K EN R A ugu st Specifications Industrial Engine. M G D (Engine) MGB (Engine)

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1 K EN R A ugu st Specifications Industrial Engine M G A (Engine) MGB (Engine) M G D (Engine)

2 Important Safety Information i Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication. Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Perkins is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose. The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Perkins dealers have the most current information available. When replacement parts are required for this product Perkins recommends using Perkins replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

3 KENR Table of Contents Table of Contents Engine Design... 4 Fuel Transfer Pump... 4 Fuel Filter Base... 5 Fuel Filter (Primary)... 5 Fuel Priming Pump... 6 Electronic Unit Injector Mechanism... 6 Electronic Unit Injector Rocker Arm... 7 Electronic Unit Injector Wiring... 7 Valve Mechanism... 8 Valve Mechanism Cover... 8 Cylinder Head Valves... 9 Cylinder Head Turbocharger Exhaust Manifold Exhaust Elbow Camshaft Engine Oil Filter Base Engine Oil Pump Engine Oil Pan Water Lines Water Temperature Regulator Water Pump Cylinder Block Cylinder Liner Crankshaft Crankshaft Seals Vibration Damper Connecting Rod Bearing Journal Main Bearing Journal Connecting Rod Piston and Rings Housing (Front) Gear Group (Front) Flywheel Flywheel Housing Flywheel Housing Cover Belt Tightener Fan Drive Alternator and Regulator Alternator Mounting Electric Starting Motor Coolant Temperature Sensor Fuel Temperature Sensor Engine Oil Pressure Sensor Atmospheric Pressure Sensor Inlet Manifold Air Pressure Sensor Inlet Air Temperature Sensor Speed/Timing Sensor Index Section Index... 35

4 4 KENR6230 Engine Design i Fuel Transfer Pump i Illustration 1 Cylinder and valve location (A) Inlet (B) Exhaust (C) Flywheel end of engine g Bore mm (5.40 inch) Stroke mm (6.75 inch) Displacement L ( cu in) Cylinder arrangement... In-Line Valves per cylinder... 4 The adjustment for the inlet valve lash is the following value ± 0.08 mm (0.015 ± inch) The adjustment for the exhaust valve lash is the following value ± 0.08 mm (0.030 ± inch) Firing order (injection sequence)... 1, 5, 3, 6, 2, 4 Crankshaft rotation... counterclockwise Note: The front end of the engine is opposite the flywheel end. The left side and the right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the front cylinder. Illustration 2 (1) Pressure regulating valve (2) Inlet port (3) Weep hole (4) Outlet port Illustration 3 (5) Bolts g g

5 KENR Tighten the bolts to the following torque N m (35 lb ft) When the fuel transfer pump is using diesel fuel, the fuel transfer pump has the following specifications. Run the pump at 2940 rpm. The bypass pressure must be between 716 kpa (103.8 psi) and 786 kpa (114.0 psi). Run the pump at 840 rpm. The flow at 550 kpa (80 psi) must be 3.0 L/min (0.80 US gpm). Runthepumpat 100 rpm with the inlet to the atmosphere for 10 seconds. The pump must maintain a vacuum of 60 kpa (9 psi) for 30 seconds once the inlet is blocked. Run the pump at 2940 rpm. The flow at 650 kpa (94 psi) must be 4.5 L/min (1.19 US gpm). Fuel Filter (Primary) i Fuel Filter Base i Illustration 5 g (1) Tighten the primary fuel filter housing (1) to the fuel filter base (2) to the following torque ± 10 N m (59 ± 7 lb ft) (2) Fuel filter base (3) Tighten the secondary fuel filter housing (3) to the fuel filter base (2) to the following torque ± 10 N m (59 ± 7 lb ft) (4) Drain Plugs Illustration 4 g (1) Retaining setscrews N m (35 lb ft) (2) Plug N m (11 lb ft) (3) Plug N m (11 lb ft) (4) Plug N m (30 lb ft)

6 6 KENR6230 Fuel Priming Pump i Electronic Unit Injector Mechanism i Illustration 6 g (1) Tighten the bolt to the following torque N m (220 lb in) (2) Priming pump (3) Tighten the bolt to the following torque N m (105 lb in) Illustration 7 (1) Cap nut g Tighten the cap nuts to the following torque ± 0.25 N m (22 ± 2 lb in) (2) Locknut for the adjustment screw Tighten the locknut for the adjustment screw to the following torque ± 10 N m (75 ± 7 lb ft) (3) Unit injector height Adjust the unit injector height to the following dimension ± 0.2 mm (3.07 ± 0.01 inch) (4) Unit injector clamp retaining bolt 1. Tighten the unit injector clamp retaining bolt to 55±10N m(41±7lbft). 2. Loosen the retaining bolt until the bolt is finger tight. 3. Tighten the retaining bolt again to 55 ± 10 N m (41±7lbft). (5) Spacer (6) Unit injector clamp

