SENR9833-01

April 2005

Specifications
800 Industrial Engine
UE11-Up (Machine)
UF11-Up (Machine)
 i01658146

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 have the most current information available.

When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SENR9833-01 3
Table of Contents

Table of Contents
Specifications Section
Engine Design ..................................................... 4
Fuel Injection Lines .............................................. 4
Fuel Injection Pump ............................................. 4
Fuel Injectors ....................................................... 5
Fuel Transfer Pump ............................................. 6
Lifter Group ........................................................... 6
Rocker Shaft ........................................................ 7
Valve Mechanism Cover ...................................... 7
Cylinder Head Valves ........................................... 7
Cylinder Head ...................................................... 8
Exhaust Manifold ................................................. 9
Camshaft ............................................................. 9
Engine Oil Relief Valve ........................................ 10
Engine Oil Pump .................................................. 11
Engine Oil Pressure ............................................. 12
Engine Oil Bypass Valve ...................................... 12
Engine Oil Pan ..................................................... 12
Water Temperature Regulator .............................. 13
Cylinder Block ...................................................... 13
Crankshaft ........................................................... 15
Crankshaft Seals ................................................. 16
Connecting Rod Bearing Journal ......................... 16
Main Bearing Journal ............................................ 16
Connecting Rod ................................................... 16
Piston and Rings .................................................. 17
Front Housing and Covers ................................... 19
Gear Group (Front) ............................................... 19
Flywheel ............................................................... 20
Crankshaft Pulley ................................................. 20
Belt Tension Chart ............................................... 21
Alternator and Regulator ...................................... 21
Electric Starting Motor ......................................... 22
Glow Plugs ........................................................... 22

Index Section
Index ..................................................................... 24
4 SENR9833-01
Specifications Section

Specifications Section When the camshaft is viewed from the flywheel end
of the engine, the camshaft rotates in the following
direction: ....................................... Counterclockwise
i01955627
Note: The left side and the right side of the engine
Engine Design are viewed from the flywheel end. The No. 1 cylinder
is the front cylinder.

i01891782

Fuel Injection Lines

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

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

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

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

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

g00993243
Illustration 2
Type of combustion
(1) Tighten the nuts for the fuel injection lines to the
Naturally aspirated engines ...... Indirect injection following torque. ..... 27 to 32 N·m (20 to 24 lb ft)
Turbocharged engines ................. Direct injection

Compression ratio i01906880

Naturally aspirated engines ......................... 22:1 Fuel Injection Pump

Turbocharged engines ................................. 19:1

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

Note: The engine is equipped with an axial piston
Valves per cylinder .................................................. 2 distributor injection pump that is mechanically
governed. Parts that are inside of the fuel injection
Valve lash pump are only serviceable by an authorized dealer.

Inlet valve ....................... 0.25 mm (0.0098 inch)

Exhaust valve ................. 0.25 mm (0.0098 inch)

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

Fuel injection timing ....................................... 5° BTC

When the crankshaft is viewed from the flywheel end

of the engine, the crankshaft rotates in the following
direction: ....................................... Counterclockwise
SENR9833-01 5
Specifications Section

i01959231

Fuel Injectors

Naturally Aspirated Engines

g00993641
Illustration 3

(1) Tighten the overflow valve for the fuel injection

pump to the following torque. ......... 22 to 31 N·m
(16 to 23 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 N·m
(43 to 51 lb ft)
Turbocharged engines .................... 83 to 98 N·m
(62 to 72 lb ft)
g01010241
Illustration 4
(1) Tighten the body in the retaining nut to the
following torque. ..... 34 to 39 N·m (25 to 29 lb ft)
Note: The fuel injector should only be disassembled
and assembled by personnel with the proper training.

