Clark Service Manual-712

SF35-45D/L
CMP40-50sD/L
SERVICE MANUAL
RATED CAPACITY : 3500~5000kg
Part No. 8034283

Manual No. SM712
Mar,2004
Manufactured by #40–1, Ungnam-Dong,

Changwon-City, Kyungnam,
Korea
Copyrighted Material
Intended for CLARK dealers only
Do not sell or distribute
GENERAL 00
• 00–01 REVISION HISTORY
• 00–02 FOREWORD
– Foreword
– How to read this manual
• 00–03 SAFETY
– General precautions
– Preparations for work
– Cautions during operation
• 00–04 STANDARDS
– Measurement conversions
– Standard tightening torque
G E N E R A L
REVISION HISTORY
Mar, 2004
00
When new or revised information is published
Mark Indication Action required 01
to update this manual the action to be taken
1
with the pages is indicated in the table. Page to be newly added Add
Pages not marked are not currently revised, Page to be replaced Replace
but are included for page numbering
continuity. ( ) Page to be deleted Discard
Revision Revision Revision Revision Revision

Mark Page Mark Page Mark Page Mark Page Mark Page
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G E N E R A L
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13–14–12 15–02–23Copyrighted 15–02–76
Material 20–03–40 20–03–57
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Intended for CLARK dealers only 20–03–50 20–03–58
G E N E R A L
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30–02–80 50–04–40 70–02–50 Material
Copyrighted
30–02–90 50–04–50 Intended for CLARK dealers only
G E N E R A L
REVISION HISTORY
00 Revision Revision Revision Revision Revision

01 number number number number number
G E N E R A L
FOREWORD
FOREWORD
00
02
1
This shop manual has been prepared as an aid to improve quality of repairs by giving the
serviceman an accurate understanding of the product and by illustrating the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual
and use it to the full effect at every opportunity.
This shop manual mainly contains the technical information necessary for operations performed
in a service workshop.
For ease of understanding, the manual is divided into sections for each main system of the
machine, and the sections are further divided into groups.
SAFETY
• Improper operation and maintenance of this machine could result in serious injury or death.
• Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
• Always keep the Operation and Maintenance Manual and Parts catalogue near the work
area.
• Obey precautions concerning flammable liquids, hazardous fluids, oils, lubricants and
cleaning solvents.
• To prevent injury to workers, this symbol is used to mark safety precautions in this
manual. The precautions accompanying this symbol should always be followed carefully.
• The specifications contained in this shop manual are subject to change at any time and
without any advance notice. Contact your SAMSUNG distributor for the latest information.
HOW TO READ THIS MANUAL
CHAPTER AND SECTION
This manual is issued as a guide to carrying out repair and maintenance. To easily understand
this manual it is divided as follows :
Example) 10 – 01
Section number (01 : Structure and function)
Chapter number (10 : Engine)
G E N E R A L
FOREWORD
00 PAGE
02
2 Page numbering is started from each section. Therefore, revised pages can be easily inserted.
Also, additional pages and revision number can be indicated.
Ex) 15 – 1 ➂
3rd revision
Additional page from page 15
15th page of the section
For the revision status in this manual, refer to REVISION HISTORY.
SYMBOLS
The following symbols as defined below are used in this manual to convey the intent of the
instructions concerning safety and repair.
Symbol Item Remarks
Special safety precautions are necessary when

Safety
performing the work.
Special technical precautions or other precautions for

Caution preserving standards are necessary when performing
the work.
Tightening Places that require special attention for the tightening

torque torque during assembly.
Places that require proper tools used in assembling

Tool
and disassembling.
Adhesive Places to be applied with adhesive.
Lubricating Places where oil or lubricant must be added.
G E N E R A L
SAFETY
00
! WARNING
SERIOUS OR FATAL INJURY MAY RESULT TO YOURSELF OR OTHERS IF NOT FOLLOWED
03
1
This fork lift should not be operated by anyone who is not authorized and properly trained.
Read the Operators Manual carefully, and make yourself familiar with your fork lift.
Inspect and check your fork lift daily before and after use. Do not operate a faulty or damaged fork lift.
Repair work should be done by authorized and trained persons only.
To protect from falling objecs, make sure that the Overhead Guard and Load Backrest are correctly mounted and in good condition.
Before starting engine, always set forward/reverse lever in neutral, with hand brake on.
Drive carefully, keeping forks and attachments as low as possible & fully tilted back.
Keep a careful lookout for people, obstructions and the path of travel. Watch clearance, especially overhead and tail swing.
Do not stick hands, feet and other parts of your body outside the OperatorÕs compartment.
Drive forward when you are climbing a slope with a load. Drive in reverse when you are descending with loads. Do not turn while on a slope.
Slow down before turning. Avoid any sudden start, stop or turning. Lateral tipover can occur if the fork lift is improperly operated.
Do not load fork lift over capacity limit designated on the load chart. Do not lift unstable loads.
This fork lift is not designed for raising or transporting people. Do not use fork lift for those purposes under any circumstances.
Before you get off fork lift make sure the hand brake is set, lower forks or attachments, put forward/reverse lever in neutral position and
turn off key switch. Do not park on a slope. P/NO.6092-13130
GENERAL PRECAUTIONS
SAFETY PRECAUTIONS
• When carrying out any operation or maintenance, have trained and experienced personnel carry
out the work.
• When carrying out any operation or maintenance, carefully read the Operation and Maintenance
Manual.
Read all the precautions given on the decals which are fixed to the machine.
SAFETY DEVICE
• Make sure that all guards and covers are mounted in their proper position. Repair or replace
if damaged.
• Pay attention to the method of using any safety locking device or safety belt.
SAFETY CLOTHES AND HELMET
• Wear the specified work clothes in the correct manner.

• Use the specified protective gear (helmet, safety glasses, safety shoes, mask, gloves).
Guard against injury from flying pieces of metal
or debris, wear goggles, gloves and helmet.
Always have a trained and experienced welder
carry out any welding work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other
clothes suitable for welding work.
EX048
G E N E R A L
SAFETY
00 PREPARE FOR EMERGENCIES

03
2 • Know where fire extinguishers are located and
how to use them.
• Keep a first aid kit and an eye wash kit near
the work area.
• Keep emergency numbers for doctors, ambul-
ance service, hospital, and fire department near
your telephone. EX036
HANDLE FLUIDS SAFELY–AVOID FIRES
• Handle fuel with care it is highly flammable.

• Do not refuel the machine while smoking or
when near open flame or sparks.
Always stop the engine before refueling
machine. Fill the fuel tank outdoors.
• Store flammable fluids away from fire hazards.
EX028
Do not incinerate or puncture pressurized
containers.
DISPOSE OF FLUIDS PROPERLY
• Improperly disposing of fluids can harm the

environment and ecology. Before draining any
fluids, find out the proper way to dispose of
waste from your local environmental agency.
• Catch draining fuel, oil, or other fluids in
suitable containers. Do not use food or
beverage containers that may mislead someone
into drinking from them. Wipe up spills at once.
• Do not pour oil into the ground, down a drain,
or into a stream, pond, or lake. Observe EX043
relevant environmental protection regulations

when disposing of oil, fuel, coolant, brake fluid,
filters, batteries, and other harmful waste.
G E N E R A L
SAFETY
AVOID HARMFUL ASBESTOS DUST

00
03
• Avoid breathing dust that may be generated 3
when handling components containing asbestos
fibers. Inhaled asbestos fibers may cause lung
cancer.
EX025
G E N E R A L
SAFETY
00 PREPARATIONS FOR WORK

03
4
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause

serious injury.
• Before performing any work on the machine,
attach a “Do Not Operate” tag to the steering
wheel or the right control lever.
• When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting.
USE TOOLS PROPERLY
• Use a tool only for its designed application.

• Keep all tools in good condition and know the
correct way to use them.
• Decide on a place in the repair workshop to
keep tools and removed parts.
EX033
• Always keep the work area clean and make
sure that there is no dirt or oil on the floor.
• Before adding oil or making any repairs, park
the machine on hard, level ground and put
blocks under the wheels to prevent the
machine from moving.
• Before starting work, lower the forks or any
other work equipment to the ground.
• Turn the engine OFF, remove the start key,
and apply the parking brake.
• Illuminate your work area adequately but safely.

Use a portable safety light for working inside
or under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of
an accidentally broken bulb can ignite spilled
fuel or oil.
EX042
EX042
G E N E R A L
SAFETY
00
CAUTIONS DURING OPERATION
03
6
SERVICE COOLING SYSTEM SAFELY
• Hot coolant can burn you. Let it cool down.

• Turn the radiator cap slowly to release
pressure. Do not remove cap if engine is
overheated.
EX039E EX029
AVOID HIGH-PRESSURE FLUIDS
• Escaping fluid under pressure can penetrate the skin causing serious injury.
• Avoid the hazard by releasing pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
• Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
EX062
• Be careful not to break, twist or damage the
high pressure pipes.
A jet spray of high pressure oil may cause
electrical fires.
EX040
HANDLING OF HEAVY OBJECTS
• When raising heavy components, use a hoist or crane.

• Check if the wire rope, chains and hooks are free from damage.
• Always use lifting equipment which has ample capacity. Install the lifting equipment at the
correct places.
• Use a hoist or crane and operate slowly to prevent the component hitting any other part.
• When disassembling or assembling, support the
Master link
machine with blocks, jacks or stands before
starting work.
• Before starting work, lower the forks or any
other work equipment to the ground.
• Do not work under the equipment when the
equipment is not sufficiently supported.
Shackle
Safety
hook
G E N E R A L
SAFETY
ELECTRICAL SYSTEM
00
03
• When welding on the machine or working on 7
the electrical system, ALWAYS turn the key
switch OFF and remove the lead from the
battery negative (–) terminal.
• When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
• When working on the battery, wear goggles or

safety glasses.
• Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin and eat holes
in clothing and cause blindness if splashed into
the eyes. If you spill acid on your clothes or
skin, immediately flush with large quantities of
water.
• If splashed into the eyes, flush with water and
get medical attention immediately.
• Keep sparks, lighted matches, and open flame

away from the top of battery. Battery
(hydrogen) gas can explode.
• Battery posts and cables touched by metal

objects can short circuit and burn you.
Keep tools away from posts, wires and
terminals.
Tighten the battery terminals to ensure good
contact.
• When disassembling and assembling the
battery, make sure that the battery terminals
are correctly connected.
• If water gets to the electrical system, abnormal

operation or failure can result.
Do not use water or steam on sensors,
connectors and instruments in the cab.
EX034
G E N E R A L
SAFETY
00 CAUTIONS DURING OPERATION

03
8 NEVER STAND UNDER FORKS
• Do not allow anyone to stand or walk under

the elevated forks, or load.
Failure to comply can cause serious injury or
death.
FX027
FX027
NEVER RIDE ON FORKS
• Never use the forks to lift people.

Failure to comply can cause serious injury or
death.
FX028
FX028
ROTATING PARTS / ALIGNING HOLES
• Never touch rotating part such as the fan

blades or fan belt.
• When aligning two holes, never insert your
fingers or hand.
Be careful not to get your fingers pinched in
a hole, or between parts or tools.
EX035
G E N E R A L
SAFETY
PINCHING AND FALLING

00
03
• Do not put your head, hands, arms or feet into 9
the mast.
Entanglement in the mast can cause serious
injury.
FX028
FX029
• Do not use the mast as a ladder.

Falling from the mast can cause serious injury.
FX030
FX030
INFLATING TIRES
• Do not add air pressure immediately to the

tires when the air pressure is low. Inspect the
rim for damage.
If air pressure is added to the tire when the
rim is damaged, the tire can be exploded
causing serious injury or death.
• Check the valve stem, tread, and side wall for
air pressure leaks. EW013
EW013
• The tire must be inflated by trained personnel

only.
• Make sure there is enough hose to permit the
operator to stand away from the safety cage
when air pressure is added to the tire.
• Add air pressure to the tires only in a safety
cage, as illustrated.
• Always wear safety glasses.
G E N E R A L
SAFETY
00 ! IN CASE OF TIP–OVER
03
10
Lateral tip–over can occur if
! the fork lift is improperly operated.

Don’t risk injury or death.
Buckle up belt
Stay in seat
WARNING Slow down before turning!
IN CASE
! OF TIP–OVER
Follow these
instructions : Hold on to
DANGER Lean away
steering wheel
Brace feet Don’t jump!
Be extremely careful to prevent the fork lift from tipping over during operation. Decelerate
the fork lift sufficiently when turning a corner or tight curve.
The following precautions should be closely observed to ensure safe operation of the fork
lift as well as to protect other persons against injury.
! Always make sure that your seat belt is securely fastened and the top panel latch is in the
locked position.
! If the fork lift begins to tip. DO NOT ATTEMPT TO JUMP CLEAR. The fork lift will fall
faster than you can jump.
Brace your feet and hold yourself inside the operator compartment by holding onto the
steering wheel with both hands.
G E N E R A L
STANDARDS
00
MEASUREMENT CONVERSIONS
04
1
LENGTH
Unit cm m km in ft yd mile
cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006
m 100 1 0.001 39.37 3.2808 1.0936 0.00062
km 100000 1000 1 39370.7 3280.8 1093.6 0.62137
in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015
ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189
yd 91.44 0.9144 0.000914 36 3 1 0.000568
mile 160930 1609.3 1.6093 63360 5280 1760 1
1mm=0.1cm, 1µm=0.001mm
AREA
Unit cm2 m2 km2 a ft2 yd2 in2
cm2 1 0.0001 – 0.000001 0.001076 0.000012 0.155000
m2 10000 1 0.000001 0.01 10.764 1.1958 1550.000
km2 – 1000000 1 10000 1076400 1195800 –
a 0.01 100 0.0001 1 1076.4 119.58 –
ft2 – 0.092903 – 0.000929 1 0.1111 144.000
yd2 – 0.83613 – 0.008361 9 1 1296.00
in2 6.4516 0.000645 – – 0.006943 0.000771 1
1ha=100a, 1mile2=259ha=2.59km2
G E N E R A L
STANDARDS
00 VOLUME
04
2 Unit cm3 = cc m3 l in3 ft3 yd3
cm3 = m l 1 0.000001 0.001 0.061024 0.000035 0.000001
m3 1000000 1 1000 61024 35.315 1.30796
l 1000 0.001 1 61.024 0.035315 0.001308
in3 16.387 0.000016 0.01638 1 0.000578 0.000021
ft3 28316.8 0.028317 28.317 1728 1 0.03704
yd3 764529.8 0.76453 764.53 46656 27 1
1gal(US)=3785.41 cm3=231 in3=0.83267gal(US)
WEIGHT
Unit g kg t oz lb
g 1 0.001 0.000001 0.03527 0.0022
kg 1000 10 0.001 35.273 2.20459
t 1000000 1000 1 35273 2204.59
oz 28.3495 0.02835 0.000028 1 0.0625
lb 453.592 0.45359 0.000454 16 1
1 tonne(metric)=1.1023 ton(US)=0.9842 ton(UK)
PRESSURE
Unit kgf/cm2 bar Pa=N/m2 kPa lbf/in2 lbf/ft2
kgf/cm2 1 0.98067 98066.5 98.0665 14.2233 2048.16
bar 1.01972 1 100000 100 14.5037 2088.6
Pa=N/m2 0.00001 0.001 1 0.001 0.00015 0.02086
kPa 0.01020 0.01 1000 1 0.14504 20.886
lbf/in2 0.07032 0.0689 6894.76 6.89476 1 144
lbf/ft2 0.00047 0.00047 47.88028 0.04788 0.00694 1
kgf/cm2=735.56 Torr(mmHg)=0.96784atm
G E N E R A L
STANDARDS
APPROXIMATE CONVERSIONS
00
04
40
40
Degree °F
Degree °C
3
SI Conv Non-SI Conv SI
20
0
Unit Factor Unit Factor Unit
Torque
32
0
× ×
40
newton meter (N·m) 10.2 = kgf·cm 0.8664 = (lb·in)
newton meter (N·m) × 0.74 = lbf·ft. × 1.36 = N·m
20
newton meter (N·m) × 0.102 = kgf·m × 7.22 = (lbf·ft.)
80
98.6
Pressure (Pa = N/m2)
37
kilopascal (kPa) × 4.0 = in. H2O × 0.249 = kPa
120
kilopascal (kPa) × 0.30 = in. Hg × 3.38 = kPa
60
kilopascal (kPa) × 0.145 = psi × 6.89 = kPa
160
(bar) × 14.5 = psi × 0.069 = (bar)
80
(kgf/cm2) × 14.22 = psi × 0.070 = (kgf/cm2)
200
(newton/mm2) × 145.04 = psi × 0.069 = (bar)
212
100
megapascal (MPa) × 145 = psi × 0.00689 = MPa
240
Power (W = J/s)
120
kilowatt (kW) × 1.36 = PS (cv) × 0.736 = kW
kilowatt (kW) × 1.34 = HP × 0.746 = kW
280
140
kilowatt (kW) × 0.948 = Btu/s × 1.055 = kW
watt (W) × 0.74 = ft·lb/s × 1.36 = kW
320
160
Energy (J = N·m)
kilojoule (kJ) × 0.948 = Btu × 1.055 = kJ
180
360
joule (J) × 0.239 = calorie × 4.19 = J

Velocity and Acceleration
200
400
meter per sec2 (m/s2) × 3.28 = ft/s2 × 0.305 = m/s2

meter per sec (m/s) × 3.28 = ft/s × 0.305 = m/s
220
440
kilometer per hour (km/h) × 0.62 = mph × 1.61 = km/h

Horse Power/Torque
240
BHP × 5252 R.P.M. =TQ (lb·ft) TQ × R.P.M. 5252 = B.H.P.

