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KENR6239

June 2007

Specifications
800D Industrial Engine
UK (Engine)
UL (Engine)

This document has been printed from SPI². Not for Resale
Important Safety Information
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 or Perkins distributors have the most current information available.

When replacement parts are required for this


product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.

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KENR6239 3
Table of Contents

Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 4
Fuel Injection Pump ............................................. 4
Fuel Injectors ....................................................... 5
Lifter Group ........................................................... 6
Fuel Transfer Pump ............................................. 6
Rocker Shaft ........................................................ 7
Valve Mechanism Cover ...................................... 7
Cylinder Head Valves ........................................... 8
Cylinder Head ...................................................... 9
Exhaust Manifold ................................................. 9
Camshaft ............................................................. 10
Engine Oil Relief Valve ........................................ 11
Engine Oil Pump .................................................. 11
Engine Oil Pressure ............................................. 12
Engine Oil Bypass Valve ...................................... 13
Engine Oil Pan ..................................................... 13
Water Temperature Regulator .............................. 14
Cylinder Block ...................................................... 14
Crankshaft ........................................................... 16
Crankshaft Seals ................................................. 17
Connecting Rod Bearing Journal ......................... 17
Main Bearing Journal ............................................ 17
Connecting Rod ................................................... 18
Piston and Rings .................................................. 18
Front Housing and Covers ................................... 20
Gear Group (Front) ............................................... 21
Flywheel ............................................................... 21
Crankshaft Pulley ................................................. 22
Belt Tension Chart ............................................... 22
Alternator and Regulator ...................................... 23
Electric Starting Motor ......................................... 23
Glow Plugs ........................................................... 24

Index Section
Index ..................................................................... 25

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4 KENR6239
Specifications Section

Specifications Section Fuel injection timing (62 kW) ......................... 6° BTC

When the crankshaft is viewed from the flywheel end


i02699078 of the engine, the crankshaft rotates in the following
direction: ....................................... Counterclockwise
Engine Design
When the camshaft is viewed from the flywheel end
of the engine, the camshaft rotates in the following
direction: ....................................... Counterclockwise

Note: The left side and the right side of the engine
are viewed from the flywheel end. The No. 1 cylinder
is the front cylinder.

i01891782

Fuel Injection Lines

g01016767
Illustration 1
Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve

Bore ............................................. 94 mm (3.70 inch)

Stroke ........................................ 120 mm (4.72 inch)

Displacement ...................................... 3.3 L (203 in3)

Cylinder arrangement ..................................... In-line

Type of combustion
Naturally aspirated engines ...... Indirect injection
Turbocharged engines ................. Direct injection

Compression ratio Illustration 2


g00993243

Naturally aspirated engines ......................... 22:1


(1) Tighten the nuts for the fuel injection lines to the
Turbocharged engines (55 kW) ................ 20.5:1
following torque. ..... 27 to 32 N·m (20 to 24 lb ft)
Turbocharged engines (62 kW) ................ 19.5:1

Number of cylinders ................................................ 4 i02723707

Valves per cylinder .................................................. 2 Fuel Injection Pump


Valve lash
Inlet valve ....................... 0.25 mm (0.0098 inch)
Exhaust valve ................. 0.25 mm (0.0098 inch) Note: The engine is equipped with an axial piston
distributor injection pump that is mechanically
Firing order ................................................. 1, 3, 4, 2 governed. Parts that are inside of the fuel injection
pump are only serviceable by an authorized dealer.
Fuel injection timing (55 kW) ......................... 3° BTC

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KENR6239 5
Specifications Section

i02506427

Fuel Injectors

Naturally Aspirated Engines

g01366244
Illustration 3
Typical example

(1) Tighten the overflow valve for the fuel injection


pump to the following torque. ......... 15 to 20 N·m
(11 to 15 lb ft)

(2) Screw for adjusting the full load setting


g01010241
(3) Tighten the nut for the fuel injection pump gear Illustration 4
to the following torque.
(1) Tighten the body in the retaining nut to the
Naturally aspirated engines ............ 59 to 69 N·m following torque. ..... 34 to 39 N·m (25 to 29 lb ft)
(43 to 51 lb ft)
Turbocharged engines .................... 83 to 98 N·m Note: The fuel injector should only be disassembled
(62 to 72 lb ft) and assembled by personnel with the proper training.
(4) Fuel shutoff solenoid (2) Tighten the fuel injector in the engine to the
following torque. ..... 53 to 65 N·m (39 to 48 lb ft)
(5) Bolt for attaching to the gear case cover
Type of fuel injector ............................... single orifice
(6) Delivery valves for the fuel
Injection pressure
Standard at assembly .......... 11.77 to 12.75 MPa
(1707 to 1849 psi)

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6 KENR6239
Specifications Section

Turbocharged Engines i01900860

Lifter Group

g00988934
Illustration 6
g00993511
Illustration 5
Clearance between the lifter and the bore in the
(1) Tighten the retaining nut to the following engine for the lifter
torque. .................... 25 to 34 N·m (18 to 25 lb ft) Standard at assembly ........... 0.016 to 0.052 mm
(0.0006 to 0.0020 inch)
Note: The fuel injector should only be disassembled Repair limit ...................... 0.08 mm (0.0031 inch)
and assembled by personnel with the proper training.