(4) Fuel shutoff solenoid
(5) Bolt for attaching to the gear case cover
(6) Delivery valves for the fuel
(2) Tighten the fuel injector in the engine to the
following torque. ..... 53 to 65 N·m (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)
6 SENR9833-01
Specifications Section

Turbocharged Engines i01907139

Fuel Transfer Pump

g00993511
Illustration 5

(1) Tighten the retaining nut to the following

torque. .................... 25 to 34 N·m (18 to 25 lb ft) g00993469
Illustration 6

Note: The fuel injector should only be disassembled

(1) Fuel transfer pump
and assembled by personnel with the proper training.
(2) Torque for one fitting ... 6 to 8 N·m (53 to 71 lb in)
Tighten the clamp bolt that secures the fuel
injector in the cylinder head to the following
(3) Fuel filter/water separator
torque. ........................... 21 to 23 N·m (16 to 17 lb ft)

Type of fuel injector ............................ multiple orifice i01900860

Injection pressure Lifter Group

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

g00988934
Illustration 7

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)
SENR9833-01 7
Specifications Section

Repair limit ...................... 0.08 mm (0.0031 inch) (5) Pushrods

Use a dial indicator to check all pushrods for runout.

i01891826
Replace the pushrod if the runout exceeds the
Rocker Shaft following value. ...................... 0.30 mm (0.0118 inch)

i01892068

Valve Mechanism Cover

g00984738
Illustration 8

(1) Rocker shaft

Diameter of the rocker Illustration 10
g00984870
shaft .................................. 18.980 to 19.000 mm
(0.7472 to 0.7480 inch) (1) Tighten the bolts for the valve mechanism cover
to the following torque. ................... 10 to 13 N·m
(2) Rocker arm (7 to 10 lb ft)
Inside diameter of the rocker arm
bushings ........................... 19.010 to 19.030 mm i01892207
(0.7484 to 0.7492 inch)
Clearance between the rocker arm bushing and Cylinder Head Valves
the rocker shaft ..................... 0.010 to 0.050 mm
(0.0004 to 0.0020 inch)
Maximum permissible clearance between
the rocker arm bushing and the rocker
shaft .............................. 0.070 mm (0.0028 inch)

(3) Spring

(4) Tighten the bolts evenly. Tighten the long

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

g01010358
Illustration 11

g01014064
(1) Valve spring
Illustration 9
8 SENR9833-01
Specifications Section

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)
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 Illustration 12
g00985069
stem .............................. 7.850 mm (0.3091 inch) Bore in the cylinder head for the valve seats
Clearance of the exhaust valve stem in the
exhaust valve guide ............... 0.080 to 0.115 mm Bore for the inlet valve seat
(0.0031 to 0.0045 inch)
Maximum allowable clearance of the exhaust A ....................................................... 45 degrees
valve stem in the exhaust valve guide .. 0.200 mm B ....... 46 to 46.0025 mm (1.8110 to 1.8111 inch)
(0.0079 inch) C ...................... 2 ± 0.1 mm (0.079 ± 0.004 inch)
D ...................... 8 ± 0.1 mm (0.315 ± 0.004 inch)
Valve depth of the exhaust valve below the cylinder
head face Bore for the exhaust valve seat
Standard at assembly ................... 0.4 to 0.6 mm A ....................................................... 45 degrees
(0.016 to 0.024 inch) B .......... 37 to 37.0025 mm (1.457 to 1.458 inch)
Service limit ........................ 1.0 mm (0.039 inch) C ...................... 2 ± 0.1 mm (0.079 ± 0.004 inch)
D ...................... 8 ± 0.1 mm (0.315 ± 0.004 inch)
(5) Inlet valve
Diameter of the inlet valve i01892090
stem ...................................... 7.940 to 7.955 mm
(0.3126 to 0.3132 inch) Cylinder Head
Service limit diameter of the inlet valve
stem ............................... 7.900 mm (0.3110 inch)
Clearance of the inlet valve stem in the inlet valve
guide ..................................... 0.065 to 0.095 mm
(0.0026 to 0.0037 inch)
Maximum allowable clearance of the inlet valve
stem in the inlet valve guide ............... 0.150 mm
(0.0059 inch)