480
Temperature
260
°C = (°F–32) ÷1.8 °F= (°C × 1.8) + 32

520
Flow Rate
280
l /min (dm3/min) × 0.264 = US gal/min × 3.785 = l /min

560
300
Note : ( ) Non-SI Unit

600
320

G E N E R A L
STANDARDS
00
STANDARD TIGHTENING TORQUE
04
4
The following charts give the standard tightening torques of bolts and nuts.
Exceptions are given in sections of “Disassembly and Assembly”
METER TABLE
Classification 4T, 5T 10T
Bolt type 10.9
Bolt size Torque kgf·m (lbf·ft) Torque kgf·m (lbf·ft)
M4 0.2 ± 0.02 (1.4 ± 0.1) 0.4 ± 0.04 (2.9 ± 0.3)

M5 0.3 ± 0.03 (2.2 ± 0.2) 0.8 ± 0.08 (5.8 ± 0.6)
M6 0.5 ± 0.05 (3.6 ± 0.4) 1.4 ± 0.14 (10.1 ± 1.0)
M8 1.2 ± 0.12 (8.7 ± 0.9) 3.3 ± 0.3 (23.8 ± 2.2)
M10 2.3 ± 0.23 (16.6 ± 1.7) 6.5 ± 0.7 (47 ± 5)
M12 4.0 ± 0.4 (29 ± 3) 11.3 ± 1.1 (82 ± 8)
<M14> 6.4 ± 0.6 (46 ± 4) 17.9 ± 1.8 (129 ± 13)
M16 9.5 ± 0.9 (69 ± 6) 26.7 ± 2.7 (193 ± 19)
<M18> 13.5 ± 1.4 (97 ± 10) 38.0 ± 3.8 (274 ± 27)
M20 18.6 ± 1.9 (134 ± 14) 52.2 ± 5.2 (377 ± 38)
<M22> 24.7 ± 2.5 (178 ± 18) 69.4 ± 6.9 (500 ± 50)
M24 32.1 ± 3.2 (232 ± 23) 90.2 ± 9.0 (650 ± 65)
M30 62.6 ± 6.3 (452 ± 45) 176.1 ± 17.6 (1270 ± 127)
M36 108.2 ± 10.8 (781 ± 78) 304.3 ± 30.4 (2200 ± 220)
M42 171.8 ± 17.2 (1240 ± 124) 483.2 ± 48.3 (3500 ± 350)
M45 211.3 ± 21.1 (1525 ± 152) 594.3 ± 50.4 (4300 ± 430)
SPECIFICATIONS 01
• 01–01 GENERAL
– Location of components
– Instrument panel
– Dimension and weight
• 01–02 LOAD CAPACITY

– Capacity charts
• 01–03 COOLANT / FUEL / LUBRICATION
• 01–04 PERIODIC MAINTENANCE
• 01–05 TIGHTENING TORQUE
S P E C I F I C A T I O N S
GENERAL
LOCATION OF COMPONENTS
01
01
1
10 18 17 9 6 3 8 7
2
1
15 11 14 16 13 12 FX983
1. Mast 10. Counterweight

2. Lift cylinder 11. Steering tire
3. Control lever (Tilt, Lift) 12. Tilt cylinder
4. Carriage 13. Driving wheel
5. Forks 14. Frame
6. Overhead guard 15. Steering axle
7. Steering wheel 16. Driving axle
8. Driver’s seat 17. Rear hood
9. Engine hood 18. LPG Tank(LPG Only)
GENERAL
OPERATOR’S CAB
01 POWERSHIFT TRANSMISSION
01
2
3 1 8 7 9 2
4
13
10 11 14 12
1. Instrument panel 8. Steering knob

2. Turn signal lever 9. Steering wheel
3. Shift lever 10. Inching pedal
(forward–reverse and speed) 11. Brake pedal
4. Parking brake lever 12. Accelerator pedal
5. Lift control lever 13. Floor plate
6. Tilt control lever 14. Start key
7. Horn
GENERAL
INSTRUMENT PANEL
POWERSHIFT TYPE 01
01
3
9 1 2 3 4 5 6 7 8 1 10
14 11 15 12 13
FX986
1. Turn signal pilot lamps 8. Battery discharging warning lamp

2. Transmission abnormality warning 9. Beacon switch (Option)
lamp 10. Panel check switch
3. Transmission oil pressure warning 11. Fuel level gauge(Diesel)
lamp 12. Hour meter
4. Engine oil pressure warning lamp 13. Coolant temperature gauge
5. Air preheating pilot lamp 14. Auto/Manual switch
6. Parking brake pilot lamp 15. LPG Gauge(LPG)
7. Transmission oil temperature
warning lamp
GENERAL
DIMENSION AND WEIGHT
01
01
4
Standard mast mounted

Specification
Item Unit Sym.
CMP40D CMP45D CMP50SD CMP40L CMP45L CMP50SL
SF35D SF40D SF45D SF35L SF40L SF45L
6341 6569 6981 6341 6569 6981
kg [6586] [6814] [7226] [6586] [6814] [7226]
Weight –
(lb) (13980 (14482 (15390 (13980 (14482 (15390
[14520]) 15022]) [15931]) [14520]) 15022]) [15931])
Overall length mm 4160 4200 4390 4160 4200 4390
A
(including forks) (in) (164) (165) (173) (164) (165) (173)
mm
Dimension
Overall width B 1550[1900] (61[75])

(in)
mm
Overall height H 2257[2221] (89[87])
(in)
mm
Min. ground clearance J/K 173[149] (7[6])
(in)
mm
Overhead guard height C 2243[2227] (88[87.5])
(in)
mm Copyrighted Material
Wheel base D 1950(77)
(in)
GENERAL
Specification
Item Unit Sym.
01
Dimension
1295 1245 1295 1245

[1423] /1150 [1423] /1150
/1150 /1150
Wheel distance mm [1423] [1423]
E/F 51 /45) 51 /45)
(Front/Rear) (in) ( [56] (
49
/45) ( [56] (
49
/45)
[56] [56]
Max. load kg 3500 4000 4500 3500 4000 4500

01
(at 600mm load center) (lb) – (7700) (8800) (9900) (7700) (8800) (9900) 5
Max. load kg 4000 4500 5000 4000 4500 5000
(at 500mm load center) (lb) – (8800) (9900) (11000) (8800) (9900) (11000)
mm
Max. lift G 3000(118)
(in)
Free lift degree I 100(4)
Tilt angle mm
M/L 8/10
Basic performance
(Fore/Back) (in)
Fork size mm 1070 125 50 1220 150 50 1070 125 50 1220 150 50
(L W T) (in) – (42 5 2) (48 6 2) (42 5 2) (48 6 2)
Attachment
Load mm
centerdistance N 570[580] (22.4[22.8])
(in)
Driver’s seat mm
height O 1196[1185] (47[46.7])
(in)
Max. steering
degree P/Q 75/53.5
angle
Min. turning radius mm
(RH/LH) R 2590(102)
(in)
Steering wheel mm
height T 1653[1637] (65[64.4])
(in)
Driver’s seat adjustment mm
(Fore/Back) V 100(50/50) (4[2/2])
(in)
8.25 15–14PR 8.25 15–16PR 300 15–18PR 8.25 15–14PR 8.25 15–16PR 300 15–18PR
Front wheel – – [7.50 15–12PR] [7.50 15–12PR] [7.50 15–12PR] [7.50 15–12PR] [7.50 15–12PR] [7.50 15–12PR]
Tire
Rear wheel – – 7.00 12–14PR
kg 66[78] 20
Fuel tank capacity –
(lb) (17.4[20.6]) (43.5)
Others
Hydraulic oil tank l

capacity – 65(17.1)
(US gal)
l
Coolant tank capacity – 17(4.5)
(US gal)
∗ Remarks : The dimension in [ ] is based on dual tire type.
GENERAL
PERFORMANCE
Specification
01 Item Unit
CMP40D
SF35D
CMP45D
SF40D
CMP50SD CMP40L CMP45L CMP50SL
SF45D SF35L SF40L SF45L
km/hr 20.3[19.0] 20.3[19.0] 20.4[19.0] 22.0[20.6] 22.0[20.6] 22.1[20.6]
01 No load
(mile/hr) (12.6[11.8]) (12.6[11.8]) (12.7[11.8]) (13.7[12.8]) (13.7[12.8]) (13.7[12.8])
6 Max. speed
km/hr 19.1[18.1] 19.0[18.0] 19.2[17.9] 20.7[19.7] 20.6[19.5] 20.9[19.4]
Full load
(mile/hr) (11.9[11.2]) (11.8[11.2]) (11.9[11.1]) (12.9[12.2]) (12.8[12.1]) (13.0[12.1])
kg 1779[1950] 1744[1915] 1729[1900] 1336[1513] 1306[1483] 1370[1464]
No load
Max. drawbar (lb) (2940[3330]) (2880[3270]) (3020[3230]) (2945[3336]) (2880[3270]) (3020[3230])
pull kg 3664[3873] 3834[4043] 3611[3886] 3208[3220] 3230[3243] 3298[3311]
Full load
(lb) (7470[7500]) (7480[7680]) (7650[7620]) (7072[7100]) (7120[7150]) (7270[7300])
Overall
Max. gradeability Full load degree 21.7[22.4] 21.1[21.8] 18.2[19.2] 17.9[18.5] 16.7[17.2] 15.0[15.9]
Braking distance m 4.5[4.4] 4.7[4.6] 4.9[4.8] 4.5[4.4] 4.7[4.6] 4.9[4.8]

(at 20km/hr) (ft) (14.8[14.4]) (15.4[15.1]) (16.1[15.7]) (14.8[14.4]) (15.4[15.1]) (16.1[15.7])
Fork lift up speed| mm/sec 540/520 540/510 540/500 590/540 590/530 590/520
(No load/Full load) (in/sec) (21.2/20.5) (21.2/20) (21.2/19.7) (23.2/21.2) (23.2/20.9) (23.2/20.5)
Lift cylinder drift mm/5min
25(0.98)
(at 50°C oil temp) (in/5min
Tilt cylinder drift mm/5min
10(0.39)
(at 50°C oil temp) (in/5min
Type – 1104C-44 V6
Rated output PS/RPM
82.4/2200(61.5/2200) 77/2000(56.7/2000)
(kw/rpm)
kg·m/
Max. torque 30.8/1400 27.7/1800
RPM
No. of cylinders EA 4 6
Cylinder diameter stroke mm(in) 105 127(4.13 5) 101.6 88.39(4.012 3.48)
Displacement CC 4400 4300
Compression ratio – 19.3 9.2
Weight (Dry) kg (lb) 273(600)
Fuel – Diesel LPG
Engine system
–
–
Idling RPM 750
R.P.M
Full load RPM 2200 2000
(Range : ±50RPM)
No load RPM 2400 2650
Cooling method Force circulation
Opening
temp °C 82 80.5~84.4
Thermostat
Cooling system
Full open
temp °C 96 94.4
Type – 7 Blade pusher type 6 Blade clutch fan
Fan Diameter mm(in) 482.6(19) 508(20)
Drive ratio – 0.85 : 1 1.324 :1
Type Copyrighted Materialraw edge type
V–Belt 6 Rib/k section
Fan belt
Size Intended for CLARK dealers only
GENERAL
Specification
Item Unit
Water pump @1600RPM l /min 140(37.0)
01
Cooling system
capacity @2400RPM (US gal/min) 213(56.2)

Recommended anti–freeze – AF–Coolant
Cooling system capacity l (US gal) 17(4.5)
01
kg/cm2 7
Pressure (Radiator cap) (lb/in2) 1.0
Fuel pump type – Diaphragm

Fuel system
Fuel injection pump – Bosch EPVE –

Governor – Mechanical Pneumatic
Fuel filter type – Single element type –
66 l [77 l ]
Engine system
Fuel tank capacity – 20kg(43.5 lb)

(17.4us gal [20.6us gal])
Lubrication system
Lubrication type – Force lubrication

Oil pump type – Gear pump
Pressure kg/cm2(lb/in2) 2.8 ~ 4.2 1.26(18)
Engine
Capacity Max. 7.0 ~ Min 5.3
oil l (US gal) 4.3(1.1)
(Including filter) (Max. 1.85 ~ Min 1.4)
System voltage V 12
Voltage V 12
Cold cranking(@–18°C) AMP 850
Electric system
Battery Min. capacity(@20Hrs)

AMP · H 110
Charging voltage V 12
Alternator V–AMP 12 – 55 12 – 65
Capacity V–KW 12 – 3.0 12 – 2.5
Starter Cranking ratio – 11.45:1 15.27:1
Vendor – Denso P95 PG260
Ignition order – 1–3–4–2 1–6–5–4–3–2
Type – Powershift
Transmission Model – SFT45
Model – S–11
Power transmission system
Torque
converter Torque ratio – 2.23
Reduction ratio, First stage – 1.774
Transmission Second stage – 1.0
Reduction ratio, Differential gear – 3.5
Driving axle Axle end – 4.895
Transmission clutch working kg/cm2 17.0~18.0
pressure (@1800RPM) (lb/in2) (240~255)
Torque converter charging kg/cm2 3.0~7.5
pressure (@2000RPM) (lb/in2) (42.5~105)
Transmission oil capacity l (US gal) 13(3.4)
Driving axle oil capacity l (US gal) 9(2.4)
Service brake type – Hydraulic (Wet disk type)
Braking system
Type – Hydraulic assist

Brake valve
Size mm(in) φ 28.6 28 (φ 1.1 1.1)
Brake oil capacity l (US gal) Copyrighted Material 1.0(0.26)
Parking brake type – Intended for CLARK dealers Hand (Drum brake)
only
GENERAL
Specification
Item Unit
01 Steering
system
Relief setting
pressure
kg/cm2
(lb/in2)
140
(2000)
110
(1550)
Steering Type – Load sensing
01 unit Displacement CC/REV 160 140
Steering system
8 Diameter mm(in) 400(16)

Steering
Rev. No. –
wheel 4.7
(Lock to lock)
Steering Diameter mm(in) φ 90 φ 60(φ 3.5 φ 2.4)

cylinder Stoke mm(in) 215(8.5)
Type – Counter balance valve built–in type
l /min
Main valve Max. flow rate (US gal/min)
150(40) 144(38)
Max. pressure kg/cm2(lb/in2) 246(3500)

Relief setting kg/cm 2
200 210 200 210
Main valve (lb/in2)
pressure (2850) (3000) (2850) (3000)
Type – Gear pump
Rated pressure kg/cm2(lb/in2) 210(3000) 270(3800)
Hydraulic system
Main pump
Displacement CC/REV 43.4 33+25
R.P.M RPM 600~2700 600~3000
Numbers EA 2
Lift cylinder Diameter (Bore) mm(in) 70(2.75)
Stroke mm(in) 1500(59)
Numbers EA 2
Tilt cylinder Diameter (Bore) mm(in) 100(3.9)
Stroke mm(in) 195(7.7)
Hydraulic tank capacity l (US gal) 65(17.2)
Type – BL834
Pitch mm(in) 25.4(1)
Lift chain Plate thickness mm(in) 4.09(0.15)
Steering system
Layers (Total) EA 7
Pin diameter mm(in) 9.56(0.38)
Chain sheave Numbers EA 2
Mast and Mast EA 4
carriage
roller aring Carriage EA 6
Carriage Numbers EA 2
thrustroller
Weight of counterweight 1825 2150 2475 1825 2150 2475

kg(lb)
(4025) (4740) (5450) (4025) (4740) (5450)
∗ Remarks : The dimension in [ ] is based on dual tire type.
LOAD CAPACITY
CAPACITY CHARTS
CMP40D/CMP40L(DUAL TIRE)
SF35D/SF35L(DUAL TIRE)
CMP45D/CMP45L(DUAL TIRE)
CMP50sD/CMP50sL(DUAL TIRE)
01
(kg) (kg)
4500 4500
(kg)
4500 02
4250 4250 4250
4000 4000 4000
MFH 3000 & 3700 1
MFH 3000 & 3700
3750 3750 3750
MFH 3000 & 3700
3500 3500 3500
3250 3250 3250
3000 3000 3000
2750 2750 2750
2500 2500 2500
MFH 4500
2250 2250 2250
MFH 4500
2000 2000 2000
MFH 4500
1750 1750 1750
1500 1500 1500
1250 1250 1250
1000 1000 1000
750 750 750
500 500 500
500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200
CMP40D/CMP40L(SINGLE TIRE) CMP45D/CMP45L(SINGLE TIRE) CMP50sD/CMP50sL(SINGLE TIRE)

SF35D/SF35L(SINGLE TIRE) SF40D/SF40L(SINGLE TIRE) SF45D/SF45L(SINGLE TIRE)
(kg) (kg) (kg)
4500 4500 4500
4250 4250 4250
MFH 3000 & 3700
4000 4000 4000
MFH 3000 & 3700
3750 3750 3750
MFH 3000 & 3700
3500 3500 3500
3250 3250 3250
3000 3000 3000

2750 2750 2750
2500 2500 2500
2250 2250 2250
MFH 4500 MFH 4500
2000 2000 2000
MFH 4500
1750 1750 1750
1500 1500 1500
1250 1250 1250

