,1 Harbour road,WanchaiHong Kong.Telephone: 852 2588 1883Fax: 852 2827 2311

ItalyMotori Perkins S.p.A.,Via Socrate 8,22070 Casnate con Bernate (Como), Italy.Telephone: 0039 (0) 31 564633 or 564625Telex: 380658 Perkit IFax: 0039 (0) 31 249092 or 564145Service Data Booklet, TPD 1361E, issue 1

is document has been printeJapanVarity (Japan) K.K.,Reinanzaka Building, 5th Floor,14-2 Akasaka, 1-chome, Minato-ku,Tokyo 107, Japan.Telephone: 0081 (0) 3 586 7377Telex: Perkoil J2424823Fax: 0081 (0) 3 582 1596United KingdomPerkins International Ltd, Eastfield, Peterborough PE1 5NA,England.Telephone: 0044 (0) 1733 67474Telex: 32501 Perken GFax: 0044 (0) 1733 582240United States of AmericaPerkins International - North America12025 Tech Center DriveLivoniaMichigan 48150USATelephone: 001 313 266 5427Fax: 001 313 266 2700

Perkins Engines Latin America Inc,Suite 620,999, Ponce de Leon Boulevard,Coral Gables,Florida 33134, U.S.A.Telephone: 001 305 442 7413Telex: 32501 Perken GFax: 001 305 442 7419

In addition to the above companies, there are Perkins distributors in most countries. Perkins International Ltd, Peterborough or one of the above companies can provide details.1

d from SPI. Not for Resale

1 Current productList of Perkins service publications

(1) Printed in English(2) Printed in French(3) Printed in German.(4) Printed in Italian.(5) Printed in Spanish.(6) Printed in English, French and German.(7) Printed in English, Italian and Spanish.

Engine type Users Handbook Workshop Manual4.41 TPD 1319E (1) TPD 1322E (1)100 Series 100816243-0695 (1) 1339/2/92E (1)

513/9/95 (1)Prima/500 Series TPD 0295 1260EFG (6)

TPD 0295 1260EIS (7)TPD 0895 1313E (1)

TPD 0192 1273 (1)

700 Series TPD 1336E (1)TPD 1336S (5)

TPD 1359E (1)

900 Series TPD 1325E (1)TPD 1325F (2)TPD 1325G (3)TPD 1325I (4)TPD 1325S (5)

TPD 1345E (1)

Phaser/1000 Series TPD 1328E (1)TPD 0696 1261EFG (6)

TPD 1312E (1)

Peregrine/1300 Series TPD 1315E (1)TPD 1315F (2)TPD 1315G (3)TPD 1315I (4)TPD 1314E (1)

TPD 1347E(1)2 Service Data Booklet, TPD 1361E, issue 1


Th 1Current productPOWERPART recommended consumable products

Perkins have made available the products recommended below in order to assist in the correct operation, service and maintenance of your engine and your machine. The instructions for the use of each product are given on the outside of each container. These products are available from your Perkins distributor.POWERPART AntifreezeProtects the cooling system against frost and corrosion. Part number 1 litre 21825166 or 5 litres 21825167.

POWERPART Atomiser thread sealantTo seal the threads of the atomiser into the cylinder head. Currently Hylomar Advance Formulation.POWERPART ChiselAllows easy removal of old gaskets and joints.Currently Loctite chisel. Part number 21825163.POWERPART CompoundTo seal the outer diameter of seals. Currently Loctite Forma Gasket No 2. Part number 1861147.POWERPART Easy FlushCleans the cooling system. Part number 2182501.POWERPART Gasket eliminatorImproves flange sealing when a gasket is not used. It provides a seal with temperature resistance that is flexible in positions where vibration and pressure occur. Currently Loctite 515. Part number 21826040.POWERPART Jointing compoundUniversal jointing compound which seals joints.Currently Hylomar. Part number 1861155 or 1861117.

POWERPART Lay-Up 1A diesel fuel additive for protection against corrosion. Part number 1772204.POWERPART Lay-Up 2Protects the inside of the engine and of other closed systems. Part number 1762811.POWERPART Lay-Up 3Protects outside metal parts. Part number 1734115.POWERPART Liquid gasketTo seal flat faces of components where no joint is used. Especially suitable for aluminium components. Currently Loctite 518. Part number 21820518.

POWERPART NutlockTo retain and seal threaded fasteners and cup plugs where easy removal is necessary. Currently Loctite 242e. Part number 21820242.POWERPART PlatelockMedium strength anaerobic threadlock for tight fitted metal surfaces. Suitable for metal plated surfaces and stainless steel. Currently Loctite 243. Part number 21826039.

POWERPART RepelDries damp equipment and gives protection against corrosion. Passes through dirt and corrosion to lubricate and to assist removal of components. Currently Loctite repel. Part number 21825164.POWERPART Retainer (high strength)To retain components which have an interference fit. Currently Loctite 638. Part number 21820638.POWERPART Retainer (oil tolerant)To retain components which have a transition fit. Currently Loctite 603. Part number 21820603.POWERPART Silicone adhesiveAn RTV silicone adhesive for application where low pressure tests occur before the adhesive sets. Used for sealing flange where oil resistance is needed and movement of the joint occurs. Currently Loctite 5900. Part number 21826038.POWERPART Silicone rubber sealantSilicone rubber sealant which prevents leakage through gaps. Currently Hylosil. Part number 1861108.

POWERPART StudlockTo permanently retain large fasteners and studs. Currently Loctite 270. Part number 21820270.

ContinuedService Data Booklet, TPD 1361E, issue 1 3


1 Current productPOWERPART recommended consumable products

POWERPART ThreadlockTo retain small fasteners where easy removal is necessary. Currently Loctite 222e. Part number 21820222.

POWERPART Threadlock (heavy duty)To provide a heavy duty seal to components that have a light interference fit. Currently Loctite 262. Part number 21820262.Engine number location guide

Notes:l Illustration A shows the left side when looked at

from the flywheel end of the engine.l Illustration B shows the right side when looked at

from the flywheel end of the engine, and the rear view of the engine.

POWERPART Threadlock (hydraulic/pnuematic)To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems. Currently Loctite 542. Part number 21820542.

POWERPART Threadlock (pipe)To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately. Currently Loctite 575. Part number 21820575.

