Perkins 2000 Series WORKSHOP MANUAL 6 cylinder diesel engines for industrial applications Publisaton TPD 2245, love 2 (© Proprietary information of Perkins Group Limite, alright reserved “The nfamraton is comec' a he ime of pen Published in September 1999 by Technical Pubicaton, Perkins Engines Compary Linited, Lancaster Road Shrewsbury, Stropstire, SY1 3NX, England 1 This document has been printed from SPI?. Not for ResaleContents 10 General information Introduction New 2000 Serles engines Cylinder bore identification Engine identification General safety precautions Safety Engine lift equipment Asbestosjoints Dangers from used engine olls Environmertal protection Viton seals Practical information 11 Specifications Basic engine data Recommended specific applied torques Recommended nominal applied torques Perks Engnes Company Limted 1" 1" 1“ 12 13 14 1“ 14 18 18 15 16 19 24 This document has been printed from SPI’. Not for Resale12 Cylinder head assembly Rocker cover 12-4 To remove and tofit 25 Rockerassembly 12.2 To remove and tofit, 2 26 ‘Tappet clearances 123 To check and to adjust. - ar Cylinder head 12-4 To remove and tofit - 28 12-6 Procedure for retighiening of the cylinder head bolts. .- 31 124 To dismantle and to assemble 2 32 12-7 To clean and to inspect the cylinder head = 34 12-8 To renew a valve spring with the cylinder head installed 34 12-9 To comect a valve seat as 35 12-10 To remove a valve seat insert % 36 12-11 Tofita vale seat insert - 36 12-12 To inspect the valve cuides - 37 12-13 To renew a valve guide - 37 Valves, valve springs and valve rotators 12-14 To remove and to ft - 38 12-15 To clean and to inspect - 38 Fuel injector sleeves. 12-46 To remove and to ft - 39 Push rods 12-17 To remove and to ft 3 4 12-18 To inspect . a Fits and clearances - Rocker assemblies = 42 Fits and clearances - Cylinder heads and valve assemblies 43 13 Piston and connecting rod assembly General description 45 Piston and connecting rod assembly 19-1 To remove end tofit, - 47 13-2 To dismantle and to assemble - 49 OSes Engines Commariy iit This document has been printed from SPI’. Not for ResalePiston and rings 13.3 To inspect : -- 50 Connecting rod 13-4 To inspect 2 -- 50 ‘Small end bushes 13-8 To renew - - 51 Fits and clearances - -- 82 14 Crankshaft assembly General description - - 87 Damper and pulley - early engines, 14-1 To remove and to fit - - 58 Damper and pulley - new engines. 14-2 To remove and to tit as a) Crankshaft hub and front oil seal 14-3 To remove and to fit . -- 60 14-4 To fit a new oil seal io a wheelcase removed from the engine ~ 61 Rear il seal 14-8 To remove and to fit 2 =. 62 Crankshaft 14-6 To remove and to fit . 263 14-7 To inspect = 2.64 Fite and clearances. - 2 65 15 Wheelcase and drive assembly General description - -.67 Wheelcase 15-1 To romove and to fit - = 68 Backplate 15-2 To remove and to fit - - 68 Perks Engnes Company Limted 5 This document has been printed from SPI’. Not for ResaleCamshaft gear-bor-on ly pe 15-3 To remove and tofit, as n Camshaft gear- integral type 15-4 To remove and tofit, 7 72 15-6 To inspect = 73 Idler gear 1546 To remove and tofit 4 15-7 To setthe gear backlash . 75 Fits and clearances - 7 16 Cylinder block assembly General description - 79 Crankcase 418-1 To fit to andto remove frm a build stand 20 16-2 To cismantle and to assemble a1 16-3 To inspect 2 90 Cylinder liners 18-4 To remove and tofit - 1 4855 To lean and to inspect 92 Cam followers 18.6 To remove and tofit - 93 Camshaft 18-7 To remove end tofit- bolton type : 94 48-6 To remove and tofit- integral type : 95 18.9 To inspect 2 96 Fits and clearances : 97 17 Engine timing Valve timing 47-4 To check 99 Fuel injection pump timing 47-2 To chesk and to adjust. - 100 Sas Engines Company Lito This document has been printed from SPI’. Not for Resale18 Aspiration system General description - Aspiration system maintenance < Turbocharger 18-1 To remove and to tit - 18-2 How to check the waste-gate 2 ‘Turbochargers: 0E49342, 050642, OE51140, and OE51430 18-3 To dismantle and toassemble z 18-4 To clean and to inspect. = ‘Turbocharger: £50674 18-5 To dismantle and toassemble as 18-6 To clean and to inspect. 