1000 1000 1000
750 750 750
500 500 500
500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200 500 600 700 800 900 1000 1100 1200
FX201
• The charts are for standard mast. Optional devices such as the high mast, attachment, will
reduce the allowable load weight.
LOAD CAPACITY
LOAD WEIGHT AND STABILITY
01 The fork lift can be regarded as a seesaw where

the front wheels act as a fulcrum upon which
the counterweight load on the rear wheels is
02 counterbalanced by the load on the forks.
2 Loads that exceed the specified allowable
limits (weight / load center / lift) will cause the
rear wheels to float, reduce steering perfor-
mance, and can tip over the fork lift.
LOAD CENTER AND CAPACITY CHART
The distance between the center of the load and

the fork carriage is called the load center. The
charts shown here represent the relation
between the load center and the allowable load
weight.
When you drive the unit, lift the forks about
30cm above the floor or road and fully tilt the
mast backward. Lifting the load or tilting the
mast forward while driving will change the load
center and may tip the fork lift over. FX104
• Position the load against the backrest and

support at least 2/3 of load length with both
forks.
• Loading by the tip of the forks may damage the mast or forks.
• Avoid extreme side unbalance to prevent the load from slipping off.
• Operate the tilt control lever carefully when you handle the load.
• Abrupt forward tilt operation may cause the fork lift to tip over.
RATED CAPACITY PLATE
Rated capacity, lifting height and actual capacity

for load center distance are shown on the rated
capacity plate.
COOLANT / FUEL / LUBRICATION
CHART
Unit : l (gal)
Division
Ambient temperature Filling capacity 01
–22 –4 14 32 50 68 86 104 122°F CMP40/45D/50SD CMP40/45L/50SL
–30 –20 –10 0 10 20 30 40 50°C SF35/40/45D SF35/40/45L 03
1
ISO VG22 or VG15
65
Hydraulic oil ISO VG32
(17)
ISO VG46
SAE 10W–50
7 5
Engine oil
(1.8)
SAE 5W–30
20
Antifreeze solution Water 50%, Antifreeze 50% (5.3)
20 kg
Propone gas HD–5 –
(43.5 lb)
Fuel ASTM D975 NO.1 ➀ 66 (17.5)

–
ASTM D975 NO.2 ➁ 78 (20.6)
Transmission oil
Model Transmission Drive Axle

SF35–SF45 Clark #2776236 Clark #2776236
CMP40–CMP50s
ASTM : American Society of Testing and Material
SAE : Society Automotive Engineers
API : American Petroleum Institute
ISO : International Standardization Organization
➀ SF 35D /40D/45D – Single tire
➁ SF 35D /40D/45D – Dual tires
PERIODIC MAINTENANCE
No.
Period
First
month
First
Every 1
month
Every
Every 3
months
Every
Every 6
months
Every
Every 12
months
Every
01
200 200 500 1000 2000
Items
hours hours hours hours hours
04
Engine system 1
1. Inspection and adjustment (or replacement)

1) Intake / Exhaust valve clearance
2) Belt tension
3) Cylinder head bolts and manifold nuts
4) Fuel strainer (Filter)
5) Idling speed
6) Electrolyte specific gravity (Battery)
7) Starting motor and alternator
8)
9)
10)
11)
12)
2. Cleaning
1) Radiator exterior (Fins)
2) Fuel strainer element (Filter)
3) Air cleaner element
4) Fuel tank interior
5) Cooling system interior (Radiator)
3. Draining
1) Water separator
2)
4. Replacement
1) Engine oil
2) Engine oil filter
3) Coolant
4) Fuel filter element
5) Air cleaner element
6) Water separator
∗ If you operate the fork lift in a dusty environment, “ ” marked items must be checked more
frequently.
First Every 1 Every 3 Every 6 Every 12

Period month month months months months
No. First Every Every Every Every
01 Items 200
hours
200
hours
500
hours
1000
hours
2000
hours
Chassis and Attachment
04 1. Inspection and adjustment (or replacement)
2
1) Brake pedal and inching pedal clearance
2) Parking brake lever and operation
3) Lift chain tension
4) Carriage bearing
5) Mast bearing
6) Mast operation
7) Tilt and lift cylinder fitting
8) Tilt and lift cylinder operation
9) Hydraulic pump operation
10) Gear oil (differential and axle end)
11) Transmission oil
12)
13)
2. Lubrication
1) Lift chain
2) Mast mounting bushing and pin
3) Joints
4) Tilt cylinder mounting pin and bearing
5) Side roller (Carriage)
6) Steering axle bearing and arm
7) Universal joint
3. Cleaning
1) Torque converter intake filter
2) Hydraulic oil tank interior
4. Replacement
1) Transmission oil
2) Transmission oil filter
3) Hydraulic oil
4) Hydraulic oil filter
5) Gear oil (differential and axle end)
6) Brake fluid
7) Wheel bearing grease
∗ If you operate the fork lift in a dusty environment, “ ” marked items must be checked more
frequently. Copyrighted Material
∗ Change oil and filter afterIntended
the first
for 50 hoursdealers
CLARK and only
again after 100 operating hours when the
transaxle is new or rebuilt. Do not sell or distribute
LUBRICATION
Perform periodic maintenance, replacement and lubricating according to following lubrication chart
to maintain optimum condition. Otherwise, service life will be reduced and breakdowns may occur
frequently. 01
04
3
CO AntiÐfreeze
Lubricant G Grease HO Hydraulic oil
Replace EO Engine oil GO Gear oil
Check TO Transmission oil BO Brake fluid
Lift chain Transmission oil

EO TO TO
RH,LH(2points)
Mast mounting
G
RH,LH(2point)
Tilt cylinder end

Axle oil G
GO GO RH,LH(4points)
Hydraulic oil
HO HO
Brake oil
BO BO
Hydraulic oil filter
Transmission oil
Fuel filter
filter
(Diesel)
Fuel(Diesel) Coolant
CO CO
Air Cleaner
Hydraulic breather
Engine oil Wheel bearing

EO EO G
RH,LH(2points)
Engine oil filter Steering linkage

LPG G
RH,LH(4points)
Steering king pin Fuel(LPG)

G
RH,LH(4points)
Every 10 hours or daily
Every 200 hours or monthly
Every 500 hours or every 3 months
Every 1000 hours or every 6 months
Every 2000 hours or yearly
FX204
TIGHTENING TORQUE
TIGHTENING TORQUE
Unit : kgf·m (lbf·ft)
No. Item Unit

Torque
01
1 Mounting bracket, engine kg f · m
(ft · lb) 10.2~12.4 (74~90) 05
2 Flange, exhaust manifold, engine kgf· m 4.1~5.1 (30~37) 5.1~6.1 (37~44) 1
(ft · lb)
3 Mounting bracket, transmission kgf· m 24~29.4 (175~210)
(ft · lb)
Bolt, mounting bracket, brake pedal kgf· m
4 (ft · lb) 5.8~7.2 (40~50)
and inching pedal
5 Bolt, mounting bracket, brake valve kgf· m 10~11 (72~80)
(ft · lb)
Bolt, mounting bracket, clutch master kgf· m
6 (ft · lb) 6~6.5 (43~47)
cylinder
7 Bolt, brake valve kgf· m
(ft · lb) 6~6.5 (43~47)
8 Bolt, steering axle and silent block kgf· m
(ft · lb) 40~50 (290~360)
9 Bolt, parking brake lever kgf· m
(ft · lb) 5.8~7.2 (40~50)
10 Bolt, silent block kgf· m
(ft · lb) 24~29.4 (175~210)
11 Nut, front wheel kgf· m
(ft · lb) 45~50 (325~360)
12 Nut, rear wheel kgf· m
(ft · lb) 35~40 (250~290)
13 Bolt, pin key, tilt cylinder kgf· m
(ft · lb) 4.4~5.4 (32~39)
14 Bolt, pin key, rod end, tilt cylinder kgf· m
(ft · lb) 4.4~5.4 (32~39)
15 Bolt, rod end and yoke, tilt cylinder kgf· m
(ft · lb) 17.1~19.1 (125~140)
16 Bolt, priority valve kgf· m
(ft · lb) 3~3.6 (22~25)
17 Bolt, mounting bracket, main valve kgf· m
(ft · lb) 5.8 ~ 7.2 (40 ~ 50)
18 Bolt, main valve kgf· m
(ft · lb) 4.4 ~ 5.4 (32 ~ 39)
19 Bolt, main pump kgf· m
(ft · lb) 10.7 ~ 12.9 (75 ~ 90) 9.0 ~ 11.0 (65 ~ 80)
20 Bolt, auxiliary pump kgf· m
(ft · lb) 5.8 ~ 7.2 (40 ~ 50) –
21 Bolt, steering unit kgf· m
(ft · lb) 3.8 ~ 4.6 (25 ~ 35)
22 Bolt, steering column kgf· m
(ft · lb) 5.8 ~ 7.2 (40 ~ 50)
23 Nut, steering wheel kgf· m
(ft · lb) 7.7 ~ 9.3 (55 ~ 65)
24 Bolt, counterweight kgf· m
(ft · lb) 45 ~ 50 (325 ~ 360)
25 Bolt, engine hood kgf· m
(ft · lb) 4.1 ~ 5.1 (30 ~ 35)
26 Bolt, overhead guard kgf· m
(ft · lb) 9.4 ~ 11.4 (70 ~ 80)
27 Bolt, rear hood kgf· m
(ft · lb) 4.1 ~ 5.1 (30 ~ 35)
28 Nut, carriage thrust roller kgf· m
(ft · lb) 15 ~ 20 (110 ~ 145)
29 Bolt, lift cylinder, mast kgf· m
(ft · lb) 5.8 ~ 7.2 (40 ~ 50)
30 Bolt, pin key, chain sheave kgf· m
(ft · lb) 4.1 ~ 5.1 (30 ~ 35)
31 Bolt, stopper, inner mast kgf· m
(ft · lb) 8.6 ~ 10.4 (60 ~ 75)
Copyrighted
kgf· m Material
32 Bolt, stopper, inner mast (Urethane)
Intended (ft
for· CLARK
lb) dealers only 3.6 (25)
ENGINE–1104C– 44
(FOR DIESEL) 13
• 13 – 01 GENERAL INFORMATION
• 13 – 02 SPECIFICATIONS
• 13 – 03 CYLINDER HEAD ASSEMBLY
• 13 – 04 PISTONS AND CONNECTING ROD ASSEMBLIES
• 13 – 05 CRANKSHAFT ASSEMBLY
• 13 – 06 TIMING CASE AND DRIVE ASSEMBLY
• 13 – 07 CYLINDER BLOCK ASSEMBLY
• 13 – 08 ENGINE TIMING
• 13 – 09 LUBRICATION SYSTEM
• 13 – 10 FUEL SYSTEM
• 13 – 11 COOLING SYSTEM
• 13 – 12 FLYWHEEL AND HOUSING
• 13 – 13 ELECTRICAL EQUIPMENT
• 13 – 14 LIST OF SPECIAL TOOLS
• 13 – 15 PREVENTIVE MAINTENANCE
• 13 – 16 SPECIAL TOOLS
E N G I N E – 1 1 0 4 C – 4 4
GENERAL INFORMATION
GENERAL INFORMATION
INTRODUCTION
This Workshop Manual has been written to provide assistance in the service and overhaul of
Perkins 1100 Series 4 cylinder engines. It should be used in conjunction with normal workshop
practise and information contained in current service bulletins. Mention of certain accepted practices
therefore, has been purposely omitted in order to avoid repetition. For overhaul procedures the
assumption is made that the engine is removed from the application.
The engine conforms with USA (EPA/CARB) stage 2 and EEC stage 2 emissions legislation for
agriculture, construction and industrial applications.
Most of the general information which is included in the relevant User’s Handbook has not
13
been repeated in this workshop manual and the two publications should be used together. 01
Where the information applies only to certain engine types, this is indicated in the text. 1
The details of some operations will be different according to the type of fuel injection pump which
is fitted. The specific pump type used can be found by reference to the manufacturer’s identification
plate on the pump body but, generally, the type of pump fitted is as shown below :
• Delphi - DP210 Series
When reference is made to the "lef" or "right" side of the engine, this is as seen from the flywheel
end of the engine.
Special tools have been made available and a list of these is given in Chapter 16, Special tools.
Reference to the relevant special tools is also made at the beginning of each operation.
POWERPART recommended consumable products are listed under "POWERPART recommended

consumable products" on page 9. Reference to the relevant consumable products is also made
at the beginning of each operation.
Data and dimensions are included in Chapter 2, Specifications.
Read and remember the "Safety precautions" on page 5.

They are given for your protection and must be used at all times.
Danger is indicated in the text by two methods :
! This indicates that there is a possible danger to the person.

! This indicates that there is a possible danger to the engine.
Note :
Is used where the information is important, but there is not a danger.
E N G I N E – 1 1 0 4 C – 4 4
GENERAL INFORMATION
ENGINE VIEWS
13
01
2
E N G I N E – 1 1 0 4 C – 4 4
GENERAL INFORMATION
ENGINE IDENTIFICATION
The Perkins 1100 Series 4 cylinder engines have been designed for industrial, construction and
agricultural applications. There are a range of four cylinder engines with or without electronics,
available in naturally aspirated, turbocharged and air to air charge cooled models.
In this Workshop Manual, the different models are indicated by their code letters. The first two
letters of the engine number are indicated below :
RE Naturally aspirated
RF Naturally aspirated, electronic
RG Turbocharged
RH
RJ
Turbocharged, electronic
Turbocharged, charge cooled
13
RK Turbocharged, charge cooled, electronic
01
3
Continued
E N G I N E – 1 1 0 4 C – 4 4
GENERAL INFORMATION
The Perkins 1100 Series 4 cylinder engines have been designed for agricultural, industrial and
construction applications.
The correct identification of the engine is by the full engine number.
The engine number is stamped on a label which is fastened to the left side (A2) of the cylinder
block. An example of an engine numbe is :
RE.....*U.......*
If you need parts, service or information for your engine, you must give the complete engine
number to your Perkins Dealer/Distributor. If there is a number in the area of the label marked
TPL No, then this number must also be given to your Perkins Dealer/Distributor.
Other identification labels fitted to the engine include :
13 • A label (A1) with the fuel injection pump part numbers.

• An emissions legislation label (A3), (A6), (A7) and (C1) can be fitted in four different positions
on the engine.
01 • A “Ether” warning label (A5) is fitted on the intake manifold.
4 • A “caution please read User’s Handbook label”(A4) is screen printed into the atomiser cover.
If a short engine has been fitted in service, two engine serial numbers and a TPL number are
stamped on the engine serial number label (B3).
The engine serial number plate (B) contains the following information :
• TPL number (1).
• Type (2).
• Serial number (3).
• List number (4).
IA
E N G I N E – 1 1 0 4 C – 4 4
GENERAL INFORMATION
SAFETY PRECAUTIONS
These safety precautions are important. You must refer also to the local regulations in the
country of use.
Some items only refer to specific applications.
• Only use these engines in the type of application for which they have been designed.
• Do not change the specification of the engine.
• Do not smoke when you put fuel in the tank.
• Clean away fuel which has been spilt. Material which has been contaminated by fuel must be
moved to a safe place.
• Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
• Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the
correct training; even then extreme care must be used to prevent injury).
• Do not make adjustments that you do not understand.
13
• Ensure that the engine does not run in a location where it can cause a concentration of toxic
emissions.
01
5
• Other persons must be kept at a safe distance while the engine or auxiliary equipment is in
operation.
• Do not permit loose clothing or long hair near moving parts.
• Keep away from moving parts during engine operation.
! Some moving parts cannot be seen clearly while the engine runs.
• Do not operate the engine if a safety guard has been removed.
• Do not remove the filler cap, or any component of the cooling system while the engine is hot
and while the coolant is under pressure because dangerous hot coolant can be discharged.
• Do not allow sparks or fire near the batteries (especially when the batteries are on charge)
because the gases from the electrolyte are highly flammable. The battery fluid is dangerous to
the skin and especially to the eyes.
• Disconnect the battery terminals before a repair is made to the electrical system.
• Only one person must control the engine.
• Ensure that the engine is operated only from the control panel or from the operator s position.
• If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
• Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain
persons. Protect your hands with gloves or a special solution to protect the skin.
• The combustible material of some components of the engine (for example certain seals) can
become extremely dangerous if it is burned. Never allow this burnt material to come into contact
with the skin or with the eyes, see "Viton seals" on page 8 for safety precautions.
• Do not wear clothing which is contaminated by lubricating oil. Do not put material which is
contaminated with oil into the pockets of clothing.
• Discard used lubricating oil in a safe place to prevent contamination.
• Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the
engine is started.
• Use extreme care if emergency repairs must be made in adverse conditions.
• Read and use the instructions relevant to "Engine lift equipment" on page 7.
Continued
E N G I N E – 1 1 0 4 C – 4 4
GENERAL INFORMATION
• Always use a safety cage to protect the operator when a component is to be pressure tested
in a container of water. Fit safety wires to secure the plugs which seal the hose connections of
a component which is to be pressure tested.
• Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain
medical help immediately.
• Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and items
away from the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
• Do not clean an engine while it runs. If cold cleaning fluids are applied to a hot engine, certain
components on the engine may be damaged.
• Fit only genuine Perkins parts.
13
01
6
E N G I N E – 1 1 0 4 C – 4 4
GENERAL INFORMATION
ENGINE LIFT EQUIPMENT
The maximum weight of the engine without coolant, lubricant, or a gearbox fitted will vary for
different applications. It is recommended that lift equipment of the minimum capacity listed below
is used :
Four cylinder engines 600 kg (1320 lbs)
Note :
Use lift equipment or obtain assistance to lift heavy
engine components such as the cylinder block,
cylinder head, balancer unit, flywheel housing,
crankshaft and flywheel.
Before the engine is lifted :

