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GN65770N

gn65770n

404D-22

2008/04/01

The information given within this parts book was correct at the time of printing and is subject to change without
notice. Always refer to your local Perkins outlet for the latest information. Only fully trained personnel should carry out servicing of engines. Before working on any engine always refer to the correct user service and maintenance
manual.
Always refer to your local Perkins outlet before purchasing any parts
Subject to any existing rights of third parties, the information given in this document is the property of Perkins Engines Limited and should not be copied, in whole or part, without the prior written consent of the Company.

Contents
1.

Introduction

Pg. 4

2.

How To Use Your Parts Book

Pg. 4

3.

Engine Breakdown

Pg. 5

4.

Symbol Descriptions

Pg. 9

5.

Parts Lists & Illustrations

Pg. 11

6.

Parts Index

Pg. 128

Introduction
The build list of your engine, found on the front page of this parts book, provides a unique
reference to the components fitted to your engine; therefore this parts book is only applicable to
this particular engine
Always quote your build list and engine serial number when contacting your Perkins outlet.

How to use your Parts Book


This parts book has been designed to provide you with all the information you need to identify
parts to service your engine. There are several features within the book to make it easy to find
the parts you require.
Front Page
This lists your build list number and the date of publication of this book
Symbol Descriptions
Provides a quick reference guide to the symbols used within the book.
Engine Breakdown
Use this to identify all the major sections of your engine and the relevant pages within the book.
Parts Lists & Illustrations
This section shows each major section of your engine broken down into individual part numbers
along with an associated illustration for identifying the parts you require.
The illustrations used in this parts book are representational only and should only be used for
identification purposes.
For fitting instructions please refer to your engine Service Manual.
Parts Index
Using either the part number or description of the part you require this section will help you
locate the page within the Parts Lists & Illustrations section where the part appears.