2 ‘Turbochargers: OE52534 and OE52535 18-7 To dismantle and toassemble - 188 To clean and to inspect. 2 Inlet manifold 18-9 To remove and to fit = Exhaust manifold 18-10 Toremove and to fit . 19 Lubrication system General description - Lubricating oil fiter 19-4 To renew the canister “ By-pass filteriseparator 19.2 To renew the canisters ‘Sump 19.3 To remove and to fit 2 Sump drain plugs - Lubricating oll pump. 19-4 To remove and to fit 3 19-6 To cismantle and toassemble . 19-46 To inspect - Perks Engnes Company Limted 103 103 105 105 106 409 mM 112 114 115 115 120 421 422 428 124 128, 125 This document has been printed from SPI’. Not for Resale‘Oipressure relief valve 19-7 To cismantle and to assemble 126 198 To inspect = 126 20 Fuel system General description - 128 Overhaul instructions = 128 Fuel injectors, 20-1 To remove and tofit z 129 20-2 To cismantle and to assemble z 131 20-3 To clean and to inspect 2 131 20-4 To setand to test a 133 Fuel it pumps - 135 Single acting type 20-5 To remove and tofit - 135 20-6 To cismantle and to assemble - 135 Doubleacting type 20-7 To remove and tofit - 136 20-8 To cismantle and to assemble - 136 20-9 To test - 137 Fuel injection pump 20-10 To remove and to ft - 1368 20-11 How to eliminate air from the fuel system - 141 Ake stop cylinder 20-12 How to set the air-operated stop cylinder - 142 21 Cooling system General description . 143 Radiator 21-1 To remove and tofit - 16 Fan 21-2 To remove and tofit - 7 = ss Engines Comma Lito This document has been printed from SPI’. Not for ResaleFan drive belts 21-3 How to check the fan belts : 148 21-4 How to agjust the tension ofthe fan bets «> 148 Cootant pump 21-8 To remove and tofit : --149 21-8 To cismantle and toassemble : “180 21-7 To inspect 3 2183 Thermostat 21-8 How tocheck the operating temperatures... --154 21-8 How to check the operating speed 2 2185 Oil cooler 21-10 Todismante and to asserrble 156 21-11 Toinspect - -187 22 Flywheel and flywheel housing General description . -.189 Flywheel 22-1 To remove and to fit as 161 22-2 To inspect 2 2161 Flywheel housing 22-3 To remove and to fit - ~162 23 Electrical equipment General description 2 168 Alternator drive belts 23-1 To check and b adjust the tension 7 2165 Alternator 23-2 To remove and to fit as = 166 ‘Starter motor . -167 23-3 To remove and to fit . -167 23-4 To cismantle and toassembie the solenoid switch 2167 23-5 To cismantle and toassemble the starter motor .. 2169 23-6 To clean = can 23-7 To inspect and to correct. 2 cama 23-8 Totest 2 Lara 23-8 To fit the mein starter cables = L172 Perks Engnes Company Limted 3 This document has been printed from SPI’. Not for ResaleEnghe stop solenoid 23-10 How to adjust the linkage - 173 24 Auxiliary equipment Compressor 24-4 To remove and tofit 175 24-2 Compressor gear alignment W7 25 Running-in and test General description : 179 Running-in and test, 25-1 To run the engine = 180 25-2 To check the consumption rate of the engine lubricating ol 181 26 List of special tools ‘Special tools “ 184 os gins Company Lito This document has been printed from SPI’. Not for Resale10 General information Introduction ‘This workshop manual has boon designed toprovico ‘assistance