Valve depth of the inlet valve below the cylinder head

face
Standard at assembly ................... 0.3 to 0.5 mm
(0.012 to 0.020 inch)
Service limit ........................ 1.0 mm (0.039 inch)

(6) Angle of the exhaust valve face from the g00984896

horizontal axis Illustration 13
SENR9833-01 9
Specifications Section

Tighten the cylinder head bolts in the sequence that i01892837

is shown to the following torque. ....... 113 to 123 N·m
(83 to 91 lb ft) Camshaft

g00984909
Illustration 14
g00988290
Illustration 16
The permissible distortion of the cylinder head is
given below.
(1) End play of a new camshaft ...... 0.10 ± 0.25 mm
Maximum at assembly .... 0.05 mm (0.0020 inch) (0.0039 ± 0.0098 inch)
Repair limit ...................... 0.20 mm (0.0079 inch)
Maximum permissible end play of a worn
camshaft ................................ 0.30 mm (0.0118 inch)
i01892688
(2) Tighten the thrust plate bolts to the following
Exhaust Manifold torque. ...................... 10 to 13 N·m (7 to 10 lb ft)

(3) The diameters of the camshaft journals are given

in the following table.

Table 1

Diameters of Camshaft Journals

Camshaft Standard Service Limit
Journals Diameter
No. 1,2 53.94 to 53.96 53.90 mm
mm (2.123 to (2.122 inch)
2.124 inch)
No. 3 52.94 to 52.96 52.90 mm
mm (2.084 to (2.083 inch)
2.085 inch)
g00985166
Illustration 15

(1) Bolt

Tighten the exhaust manifold bolts to the following

torque.
Naturally aspirated engines ............ 15 to 22 N·m
(11 to 16 lb ft)
Turbocharged engines .................... 28 to 33 N·m
(21 to 24 lb ft)

Maximum warpage of the flange for the exhaust

manifold .................................. 0.20 mm (0.008 inch)
10 SENR9833-01
Specifications Section

g01014070
Illustration 18

(4) Camshaft

Deflection over the full length of the camshaft

Maximum at assembly .... 0.02 mm (0.0008 inch)
g00987844
Illustration 17 Repair limit ...................... 0.05 mm (0.0020 inch)

(A) Camshaft lobe lift

i01893227
Naturally aspirated engines
Inlet lobe ....................... 6.722 mm (0.2646 inch)
Engine Oil Relief Valve
Exhaust lobe ................. 6.720 mm (0.2645 inch)
Turbocharged engines
Inlet lobe ....................... 6.620 mm (0.2606 inch)
Exhaust lobe ................. 6.722 mm (0.2646 inch)

The service limit for camshaft lobe lift is given below:

Naturally aspirated engines
Inlet lobe ....................... 6.222 mm (0.2450 inch)
Exhaust lobe ................. 6.220 mm (0.2449 inch)
Turbocharged engines
Inlet lobe ....................... 6.182 mm (0.2434 inch)
Exhaust lobe ................. 6.222 mm (0.2450 inch)
g00987876
(B) Camshaft lobe height Illustration 19

(C) Base circle (1) Tighten the engine oil relief valve to the following
torque. .................... 44 to 54 N·m (33 to 40 lb ft)
To determine the lobe lift, use the procedure that
follows: Opening pressure of engine oil relief
valve ................................. 350 ± 50 kPa (50 ± 7 psi)
1. Measure the camshaft lobe height (B).
Note: The engine oil relief valve is located on the left
2. Measure the base circle (C). side of the cylinder block.

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.

