KENR6239

June 2007

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

This document has been printed from SPI. 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 premature failures, product damage, personal injury or
death.

This document has been printed from SPI. Not for Resale

KENR6239

3
Table of Contents

Table of Contents
Specifications Section
Engine Design .....................................................
Fuel Injection Lines ..............................................
Fuel Injection Pump .............................................
Fuel Injectors .......................................................
Lifter Group ...........................................................
Fuel Transfer Pump .............................................
Rocker Shaft ........................................................
Valve Mechanism Cover ......................................
Cylinder Head Valves ...........................................
Cylinder Head ......................................................
Exhaust Manifold .................................................
Camshaft .............................................................
Engine Oil Relief Valve ........................................
Engine Oil Pump ..................................................
Engine Oil Pressure .............................................
Engine Oil Bypass Valve ......................................
Engine Oil Pan .....................................................
Water Temperature Regulator ..............................
Cylinder Block ......................................................
Crankshaft ...........................................................
Crankshaft Seals .................................................
Connecting Rod Bearing Journal .........................
Main Bearing Journal ............................................
Connecting Rod ...................................................
Piston and Rings ..................................................
Front Housing and Covers ...................................
Gear Group (Front) ...............................................
Flywheel ...............................................................
Crankshaft Pulley .................................................
Belt Tension Chart ...............................................
Alternator and Regulator ......................................
Electric Starting Motor .........................................
Glow Plugs ...........................................................

4
4
4
5
6
6
7
7
8
9
9
10
11
11
12
13
13
14
14
16
17
17
17
18
18
20
21
21
22
22
23
23
24

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

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4
Specifications Section

KENR6239

Specifications Section

Fuel injection timing (62 kW) ......................... 6 BTC

i02699078

Engine Design

When the crankshaft is viewed from the flywheel end

of the engine, the crankshaft rotates in the following
direction: ....................................... Counterclockwise
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

Illustration 1

g01016767

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

Turbocharged engines (55 kW) ................ 20.5:1
Turbocharged engines (62 kW) ................ 19.5:1

(1) Tighten the nuts for the fuel injection lines to the
following torque. ..... 27 to 32 Nm (20 to 24 lb ft)

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)
Firing order ................................................. 1, 3, 4, 2

Note: The engine is equipped with an axial piston

distributor injection pump that is mechanically
governed. Parts that are inside of the fuel injection
pump are only serviceable by an authorized dealer.

Fuel injection timing (55 kW) ......................... 3 BTC

This document has been printed from SPI. Not for Resale

KENR6239

5
Specifications Section

i02506427

Fuel Injectors

Naturally Aspirated Engines

Illustration 3

g01366244

Typical example

(1) Tighten the overflow valve for the fuel injection

pump to the following torque. ......... 15 to 20 Nm
(11 to 15 lb ft)
(2) Screw for adjusting the full load setting
(3) Tighten the nut for the fuel injection pump gear
to the following torque.
Naturally aspirated engines ............ 59 to 69 Nm
(43 to 51 lb ft)
Turbocharged engines .................... 83 to 98 Nm
(62 to 72 lb ft)
(4) Fuel shutoff solenoid
(5) Bolt for attaching to the gear case cover
(6) Delivery valves for the fuel

Illustration 4

g01010241

(1) Tighten the body in the retaining nut to the

following torque. ..... 34 to 39 Nm (25 to 29 lb ft)
Note: The fuel injector should only be disassembled
and assembled by personnel with the proper training.
(2) Tighten the fuel injector in the engine to the
following torque. ..... 53 to 65 Nm (39 to 48 lb ft)
Type of fuel injector ............................... single orifice
Injection pressure
Standard at assembly .......... 11.77 to 12.75 MPa
(1707 to 1849 psi)