in the servce andthe ovemau of 2000 Series engines. Most ofthe genera infomation, \which is ncludedin the Users Handbook (sections 1 108), nasinat been epeatod in mis Workstop Manual _and ihe tno publications should beused logathe. Read the Safely precautons’ and rember tham, ‘They are given for your protection and must be ‘appted a all tines. ‘To ensue that you use the comect information for your speciic egina ype, reer to Engine identitoaion’ on page 12 Dangers indicated in the text by two methods: Warning! This indicates that there isa possible ‘danger othe person. Caution: This indicates tha! thre is» possible danger to the engine. Note: e used whore the nfermationisimporant, but there snot a danger New 2000 Series engines ‘A oumber of specication changes were made to ‘engines produced after July 996. Thechanges.vere introduced on generator set engines fom the Totowang engine specticatio numbers: 20067 1A ssc080223 20067628 scHo50224 2on6Twa2 ‘SGK050225 2006TAG2 ‘S@B050228 20067TAG 8060227 “Those engines can be identi by the type of sum fited. Engines manufactured tothelater specication are fied wih a sump made ftom aconpostie ‘materal. The sumps eater engines aremadefrom ‘auminin, ‘The specification changes were not applied to industial engines unt August 1998 (specication number: SP20e0427) and then to only cera engines. Additonal, industial engines may be ‘manuiacturedte the now apecifeation but retain tho Bar Engines Company Liitod This document has been printed from SPI’. Not for Resale14 Induction/exhaust system Aspiration 2006 TTAG. Pressure charged by twin turbochargers: OF50042 and OESOO74 ‘Omer 2000 sere, Pressure charged by 2 single tubocharger 0649342, 050042, ‘OE61149, OES1420, OF52524 or OES2605 Al inlet doprossion mits (Clean fitor 254 mm (10 in) Wg, nominal Dity ter .559 mm (22in} Wa. maximum Air charge coolor 16 Not ited TA, TAG and TAG, Airtoairtyp, intagralwit radiator Tw We Aicto coolant type intagal with induction manifold Cald startalds ‘Optional- Stan Piot or Fleexguara Electrical equipment Atwrnator Belt ven unit, 24 vot, 40 amp Starter motor Single, 24 vt -flange- mounted Auxiliary equipment ‘Air compressor (if fited). Single or twin cylincer, flange mounted Perks Engnes Company Limted a This document has been printed from SPI’. Not for Resale14 Recommended specific applied torques Caution: Tho torque loads sted bolew apy to thas in an cil wot corstin, unoss the use of thread Jocking compounds recemmerded. Application ef atomue loed spesfication is NOT enough i ensure thatthe rlevant components ar renined ‘secur as an assamy.It is inpartant to cenfermalso te the recammarsatons fer assemby and, given, the sequencain which the bots or nuts must betightened. This infamation is givenin therelevant secion of this pubtication, If abot or nuts otained witha lockingwasher, lacking plete er eplipin the speciation for atomue load ean be exceeded, if necessary. bythe MINIMUM arrount thats needed for coect assembly, Alternator pulley nut Prestolite cave. cav7 Camshats ‘Thrusiplate settots/capsorews Drive gear setbots ‘Compresscr- single cylinder mode! Drive gear nut ‘Compressor - twin cylinder model Drive gear nut Connecting rods Big end bearing bolts and nuts Coolant pump Pulley retaining screws (lowmounted pump) Cylinderheads Inia igttering of at polis and nuts Intrredate tightening of allbots and nus Firal ighiennngat postions 1 0 23in black crcles ONLY Caution: ™e eriog dat wnichisiaenaea by the werd "O1L" stamped on its head foreary angines ‘and by arecoeein ts head for lator enginos, MUST bo fied at positon 2. The old andinew ciled botts are interchangeabb. Ceraineary engines have a ‘stud ited at postion 