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

replace the camshaft.
SENR9833-01 11
Specifications Section

i01893490

Engine Oil Pump

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

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

g00987863
Illustration 22

(3) Clearance between the rotors and the body

Standard ................................... 0.04 to 0.09 mm
(0.0016 to 0.0035 inch)
Service limit .................... 0.15 mm (0.0059 inch)

g00987857
Illustration 20

(1) Clearance between the outer rotor and the body

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

g00996150
Illustration 23

(4) Diameter of main shaft (near

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

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)
g00987861
Illustration 21 (5) Diameter of main shaft (near
bushing) ............................ 13.957 to 13.975 mm
(2) Clearance between the outer rotor and the inner (0.5495 to 0.5502 inch)
rotor
Clearance between the main shaft and the bushing
Standard ................................... 0.13 to 0.15 mm
(0.0051 to 0.0059 inch) Standard ................................ 0.025 to 0.111 mm
Service limit .................... 0.20 mm (0.0079 inch) (0.0010 to 0.0044 inch)
Service limit .................. 0.200 mm (0.0079 inch)
12 SENR9833-01
Specifications Section

i01893585 i01959273

Engine Oil Pressure Engine Oil Pan

Table 2

Oil Pressure(1)
300 to 500 kPa
Oil Pressure at 1500 rpm
(44 to 73 psi)
100 kPa (14.5 psi)
Oil pressure at idle
or more
(1) The oil temperature must be 70° to 90°C (158° to 194°F).

The minimum acceptable oil pressure at low

idle ...................................................... 50 kPa (7 psi)

i01935709

Engine Oil Bypass Valve

g00987891
Illustration 25

(1) Apply 21826038 or 21826051 POWERPART

silicon rubber to the flange of the oil pan. Refer
to illustration 26.

g00987878
Illustration 24

Engine oil bypass valve

Tighten the engine oil bypass valve to the
following torque. ..... 64 to 74 N·m (47 to 55 lb ft)
Opening pressure of engine oil bypass
g01020644
valve ....................................... 1.1 MPa (160 psi) Illustration 26

Note: The engine oil bypass valve is mounted on Note: Apply 21820117 POWERPART threadlock
the inside of the engine oil pan along the left side and nutlock in order to reuse the bolts for the oil pan.
oil pan rail. Apply the sealant to the first 13 mm (0.5118 inch) of
the thread.

(2) Tighten the oil pan bolts to the following

torque. ...................... 10 to 13 N·m (7 to 10 lb ft)
SENR9833-01 13
Specifications Section

i01959901

Cylinder Block

g00987892
Illustration 27

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

torque. .................... 34 to 44 N·m (25 to 33 lb ft)

i01893737

Water Temperature Regulator

g00987933
Illustration 29

(1) Cylinder bore

Table 3
Tolerances of Cylinder Bores
Standard at Repair Service
Assembly Limit(1) Limit(2)
94.000 to
94.200 mm 94.700 mm
Inside 94.035 mm
(3.7087 (3.7283
Diameter (3.7008 to
inch) inch)
3.7022 inch)

Illustration 28
g00877006 0.010 mm
Out of
(0.0004 N/A N/A
Round
inch)
The water temperature regulator starts to open at the
following temperature. .... 82° ± 1.5°C (180° ± 2.7°F) 0.015 mm
Taper (0.0006 N/A N/A
The water temperature regulator has a lift of inch)
more than 8 mm (0.3 inch) at the following (1) Bore the cylinder to the specified oversize dimension if the
temperature. ...................................... 95 °C (203 °F) repair limit has been reached.
(2) Install a cylinder liner or replace the cylinder block if the service
limit has been reached.

Bore the cylinder to the oversize dimension if the

cylinder has uneven wear. Refer to Table 4.

Table 4

Oversize Bore Cylinder Bore Size

94.250 to 94.285 mm
0.250 mm (0.0100 inch)
(3.7106 to 3.7120 inch)
94.500 to 94.535 mm
0.500 mm (0.0197 inch)
(3.7205 to 3.7218 inch)
14 SENR9833-01
Specifications Section

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.

