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Specifications: 800D Industrial Engine
Specifications: 800D Industrial Engine
June 2007
Specifications
800D Industrial Engine
UK (Engine)
UL (Engine)
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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.
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KENR6239 3
Table of Contents
Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 4
Fuel Injection Pump ............................................. 4
Fuel Injectors ....................................................... 5
Lifter Group ........................................................... 6
Fuel Transfer Pump ............................................. 6
Rocker Shaft ........................................................ 7
Valve Mechanism Cover ...................................... 7
Cylinder Head Valves ........................................... 8
Cylinder Head ...................................................... 9
Exhaust Manifold ................................................. 9
Camshaft ............................................................. 10
Engine Oil Relief Valve ........................................ 11
Engine Oil Pump .................................................. 11
Engine Oil Pressure ............................................. 12
Engine Oil Bypass Valve ...................................... 13
Engine Oil Pan ..................................................... 13
Water Temperature Regulator .............................. 14
Cylinder Block ...................................................... 14
Crankshaft ........................................................... 16
Crankshaft Seals ................................................. 17
Connecting Rod Bearing Journal ......................... 17
Main Bearing Journal ............................................ 17
Connecting Rod ................................................... 18
Piston and Rings .................................................. 18
Front Housing and Covers ................................... 20
Gear Group (Front) ............................................... 21
Flywheel ............................................................... 21
Crankshaft Pulley ................................................. 22
Belt Tension Chart ............................................... 22
Alternator and Regulator ...................................... 23
Electric Starting Motor ......................................... 23
Glow Plugs ........................................................... 24
Index Section
Index ..................................................................... 25
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4 KENR6239
Specifications Section
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
g01016767
Illustration 1
Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve
Type of combustion
Naturally aspirated engines ...... Indirect injection
Turbocharged engines ................. Direct injection
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KENR6239 5
Specifications Section
i02506427
Fuel Injectors
g01366244
Illustration 3
Typical example
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6 KENR6239
Specifications Section
Lifter Group
g00988934
Illustration 6
g00993511
Illustration 5
Clearance between the lifter and the bore in the
(1) Tighten the retaining nut to the following engine for the lifter
torque. .................... 25 to 34 N·m (18 to 25 lb ft) Standard at assembly ........... 0.016 to 0.052 mm
(0.0006 to 0.0020 inch)
Note: The fuel injector should only be disassembled Repair limit ...................... 0.08 mm (0.0031 inch)
and assembled by personnel with the proper training.
Injection pressure
Standard at assembly .......... 18.14 to 19.12 MPa
(2631 to 2773 psi)
g01353240
Illustration 7
Typical example
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KENR6239 7
Specifications Section
i02509351
Rocker Shaft
Table 1
g01256133
Illustration 9
Required Tools
Part (5) Pushrods
Tool Number Part Description Qty
Place the pushrod in Tooling (B). Use Tooling (A)
A 21825617 Dial Indicator Group 1
in order to check all pushrods for runout. Replace
B - V Block 2 the pushrod if the runout exceeds the following
value. ..................................... 0.30 mm (0.0118 inch)
i01892068
g00984738
Illustration 8
(3) Spring
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8 KENR6239
Specifications Section
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KENR6239 9
Specifications Section
g00985069 g00984909
Illustration 12 Illustration 14
Bore in the cylinder head for the valve seats
The permissible distortion of the cylinder head is
Bore for the inlet valve seat given below.
i01892090
Cylinder Head
g00985166
Illustration 15
(1) Bolt
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10 KENR6239
Specifications Section
i02697692
Camshaft
g00988290 g01353497
Illustration 16 Illustration 17
Typical example
(1) End play of a new camshaft ...... 0.10 ± 0.25 mm
(0.0039 ± 0.0098 inch) (A) Camshaft lobe lift
Maximum permissible end play of a worn Naturally aspirated engines
camshaft ................................ 0.30 mm (0.0118 inch) Inlet lobe ....................... 6.722 mm (0.2646 inch)
Exhaust lobe ................. 6.720 mm (0.2645 inch)
(2) Tighten the thrust plate bolts to the following
torque. ...................... 10 to 13 N·m (7 to 10 lb ft) Turbocharged engines
Inlet lobe ....................... 6.682 mm (0.2631 inch)
(3) The diameters of the camshaft journals are given Exhaust lobe ................. 6.722 mm (0.2646 inch)
in the following table.