Engine type Position100 Series B34.41 A3Prima/500 Series A2700 Series B2900 Series A1Phaser/1000 Series A3 or B1Peregrine/1300 Series A44 Service Data Booklet, TPD 1361E, issue 1


Th 1Current productEngine number guide For engines made after 1974Example of an engine number is TU20300U510256FTU Engine Family and type code, see Table 120300 Parts list number or SOS order reference numberU Country of manufacture code, see Table 2510256 Engine serial numberF Year of manufacture code, see Table 3

Table 1 - Engine Family and Type CodeA Phaser/1004AA Naturally

aspiratedAB TurbochargedAC CompensatedAD Charge cooledAE Fed. Charge

cooledAG Narrow front end

naturally aspiratedAH Narrow front end

turbochargedNew Phaser/1004AJ Naturally

aspiratedAK TurbochargedAM Turbocharged

intercooledAP Naturally

aspiratedAQ TurbochargedB Prima/500BA Naturally

aspiratedBB TurbochargedBC GasoleneC 3.152CA P3CB 3.144CC P3.144CD 3.152CE D3.152CF G3.152CG P3.152CJ 3.1522CM 3.1524CN T3.1524C 900 SeriesCP 3.27CR T3.27CS 3.25C CompensatedCC Charge cooledD Direct injection

E 4.108EA 4.99EB 4.107EC T4.107ED 4.108EE T4.108G 4.154/200GA 4.154GB 4.135GC 4.182GD 4.25GE 4.30H 4.165HA 4.165J 4.203JA P4JB 4.192JC P4.192JD 4.203JE D4.203JF G4.203JG 4.2032K Perama/100KA 2 cyl. 0,4 litresKB 3 cyl. 0,6 litresKC 3 cyl. 0,9 litresKD 3 cyl. 1,0 litresKE 3 cyl. 1,5 litresKF 4 cyl. 1,9 litresKG 3 cyl. 1,2 litresKH 3 cyl. 1,3 litresKJ 3 cyl. 1,5 litres DKK 4 cyl. 1,9 litres DKL 3 cyl. 0,7 litresKN 2 cyl. 0,5 litresKR 4 cyl. 2,2 litresL 4.236LA 4.212LB G4.212LC 4.224LD 4.236F Made in FranceFed. FederalG Gasolene or gas

LE G4.236LF 4.248LG 4.2482LH C4.236LJ T4.236LK D4.236LL 4.38LM 4.41N 4.318NA 4.270NB 4.300NC 4.318ND 4.3182P6.305PA P6PB 6.288PC 6.305PD PF6.305R 6.247RA 6.247T 6.354TA 6.306TB 6.335TC 6.354TD H6.354TE T6.354TF H6.354TG 6.3541TH T6.3541TJ 6.3542TK C6.3542TL 6.3543TM C6.3543TN H6.3543TP T6.3543TQ HT6.3543TR 6.372TS 6.3723TT TC6.3541TU T6.3544TV 6.3724H HorizontalN Narrow front end (Belt driven water pump)

TW 6.3544TX C6.3544TY H6.3544TZ HT6.3544U 700 SeriesUA 704-26UB 704-30W Peregrine/1300WA 6.466WB T6.466WC CC6.466WD T6.67WE CC6.67WF T6.76WG CC6.76WH T6.87WJ CC6.87X V8.540XA V8.510XB TV8.510XC V8.540XD V8.605XE TV8.540Y Phaser/1006YA Naturally

aspiratedYB TurbochargedYC CompensatedYD Charge cooledYE Fed. Charge

cooledNew Phaser/1006YG Naturally

aspiratedYH TurbochargedYK Turbocharged

intercooledZ V8.640ZA V8.640ZB TV8.640P Timing chainT TurbochargedV Vee formService Data Booklet, TPD 1361E, issue 1 5


1 Current product

This code indicates the country of manufacture of the basic engine.

This code indicates the year of manufacture. The letters I, O, Q, R and Z will not be used.

Table 2 - Country of manufacture code

A ArgentinaB BrazilC AustraliaD GermanyE SpainF FranceG Greece

H GroupHM IndonesiaHK IraqHU HungaryJ JapanK KoreaL Italy

M MexicoMX MexicoN USAP PolandS IndiaSA South AfricaT Turkey

U United KingdomV PakistanW IranX PeruY Yugoslavia

Table 3 - Year of manufacture code

A 1974B 1975C 1976D 1977E 1978F 1979G 1980

H 1981J 1982K 1983L 1984M 1985N 1986P 1987

S 1988T 1989U 1990V 1991W 1992X 1993Y 1994

A 1995B 1996C 1997D 1998E 1999F 2000G 20016 Service Data Booklet, TPD 1361E, issue 1


Th 1Current productBasic fault-finding guideThe chart below is given to assist in the correct diagnosis of basic engine faults.Problems and possible causes

Problem Possible causesThe starter motor turns the engine too slowly 1, 2, 3, 4The engine does not start 5, 6, 7, 8, 9, 10, 12, 13, 14, 15, 17, 34, 35, 36, 37,38, 40,

42, 43, 44The engine is difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 19, 34, 36, 37, 38,

40, 42, 43, 44Not enough power 8, 9, 10, 11, 12, 13, 16, 17, 18, 19, 20, 21, 34, 36, 37, 38,

39, 42, 43, 44, 61, 63, 64Misfire 8, 9, 10, 12, 13, 15, 20, 22, 34, 36, 37, 38, 39, 40, 41, 43High fuel consumption 11, 13, 15, 17, 18, 19, 21, 22, 34, 36, 37, 38, 39, 40, 42,

43, 44, 63Black exhaust smoke 11, 13, 15, 17, 19, 21, 22, 34, 36, 37, 38, 39, 40, 42, 43,

44, 61, 63Blue or white exhaust smoke 4, 15, 21, 23, 36, 37, 38, 39, 42, 44, 45, 52, 58, 62The pressure of the lubricating oil is too low 4, 24, 25, 26, 46, 47, 48, 50, 51, 59The engine knocks 9, 13, 15, 17, 20, 22, 23, 36, 37, 40, 42, 44, 46, 52, 53, 60The engine runs erratically 7, 8, 9, 10, 11, 12, 13, 15, 16, 18, 20, 22, 23, 34, 38, 40,

41, 44, 52, 60Vibration 13, 18, 20, 27, 28, 34, 38, 39, 40, 41, 44, 52, 54The pressure of the lubricating oil is too high 4, 25, 49The engine temperature is too high 11, 13, 15, 19, 27, 29, 30, 32, 34, 36, 37, 39, 52, 55, 56,

57, 64Crankcase pressure 31, 33, 39, 42, 44, 45, 52Bad compression 11, 22, 37, 39, 40, 42, 43, 44, 45, 53, 60The engine starts and stops 10, 11, 12Service Data Booklet, TPD 1361E, issue 1 7


1 Current productList of possible causes1 Battery capacity low.2 Bad electrical connections.3 Fault in starter motor.4 Wrong grade of lubricating oil.5 Starter motor turns engine too slowly.6 Fuel tank empty.7 Fault in stop control.8 Restriction in a fuel pipe.9 Fault in fuel lift pump.