Engine Breakdown

Section

Page

Section

Page

Level 1 - Service
AAAAAAGN

11

Relief Valve
ACPG0004

37

Level 2 - Repair
AAAAAAGN

13

Timing Case
ADPG0016

39

Level 3 - Overhaul
AAAAAAGN

15

Timing Case
ADPG0016

41

Cylinder Block
ACPG0004

17

Timing Case
ADPG0016

43

Cylinder Block
ACPG0004

19

Timing Case
ADPG0016

45

Crankshaft, Pistons & Connecting Rods


ACPG0004

21

Timing Case
ADPG0016

47

Crankshaft, Pistons & Connecting Rods


ACPG0004

23

Camshaft & Gears


ADPG0016

49

Rear End Oil Seal


ACPG0004

25

Fuel Injection Pump


AFPG0016

51

Cylinder Head
ACPG0004

27

High Pressure Fuel Pipes


AFPG0016

53

Cylinder Head
ACPG0004

29

Atomisers
AFPG0016

55

Rocker Shaft Assembly


ACPG0004

31

Fuel Leak-Off Pipe


AFPG0016

57

Oil Pump
ACPG0004

33

Flywheel Housing
CDPG0001

59

Pipes
ACPG0004

35

Flywheel & Starter Ring


DDPG0000

61

Page 5

Engine Breakdown

Section

Page

Section

Page

Starter Motor
EDPG0001

63

Fan
MDPG0003

89

Pulleys
FBPG0001

65

Fan Drive
MEPG0017

91

Sump
GBPG0001

67

Alternator
NDPG0002

93

Dipstick & Filler Tube


GBPG0001

69

Drive Belt & Tensioner


NEPG0001

95

Dipstick & Filler Tube


GBPG0001

71

Front End Drive Output


QCPG0001

97

Sump
GCPG0001

73

Cylinder Head Cover


TBPG0002

99

Filler
HBPG0000

75

Cylinder Head Cover


TBPG0002

101

Oil Filter
JBPG0000

77

Feed Pipes
TBPG0002

103

Oil Filter
JCPG0000

79

Exhaust Manifold
UBPG0002

105

Front End Drive Input


KBPG0001N

81

Exhaust Manifold
UDPG5503

107

Water Pump
LBPG0003

83

Lift Pump
VBPG0006

109

Thermostat & Housing


LBPG0003

85

Fuel Filter
VBPG0006

111

Water Outlet & Inlet


LDPG0001

87

Page 6

Engine Breakdown

Section

Page

Pipework & Connections


VBPG0006

113

Cold Start System


WDPG0000

115

Engine Lifting Eyes


XBPG0000

117

Throttle & Stop Controls


ZAPG0002

119

Instrumentation
ZJPG0000

121

Instrumentation
ZLPG0002

123

Electrical Wiring & Fittings


ZPPG0001

125

Fuel Pre-Lift Pump


ZVPG0001

127

Page 7

Engine Breakdown

Page 8

Symbols and Notes


Symbol

Description

From Engine Number

Upto Engine Number

Repairs and Replaces

See Appropriate Section - Reference Number

Alternative

Order

Remanufactured Part

New for Old Part

Number of Teeth

Thickness

Bottom

Top

Left Hand

Right Hand

Reference for Detailed Breakdown

Other Service Options Available

Cylinder Number

See History Section

Page 9

Level 1 - Service

Plate A

AAAAAAGN

Recommended stocking and service lists


Perkins provides Recommended stocking and service lists, for Distributor use when
recommending parts stocks for Dealers, preferred customers (eg fleets) etc. These lists
are based on agreed workshop capability and are at three distinct levels:
Level 1 - Service
The Level 1 workshop has the ability to perform basic non-intrusive maintenance on
Perkins engines.
Listes recommandes pour le stock et la maintenance
Perkins fournit des listes recommandes pour le stock et la maintenance afin d'aider le
Distributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont
bases sur le niveau technique des Ateliers avec trois niveaux distincts :
Niveau 1- Maintenance
L'atelier de niveau 1 est capable d'executer l'entretien de base des moteurs Perkins (sans
demontage).
Empfohlene Lagerbestands- und Servicelisten
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die
Vertragshndler verwenden knnen, um Hndlern und Kunden (z.B. Fuhrparks) einen
bestimmten Ersatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbarten
Werkstattfhigkeiten, welche in die folgenden drei Stufen unterteilt werden:
Stufe 1 - Service
Werksttten der Stufe 1 knnen grundlegende und einfache Wartungsarbeiten an
Perkins-Motoren ohne Spezialwerkzeug durchfhren.
Listas de servicio y de stock recomendadas
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el
Distribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientes
preferidos (por ejemplo, flotas), etc. Estas listas se basan en capacidad del taller
acordada y se dividen en tres niveles diferentes:
Nivel 1 - Servicio
El taller del Nivel 1 puede llevar a cabo un mantenimiento no intrusivo en los motores
Perkins.
Elenco parti consigliate ad uso stock ed assistenza
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza;
ci per soddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono
in considerazione la capacit operativa concordata con lofficina e sono distinti in tre livelli
Livello 1 - Assistenza
Il livello 1 prevede che lofficina sia in grado di operare in maniera basilare sui motori
Perkins.

Page 10

Level 1 - Service

Plate A

AAAAAAGN

Item
1

Part No.

References

Qty.
1

Description

Notes

LEVEL 1 - SERVICE

Page 11

Level 2 - Repair

Plate A

AAAAAAGN

Recommended stocking and service lists


Perkins provides Recommended stocking and service lists, for Distributor use when
recommending parts stocks for Dealers, preferred customers (eg fleets) etc. These lists are
based on agreed workshop capability and are at three distinct levels:
Level 2 - Repair
The Level 2 workshop has the ability to perform maintenance service,and inspection service on
Perkins engines.
Listes recommandes pour le stock et la maintenance
Perkins fournit des listes recommandes pour le stock et la maintenance afin d'aider le
Distributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont bases sur
le niveau technique des Ateliers avec trois niveaux distincts :
Niveau 2 - Maintenance & reparation
L'atelier de niveau 2 est capable dexecuter toutes les oprations d'entretien, la reparation des
composants externes (demarreur, alternateur,etc) et le diagnostic pour les problmes touchant
l'electronique
Empfohlene Lagerbestands- und Servicelisten
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshndler
verwenden knnen, um Hndlern und Kunden (z.B. Fuhrparks) einen bestimmten
Ersatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbarten
Werkstattfhigkeiten, welche in die folgenden drei Stufen unterteilt werden:
Stufe 2 - Reparatur
Werksttten der Stufe 2 knnen Instandsetzungs- und Inspektionsarbeiten an Perkins-Motoren
durchfhren.
Listas de servicio y de stock recomendadas
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el
Distribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientes preferidos
(por ejemplo, flotas), etc. Estas listas se basan en capacidad del taller acordada y se dividen en
tres niveles diferentes:
Nivel 2 - Reparacin
El taller de Nivel 2 puede llevar a cabo el servicio de mantenimiento y el servicio de inspeccin
en los motores Perkins.
Elenco parti consigliate ad uso stock ed assistenza
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ci per
soddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono in
considerazione la capacit operativa concordata con lofficina e sono distinti in tre livelli :
Livello 2 - Riparazione
Nel livello 2 lofficina in grado di svolgere la manutenzione e di fare controlli di
assistenza sui motori Perkins.

Page 12

Level 2 - Repair

Plate A

AAAAAAGN

Item
1

Part No.

References

Qty.
1

Description

Notes

LEVEL 2 - REPAIR

Page 13

Level 3 - Overhaul

Plate A

AAAAAAGN

Recommended stocking and service lists


Perkins provides Recommended stocking and service lists, for Distributor use when recommending parts
stocks for Dealers, preferred customers (eg fleets) etc. These lists are based on agreed workshop capability
and are at three distinct levels:
Level 3 - Overhaul.
The Level 3 workshop has the ability to perform complete service work on Perkins engines. Can repair and
fully overhaul engine, including engine test. Can perform all levels of electronics diagnosis and application
related faults.
Listes recommandes pour le stock et la maintenance
Perkins fournit des listes recommandes pour le stock et la maintenance afin d'aider le Distributeur dans ses
conseils aux Agents, aux clients habituels, etc.. Ces listes sont bases sur le niveau technique des Ateliers
avec trois niveaux distincts :
Niveau 3 - Maintenance, reparation & refection
L' atelier de niveau 3 est capable de couvrir toutes les oprations d'entretien des moteurs Perkins. Il peut
aussi rparer et entirement refaire des moteurs ainsi que les tester. Il est capable d'effectuer un diagnostic
pour les problmes touchant l'electronique et aux applications.
Empfohlene Lagerbestands- und Servicelisten
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshndler verwenden
knnen, um Hndlern und Kunden (z.B. Fuhrparks) einen bestimmten Ersatzteilbestand zu empfehlen. Diese
Listen basieren auf den vereinbarten Werkstattfhigkeiten, welche in die folgenden drei Stufen unterteilt
werden:
Stufe 3 - berholung
Werksttten der Stufe 3 knnen umfassende Servicearbeiten an Perkins-Motoren durchfhren. Sie knnen
Motoren reparieren und komplett berholen und auerdem Motorprfungen durchfhren. Sie knnen
umfassende elektronische Diagnoseprfungen durchfhren und anwendungsspezifische Strungen
untersuchen.
Listas de servicio y de stock recomendadas
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el Distribuidor al
recomendar stocks de repuestos a los Distribuidores, a los clientes preferidos (por ejemplo, flotas), etc. Estas
listas se basan en capacidad del taller acordada y se dividen en tres niveles diferentes:
Nivel 3 - Reparacin general
El taller de Nivel 3 puede llevar a cabo un trabajo de servicio completo en los motores Perkins. Puede
reparar y reacondicionar completamente un motor, incluyendo probar el motor. Puede llevar a cabo todos los
niveles de diagnstico electrnico y las fallas relacionadas con la aplicacin.
Elenco parti consigliate ad uso stock ed assistenza
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ci per soddisfare le
richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono in considerazione la capacit operativa
concordata con lofficina e sono distinti in tre livelli :
Livello 3 - Revisione
Nel livello 3 lofficina in grado di svolgere lavori di assistenza completi sui motori Perkins. E in grado di
riparare e svolgere una revisione completa del motore, incluso le prove. Pu anche effettuare diagnosi sull
elettronica a tutti i livelli e sui relativi difetti nelle applicazioni.