7 KENR (7) O-ring seals Before installation of the unit injector, lubricate the top two O-ring seals with clean engine oil. i Electronic Unit Injector Wiring Note: Refer to Testing and Adjusting, Electronic Unit Injector - Adjust for the correct procedure for setting the lash on the electronic unit injector. i Electronic Unit Injector Rocker Arm Illustration 9 g Illustration 8 g (A) Bore in the rocker arm bearing for the rocker arm shaft Dimension for bore of new bearing after installation ± mm ( ± inch) Maximum dimension for worn bearing mm ( inch) (1) Tighten the nuts that are on the cap assembly to the following torque ± 0.25 N m (22±2lbin) Position connectors so that the wires are not contacting any other surfaces. (1) Location of bearing joint The rocker arm bearing must not extend beyond either face of the rocker arm.

8 8 KENR6230 Valve Mechanism i (6) Camshaft (7) Valve bridge assembly Valve Mechanism Cover i Illustration 10 g (1) Valve rocker arm assembly (2) Adjusting the screw locknut Tighten the locknut to the following torque ± 7 N m (22 ± 5 lb ft) (3) Bolt Tighten the bolts to the following torque ± 15 N m (80 ± 11 lb ft) (4) Rocker arm shaft Diameter of a new rocker arm shaft ± mm ( ± inch) Bore in a new rocker arm bearing for the rocker arm shaft ± mm ( ± inch) (5) Valve lash Illustration 11 Valve cover g Inlet valves ± 0.08 mm (0.015 ± inch) Exhaust valves ± 0.08 mm (0.030 ± inch) Note: Refer to Testing and Adjusting, Engine Valve Lash - Inspect/Adjust for the correct procedure on setting the engine valve lash. Illustration 12 Tightening sequence g Refer to Illustration12 for the tightening sequence of the valve cover bolts.

9 KENR (1) Bolts Torque for bolts N m (15 lb ft) (2) Valve mechanism cover (3) Harness connector (4) Integral breather Load at minimum operating length ± 45 N (202 ± 10 lb) Free length after test mm (3.020 inch) Outside diameter mm (1.429 inch) (2) Valve guide Bore of installed valve guide (new parts) ± mm ( ± inch) Cylinder Head Valves i Maximum recommended diameter of the valve guide bore mm ( inch) Note: Do not use a combination of a valve and a valve guide that has a difference of 0.13 mm (0.005 inch) or more. (3) Height to top of valve guide ± 0.50 mm (1.378 ± inch) (4) Valve recess Inlet (new parts) to 2.80 mm (0.087 to inch) Exhaust (new parts) to 1.80 mm (0.047 to inch) Inlet (reconditioned parts) to 3.29 mm (0.087 to inch) Exhaust (reconditioned parts) to 2.29 mm ( to inch) Illustration 13 g Note: Apply engine oil to the valve stems prior to installation in the cylinder head. (1) Valve springs Inner Spring Assembled length mm (2.368 inch) Load at assembled length ± 12 N (34±3lb) Operating length (minimum) mm (1.733 inch) Load at minimum operating length ± 18 N (90±4lb) Free length after test mm (2.823 inch) Outside diameter mm (0.991 inch) Outer Spring Assembled length mm (2.643 inch) Load at assembled length ± 25 N (72±6lb) Operating length (minimum) mm (2.008 inch) Illustration 14 (5) Valve face angle g Inlet /4 ± 1/4 degrees Exhaust /4 ± 1/4 degrees (6) Valve stem diameter New valve stem diameter ± mm ( ± inch) Minimum recommended valve stem diameter mm ( inch) (7) Diameter of valve head Inlet mm (1.850 inch) Exhaust mm (1.646 inch)

10 10 KENR6230 (8) Minimum recommended valve lip thickness Inlet mm (0.108 inch) Exhaust mm (0.081 inch) (9) Overall length of valve Inlet ± 0.45 mm (7.953 ± inch) Exhaust ± 0.45 mm (7.955 ± inch) Illustration 15 g (10) Width of the valve seat Inlet mm ( inch) Exhaust mm ( inch) (11) Depth of bore in the cylinder head for the valve seat insert Inlet ± 0.05 mm (0.551 ± inch) Exhaust ± 0.05 mm (0.547 ± inch) (12) Inside diameter of valve seat insert Inlet ± 0.50 mm (1.614 ± inch) Exhaust ± 0.50 mm (1.437 ± inch) (13) Angle of valve seat face Inlet ± 1 degree Exhaust ± 1 degree (14) Outside diameter of valve seat insert Inlet ± mm ( ± inch) Exhaust ± mm ( ± inch) Diameter of the bore in the cylinder head for the valve seat insert Inlet ± mm ( ± inch) Exhaust ± mm ( ± inch)