This document has been printed from SPI. Not for Resale

6
Specifications Section

KENR6239

Turbocharged Engines

i01900860

Lifter Group

Illustration 6
Illustration 5

g00988934

g00993511

(1) Tighten the retaining nut to the following

torque. .................... 25 to 34 Nm (18 to 25 lb ft)
Note: The fuel injector should only be disassembled
and assembled by personnel with the proper training.
Tighten the clamp bolt that secures the fuel
injector in the cylinder head to the following
torque. ........................... 21 to 23 Nm (15 to 17 lb ft)

Clearance between the lifter and the bore in the

engine for the lifter
Standard at assembly ........... 0.016 to 0.052 mm
(0.0006 to 0.0020 inch)
Repair limit ...................... 0.08 mm (0.0031 inch)
i02697359

Fuel Transfer Pump

Type of fuel injector ............................ multiple orifice

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

Illustration 7

g01353240

Typical example

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KENR6239

7
Specifications Section

(1) Fuel transfer pump

(2) Torque for one fitting ... 6 to 8 Nm (53 to 71 lb in)
(3) Fuel filter/water separator
i02509351

Rocker Shaft

Table 1

Illustration 9

Required Tools
Tool

Part
Number

21825617

g01256133

(5) Pushrods
Part Description

Qty

Dial Indicator Group

V Block

Place the pushrod in Tooling (B). Use Tooling (A)

in order to check all pushrods for runout. Replace
the pushrod if the runout exceeds the following
value. ..................................... 0.30 mm (0.0118 inch)
i01892068

Valve Mechanism Cover

Illustration 8

g00984738

(1) Rocker shaft

Diameter of the rocker
shaft .................................. 18.980 to 19.000 mm
(0.7472 to 0.7480 inch)
(2) Rocker arm
Inside diameter of the rocker arm
bushings ........................... 19.010 to 19.030 mm
(0.7484 to 0.7492 inch)
Clearance between the rocker arm bushing and
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)

Illustration 10

g00984870

(1) Tighten the bolts for the valve mechanism cover

to the following torque. ................... 10 to 13 Nm
(7 to 10 lb ft)

(3) Spring
(4) Tighten the bolts evenly. Tighten the long
bolt first. Tighten the bolts to the following
torque. ...................... 10 to 20 Nm (7 to 15 lb ft)

This document has been printed from SPI. Not for Resale

8
Specifications Section

KENR6239

i01892207

Cylinder Head Valves

Clearance of the exhaust valve stem in the

exhaust valve guide ............... 0.080 to 0.115 mm
(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

Illustration 11

g01010358

(1) Valve spring

Free length of the valve springs ......... 48.85 mm
(1.92 inch)
Service limit for free length of the valve
springs .............................. 47.60 mm (1.87 inch)
Length of the valve springs under set
force ....................................... 43 mm (1.69 inch)
Set force of the valve springs ......... 176 to 196 N
(40 to 44 lb)
Service limit for set force of the valve
springs ........................................... 147 N (33 lb)

Standard at assembly ................... 0.3 to 0.5 mm

(0.012 to 0.020 inch)
Service limit ........................ 1.0 mm (0.039 inch)
(6) Angle of the exhaust valve face from the
horizontal axis
Valve face angle ............................... 30 degrees
Valve seat angle ............................... 30 degrees
(7) Angle of the inlet valve face from the horizontal
axis
Valve face angle ............................... 30 degrees
Valve seat angle ............................... 30 degrees

(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)

This document has been printed from SPI. Not for Resale

KENR6239

Illustration 12

9
Specifications Section

g00985069

Bore in the cylinder head for the valve seats

....................................................... 45 degrees
....... 46 to 46.0025 mm (1.8110 to 1.8111 inch)
...................... 2 0.1 mm (0.079 0.004 inch)
...................... 8 0.1 mm (0.315 0.004 inch)

Maximum at assembly .... 0.05 mm (0.0020 inch)

Repair limit ...................... 0.20 mm (0.0079 inch)
i02697374

Exhaust Manifold

Bore for the exhaust valve seat

A
B
C
D

g00984909

The permissible distortion of the cylinder head is

given below.