Page 14

Level 3 - Overhaul

Plate A

AAAAAAGN

Item
1

Part No.

References

Qty.
1

Description

Notes

LEVEL 3 - OVERHAUL

Page 15

Cylinder Block

Plate A

ACPG0004

14
22

13

18

19
8

20
6
3
2
11
12
16

17

21

15

10
9

Page 16

Cylinder Block

Plate A

ACPG0004

Item

Part No.

1
2 198466940
3 198466010
4 198466020
5 064210025
6 064210040
7 064210040
8 064210040
9 198466920
10 198517222
11 042309017
12 042309018
13 040106203
14 064100045
15 165296220
16 012110635
17 012110660
18 010109441
19 030500612
20 030500616
21 030501025
22 030309005
Service Options
10
10

198517226
198517229

References

J (-)0.25MM
J (-)0.50MM

Qty.

Description

1
4
3
2
2
3
1
1
3
1
1
1
1
1
1
1
1
3
2
2
2
2

CYLINDER BLOCK
PLUG
PLUG
PLUG
PLUG
PLUG
PLUG
PLUG
PLUG
BUSH
NEEDLE BEARING
NEEDLE BEARING
BALL BEARING
PLUG
SHAFT
STUD
STUD
STUD
DOWEL
DOWEL
DOWEL
PIN

1
1

BUSH
BUSH

Notes
(A)

Footnotes
(A)

SERVICE BY COMPLETE ENGINE

Page 17

Cylinder Block

Plate B

ACPG0004

2
1

Page 18

Cylinder Block

Plate B

ACPG0004

Item

Part No.

1
2

165996590
011310612

References

Qty.

Description

1
2

GASKET - TIMING CASE


SCREW

PLATE

Notes

History
a.
4

U65166580

Page 19

Crankshaft, Pistons & Connecting Rods

Plate A

ACPG0004

33

4
7
6
3

30
26
27
24
20

29
21

18
28

14

23
15

12

31
22

8
17
9

25
16
11
19
10
32
13

Page 20

Crankshaft, Pistons & Connecting Rods

Plate A

ACPG0004

Item

Part No.

1 115256990
2
3
115276270
4
030509020
5 199266210
6 199266200
7 199266200
8 110156360
9
10
11
030500612
12
010109406
13 011511070
14 110156370
15
16
17
030500612
18
010109406
19 011511070
20 110156380
21
22
23
030500612
24
010109406
25 011511070
26 110156390
27
28
29
030500612
30
010109406
31 010700860
32 U5MB0025
33 U5ME0030
Service Options
32

U5MB0025A

References

F 115256990

Q 1
F 110156360
F 110156360

Q 2
F 110156370
F 110156370

Q 3
F 110156380
F 110156380

Q 4
F 110156390
F 110156390

J (-) 0.25MM

Qty.

Description

1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
2
1
1
1
1
2
2
1
1
1
1
2
2
2
1
1

CRANKSHAFT ASSEMBLY
CRANKSHAFT ASSEMBLY
CRANKSHAFT GEAR
KEY
THRUST WASHER
THRUST WASHER
THRUST WASHER
HOLDER
CAP
CAP
DOWEL
SCREW
SCREW
HOLDER
CAP
CAP
DOWEL
SCREW
SCREW
HOLDER
CAP
CAP
DOWEL
SCREW
SCREW
HOLDER
CAP
CAP
DOWEL
SCREW
BOLT
MAIN BEARING KIT
BIG END BEARING KIT

MAIN BEARING KIT

Notes

Page 21

Crankshaft, Pistons & Connecting Rods

Plate B

ACPG0004

12

7
8
10

11

5
4

Page 22

Crankshaft, Pistons & Connecting Rods

Plate B

ACPG0004

Item

Part No.

1
2
3
4
5
6
7
8
9
10
11
12

115017491

References

F 115017491
115107970
115026330
F 115026330
F 115026330
198517265
115176140
020109120
115326220
036500028
036500028

Qty.
4
1
1
4
1
1
1
2
2
4
4
4

Description

Notes

PISTON AND RING KIT


PISTON
PISTON RING KIT
CON ROD ASSEMBLY
ROD
CAP
SMALL END BUSH
CON ROD BOLT
CON ROD NUT
GUDGEON PIN
CIRCLIP
CIRCLIP

Page 23

Rear End Oil Seal

Plate A

ACPG0004

Page 24

Rear End Oil Seal

Plate A

ACPG0004

Item

Part No.

050209083

References

Qty.
1

Description
SEAL - REAR END OIL

Notes
(A,B)

Footnotes
(A)

SEE SERVICE BULLETIN NO.195

(B)

ALSO ORDER WEAR SLEEVE - 29990037

Page 25

Cylinder Head

Plate A

ACPG0004

21

22
1
20

14

19

13
18
7
12

17

11
5

16
10

15
9

Page 26

Cylinder Head

Plate A

ACPG0004

Item

Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22

111011030

References

F 111011030
064210010
064210018
064210025
064210025
064210030
064210030
120166380
TPN646
120406070
198216700
120186080
120226070
120176380
TPN645
120406050
198216700
120186080
120226070
120216041
120216041

Qty.
1
1
3
7
3
3
1
1
4
4
4
4
4
4
4
4
4
4
4
4
4
4

Description
CYLINDER HEAD ASSEMBLY
CYLINDER HEAD
PLUG
CAP
PLUG
PLUG
CAP
CAP
INTAKE VALVE
VALVE SEAT INSERT
SEAL - VALVE STEM
VALVE SPRING
CAP
VALVE COLLET
EXHAUST VALVE
VALVE SEAT INSERT
SEAL - VALVE STEM
VALVE SPRING
CAP
VALVE COLLET
VALVE SPRING CAP
VALVE SPRING CAP

Notes

(A)

(B)

Footnotes
(A)

INLET

(B)

EXHAUST

Page 27

Cylinder Head

Plate B

ACPG0004

Page 28

Cylinder Head

Plate B

ACPG0004

Item

Part No.