11 KENR Cylinder Head i Illustration 16 g Table 1 Required Tools Tool Part Number Part description A CV60895 POWERPART Special Lubricant The bolts that are marked X are 216 mm (8.5 inch) long. The remainder of the bolts are 194 mm (7.6 inch) long. Apply Tooling (A) to the bolt threads and both sides of the washers. Tighten the bolts in the following step sequence: 1. In a numerical sequence, tighten bolts 1 through 26. Torque for bolts ± 15 N m (200 ± 11 lb ft) 2. In a numerical sequence, tighten bolts 1 through 26. Illustration 17 (A) Cylinder Head Thickness g Thickness of a new cylinder head ± 0.15 mm (4.724 ± inch) Minimum thickness of a used cylinder head mm (4.713 inch) Torque for bolts ± 15 N m (330 ± 11 lb ft) 3. In a numerical sequence, again tighten bolts 1 through 26. Torque for bolts ± 15 N m (330 ± 11 lb ft) Note: The flatness of the cylinder head should be within a total of 0.13 mm (.005 inch). Also, the flatness ofthecylinderheadshouldbewithinamaximumof 0.05 mm (.002 inch) for any 150 mm (5.9 inch) span.

12 12 KENR6230 Illustration 18 g (27) Oil gallery (28) Bearing joint (29) Oil holes (30) Camshaft bearing NOTICE Camshaft bearings must be installed into their correct position. Failure to do so will result in engine damage. Illustration 19 (B) Orientation of bearing joint (28) Bearing joint (31) Diameter of Camshaft Bore g (31) Diameter of camshaft bore ± mm (3.582 ± inch) Orientation of bearing joint (B) ± 5 above horizontal

13 KENR Illustration 20 g The depth of installation of the camshaft bearings is very important. Install bearings (30) to the following depths: Installation depth for camshaft bearings (30) C ± 0.50 mm (0.75 ± 0.02 inch) D ± 0.5 mm (6.09 ± 0.02 inch) E ± 0.5 mm (12.84 ± 0.02 inch) F ± 0.5 mm (19.59 ± 0.02 inch) G ± 0.5 mm (26.34 ± 0.02 inch) H ± 0.5 mm (33.09 ± 0.02 inch) I ± 0.5 mm (39.84 ± 0.02 inch) Turbocharger i Table 2 Required Tools Tool Part Number Part Description A CV60889 Anti-Seize Compound Illustration 21 g (1) Tighten the clamp nuts to the following torque N m (10 lb ft) Lightly hit the clamps with a soft faced hammer. Again tighten the clamp nuts to the following torque N m (10 lb ft) (2) Tighten the bolts to the following torque N m (35lbft) (3) Apply Tooling (A) to the fasteners for the turbocharger and tighten to the following torque N m (41 lb ft)

14 14 KENR6230 Exhaust Manifold i Apply Tooling (A) to the threads of the studs that engage the locknuts. Tighten the studs(4)in thecylinderheadtothe following torque N m (26 lb ft) Table 3 Required Tools Exhaust Elbow i Tool Part Number Part Description A CV60889 Anti-Seize Compound Illustration 22 g Illustration 24 g (1) Tighten the nut for the clamp to the following torque N m (10 lb ft) Illustration 23 Tightening sequence (1) Spacer (2) Washer g (3) Tighten the locknuts to the following torque N m (28 lb ft) (4) Taperlock studs

15 KENR Camshaft i Injector lobe mm ( inch) (7) Camshaft lobe height (8) Base circle To find the lobe lift, use the procedure that follows: 1. Measure camshaft lobe height (7). 2. Measure base circle (8). 3. Subtract the base circle measurement (Step 2) from the camshaft lobe height (Step 1). The difference is the actual lobe lift. Maximum permissible difference between the actual lobe lift (Step 3) and the specified lobe lift of a new camshaft mm (0.004 inch) Illustration 25 g (1) Exhaust lobe (2) Injector lobe (3) Inlet lobe Note: Lubricate the camshaft lobes with clean engine oil. (4) Bearing journal Diameter of the bearing journals ± 0.02 mm (3.341 ± inch) Note: Lubricate the camshaft bearings with clean engine oil prior to installing the camshaft. (5) Front of camshaft Illustration 27 (9) Screw g Tighten the screws that fasten the cover to the cylinder head to the following torque... 6 ± 1 N m (53±9lbin) Engine Oil Filter Base i Table 4 Illustration 26 (6) Camshaft lobe lift g Required Tools Tool Part Number Part Description A POWERPART Thread Lock and Nut Lock Specified camshaft lobe lift Exhaust lobe mm ( inch) Inlet lobe mm ( inch)