Bore for the inlet valve seat

A
B
C
D

Illustration 14

....................................................... 45 degrees
.......... 37 to 37.0025 mm (1.457 to 1.458 inch)
...................... 2 0.1 mm (0.079 0.004 inch)
...................... 8 0.1 mm (0.315 0.004 inch)
i01892090

Cylinder Head

Illustration 15

g00985166

(1) Bolt
Tighten the exhaust manifold bolts to the following
torque.

Illustration 13

g00984896

Tighten the cylinder head bolts in the sequence that

is shown to the following torque. ....... 113 to 123 Nm
(83 to 91 lb ft)

Naturally aspirated engines ............ 28 to 33 Nm

(21 to 24 lb ft)
Turbocharged engines .................... 28 to 33 Nm
(21 to 24 lb ft)
Maximum warpage of the flange for the exhaust
manifold .................................. 0.20 mm (0.008 inch)

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10
Specifications Section

KENR6239

i02697692

Camshaft

g00988290

Illustration 16

(1) End play of a new camshaft ...... 0.10 0.25 mm

(0.0039 0.0098 inch)
Maximum permissible end play of a worn
camshaft ................................ 0.30 mm (0.0118 inch)
(2) Tighten the thrust plate bolts to the following
torque. ...................... 10 to 13 Nm (7 to 10 lb ft)
(3) The diameters of the camshaft journals are given
in the following table.

Illustration 17

g01353497

Typical example

(A) Camshaft lobe lift

Naturally aspirated engines
Inlet lobe ....................... 6.722 mm (0.2646 inch)
Exhaust lobe ................. 6.720 mm (0.2645 inch)
Turbocharged engines
Inlet lobe ....................... 6.682 mm (0.2631 inch)
Exhaust lobe ................. 6.722 mm (0.2646 inch)
The service limit for camshaft lobe lift is given below:

Table 2

Diameters of Camshaft Journals

Naturally aspirated engines

Camshaft
Journals

Standard
Diameter

Service Limit

Inlet lobe ....................... 6.222 mm (0.2450 inch)

Exhaust lobe ................. 6.220 mm (0.2449 inch)

No. 1,2

53.94 to 53.96
mm (2.123 to
2.124 inch)

53.90 mm
(2.122 inch)

Turbocharged engines

52.94 to 52.96
mm (2.084 to
2.085 inch)

52.90 mm
(2.083 inch)

No. 3

Inlet lobe ....................... 6.182 mm (0.2434 inch)

Exhaust lobe ................. 6.222 mm (0.2450 inch)
(B) Camshaft lobe height
(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

from the camshaft lobe height that is found in Step
1. The difference is the camshaft lobe lift.

i02509468

Engine Oil Pump

If the camshaft lobe lift is less than the service limit,

replace the camshaft.
Table 3

Required Tools
Tool

Part
Number

Part Description
Feeler Gauge

Qty
1

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

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

g01014070

(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

Illustration 20

g01256201

(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)

Illustration 19

g00987876

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

torque. .................... 44 to 54 Nm (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.

This document has been printed from SPI. Not for Resale

12
Specifications Section

KENR6239

g00996150

Illustration 23

(4) Diameter of main shaft (near

body) ................................. 15.985 to 16.000 mm
(0.6293 to 0.6299 inch)
Illustration 21

g01256201

Clearance between the main shaft and the body

Standard ............................... 0.032 to 0.074 mm
(0.0013 to 0.0029 inch)
Service limit .................... 0.15 mm (0.0059 inch)

(2) Clearance between the outer rotor and the inner

rotor
Standard ................................... 0.13 to 0.15 mm
(0.0051 to 0.0059 inch)
Service limit .................... 0.20 mm (0.0079 inch)

(5) Diameter of main shaft (near

bushing) ............................ 13.957 to 13.975 mm
(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)

Illustration 22

g01256204

(3) Clearance between the rotors and the body

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).