10 Dirty fuel filter element.11 Restriction in filter/cleaner or air induction system.12 Air in fuel system.13 Fault in atomisers or atomisers of an incorrect

type.14 Cold start system used incorrectly.15 Fault in cold start system.16 Restriction in fuel tank vent.17 Wrong type or grade of fuel used.18 Restricted movement of engine speed control.19 Restriction in exhaust pipe.20 Engine temperature is too high.21 Engine temperature is too low.22 Valve tip clearances are incorrect.23 To much oil or oil of wrong specification used in

wet type oil cleaner.24 Not enough lubricating oil in sump.25 Defective gauge.26 Dirty lubricating oil filter element.27 Fan damaged.28 Fault in engine mounting or flywheel housing.29 Too much lubricating oil in sump.30 Restriction in air or water passages of radiator.31 Restriction in breather pipe.32 Insufficient coolant in system.33 Vacuum pipe leaks or fault in exhauster.34 Fault in fuel injection pump.35 Broken drive on fuel injection pump.36 Timing of fuel injection pump is incorrect.37 Valve timing is incorrect.38 Bad compression.39 Cylinder head gasket leaks.40 Valves are not free.41 Wrong high-pressure pipes.42 Worn cylinder bores.43 Leakage between valves and seats.44 Piston rings are not free or they are worn or

broken.

45 Valve stems and/or guides are worn.46 Crankshaft bearings are worn or damaged.47 Lubricating oil pump is worn.48 Relief valve does not close.49 Relief valve does not open.50 Relief valve spring is broken.51 Fault in suction pipe of lubricating oil pump.52 Piston is damaged.53 Piston height is incorrect.54 Flywheel housing or flywheel is not aligned

correctly.55 Fault in thermostat or thermostat is of an incorrect

type.56 Restriction in coolant passages.57 Fault in water pump.58 Valve stem seal is damaged (if there is one fitted).59 Restriction in sump strainer.60 Valve spring is broken.61 Turbocharger impeller is damaged or dirty.62 Lubricating oil seal of turbocharger leaks.63 Induction system leaks (turbocharged engines).64 Turbocharger waste-gate does not work correctly

(if there is one fitted).8 Service Data Booklet, TPD 1361E, issue 1


Th 1Current productTurbocharger fault guideThe chart below is given to assist in the correct diagnosis of turbocharger faults.If the inside of the induction manifold is wet, check that there is not a fuel leak from the fuelled starting aid, if there is one fitted.Problems and possible causes

Problem Possible causesNot enough power 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34,

35, 36Black smoke 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34,

35, 36Blue smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32, 34High lubricating oil consumption 2, 8, 15, 17, 19, 20, 28, 29, 31, 32, 34Too much lubricating oil at turbine end 2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32Too much lubricating oil at compressor end 1, 2, 4, 5, 6, 8, 19, 20, 21, 28, 31, 32Not enough lubrication 8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 37, 38Lubricating oil in the exhaust manifold 2, 7, 17, 18, 19, 20, 22, 28, 31, 32Inside of the induction manifold wet 1, 2, 3, 4, 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 34, 39,

40Damaged compressor impeller 3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 37, 38Damaged turbine rotor 7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 32,

33, 37, 38Rotating assembly does not turn freely 3, 6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32,

33, 37, 38Worn bearings, bearing bores, journals 6, 7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 33, 37, 38Noise from turbocharger 1, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 20, 21,

22, 23, 24, 29, 32, 33, 34, 37, 38Sludge or carbon deposit in bearing housing 2, 11, 13, 14, 15, 17, 18, 24, 29, 33, 37, 38Service Data Booklet, TPD 1361E, issue 1 9


1 Current productList of possible causes1 Element of the air filter dirty 2 Restricted crankcase breather 3 Element of the air filter not fitted, or not sealing

correctly. Loose connection to turbocharger.4 Internal distortion or restriction in pipe from air

filter to turbocharger.5 Damaged/restricted crossover pipe,

turbocharger to induction manifold.6 Restriction between air filter and turbocharger.7 Restriction in exhaust system.8 Turbocharger loose or clamps/setscrews loose.9 Induction manifold has cracks, is loose, or has

flange distortion.10 Exhaust manifold has cracks, is loose, or has

flange distortion. 11 Restricted exhaust system.12 Delay of lubricating oil to turbocharger at engine

start.13 Insufficient lubrication.14 Dirty lubricating oil.15 Incorrect lubricating oil.16 Restricted lubricating oil supply pipe.17 Restricted lubricating oil drain pipe.18 Turbine housing damaged or restricted.19 Leakage from turbocharger seals.20 Worn turbocharger bearings.21 Excessive dirt in compressor housing.22 Excessive carbon behind turbine rotor.23 Engine speed raised too rapidly at initial start.24 Insufficient engine idle period.25 Faulty fuel injection pump.26 Worn or damaged atomisers.27 Valves burned.28 Worn piston rings.29 Lubricating oil leakage from supply pipe.30 Excessive preservation fluid (on initial engine

start).31 Excessive engine idle period.32 Restriction in turbocharger bearing housing.33 Restriction in lubricating oil filter.34 Wet type air cleaner: Restricted, dirty element,

viscosity of oil to low/high.35 Waste-gate actuator faulty or damaged.36 Waste-gate valve not free.37 Engine stopped too soon from high load.38 Insufficient lubricating oil.39 Fuel leakage from fuelled starting aid.40 Crack in backplate of compressor.10 Service Data Booklet, TPD 1361E, issue 1


Th 1Current productGeneral safety precautionsThese safety precautions are important. You must refer also to the local regulations in the country of use. Some items only refer to specific applications.l Only use these engines in the type of application

for which they have been designed.l Do not change the specification of the engine.l Do not smoke when you put fuel in the tank.l Clean away fuel which has been spilt. Material

which has been contaminated by fuel must be moved to a safe place.l Do not put fuel in the tank while the engine runs