13
• Always use lift equipment of the approved type and
of the correct capacity to lift the engine. It is 01
recommended that lift equipment of the type shown 7
in (A) is used, to provide a vertical lift directly
above the engine lift brackets (A1). Never use a
single lift bracket to raise an engine.
• Check the engine lift brackets for damage and that

they are secure before the engine is lifted. The
torque for the setscrews for the engine lift brackets
is 44 Nm (33 lbf ft) 4,5 kgf m.
• To prevent damage to the rocker cover, ensure that

there is clearance between the hooks and the
rocker cover.
E N G I N E – 1 1 0 4 C – 4 4
GENERAL INFORMATION
VITON SEALS
Some seals used in engines, and in components fitted to engines, are made of Viton. Viton is
used by many manufacturers and is a safe material under normal conditions of operation.
If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never
allow this burnt material to come into contact with the skin or with the eyes.
If it is necessary to come into contact with components which have been burnt, ensure that the
precautions which follow are used:
• Ensure that the components have cooled.
• Use neoprene gloves and discard the gloves safely after use.
• Wash the area with calcium hydroxide solution and then with clean water.
13 • Disposal of components and gloves which are contaminated must be in accordance with local
regulations.
If there is contamination of the skin or eyes, wash the affected area with a continuous supply of
01 clean water or with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical
8
attention.
SAFETY CAUTIONS WHEN AN ENGINE IS CLEANED
Care should be taken, when an engine is cleaned with a high pressure cleaning system.
! • Do not wash an engine while it runs or while it is hot. If cold cleaning fluids are applied to
a hot engine, certain components on the engine could be damaged.
• Leave the engine to cool for at least one hour and disconnect the battery connections before
cleaning.
• Do not wash any part of the fuel injection pump (FIP), cold start device, electrical shut off
solenoid (ESOS) or electrical connectors.
• Ensure that the alternator, starter motor and any other electrical components are shielded
and not directly cleaned by the high pressure cleaning system.
If these cautions are ignored, the engine or certain components could be damaged, fail to operate
and also make the manufacturer’s warranty invalid.
E N G I N E – 1 1 0 4 C – 4 4
GENERAL INFORMATION
POWERPART RECOMMENDED CONSUMABLE PRODUCTS
Perkins have made available the products recommended below in order to assist in the correct
operation, service and maintenance of your engine and your machine. The instructions for the use
of each product are given on the outside of each container. These products are available from
your Perkins distributor.
POWERPART Antifreeze
Protects the cooling system against frost and corrosion. Part number 21825166.
POWERPART Atomiser thread sealant

To seal the threads of the atomiser into the cylinder head. Part number 21825474. 13
POWERPART Easy Flush
01
Cleans the cooling system. Part number 21825001. 9
POWERPART Gasket and flange sealant

To seal flat faces of components where no joint is used. Especially suitable for aluminium
components. Part number 21820518.
POWERPART Gasket remover

An aerosol for the removal of sealants and adhesives. Part number 21820116.
POWERPART Griptite
To improve the grip of worn tools and fasteners. Part number 21820129.
POWERPART Hydraulic threadseal

To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and
pneumatic systems. Part number 21820121.
POWERPART Industrial grade super glue

Instant adhesive designed for metals, plastics and rubbers. Part number 21820125.
POWERPART Lay-Up 1
A diesel fuel additive for protection against corrosion. Part number 1772204.
POWERPART Lay-Up 2
Protects the inside of the engine and of other closed systems. Part number 1762811.
POWERPART Lay-Up 3
Protects outside metal parts. Part number 1734115.
Intended for CLARK dealers only Continued
E N G I N E – 1 1 0 4 C – 4 4
GENERAL INFORMATION
POWERPART Metal repair putty

Designed for external repair of metal and plastic. Part number 21820126.
POWERPART Pipe sealant and sealant primer

To retain and seal pipe connections with coarse threads. Pressure systems can be used
immediately. Part number 21820122.
POWERPART Radiator stop leak

For the repair of radiator leaks. Part number 21820127.
POWERPART Red rubber grease

13 Provides lubrication for the fitting of O rings. Part number 21820221.
0101 POWERPART Retainer (high strength)

10 To retain components that have an interference fit. Part number 21820638.
POWERPART Retainer (oil tolerant)

To retain components that have an interference fit, but is in contact with oil. Part number 21820603.
POWERPART Safety cleaner

General cleaner in an aerosol container. Part number 21820128.
POWERPART Silicone adhesive

An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets.
Used for sealing flange where oil resistance is needed and movement of the joint occurs. Part
number 21826038.
POWERPART Silicone RTV sealing and jointing compound

Silicone rubber sealant that prevents leakage through gaps. Part number 1861108.
POWERPART Stud and bearing lock

To provide a heavy duty seal to components that have a light interference fit. Part number
21820119 or 21820120.
POWERPART Threadlock and nutlock

To retain small fasteners where easy removal is necessary. Part number 21820117 or 21820118.
POWERPART Universal jointing compound

Universal jointing compound that seals joints. Part number 1861117.
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
SPECIFICATIONS
BASIC ENGINE DATA
Number of cylinders :
RE, RF, RG, RH, RJ, RK ......................................................................................................................................................... 4
Cylinder arrangement ......................................................................................................................................................... In line
Cycle ................................................................................................................................................................................. Four stroke
Direction of rotation .................................................................................................................... Clockwise from the front
Induction system :
RE, RF ............................................................................................................................................................ Naturally aspirated
RG, RH ...................................................................................................................................................................... Turbocharged
13
RJ, RK ..................................................................................................................................... Turbocharged, charge cooled
Combustion system. ......................................................................................................................................... Direct injection 02
1
Nominal bore :
RE, RF, RG, RH, RJ, RK .................................................................................................................. 105 mm (4.133 in)
Stroke ................................................................................................................................................................. 127 mm (5.00 in)
Compression ratio :
RE, RF ........................................................................................................................................................................................ 19.3:1
RG, RH, RJ, RK ................................................................................................................................................................... 18.2:1
Cubic capacity :
RE, RF, RG, RH, RJ, RK .................................................................................................................. 4,4 litres (268 in3)
Firing order :
RE, RF, RG, RH, RJ, RK ...................................................................................................................................... 1, 3, 4, 2
Valve tip clearances (cold) :

Inlet .................................................................................................................................................................. 0,20 mm (0.008 in)
Exhaust ......................................................................................................................................................... 0,45 mm (0.018 in)
Lubricating oil pressure (1)
RE, RF, RG, RH, RJ, RK. .................................................................................. 300 kpa (43 lbf/in2) 3,0 kgf/cm2
(1) Minimum at maximum engine speed and normal engine temperature.
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
DATA AND DIMENSIONS
Note :
This information is given as a guide for personnel engaged on engine overhauls. The dimensions
which are shown are those which are mainly used in the factory. The information applies to all
engines, unless an engine type code is shown.
CYLINDER HEAD
Angle of valve seat :
13 - Intake ................................................................................................................................................ 30 (120 included angle)

- Exhaust ....................................................................................................................................... 30 (120 included angle)
Leak test pressure ................................................................................................. 200 kPa (29 lbf/in2) 2,04 kgf/cm2
02 Head thickness ...................................................................................................... 117,95/118,05 mm (4.643/4.647 in)
2
Rz and Rmaz to be measured to DIN EN ISO 4287
Surface finish of head face for cylinder head joint .......................................... Rz < 15um Rmax < 20um
Permissible wave depth :
Wt < 4um with a wave distance Wd < 2,0 mm
Diameter of parent bore for valve guide :
- Intake .................................................................................................................. 13,000/13,027 mm (0.5118/0.5129 in)
- Exhaust ............................................................................................................. 13,000/13,027 mm (0.5118/0.5128 in)
Minimum permissible thickness after head face has been machined .............. 117,20 mm (4.614 in)
Maximum permissible distortion of cylinder head face

A1 .................................................................................................................................................................. 0,03 mm (0.0012 in)
A2 .................................................................................................................................................................. 0,05 mm (0.0019 in)
A3 .................................................................................................................................................................. 0,05 mm (0.0019 in)
A4 .................................................................................................................................................................. 0,03 mm (0.0012 in)
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
INTAKE AND EXHAUST VALVES
Intake valves
Diameter of valve stem .................................................................................... 8,953/8,975 mm (0.3525/0.3533 in)
Clearance in valve guide ................................................................................... 0,025/0,069 mm (0.001/0.0027 in)
Maximum permissible clearance in valve guide :
- Production limit ................................................................................................................................ 0,069 mm (0.0027 in)
- Service limit ............................................................................................................................................ 0,13 mm (0.005 in)
Diameter of valve head ......................................................................................... 46,20/46,45 mm (1.819/1.829 in)
Angle of valve face ................................................................................................................................................................... 30
Full length ................................................................................................................. 128,92/129,37 mm (5.076/5.093 in)
Seal arrangement ........................................................................................ Stem seal with integral seating washer
Depth of valve head below the face of cylinder head :
13
- Production limits, RE and RF ............................................................................. 0,58/0,84 mm (0.023/0.033 in) 02
- Service limit, RE and RF .............................................................................................................. 1,09 mm (0.043 in) 3
- Production limits, RG, RH, RJ, RK ................................................................. 1,58/1,84 mm (0.062/0.072 in)
- Service limit, RG, RH, RJ, RK ................................................................................................... 2,09 mm (0.082 in)
Exhaust valves
Diameter of valve stem .................................................................................... 8,938/8,960 mm (0.3519/0.3528 in)
Clearance in valve guide ...................................................................................... 0,040/0,84 mm (0.0016/0.033 in)
Maximum permissible clearance in valve guide :
- Production limits ................................................................................................................................ 0,084 mm (0.003 in)
- Service limit ............................................................................................................................................ 0,15 mm (0.006 in)
Diameter of valve head ......................................................................................... 41,51/41,75 mm (1.634/1.644 in)
Angle of valve face ................................................................................................................................................................... 30
Full length ................................................................................................................. 128,92/129,37 mm (5.075/5.093 in)
Seal arrangement ........................................................................................ Stem seal with integral seating washer
Depth of valve head below face of cylinder head :
- Production limits, RE and RF ............................................................................. 0,53/0,81 mm (0.021/0.032 in)
- Service limit, RE and RF .............................................................................................................. 1,06 mm (0.042 in)
- Production limits, RG, RH, RJ, RK ................................................................. 1,53/1,81 mm (0.060/0.071 in)
- Service limit, RG, RH, RJ, RK ................................................................................................... 2,06 mm (0.081 in)
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
DIMENSIONS OF RECESSES FOR VALVE SEAT INSERTS
MODELS RE AND RF
Intake
A1 .............................................................................................................................. 9,910/10,040 mm (0.3902/0.3953 in)
A2 ............................................................................................................................ 47,820/47,845 mm (1.8827/1.8837 in)
A3 ........................................................................................................................... Radius 0,38 mm (0.015 in) maximum
Exhaust
A1 .............................................................................................................................. 9,910/10,040 mm (0.3901/0.3952 in)
13 A2 ............................................................................................................................ 42,420/42,445 mm (1.6701/1.6711 in)
02
4 MODELS RG, RH, RJ AND RK
Intake
A1 ............................................................................................................................ 10,910/11,040 mm (0.4295/0.4346 in)
A2 ............................................................................................................................ 47,820/47,845 mm (1.8827/1.8837 in)
Exhaust
A1 ............................................................................................................................ 10,910/11,040 mm (0.4295/0.4346 in)
A2 ............................................................................................................................ 42,420/42,445 mm (1.6701/1.6711 in)
A3 ................................................................................................................................................... Radius 0,38 mm (0.015 in)
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
VALVE SEAT INSERT TOOL
Intake
A1 ......................................................................................................................................................................... 1,5 mm (0.06 in)
A2 ........................................................................................................................................................................ 20 mm (0.800 in)
A3 ................................................................................................................................................. 6,8/7,1 mm (0.267/0.279 in)
A4 ........................................................................................................................................................................ 100 mm (3.94 in)
A5 ...................................................................................................................................... 38,10/38,30 mm (1.500/1.507 in)
A6 ...................................................................................................................................... 46,25/46,50 mm (1.820/1.830 in)
A7 .............................................................................................................................. Radius 1,4 mm (0.055 in) maximum
A8 ........................................................................................................................................................ Radius 1,5 mm (0.06 in)
A9 ......................................................................................................................................................................... 1,5 mm (0.06 in)
A10 ......................................................................................................................................... 8,77/8,80 mm (0.345/0.346 in) 13
Exhaust 02
5
A1 ......................................................................................................................................................................... 1,5 mm (0.06 in)
A2 ........................................................................................................................................................................ 20 mm (0.800 in)
A3 ................................................................................................................................................. 7,2/7,5 mm (0.283/0.295 in)
A4 ........................................................................................................................................................................ 100 mm (3.94 in)
A5 ...................................................................................................................................... 34,38/34,58 mm (1.353/1.361 in)
A6 ...................................................................................................................................... 41,75/42,00 mm (1.643/1.653 in)
A7 .............................................................................................................................. Radius 1,4 mm (0.055 in) maximum
A8 ........................................................................................................................................................ Radius 1,5 mm (0.06 in)
A9 ......................................................................................................................................................................... 1,5 mm (0.06 in)
A10 ......................................................................................................................................... 8,77/8,80 mm (0.345/0.346 in)
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
VALVE GUIDES AND VALVE SPRINGS
Valve guides
Inside diameter of partially finished guide ........................................... 8,250/8,350 mm (0.3248/0.3287 in)
Inside diameter of finished guide .............................................................. 9,000/9,022 mm (0.3543/0.3552 in)
Outside diameter :
- Intake .................................................................................................................. 13,034/13,047 mm (0.5131/0.5137 in)
- Exhaust ............................................................................................................. 13,034/13,047 mm (0.5131/0.5137 in)
Interference fit of valve guide in cylinder head ................................ 0,007/0,047 mm (0.0003/0.0019 in)
Full length ...................................................................................................................... 51,00/51,50 mm (2.008/2.028 in)
Protrusion from bottom of recess for valve spring ............................... 12,35/12,65 mm (0.486/0.498 in)
13 Valve springs
02 Fitted length :
6 Models, RE and RF .............................................................................................................................. 33,5 mm (1.319 in)
Models RG, RH, RJ and RK .......................................................................................................... 34,5 mm (1.358 in)
Load at fitted length :
Models, RE and RF ..................................................................................................................... 254 N (57 lbf) 26,0 kgf
Models RG, RH, RJ and RK ................................................................................................. 229 N (51 lbf) 23,0 kgf
Number of active coils ............................................................................................................................................................. 3.8
Number of damper coils ............................................................................................................................................................. 0
Direction of coils ......................................................................................................................................................... Right hand
TAPPETS, ROCKER SHAFT, ROCKER LEVERS
Tappets
Diameter of tappet stem ............................................................................ 18,987/19,012 mm (0.7480/0.7485 in)
Diameter of tappet bore in cylinder block ....................................... 19,050/19,082 mm (0.7500/0.7513 in)
Clearance of tappet in cylinder block ...................................................... 0,038/0,095 mm (0.0015/0.0037 in)
Rocker shaft
Outside diameter ............................................................................................. 24,962/24,987 mm (0.9828/0.9837 in)
Rocker levers and bushes

Diameter of parent bore for rocker lever ......................................... 25,013/25,051 mm (0.9848/0.9863 in)
Clearance between rocker lever bore and rocker shaft ................. 0,026/0,89 mm (0.0010/0.0035 in)
Maximum permissible clearance between rocker lever bore and rocker shaft .................. 0,17 mm (0.007 in)
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
PISTONS AND PISTON COOLING JETS
Pistons
Type ..................... Fastram combustion bowl, re-entrant angle 80 (turbocharged), 70 (naturally aspirated)
Diameter of bore for gudgeon pin ...................................................... 39,703/39,709 mm (1.5631/1.5633 in)
Height of piston above top face of cylinder block ................................. 0,21/0,35 mm (0.008/0.0137 in)
Width of groove for top ring :
- Engine types RE and RF ................................................................................ 2,58/2,60 mm (0.1015/0.1023 in)
- Engine types RG, RH, RJ, RK .......................................................................................................................... Tapered
Width of groove for second ring ..................................................................... 2,54/2,56 mm (0.0999/0.1007 in)
Width of groove for third ring ........................................................................... 3,52/3,54 mm (0.1385/0.1393 in)
Piston cooling jets

13
Valve open pressure ...................................................................... 150/250 kPa (22/36 lbf/in2) 1,5/2,5 kgf/cm2 02
7
PISTON RINGS
Top compression ring :