Note: Apply a small amount of

21826038 or 21826051 POWERPART
silicone rubber 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. g01007117
Illustration 31

2. Install the cap to the crankcase so that the rear

(6) Seal for the front and rear main bearing caps.
face of the cap is even with the rear face of the
crankcase.
(7) The seals for the front and the rear main bearing
caps have a curve at one end. The curved side
3. Apply clean engine oil to the threads of the main
must be installed toward the side of the engine.
bearing cap bolts.
The curved end is inserted first into the hole.
Tighten the main bearing cap bolts to the following
Note: Use the 27610013 Rubber plug replacer in
torque. .................... 98 to 108 N·m (72 to 80 lb ft)
order to install the seal correctly.

(8) Before installing the seals, inject a small quantity

of 21826038 or 21826051 POWERPART
silicone rubber in the holes for the seals.

g01007113
Illustration 30

(3) Rear main bearing cap

(4) Main bearing caps should have a marking that Illustration 32

g01007175
indicates placement and orientation.
(9) Seal for the front main bearing cap.
(5) Front main bearing cap
SENR9833-01 15
Specifications Section

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)

g00988954
Illustration 33

(10) Inside diameter of the lifter bore

Standard at assembly ....... 14.000 to 14.018 mm Illustration 35
g00994009
(0.5512 to 0.5519 inch)
Service limit ................ 14.100 mm (0.5551 inch) (A) Original width of the rear crankshaft
journal ............................... 31.000 to 31.039 mm
i01894898 (1.2205 to 1.2220 inch)

Crankshaft Table 5
Width of Crankshaft Journal for Oversize
Thrust Washers
Oversize Width Oversize Width
Oversize Thrust
for Front OR for Front AND
Washer
Rear Rear
31.150 to 31.189 31.300 to 31.339
0.15 mm
mm (1.2264 to mm (1.2323 to
(0.006 inch)
1.2279 inch) 1.2338 inch)
31.300 to 31.339 31.450 to 31.489
0.30 mm
mm (1.2323 to mm (1.2382 to
(0.012 inch)
1.2338 inch) 1.2397 inch)
31.450 to 31.489 31.600 to 31.639
0.45 mm
mm (1.2382 to mm (1.2441 to
(0.018 inch)
1.2397 inch) 1.2456 inch)

Refer to Specifications, “Connecting Rod Bearing

Journal” for information on the connecting rod bearing
journals.

Refer to Specifications, “Main Bearing Journal” for

information on the main bearing journals and the
Illustration 34
g00987940 main bearings.

(1) Crankshaft end play

Standard at assembly ........... 0.100 to 0.264 mm
(0.0039 to 0.0104 inch)
Repair limit ..................... 0.300 mm (0.0118 inch)
16 SENR9833-01
Specifications Section

i01059939 Service limit for clearance between a connecting

rod bearing and a connecting rod bearing
Crankshaft Seals journal ................................. 0.200 mm (0.0079 inch)

i01907583

Main Bearing Journal

Table 7

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)
Undersize Journal 77.705 to 77.720 mm
0.25 mm (0.010 inch) (3.0592 to 3.0598 inch)

g00554030
Undersize Journal 77.455 to 77.470 mm
Illustration 36 0.50 mm (0.020 inch) (3.0494 to 3.0500 inch)

(1) Oil seal Undersize Journal 77.205 to 77.220 mm

0.75 mm (0.030 inch)(2) (3.0396 to 3.0402 inch)
(2) Oil seal sleeve (1) Regrind the main bearing journals to the next undersize
dimension if the repair limit of 77.850 mm (3.0650 inch) is
exceeded.
Inspect the contact surface between the oil seal and (2) Service limit 77.100 mm (3.0354 inch)
the crankshaft for wear. If the crankshaft is worn,
replace the oil seal with an oil seal and a sleeve
The clearance between a new main bearing
assembly.
and a new main bearing journal is the following
value. ..... 0.050 to 0.110 mm (0.0020 to 0.0043 inch)
i01907581