16 16 KENR6230 (4) Tighten the plug to the following torque ± 15 N m(74±11lbft) Engine Oil Pump i Illustration 28 g (1) Apply Tooling (A) on the tapered end of the stud to the following dimension ± 1.5 mm (0.41 ± 0.06 inch) Tighten the stud to the following torque ± 7 N m (50±5lbft) (2) Apply engine oil to the oil filter seal. Put the oil filter in position. Turn the oil filter by hand until the seal makes contact with the base. Additionally tighten the oil filter by 3/4 of a turn. Illustration 30 g NOTICE Before operation, the pump must be lubricated with clean engine oil and the pump must turn freely by hand or damage to parts can be the result. (1) Diameter of shafts ± mm ( ± inch) Diameter of bores in cover for shafts ± mm ( ± inch) (2) Length of gears ± mm ( ± inch) Illustration 29 View A-A (3) Spring g Length under test force mm (2.175 inch) Test force ± 5.8 N (17 ± 1.30 lb) Free length after test mm (3.69 inch) Outside diameter mm (0.81 inch) The filter and the cooler bypass valves will open with the following pressure difference ± 20 kpa (37 ± 3 psi) Depth of bores for gears ± mm ( ± inch) (3) Spring Length under test force mm (4.64 inch) Test force ± 8 N m (110 ± 6 lb ft) Free length after test mm (6.02 inch) Outside diameter mm (1.063 inch)

17 KENR Illustration 31 g Illustration 33 g Pump body Tightening sequence (4) Bearings (1) Joint Install the bearings so the bearings are even with the outside of the pump body. (A) Position of bearing joint from the centerline through bearing bores ± 15 degrees (2) Washer (3) Plug Torque N m (33 lb ft) Engine Oil Pan i (4) Engine Oil Pan (5) Tighten the bolts to the following torque N m (35lbft) Water Lines i Illustration 32 g Illustration 34 (1) Seal bores g Apply a light coat of glycerin to the seal bores.

18 18 KENR6230 i Water Temperature Regulator Water Pump i Illustration 35 g Completely open temperature C (208 F) Minimum openingdistanceat98 C (208 F) mm (0.41 inch) Illustration 36 g (1) Bolt Tighten the bolt that holds the impeller to the following torque ± 3 N m (29 ± 2 lb ft) (2) The shaft diameter at the carbon seal assembly seat area is the following dimension ± 0.01 mm ( ± inch) (3) Coolant seal Press the seal assembly onto the water pump shaft until the stationary cup is fully seated in the pump housing. (4) Oil seal Install the oil seal with the primary lip toward the water pump drive gear. Press the oil seal into the counterbore with a press.

19 KENR Cylinder Block i Illustration 37 Right side view (1) Dowel The dowel extends above the top surface of the cylinder block by the following distance ± 0.5 mm (0.73 ± 0.02 inch) (2) Spacer plate Thickness of the spacer plate ± mm ( ± inch) Thickness of the gasket that is placed between the spacer plate and the cylinder block ± 0.02 mm (0.008 ± inch) Cylinder liner projection above the spacer plate to mm ( to inch) (3) Dowel g The dowel extends above the top surface of the cylinder block by the following distance ± 0.5 mm (0.63 ± 0.02 inch) (4) Dowel The dowel extends above the top surface of the cylinder block by the following distance ± 0.5 mm (0.79 ± 0.02 inch) (5) Plug Tighten the plug to the following torque ± 10 N m (52±7lbft)

20 20 KENR6230 (6) Dowel The dowels extend past the end of the cylinder block by the following distance ± 0.5 mm (0.75 ± 0.02 inch) Illustration 38 View A-A g Illustration 40 Front view g (8) Dimension from the centerline of the crankshaft bearing bore to the top of the cylinder block Illustration 39 View B-B g (7) Installation depth of the plug ± 2.0 mm (0.08 ± 0.08 inch) New ± 0.15 mm ( ± inch) Minimum mm ( inch) Note: The total flatness of the top contact surface of the cylinder block must be within 0.10 mm (0.004 inch). The flatness must also be within 0.05 mm (0.002 inch) for any mm (6.99 inch) section of the surface. (9) Bore in the cylinder block for the main bearings (10) Main bearing cap Main bearing cap width ± mm ( ± inch) Width of the cylinder block for the main bearing cap ± mm ( ± inch) (11) New dimension from the centerline of the crankshaft bearing bore to the bottom of the cylinder block pan rails ± 0.10 mm (6.500 ± inch) (12) Main bearing cap bolts