Tighten the clamp bolt that secures the fuel i02697359


injector in the cylinder head to the following
torque. ........................... 21 to 23 N·m (15 to 17 lb ft) Fuel Transfer Pump
Type of fuel injector ............................ multiple orifice

Injection pressure
Standard at assembly .......... 18.14 to 19.12 MPa
(2631 to 2773 psi)

g01353240
Illustration 7
Typical example

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KENR6239 7
Specifications Section

(1) Fuel transfer pump

(2) Torque for one fitting ... 6 to 8 N·m (53 to 71 lb in)

(3) Fuel filter/water separator

i02509351

Rocker Shaft

Table 1
g01256133
Illustration 9
Required Tools
Part (5) Pushrods
Tool Number Part Description Qty
Place the pushrod in Tooling (B). Use Tooling (A)
A 21825617 Dial Indicator Group 1
in order to check all pushrods for runout. Replace
B - V Block 2 the pushrod if the runout exceeds the following
value. ..................................... 0.30 mm (0.0118 inch)

i01892068

Valve Mechanism Cover

g00984738
Illustration 8

(1) Rocker shaft


Diameter of the rocker
shaft .................................. 18.980 to 19.000 mm
(0.7472 to 0.7480 inch)

(2) Rocker arm


g00984870
Illustration 10
Inside diameter of the rocker arm
bushings ........................... 19.010 to 19.030 mm (1) Tighten the bolts for the valve mechanism cover
(0.7484 to 0.7492 inch) to the following torque. ................... 10 to 13 N·m
Clearance between the rocker arm bushing and (7 to 10 lb ft)
the rocker shaft ..................... 0.010 to 0.050 mm
(0.0004 to 0.0020 inch)
Maximum permissible clearance between
the rocker arm bushing and the rocker
shaft .............................. 0.070 mm (0.0028 inch)

(3) Spring

(4) Tighten the bolts evenly. Tighten the long


bolt first. Tighten the bolts to the following
torque. ...................... 10 to 20 N·m (7 to 15 lb ft)

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8 KENR6239
Specifications Section

i01892207 Clearance of the exhaust valve stem in the


exhaust valve guide ............... 0.080 to 0.115 mm
Cylinder Head Valves (0.0031 to 0.0045 inch)
Maximum allowable clearance of the exhaust
valve stem in the exhaust valve guide .. 0.200 mm
(0.0079 inch)

Valve depth of the exhaust valve below the cylinder


head face
Standard at assembly ................... 0.4 to 0.6 mm
(0.016 to 0.024 inch)
Service limit ........................ 1.0 mm (0.039 inch)

(5) Inlet valve


Diameter of the inlet valve
stem ...................................... 7.940 to 7.955 mm
(0.3126 to 0.3132 inch)
Service limit diameter of the inlet valve
stem ............................... 7.900 mm (0.3110 inch)
Clearance of the inlet valve stem in the inlet valve
guide ..................................... 0.065 to 0.095 mm
(0.0026 to 0.0037 inch)
Maximum allowable clearance of the inlet valve
stem in the inlet valve guide ............... 0.150 mm
(0.0059 inch)

Valve depth of the inlet valve below the cylinder head


face
Standard at assembly ................... 0.3 to 0.5 mm
g01010358 (0.012 to 0.020 inch)
Illustration 11
Service limit ........................ 1.0 mm (0.039 inch)
(1) Valve spring
(6) Angle of the exhaust valve face from the
Free length of the valve springs ......... 48.85 mm horizontal axis
(1.92 inch)
Valve face angle ............................... 30 degrees
Service limit for free length of the valve
Valve seat angle ............................... 30 degrees
springs .............................. 47.60 mm (1.87 inch)
Length of the valve springs under set
(7) Angle of the inlet valve face from the horizontal
force ....................................... 43 mm (1.69 inch)
axis
Set force of the valve springs ......... 176 to 196 N
(40 to 44 lb) Valve face angle ............................... 30 degrees
Service limit for set force of the valve Valve seat angle ............................... 30 degrees
springs ........................................... 147 N (33 lb)