Connecting Rod Bearing i01895665

Journal Connecting Rod

Table 6
Diameter of Crankshaft Journal (Bearing Surface)
For Connecting Rod Bearings
57.955 to 57.970 mm
Original Size Journal(1)
(2.2817 to 2.2823 inch)
Undersize Journal 57.705 to 57.720 mm
0.25 mm (0.010 inch) (2.2718 to 2.2724 inch)
Undersize Journal 57.455 to 57.470 mm
0.50 mm (0.020 inch) (2.2620 to 2.2626 inch)
Undersize Journal 57.205 to 57.220 mm
0.75 mm (0.030 inch) (2.2522 to 2.2528 inch)
(1) Regrind the connecting rod bearing journals to the next
undersize dimension if the repair limit of 57.800 mm
(2.2756 inch) is exceeded.

The clearance between a new connecting rod

bearing and a new connecting rod bearing journal is
the following value. ..................... 0.030 to 0.090 mm
(0.0012 to 0.0035 inch) g00987949
Illustration 37
SENR9833-01 17
Specifications Section

Prior to assembly, apply engine oil to the bearing. Service limit .................. 0.050 mm (0.0020 inch)

(1) Install the bearing cap to the connecting rod Refer to table 8 for the outside diameters of the
and tighten the cap nuts to the following pistons.
torque. .................... 49 to 59 N·m (36 to 44 lb ft)
Table 8
Inside diameter of the piston pin bearing Standard at
Item Service Limit
Assembly
Nominal value ........................ 30 mm (1.18 inch)
Standard at assembly ....... 30.020 to 30.045 mm 93.955 to 93.985
93.770 mm
(1.1819 to 1.1829 inch) Standard mm (3.6990 to
(3.6917 inch)
3.7002 inch)
Clearance between the piston pin and the piston pin 0.25 mm 94.205 to 94.235
bearing 94.020 mm
(0.0098 inch) mm (3.7089 to
(3.7016 inch)
oversize 3.7100 inch)
Standard at assembly ........... 0.020 to 0.051 mm
(0.0008 to 0.0020 inch) 0.50 mm 94.455 to 94.485
94.270 mm
Service limit .................. 0.080 mm (0.0031 inch) (0.0197 inch) mm (3.7187 to
(3.7114 inch)
oversize 3.7199 inch)
End play of the connecting rod that is attached to the
crankshaft. Maximum difference in weight of the piston per
engine ........................................ 0.005 kg (0.0110 lb)
Standard at assembly ............... 0.15 to 0.35 mm
(0.0059 to 0.0138 inch)
Service limit ...................... 0.50 mm (0.020 inch)

i01895761

Piston and Rings

g00987967
Illustration 39

Piston ring end gap

Standard at assembly ............... 0.30 to 0.50 mm
(0.0118 to 0.0197 inch)
Service limit .................... 1.50 mm (0.0591 inch)

g00996359
Illustration 38

(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)
18 SENR9833-01
Specifications Section

Standard at Assembly
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)

Compressed thickness of cylinder head

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

g00987968
Illustration 40

g00987977
Clearance between the piston groove and a new Illustration 42
piston ring
(3) Piston from naturally aspirated engines
No. 1 ring
Standard at assembly ................ 0.07 to 0.11 mm (4) Piston from turbocharged engines
(0.0028 to 0.0043 inch)
Repair limit .................... 0.200 mm (0.0079 inch) (5) “WEIGHT” mark
No. 2 ring (6) “MATCHING” mark
Standard at assembly ........... 0.045 to 0.085 mm
(0.0018 to 0.0033 inch) Note: Assemble the piston and the connecting rod
Repair limit .................... 0.150 mm (0.0059 inch) with the “WEIGHT” mark on the piston and with the
“MATCHING” mark on the rod on the same side.
Oil ring
Standard at assembly ........... 0.025 to 0.065 mm
(0.0010 to 0.0026 inch)
Repair limit .................... 0.150 mm (0.0059 inch)