Table 2
The service limit for camshaft lobe lift is given below:
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KENR6239 11
Specifications Section
Table 3
Required Tools
Part
Tool Number Part Description Qty
A - Feeler Gauge 1
Number of lobes
Inner rotor ......................................................... 4
Outer rotor ........................................................ 5
g01014070
Illustration 18
(4) Camshaft
i01893227
g01256201
Illustration 20
g00987876
Illustration 19
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12 KENR6239
Specifications Section
g00996150
Illustration 23
i02502471
Table 4
Oil Pressure(1)
Oil Pressure at 1500 rpm 262 ± 48 kPa (38 ± 7 psi)
Oil pressure at idle 200 ± 48 kPa (29 ± 7 psi)
(1) The oil temperature must be 70 ° to 90 °C (158 ° to 194 °F).
g01256204
Illustration 22
The minimum acceptable oil pressure at low
(3) Clearance between the rotors and the body idle .................................................. 152 kPa (22 psi)
Standard ................................... 0.04 to 0.09 mm
(0.0016 to 0.0035 inch)
Service limit .................... 0.15 mm (0.0059 inch)
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KENR6239 13
Specifications Section
i01935709
g01256709
Illustration 25
g00987878
Illustration 24
i02509965
Table 5
Note: Apply Tooling (C) in order to reuse the bolts
for the oil pan. Apply Tooling (C) to the first 13 mm
Required Tools (0.5118 inch) of the thread.
Part
Tool Number Part Description Qty (1) Tighten the oil pan bolts to the following
torque. ...................... 10 to 13 N·m (7 to 10 lb ft)
21826038 POWERPART Silicone
A 1
Sealant
21826051 POWERPART Sealing
B 1
Compound
21820117 POWERPART Threadlock
C 1
and Nutlock
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14 KENR6239
Specifications Section
i02699076
Cylinder Block
Table 6
Required Tools
Part
Tool Number Part Description Qty
21826038 POWERPART Silicone
A 1
Sealant
g01256710
Illustration 27 21826051 POWERPART Sealing
B 1
Compound
(2) Tighten the oil pan drain plug to the following
torque. .................... 34 to 44 N·m (25 to 33 lb ft) 27610013 POWERPART Rubber
C 1
Plug Replacer
i01893737
g00987933
g00877006 Illustration 29
Illustration 28
The water temperature regulator starts to open at the (1) Cylinder bore
following temperature. .... 82° ± 1.5°C (180° ± 2.7°F)
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KENR6239 15
Specifications Section
3. Apply clean engine oil to the threads of the main (8) Before installing the seals, inject a small quantity
bearing cap bolts. of Tooling (A) or Tooling (B) in the holes for the
seals.
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16 KENR6239
Specifications Section
Crankshaft deflection
Maximum at assembly .... 0.02 mm (0.0008 inch)
Repair limit ...................... 0.05 mm (0.0020 inch)
g01353554
Illustration 32
g00994009
i01894898 Illustration 34
Table 8
Illustration 33
g00987940 Refer to Specifications, “Main Bearing Journal” for
information on the main bearing journals and the
(1) Crankshaft end play main bearings.
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KENR6239 17
Specifications Section
i01907583
Table 10
Diameter of Crankshaft Journal (Bearing
Surface) For Main Bearings
77.955 to 77.970 mm
Original Size Journal(1)
(3.0691 to 3.0697 inch)
g01353567
Illustration 35 Undersize Journal 77.705 to 77.720 mm
Typical example 0.25 mm (0.010 inch) (3.0592 to 3.0598 inch)
Undersize Journal 77.455 to 77.470 mm
(1) Oil seal 0.50 mm (0.020 inch) (3.0494 to 3.0500 inch)
Undersize Journal 77.205 to 77.220 mm
(2) Oil seal sleeve
0.75 mm (0.030 inch)(2) (3.0396 to 3.0402 inch)
Inspect the contact surface between the oil seal and (1) Regrind the main bearing journals to the next undersize
the crankshaft for wear. If the crankshaft is worn, dimension if the repair limit of 77.850 mm (3.0650 inch) is
exceeded.
replace the oil seal with an oil seal and a sleeve (2) Service limit 77.100 mm (3.0354 inch)
assembly.