(2) Valve spring recess

(3) Valve guides


Projection of the valve guide above the valve
spring recess ... 14 ± 0.1 mm (0.55 ± 0.004 inch)

(4) Exhaust valve


Diameter of the exhaust valve
stem ...................................... 7.920 to 7.940 mm
(0.3118 to 0.3126 inch)
Service limit diameter of the exhaust valve
stem .............................. 7.850 mm (0.3091 inch)

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KENR6239 9
Specifications Section

g00985069 g00984909
Illustration 12 Illustration 14
Bore in the cylinder head for the valve seats
The permissible distortion of the cylinder head is
Bore for the inlet valve seat given below.

A ....................................................... 45 degrees Maximum at assembly .... 0.05 mm (0.0020 inch)


B ....... 46 to 46.0025 mm (1.8110 to 1.8111 inch) Repair limit ...................... 0.20 mm (0.0079 inch)
C ...................... 2 ± 0.1 mm (0.079 ± 0.004 inch)
D ...................... 8 ± 0.1 mm (0.315 ± 0.004 inch)
i02697374

Bore for the exhaust valve seat Exhaust Manifold


A ....................................................... 45 degrees
B .......... 37 to 37.0025 mm (1.457 to 1.458 inch)
C ...................... 2 ± 0.1 mm (0.079 ± 0.004 inch)
D ...................... 8 ± 0.1 mm (0.315 ± 0.004 inch)

i01892090

Cylinder Head

g00985166
Illustration 15

(1) Bolt

Tighten the exhaust manifold bolts to the following


torque.
Naturally aspirated engines ............ 28 to 33 N·m
(21 to 24 lb ft)
Illustration 13
g00984896 Turbocharged engines .................... 28 to 33 N·m
(21 to 24 lb ft)
Tighten the cylinder head bolts in the sequence that
is shown to the following torque. ....... 113 to 123 N·m Maximum warpage of the flange for the exhaust
(83 to 91 lb ft) manifold .................................. 0.20 mm (0.008 inch)

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10 KENR6239
Specifications Section

i02697692

Camshaft

g00988290 g01353497
Illustration 16 Illustration 17
Typical example
(1) End play of a new camshaft ...... 0.10 ± 0.25 mm
(0.0039 ± 0.0098 inch) (A) Camshaft lobe lift
Maximum permissible end play of a worn Naturally aspirated engines
camshaft ................................ 0.30 mm (0.0118 inch) Inlet lobe ....................... 6.722 mm (0.2646 inch)
Exhaust lobe ................. 6.720 mm (0.2645 inch)
(2) Tighten the thrust plate bolts to the following
torque. ...................... 10 to 13 N·m (7 to 10 lb ft) Turbocharged engines
Inlet lobe ....................... 6.682 mm (0.2631 inch)
(3) The diameters of the camshaft journals are given Exhaust lobe ................. 6.722 mm (0.2646 inch)
in the following table.

Table 2
The service limit for camshaft lobe lift is given below:

Diameters of Camshaft Journals Naturally aspirated engines


Camshaft Standard Service Limit Inlet lobe ....................... 6.222 mm (0.2450 inch)
Journals Diameter Exhaust lobe ................. 6.220 mm (0.2449 inch)
No. 1,2 53.94 to 53.96 53.90 mm Turbocharged engines
mm (2.123 to (2.122 inch)
2.124 inch) Inlet lobe ....................... 6.182 mm (0.2434 inch)
Exhaust lobe ................. 6.222 mm (0.2450 inch)
No. 3 52.94 to 52.96 52.90 mm
mm (2.084 to (2.083 inch) (B) Camshaft lobe height
2.085 inch)
(C) Base circle

(D) Lift for second camshaft lobe


Inlet valve for turbocharged engines
55 kW ........................... 0.923 mm (0.0363 inch)
62 kW ........................... 1.108 mm (0.0436 inch)

To determine the lobe lift, use the procedure that


follows:

1. Measure the camshaft lobe height (B).

2. Measure the base circle (C).

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KENR6239 11
Specifications Section

3. Subtract the base circle that is found in Step 2 i02509468


from the camshaft lobe height that is found in Step
1. The difference is the camshaft lobe lift. Engine Oil Pump
If the camshaft lobe lift is less than the service limit,
replace the camshaft.