(unless it is absolutely necessary).l Do not clean, add lubricating oil, or adjust the

engine while it runs (unless you have had the correct training; even then extreme care must be used to prevent injury).l Do not make adjustments that you do not

understand.l Ensure that the engine does not run in a location

where it can cause a concentration of toxic emissions.l Other persons must be kept at a safe distance

while the engine or auxiliary equipment is in operation.l Do not permit loose clothing or long hair near

moving parts.l Keep away from moving parts during engine

operation. Warning! Some moving parts cannot be seen clearly while the engine runs.l Do not operate the engine if a safety guard has

been removed.l Do not remove the filler cap or any component of

the cooling system while the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged.l Do not use salt water or any other coolant which

can cause corrosion in the closed circuit of the cooling system.l 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.l Disconnect the battery terminals before a repair is

made to the electrical system.l Only one person must control the engine.l Ensure that the engine is operated only from the

control panel or from the operators position.l If your skin comes into contact with high-pressure

fuel, obtain medical assistance immediately.

l 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.l Do not wear clothing which is contaminated by

lubricating oil. Do not put material which is contaminated with oil into the pockets of clothing.l Discard used lubricating oil in accordance with

local regulations to prevent contamination.l Ensure that the control lever of the transmission

drive is in the "out-of-drive" position before the engine is started.l 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. l Read and use the instructions relevant to lift

equipment.l Wear a face mask if the glass fibre cover of the

turbocharger is to be removed or fitted.l Always use a safety cage to protect the operator

when a component is to be pressure tested in a container of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to be pressure tested.l Do not allow compressed air to contact your skin.

If compressed air enters your skin, obtain medical help immediately.l Turbochargers operate at high speed and at high

temperatures. Keep fingers, tools and debris away from the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.l Fit only genuine Perkins parts.Service Data Booklet, TPD 1361E, issue 1 11


12

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Th2Current product

Engine data 2

100 Series

Basic technical data

Horse power- 102.04, 102.05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8,2 kW (11.0 bhp)- 103.06, 103.07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12,3 kW (16.5 bhp)- 103.09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,5 kW (21.5 bhp)- 103.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17,5 kW (23.5 bhp)- 103.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19,8 kW (26.5 bhp)- 103.13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20,9 kW (28.0 bhp)- 103.15 (KE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23,5 kW (31.5 bhp)- 103.15 (KJ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24,6 kW (33.0 bhp)- 104.19 (KK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32,8 kW (44.0 bhp)- 104.19 (KF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31,3 kW (42.0 bhp)- 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37,3 kW (50.0 bhp)Number of cylinders- 102.04, 102.05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

- 103.06, 103.07, 103.09, 103.10, 103.12, 103.13, 103.15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

- 104.19, 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 strokeInduction system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspiratedCombustion system- 103.15 (KJ), 104.19 (KK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct injection- remainder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect injectionNominal bore- 102.04, 103.06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 mm (2.5 in)- 102.05, 103.07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 mm (2.6 in)- 103.09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 mm (2.8 in)- 103.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 mm (3.0 in)- 103.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 mm (3.2 in)- 103.13, 103.15 (KE), 103.15 (KJ), 104.19 (KK), 104.19 (KF), 104.22 . . . . . . . . . . . . . . . . . . . 84 mm (3.3 in)

ContinuedService Data Booklet, TPD 1361E, issue 1 13


2 Current productBasic technical data

Stroke- 102.04, 102.05, 103.06, 103.07. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 mm (2.5 in)- 103.09, 103.10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 mm (2.8 in)- 103.12, 103.13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 mm (3.2 in)- 103.15, 104.19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 mm (3.5 in)- 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 mm (3.9 in)Compression ratio- 102.04,103.10, 103.13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23:1

- 102.05, 103.07, 103.09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24:1

- 103.06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.5:1

- 103.12, 103.15 (KE), 104.19 (KK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5:1- 103.15 (KJ), 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19:1- 104.19 (KF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22:1Cubic capacity

- 102.04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,4 litres (24.4 in3)- 102.05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,5 litres (30.5 in3)- 103.06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,6 litres (36.6 in3)- 103.07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,7 litres (42.7 in3)- 103.09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,9 litres (54.9 in3)- 103.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,0 litres (61.0 in3)- 103.12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,2 litres (73.3 in3)- 103.13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,3 litres (79.3 in3)- 103.15 (KE), 103.15 (KJ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,5 litres (91.5 in3)- 104.19 (KK), 104.19 (KF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,9 litres (116.0 in3)- 104.22 (KR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2,2 litres (134.3 in3)Firing order- 102.04, 102.05. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

- 103.06, 103.07, 103.09, 103.10, 103.12, 103.13, 103.15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3

- 104.19, 104.22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2

Valve tip clearances- Inlet (hot or cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,22 mm (0.008 in)- Exhaust (hot or cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,22 mm (0.008 in)

Continued14 Service Data Booklet, TPD 1361E, issue 1


Th 2Current productBasic technical data

Lubricating oil pressure at maximum engine speed and normal engine temperature

- 102.04, 02.05, 103.06, 103.07, 103.09, 103.10 . . . . . . . . . . . . . 290/490 kPa (42/71 lbf/in2) 3,0/5,0 kgf/cm2- 103.12, 103.13, 103.15,

- 104.19, 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241/359 kPa (35/52 lbf/in2) 2,5/3,7 kgf/cm2Coolant temperature- 102.04, 02.05, 103.06, 103.07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 C (189 F)- 103.09, 103.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 C (203 F)- 103.12, 103.13, , 103.15, 104.19, 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 C (199 F)Thermostat starts to open- horizontal type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69/73 C (156/163 F)- vertical type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80/84 C (176/183 F)Thermostat fully open- horizontal type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 C (180 F)- vertical type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 C (203 F)Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise from frontIdling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800 to 1200 according to the applicationLocation of maximum no-load speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NoneLocation of number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft pulley endLocation of engine timing marks . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft, camshaft gear and idler gearsAtomiser codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part numbers only- 102.04, 102.05, 103.06, 103.07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131406340

- 103.09, 103.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131406330

- 103.12, 103.13, 103.15 (KE), 04.19 (KF), 104.22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131406360- 103.15 (KJ), 104.19 (KK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131406370Fuel pump codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . None, one pump supplied which is adjusted by shimsLocation of fuel pump code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NoneLocation of fuel pump timing marks. . . . . . . . . . . . . . . . . . . . . . . . . . . Front crankshaft pulley and timing caseBelt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 kgf (lbf)Belt deflection at longest free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.2 in)Service Data Booklet, TPD 1361E, issue 1 15


2 Current productPreventive maintenance periods

These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed. Use the periods which are shortest. When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine.It is good preventive maintenance to check for leakage and loose fasteners at each service.