1
2 111136480
3 111136490
4 012110655
5 012110860
Service Options
1
1

111147711
111147721

References

Qty.

Description

1
14
4
2
2

GASKET - CYLINDER HEAD


SCREW
SCREW
STUD
STUD

J 1.2MM
J 1.3MM

1
1

GASKET - CYLINDER HEAD


GASKET - CYLINDER HEAD

Notes

Page 29

Rocker Shaft Assembly

Plate A

ACPG0004

1
7
8
10
3

16

15

14

12

11

13

Page 30

Rocker Shaft Assembly

Plate A

ACPG0004

Item

Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

120036821

References

F 120036821
120316201
052109076
120356131
120356141
198217170
199486220
020109076
199280300
120996130
120456310
120116160
012109044
023100010
011310635

Qty.
1
1
1
1
4
4
3
8
8
6
1
8
8
4
4
2

Description
ROCKER BOX
ROCKER BOX
ROCKER SHAFT
SEAL - O RING
ROCKER ARM ASSEMBLY
ROCKER ARM ASSEMBLY
ROCKER SHAFT SPRING
ADJUSTING SCREW
NUT
WASHER
SEAL - ROCKER BOX
PUSHROD
TAPPET
STUD
NUT
SCREW

Notes

INLET
EXHAUST

Page 31

Oil Pump

Plate A

ACPG0004

14
2

1
5
3
6
4

8
9
10
11
12

Page 32

Oil Pump

Plate A

ACPG0004

Item

Part No.

1 165026270
2
3
4
5
198517290
6
030509018
7
198217760
8 140116220
9
10 198216720
11 199236540
12 036800010
14 199266270
Service Options
9
9
9
9

199286150
199286160
199286170
199286180

References

F 165026270
F 165026270
F 165026270

J
J
J
J

(+)0.10MM
(+)0.15MM
(+)0.20MM
(+)0.50MM

Qty.

Description

1
1
1
1
3
3
1
1
1
1
1
1
1

IDLER GEAR
IDLER GEAR
ROTOR
ROTOR
BUSH
DOWEL
SPRING
COVER
SHIM
SPRING
COLLAR
CIRCLIP
THRUST WASHER

1
1
1
1

SHIM
SHIM
SHIM
SHIM

Notes

Page 33

Pipes

Plate A

ACPG0004

4
1

3
2

Page 34

Pipes

Plate A

ACPG0004

Item

Part No.

1
2
3
4

140607020
198486780
140996260
140996260

References

Qty.
1
1
1
1

Description

Notes

OIL PIPE
BOLT
WASHER
WASHER

Page 35

Relief Valve

Plate A

ACPG0004

Page 36

Relief Valve

Plate A

ACPG0004

Item

Part No.

1
2

140036220
052109078

References

Qty.
1
1

Description

Notes

RELIEF VALVE
SEAL - O RING

Page 37

Timing Case

Plate A

ADPG0016

Page 38

Timing Case

Plate A

ADPG0016

Item

Part No.

1
2
3
4
5

165996630
011310640
011310660
023100006

References

Qty.
1
1
7
4
1

Description
TIMING CASE
GASKET - TIMING CASE
SCREW
SCREW
NUT

Notes
(A)

Footnotes
(A)

SEE FOLLOWING PARTS LIST FOR SERVICE COMPONENTS

Page 39

Timing Case

Plate B

ADPG0016

Page 40

Timing Case

Plate B

ADPG0016

Item

Part No.

1
2
3

165106870
030300414
198636160

References

Qty.

Description

1
1
1

TIMING CASE
PIN
SEAL - FRONT END OIL

1
1

SEAL - O RING
BEARING HOLDER ASSEMBLY

Notes

History
a.
052300850
110416290

Page 41

Timing Case

Plate C

ADPG0016

10

8
7
6

9
5
1
2

12
11
3

13

Page 42

Timing Case

Plate C

ADPG0016

Item

Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13

125616120
165996640
125156262
198217870
052100070
198217750
023100008
2315C039
2648A120
26420462
2315C039
2318A207
011310614

References

R a.

Qty.

Description

1
1
1
1
1
1
1
1
1
1
1
1
4

BRACKET
GASKET
ARM
SPRING
SEAL - O RING
SPRING
NUT
SCREW
NUT
ANTI-TAMPER CAP
SCREW
NUT
SCREW

ARM

Notes

History
a.
3

125156261

Page 43

Timing Case

Plate D

ADPG0016

11
2

6
3

1
10
4

8
9

7
5

Page 44

Timing Case

Plate D

ADPG0016

Item

Part No.

1
2
3
4
5
6
7
8
9
10
11

125046613
125116221
025100008
131046560
020800010
125306151
125116211
024500006
025100006
198217880
031100004

References
R a.

R b.

Qty.

Description

1
1
1
1
1
1
1
1
1
1
1

CONTROL LEVER
SHAFT
WASHER
SPEED SENSOR
NUT
CONTROL LEVER
SHAFT
NUT
WASHER
SPRING
PIN

Notes

History
a.
1

125046612

CONTROL LEVER

125306150

CONTROL LEVER

b.

Page 45

Timing Case

Plate E

ADPG0016

1
3
4
5
8

10
9
12
11

Page 46

Timing Case

Plate E

ADPG0016

Item

Part No.

1
2
3
4
5
6
7
8
9
10
11
12

131046650

References

F 131046650
020109177
025100010
198217910
198346160
131276440
131466251
020109239
025100006
064210012
131466270

Qty.
1
1
1
1
1
1
1
1
1
1
1
1

Description

Notes

SCREW
BOLT
NUT
WASHER
SPRING
RING
ANTI-TAMPER CAP
BOLT
NUT
WASHER
CAP
ANTI-TAMPER CAP

Page 47

Camshaft & Gears

Plate A

ADPG0016

9
1
2

5
6

Page 48

Camshaft & Gears

Plate A

ADPG0016

Item

Part No.