Table 3
Required Tools
Part
Tool Number Part Description Qty
A - Feeler Gauge 1

Type ............................. Gear-driven differential rotor

Number of lobes
Inner rotor ......................................................... 4
Outer rotor ........................................................ 5
g01014070
Illustration 18

(4) Camshaft

Deflection over the full length of the camshaft


Maximum at assembly .... 0.02 mm (0.0008 inch)
Repair limit ...................... 0.05 mm (0.0020 inch)

i01893227

Engine Oil Relief Valve

g01256201
Illustration 20

(1) Clearance between the outer rotor and the body


Standard ................................... 0.20 to 0.30 mm
(0.0079 to 0.0118 inch)
Service limit .................... 0.50 mm (0.0197 inch)

g00987876
Illustration 19

(1) Tighten the engine oil relief valve to the following


torque. .................... 44 to 54 N·m (33 to 40 lb ft)

Opening pressure of engine oil relief


valve ................................. 350 ± 50 kPa (50 ± 7 psi)

Note: The engine oil relief valve is located on the left


side of the cylinder block.

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12 KENR6239
Specifications Section

g00996150
Illustration 23

(4) Diameter of main shaft (near


body) ................................. 15.985 to 16.000 mm
(0.6293 to 0.6299 inch)

g01256201 Clearance between the main shaft and the body


Illustration 21
Standard ............................... 0.032 to 0.074 mm
(2) Clearance between the outer rotor and the inner (0.0013 to 0.0029 inch)
rotor Service limit .................... 0.15 mm (0.0059 inch)
Standard ................................... 0.13 to 0.15 mm (5) Diameter of main shaft (near
(0.0051 to 0.0059 inch) bushing) ............................ 13.957 to 13.975 mm
Service limit .................... 0.20 mm (0.0079 inch) (0.5495 to 0.5502 inch)

Clearance between the main shaft and the bushing


Standard ................................ 0.025 to 0.111 mm
(0.0010 to 0.0044 inch)
Service limit .................. 0.200 mm (0.0079 inch)

i02502471

Engine Oil Pressure

Table 4

Oil Pressure(1)
Oil Pressure at 1500 rpm 262 ± 48 kPa (38 ± 7 psi)
Oil pressure at idle 200 ± 48 kPa (29 ± 7 psi)
(1) The oil temperature must be 70 ° to 90 °C (158 ° to 194 °F).
g01256204
Illustration 22
The minimum acceptable oil pressure at low
(3) Clearance between the rotors and the body idle .................................................. 152 kPa (22 psi)
Standard ................................... 0.04 to 0.09 mm
(0.0016 to 0.0035 inch)
Service limit .................... 0.15 mm (0.0059 inch)

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KENR6239 13
Specifications Section

i01935709

Engine Oil Bypass Valve

g01256709
Illustration 25

Apply tooling (A) or Tooling (B) to the flange of the oil


pan. Refer to illustration 26.

g00987878
Illustration 24

Engine oil bypass valve


Tighten the engine oil bypass valve to the
following torque. ..... 64 to 74 N·m (47 to 55 lb ft)
Opening pressure of engine oil bypass
valve ....................................... 1.1 MPa (160 psi)

Note: The engine oil bypass valve is mounted on


the inside of the engine oil pan along the left side
oil pan rail.

i02509965

Engine Oil Pan


g01020644
Illustration 26

Table 5
Note: Apply Tooling (C) in order to reuse the bolts
for the oil pan. Apply Tooling (C) to the first 13 mm
Required Tools (0.5118 inch) of the thread.
Part
Tool Number Part Description Qty (1) Tighten the oil pan bolts to the following
torque. ...................... 10 to 13 N·m (7 to 10 lb ft)
21826038 POWERPART Silicone
A 1
Sealant
21826051 POWERPART Sealing
B 1
Compound
21820117 POWERPART Threadlock
C 1
and Nutlock

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14 KENR6239
Specifications Section

i02699076

Cylinder Block

Table 6
Required Tools
Part
Tool Number Part Description Qty
21826038 POWERPART Silicone
A 1
Sealant
g01256710
Illustration 27 21826051 POWERPART Sealing
B 1
Compound
(2) Tighten the oil pan drain plug to the following
torque. .................... 34 to 44 N·m (25 to 33 lb ft) 27610013 POWERPART Rubber
C 1
Plug Replacer

i01893737

Water Temperature Regulator

g00987933
g00877006 Illustration 29
Illustration 28

The water temperature regulator starts to open at the (1) Cylinder bore
following temperature. .... 82° ± 1.5°C (180° ± 2.7°F)

The water temperature regulator has a lift of


more than 8 mm (0.3 inch) at the following
temperature. ...................................... 95 °C (203 °F)

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KENR6239 15
Specifications Section

Table 7 Tighten the main bearing cap bolts to the following


Tolerances of Cylinder Bores
torque. .................... 98 to 108 N·m (72 to 80 lb ft)