The minimum acceptable oil pressure at low

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

Illustration 25

g01256709

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 Nm (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

Illustration 26

Note: Apply Tooling (C) in order to reuse the bolts

for the oil pan. Apply Tooling (C) to the first 13 mm
(0.5118 inch) of the thread.

Table 5

Required Tools
Tool
A
B
C

Part
Number

Part Description

g01020644

Qty

21826038

POWERPART Silicone
Sealant

21826051

POWERPART Sealing
Compound

21820117

POWERPART Threadlock
and Nutlock

(1) Tighten the oil pan bolts to the following

torque. ...................... 10 to 13 Nm (7 to 10 lb ft)

This document has been printed from SPI. Not for Resale

14
Specifications Section

KENR6239

i02699076

Cylinder Block

Table 6

Required Tools
Tool
A
Illustration 27

g01256710

(2) Tighten the oil pan drain plug to the following

torque. .................... 34 to 44 Nm (25 to 33 lb ft)

Part
Number

Part Description

Qty

21826038

POWERPART Silicone
Sealant

21826051

POWERPART Sealing
Compound

27610013

POWERPART Rubber
Plug Replacer

i01893737

Water Temperature Regulator

Illustration 28

g00877006

The water temperature regulator starts to open at the

following temperature. .... 82 1.5C (180 2.7F)

Illustration 29

g00987933

(1) Cylinder bore

The water temperature regulator has a lift of

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

This document has been printed from SPI. Not for Resale

KENR6239

15
Specifications Section

Tighten the main bearing cap bolts to the following

torque. .................... 98 to 108 Nm (72 to 80 lb ft)

Table 7

Tolerances of Cylinder Bores

Internal
Diameter

Out of
Round

Taper

Standard at
Assembly

94.000 to
94.035 mm
(3.7008 to
3.7022 inch)

0.010 mm
(0.0004
inch)

0.015 mm
(0.0006
inch)

Repair Limit

94.200 mm
(3.7087
inch)

N/A

N/A

1st
Standard
Oversize
+0.25 mm
(0.001 inch)

94.250 to
94.285 mm
(3.7106 to
3.7120 inch)

0.010 mm
(0.0004
inch)

0.015 mm
(0.0006
inch)

Repair Limit

94.450 mm
(3.7185
inch)

N/A

N/A

2nd
Standard
Oversize
+0.50 mm
(0.02 inch)

94.500 to
94.535 mm
(3.7205 to
3.7218 inch)

0.010 mm
(0.0004
inch)

0.015 mm
(0.0006
inch)

Service
Limit

94.700 mm
(3.7283
inch)

N/A

N/A

Illustration 30

g01007113

(3) Rear main bearing cap

(4) Main bearing caps should have a marking that
indicates placement and orientation.
(5) Front main bearing cap

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.
Illustration 31

Note: Apply a small amount of Tooling (A) or Tooling

(B) to the corners of the cylinder block for the rear
main bearing cap. After the rear main bearing cap is
installed, remove any excess sealant from the inside
of the recess for the rear oil seal. Excess sealant
prevents the correct seating of the rear oil seal.
2. Install the cap to the crankcase so that the rear
face of the cap is even with the rear face of the
crankcase.
3. Apply clean engine oil to the threads of the main
bearing cap bolts.

g01007117

(6) Seal for the front and rear main bearing caps.
(7) The seals for the front and the rear main bearing
caps have a curve at one end. The curved side
must be installed toward the side of the engine.
The curved end is inserted first into the hole.
Note: Use Tooling (C) in order to install the seal
correctly.
(8) Before installing the seals, inject a small quantity
of Tooling (A) or Tooling (B) in the holes for the
seals.