21 KENR (15) Straight thread O-ring plug (16) Piston cooling jet To prevent damage to the piston cooling jets during service, the piston cooling jets must be removed. Minimum permissible clearance between the piston, the piston cooling jet, and the crankshaft mm (0.025 inch) g Illustration 41 Torque-turn tightening method for main bearing cap bolts Use the following procedure in order to tighten the main bearing cap bolts: 1. Apply clean engine oil to the threads of the bolts. 2. Tighten the bolts first on the bearing tab side (13) of the cap. Torque for bolts ± 14 N m (190 ± 10 lb ft) 3. Tighten the bolts on the opposite end (14) of the cap. Cylinder Liner i Torque for bolts ± 14 N m (190 ± 10 lb ft) 4. Put a mark on each bolt and each cap. 5. Tighten the bolts on the opposite end of the bearing tab (14) from the mark to angle (A). Angle (A) ± 5 degrees (2 flats) 6. Tighten the bolts on the bearing tab side (13) of the cap from the mark to the following value. Angle (A) ± 5 degrees (2 flats) Illustration 43 g (1) Bore in new liner ± mm (5.40 ± inch) (2) Thickness of flange on liner ± mm ( ± inch) The minimum thickness of the part that can be used again is the following value mm ( inch) (3) Filler band Illustration 42 Right side view g

22 22 KENR6230 Crankshaft i Crankshaft Seals i Illustration 44 g (1) The length of the dowel out of the crankshaft ± 0.5 mm (0.16 ± 0.02 inch) (2) The maximum length of the dowel out of the crankshaft mm (0.252 inch) (3) Main bearing journal (4) Connecting rod bearing journal Refer to Specifications, Connecting Rod Bearing Journal and Specifications, Main Bearing Journal for more information about the crankshaft journals. (5) Crankshaft end play to 0.57 mm (0.004 to.022 inch) The maximum permissible end play with used bearings mm (0.035 inch) (6) Timing gear Illustration 45 (1) Front crankshaft seal g The front seal should be installed even with the front of the crankshaft with the following tolerance to 0.13 mm ( to inch) The seal driver should not contact the seal within the following diameter ± 0.25 mm (7.000 ± inch) (2) Rear crankshaft seal Install the rear seal to the following distance from the end of the crankshaft ± 0.6 mm (0.21 ± inch) The seal driver should not contact the seal within the following diameter ± 0.25 mm (7.000 ± inch) Note: Do not separate the seal from the sleeve. Replace the seal if the seal is separated from the sleeve.

23 KENR Vibration Damper i Connecting Rod Bearing Journal i Table 5 Required Tools Tool Part Number Part Description A CV60890 Anti-Seize Compound Table 6 Connecting Rod Bearing Journal Original Size Journal Undersize Journal 0.63 mm (0.025 inch) Undersize Journal 1.27 mm (0.050 inch) 97 ± 0.02 mm (3.819 ± inch) mm (3.794 inch) mm (3.769 inch) Clearance between the new bearing and the journal mm to mm ( inch to inch) Maximum permissible clearance between the bearing and the journal mm (0.008 inch) Main Bearing Journal i Illustration 46 (1) Adapter (2) Damper g (3) Tighten the bolts to the following torque N m (77 lb ft) (4) Apply Tooling (A) to the bolts and tighten the bolts to the following torque N m (200 lb ft) Table 7 Original Size Journal Undersize Journal 0.63 mm (0.025 inch) Undersize Journal 1.27 mm (0.050 inch) Main Bearing Journals ± mm ( ± inch) ± mm ( ± inch) ± mm ( ± inch) Clearance between the new bearing and the journal mm to mm ( inch to inch) Maximum permissible clearance between the bearing and the journal mm (0.010 inch) Table 8 Original Size of the Bore In the Block Oversize Bore 0.63 mm (0.025 inch) Main Bearing Bore ± mm ( ± inch) ± mm ( ± inch)