Internal Out of Taper


Diameter Round
Standard at 94.000 to 0.010 mm 0.015 mm
Assembly 94.035 mm (0.0004 (0.0006
(3.7008 to inch) inch)
3.7022 inch)
Repair Limit 94.200 mm N/A N/A
(3.7087
inch)
1st 94.250 to 0.010 mm 0.015 mm
Standard 94.285 mm (0.0004 (0.0006
Oversize (3.7106 to inch) inch)
+0.25 mm 3.7120 inch)
(0.001 inch) g01007113
Illustration 30
Repair Limit 94.450 mm N/A N/A
(3.7185 (3) Rear main bearing cap
inch)
2nd 94.500 to 0.010 mm 0.015 mm (4) Main bearing caps should have a marking that
Standard 94.535 mm (0.0004 (0.0006 indicates placement and orientation.
Oversize (3.7205 to inch) inch)
+0.50 mm 3.7218 inch) (5) Front main bearing cap
(0.02 inch)
Service 94.700 mm N/A N/A
Limit (3.7283
inch)

Bore the cylinder to the oversize dimension if the


cylinder has uneven wear. Refer to Table 7.

The permissible distortion of the contact surface of


the gasket is given below.
Maximum at assembly .... 0.05 mm (0.0020 inch)
Repair limit ...................... 0.20 mm (0.0079 inch)

(2) Main bearing cap bolts

Use the following procedure in order to install the


main bearing cap bolts:

1. Apply engine oil to the bearings and install the


bearings to the caps.
g01007117
Illustration 31
Note: Apply a small amount of Tooling (A) or Tooling
(B) to the corners of the cylinder block for the rear (6) Seal for the front and rear main bearing caps.
main bearing cap. After the rear main bearing cap is
installed, remove any excess sealant from the inside (7) The seals for the front and the rear main bearing
of the recess for the rear oil seal. Excess sealant caps have a curve at one end. The curved side
prevents the correct seating of the rear oil seal. must be installed toward the side of the engine.
The curved end is inserted first into the hole.
2. Install the cap to the crankcase so that the rear
face of the cap is even with the rear face of the Note: Use Tooling (C) in order to install the seal
crankcase. correctly.

3. Apply clean engine oil to the threads of the main (8) Before installing the seals, inject a small quantity
bearing cap bolts. of Tooling (A) or Tooling (B) in the holes for the
seals.

This document has been printed from SPI². Not for Resale
16 KENR6239
Specifications Section

Standard at assembly ........... 0.100 to 0.264 mm


(0.0039 to 0.0104 inch)
Repair limit ..................... 0.300 mm (0.0118 inch)

Crankshaft deflection
Maximum at assembly .... 0.02 mm (0.0008 inch)
Repair limit ...................... 0.05 mm (0.0020 inch)

Clearance between crankshaft bearing and


crankshaft journal
Standard at assembly ............ 0.050 to 0.110 mm
(0.0020 to 0.0043 inch)
Repair limit .................... 0.200 mm (0.0079 inch)

g01353554
Illustration 32

(9) Inside diameter of the lifter bore


Standard at assembly ....... 14.000 to 14.018 mm
(0.5512 to 0.5519 inch)
Service limit ................ 14.100 mm (0.5551 inch)

g00994009
i01894898 Illustration 34

Crankshaft (A) Original width of the rear crankshaft


journal ............................... 31.000 to 31.039 mm
(1.2205 to 1.2220 inch)

Table 8

Width of Crankshaft Journal for Oversize


Thrust Washers
Oversize Width Oversize Width
Oversize Thrust
for Front OR for Front AND
Washer
Rear Rear
31.150 to 31.189 31.300 to 31.339
0.15 mm
mm (1.2264 to mm (1.2323 to
(0.006 inch)
1.2279 inch) 1.2338 inch)
31.300 to 31.339 31.450 to 31.489
0.30 mm
mm (1.2323 to mm (1.2382 to
(0.012 inch)
1.2338 inch) 1.2397 inch)
31.450 to 31.489 31.600 to 31.639
0.45 mm
mm (1.2382 to mm (1.2441 to
(0.018 inch)
1.2397 inch) 1.2456 inch)

Refer to Specifications, “Connecting Rod Bearing


Journal” for information on the connecting rod bearing
journals.

Illustration 33
g00987940 Refer to Specifications, “Main Bearing Journal” for
information on the main bearing journals and the
(1) Crankshaft end play main bearings.