g00987981
Illustration 43

(7) Camshaft side

Illustration 41
g00987974 (8) End gap of No. 1 compression ring

(2) Protrusion of the piston (9) End gap of No. 2 compression ring

(10) Side with the inlet valve

SENR9833-01 19
Specifications Section

(11) End gap of oil ring i02296835

Apply engine oil to the piston rings. Refer to Gear Group (Front)
Illustration 43 for the assembled configuration of the
ends of the piston rings.

Note: Install the piston with the “O” mark toward the
front of the engine.

i01896193

Front Housing and Covers

g00988013
Illustration 46

(1) Camshaft gear

g00987995
Illustration 44
(2) Idler gear
(1) Tighten the bolts that fasten the front
End play of idler gear
plate to the cylinder block to the following
torque. ...................... 10 to 13 N·m (7 to 10 lb ft) Standard at assembly ............... 0.05 to 0.20 mm
(0.0020 to 0.0079 inch)
(2) Remove the excess gasket with a cutter. 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)

(3) Fuel Injection pump gear

Tighten the bolts for the fuel injection pump gear
to the following torque.
Naturally aspirated engines ............ 59 to 69 N·m
(43 to 51 lb ft)
Turbocharged engines .................... 83 to 98 N·m
(62 to 72 lb ft)
g00987996
Illustration 45
(4) Crankshaft gear
(3) Tighten the bolts that fasten the timing
gear case to the front plate to the following (5) Oil pump gear
torque. ...................... 10 to 13 N·m (7 to 10 lb ft)
(6) Tighten the thrust plate bolts for the idler gear to
the following torque. ....................... 29 to 39 N·m
(21 to 29 lb ft)

(7) Tighten the locknut for the oil pump gear to the
following torque. ..... 28 to 38 N·m (21 to 28 lb ft)
20 SENR9833-01
Specifications Section

Backlash for gears Maximum at assembly .... 0.15 mm (0.0059 inch)

Helical gears at assembly ......... 0.03 to 0.18 mm
(0.0012 to 0.0071 inch)
Spur gears at assembly ................ .03 to .20 mm
(0.0012 to 0.0079 inch)
Service Limit ................... 0.25 mm (0.0098 inch)
Repair limit ........................ 0.50 mm (0.020 inch)
Face and bore runout’s of flywheel
Maximum at assembly .... 0.15 mm (0.0059 inch)
Repair limit ........................ 0.50 mm (0.020 inch)

Engines that have a Balancer

g00988073
Illustration 48
g01152815
Illustration 47
(1) Tighten the bolts for the flywheel to the following
torque. .................... 79 to 88 N·m (58 to 65 lb ft)
1. Measure the balancer shaft. Refer to illustration
47.
i01963669
2. For information on the diameter of the balancer
shaft, refer to table 9. Crankshaft Pulley
Table 9
Balancer Shaft
Shaft diameter Service limit 53.900 mm
53.940 to 53.960 mm (2.1220 inch)
(2.1236 to 2.1244 inch)
Clearance between Service limit 0.15 mm
balancer shaft and the (0.0059 inch)
bushing 0.04 to 0.09 mm
(0.0016 to 0.0035 inch)

Backlash for the balancer gears

Backlash between left hand gear and the right
hand gear ................................. 0.07 to 0.14 mm
(0.0028 ± 0.0055 inch)
Service Limit ................... 0.25 mm (0.0098 inch)
Backlash between right hand gear and the
crankshaft gear ......................... 0.03 to 0.17 mm
(0.0012 to 0.0067 inch)
Service Limit ................... 0.25 mm (0.0098 inch)
g00988100
Illustration 49
i01896629

Flywheel Note: Apply 21826038 POWERPART silicon

adhesive to the threads of the crankshaft before the
pulley nut is installed.