- Engine types, RE and RF ...................................................... Barrel face, molybdenum insert, rectangular
- Engine types RG, RH, RJ, RK ................................................ Barrel face, molybdenum insert, keystone
Second compression ring ...................................................... Taper face, cast iron, internal bottom chamfer
Oil scraper ring ........................................................................... Two piece coil spring loaded, chromium faced
Width of top ring :
- Engine types, RE and RF .................................................................................... 2,47/2,49 mm (0.097/0.098 in)
- Engine types RG, RH, RJ, RK .......................................................................................................................... Tapered
Width of second ring ................................................................................................... 2,47/2,49 mm (0.097/0.098 in)
Width of third ring .................................................................................................... 3,47/3,49 mm (0.1366/0.1374 in)
Clearance of top ring in groove :
- Engine types, RE and RF .............................................................................. 0,09/0,13 mm (0.0035/0.0051 in)
- Engine types RG, RH, RJ, RK ............................................................................................................................. Wedge
Clearance of second ring in groove .................................................................. 0,05/0,09 mm (0.002/0.003 in)
Clearance of third ring in groove ................................................................... 0,03/0,07 mm (0.0011/0.0027 in)
Gap of top ring .......................................................................................................... 0,30/0,55 mm (0.0118/0.0216 in)
Gap of second ring ................................................................................................. 0,70/0,95 mm (0.0275/0.0374 in)
Gap of third ring ....................................................................................................... 0,30/0,55 mm (0.0118/0.0216 in)
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
CONNECTING RODS AND BIG END BEARINGS
Connecting rods
Type ............................................................................................................ H shape section, wedge shape small end
Location of cap to connecting rod .............................................................................................................. Fracture split
Diameter of parent bore for big end ....................................................... 67,21/67,22 mm (2.6460/2.6465 in)
Diameter of parent bore for small end ........................................................ 43,01/43,03 mm (1.693/1.694 in)
Length grades .................................................................................................................................................. F, G, H, J, K, L
Length between centres (parent bores) ................................................. 219,05/219,10 mm (8.624/8.626 in)
Big end bearings
13 Type :
- Naturally aspirated engines ............................................... 8 x Steel back, tin/aluminium bearing material
- Turbocharged engines bearing cap .............................. 4 x Steel back, tin/aluminium bearing material
02 - Turbocharged engines bearing rod ........................... 4 x Steel back, leaded bronze bearing material
8
Width ................................................................................................................................. 31,55/31,88 mm (1.240/1.255 in)
Thickness at centre of bearings ................................................................. 1,835/1,842 mm (0.0723/0.0725 in)
Bearing clearance ................................................................................................ 0,030/0,081 mm (0.0012/0.0032 in)
Available undersize bearings .......................... 0,25 mm (-0.010 in); -0,50 mm (-0.020 in); -0,75 mm (-0.030 in)
GUDGEON PINS AND SMALL END BUSHES
Gudgeon pins
Production :
Type ............................................................................................................................................................................... Fully floating
Outside diameter ............................................................................................. 39,694/39,700 mm (1.5628/1.5630 in)
Clearance fit in piston boss ........................................................................ 0,003/0,015 mm (0.0001/ 0.0006 in)
Small end bushes

Type ...................................................................................................................................................... Steel back, lead bronze
Outside diameter .................................................................................................. 43,66/43,84 mm (1.7190/1.7259 in)
Inside diameter ................................................................................................. 39,723/39,738 mm (1.5638/1.5645 in)
Surface finish grade ............................................................................................................................. Ra 0,8 micrometers
Clearance between bush in small end and gudgeon pin ....................... 0,023/0,044 mm (0.0009/0.0017 in)
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
CRANKSHAFT
Diameter of main journals ......................................................................... 76,159/76,180 mm (2.9984/2.9992 in)

Maximum wear and ovality on journals and crank pins .............................................. 0,04 mm (0.0016 in)
Width of centre journa ........................................................................................... 44,15/44,22 mm (1.738/1.741 in)
Width of all other journals ................................................................................... 39,24/39,34 mm (1.545/1.549 in)
Diameter of crank pins. ......................................................................................... 63,47/63,49 mm (2.499/2.500 in)
Width of crank pins .................................................................................................. 40,35/40,42 mm (1.589/1.591 in)
Diameter of flange ......................................................................................... 135,27/135,32 mm (5.3257/5.3277 in)
Depth of recess for spigot bearing ............................................................. 20,40/20,60 mm(0.8031/0.8112 in)
Bore of recess for spigot bearing ........................................................... 46,96/46,99 mm (1.8488/ 1.8499 in)
Crankshaft end-float ...................................................................................................... 0,05/0,38 mm (0.002/0.015 in)
Maximum permissible end-float ...................................................................................................... 0,51 mm (0.020 in)
Fillet radii of journals and crank pins ................................................................ 3,68/3,96 mm (0.145/0.156 in)
13
Undersize journals and crank pins ..................... -0,25 mm (-0.010 in); -0,51 mm (-0.020 in); -0,76 mm (-0.030 in)
02
9
Crankshaft heat treatment
- Induction hardened .......................................................................................... Part number 3131D074, 4114A006
- Nitrocarburised .................................................................................................... Part number 3131D072, 4112A005
CRANKSHAFT OVERHAUL
Note :
• Nitrocarburised crankshafts must be hardened again each time they are machined. These
crankshafts must be nitrocarburised or, if this process is not available, they can be nitrided for
20 hours. If neither process is available a new crankshaft, or a “new for old” crankshaft, must
be fitted.
• Check the crankshaft for cracks before and after it is ground. Demagnetise the crankshaft after
it has been checked for cracks.
• After the crankshaft has been machined remove any sharp corners from the lubricating oil holes.
• Surface finish and fillet radii must be maintained and require Ra 0.4 um.
Continued
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
The finished sizes for crankshaft journals (A) which have been ground undersize are given in the
table below :
0.25 mm 0.51 mm 0.76 mm

Item
(0.010 in) (0.020 in) (0.030 in)
75.909 / 75.930 mm 75.649 / 75.670 mm 75.399 / 75.420 mm
1
(2.9884 / 2.9892 in) (2.9784 / 2.9792 in) (2.9684 / 2.9692 in)
63.220 / 63.240 mm 62.960 / 62.982 mm 62.708 / 62.728 mm
2
(2.488 / 2.4896 in) (2.4788 / 2.4796 in) (2.4688 / 2.4696 in)
3 39.47 mm (1.554 in) maximum – –
4 37.44 mm (1.474 in) maximum – –
5 44.68 mm (1.759 in) maximum – –
13 6
7
8
40.55 mm (1.596 in) maximum
Do not machine
Do not machine
–
–
–
–
–
–
02 9 3.68/3.96 mm (0.1448/0.1452 in) – –
10
Surface finish for journals, crank pins and fillet radii must be 0,4 microns (16 micro inches). Surface
finish for the seal area of the crankshaft palm must be 0,4/1,1 microns (16/43 micro inches).
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
With the crankshaft on mountings at the front and rear journals, the maximum run-out (total indicator
reading) at the journals must not be more than shown below:
Journal Maximum run-out

1 Mounting
2 0.08 mm (0.0031 in)
3 0.15 mm (0.0059 in)
4 0.08 mm (0.0031 in)
5 Mounting
Run-out must not be opposite. The difference in run-out between one journal and the next must
not be more than 0,10 mm (0.004 in).
Run-out on the crankshaft pulley diameter, rear oil seal diameter and the rear flange diameter
must not be more than 0,05 mm (0.002 in) total indicator reading.
13
MAIN BEARINGS 02
11
Type ................................................................................................... Steel back with, tin/aluminium bearing material
Bearing width
All bearings ................................................................................................................... 31,62/31,88 mm (1.244/1.255 in)
Bearing thickness at centre .............................................................................. 2,083/2,089 mm (0.0820/0.823 in)
Bearing clearance
All bearings .............................................................................................................. 0,057/0,117 mm (0.0022/0.0046 in)
Available undersize bearings ......................... -0,25 mm (-0.010 in): -0,50 mm (-0.020 in); -0,75 mm (-0.030 in)
CRANKSHAFT THRUST WASHERS
Type .............................................................................................................................................. Steel back bearing material

Position .......................................................................................................................... Each side of centre main bearing
Thickness :
- Standard ........................................................................................................................... 2,26/2,31 mm (0.089/0.091 in)
- Oversize ............................................................................................................................ 2,45/2,50 mm (0.096/0.098 in)
Balancer unit
Number of teeth on gear of drive shaft ......................................................................................................................... 17
Backlash from gear of drive shaft to idler gear .................................. 0,097/0,17 mm (0.0038/0.0066 in)
Diameter of bore for idler gearr ............................................................ 37,197/37,212 mm (1.5431/1.5437 in)
Diameter of hub of idler gearr ............................................................... 37,152/37,162 mm (1.4626/1.4630 in)
End-float of idler gearr ........................................................................................... 0,12/0,27 mm (0.0047/0.0106 in)
Number of teeth on idler gearr ............................................................................................................................................ 44
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
Lubricating oil pump on the balancer

Type ............................................................................................................................................ Differential rotor, gear driven
Number of lobes :
- Inner rotor ........................................................................................................................................................................................ 4
- Outer rotor ....................................................................................................................................................................................... 5
Clearance of outer rotor to body .......................................................................... 0,13/0,23 mm (0.005/0.009 in)
Clearance of inner rotor to outer rotor ........................................................ 0,05/0,20 mm (0.0020/0.0079 in)
End clearance :
- Inner rotor ............................................................................................................. 0,032/0,125 mm (0.0013/0.0049 in)
- Outer rotor ............................................................................................................ 0,032/0,125 mm (0.0013/0.0049 in)
13 TIMING CASE AND DRIVE ASSEMBLY

02
12 Camshaft
Diameter of number 1 journal ................................................................ 50,711/50,737 mm (1.9965/1.9975 in)
Cam lift :
- Intake for models RE, RF ......................................................................... 7,382/7,482 mm (0.2906/0.2946 in)
- Intake for models RG, RH, RJ, RK ........................................................ 7,031/7,13 mm (0.2768/0.2807 in)
- Exhaust for models RE, RF ..................................................................... 7,404/7,504 mm (0.2914/0.2954 in)
- Exhaust for models RG, RH, RJ, RK ................................................ 7,963/8,063 mm (0.3135/0.3174 in)
Maximum permissible ovality and wear on journals ......................................................... 0,05 mm (0.021 in)
End-float :
- Production limits .......................................................................................................... 0,10/0,55 mm (0.004/0.022 in)
- Service limits ......................................................................................................................................... 0,60 mm (0.023 in)
Width of spigot for thrust washer ......................................................................... 5,64/5,89 mm (0.222/0.232 in)
Camshaft thrust washer

Type ................................................................................................................................................................................................ 360
Depth of recess in cylinder block for thrust washer ................................ 5,54/5,64 mm (0.218/0.222 in)
Thickness of thrust washer ................................................................................. 5,486/5,537 mm (0.216/0.218 in)
Relationship of thrust washer to front face of cylinder block ................. -0,154/-0,003 mm (-0.0006/-0.0001 in)
Camshaft gear
Number of teeth ........................................................................................................................................................................... 68
Diameter of bore .................................................................................................. 34,92/34,95 mm (1.3750/1.3760 in)
Outside diameter of the camshaft hub ................................................... 34,90/34,92 mm (1.3741/1.3747 in)
Fuel pump gear electronic engines

Number of teeth ........................................................................................................................................................................... 68
Bore ............................................................................................................................. 29,995/30,021 mm (1.417/1.419 in)
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
Fuel pump gear mechanical engines

Number of teeth ........................................................................................................................................................................... 68
Bore ............................................................................................................................. 36,00/36,06 mm (1.1809/1.1819 in)
Crankshaft gear
Number of teeth ........................................................................................................................................................................... 34
Diameter of bore ............................................................................................ 47,625/47,650 mm (1.8750/1.8760 in)
Diameter of hub for gear on crankshaft ......................................... 47,625/47,645 mm (1.8750/1.8758 in)
Transition fit of gear on crankshaft .............................................. -0,020/+0,020 mm (-0.0008/ +0.0008 in)
Idler gear and hub

Number of teeth ...........................................................................................................................................................................
Diameter of bore of gear ................................................................................ 57,14/57,18 mm (2.2495/2.2512
73
in)
13
- with roller bearings .......................................................................................... 72,35/72,36 mm (2.8482/2.8489 in)
Width of gear and split bush assembly (fitted in position) ............ 30,14/30,16 mm (1.186/1.187 in)
02
Inside diameter of flanged bushes (fitted in position) ....................... 50,78/50,80 mm (1.999/2.000 in)
13
Outside diameter of hub ................................................................................. 50,70/50,74 mm (1.9990/1.9999 in)
- with needle roller bearings ........................................................................ 49,975/49,988 mm (1.967/1.968 in)
Clearance of bushes on hub ............................................................................ 0,04/0,10 mm (0.0016/0.0039 in)
End float of gear :
- Production limits .......................................................................................................... 0,10/0,20 mm (0.004/0.008 in)
- with needle roller bearings ............................................................................. 0,10/0,75 mm (0.0039/0.0295 in)
- Service limit ........................................................................................................................................... 0,38 mm (0.015 in)
Timing gear backlash values

Oil pump gear (with oil pump idler) ........................................................ 0,046/0,106 mm (0.0018/0.0041 in)
Oil pump idler gear (with crankshaft gear) ......................................... 0,095/0,160 mm (0.0037/0.0063 in)
Crankshaft gear (with idler gear) .............................................................. 0,064/0,124 mm (0.0025/0.0049 in)
Camshaft gear (with idler gear) ................................................................. 0,052/0,107 mm (0.0020/0.0042 in)
Power take off LHS (PTO) gear (with idler gear) .......................... 0,112/0,172 mm (0.0044/0.0068 in)
Fuel injection pump gear (with idler gear) .......................................... 0,054/0,109 mm (0.0021/0.0043 in)
Coolant pump gear (with fuel injection pump gear) ...................... 0,073/0,133 mm (0.0028/0.0052 in)
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
CYLINDER BLOCK ASSEMBLY
Cylinder block
Height between top and bottom faces .................................. 441,073/441,374 mm (17.3657/17.3769 in)
Diameter of cylinder bore .................................................................... 105,000/105,025 mm (4.1338/4.1348 in)
Diameter of first oversize cylinder bore ..................................... 105,500/105,525 mm (4.1535/4.1545 in)
Diameter of second oversize cylinder bore .............................. 106,000/106,025 mm (4.1732/4.1742 in)
Maximum permissible cylinder bore wear ............................................................................ 0,15 mm (0.0059 in)
Diameter of parent bore for main bearing ..................................... 80,416/80,442 mm (3.1660/3.1670 in)
Camshaft bore diameter
13 Number 1 (for bush) ......................................................................................... 55,563/55,593 mm (2.188/2.189 in)

Number 2 ................................................................................................................. 50,546/50,597 mm (1.990/1.992 in)
Number 3 .............................................................................................................. 50,038/50,089 4mm (1.969/1.972 in)
02
14
TURBOCHARGER
The make and type and part number of turbocharger fitted is marked on the turbocharger
identification plate, that is fitted to the turbocharger body.
As a general guide, the make and type of turbocharger fitted is ........................................ Garrett GT25
Waste-gate test pressure for rod movement of 1,00 mm (0.039 in)
Waste-gate pressure
Turbocharger
(kPa) (lbf/in2) (kgf/cm2)
part unmber
(+/-5) (+/-0.72) (+/-0.05)
2674A200 100 14.5 1,01
2674A201 110 15.9 1,12
2674A202 128 18.5 1,30
2674A209 100 14.5 1,01
2674A211 128 18.5 1,30
2674A215 128 18.5 1,30
2674A223 136 19.7 1,38
2674A224 136 19.7 1,30
2674A225 136 19.7 1,38
2674A226 100 14.5 1,01
2674A227 128 18.5 1,30
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
LUBRICATION SYSTEM
Canister type oil filter

Type .................................................................................................................................. Full flow, screw-on type canister
Pressure to open by-pass valve in filter .................................................................. 80/120 kPa (16/24 lbf/in2)
Element type oil filter

Type ........................................................................................................................................ Full flow, replaceable element
Pressure to open by-pass valve in filter ................................................................ 130/170 kPa (26/12 lbf/in2)
Lubricating oil pump

Type ........................................................................................................................................... Differential rotor, gear driven 13
Number of lobes :
- Inner rotor ....................................................................................................................................................................................... 5
02
- Outer rotor ...................................................................................................................................................................................... 6
15
Clearance of outer rotor to body .............................................................. 0,152/0,330 mm (0.0059/0.0129 in)
End clearance :
- Inner rotor ............................................................................................................ 0,038/0,089 mm (0.0014/0.0035 in)
- Outer rotor ........................................................................................................... 0,025/0,076 mm (0.0010/0.0029 in)
Idler gear for lubricating oil pump

End float ................................................................................................................... 0,050/0,275 mm (0.0019/0.0108 in)
Inside diameter of bush (fitted) ............................................................. 16,012/16,038 mm (0.6303/0.6314 in)
Outside diameter of idler shaft .............................................................. 15,966/15,984 mm (0.6285/0.6292 in)
Clearance of bush of idler gear on shaft ............................................ 0,028/0,072 mm (0.0011/0.0028 in)
Oil pressure relief valve (oil pump)

Diameter of bore for plunger .................................................................. 19,250/19,300 mm (0.7578/0.7598 in)
Outside diameter of plunger ................................................................. 19,186/19,211 mm (0.75553/0.7563 in)
Clearance of plunger in bore ...................................................................... 0,039/0,114 mm (0.0015/0.0044 in)
Length of spring (fitted) ................................................................................................................... 59,8 mm (2.3543 in)
Load on spring (fitted) turbocharged with lubricating oil cooler .................. 121 N (27.1 lbf) 12,0 kgf
Load on spring (fitted) naturally aspirated without lubricating oil cooler ................. 90,9 N (20.1 lbf) 9,2 kgf
Oil pressure relief valve (balancer)