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KENR6239 17
Specifications Section

i02697791 the following value. ..................... 0.030 to 0.090 mm


(0.0012 to 0.0035 inch)
Crankshaft Seals
Service limit for clearance between a connecting
rod bearing and a connecting rod bearing
journal ................................. 0.200 mm (0.0079 inch)

i01907583

Main Bearing Journal

Table 10
Diameter of Crankshaft Journal (Bearing
Surface) For Main Bearings
77.955 to 77.970 mm
Original Size Journal(1)
(3.0691 to 3.0697 inch)
g01353567
Illustration 35 Undersize Journal 77.705 to 77.720 mm
Typical example 0.25 mm (0.010 inch) (3.0592 to 3.0598 inch)
Undersize Journal 77.455 to 77.470 mm
(1) Oil seal 0.50 mm (0.020 inch) (3.0494 to 3.0500 inch)
Undersize Journal 77.205 to 77.220 mm
(2) Oil seal sleeve
0.75 mm (0.030 inch)(2) (3.0396 to 3.0402 inch)
Inspect the contact surface between the oil seal and (1) Regrind the main bearing journals to the next undersize
the crankshaft for wear. If the crankshaft is worn, dimension if the repair limit of 77.850 mm (3.0650 inch) is
exceeded.
replace the oil seal with an oil seal and a sleeve (2) Service limit 77.100 mm (3.0354 inch)
assembly.
The clearance between a new main bearing
i01907581 and a new main bearing journal is the following
value. ..... 0.050 to 0.110 mm (0.0020 to 0.0043 inch)
Connecting Rod Bearing
Journal

Table 9
Diameter of Crankshaft Journal (Bearing Surface)
For Connecting Rod Bearings
57.955 to 57.970 mm
Original Size Journal(1)
(2.2817 to 2.2823 inch)
Undersize Journal 57.705 to 57.720 mm
0.25 mm (0.010 inch) (2.2718 to 2.2724 inch)
Undersize Journal 57.455 to 57.470 mm
0.50 mm (0.020 inch) (2.2620 to 2.2626 inch)
Undersize Journal 57.205 to 57.220 mm
0.75 mm (0.030 inch) (2.2522 to 2.2528 inch)
(1) Regrind the connecting rod bearing journals to the next
undersize dimension if the repair limit of 57.800 mm
(2.2756 inch) is exceeded.

The clearance between a new connecting rod


bearing and a new connecting rod bearing journal is

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18 KENR6239
Specifications Section

i02697820 i02699075

Connecting Rod Piston and Rings

Table 11
Required Tools
Part
Tool Number Part Description Qty
A - Feeler Gauge 1
B 21825617 Dial Indicator Group 1

g00987949
Illustration 36

Prior to assembly, apply engine oil to the bearing.

(1) Install the bearing cap to the connecting


rod and tighten the cap nuts to the following
torque. .................... 49 to 59 N·m (36 to 44 lb ft)

Inside diameter of the piston pin bearing


g00996359
Illustration 37
Nominal value ........................ 30 mm (1.18 inch)
Standard at assembly ....... 30.020 to 30.045 mm (1) Diameter of the piston pin
(1.1819 to 1.1829 inch)
Nominal value ........................ 30 mm (1.18 inch)
Clearance between the piston pin and the piston pin Standard at assembly ....... 29.994 to 30.000 mm
bearing (1.1809 to 1.1811 inch)
Standard at assembly ........... 0.020 to 0.051 mm Clearance between the piston pin and the bore
(0.0008 to 0.0020 inch)
Service limit .................. 0.120 mm (0.0047 inch) Standard at assembly ........... 0.000 to 0.016 mm
(0.0000 to 0.0006 inch)
End play of the connecting rod that is attached to the Service limit .................. 0.050 mm (0.0020 inch)
crankshaft.
Refer to table 12 for the outside diameters of the
Standard at assembly ............... 0.15 to 0.35 mm pistons.
(0.0059 to 0.0138 inch)
Service limit ...................... 0.50 mm (0.020 inch)

This document has been printed from SPI². Not for Resale
KENR6239 19
Specifications Section

Table 12
Standard at
Item Service Limit
Assembly
93.955 to 93.985
93.770 mm
Standard mm (3.6990 to
(3.6917 inch)
3.7002 inch)
0.25 mm 94.205 to 94.235
94.020 mm
(0.0098 inch) mm (3.7089 to
(3.7016 inch)
oversize 3.7100 inch)
0.50 mm 94.455 to 94.485
94.270 mm
(0.0197 inch) mm (3.7187 to
(3.7114 inch)
oversize 3.7199 inch)