1
2
3
4
5
6
7
8
9

120026950

References

F 120026950
034100508
120016240
040109057
199216320
125256240
199566750
011310612

Qty.
1
1
1
1
1
1
1
1
1

Description

Notes

CAMSHAFT
CAMSHAFT
WOODRUFF KEY
CAMSHAFT GEAR
BALL BEARING
SPACER
SLIDER
PLATE
SCREW

Page 49

Fuel Injection Pump

Plate A

AFPG0016

5
1

Page 50

Fuel Injection Pump

Plate A

AFPG0016

Item

Part No.

1 131010080
2
3 010800820
4 010700820
5 027100008
6 023100008
Service Options
2
2
2
2
2
2
2

131437490
131437730
131437500
131437760
131437510
131437520
131437530

References

J
J
J
J
J
J
J

(+) 0.2MM
(+) 0.25MM
(+) 0.3MM
(+) 0.35MM
(+) 0.4MM
(+) 0.5MM
(+) 0.5MM

Qty.

Description

1
1
2
1
1
3

FUEL INJECTION PUMP


SHIM
SCREW
SCREW
WASHER
NUT

1
1
1
1
1
1
1

SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM

Notes

(A)

Footnotes
(A)

FLAT

Page 51

High Pressure Fuel Pipes

Plate A

AFPG0016

Page 52

High Pressure Fuel Pipes

Plate A

AFPG0016

Item

Part No.

1
2
3
4
5
6
7
8

131507520
131507530
131507540
131507550
199106021
199106021
010110625
023100006

References
Q
Q
Q
Q

1
2
3
4

Qty.
1
1
1
1
3
3
3
3

Description

Notes

FUEL INJECTION PIPE


FUEL INJECTION PIPE
FUEL INJECTION PIPE
FUEL INJECTION PIPE
CLAMP
CLAMP
SCREW
NUT

Page 53

Atomisers

Plate A

AFPG0016

Page 54

Atomisers

Plate A

AFPG0016

Item
1
2
3

Part No.
131406440
131426230
131426200

References

Qty.
4
1
4

Description

Notes

INJECTOR
SEAL - INJECTOR
SEAL - INJECTOR

Page 55

Fuel Leak-Off Pipe

Plate A

AFPG0016

4
2
3

Page 56

Flywheel Housing

Plate A

CDPG0001

Page 58

Flywheel Housing

Plate A

CDPG0001

Item

Part No.

1
2
3
4
5
6
7

110367570
011510816
011511220
010111030
020900010
026200010
027100010

References

Qty.
1
10
2
2
2
2
2

Description

Notes

BACKPLATE
SCREW
SCREW
BOLT
NUT
WASHER
WASHER

Page 59

Flywheel & Starter Ring

Plate A

DDPG0000

Page 60

Flywheel & Starter Ring

Plate A

DDPG0000

Item

Part No.

010109341

References

Qty.
6

Description

Notes

BOLT

Page 61

Starter Motor

Plate A

EDPG0001

Page 62

Starter Motor

Plate A

EDPG0001

Item

Part No.

185086600

References

Qty.
1

Description

Notes

STARTER MOTOR

Page 63

Pulleys

Plate A

FBPG0001

Page 64

Pulleys

Plate A

FBPG0001

Item

Part No.

145336620

References

Qty.
1

Description

Notes

WATER PUMP PULLEY

Page 65

Sump

Plate A

GBPG0001

Page 66

Sump

Plate A

GBPG0001

Item

Part No.

1
2
3
4
5
6
7

110708390
110996920
010109235
140406680
140987020
052109076
011310612

References

A U713161N
A U713161N

Qty.
1
1
30
1
1
1
2

Description

Notes

SUMP
GASKET - SUMP
SCREW
STRAINER
PIPE - OIL SUCTION
SEAL - O RING
SCREW

Page 67

Dipstick & Filler Tube

Plate A

GBPG0001

Page 68

Dipstick & Filler Tube

Plate A

GBPG0001

Item

Part No.

1
2
3
4

198416690
110756490
010109235
052100100

References

Qty.
1
1
1
2

Description

Notes

DIPSTICK
DIPSTICK TUBE
SCREW
SEAL - O RING

Page 69

Dipstick & Filler Tube

Plate B

GBPG0001

Page 70

Dipstick & Filler Tube

Plate B

GBPG0001

Item

Part No.

1
2
3
4

198436290
052100100
052100100
011310612

References

Qty.
1
1
1
1

Description

Notes

PLUG
SEAL - O RING
SEAL - O RING
SCREW

Page 71

Sump

Plate A

GCPG0001

4
3

2
1

Page 72

Sump

Plate A

GCPG0001

Item

Part No.

1
2
3
4

198736310
025100016
010109238
025100016

References

Qty.
1
1
1
1

Description

Notes

VALVE
WASHER
SCREW
WASHER

Page 73

Filler

Plate A

HBPG0000

Page 74

Filler

Plate A

HBPG0000

Item

Part No.

1
2
3
4

198436350
052100400
398430080
052100280

References

Qty.
1
1
1
1

Description

Notes

OIL FILLER CAP


SEAL - O RING
OIL FILLER CAP
SEAL - O RING

Page 75

Oil Filter

Plate A

JBPG0000

Page 76

Oil Filter

Plate A

JBPG0000

Item

Part No.

140517050

References

Qty.
1

Description

Notes

OIL FILTER

Page 77

Oil Filter

Plate A

JCPG0000

Page 78

Oil Filter

Plate A

JCPG0000

Item

Part No.

140546020

References

Qty.
1

Description

Notes

CONNECTION

Page 79

Front End Drive Input

Plate A

KBPG0001N

Page 80

Front End Drive Input

Plate A

KBPG0001N

Item

Part No.