This document has been printed from SPI. Not for Resale

16
Specifications Section

KENR6239

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)

Illustration 32

g01353554

(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)
i01894898

Crankshaft

g00994009

Illustration 34

(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 Thrust
Washer

Oversize Width
for Front OR
Rear

Oversize Width
for Front AND
Rear

0.15 mm
(0.006 inch)

31.150 to 31.189
mm (1.2264 to
1.2279 inch)

31.300 to 31.339
mm (1.2323 to
1.2338 inch)

0.30 mm
(0.012 inch)

31.300 to 31.339
mm (1.2323 to
1.2338 inch)

31.450 to 31.489
mm (1.2382 to
1.2397 inch)

0.45 mm
(0.018 inch)

31.450 to 31.489
mm (1.2382 to
1.2397 inch)

31.600 to 31.639
mm (1.2441 to
1.2456 inch)

Refer to Specifications, Connecting Rod Bearing

Journal for information on the connecting rod bearing
journals.
Illustration 33

(1) Crankshaft end play

g00987940

Refer to Specifications, Main Bearing Journal for

information on the main bearing journals and the
main bearings.

This document has been printed from SPI. Not for Resale

KENR6239

17
Specifications Section

i02697791

Crankshaft Seals

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

(0.0012 to 0.0035 inch)
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
Original Size Journal(1)

77.955 to 77.970 mm
(3.0691 to 3.0697 inch)

Typical example

Undersize Journal
0.25 mm (0.010 inch)

77.705 to 77.720 mm
(3.0592 to 3.0598 inch)

(1) Oil seal

Undersize Journal
0.50 mm (0.020 inch)

77.455 to 77.470 mm
(3.0494 to 3.0500 inch)

Undersize Journal
0.75 mm (0.030 inch)(2)

77.205 to 77.220 mm
(3.0396 to 3.0402 inch)

g01353567

Illustration 35

(2) Oil seal sleeve

Inspect the contact surface between the oil seal and
the crankshaft for wear. If the crankshaft is worn,
replace the oil seal with an oil seal and a sleeve
assembly.
i01907581

Connecting Rod Bearing

Journal

(1)

Regrind the main bearing journals to the next undersize

dimension if the repair limit of 77.850 mm (3.0650 inch) is
exceeded.
(2) Service limit 77.100 mm (3.0354 inch)

The clearance between a new main bearing

and a new main bearing journal is the following
value. ..... 0.050 to 0.110 mm (0.0020 to 0.0043 inch)

Table 9

Diameter of Crankshaft Journal (Bearing Surface)

For Connecting Rod Bearings

(1)

Original Size Journal(1)

57.955 to 57.970 mm
(2.2817 to 2.2823 inch)

Undersize Journal
0.25 mm (0.010 inch)

57.705 to 57.720 mm
(2.2718 to 2.2724 inch)

Undersize Journal
0.50 mm (0.020 inch)

57.455 to 57.470 mm
(2.2620 to 2.2626 inch)

Undersize Journal
0.75 mm (0.030 inch)

57.205 to 57.220 mm
(2.2522 to 2.2528 inch)

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

This document has been printed from SPI. Not for Resale

18
Specifications Section

KENR6239

i02697820

Connecting Rod

i02699075

Piston and Rings

Table 11

Required Tools

Illustration 36

Tool

Part
Number

21825617

Part Description

Qty

Feeler Gauge

Dial Indicator Group

g00987949

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 Nm (36 to 44 lb ft)
Inside diameter of the piston pin bearing
Nominal value ........................ 30 mm (1.18 inch)
Standard at assembly ....... 30.020 to 30.045 mm
(1.1819 to 1.1829 inch)
Clearance between the piston pin and the piston pin
bearing
Standard at assembly ........... 0.020 to 0.051 mm
(0.0008 to 0.0020 inch)
Service limit .................. 0.120 mm (0.0047 inch)
End play of the connecting rod that is attached to the
crankshaft.
Standard at assembly ............... 0.15 to 0.35 mm
(0.0059 to 0.0138 inch)
Service limit ...................... 0.50 mm (0.020 inch)

Illustration 37

g00996359

(1) Diameter of the piston pin

Nominal value ........................ 30 mm (1.18 inch)
Standard at assembly ....... 29.994 to 30.000 mm
(1.1809 to 1.1811 inch)
Clearance between the piston pin and the bore
Standard at assembly ........... 0.000 to 0.016 mm
(0.0000 to 0.0006 inch)
Service limit .................. 0.050 mm (0.0020 inch)
Refer to table 12 for the outside diameters of the
pistons.