Maximum difference in weight of the piston per


engine ........................................ 0.005 kg (0.0110 lb)

g01256909
Illustration 39

Use Tooling (A) in order to measure the clearance


between the piston groove and a new piston ring.
No. 1 ring
Standard at assembly ........... 0.036 to 0.076 mm
(0.0014 to 0.0030 inch)
Repair limit .................... 0.150 mm (0.0059 inch)
No. 2 ring
Standard at assembly ........... 0.045 to 0.085 mm
(0.0018 to 0.0033 inch)
Repair limit .................... 0.150 mm (0.0059 inch)
Oil ring
g01256908
Standard at assembly ........... 0.025 to 0.065 mm
Illustration 38 (0.0010 to 0.0026 inch)
Repair limit .................... 0.150 mm (0.0059 inch)
Use Tooling (A) in order to measure the piston ring
end gap.
Standard at assembly ............... 0.30 to 0.50 mm
(0.0118 to 0.0197 inch)
Service limit .................... 1.50 mm (0.0591 inch)

g01256910
Illustration 40

Use Tooling (B) in order to measure the protrusion of


the piston (2).

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20 KENR6239
Specifications Section

Standard at Assembly (11) End gap of oil ring


Naturally aspirated engines .... −0.25 to 0.15 mm
(−0.0098 to 0.0059 inch) Apply engine oil to the piston rings. Refer to
Turbocharged engines .............. 0.05 to 0.45 mm Illustration 42 for the assembled configuration of the
(0.0020 to 0.0177 inch) ends of the piston rings.

Compressed thickness of cylinder head Note: Install the piston with the “O” mark toward the
gasket ................. 1.2 ± 0.05 mm (0.05 ± 0.002 inch) front of the engine.

i02506518

Front Housing and Covers

g00987977
Illustration 41

(3) Piston from naturally aspirated engines

(4) Piston from turbocharged engines

(5) “WEIGHT” mark


g00987995
Illustration 43
(6) “MATCHING” mark

Note: Assemble the piston and the connecting rod (1) Tighten the bolts that fasten the front
with the “WEIGHT” mark on the piston and with the plate to the cylinder block to the following
“MATCHING” mark on the rod on the same side. torque. ...................... 10 to 13 N·m (7 to 10 lb ft)

(2) Remove the excess gasket with a cutter.

g00987981
Illustration 42
g00987996
(7) Camshaft side Illustration 44

(8) End gap of No. 1 compression ring (3) Tighten the bolts that fasten the timing
gear case to the front plate to the following
(9) End gap of No. 2 compression ring torque. .................... 17 to 20 N·m (12 to 15 lb ft)

(10) Side with the inlet valve

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KENR6239 21
Specifications Section

i01896267 (7) Tighten the jam nut for the oil pump gear to the
following torque. ..... 28 to 38 N·m (21 to 28 lb ft)
Gear Group (Front)
Backlash for all gears
Standard at assembly ............... 0.03 to 0.18 mm
(0.0012 to 0.0071 inch)
Service Limit ................... 0.25 mm (0.0098 inch)

i01896629

Flywheel

Flatness of friction surface of the flywheel


Maximum at assembly .... 0.15 mm (0.0059 inch)
Repair limit ........................ 0.50 mm (0.020 inch)

Face and bore runout’s of flywheel


Maximum at assembly .... 0.15 mm (0.0059 inch)
Repair limit ........................ 0.50 mm (0.020 inch)

g00988013
Illustration 45

(1) Camshaft gear

(2) Idler gear


End play of idler gear
Standard at assembly ............... 0.05 to 0.20 mm
(0.0020 to 0.0079 inch)
Service limit .................... 0.35 mm (0.0138 inch)

Clearance between idler gear bushing and shaft


g00988073
Illustration 46
Standard at assembly ........... 0.009 to 0.050 mm
(0.0004 to 0.0020 inch)
Service limit .................. 0.100 mm (0.0039 inch) (1) Tighten the bolts for the flywheel to the following
torque. .................... 79 to 88 N·m (58 to 65 lb ft)
(3) Fuel Injection pump gear
Tighten the bolts for the fuel injection pump gear
to the following torque.
Naturally aspirated engines ............ 59 to 69 N·m
(43 to 51 lb ft)
Turbocharged engines .................... 83 to 98 N·m
(62 to 72 lb ft)

(4) Crankshaft gear

(5) Oil pump gear

(6) Tighten the thrust plate bolts for the idler gear to
the following torque. ....................... 29 to 39 N·m
(21 to 29 lb ft)

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22 KENR6239
Specifications Section

i02510696

Crankshaft Pulley

Table 13
Required Tools
Part
Tool Number Part Description Qty
g00988022
Illustration 48
21826038 POWERPART Silicone
A 1
Sealant
(3) Maximum depth for the top of the V-belt in the
groove ................................... 1.6 mm (0.06 inch)

i02506524

Belt Tension Chart

Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.

g00988100
Illustration 47

Note: Apply Tooling (A) to the threads of the


crankshaft before the pulley nut is installed.