Diameter of bore for plunger ....................................................................... 14,52/14,54 mm (0.5716/0.5724 in)
Outside diameter of plunger ......................................................................... 14,46/14,48 mm (0.5692/0.5700 in)
Clearance of plunger in bore ............................................................................ 0,04/0,08 mm (0.0015/0.0031 in)
Length of spring (fitted) ............................................................................................................................ 45 mm (1.77 in)
Load on spring (fitted) Turbocharged ....................................................... 77/84 N (17.3/18.9 lbf) 7,8/8,5 kgf
Load on spring (fitted) Naturally aspirated oil cooled .................... 70/77 N (15.7/17.3 lbf) 7,1/7,8 kgf
Load on spring (fitted) Naturally aspirated non oil cooled ......... 59/65 N (13.3/14.6 lbf) 6,0/6,6 kgf
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
COOLING SYSTEM
Coolant pump
Type ........................................................................................................................................................ Centrifugal gear driven
Outside diameter of shaft ......................................................................... 21,425/21,438 mm (0.8435/0.8440 in)
Diameter of bore of drive gear ............................................................. 21,375/21,400 mm (0.8415/0.8425 in)
Interference fit of drive gear on shaft .................................................... 0,025/0,063 mm (0.0009/0.0024 in)
Diameter of bore of impeller .................................................................. 11,943/11,971 mm (0.4701/0.4712 in)
Outside diameter of shaft for impeller .............................................. 11,997/12,008 mm (0.4723/0.4727 in)
Interference fit of impeller on shaft ......................................................... 0,026/0,065 mm (0.0010/0.0025 in)
Diameter of bore for bearing .................................................................. 39,989/40,014 mm (1.5743/1.5753 in)
13 Diameter of bearing ..................................................................................... 39,989/40,000 mm (1.5743/1.5747 in)
Interference fit of bearing in pump body (transition fit) ........ +0,025/-0,011 mm (0.0009/-0.0005 in)
Dimension of impeller boss to front face of pump body (fitted) ................. 7,030/7,33 mm (0.276/0.288 in)
02 Dimension of gear from rear flat face of pump body (fitted) ....... 31,60/32,10 mm (1.244/1.263 in)
16
Fan drive housing
Bore of housing for bearing .................................................................... 61,986/62,005 mm (2.4403/2.4411 in)
Outside diameter of bearing ................................................................... 61,987/62,000 mm (2.4404/2.4409 in)
Interference fit of bearing in housing .................................................. 0,014/-0,018 mm (0.0006/-0.0007 in)
Outside diameter of shaft ......................................................................... 25,002/25,011 mm (0.9843/0.9846 in)
Maximum permissible end-float of shaft ............................................................................. 0,200 mm (0.0079 in)
THERMOSTAT
Type:
- Single .............................................................................................................................. Wax element, by-pass blanking
Nominal temperature
“Start to open” “Fully open” Mnimum valve lift
Part number stamped on thermostat
temperature temperature full open
by pass valve
2485C034 82 C 79/84 C 93 C 10 mm
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
FUEL SYSTEM
Bosch fuel injection pump

Type .............................................................................. Bosch VP30 electronic, pin timed, with a locking screw
Direction of rotation from drive end .............................................................................. Clockwise from drive end

Type ............................................................................................................................................ EPVE, with a locking screw
Direction of rotation from drive end .............................................................................. Clockwise from drive end
Fuel lift pump

Type .............................................................................................................................................................. Electrically operated
Method of drive ............................................................................................................................ Electric motor 12v / 24v
13
02
Green fuel filter 17
Type .............................................................................................................................................. Replaceable paper element
ATOMISER SERVICE SETTINGS
Set and reset pressure

Colour code Holder Nozzle
atm (lbf/in2) MP
Yellow 2645A321 2645A611 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Blue 2645A321 2645A612 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Red 2645A322 2645A613 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
Black 2645A322 2645A614 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
White 2645A322 2645A612 290 +8/-0 4262 +117.6/-0 29,4 +0,8/-0
FLYWHEEL AND HOUSING
Limits for flywheel housing run-out and alignment (total indicator reading)
Diameter of housing flange bore Maximum limit (total indicator reading)

mm in mm in
410 16.14 0.25 0.010
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
ELECTRICAL EQUIPMENT
Alternators
Note :
The information which follows is general and can change with specific applications.
Make and type ..................................................................................................................................................................... Mando
Rating :
Mando 12V ......................................................................................................................................................................... 12V-50A
Rotation ................................................................................................................................. Clockwise from the drive end
13 Starter motors
Note :
02
18 Make and type ...................................................................................................................................................................... Denso
Voltage :
Denso P95RL .................................................................................................................................................. 12V 3,0 kW rhs
Number of teeth on pinion .................................................................................................................................................... 10
Maximum starter cable resistance at 200 C (680 F) :
- 12V ............................................................................................................................................................................ 0.0017 ohms
Starting aids
Type .................................................................................................................................................................................. Glow plugs
Voltage ........................................................................................................................................................................... 12V or 24V
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
THREAD SEALANT
When setscrews or studs are fitted into holes which are tapped through the cylinder block, a
suitable sealant must be used to prevent leakage.
Micro encapsulated anaerobic sealant (M.E.A.S) fasteners have been introduced instead of jointing
compounds or other sealants when the fasteners are fitted in through holes into oil or coolant
passages. The identification of these fasteners, as supplied, is by a red, blue, or other colour
sealant around the fastener threads.
With M.E.A.S. sealed studs, the sealed end must be fitted into the cylinder head / cylinder block
etc. Ensure that the threaded holes have a 1,59 mm (0.0625 in) 45¡Æ chamfer, to ensure that
when the new fasteners are fitted the M.E.A.S. sealant is not removed. If the fasteners have to
be removed and fitted again, the threads must be cleaned and a suitable sealant used.
13
Note : 02
New setscrews have sealant applied by the manufacturer to the first 13,0 mm (0.50 in) of the 19
threads. If the setscrews are to be used again, clean the old sealant from the male and female
threads and apply new sealant, (POWERPART Threadlock and Nutlock) to the setscrews.
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
STANDARD TORQUE VALUES
Most of the torque values on the engine are standard. Special torque values are listed in the
separate special torque tables. The standard torque values listed in the tables below can be used
when a special torque is not necessary.
The torque values below apply to components lubricated with a little clean engine oil before they
are fitted.
Standard torques for setscrews and nuts
Torque
Thread size
Nm lbf ft kgf m
13 M6 x 1,00
M8 x 1,25
9
22
7
16
0,9
2,2
M10 x 1,50 44 32 4,5
02 M12 x 1,25 78 58 8,0
20 M14 x 2,00 124 92 13,0
M16 x 2,00 190 140 19,3
Standard torques for studs (metal end)
Torque
Thread size
Nm lbf ft kgf m
M6 x 1,00 5 4 4
M8 x 1,25 11 8 1.1
M10 x 1,50 18 13 1.8
M12 x 1,75 25 18 2.5
Standard torques for pipe unions, plugs, and adaptors
Torque
Thread size
Nm lbf ft kgf m
1/8 PTF 9.5 7 0.9
1/8 PTF 17 12 1.7
3/8 & 1/2 PTF 30 22 3.0
3/4 PTF 45 33 4.6
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
SPECIFIC TORQUE VALUES
The torque values below apply to components lubricated with a little clean engine oil before they
are fitted.
Special torques for setscrews and nuts
Thread Torque
Description
size Nm lbf ft kgf m
Cylinder head assembly
Setscrew cylinder head See Operation 3-10
Torx screw, rocker shaft M8 35 26 3,5
Lock nut, rocker lever adjustment
Fastener, rocker cover
3/8 UNF
M6
27
9
20
7
2,7
0,9
13
Setscrew, heatshield to cover M6 9 7 0,9
Setscrew, exhaust manifold to cylinder head M10 33 24 3,3
02
21
Piston and connecting rod assemblies
Setscrew, fracture split connecting rod See Operation 4-2
Crankshaft assembly
Setscrews, main bearings 5/8 UNF 245 180 25
Setscrew, crankshaft pulley 7/16 UNF 115 85 12
Allen screws, bridge piece to cylinder block m6 16 12 1,6
Torx screw, rear end oil seal housing M8 22 16 2,2
Setscrews, balancer to cylinder block M10 54 39 5,5
Timing case and drive assembly
Setscrew, camshaft gear M12 95 70 9,7
Setscrew, PTO blanking plate plastic M10 22 16 2,2
Setscrew, plastic oil filler M8 22 16 2,2
Cylinder block
Plug, compressor oil feed M10 22 16 2,2
Plug, oil rail rear face 7/8 UNF 68 50 7,0
Plug, front feet M12 46 34 4,6
Plug, turbocharger feed M10x1 19 14 1,9
Plug, coolant drain 1/4 NSPM 40 29 4,0
Fuel system
Nuts, high-pressure fuel pipes M12 30 22 3,0
Setscrew, atomiser clamp M8 35 26 3,5
Nut, fuel injection pump to gear (mechanical) M14 88 65 9,0
Setscrews, gear to fuel injection pump electronic M8 22 16 2,2
Setscrew, timing case to fuel injection pump M8 25 18 2,5
Locking screw on shaft of Bosch fuel injection pump M10 31 23 3,1
Locking screw in run position of Bosch fuel injection pump M10 17 12 1,7
Locking screw on shaft of DP 210 fuel injection pump M12 17 12 1,7
Locking screw in run position of DP 210 fuel injection pump M12 12 9 1,2
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
Thread Torque
Description
size Nm lbf ft kgf m
Lubrication system
Plug, lubricating oil sump G 3/4 34 25 3,4
Oil inspection valve M10x1 12 9 1,2
Oil inspection valve plug M10x1 12 9 1,2
Nut, dipstick tube M16 18 13 1,8
Element oil filter 3 1/2 ACME 25 18 2,5
Cooling system
Setscrews, fan drive housing to cylinger head M10 44 32 4,5
Setscrews, fan drive pulley to hub M8 12 9 1,2
Setscrews, fan M8 12 9 1,2
13 Flywheel and housing

Engine types RE, RF, RG, RJ and RH
1/2 UNF 105 77 10,7
Setscrews, flywheel to crankshaft
02 Engine type RK
22 1/2 UNF 115 85 11,7
Setscrews, flywheel to crankshaft
Setscrews, cast iron flywheel housing to cylinder block: M10 44 32 4,5
- Head stamped 8.8 M12 75 55 7,6
- Head stamped 10.9 M10 63 46 6,4
- Head stamped 10.9 M12 115 85 11,7
Setscrews, flywheel housing to cylinder block
M10 70 52 7,1
(paper joint)
Aspiration system
Nuts, turbocharger to manifold M10 47 35 4,8
Banjo bolt, turbo feed M10x1 22 16 2,2
Fastener, breather pipe to cylinder head M6 9 7 0,9
Electrical equipment
Sensor, engine oil pressure M12 x 1,5 10 7 1,0
Plug, engine oil pressure M12 x 1,5 12 9 1,2
Sensor, inlet manifold temperature M18 20 15 2,0
Plug, inlet manifold temperature M18 20 15 2,0
Sensor, inlet manifold pressure M12 10 7 1,0
Plug, inlet manifold pressure M12 10 7 1,0
Sensor, coolant temperature M18 20 15 2,0
Plug, coolant temperature M18 20 15 2,0
Setscrew, ECM plug to ECM. M5 6 4 0,6
KSB 1/2 PTF 30 22 3,0
Glow plug to cylinder head M10 18 13 1,8
Nut, bus-bar to glow plug M4 2 1 0,2
Nut, alternator pulley: M16 80 59 8,1
- CAV AC5RA and AC5RS
- Thin nut A127, and Motorola pulley, 22 mm A/F
- Thick nut A127, and Motorola pulley, 24 mm A/F
- Bosch 55A
- Bosch 55A
- Butec 5524
Nut, starter motor Intended for CLARK dealers only M10 44 35 4,5
E N G I N E – 1 1 0 4 C – 4 4
SPECIFICATIONS
COMPRESSION TEST DATA
Tests have shown that many factors affect compression pressures. Battery and starter motor condition,
ambient conditions and the type of gauge used can give a wide variation of results for a given engine.
It is not possible to give accurate data for compression pressure, but tests have shown that the
results should be within 2000/3500 kPa (300/500 lbf/in2) 21,0/35,0 kgf/cm2 for diesel engines.
Compression tests should only be used to compare between the cylinders of an engine. If one or
more cylinders vary by more than 350 kPa (50 lbf/in2) 3,5 kgf/cm2, then those cylinders may be
faulty.
Compression tests should not be the only method used to show the condition of an engine, but they
should be used together with other symptoms and tests.
How to do a compression test 13

! Before the compression test, ensure that the battery is in good condition and that it
02
is fully charged. Also ensure that the starter motor is in good condition.
23
1 Ensure that the valve tip clearances are set correctly, see Operation 3-7.
2 Remove the atomisers, see Operation 11-3.
3 Fit a suitable gauge into the atomiser hole of the cylinder to be tested.
! Ensure that the engine cannot start.

4 Operate the starter motor and record the pressure indicated on the gauge for each cylinder.
E N G I N E – 1 1 0 4 C – 4 4
CYLINDER HEAD ASSEMBLY
GENERAL DESCRIPTION
In a diesel engine there is little carbon deposit and for this reason the number of hours run is no
indication of when to overhaul a cylinder head assembly. The factors which indicate when an
overhaul is necessary are how easily the engine starts and its general performance.
The cast iron cylinder head is fastened to the cylinder block by flanged head setscrews. The
cylinder head gasket is a multi-layer construction. The individual inlet and exhaust ports are
designed to assist air swirl and improve air flow.
The intake manifold is integral within the cylinder head, and the rocker cover also contains the
engine breather pipe.
13
The cylinder head assembly has two overhead valves fitted for each cylinder. Each overhead valve 03
is held in place by a single coil spring, cap, and two collets. The face angle of the intake and 1
the exhaust valves are both 30 . The cylinder head has steel valve seat inserts fitted for both the
intake and the exhaust valves, and these can be renewed. The angles of the valve seats in the
cylinder head for the intake and the exhaust valves are both 30 . The valves move in sintered
steel valve guides which can also be renewed. The exhaust valve guides have a counterbore to
prevent seizure of the valve stem caused by a build up of carbon under the head of the valve.
Each valve stem is fitted with a synthetic rubber oil seal.
The overhead valves are operated by a rocker shaft assembly fitted to the top of the cylinder
head and under a composite rocker cover. The forged steel rocker levers are operated by cold
drawn push rods with hardened heads. The rocker shaft is secured to the cylinder head by sintered
steel brackets between each pair of valves.
The rockers and valve gear are lubricated by an oil flow from the hollow rocker shaft that receives
a reduced oil flow from the camshaft oil feed.
Tappet adjustment is achieved by adjustment screws and locknuts at the push rod end of each
rocker lever.
E N G I N E – 1 1 0 4 C – 4 4
ATOMISER COVER
To remove and to fit Operation 3-1
To remove
1 Remove the atomiser cover setscrews (A1)
and remove the atomiser cover (A2).
To fit
1 Fit the atomiser cover (A2) and tighten the
setscrews (A1) to 9 Nm (7 lbf ft) 0,9 kgf m.
13
03
2
E N G I N E – 1 1 0 4 C – 4 4
ROCKER COVER
To remove Operation 3-2
Note :
If a top mounted turbocharger is fitted, the heat
shield must be removed first.
1 Remove the atomiser cover, see Operation
3-1
2 Remove the breather pipe, see Operation 9-
5 or Operation 9-6.
3 Release the fasteners (A), remove the rocker
cover and discard the joint.
13
03
3
Note :
Reflective heat shields fitted to the rocker covers must be kept clean and free from dust, oil or
paint. If the surface of the heat shield is not shiny, the component that is protected by the heat
shield could be damaged.
1 If the rocker cover has an oil filler, check the condition of the “O” ring, renew as required.
2 Ensure that the rocker cover and the groove for the joint are clean and free from oil and grease.
3 Fit a new joint (A1) to the rocker cover.
4 Check the condition of the fasteners (B),
renew as required.
5 Clean the seal face of the cylinder head and
fit the rocker cover.
6 Secure the rocker cover to the cylinder head
with the fasteners and tighten in sequence
(C) to 9 Nm (7 lbf ft) 0,9 kgf m.
7 Fit the breather pipe, see Operation 9-5 or
Operation 9-6.
E N G I N E – 1 1 0 4 C – 4 4
ROCKER ASSEMBLY
Special requirements
Special tools
Description Part number
Rocker assembly tools 27610227
To remove
13 1
2
Remove the atomiser cover, see Operation 3-1.
Remove the rocker cover, see Operation 3-2.
3 Fit the rocker assembly tools between each pair of rocker levers (A1).
03 4 Release evenly and gradually the Torx screws of the rocker shaft; begin with the end Torx
4
screws and move toward the centre. Remove the Torx screws and lift off the rocker assembly.
To fit
Note :
Ensure that the machined square is facing upwards before the rocker assembly is fitted and that
the longest Torx screw is fitted in (A2).
1 Check that the push rods fit correctly in the sockets of the tappets and ensure that the rocker
assembly tools are correctly fitted between each pair of rocker levers (A1). Fit the rocker
assembly. Check that the ends of theadjustment screws fit correctly in the sockets of the push
rods.
2 Fit the Torx screws for the rocker shaft and tighten the Torx screws 35 Nm (26 lbf ft) 3,6 kgf
m; begin with the inner Torx screws and work outwards.
3 Set valve tip clearance, see Operation 3-7.
4 Fit the rocker cover, see Operation 3-3.
5 Fit the atomiser cover, see Operation 3-1.
E N G I N E – 1 1 0 4 C – 4 4
To dismantle and to assemble Operation 3-5
To dismantle
1 Remove the circlips from both ends of the rocker shaft. Ensure that the ends of the rocker shaft
are not damaged.
2 Dismantle the assembly and make a note of the position of each component to ensure that they
can be assembled in the same position.
To assemble
1 Ensure that the oil holes in the rocker shaft and in the rocker levers are not restricted.
2 Lubricate the components with clean engine lubricating oil before assembly. Assemble the
13
components in the correct order. Fit the circlips to the ends of the rocker shaft.
03
5
To inspect and to correct Operation 3-6
To inspect
1 Clean and inspect all the components for wear and any other damage.
2 Check the clearance of the rocker levers on the rocker shaft. If the clearance is greater than
0,13 mm(0.005 in), renew the rocker lever and/or the rocker shaft.
E N G I N E – 1 1 0 4 C – 4 4
VALVE TIP CLEARANCES
To check and to adjust Operation 3-7
The valve tip clearances are checked between the top of the valve stem and the rocker lever (A),
with the engine cold. The correct clearance for intake valves is 0,20 mm (0.008 in) and 0,45 mm
(0.018 in) for exhaust valves. The valve positions are shown at (B).
The sequence of valves from number 1 cylinder is shown in the table below.
Note :
Number 1 cylinder is the furthest cylinder from the flywheel end of the engine.
13 1 Rotate the crankshaft in the normal direction of rotation until the intake valve (B7) of number 4
cylinder has just opened and the exhaust valve (B8) of the same cylinder has not closed
03 completely. Check the clearances of the valves (B1 and B2) of number 1 cylinder and adjust
6 them, if necessary.
Note :
The correct torque for the locknut on the adjusting screws is 27 Nm (20 lbf ft) 2,8 kgf m.
2 Set the valves (B3 and B4) of number 2 cylinder as indicated above for number 4 cylinder.
Then check / adjust the clearances of the valves (B5 and B6) of number 3 cylinder.
3 Set the valves (B1 and B2) of number 1 cylinder. Then check / adjust the clearances of the
valves (B7 and B8) of number 4 cylinder.
4 Set the valves (B5 and B6) of number 3 cylinder. Then check / adjust the clearances of the
valves (B3 and B4) of number 2 cylinder.
Note :
After the valve tip clearances have been adjusted, lubricate the rocker assembly with clean engine
oil. Apply particular attention to the rocker shaft bearing surfaces, valve tips, push rod sockets and
the push rods so that the oil will drain to lubricate the cam followers.
1 2 3 4
Cylinder and Valve number
1 2 3 4 5 6 7 8
Valve
I = Intake I E I E I E I E
E = Exhaust
E N G I N E – 1 1 0 4 C – 4 4
VALVE SPRINGS
To change the valve springs (with cylinder head fitted) Operation 3-8
Note :
Steps 1 to 11 refer to a change of valve spring for a single cylinder.
! Wear eye protection during this operation.