This document has been printed from SPI. Not for Resale

KENR6239

19
Specifications Section

Table 12

Item

Standard at
Assembly

Service Limit

Standard

93.955 to 93.985
mm (3.6990 to
3.7002 inch)

93.770 mm
(3.6917 inch)

0.25 mm
(0.0098 inch)
oversize

94.205 to 94.235
mm (3.7089 to
3.7100 inch)

94.020 mm
(3.7016 inch)

0.50 mm
(0.0197 inch)
oversize

94.455 to 94.485
mm (3.7187 to
3.7199 inch)

94.270 mm
(3.7114 inch)

Maximum difference in weight of the piston per

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

Illustration 39

g01256909

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
Illustration 38

g01256908

Use Tooling (A) in order to measure the piston ring

end gap.

Standard at assembly ........... 0.025 to 0.065 mm

(0.0010 to 0.0026 inch)
Repair limit .................... 0.150 mm (0.0059 inch)

Standard at assembly ............... 0.30 to 0.50 mm

(0.0118 to 0.0197 inch)
Service limit .................... 1.50 mm (0.0591 inch)

Illustration 40

g01256910

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

the piston (2).

This document has been printed from SPI. Not for Resale

20
Specifications Section

KENR6239

Standard at Assembly

(11) End gap of oil ring

Naturally aspirated engines .... 0.25 to 0.15 mm

(0.0098 to 0.0059 inch)
Turbocharged engines .............. 0.05 to 0.45 mm
(0.0020 to 0.0177 inch)

Apply engine oil to the piston rings. Refer to

Illustration 42 for the assembled configuration of the
ends of the piston rings.

Compressed thickness of cylinder head

gasket ................. 1.2 0.05 mm (0.05 0.002 inch)

Note: Install the piston with the O mark toward the

front of the engine.
i02506518

Front Housing and Covers

Illustration 41

g00987977

(3) Piston from naturally aspirated engines

(4) Piston from turbocharged engines
(5) WEIGHT mark
Illustration 43

(6) MATCHING mark

Note: Assemble the piston and the connecting rod
with the WEIGHT mark on the piston and with the
MATCHING mark on the rod on the same side.

g00987995

(1) Tighten the bolts that fasten the front

plate to the cylinder block to the following
torque. ...................... 10 to 13 Nm (7 to 10 lb ft)
(2) Remove the excess gasket with a cutter.

Illustration 42

g00987981
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
torque. .................... 17 to 20 Nm (12 to 15 lb ft)

(9) End gap of No. 2 compression ring

(10) Side with the inlet valve

This document has been printed from SPI. Not for Resale

KENR6239

21
Specifications Section

i01896267

Gear Group (Front)

(7) Tighten the jam nut for the oil pump gear to the
following torque. ..... 28 to 38 Nm (21 to 28 lb ft)
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 runouts of flywheel
Maximum at assembly .... 0.15 mm (0.0059 inch)
Repair limit ........................ 0.50 mm (0.020 inch)

Illustration 45

g00988013

(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
Standard at assembly ........... 0.009 to 0.050 mm
(0.0004 to 0.0020 inch)
Service limit .................. 0.100 mm (0.0039 inch)

Illustration 46

g00988073

(1) Tighten the bolts for the flywheel to the following

torque. .................... 79 to 88 Nm (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 Nm
(43 to 51 lb ft)
Turbocharged engines .................... 83 to 98 Nm
(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 Nm
(21 to 29 lb ft)

This document has been printed from SPI. Not for Resale

22
Specifications Section

KENR6239

i02510696

Crankshaft Pulley

Table 13

Required Tools
Tool
A

Part
Number
21826038

Part Description

Qty
Illustration 48

POWERPART Silicone
Sealant

g00988022

(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.