22 and require anut ard washer Rocker pedestal bolts Tappet sew lock nuts Rocker cover stud (apply Loctite 270 to thread before fiting to pedestal) Rocker cover nuts Fu injector sleeves 2 Ne wert 95 7 o 40 oo 65 se 40 6 45 178 19 200 to 280 14810184 2 160 2m 8 190 100 208 10 +40 degrees @ @ ® ©0960 06 ® 0, o, @ @ ‘© ‘e © eo ORO) a 30 4a 30 163 2 108 a a 2m Parkins Engines Company Lied This document has been printed from SPI’. Not for Resale14 Nev it Crankease Fret, cantre ard rar bearing capbots a 160 Intanedate bearing capbate 353 260 Lota batts for main besring cape 05 7 Crankshaft Hub retaining nut 9 70 Neto: If toque wrench snot avaiable, igionby hand and thenuse the specal 00, 21825 B07, 10 shen bya {ure to Tals Damper setts a » Exhaust manifolds Bats 4s a Frywnee! Frcton face bots "/ gen UNG a 6 Friction fae bots “inch UNF 45 3 Flywheel retaining bots 1m * Flywhea! using Baits, yahoo! novsing to rankeaso °s n Fronttiming gears Ider goa axle bot- New 2000 sores 300 20 Ider goa axe bts -earier engines i 45 Fol injoctors Cap exo, njector damp 108 e Cap ut nozzle 46 2 Fual injection pump Bats, punpto crarkease ar 3 Hub rut 163 120 Seiscous, FIP drive coar 45 3 Nut for high pressure fel pipes 25 8 Pinch bot of Eeonccnise actuator vee " e Luoricatng ot tors ‘Adapior set 6 45 sume Sump robining bots fall ypes af sum) 4 » Sump arin plug Naw 2000 sores only 6 45 Caution: Ono of fe diferent types of sump cain plug 15 ted. Rotor f Secton 19 © oruty no correct trque figure forthe dan pug of your angie. Turbochargers Veo band damp " 6 Perkins Engines Compary Limited 2 This document has been printed from SPI’. Not for Resale14 Recommended nominal applied torques \Whereinstructions are nct given forthe coracttrquato bo applet nuts and bolts, th gues which follow ‘should be used Bolt size Nm wert Ns. 6 45 Ne 9s 7 Na a wv Mio 6 wu m2 0 2 mia var o mie 198 “6 mie 2a 201 Meo 37 285 M2 526 388 Mos 9 483 4 Ba gins Company Liitod This document has been printed from SPI’. Not for Resale12 Cylinder head assembly Rocker cover To remove and to fit 124 Toremove 1 Remove tne tne cap nuts (A) fom ihe top of the 2. The cover and jointcan now be removed. Fo ‘ortain onginaa it may be nososcary te fist romave ‘hear citing between th turbocharger andthe inlat manila Tofit 1 Remove tne joint om the rocker cover and dean thetwo corresponding faces of he cover and oyindar head. 2 Fite naw into therockercover ang, ensuring that it is cerracty locate within the sits inthe cover, ‘secure ito the cover wth a suitable adhesive, Placa the coverinposton onthe head 3 Secure the cover withthe three cap nuts and check ‘that the pinthas not moved. Tighin the cap nuts ‘evenly toa torque of 11 Nm if). Do NOT overtgnten Perks Engnes Company Limted 25 This document has been printed from SPI’. Not for Resale12 Rocker assembly To remove andto fit 122 Toremove 1 Remove ine exter cover as previously described, 2 Unscrew tne bots (A1) which secur the rocker pedestals othe cyinder head 3 Remove te wcker asverrbly compete and ‘cavtulyiftcut he push eds. Ensure hatthetappets sain in postion in the crankcase, Tortt 41 Ensure thatthe ‘appets have rerained corectly positioned inthe crankcase andthe push ods, 2. Check thatthe lover ends ofthe push rods ae located inside the tapes, {3 Fit ne rocker assembly wth the tappet adusting ‘sciews seating in the upper end ofthe push rods, 4 Screwin be pouksial securing bolls and ughten ‘evenly, outwards fomthecentra toa torque cf41 Nm (owtn, 5 Check and adusithe tappet cloarancosaagiven on page 27. {6 Oncomphtion of tappet clearance adjustment, the rocker cavers. = Ba Engin Cominy Liitod This document has been printed from SPI’. Not for Resale