1
2
3

U15397401
020109086
034100508

References
R a.

Qty.

Description

1
1
1

CRANKSHAFT PULLEY
NUT
WOODRUFF KEY

CRANKSHAFT PULLEY

Notes

History
a.
1

115397400

Page 81

Water Pump

Plate A

LBPG0003

2
7

4
5

Page 82

Water Pump

Plate A

LBPG0003

Item

Part No.

1
2
3
4
5
6
7

145010060
145996921
145537300
2481877
2481877
011310635
023100006

References

Qty.
1
1
1
1
1
4
1

Description

Notes

WATER PUMP
GASKET
HOSE
HOSE CLIP
HOSE CLIP
SCREW
NUT

Page 83

Thermostat & Housing

Plate A

LBPG0003

6
3

Page 84

Thermostat & Housing

Plate A

LBPG0003

Item

Part No.

1
2
3
4
5
6
7

145046110
145206230
145996930
011310655
023100006
064500030
064500060

References

Qty.
1
1
1
2
2
1
1

Description

Notes

THERMOSTAT HOUSING
THERMOSTAT
GASKET - THERMOSTAT HSG
BOLT
NUT
PLUG
PLUG

Page 85

Water Outlet & Inlet

Plate A

LDPG0001

Page 86

Water Outlet & Inlet

Plate A

LDPG0001

Item

Part No.

1
2
3

145226320
145996051
011510825

References

Qty.
1
1
2

Description

Notes

CONNECTION
GASKET - THERMOSTAT HSG
SCREW

Page 87

Fan

Plate A

MDPG0003

Page 88

Fan

Plate A

MDPG0003

Item

Part No.

145306730

References

Qty.
1

Description

Notes

FAN

Page 89

Fan Drive

Plate A

MEPG0017

Page 90

Fan Drive

Plate A

MEPG0017

Item

Part No.

1
2

145386390
011310620

References

Qty.
1
4

Description

Notes

PLATE
SCREW

Page 91

Alternator

Plate A

NDPG0002

9
8
11
10

2
3

1
6
12
4

Page 92

Alternator

Plate A

NDPG0002

Item
1
2
3
4
5
6
7
8
9
10
11
12

Part No.

References

TPN766
F TPN766
3113E031
TPN744
2314H022
011510820
185727130
011510825
026100008
011510825
026109017
023100008

Qty.
1
1
1
1
1
3
1
1
1
1
1
1

Description

Notes

ALTERNATOR
ALTERNATOR
ALTERNATOR PULLEY
ALTERNATOR BRACKET
SCREW
SCREW
LEVER
SCREW
WASHER
SCREW
WASHER
NUT

Page 93

Drive Belt & Tensioner

Plate A

NEPG0001

Page 94

Drive Belt & Tensioner

Plate A

NEPG0001

Item

Part No.

080109107

References

Qty.
1

Description

Notes

BELT

Page 95

Front End Drive Output

Plate A

QCPG0001

4
9

1
8

Page 96

Front End Drive Output

Plate A

QCPG0001

Item

Part No.

1
2
3
4
5
6
7
8
9

U65166580
110416290
U65206791
052300850
052300850
U65206791
052300850
2314J017
2318A604

References

Qty.
1
1
1
1
1
1
1
2
2

Description

Notes

PLATE
BEARING HOLDER ASSEMBLY
COVER
SEAL - O RING
SEAL - O RING
COVER
SEAL - O RING
SCREW
NUT

Page 97

Cylinder Head Cover

Plate A

TBPG0002

3
9

10
11

8
1

Page 98

Cylinder Head Cover

Plate A

TBPG0002

Item

Part No.

1
2
3
4
5
6
7
8
9
10
11

111217411
111996401
110566080
011100408
110666210
110666060
015600406
011310640
011310660
024600010
140996270

References

Qty.
1
1
1
4
1
1
6
2
3
4
4

Description

Notes

CYLINDER HEAD COVER


GASKET - CYL. HEAD COVER
BREATHER VALVE
METRIC BOLT
RETAINING PLATE
GAUZE
SCREW
SCREW
SCREW
NUT
WASHER

Page 99

Cylinder Head Cover

Plate B

TBPG0002

Page 100

Cylinder Head Cover

Plate B

TBPG0002

Item

Part No.

1
2
3

135566570
135996950
011310620

References

Qty.
1
1
2

Description

Notes

PIPE - AIR
GASKET
SCREW

Page 101

Feed Pipes

Plate A

TBPG0002

Page 102

Feed Pipes

Plate A

TBPG0002

Item

Part No.

1
2
3

165206810
3688A035
010109600

References

Qty.
1
1
2

Description

Notes

COVER
GASKET
SCREW

Page 103

Exhaust Manifold

Plate A

UBPG0002

1
6
5

4
3

Page 104

Exhaust Manifold

Plate A

UBPG0002

Item

Part No.

1
2
3
4
5
6

135617150
135996780
011510860
010310880
023100008
027100008

References

Qty.
1
1
4
2
2
2

Description

Notes

EXHAUST MANIFOLD
GASKET - EXHAUST MANIFOLD
SCREW
SCREW
NUT
WASHER

Page 105

Exhaust Manifold

Plate A

UDPG5503

Page 106

Exhaust Manifold

Plate A

UDPG5503

Item

Part No.

1
2

314990013
011510825

References

Qty.
1
1

Description

Notes

GASKET - EXHAUST
SCREW

Page 107

Lift Pump

Plate A

VBPG0006

Page 108

Lift Pump

Plate A

VBPG0006

Item

Part No.

1
2
3

130506351
2415A070
2314F003

References

Qty.
1
1
2

Description

Notes

LIFT PUMP
SEAL - O RING
SCREW

Page 109

Fuel Filter

Plate A

VBPG0006

1
6

10

Page 110

11

Fuel Filter

Plate A

VBPG0006

Item

Part No.