Maintenance schedules

A Every day or every 8 hours D Every 200 hours or 6 monthsB First service 20/50 hours E Every 400 hours or 12 monthsC Every 100 hours or 3 months F Every 600 hours or 18 monthsThe schedules which follow must be applied at the interval (hours or months) which occur first.

(1) By a person who has had the correct training.The operations above are to be carried out by trained personnel with reference to the Workshop Manual where necessary. These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed. If necessary, use the shorter periods.The oil change interval will change with the amount of sulphur in the fuel (see the table on page 52 and the fuel specification). The interval to change the canister of the lubricating oil filter is not affected.

A B C D E F Operationl

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

l

Check the level of coolant (top up with coolant only)Check concentration of coolantRenew coolant (fill slowly, ensure correct quantity is used)Check engine lubricating oil levelRenew engine lubricating oil (fill slowly, ensure correct quantity is used)Renew engine oil filterDrain water from fuel filter and pre-filterRenew fuel filter canister (N.B. air vent screws on filter and fuel pump)Check tension of alternator drive beltCheck alternator drive belt for wearRenew alternator drive beltCheck and adjust idle speed (1)Tighten cylinder head (1)Check and adjust valve clearances (1)Check electrical systems (1)Check all nuts and bolts for tightnessCheck injectors for performance (1)Clean air filter (earlier check may be necessary)Renew air filter elementCheck and correct any leaks or engine damage16 Service Data Booklet, TPD 1361E, issue 1


Th 2Current productRecommended torque tensions

The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted.

Description Threadsize

TorqueNm lbf ft kgf m

Setscrews, cylinder head, refer to head tightening sequence - - -Plug, lubricating oil sump 34 25 3,5Atomiser- 102.04, 102.05, 103.06, 103.07, 103.09, 103.10- 103.12, 103.13, 103.15 (KE), 104.19 (KF), 104.22Setscrew, atomiser clamp- 103.15 (KJ), 104.19 (KK)

8165

23

6047

17

8,36,5

2,3Nuts, high-pressure fuel pipes- 102.04, 102.05, 103.06, 103.07, 103.09, 103.10- 103.12, 103.13, 103.15, 104.19, 104.22

2319

1714

2,32,0

Setscrews, main bearing - holder, upper and lower 102.04, 102.05, 103.06, 103.07, 103.09, 103.10- holder, to cylinder block 102.04, 102.05, 103.06, 103.07, 103.09, 103.10- holder, hexagonal hole type 103.12, 103.13, 103.15, 104.19,104.22- holder, hexagonal bolt type 103.12, 103.13, 103.15, 104.19, 104.22

21

28

26

51

16

20

20

38

2,1

2,8

2,8

5,2Nuts, connecting rods- 102.04, 102.05, 103.06, 103.07- 103.09, 103.10- 103.12, 103.13, 103.15, 104.19, 104.22

233251

172338

2,33,25,2

Nut, crankshaft pulley- 102.04, 102.05, 103.06, 103.07, 103.09, 103.10- 103.12, 103.13, 103.15, 104.19, 104.22

122305

90224

1231

Setscrews, flywheel to crankshaft- 102.04, 102.05, 103.06, 103.07- 103.09, 103.10, 103.12, 103.13, 103.15, 104.19, 104.22

7565

5447

7,56,5Service Data Booklet, TPD 1361E, issue 1 17


2 Current productCylinder head torque sequenceCaution: This operation must be done by a person with the correct training. If in doubt, refer to the workshop manual.1 Lightly lubricate the threads and the thrust faces of the setscrews.2 Gradually and evenly tighten the setscrews to the correct torque in the correct sequence shown in the tables below.

Note: Release the cylinder head setscrews evenly and gradually in the reverse sequence to that shown in (A).

Engine type TorqueNm lbf ft kgf m

102-4, 102-4, 103-6, 103-7 37 27 3,7103-9, 103-10 51 37 5,2103-12, 103-13, 103-15, 104-19, 104-22 92 67 9,2

Engine type Sequence2 cylinder Illustration A3 cylinder Illustration B4 cylinder Illustration C18 Service Data Booklet, TPD 1361E, issue 1


Th 2Current product4.41


Horse power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 kW (81 bhp)Number of cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four strokeInduction system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspiratedCombustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Direct injectionNominal bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 mm (3.98 in)Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm (5.00 in)Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.3:1

Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .407 litres (248 in3)Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3-4-2Valve tip clearances- Inlet (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 mm (0.008 in)- Exhaust (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,45 mm (0.018 in)Lubricating oil pressure- maximum engine speed and

normal engine temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207/414 kPa (30/60 lbf/in2) 2,1/4,2 kgf/cm2Coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 C (140 F)Thermostat starts to open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77/85 C (170/185 F)Thermostat fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92/98 C (197/208 F)Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise from frontIdling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .See application manualLocation of maximum no-load speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection pump data plateLocation of number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft pulley endLocation of engine timing marks . . . . . . . . . . . . . . . . . . . . . . . . . . .Marks on the pulley/damper or crankshaft,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .camshaft gear, fuel pump gear and idler gearsAtomiser codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HD, HL, HU, HZ, NPFuel pump codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AD, BD, CD, DD, FD Location of fuel pump code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel injection pump data plateLocation of fuel pump timing marks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump flange and timing caseBelt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 N (10 lbf) 4,5 kgfBelt deflection at longest free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm (3/8 in)Service Data Booklet, TPD 1361E, issue 1 19



These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed. Use the periods which are shortest. When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine.It is good preventive maintenance to check for leakage and loose fasteners at each service.Maintenance schedulesA First service at 20/40 hours D Every 400 hours or 12 monthsB Every day or every 8 hours E Every 2000 hoursC Every 200 hours or 6 monthsThe schedules which follow must be applied at the interval (hours or months) which occur first.

(1) If one is fitted.(2) Renew the antifreeze every 2 years. If a coolant inhibitor is used instead of antifreeze, it should be renewed every 6 months.(3) By a person who has had the correct training.(4) The lubricating oil and the filter canister must be renewed every 250 hours or 12 months for applications where the engine normally

runs at full load for periods of more than 20 minutes, for example: generating sets or water pumps.(5) The oil change interval will change with the amount of sulphur in the fuel (see the table on page 52 and the fuel specification). The

interval to change the canister of the lubricating oil filter is not affected.