1 Remove the atomiser cover, see Operation 3-1.
2 Remove the rocker cover, see Operation 3-2.
3 Rotate the crankshaft in the normal direction of rotation until the intake valve of the relevant
cylinder has opened and the exhaust valve has not fully closed. In this position the piston will
13
be at approximately top dead centre (TDC). 03
4 Remove the rocker assembly, see Operation 3-4. 7
5 Fit the valve spring compressor (A1) and the adaptor (A2).
! Ensure that the valve spring is compressed squarely or damage can occur to the
valve stem.
Note :
Do not over compress the valve springs so that coils are touching.
6 Compress the valve spring and remove the collets. Ensure that the valve spring is compressed
squarely damage to the valve stem can occur.
! Do not rotate the crankshaft while the valve spring is removed.
7 Release the valve spring compressor and remove the valve spring, cap and valve seal.
Note :
The valve stem seal must only be used once.
8 Ensure that the new valve stem seal is
clean, not damaged and that the spring is
present and correctly located on the seal.
9 Lubricate the valve stem with clean engine
oil. Fit the valve stem seal onto the valve
guide and ensure that the seal and the
seating washer are correctly located.
10 Put the new valve spring in position, ensure
that the larger diameter is against the
cylinder head.
Continued
E N G I N E – 1 1 0 4 C – 4 4
11 Fit the valve spring cap.
valve stem.
Note :
12 Fit the valve spring compressor, compress the valve spring and fit the collets. Remove the
valve spring compressor.
13 Fit the rocker assembly, see Operation 3-4.
14 Check the valve tip clearances, see Operation 3-7.
13 Note :
If other or all of the valve springs are to be
changed, they can be changed two cylinders
03 at a time. The sets of cylinders are 1 and 4,
2 and 3.
8
If the rocker assembly has been removed,
piston TDC can be found as follows:
1 Fit the valve spring compressor and
compress the valve springs to open the
valve.
2 Rotate the crankshaft, by hand, in the
normal direction of rotation until the piston
touches the valve.
Note :
Ensure that the collets are fully located before
the pressure is released on the valve spring
compressor.
3 Continue to rotate the crankshaft, and at the
same time, release pressure on the valve
spring compressor until the piston is at TDC
(B).
E N G I N E – 1 1 0 4 C – 4 4
1 Drain the cooling system.

2 Disconnect the battery terminals.
3 Remove the air filter / cleaner hose at the intake manifold.
4 For engines fitted with a boost control device, remove the boost control pipe that is fitted between
the intake manifold and the top of the fuel
injection pump.
5 For engines fitted with a turbocharger, disconnect
all connections to the turbocharger and remove
the turbocharger, see Operation 9-2.
13
6 Release the exhaust manifold fasteners in the
reverse sequence to that shown in (A).
03
9
7 Remove the low-pressure fuel pipes which
are fitted between the fuel injection pump and
the fuel lift pump with integral fuel filter.
8 Remove the fuel lift pump with integral fuel
filter.
! Where access to the fuel injection pump outlet unions is possible, ensure that a
separate spanner is used to prevent movement of the fuel injection pump outlets
when the connections of the high-pressure pipes are released. Fit suitable covers
to all open connections on the fuel injection pump.
9 Remove the atomiser cover, see Operation 3-2.
10 Remove the high-pressure fuel pipes.
11 Remove the atomiser leak-off hoses.
12 Remove the atomisers, see Operation 11-3. Fit suitable covers to the nozzles and the open
connections.
13 Remove the bus-bar and glow plugs.
14 Release the setscrews of the coolant by-pass pipe at the timing case. Remove the coolant by-
pass pipe from the cylinder head.
15 Disconnect the coolant temperature sensor/sender unit.
17 Remove the rocker assembly, see Operation 3-4.
18 Remove the push rods.
Continued
E N G I N E – 1 1 0 4 C – 4 4
19 Release the cylinder head setscrews evenly and gradually in the reverse sequence to that
shown in (B).
20 Check the setscrews for distortion with a straight edge (C1) held along the setscrew (C2). If
there is a visual reduction in the diameter of the thread that has not been in engagement with
the cylinder block, the setscrew must be discarded.
! Do not use a lever to separate the cylinder head from the cylinder block, as this
may damage the face of either the cylinder head or the cylinder block.
21 Remove the cylinder head and put it on a surface that will not damage the bottom face of the
cylinder head.
22 Remove the cylinder head gasket.
13
03
10
E N G I N E – 1 1 0 4 C – 4 4
To fit Operation 3-10
1 With a suitable cleaner, clean thoroughly the bottom face of the cylinder head and the top face
of the cylinder block. Hard carbon and corrosion can be removed with a hard plastic or hard
wood scraper. Ensure that the top face of the cylinder block and the bottom face of the cylinder
head are free from scratches or other damage and there is no debris in the cylinder bores, see
"Cylinder head" on page 12.
Note :
The engines have two location pins (A2), one at each end of the cylinder head, pressed into the
cylinder block to hold the cylinder head and cylinder head gasket in the correct position when the
cylinder head is fitted.
! • To prevent damage to the cylinder head gasket, ensure that the location pins are
13
pressed in the cylinder block before the cylinder head is fitted. 03
11
• The cylinder head gasket must be fitted without jointing compound.
2 Fit a new cylinder head gasket in the correct position.
3 To ensure the cylinder head is fitted into the correct position, fit two suitable M15 guide studs
(A1). Put the cylinder head in position. Ensure that the two location pins are fully engaged in
the cylinder head.
4 Apply a small amount of lubricant to the threads and the thrust faces of the cylinder head
setscrews . Engage the seven short setscrews in positions 2, 5, 6, 7, 8, 9, 10, then remove
the guide studs(A1). Fit the three long setscrews in positions 1, 3, 4.
5 Tighten the setscrews to 50 Nm (37 lbf ft) 5,1 kgf m in the sequence shown in (B).
6 Tighten the setscrews to 100 Nm (74 lbf ft) 10,0 kgf m in the sequence shown in (B).
Continued
E N G I N E – 1 1 0 4 C – 4 4
7 Tighten the setscrews, in the correct sequence, a further part of a turn according to the length
of the setscrews. Short setscrews (S) must be turned a further 225 . Long setscrews (L) must
be turned a further 270 . A special tool (C) can be used for this operation.
Fit the tool between the socket and the handle. Position the stop (C1) against a suitable
protrusion on the cylinder head to prevent movement of the degree dial in a clockwise direction.
Rotate the pointer to align with the relevant angle on the degree dial for the length of setscrew.
Tighten the setscrew until the pointer on the tool is aligned with the zero position on the degree
dial.
13 ˚ ˚
03
12
If no tool is available, make a suitable mark on the cylinder head in line with a corner of each
setscrew (D).
Make another mark, at the correct angle (counter-clockwise), on the edge of the flange of each
fastener according to the length of the setscrew. Tighten each setscrew in the correct sequence
until the marks on the flange are next to, and in line with, the marks on the cylinder head.
8 Put the push rods in position. Ensure that the end of each push rod fits correctly in the tappet
socket.
10 Set the valve tip clearances, see Operation 3-7.
11 Fit the atomisers, see Operation 11-4.
12 Fit the atomiser leak-off hoses.
13 Fit the glow plugs and bus-bar, see Operation 14-10.
14 Fit the high-pressure fuel pipes; tighten the connection nuts to 22 Nm (16 lbf ft) 2,2 kgf m.
! Where access to the fuel injection pump outlet unions is possible, ensure that a
separate spanner is used to prevent movement of the fuel injection pump outlets
when the connections of the high pressure pipes are tightened.
15 Fit the fuel lift pump with integral fuel filter and the bracket. Fit the low-pressure fuel pipes
between the fuel injection pump and the fuel lift pump with integral fuel filter.
16 Fit the coolant by-pass pipe, see Operation 12-13.
Continued
E N G I N E – 1 1 0 4 C – 4 4
17 Fit two suitable temporary studs (E1) then fit the exhaust manifold joint (E2).
! Damage to the exhaust manifold can occur if not aligned and tightened correctly.
13
03
18 Fit the exhaust manifold and the fasteners, lightly tighten the fasteners 1 and 2 (F). 13
19 Remove the two temporary studs, fit the remaining fasteners and lightly tighten.
20 Evenly and gradually tighten the exhaust manifold fasteners to 33 Nm (24 lbf ft) 3,4 kgf m in
the sequence shown (F).
21 For engines fitted with turbochargers, fit the turbocharger, see Operation 9-3.
22 Connect the electrical connection to the cold start device.
23 For engines fitted with a boost control device, fit the boost control pipe between the intake
manifold and the top of the fuel injection pump.
24 Fit the electrical connection to the coolant temperature sensor/sender unit.
25 Connect the coolant outlet and the hoses for the cab heater. Tighten the clips.
26 Fill the cooling system.
27 Connect the air filter/cleaner.
28 Connect the battery.
29 Eliminate air from the fuel system, see Operation 11-8.
30 Start the engine and run it at low speed. Check that oil flows from the holes in the rocker
levers. If the oil flow is correct, fit the rocker cover, see Operation 3-3.
Note:
It is not necessary to tighten the cylinder head setscrews again with the engine hot or after a
limited period in service.
E N G I N E – 1 1 0 4 C – 4 4
Special tools
Description Part number Description Part number
Valve spring compressor 21825666 Setscrew adaptor used with 21825666 27610235
13 1 Remove the cylinder head, see Operation 3-9.

2 Clean the bottom face of the cylinder head and check the depth of the heads of the valves
below the face of the cylinder head, see Operation 3-13.
03 3 Make a suitable mark on the heads of the valves to ensure that the valves can be fitted in
14 their original positions, if they are to be used again.
! Ensure that the valve springs are compressed squarely or the valve stem can be
damaged.
Note :
4 Use the valve spring compressor and the relevant adaptor to compress the valve spring (A3)
and remove the collets (A1).
5 Release the valve spring compressor and remove the valve spring cap (A2), valve spring and
valve stem seal (A4).
6 Repeat steps 4 and 5 for the other valves.
E N G I N E – 1 1 0 4 C – 4 4
Special tools
Valve spring compressor 21825666 Setscrew adaptor used with 21825932 27610235
! • Valves must not be lapped, as the special heat resistant layer on the face of the
valve will be destroyed.
Note :
• If inlet valves are badly worn or damaged they must be replaced.
13
The intake valve has a larger diameter head than the exhaust valve.
03
1 Lubricate the valve stem (A5) with clean engine oil and fit the valves in their respective guides. 15
Note :
The valve stem seal must only be used once.
2 Fit new valve stem seals (A4) on the valve guides.
3 |Put the valve springs in position, ensure that the larger diameter is against the cylinder head.
Fit the valve spring cap (A2).
valve stem.
4 Use the valve spring compressor and the relevant adaptor to compress the valve spring (A3)
and fit the collets (A1).
E N G I N E – 1 1 0 4 C – 4 4
Special tools
Gauge, valve depth 21825496 Dial gauge for use with 21825496 21825617
1 Ensure that the heads of the valves and the bottom face of the cylinder head are clean.
2 Put the valve depth gauge on the face of the cylinder head and zero the dial gauge.
3 Carefully put the valve depth gauge in position over the head of each valve (A) and make a
note of the measurement. The maximum depth, in service, is given in the relevant Data and
13 dimensions for the "Intake and exhaust valves" on page 13.

4 If a valve is below the depth limit, check the valve depth with a new valve in position. If the
valve depth is still below the limit the valve seat insert must be renewed, see Operation 3-19.
03 5 Check the valves for cracks. Check the stems of the valves for wear and for correct fit in their
16 valve guides.
! • Valves must not be lapped, as the special heat resistant layer on the face of the
valve will be destroyed.
• If inlet valves are badly worn or damaged they must be replaced.

6 Check that the seat faces of the valves are
not badly burnt or damaged. Seat faces of
valves which are damaged can be ground on
a special machine.
When new valves are fitted, the valve depths
must be checked after the valve springs are
fitted.
7 Check that the load on the valve springs is
correct at their fitted length, refer to the
relevant Data and dimensions for the "Valve
guides and valve springs" on page 16. Fit
new valve springs at every complete engine
overhaul.
E N G I N E – 1 1 0 4 C – 4 4
VALVE GUIDES
To inspect Operation 3-14
To check the valve guides for wear. The maximum permissible clearance (A5) with a valve lift of
15,0 mm (0.6 in), between the valve stem and the bore of the guide is 0,22 mm (0.009 in) for
intake valves and 0,25 mm (0.010 in) for exhaust valves. If the clearance, with a new valve fitted,
is more than the limit, then a new valve guide (A4) must be fitted.
It is recommended that the procedure given below is used to check the valve guide clearance:
1 Put a new valve in the valve guide.
2 Put a dial test indicator with a magnetic base
(A1) onto the face of the cylinder head.
13
3 With the valve lifted 15,0 mm (0.6 in) and
the gauge (A2) in contact with the edge of
03
the valve head (A3), move the valve radially 17
away from the gauge. With the valve held in
this position, set the gauge to zero.
4 Move the valve radially across the axis of the
cylinder head towards the gauge. Make a
note of the reading on the gauge. If the
reading is equal to or greater than the data
/
given above, a new valve guide (A4) must
be fitted.
E N G I N E – 1 1 0 4 C – 4 4
Special tools
Remover/replacer for valve guides 21825478 Adaptor used with 21825478 21825479
1 Fit the adaptor (A4) into the remover/replacer

tool (A3).
2 With the adaptor fitted to the tool, put the
spacer (A5) in position on the tool. Pass the
13 adaptor (A4) through the valve guide (A6)

and put the spacer and tool in position on
the valve seat.
03 3 Fit the attachment (A7) to secure the
18 adaptor to the valve guide.
4 Hold the top handle (A1) and turn the
bottom handle (A2) clockwise to pull the
valve guide out of the cylinder head.
E N G I N E – 1 1 0 4 C – 4 4
Special tools
Remover/replacer for valve guides 21825478 Adaptor, used with
27610234
Adaptor used with 21825478 21825479 21825478, and 21825479
Note :
The partially finished valve guides are reamed
and the valve seats are cut in one operation
with a special tool. The valve seat and the
guide are cut in one operation to ensure the
concentricity of the valve seat to the valve
13
guide. This will ensure a good seal between 03
the guide and its seat. New valves and new 19
valve seat inserts must be fitted each time a
new valve guide is fitted. Valves must not be
lapped. If all or most of the original valve
guides need to be renewed it may be cost
effective to overhaul or exchange the cylinder
head.
1 Clean the parent bore in the cylinder head
for the valve guide.
2 Lubricate the outer surface of the new valve
guide (A6) with clean engine lubricating oil.
3 Fit the adaptor (A5) into the remover/replacer
tool (A3).
4 With the adaptor fitted to the tool, put the
spacer (A4) in position on the tool. Pass the
adaptor through the cylinder head and put
the spacer and tool assembly in position on
the valve seat.
Continued
E N G I N E – 1 1 0 4 C – 4 4
5 Put the valve guide in position on the

adaptor and fit the adaptor (B7). Fit the
attachment (B8) to secure the valve guide
to the adaptor.
6 Hold the top handle (B1) and turn the
bottom handle (B2) clockwise to pull the
valve guide until the distance piece contacts
the cylinder head.
7 When the valve guide is fitted correctly, the
top of the valve guide will have a protrusion
(B9) of 12,35/12,65 mm (0.486/0.498 in)
above the valve spring seat.
13 8 Ream the valve guide to the finished size,

see Operation 3-18.
03
20
E N G I N E – 1 1 0 4 C – 4 4
CYLINDER HEAD
1 Remove the cylinder head assembly, see Operation 3-9.