(1) Tighten the nut that fastens the crankshaft


pulley to the crankshaft to the following
torque. ............ 480 to 500 N·m (354 to 369 lb ft)

(2) Crankshaft pulley

This document has been printed from SPI². Not for Resale
KENR6239 23
Specifications Section

Table 14
Belt Tension Chart
Belt Type Deflection Applied Force for Specified Deflection
Type B 10 to 12 mm (0.4 to 0.6 inch) 98 N (22 lb)

i02535554 i02506531

Alternator and Regulator Electric Starting Motor

Note: Apply a suitable Load to the battery in order to


get the maximum alternator output.

g01024163
Illustration 50
The starting motor

(1) Electric starting motor

(2) Tighten the nut on the starting motor terminal to


the following torque. ....................... 18 to 25 N·m
(13.3 to 18.4 lb ft)

g01268996 (3) Tighten the starting motor terminal to the following


Illustration 49
torque. .......................................... 2.6 to 4.6 N·m
(23.0119 to 40.7134 lb in)
(1) Alternator and regulator
Voltage ...................................................... 13.5 V No load conditions at 25 °C (77 °F)

Output current at 1500 rpm ..... 20 amp or higher Speed .................................. 3000 rpm minimum
Current draw ......................... 200 amp maximum
Output current at 3000 rpm ..... 50 amp or higher Voltage ......................................................... 11 V
Output current at 5000 rpm ..... 60 amp or higher When the electric starting motor is viewed from
the drive end, the motor rotates in the following
Adjusting voltage of the regulator at 5000 rpm with a direction. ................................................... Clockwise
load of 5 amp or lower .................... 14.2 V to 14.8 V

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24 KENR6239
Specifications Section

i02699074 Type ............................................................... 12 Volt


Glow Plugs Current (30 second rating) .................... 5.5 amperes

Naturally Aspirated Engines

g00988137
Illustration 51

(1) Tighten the glow plugs in the cylinder head to the


following torque. ...... 15 to 20 N·m (11 to 15 lb ft)

Type ............................................................... 12 Volt

Current (30 second rating) .................... 9.7 amperes

Turbocharged Engines

g01353859
Illustration 52

(1) Tighten the glow plugs in the cylinder head to the


following torque. ..... 20 to 30 N·m (15 to 22 lb ft)

This document has been printed from SPI². Not for Resale
KENR6239 25
Index Section

Index
A L

Alternator and Regulator ....................................... 23 Lifter Group............................................................ 6

B M

Belt Tension Chart ................................................. 22 Main Bearing Journal............................................. 17

C P

Camshaft ............................................................... 10 Piston and Rings ................................................... 18


Connecting Rod..................................................... 18
Connecting Rod Bearing Journal........................... 17
Crankshaft ............................................................ 16 R
Crankshaft Pulley .................................................. 22
Crankshaft Seals ................................................... 17 Rocker Shaft.......................................................... 7
Cylinder Block........................................................ 14
Cylinder Head........................................................ 9
Cylinder Head Valves ............................................ 8 S

Specifications Section ........................................... 4


E

Electric Starting Motor ........................................... 23 T


Engine Design ....................................................... 4
Engine Oil Bypass Valve ....................................... 13 Table of Contents................................................... 3
Engine Oil Pan....................................................... 13
Engine Oil Pressure............................................... 12
Engine Oil Pump.................................................... 11 V
Engine Oil Relief Valve .......................................... 11
Exhaust Manifold ................................................... 9 Valve Mechanism Cover........................................ 7

F W

Flywheel ................................................................ 21 Water Temperature Regulator ............................... 14


Front Housing and Covers..................................... 20
Fuel Injection Lines................................................ 4
Fuel Injection Pump............................................... 4
Fuel Injectors ......................................................... 5
Naturally Aspirated Engines............................... 5
Turbocharged Engines....................................... 6
Fuel Transfer Pump ............................................... 6

Gear Group (Front)................................................ 21


Glow Plugs ............................................................ 24
Naturally Aspirated Engines............................... 24
Turbocharged Engines....................................... 24

Important Safety Information ................................. 2

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26 KENR6239
Index Section

This document has been printed from SPI². Not for Resale
KENR6239 27
Index Section

This document has been printed from SPI². Not for Resale
©2007 Perkins Engines Company Limited
All Rights Reserved Printed in U. K.
This document has been printed from SPI². Not for Resale