24 24 KENR6230 Connecting Rod i To install the piston pin bearing, the connecting rod must be heated. Do not use a torch to heat the connecting rod. Maximum temperature for heating of connecting rod C to 260 C (347 F to 500 F) (A) The bearing junction and the locating hole are angled 180 degrees from each other. The bearing junction and the locating hole must be assembled within area (A). (X) Tolerance for installation of bearing junction and locating hole... ± 5 degrees (2) Dimension Distance between center of bearings mm ( inch) (3) Bore Bore in the connecting rod bearing after torquing of the connecting rod bolts ± mm (4.063 ± inch) Illustration 47 g Illustration 49 g (4) Piston pin Bore in new bearing for piston pin ±.008 mm ( ± inch) Diameter of new piston pin ± mm ( ± inch) Maximum clearance between bearing and worn piston pin mm (0.003 inch) Illustration 48 Positioning the piston pin bearing (1) Bore for piston pin bearing g Dimension ± mm ( ± inch) Tight fit between connecting rod eye and piston pin bearing to 0.10 mm (0.002 to inch) (5) Crankshaft bearing Bore in bearing for crankshaft ± mm ( ± inch) Clearance between new bearing and crankshaft ± mm ( ± inch)

25 KENR Piston and Rings i Illustration 50 Connecting rod bolts (6) Connecting rod bolts g Use the following procedure to tighten the connecting rod bolts: 1. Put engine oil on the bolt threads and the contact surfaces before assembly. 2. Tighten the bolts in the following order. Tighten the bolts (A) and (C) ± 4 N m (52±3lbft) Tighten the bolts (B) and (D) ± 4 N m (52±3lbft) Additionally tighten each bolt. (B) and (D) ± 5 degrees Again, tighten the bolts (A) and (C) ± 4 N m (52±3lbft) Additionally tighten each bolt. (A) and (C) ± 5 degrees (7) Bolt for piston cooling jet Tighten the bolt to following torque ± 8 N m (30±6lbft) To prevent damage to the piston cooling jet during service, the piston cooling jets must be removed. Minimum permissible clearance between the piston, the piston cooling jet, and the crankshaft mm (0.025 inch) Illustration 51 (1) Top piston ring g Install the piston ring with UP-1 mark toward the top of the piston. There is a clearance between the ends of the piston ring. When the piston ring is installed in a cylinder liner with a bore of mm ( inch), the clearance is the following value ± 0.10 mm (0.02 ± inch) There is an increase in the clearance between the ends of the piston rings for each mm ( inch) increase in the cylinder liner bore. Increase mm (0.003 inch) (2) Intermediate piston ring Install the piston ring with UP-2 mark toward the top of the piston. There is a clearance between the ends of the piston ring. When thepistonringisinstalledinacylinder liner with a bore of mm ( inch), the clearance is the following value ± 0.10 mm (0.02 ± inch) There is an increase in the clearance between the ends of the piston rings for each mm ( inch) increase in the cylinder liner bore. Increase mm (0.003 inch) (3) Oil Control Ring The spring ends of the oil control ring should be assembled 180 degrees from the ring end gap. Width of groove in new piston for oil control ring ± mm (0.158 ± inch)

26 26 KENR6230 Thickness of new piston ring... 3 ± 0.2 mm (0.118 ± inch) Clearance between groove and new piston ring to 1.2 mm (0.031 to inch) (2) Joint (3) Tighten the bolts to the following torque N m (37lbft) There is a clearance between the ends of the piston ring. When the piston ring is installed in a cylinder liner with a bore of mm ( inch), the clearance is the following value ± 0.15 mm (0.028 ± inch) Gear Group (Front) i There is an increase in the clearance between the ends of the piston rings for each mm ( inch) increase in the cylinder liner bore. Increase mm (0.003 inch) (4) Piston pin bore Bore in piston assembly for pin ± mm ( ± inch) Diameter of the new piston pin ± mm ( ± inch) Table 9 Required Tools Tool Part Number Part Description A POWERPART Rubber Grease B POWERPART Thread Lock and Nut Lock Clearance between the piston pin and the bore in the piston to 0.13 mm ( to inch) Housing (Front) i Illustration 53 g (1) Water pump drive gear Illustration 52 g (1) Housing

27 KENR Illustration 54 Stub shaft for cluster gear g (2) Cluster gear Apply Tooling (B) to the five bolts for the stub shaft. Tighten the five bolts for the stub shaft in the following sequence. See Illustration 54 for the numbering of the bolts.... 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1 Apply Tooling (B) to the four bolts that fasten the cluster gear to the stub shaft. Tighten the four bolts that fasten the cluster gear to the stub shaft to the following torque N m (21 lb ft) Illustration 55 (3) Camshaft gear (12) Sealing plate for the camshaft bolts (13) Seals (14) Camshaft gear bolts g Illustration 56 Camshaft gear g (4) Align thetimingmarkonthecamshaftgearwith the timing mark on the front housing when the No. 1 piston is at top center. (3) Camshaft gear