A B C D E Operationl

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Check the amount of coolantCheck the concentration of the coolant (2)Check the drive belt of the alternator

Clean the sediment chamber and the strainer of the fuel lift pumpCheck for water in the pre-filter (1)Renew the elements of the fuel filterEnsure that the atomisers are checked (3)Ensure that the idle speed is checked and adjusted, if it is necessary (3)

Check the amount of lubricating oil in the sumpCheck the lubricating oil pressure at the gauge (1)Renew the engine lubricating oil (4) (5)Renew the canister of the lubricating oil filter (4)

Clean the engine breather systemClean the air cleaner or empty the dust bowl of the air filter - extremely dusty conditions- normal conditionsClean or renew the air filter element, if it has not been indicated earlier

Check the engine mountsCheck all hoses and connections

Ensure that the valve tip clearances of the engine are checked and, if necessary, adjusted (3)Ensure that the alternator, the starter motor are checked (3) 20 Service Data Booklet, TPD 1361E, issue 1


Th 2Current productFuel pump codes and timingCAV fuel injection pumpType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DPADirection of rotation from drive end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ClockwiseOutlet for number 1 cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Letter "W"Static timingThe engine check angle must be used with special tool MS.67B and with the engine set with number 1 piston at top dead centre (TDC) on the compression stroke. The pump is checked with the pump set at the start of injection for number 1 cylinder.The code letters are included in the setting code stamped on the data plate of the fuel injection pump. Some fuel pumps may have the setting code stamped on a modification plate which is fastened to the flange of the pump. If a modification plate is fitted, use the code letters stamped on this plate. A typical setting code is 2643D000AD/2/2420; in this example the code letters are "AD".

Stanadyne fuel injection pumpType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stanadyne DB2Outlet for number 1 cylinder. . . . . . . . . . . . . . . . . . . . . . . 8 oclock position as seen from the rear of the pumpDirection of rotation from drive end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ClockwiseFuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-ventStatic timingThe engine check angle must be used with special tool MS.67B and with the engine set with the piston of the number 1 cylinder at top dead centre (TDC) on the compression stroke. The pump is checked with the pump set at the start of injection for the number one cylinder.

Fuel pump code letters

Engine check angle (degrees)

Pump mark angle (degrees)

AD 280.5 291BD 280.5 293CD 280.5 287FD 286 296


Engine check angle(degrees)

Pump mark angle(degrees)

DD 286 297Service Data Booklet, TPD 1361E, issue 1 21


2 Current productRecommended torque tensions




Setscrews, cylinder head, refer to head tightening sequence 1/2 UNF 110 80 11,1Plug, lubricating oil sump 3/4 UNF 34 25 3,5Setscrews, atomiser clamp M8 12 9 1,2Union nuts, high-pressure fuel pipes M12 22 16 2,2Setscrews, main bearings 5/8 UNF 250 185 26,0Nuts, connecting rods 1/2 UNF 125 92 12,7Setscrews, crankshaft pulley 7/16 UNF 115 85 11,8Setscrews, flywheel to crankshaft 1/2 UNF 105 77 10,722 Service Data Booklet, TPD 1361E, issue 1


Th 2Current productCylinder head torque sequenceCaution: This operation must be done by a person with the correct training. If in doubt, refer to the workshop manual.It is important that the studs and the three different lengths of setscrews are fitted in their correct positions.

1 Lightly lubricate the threads and the thrust faces of the setscrews.2 Gradually and evenly tighten the setscrews to 110 Nm (80 lbf ft) 11,1 kgf m in the sequence shown in (A). Repeat to ensure that all the setscrews are tightened to the correct torque.3 Use the special angle gauge MS.1531 to tighten the setscrews, in the correct sequence (A), a further part of a turn according to the length of the setscrews, see the table below.

4 If the special angle gauge MS.1531 is not available, make a suitable mark on the cylinder head in line with a corner of each setscrew (B). Make another mark, at the correct angle (counter-clockwise), on the edge of the flange of each fastener according to the length of the setscrew. Tighten each setscrew in the correct sequence until the marks on the flange are next to, and in line with, the marks on the cylinder head.Note: Release the cylinder head setscrews evenly and gradually in the reverse sequence to that shown in (A).

Fastenertype

Fastenerlength mm (in)

Illustrationand position

Setscrew Short A 5, 6, 11, 12, 16, 17, 21, 22

Setscrew Medium A 1, 2, 3, 4, 7, 8, 9,10, 13, 15, 18, 20

Setscrew Long A 14, 19

Fastener Further part of a turnA 5, 6, 11, 12, 16, 17, 21,

22150 or 2 1/2 flats

A 1, 2, 3, 4, 7, 8, 9, 10, 13,15, 18, 20

180 or 3 flats

A 14, 19 210 or 3 1/2 flatsService Data Booklet, TPD 1361E, issue 1 23


2 Current productPrima/500 Series


Horse power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36,5 to 59,7 kW (49 to 80 bhp)Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four strokeInduction system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspirated or turbochargedCombustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injectionNominal bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84,5 mm (3.33 in)Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88,9 mm (3.50 in)Compression ratio- Prima naturally aspirated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1:1- Prima turbocharged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.2:1- 500 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17:1

Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,994 litres (122 in3)Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2Valve tip clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to the workshop manualLubricating oil pressure- maximum engine speed and

normal engine temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 kPa (36 lbf/in2) 2,5 kgf/cm2Coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 C (140 F)Thermostat starts to open- Prima . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85/89 C (185/192 F)- 500 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77/85 C (170/185 F)Thermostat fully open- Prima . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99/102 C (210/215 F)- 500 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92/98 C (197/208 F)Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise from frontIdling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820 to 1050 rev/minLocation of maximum no-load speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NoneLocation of number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft pulley endLocation of engine timing marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timing pin methodAtomiser codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .JC, JD, RG, JP, RLFuel pump codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NoneLocation of fuel pump code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NoneLocation of fuel pump timing marks . . . . . . . . . . . . . . . . . . . . . . . . .Timing pin method, camshaft and flywheelBelt tension

- new belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440 N (100 lbf) 45,0 kgf- after 20 hours service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355 N (80 lbf) 3,6 kgf24 Service Data Booklet, TPD 1361E, issue 1


Th 2Current productBelt deflection at longest free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9,5 mm (0.375 in)

Preventive maintenance periods

These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed. Use the periods which are shortest. When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine.It is good preventive maintenance to check for leakage and loose fasteners at each service.Maintenance schedulesA First service at 25/50 hours E Every 400 hours or 6 monthsB Every day or every 8 hours F Every 800 hours or 12 monthsC Every week G Every 1600 hours or 24 monthsD Every month H Every 2000 hours or 30 months

The schedules which follow must be applied at the interval (hours or months) which occur first.