Illustration 47

g00988100

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 Nm (354 to 369 lb ft)
(2) Crankshaft pulley

This document has been printed from SPI. 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

Alternator and Regulator

i02506531

Electric Starting Motor

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

get the maximum alternator output.

Illustration 50

g01024163

The starting motor

(1) Electric starting motor

(2) Tighten the nut on the starting motor terminal to
the following torque. ....................... 18 to 25 Nm
(13.3 to 18.4 lb ft)
Illustration 49

g01268996

(1) Alternator and regulator

Voltage ...................................................... 13.5 V
Output current at 1500 rpm ..... 20 amp or higher
Output current at 3000 rpm ..... 50 amp or higher
Output current at 5000 rpm ..... 60 amp or higher
Adjusting voltage of the regulator at 5000 rpm with a
load of 5 amp or lower .................... 14.2 V to 14.8 V

(3) Tighten the starting motor terminal to the following

torque. .......................................... 2.6 to 4.6 Nm
(23.0119 to 40.7134 lb in)
No load conditions at 25 C (77 F)
Speed .................................. 3000 rpm minimum
Current draw ......................... 200 amp maximum
Voltage ......................................................... 11 V
When the electric starting motor is viewed from
the drive end, the motor rotates in the following
direction. ................................................... Clockwise

This document has been printed from SPI. Not for Resale

24
Specifications Section

KENR6239

i02699074

Glow Plugs

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

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

Naturally Aspirated Engines

Illustration 51

g00988137

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

following torque. ...... 15 to 20 Nm (11 to 15 lb ft)
Type ............................................................... 12 Volt
Current (30 second rating) .................... 9.7 amperes

Turbocharged Engines

Illustration 52

g01353859

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

following torque. ..... 20 to 30 Nm (15 to 22 lb ft)

This document has been printed from SPI. Not for Resale

KENR6239

25
Index Section

Index
A

Alternator and Regulator ....................................... 23

Lifter Group............................................................ 6

Belt Tension Chart ................................................. 22

Main Bearing Journal............................................. 17

Camshaft ...............................................................
Connecting Rod.....................................................
Connecting Rod Bearing Journal...........................
Crankshaft ............................................................
Crankshaft Pulley ..................................................
Crankshaft Seals ...................................................
Cylinder Block........................................................
Cylinder Head........................................................
Cylinder Head Valves ............................................

10
18
17
16
22
17
14
9
8

Piston and Rings ................................................... 18

R
Rocker Shaft.......................................................... 7
S
Specifications Section ........................................... 4

E
Electric Starting Motor ...........................................
Engine Design .......................................................
Engine Oil Bypass Valve .......................................
Engine Oil Pan.......................................................
Engine Oil Pressure...............................................
Engine Oil Pump....................................................
Engine Oil Relief Valve ..........................................
Exhaust Manifold ...................................................

23
4
13
13
12
11
11
9

Table of Contents................................................... 3
V
Valve Mechanism Cover........................................ 7
W

F
Flywheel ................................................................
Front Housing and Covers.....................................
Fuel Injection Lines................................................
Fuel Injection Pump...............................................
Fuel Injectors .........................................................
Naturally Aspirated Engines...............................
Turbocharged Engines.......................................
Fuel Transfer Pump ...............................................

21
20
4
4
5
5
6
6

Water Temperature Regulator ............................... 14

G
Gear Group (Front)................................................
Glow Plugs ............................................................
Naturally Aspirated Engines...............................
Turbocharged Engines.......................................

21
24
24
24

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

This document has been printed from SPI. Not for Resale

26
Index Section

KENR6239

This document has been printed from SPI. Not for Resale

KENR6239

27
Index Section

This document has been printed from SPI. Not for Resale

2007 Perkins Engines Company Limited

All Rights Reserved

Printed in U. K.

This document has been printed from SPI. Not for Resale