28 28 KENR6230 Lightly lubricate the O-ring seal on the outside of the camshaft sealing plate with a 50/50 mixture of Tooling (A) and clean engine oil. Apply Tool (B) to the three bolts for the camshaft sealing plate. Tighten the six bolts for the camshaft gear in the following sequence. refer to 56 for the numbering of the bolts.... 1, 4, 2, 5, 3, 6, 1, 4 Tighten the three camshaft sealing plate bolts to the following torque. See Illustration N m (106 lb in) Tighten the camshaft bolts in the following sequence. See Illustration 56 for the numbering of the bolts.... 1, 4, 2, 5, 3, 6, 1, 4 Tighten the six camshaft gear bolts to the following torque N m (177 lb ft) (5) Adjustable idler gear Tighten the bolt for the oil pump drive gear to the following torque N m (41 lb ft) Flywheel Table 10 Required Tools i Tool Part Number Part Description A CV60890 Anti-Seize Compound Install the plate with the oil groove toward the gear face. Apply Tooling (B) to the three bolts that fasten the adjustable idler gear to the stub shaft. Tighten the three bolts for the adjustable idler gear to the stub shaft to the following torque N m (21 lb ft) Refer to Testing and Adjusting, Gear Group (Front) - Time for the backlash adjustment procedure. Backlash between the camshaft gear and the adjustable idler gear ± mm ( ± inch) Apply Tooling (B) to the one bolt and five studs for the stub shaft. Tighten the one bolt and five nuts for the stub shaft to the following torque N m (41 lb ft) (6) Air compressor gear (if equipped) (7) Idler gear Apply Tooling (B) to the one bolt and five studs for the stub shaft. Tighten the one bolt and five nuts for the stub shaft to the following torque N m (41 lb ft) Illustration 57 g Note: Refer to the System Operation, Testing & Adjusting, Flywheel Runout for the correct method of flywheel inspection. (1) Apply Tooling (A) to the threads of the bolts. Tighten the bolts to the following torque N m (200 lb ft) (2) The maximum temperature of the ring gear for installation C (600 F) Apply Tooling (B) to the three bolts that fasten the idler gear to the stub shaft. Tighten the three bolts that fasten the idler gear to the stub shaft to the following torque N m (21 lb ft) (8) Gear for the fuel transfer pump drive (9) Align the timing mark on the crankshaft gear with the timing mark on the cluster gear. (10) Crankshaft gear (11) Oil pump drive gear

29 KENR Flywheel Housing i In a numerical sequence, tighten bolt 1 through bolt 9 to a torque of135n m(100lbft). 4. In a numerical sequence, tighten bolt 10 through bolt24toatorqueof55n m(41lbft). Table 11 Required Tools Tool Part Number Part Description A CH10879 liquid Gasket Flywheel Housing Cover i Illustration 58 Tightening sequence g Note: During assembly, inspect the following components for any foreign materials: the front face of the flywheel housing, the two sides of the flywheel housing gasket and the rear face of the cylinder block. These components must be free of the following substances: oil, fuel, water, gasket adhesive, assembly compounds, and any other foreign material. Apply a small amount of Tooling (A) in order to fill the space between the cylinder block, the flywheel housing, and the oil pan before installing the oil pan gasket and the oil pan. The components must be assembled within twenty minutes of applying the sealant. Illustration 59 (1) Bolt g Tighten the three bolts on the cover to the following torque N m (35 lb ft) Use the following procedure to tighten the flywheel housing bolts. 1. In a numerical sequence, tighten bolt 1 through bolt 9 to a torque of 100 N m (74 lb ft). 2. In a numerical sequence, tighten bolt 10 through bolt 24 to a torque of 40 N m (30 lb ft).

30 30 KENR6230 Belt Tightener i (6) Grease fitting Fan Drive i Illustration 60 g Illustration 62 g Illustration 61 g (1) Nut Tighten the nut to the following torque N m (75 lb ft) (2) Tension bolt (3) Belt Tightener (4) Bolt Tighten the bolt to the following torque N m (35 lb ft) (5) Pulley Illustration 63 (1) Fan drive assembly (2) Pulley g