(1) If there is one fitted(2) By a person who has had the correct training.(3) The oil change interval will change with the amount of sulphur in the fuel (see the table on page 52 and the fuel specification). The

interval to change the canister of the lubricating filter is not affected.

A B C D E F G H Operationl

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Check the amount of coolantCheck the concentration of the coolantRenew the coolant Check the drive belt of the alternatorRenew the drive belt of the alternator

Drain water from the fuel pre-filterRenew the canister of the fuel filterClean the sediment chamber of the fuel lift pump

Check the amount of lubricating oil in the sumpCheck the lubricating oil pressure at the gauge (1)Renew the engine lubricating oil (3)Renew the canister of the lubricating oil filter

Clean the air cleaner or empty the dust bowl of the air filter - extremely dusty conditions- normal conditionsClean or renew the air filter element, if it has not been indicated earlier Clean the engine breatherCheck the performance of the glow plugs

Ensure idle speed is checked and adjusted, if necessary (2)Ensure that the valve tip clearances of the engine are checked and, if necessary, adjusted (2)Ensure that the timing belt is checked for wear, damage and the correcttension (2)Ensure that the timing belt is renewed (2)Ensure that the alternator and the starter motor are checked (2)Service Data Booklet, TPD 1361E, issue 1 25


2 Current productRecommended torque tensions


Description Thread size


Setscrews, cylinder head, see cylinder head torque sequence M12 - - -Sump plug 1/4 BSP 43 32 4,4Setscrew, atomiser clamp M10 43 32 4,4Union nut, high pressure fuel pipes M12 22 16 2,2Setscrews, main bearing M12 112 83 11,4Nuts, big end bearing 11/32 UNF 47 35 4,8Front pulley, refer to the workshop manual - - - -Setscrews, flywheel 7/16 UNF 65 48 6,626 Service Data Booklet, TPD 1361E, issue 1


Th 2Current productCylinder head torque sequenceCaution: Refer to Section 12 of the workshop manual before following these instructions. There is a special timing pin fitted to the engine that must be fitted in the correct position. If it is not, the engine will be damaged.1 Lightly lubricate the threads and the thrust faces of the cylinder head setscrews.2 Fit the setscrews in their correct positions and tighten them finger tight.

3 Gradually and evenly tighten the setscrews to 50 Nm (37 lbf ft) 5,1 kgf m, in the correct sequence (A).4 Tighten the setscrews to 100 Nm (74 lbf ft) 10,2 kgf m, in the correct sequence (A).5 Use the special angle gauge MS.1531 to tighten the setscrews, in the correct sequence, a further quarter of a turn (90).If the special angle gauge MS 1531 is not available, make a suitable mark on the cylinder head in line with a corner of each setscrew (B). Make another mark, at 90 (counter-clockwise), on the edge of the flange of each setscrew. Tighten each setscrew in the correct sequence until the marks on the flange are next to, and in line with, the marks on the cylinder head.Caution: If the original setscrews have been fitted again, mark the top of each setscrew with a centre punch to indicate it has been tightened in service. A maximum of four centre punch marks is permitted. Note: Note: Release the cylinder head setscrews evenly and gradually in the reverse sequence to that shown in (A).

Setscrewtype

Illustrationand position

Short A 1 to 6Long A 7 to 10Service Data Booklet, TPD 1361E, issue 1 27


2 Current product700 Series


Horse power- 704-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 to 47 kW (57.7 to 63.0 bhp)- 704-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 kW (57.7 bhp)Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four strokeInduction system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspiratedCombustion system- 704-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indirect injection- 704-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injectionNominal bore- 704-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91,0 mm (3.58 in)- 704-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97,0 mm (3.82 in)Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 mm (3.90 in)Compression ratio- 704-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22:1

- 704-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5:1

Cubic capacity

- 704-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,6 litres (159 in3)- 704-30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3,0 litres (183 in3)Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3-4-2Valve tip clearances- Inlet (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm (0.014 in)- Exhaust (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,35 mm (0.014 in)Lubricating oil pressure- maximum engine speed and

normal engine temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420 kPa (61 lbf/in2) 4,3 kgf/cm2Coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 C (140 F)Thermostat starts to open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82 C (179 F)Thermostat fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 C (203 F)Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ClockWise from frontIdling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refer to the User's Handbook of the applicationLocation of maximum no-load speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump data plateLocation of number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft pulley endLocation of engine timing marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft pulley

Continued28 Service Data Booklet, TPD 1361E, issue 1


Th 2Current productBasic technical data

Atomiser codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UA, UBFuel pump codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AJ, BJLocation of fuel pump code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump data plateLocation of fuel pump timing marks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NoneBelt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 N (10 lbf) 4,5 kgfBelt deflection at longest run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 mm (3/8 in)Service Data Booklet, TPD 1361E, issue 1 29



These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed. Use the periods which are shortest. When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine. It is good preventive maintenance to check for leakage and loose fasteners at each service.Maintenance scheduleThe schedules which follow must be applied at the interval (hours or months) which occur first.A First service at 25/50 hours F Every 500 hours or 12 months (704-26)B Every day or every 8 hours G Every 1000 hoursC Every 250 hours or 6 months (704-30) H Every 2000 hoursD Every 250 hours or 6 months (704-26) J Every 3000 hoursE Every 500 hours or 12 months (704-30)

(1) If one is fitted.(2) By a person who has had the correct training.(3) Renew the antifreeze every 2 years.(4) The oil change interval will change if a lubricating oil sump with a capacity of less than 8 litres is used. If there is doubt, contact

Technical Services, Perkins International Limited, Peterborough.(5) The oil change interval will change with the sulphur content of the fuel (see the table on page 52 and the Fuel Specification in section

5). The interval to change the canister of the lubricating oil filter is not affected.