1
2
3
4
5
6
7
8
9
10
11

130316190
130366120
130976260
130976250
010111035
026200010
020900010
027100010
010310820
023100008
011510816

References

Qty.
1
1
1
1
2
2
2
2
2
2
2

Description

Notes

FUEL FILTER HEAD


FUEL FILTER
BRACKET
STAY
BOLT
WASHER
NUT
WASHER
BOLT
NUT
SCREW

Page 111

Pipework & Connections

Plate A

VBPG0006

7
9
6
8

2
1
12

13

10

Page 112

11

Pipework & Connections

Plate A

VBPG0006

Item

Part No.

1
2
3
4
5
6
7
8
9
10
11
12
13

TPN673
2411156
068209227
067100015
067100015
131246240
TPN731
2411156
2411156
068209126
067100015
067100015

References

Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1

Description

Notes

FUEL PIPE
WASHER
FUEL PIPE
CLIP
CLIP
CONNECTION
BANJO BOLT
WASHER
WASHER
HOSE
CLIP
CLIP
FUEL FILTER HEAD

Page 113

Cold Start System

Plate A

WDPG0000

Page 114

Cold Start System

Plate A

WDPG0000

Item

Part No.

1
2
3
4
5
6

185366190

References

F 185366190
F 185366190
185376150
020100004
027100004

Qty.
4
1
1
1
1
1

Description

Notes

GLOWPLUG
GLOWPLUG
NUT
BAR
NUT
WASHER

Page 115

Engine Lifting Eyes

Plate A

XBPG0000

2
3

Page 116

Engine Lifting Eyes

Plate A

XBPG0000

Item

Part No.

1
2
3
4

195816100
011510820
026100008
195816100

References

Qty.
1
1
1
1

Description

Notes

LIFTING EYE
SCREW
WASHER
LIFTING EYE

Page 117

Throttle & Stop Controls

Plate A

ZAPG0002

Page 118

Throttle & Stop Controls

Plate A

ZAPG0002

Item

Part No.

1
2
3

U25416480
185206450
025100016

References

Qty.
1
1
1

Description

Notes

CONTROL LEVER
SOLENOID
WASHER

Page 119

Instrumentation

Plate A

ZJPG0000

Page 120

Instrumentation

Plate A

ZJPG0000

Item

Part No.

1
2
3
4
5

198486871
140996260
140996260
064400010

References

Qty.
1
1
1
1
1

Description

Notes

BANJO BOLT
WASHER
WASHER
PLUG
ROCKER BOX ASSEMBLY

Page 121

Instrumentation

Plate A

ZLPG0002

Page 122

Instrumentation

Plate A

ZLPG0002

Item

Part No.

385720500

References

Qty.
1

Description

Notes

WATER TEMPERATURE SENSOR

Page 123

Electrical Wiring & Fittings

Plate A

ZPPG0001

Page 124

Electrical Wiring & Fittings

Plate A

ZPPG0001

Item
1
2

Part No.

References

20195
F 20195

Qty.
1
3

Description

Notes

CONNECTION KIT
CONNECTION

Page 125

Fuel Pre-Lift Pump

Plate A

ZVPG0001

Page 126

Fuel Pre-Lift Pump

Plate A

ZVPG0001

Item

Part No.

1
2
3
5
4
6

130306380

References

F 130306380
26560182
26560183
130306360
26560184

Qty.
1
1
1
3
1
1

Description

Notes

PRE-FUEL FILTER ASSY


FUEL FILTER HEAD
FUEL FILTER BOWL
DRAIN PLUG
FUEL FILTER
SEAL - O RING

Page 127

Parts Index

Page 128

Parts Index

Description

Part No.

Page

ADJUSTING SCREW

199486220

ALTERNATOR

Part No.

Page

31

198486780

35

TPN766

93

198487450

57

ALTERNATOR
BRACKET

TPN744

93

125616120

43

130976260

111

ALTERNATOR
PULLEY

3113E031

93

BREATHER VALVE

110566080

99

ANTI-TAMPER CAP

131276440

47

BUSH

198517222

17

131466270

47

198517226

17

26420462

43

198517229

17

125156261

43

198517290

33

125156262

43

CAMSHAFT

120026950

49

BACKPLATE

110367570

59

CAMSHAFT GEAR

120016240

49

BALL BEARING

040106203

17

CAP

064210012

47

040109057

49

064210018

27

198486871

121

064210030

27, 27

TPN731

113

120186080

27, 27

BAR

185376150

115

036500028

23, 23

BEARING HOLDER
ASSEMBLY

110416290

41, 97

036800010

33

CLAMP

199106021

53, 53

BELT

080109107

95

CLIP

067100015

BIG END BEARING


KIT

U5ME0030

21

113, 113,
113, 113

COLLAR

199236540

33

BOLT

010109341

61

115026330

23

010111030

59

CON ROD
ASSEMBLY

010111035

111

CON ROD BOLT

115176140

23

010310820

111

CON ROD NUT

020109120

23

010700860

21

CONNECTION

131246240

113

011310655

85

140546020

79

131466251

47

145226320

87

ARM

BANJO BOLT

Description

BRACKET

CIRCLIP

Page 129

Parts Index

Description

Part No.

Page

Description

Part No.

Page

CONNECTION KIT

20195

125

FAN

145306730

89

CONTROL LEVER

125046612

45

FUEL FILTER

130306360

127

125046613

45

130366120

111

125306150

45

FUEL FILTER BOWL

26560182

127

125306151

45

FUEL FILTER HEAD

130316190

111

U25416480

119

131507520

53

140116220

33

FUEL INJECTION
PIPE

165206810

103

131507530

53

U65206791

97, 97

131507540

53

CRANKSHAFT
ASSEMBLY

115256990

21

131507550

53

131010080

51

CRANKSHAFT
GEAR

115276270

FUEL INJECTION
PUMP
FUEL PIPE

068209227

113

CRANKSHAFT
PULLEY

115397400

TPN673

113

135996950

101

145996921

83

165996640

43

3688A035

103

GASKET - CYL.
HEAD COVER

111996401

99

GASKET CYLINDER HEAD

111147711

29

111147721

29

GASKET EXHAUST

314990013

107

GASKET EXHAUST
MANIFOLD

135996780

105

GASKET - SUMP

110996920

67

GASKET THERMOSTAT HSG

145996051

87

COVER

21
81

GASKET
U15397401

81

CYLINDER HEAD
ASSEMBLY

111011030

27

CYLINDER HEAD
COVER

111217411

99

DIPSTICK

198416690

69

DIPSTICK TUBE

110756490

69

DOWEL

030500612

17, 21,
21, 21, 21

030500616

17

030501025

17

030509018

33

DRAIN PLUG

26560183

127

EXHAUST
MANIFOLD

135617150

105

EXHAUST VALVE

120176380

Page 130

27

Parts Index

Description

GASKET - TIMING
CASE

Part No.