The clearance between a new main bearing
i01907581 and a new main bearing journal is the following
value. ..... 0.050 to 0.110 mm (0.0020 to 0.0043 inch)
Connecting Rod Bearing
Journal
Table 9
Diameter of Crankshaft Journal (Bearing Surface)
For Connecting Rod Bearings
57.955 to 57.970 mm
Original Size Journal(1)
(2.2817 to 2.2823 inch)
Undersize Journal 57.705 to 57.720 mm
0.25 mm (0.010 inch) (2.2718 to 2.2724 inch)
Undersize Journal 57.455 to 57.470 mm
0.50 mm (0.020 inch) (2.2620 to 2.2626 inch)
Undersize Journal 57.205 to 57.220 mm
0.75 mm (0.030 inch) (2.2522 to 2.2528 inch)
(1) Regrind the connecting rod bearing journals to the next
undersize dimension if the repair limit of 57.800 mm
(2.2756 inch) is exceeded.
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18 KENR6239
Specifications Section
i02697820 i02699075
Table 11
Required Tools
Part
Tool Number Part Description Qty
A - Feeler Gauge 1
B 21825617 Dial Indicator Group 1
g00987949
Illustration 36
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KENR6239 19
Specifications Section
Table 12
Standard at
Item Service Limit
Assembly
93.955 to 93.985
93.770 mm
Standard mm (3.6990 to
(3.6917 inch)
3.7002 inch)
0.25 mm 94.205 to 94.235
94.020 mm
(0.0098 inch) mm (3.7089 to
(3.7016 inch)
oversize 3.7100 inch)
0.50 mm 94.455 to 94.485
94.270 mm
(0.0197 inch) mm (3.7187 to
(3.7114 inch)
oversize 3.7199 inch)
g01256909
Illustration 39
g01256910
Illustration 40
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20 KENR6239
Specifications Section
Compressed thickness of cylinder head Note: Install the piston with the “O” mark toward the
gasket ................. 1.2 ± 0.05 mm (0.05 ± 0.002 inch) front of the engine.
i02506518
g00987977
Illustration 41
Note: Assemble the piston and the connecting rod (1) Tighten the bolts that fasten the front
with the “WEIGHT” mark on the piston and with the plate to the cylinder block to the following
“MATCHING” mark on the rod on the same side. torque. ...................... 10 to 13 N·m (7 to 10 lb ft)
g00987981
Illustration 42
g00987996
(7) Camshaft side Illustration 44
(8) End gap of No. 1 compression ring (3) Tighten the bolts that fasten the timing
gear case to the front plate to the following
(9) End gap of No. 2 compression ring torque. .................... 17 to 20 N·m (12 to 15 lb ft)
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KENR6239 21
Specifications Section
i01896267 (7) Tighten the jam nut for the oil pump gear to the
following torque. ..... 28 to 38 N·m (21 to 28 lb ft)
Gear Group (Front)
Backlash for all gears
Standard at assembly ............... 0.03 to 0.18 mm
(0.0012 to 0.0071 inch)
Service Limit ................... 0.25 mm (0.0098 inch)
i01896629
Flywheel
g00988013
Illustration 45
(6) Tighten the thrust plate bolts for the idler gear to
the following torque. ....................... 29 to 39 N·m
(21 to 29 lb ft)
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22 KENR6239
Specifications Section
i02510696
Crankshaft Pulley
Table 13
Required Tools
Part
Tool Number Part Description Qty
g00988022
Illustration 48
21826038 POWERPART Silicone
A 1
Sealant
(3) Maximum depth for the top of the V-belt in the
groove ................................... 1.6 mm (0.06 inch)
i02506524
Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
g00988100
Illustration 47
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KENR6239 23
Specifications Section
Table 14
Belt Tension Chart
Belt Type Deflection Applied Force for Specified Deflection
Type B 10 to 12 mm (0.4 to 0.6 inch) 98 N (22 lb)
i02535554 i02506531
g01024163
Illustration 50
The starting motor
Output current at 1500 rpm ..... 20 amp or higher Speed .................................. 3000 rpm minimum
Current draw ......................... 200 amp maximum
Output current at 3000 rpm ..... 50 amp or higher Voltage ......................................................... 11 V
Output current at 5000 rpm ..... 60 amp or higher When the electric starting motor is viewed from
the drive end, the motor rotates in the following
Adjusting voltage of the regulator at 5000 rpm with a direction. ................................................... Clockwise
load of 5 amp or lower .................... 14.2 V to 14.8 V
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24 KENR6239
Specifications Section
g00988137
Illustration 51
Turbocharged Engines
g01353859
Illustration 52
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KENR6239 25
Index Section
Index
A L
B M
C P
F W
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26 KENR6239
Index Section
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KENR6239 27
Index Section
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©2007 Perkins Engines Company Limited
All Rights Reserved Printed in U. K.
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