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Check the amount of coolantCheck the concentration of the coolant (3)Check the condition of the drive belt

Drain water from the fuel pre-filter (1)Renew the canister of the fuel filter and renew the fuel strainerEnsure that the atomisers are checked (2) always use new clamps on 704-30Ensure that the idle speed is checked and adjusted, if it is necessary (2)

Check the amount of lubricating oil in the sumpCheck the lubricating oil pressure at the gauge (1)Renew the engine lubricating oil (5) (4)Renew the canister of the lubricating oil filter

Clean the air cleaner or empty the dust bowl of the air filter-extremely dusty conditions-normal conditionsClean or renew the air filter element, if this has not been indicated earlier

Ensure that the valve tip clearances of the engine are checked and, if necessary, adjusted (2)Check all hoses and connectionsRemove and clean the engine breather pipe)Renew the engine breather (2)

Ensure that the alternator, the starter motor, etc. are checked (2)Ensure that the glow plugs are checked (2)

Inspect the electrical system (2)30 Service Data Booklet, TPD 1361E, issue 1


Th 2Current productRecommended torque tensions


Cylinder head torque sequenceCaution: This operation must be done by a person with the correct training. If in doubt, refer to the workshop manual.

1 Lightly lubricate the threads and the thrust faces of the setscrews.2 Gradually and evenly tighten the setscrews to 70 Nm (52 lbf ft) 7,1 kgf m in the correct sequence, shown in (A).3 Tighten the setscrews to 100 Nm (74 lbf ft) 10,2 kgf m in the correct sequence, shown in (A).4 Repeat stage 3.Note: Release the cylinder head setscrews evenly and gradually in the reverse sequence to that shown in (A).



Setscrews, cylinder head, refer to head tightening sequence M11 - - -Plug, lubricating oil sump 3/4 UNF 34 25 3,5Setscrews, atomiser clamp M8 12 9 1,2Union nuts, high-pressure fuel pipes M12 22 16 2,2Setscrews, main bearings M14 147 108 15,0Nuts, connecting rods M9 54 40 5,5Setscrews, crankshaft pulley M16 185 136 19,0Setscrews, flywheel to crankshaft M12 100 77 10,7Service Data Booklet, TPD 1361E, issue 1 31


2 Current product900 Series


Horse power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39,5 kW (53 bhp)Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four strokeInduction system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Naturally aspiratedCombustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direct injectionNominal bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 mm (3.74 in)Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 mm (5.00 in)Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5:1

Cubic capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2,7 litres (164.76 in3)Firing order. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2-3Valve tip clearances- Inlet (cold) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0,20 mm (0.008 in)Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,45 mm (0.018 in)Lubricating oil pressure- maximum engine speed and

normal engine temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207/414 kPa (30/60 lbf/in2) 2,1/4,2 kgf/cm2Coolant temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 C (140 F)Thermostat starts to open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80/84 C (176/183 F)Thermostat fully open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 C (205 F)Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ClockWise from frontIdling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 rev/minLocation of maximum no-load speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump data plateLocation of number 1 cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft pulley endLocation of engine timing marks . . . . . . . . . . . . . . . . Crankshaft, fuel pump gear, camshaft gear, idler gears,

and alignment of holes in the flywheel backplateAtomiser codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KBFuel pump codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AN - BNLocation of fuel pump code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Left side of pump from rear of engineLocation of fuel pump timing marks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel pump flangeBelt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 N (10 lbf) 4,5 kgfBelt deflection at longest run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 mm (3/8 in)32 Service Data Booklet, TPD 1361E, issue 1


Th 2Current productPreventive maintenance periods

These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed. Use the periods which are shortest. When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine.It is good preventive maintenance to check for leakage and loose fasteners at each service.Maintenance schedulesA First service at 25/50 hours E Every 1000 hoursB Every day or every 8 hours F Every 2000 hoursC Every 200 hours or 4 months G Every 4000 hoursD Every 500 hours or 12 monthsThe schedules which follow must be applied at the interval (hours or months) which occur first.

(1) Renew the antifreeze every 2 years. If a coolant inhibitor is used instead of antifreeze, it should be renewed every 6 months.(2) If there is one fitted(3) By a person who has the correct training.(4) The oil change interval will change with the amount of sulphur in the fuel (see the table on page 52 and the fuel specification). The

interval to change the canister of the lubricating oil filter is not affected.(5) Caution: If there is a failure in the electrical circuit for the cold start advance, the engine will run continuously with the timing in the

fully advanced position and damage the engine.

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Check the amount of coolantCheck the concentration of the coolant (1)Check the drive belt of the alternator

Drain water from the fuel pre-filterRenew the elements of the fuel filterEnsure that the atomisers are checked (3)Ensure idle speed is checked and adjusted, if necessary (3)

Check the amount of lubricating oil in the sumpCheck the lubricating oil pressure at the gauge (2)Renew the engine lubricating oil (4)Renew the canister of the lubricating oil filterClean external vent holes on breather valveRenew the engine breather valve

Clean the air cleaner or empty the dust bowl of the air filter - extremely dusty conditions- normal conditionsClean or renew the air filter element, if it has not been indicated earlier

Check the engine mountsCheck all hoses and connections (also includes breather pipe)

Ensure that the valve tip clearances of the engine are checked and, if necessary, adjusted (3)Check all electrical cables and connections (5)Ensure that the alternator and the starter motor are checked (3) Service Data Booklet, TPD 1361E, issue 1 33


2 Current productFuel pump codes

Lucas fuel injection pumpType. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lucas DP 200Direction of rotation from drive end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ClockWiseOutlet for number 1 cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Letter "U"Static timingAn example of the pump code is 2644A000AN/2/2270. The fuel pump code begins with the pump part number, followed by two letters, then a number for the governor spring position and lastly the maximum no-load speed. For identification purposes, only the two code letters are used. This information can be found on the data plate of the fuel pump. The mark on the flange of the pump can be checked with timing tool MS.67B. The lock angle is set with timing tool MS.67B.The fuel injection pump is timed to the engine with the engine set at TDC No.1 cylinder on the compression stroke.

Recommended torque tensionsThe torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted.


Pump mark angle (degrees)

AN 89BN 88

Description Thread size


Setscrews, cylinder head M12/M14 - - -Sump plug 3/4 UNF 34 25 3,5Atomiser clamp M8 22 16 2,2Union nuts, high-pressure fuel pipes M12 22 16 2,2Main bearing 9/16 UNF 152 112 15,5Big end bearing 7/16 UNF 77 57 7,9Crankshaft pulley 7/8 UNF 325 240 33,2Flywheel 1/2 UNF 105 77 10,734 Service Data Booklet, TPD 1361E, issue 1


Th 2Current productCaution: This operation must be done by a person

Perkins companies 2TPD1361E1.pdf

Documents

Transcript of Perkins companies 2TPD1361E1.pdf