Page

145996930
165996590

Description

Part No.

Page

85

020109086

81

19

020109177

47

020109239

47

020800010

45

020900010

59, 111

023100006

39, 53,
83, 85

023100008

43, 51,
93, 105,
111

165996630

39

GAUZE

110666060

99

GLOWPLUG

185366190

115

GUDGEON PIN

115326220

23

HOLDER

110156360

21

110156370

21

110156380

21

023100010

31

110156390

21

024500006

45

068209126

113

024600010

99

145537300

83

2318A207

43

HOSE CLIP

2481877

83, 83

2318A604

97

IDLER GEAR

165026270

33

2648A120

43

INJECTOR

131406440

55

198436350

75

INTAKE VALVE

120166380

27

398430080

75

KEY

030509020

21

OIL FILTER

140517050

77

LEVER

185727130

93

OIL PIPE

140607020

35

LIFT PUMP

130506351

109

PIN

030300414

41

LIFTING EYE

195816100

117, 117

030309005

17

MAIN BEARING KIT

U5MB0025

21

031100004

45

U5MB0025A

21

PIPE - AIR

135566570

101

METRIC BOLT

011100408

99

U31607080

57

NEEDLE BEARING

042309017

17

PIPE - FUEL INJ


LEAK OFF

042309018

17

PIPE - OIL SUCTION

140987020

67

020100004

115

PISTON AND RING


KIT

115017491

23

020109076

31

PISTON RING KIT

115107970

23

HOSE

NUT

OIL FILLER CAP

Page 131

Parts Index

Description

Part No.

Page

PLATE

145386390

Part No.

Page

91

010109238

73

199566750

49

010109406

U65166580

19, 97

21, 21,
21, 21

064100045

17

010109600

103

064210010

27

010110625

53

064210025

17, 27, 27

010310880

105

064210040

17, 17, 17

010700820

51

064400010

121

010800820

51

064500030

85

011310612

19, 49,
67, 71

064500060

85

011310614

43

198436290

71

011310620

91, 101

198466010

17

011310635

31, 83

198466020

17

011310640

39, 99

198466920

17

011310660

39, 99

198466940

17

011510816

59, 111

PRE-FUEL FILTER
ASSY

130306380

127

011510820

93, 117

PUSHROD

120456310

31

011510825

87, 93,
93, 107

RELIEF VALVE

140036220

37

011510860

105

RETAINING PLATE

110666210

99

011511070

21, 21, 21

RING

198346160

47

011511220

59

ROCKER ARM
ASSEMBLY

120356131

31

015600406

99

120356141

31

111136480

29

ROCKER BOX

120036821

31

111136490

29

ROCKER SHAFT

120316201

31

131046650

47

ROCKER SHAFT
SPRING

198217170

31

2314F003

109

2314H022

93

SCREW

010109235

2314J017

97

PLUG

Page 132

67, 69

Description

Parts Index

Description

Part No.

Page

2315C039
SEAL - FRONT END
OIL

198636160

SEAL - INJECTOR

131426200

55

131426230

55

Part No.

Page

43, 43

131437730

51

41

131437760

51

199286150

33

199286160

33

052100070

43

199286170

33

052100100

69, 71, 71

199286180

33

SLIDER

125256240

49

052100280

75

052100400

75

SMALL END BUSH

198517265

23

052109076

31, 67

SOLENOID

185206450

119

052109078

37

SPACER

199216320

49

SPEED SENSOR

131046560

45

052300850

41, 97,
97, 97

SPRING

198216720

33

2415A070

109

198217750

43

26560184

127

198217760

33

SEAL - REAR END


OIL

050209083

25

198217870

43

198217880

45

SEAL - ROCKER
BOX

120996130

31

198217910

47

SEAL - VALVE
STEM

120406050

27

STARTER MOTOR

185086600

63

STAY

130976250

111

SEAL - O RING

SHAFT

SHIM

Description

120406070

27

STRAINER

140406680

67

125116211

45

STUD

010109441

17

125116221

45

012109044

31

165296220

17

012110635

17

131437490

51

012110655

29

131437500

51

012110660

17

131437510

51

012110860

29

131437520

51

110708390

67

131437530

51

SUMP

Page 133

Parts Index

Description

Part No.

Page

TAPPET

120116160

31

THERMOSTAT

145206230

85

THERMOSTAT
HOUSING

145046110

85

THRUST WASHER

199266200

21, 21

199266210

21

199266270

33

TIMING CASE

165106870

41

VALVE

198736310

73

VALVE COLLET

120226070

27, 27

VALVE SEAT
INSERT

TPN645

27

TPN646

27

VALVE SPRING

198216700

27, 27

VALVE SPRING CAP

120216041

27, 27

WASHER

025100006

45, 47

025100008

45, 57, 57

025100010

47

025100016

73, 73,
119

026100008

93, 117

026109017

93

026200010

59, 111

027100004

115

027100008

51, 105

027100010

59, 111

Page 134

Description

Part No.

Page

140996260

35, 35,
121, 121

140996270

99

199280300

31

2411156

113, 113,
113

WATER PUMP

145010060

83

WATER PUMP
PULLEY

145336620

65

WATER
TEMPERATURE
SENSOR

385720500

123

WOODRUFF KEY

034100508

49, 81