Flatness of friction surface of the flywheel

SENR9833-01 21
Specifications Section

(1) Tighten the nut that fastens the crankshaft

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

(2) Crankshaft pulley

g00988022
Illustration 50

(3) Maximum depth for the top of the V-belt in the

groove ................................... 1.6 mm (0.06 inch)

i01948258

Belt Tension Chart

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

Table 10

Belt Tension Chart

Belt Type Deflection Applied Force for Specified Deflection
Type B 10 to 15 mm (0.4 to 0.6 inch) 98 to 147 N (22 to 33 lb)

i01961063

Alternator and Regulator

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

get the maximum alternator output.

g01014132
Illustration 51

(1) Alternator and regulator

Voltage ...................................................... 13.5 V
Output current at 1500 rpm ..... 20 amp or higher
22 SENR9833-01
Specifications Section

Output current at 3000 rpm ..... 50 amp or higher i01899831

Output current at 5000 rpm ..... 60 amp or higher Glow Plugs

Adjusting voltage of the regulator at 5000 rpm with a
load of 5 amp or lower .................... 14.2 V to 14.8 V
Naturally Aspirated Engines
i01972534

Electric Starting Motor

g01024163
Illustration 52
The starter motor
g00988137
Illustration 53
(1) Electric starting motor
(1) Tighten the glow plugs in the cylinder head to the
(2) Tighten the nut on the starter motor terminal to following torque. ...... 15 to 20 N·m (11 to 15 lb ft)
the following torque. ....................... 18 to 25 N·m
(13.3 to 18.4 lb ft) Type ............................................................... 12 Volt

(3) Tighten the starter motor terminal to the following Current (30 second rating) .................... 9.7 amperes
torque. .................. 2.6 to 4.2 N·m (23 to 37 lb in)
Turbocharged Engines
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

g00988138
Illustration 54

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

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

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

SENR9833-01 23
Specifications Section

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

Index
A I

Alternator and Regulator ....................................... 21 Important Safety Information ................................. 2

B L

Belt Tension Chart ................................................. 21 Lifter Group............................................................ 6

C M

Camshaft ............................................................... 9 Main Bearing Journal............................................. 16

Connecting Rod..................................................... 16
Connecting Rod Bearing Journal........................... 16
Crankshaft ............................................................ 15 P
Crankshaft Pulley .................................................. 20
Crankshaft Seals ................................................... 16 Piston and Rings ................................................... 17
Cylinder Block........................................................ 13
Cylinder Head........................................................ 8
Cylinder Head Valves ............................................ 7 R

Rocker Shaft.......................................................... 7
E

Electric Starting Motor ........................................... 22 S

Engine Design ....................................................... 4
Engine Oil Bypass Valve ....................................... 12 Specifications Section ........................................... 4
Engine Oil Pan....................................................... 12
Engine Oil Pressure............................................... 12
Engine Oil Pump.................................................... 11 T
Engine Oil Relief Valve .......................................... 10
Exhaust Manifold ................................................... 9 Table of Contents................................................... 3

F V

Flywheel ................................................................ 20 Valve Mechanism Cover........................................ 7

Front Housing and Covers..................................... 19
Fuel Injection Lines................................................ 4
Fuel Injection Pump............................................... 4 W
Fuel Injectors ......................................................... 5
Naturally Aspirated Engines............................... 5 Water Temperature Regulator ............................... 13
Turbocharged Engines....................................... 6
Fuel Transfer Pump ............................................... 6

Gear Group (Front)................................................ 19

Engines that have a Balancer ............................ 20
Glow Plugs ............................................................ 22
Naturally Aspirated Engines............................... 22
Turbocharged Engines....................................... 22

©2005 Perkins Engines Company Limited

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