31 KENR (3) Tighten the nuts to the following torque N m (77 lb ft) (4) Tighten the Bolts to the following torque N m (35 lb ft) (5) Tighten the Bolts to the following torque N m (35 lb ft) Polarity... Negative Ground Rotation... Either Direction Minimum full load current at 5000 rpm Amp Minimum full load current at 2000 rpm Amp Output voltage ± 1 V Alternator and Regulator i (1) Torque for the ground terminal nut ± 0.25 N m (20 ± 2 lb in) (2) Torque for the pulley nut ± 7 N m (75±5lbft) (3) Torque for the output terminal nut ± 0.6 N m (55±5lbin) Regulator Assembly Voltage setting... No Adjustment Permissible voltage range to 29 V Voltage rating V Alternator Mounting i Illustration 64 g Illustration 66 g Illustration 65 g (1) Tighten the bolt to the following torque N m (52lbft) (2) Alternator

32 32 KENR6230 (3) Tighten the nut to the following torque N m (77 lb ft) (4) Tighten the bolt (4) for the link to the following torque N m (77 lb ft) (3) Tighten the bolts to the following torque N m (160 lb ft) (4) Tighten the nut on the ground terminal to the following torque ± 0.25 N m (20 ± 2 lb in) Electric Starting Motor i (5) Tighten the nut on the switch terminal to the following torque ± 0.25 N m (20 ± 2 lb in) (6) Tighten the nut on the motor terminal to the following torque ± 3.5 N m (22 ± 3 lb ft) (7) Tighten the nut on the motor frame terminal to the following torque ± 3 N m (71 ± 27 lb in) i Coolant Temperature Sensor Illustration 67 g Illustration 69 g Illustration 68 g (1) Sensor assembly Tighten the sensor assembly to the following torque N m (15lbft) When the electric starting motor is viewed from the drive end, the motor rotates in the following direction.... Clockwise No load conditions at 25 C (77 F) Speed ± 1683 rpm Current draw ± 14.5 amp Voltage V (1) Tighten the nut on the battery terminal to the following torque ± 3.5 N m (22 ± 3 lb ft) (2) Tighten the nut on the ground terminal to the following torque ± 3.5 N m (22 ± 3 lb ft)

33 KENR Fuel Temperature Sensor i i Atmospheric Pressure Sensor Illustration 70 g Illustration 72 g (1) Sensor assembly Tighten the sensor assembly to the following torque N m (15 lb ft) (1) Sensor assembly Tighten the sensor assembly to the following torque N m (90 lb in) i Engine Oil Pressure Sensor i Inlet Manifold Air Pressure Sensor Illustration 71 g (1) Sensor assembly Illustration 73 g Tighten sensor assembly to the following torque N m (90 lb in) (1) Tighten the sensor to the following torque N m (90 lb in)

34 34 KENR6230 i Inlet Air Temperature Sensor Ensure that the bracket is installed in the orientation that is shown. (3) Tighten the bolt for the sensor to the following torque N m (18lbft) Ensure that the sensor is seated before the bolt is tightened. Camshaft Position Sensor Illustration 74 g (1) Sensor assembly Torque for sensor N m (15 lb ft) Illustration 76 g Speed/Timing Sensor Crankshaft Position Sensor i (1) Sensor (2) Bracket Ensure that the bracket is installed in the orientation that is shown. (3) Tighten the bolt for the sensor to the following torque N m (18 lb ft) Ensure that the sensor is seated before the bolt is tightened. Illustration 75 (1) Sensor (2) Bracket g

35 KENR Index Section Index A Alternator and Regulator Alternator Mounting Atmospheric Pressure Sensor B Belt Tightener H Housing (Front) I Important Safety Information... 2 Inlet Air Temperature Sensor Inlet Manifold Air Pressure Sensor C Camshaft Connecting Rod Connecting Rod Bearing Journal Coolant Temperature Sensor Crankshaft Crankshaft Seals Cylinder Block Cylinder Head Cylinder Head Valves... 9 Cylinder Liner E Electric Starting Motor Electronic Unit Injector Mechanism... 6 Electronic Unit Injector Rocker Arm... 7 Electronic Unit Injector Wiring... 7 Engine Design Engine Oil Filter Base Engine Oil Pan Engine Oil Pressure Sensor Engine Oil Pump Exhaust Elbow Exhaust Manifold F Fan Drive Flywheel Flywheel Housing Flywheel Housing Cover Fuel Filter (Primary)... 5 Fuel Filter Base... 5 Fuel Priming Pump... 6 Fuel Temperature Sensor Fuel Transfer Pump... 4 M Main Bearing Journal P Piston and Rings S... 4 Speed/Timing Sensor Camshaft Position Sensor Crankshaft Position Sensor T Table of Contents... 3 Turbocharger V Valve Mechanism... 8 Valve Mechanism Cover... 8 Vibration Damper W Water Lines Water Pump Water Temperature Regulator G Gear Group (Front)... 26

36 Copyright Perkins Engines Company Limited All Rights Reserved Printed in U.K.

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