2 Remove the thermostat housing, see Operation 12-1.
3 Inspect the cylinder head for signs of gas or coolant leakage.
4 Remove the valve springs and the valves, see Operation 3-11.
5 Clean the face of the cylinder head and the passages for coolant and for lubricating oil. The
coolant jacket can be cleaned with a special solvent which must be used in accordance with
the manufacturer s instructions.
6 Test the cylinder head for leaks at the pressure given in the relevant Data and dimensions for
the "Cylinder head" on page 12.
13
7 When the cylinder head is thoroughly clean, check it for cracks. Inspect carefully the areas
around the valve seats and around the holes for the atomiser nozzles.
03
21
! Remove only the minimum material and ensure that the thickness of the cylinder
head will not be less than 117,20mm (4.614 in) after the cylinder head has been
machined.
8 The bottom face of the cylinder head can be machined if there is distortion, or deep scratches,
see step 9.
9 Use a straight edge and feeler gauges to check the cylinder head for distortion. Refer to the
relevant Data and dimensions for the "Cylinder head" on page 12.
If the distortion is more than the given limit, the bottom face can be machined. Refer to the relevant
Data and dimensions for the "Cylinder head" on page 12 for the surface grade finish of the cylinder
head face.
! • After the cylinder head has been machined the valve seats must be corrected to
give the correct valve head depth.
• Work to the minimum limit to allow for later wear.
10 Check the valve seats for wear and for damage.

11 Before any work is done on the valve seats, new valve guides must be fitted, see Operation
3-16.
12 Badly damaged valve seats can be corrected by use of the cutter tool, see Operation 3-18,
or new inserts can be fitted, see Operation 3-19.
E N G I N E – 1 1 0 4 C – 4 4
To correct a valve seat with a valve seat cutter Operation 3-18
Special tools
Cutter (30 ) for inlet and exhaust valve seats and valve guide reamer 27610030
! Valves must not be lapped.
Note :
The partially finished valve guides are reamed and the valve seats are cut in one operation with
a special tool. The valve seat and the guide are cut in one operation to ensure the concentricity
13 of the valve seat to the valve guide. This will ensure a good seal between the guide and its seat.
New valves and new valve seat inserts must be fitted each time a new valve guide is fitted. Valves
must not be lapped. If all or most of the original valve guides need to be renewed it may be cost
03 effective to overhaul or exchange the cylinder head.
22
1 Before any work is done on the valve seats,
new valve guides must be fitted, see Operation
3-16.
! • Ensure that the correct cutter is

fitted, for 30 valve seats.
• Ensure that the valve seat cutter is
not allowed to fall onto the seat as
this can damage the blades.
Note :
The intake valve has a larger diameter head
than the exhaust valve
2 Select the relevant valve seat cutter, 30 (A2)
and the valve guide reamer (A1). Set the 2
blades of the cutters to the diameter of the
valve seat to be cut, see "Intake and exhaust
valves" on page 13.
Continued
E N G I N E – 1 1 0 4 C – 4 4
Note :
The blades of the reamer must not cut the valve guide when the seat is cut.
3 Fit the cutter onto the reamer and push the handle fully onto the reamer. Ensure that the flat
part of the reamer shank is towards the Allen screw. Tighten the Allen screw to secure the
reamer to the handle.
4 Fit the reamer/cutter assembly into the valve guide. Ensure that the valve seat cutter is not
allowed to fall onto the seat as this can damage the blades. Carefully turn the handle in a
clockwise direction (B3) and gradually move the reamer into the valve guide until the valve guide
is reamed to the finished size. A lubricant is not necessary.
5 Continue to turn the handle in a clockwise
direction to cut the valve seat. Remove only
the minimum material to ensure a good valve
seat. Keep the seat as narrow as possible.
6 When the seat is cut, remove the
13
reamer/cutter assembly. Remove any debris
from the area of the valve guide, valve seat 03
and the port. 23
7 Fit the valve, see Operation 3-12.
8 Check that the valve depth is within limits,
refer to the relevant Data and dimensions for
the "Intake and exhaust valves" on page 13.
Note :
If a valve seat has become too damaged or too
2
worn to correct, a valve seat insert can be
fitted, see Operation 3-19. If all or most of the
original valve seat inserts need to be renewed,
it may be cost effective to overhaul or exchange
the cylinder head.
E N G I N E – 1 1 0 4 C – 4 4
To fit valve seat inserts Operation 3-19
1 Remove the valve guide, see Operation 3-15, and clean the bore into which the guide is to be
fitted.
2 Fit new partially finished valve guides, see Operation 3-16.
3 With the bore of the new partially finished valve guide used as a pilot, machine the recess in
the cylinder head to the dimensions shown in "Dimensions of recesses for valve seat inserts"
on page 14, or machine out the old insert. Remove all debris and clean the insert recess.
4 If the bottom face of the cylinder head has been machined, the insert will have to be surface
ground on the back face to ensure that there is no protrusion of the insert above the bottom
face of the cylinder head. After the back of the insert has been ground, ensure that the outer
13 edge of the back face has a 0,9/1,3 mm (0.035/0.051 in) chamfer at 30¡Æ to the vertical.
5 With the bore of the new, partially finished, valve guide used as a pilot, and with the rear face
of the insert towards the cylinder head, press in the insert with the valve seat insert tool, see
03 "Valve seat insert tool" on page 15.
24 ! Do not use a hammer on the insert and do not use lubrication.
Use a hydraulic press or a hand press in one continuous movement. Ensure that the bottom of
the insert is in contact with the bottom of the recess.
6 Ream the valve guide and cut the valve seat at an included angle of 120¡Æ for 30¡Æ valve
seats, see Operation 3-18.
Ensure that the depth of the valve head below the face of the cylinder head is within the production
limits, refer to the relevant Data and dimensions for the "Intake and exhaust valves" on page 13.
Note :
Work as near as possible to the minimum value to allow for future wear on the valve seat.
Continued
E N G I N E – 1 1 0 4 C – 4 4
PISTON AND CONNECTING ROD ASSEMBLIES
GENERAL DESCRIPTION
The pistons used in the 1100 Series 4 cylinder engines have a combustion chamber in the top
of the piston.
Piston (A) is for models RE, RF, and piston (B) is for models RG, RH, RJ, and RK. The combustion
chamber is designed to give an efficient mix of fuel and air.
13
04
1
The pistons and connecting rods are matched to the relevant cylinder.
The pistons have two compression rings and an oil control ring. The groove for the top ring has
a hard metal insert to reduce wear of the groove. The piston skirt has a layer of graphite to
improve the wear characteristics.
Axial location of the fully floating gudgeon pin is by circlips. The gudgeon pin is off-centre to
reduce the noise level.
Piston cooling jets are fitted in the cylinder block to spray lubricating oil onto the inner surface of
the pistons.
The correct piston height is important to ensure that the piston does not contact the cylinder head
and to ensure the efficient combustion of fuel.
The piston height is controlled by the length of the connecting rod. There are six length grades
of connecting rods used to obtain the correct piston height.
To obtain the different grades, the small-end bush is machined off-centre. The amount that the
bush is offcentre gives the different length grades.
Continued
E N G I N E – 1 1 0 4 C – 4 4
In service, a partially finished small-end bush is available, which can be fitted to the original
connecting rod and machined to obtain the correct length grade, see Operation 4-14. Specialist
equipment and personnel with the correct training are needed to machine the partially finished
small-end bush. Connecting rod kits are also available with the small end bush fitted and machined
to obtain the correct connecting rod grade. For further information refer to your nearest Perkins
Dealer/Distributor.
Notes :
• If the crankshaft or the cylinder block is to be renewed, it may be necessary to change the grade
of the connecting rods, see Operation 4-11. This will occur if the correct piston height above the
cylinder block face cannot be maintained with the original connecting rod assemblies, see
Operation 4-6.
• Always use the engine identification number
13 to order new parts.
The connecting rod is a one-piece forging that

04 is fractured hydraulically to split the big end
2 cap from the connecting rod. This process
produces rough but accurately matched
surfaces (C1).
E N G I N E – 1 1 0 4 C – 4 4
BIG END BEARING
1 Drain the engine lubricating oil.

2 Remove the lubricating oil sump, see Operation 10-4.
3 Remove the lubricating oil pump, see Operation 10-9 or remove the balancer unit, see Operation
5-15.
4 Release the fasteners (A4) and remove the bearing cap (A3).
Caution: Do not stamp or punch the connecting rod assembly, as this could cause a fracture.
5 Mark the bearing cap and the connecting rod with the cylinder number to ensure correct
assembly.
! Engine models RG, RH, RJ and RK have a different shell bearing fitted to the cap
13
and connecting rod. Ensure that the relevant shell bearing is kept with the correct 04
cap or connecting rod. 3
6 Rotate the crankshaft until the relevant
connecting rod is at its lowest position.
7 Remove the shell bearing (A5) from the cap
(A3). Keep the bearing with the cap.
8 Carefully push the connecting rod up the
cylinder bore just enough to allow access to
the upper half of the shell bearing. Remove the
shell bearing (A6) from the connecting rod
(A1). Keep the bearing with the connecting rod.
! Do not allow the connecting rod to hit

the piston cooling jet, if fitted.
E N G I N E – 1 1 0 4 C – 4 4
1 Clean the bearing faces of the connecting rod and the crank pin.
! • Engine models RG, RH, RJ and RK have a different shell bearing fitted to the
cap and connecting rod. Ensure that the relevant shell bearing is kept with the
correct cap or connecting rod.
• Do not stamp or punch the connecting rod assembly, as this could cause a
fracture.
2 Clean the complete bearing and lubricate the bearing surface and the crank pin with clean
engine lubricating oil.
13 3 Fit the upper half of the shell bearing to the connecting rod; ensure that the bearing shell is
fitted centrally (A1). Fit the connecting rod to the crank pin. Ensure that the forged marks (B1)
face to the front of the engine.
04
4 Note :
The fasteners used with these connecting rods must only be used once.
4 Clean, lubricate and fit the lower half of the shell bearing into the cap; ensure that the bearing
shell is fitted centrally (A1). Fit the connecting rod fasteners. Fit the cap to the connecting rod.
Ensure that the assembly has both of the forged marks on the same side (B1).
5 Tighten the new fasteners to an initial torque of 18 Nm (13 lbf ft) 1,9 kgf m.
6 Tighten the new fasteners to 70 Nm (52 lbf ft) 7,1 kgf m. The fasteners must then be tightened
a further 120 .
7 Ensure that the crankshaft rotates freely.
8 Fit the lubricating oil pump, see Operation 10-10, or fit the balancer unit, see Operation 5-15.
9 Fit the lubricating oil sump, see Operation 10-5 and fill the sump to the correct level with
lubricating oil of an approved grade, refer to Chapter 5 in the User’s Handbook.
1 Check the bearings and the crank pin for wear or other damage.
E N G I N E – 1 1 0 4 C – 4 4
PISTON AND CONNECTING ROD
1 Drain the lubricating oil and the cooling system.

2 Remove the cylinder head assembly, see Operation 3-9.
3 Remove all carbon from the top of the bores of the cylinders.
5 Remove the lubricating oil pump, see Operation 10-9 or remove the balancer unit, see Operation
5-15.
! • Do not stamp or punch the connecting rod assembly, as this could cause a
fracture 13
• The pistons and connecting rods are matched to the relevant cylinder. Mark
04
each connecting rod and piston with the cylinder number to ensure correct
5
assembly.
6 Remove the big end caps and the big end bearings from the connecting rods, see Operation 4-1.
! Do not allow the connecting rods to hit the piston cooling jets. If a cooling jet is
hit, renew it if necessary.
7 Rotate the connecting rods 90 to prevent contact with the piston cooling jets. Push the pistons
and the connecting rods out through the top of the cylinder liners. Keep the bearings and caps
together to ensure that they can be fitted in their original positions.
8 Inspect the crank pins for damage.
E N G I N E – 1 1 0 4 C – 4 4
Special tools
Piston replacer tool 21825491
1 Ensure that the piston, the cylinder bore, the crank pin and the big end of the connecting rod
are clean. Lubricate the piston and the cylinder bore with clean engine lubricating oil.
2 Rotate the crankshaft until the relevant crank pin is at its lowest position. Lubricate the crank
pin with clean engine lubricating oil.
13 3 Fit the upper half of the shell bearings to the connecting rod. Ensure that the bearing shell is
fitted correctly, see Operation 4-2. Lubricate the bearing with clean engine lubricating oil.
4 Put the piston replacer tool in position at the top of the relevant cylinder. The tool has a tapered
04 bore to compress the piston rings when the piston and connecting rod assembly is fitted. Ensure
6 that the smaller end of the tapered bore is towards the face of the cylinder block.
5 Put the piston ring gaps 120¡Æ apart. Pass the connecting rod through the piston replacer tool
and allow the piston to enter the tool. The arrow mark on the top of the piston (B) must be
towards the front of the engine.
! Ensure that the connecting rod will not hit the piston cooling jet (if fitted) as the
connecting rod assembly is fitted.
6 Push the piston and connecting rod assembly through the piston replacer tool (A) and onto the
crank pin. The piston and connecting rod assembly must be rotated to ensure that the connecting
rod will not hit the piston cooling jet as the assembly is fitted. When the connecting rod has
passed the piston cooling jet, rotate the connecting rod until the arrow mark on top of the piston
is towards the front of the engine.
Continued
E N G I N E – 1 1 0 4 C – 4 4
7 Clean the connecting rod cap and the lower half of the bearing. Fit the bearing to the cap;
ensure that the bearing is fitted correctly, see Operation 4-2. Lubricate the bearing with clean
engine lubricating oil. Fit the cap and ensure that the assembly number is the same as that on
the connecting rod and that the numbers are on the same side. Tighten the fasteners gradually
and evenly, see Operation 4-2.
8 Check that the crankshaft will rotate freely.
9 Check the piston height above the top face of the cylinder block, see Operation 4-6.
10 Fit the lubricating oil pump, see Operation 10-10 or fit the balancer unit, see Operation 5-15.
11 Fit the lubricating oil sump, see Operation 10-5
12 Fit the cylinder head assembly, see Operation 3-10.
13 Fill the sump to the correct level with lubricating oil of an approved grade, refer to Chapter 5
in the User’s Handbook.
13
To check the piston height above the cylinder block Operation 4-6
04
7
Special tools
Piston height tool 21825496 Dial gauge for use with 21825496 21825617
! If the correct piston height above the cylinder block is not obtained, damage to
the engine can occur and the engine may not be emissions compliant.
Put the piston height tool (A) on the face of the cylinder block and rotate the gauge dial to the
zero position. Rotate the crankshaft until the piston crown is approximately at top dead centre
(TDC). Carefully put the tool over the top of the piston with the plunger of the gauge in contact
with the piston above the axis of the gudgeon pin. Rotate the crankshaft to ensure that the piston
is at the highest position and make a note of the gauge indication.
The piston height above the top face of the cylinder block should be 0,21/0,35 mm (0.008/0.014 in).
Note :
• The top of the piston should not be machined.
• If the original piston is used, ensure that it is
assembled to the correct connecting rod and
is used in the original cylinder.
If any of the components listed below are

renewed, refer to the relevant operation :
• The connecting rod, see Operation 4-11
• The small end bush, see Operation 4-14
E N G I N E – 1 1 0 4 C – 4 4
PISTON RINGS
Note :
The pistons have two compression rings and an oil control ring. All the piston rings are above
the gudgeon pin. To ensure that the correct type is obtained always use the engine identification
number to order new parts.
! Only expand the ring gaps enough to ensure that the ends of the rings do not
damage the piston when the ring is removed or put into position.
13 1 Remove the piston rings with a suitable ring expander. Keep the rings with their relevant piston.
04
8 To fit Operation 4-8
Use a suitable piston ring expander to fit the piston rings.
! Only expand the ring gaps enough to ensure that the ends of the rings do not
damage the piston when the ring is removed or put into position.
1 Fit the spring of the oil control ring in the bottom groove with the latch pin (A1) inside both
ends of the spring(A). Fit the oil control ring over the spring. Ensure that the ring gap is at
180 to the latch pin.
2 Fit the cast iron ring with the taper face into
the second groove.
3 The second ring has a green identification
mark which must be on the left of the ring
gap when the ring is fitted and the piston is
upright, with the word "TOP" towards the top
of the piston.
4 The first ring has a red identification mark
which must be on the left of the ring gap
when the ring is fitted and the piston is
upright.
5 Ensure that the ring gaps are 120 apart.
E N G I N E – 1 1 0 4 C – 4 4
PISTON AND CONNECTING ROD ASSEMBLY
To dismantle Operation 4-9
! The pistons and connecting rods are matched to the relevant cylinder. Note the
position of each connecting rod and piston for correct assembly.
1 Remove the piston rings, see Operation 4-7.
2 Remove the circlips which retain the gudgeon pin.
! Do not scratch, etch or stamp the piston surface.
3 Put a temporary mark on the piston to indicate the cylinder number as shown on the connecting
rod. Put the temporary mark on the piston on the same side as the mark on the big end to
13
ensure that they are assembled correctly (A).
4 Push the gudgeon pin out by hand. If the gudgeon pin is tight, heat the piston to 40/50
04
9
(100/120 F) for easy removal of the gudgeon pin.
5 Inspect the piston and connecting rod assembly, see Operation 4-12 and Operation 4-13.
E N G I N E – 1 1 0 4 C – 4 4
To assemble Operation 4-10
1 Clean the bore of the small end bush and lubricate it with clean engine lubricating oil.
2 Fit a new circlip in the circlip groove of one of the gudgeon pin bosses. Ensure that it fits
correctly in the groove.
3 With the piston upside down, put the connecting rod in position with the forged mark (A1) on
the same side as the recess in the gudgeon pin boss (A2). If the original piston is used, ensure
that it is assembled to the correct connecting rod and is used in the original cylinder.
Note :
1100 Series 4 cylinder engines have six connecting rod length grades controlled by the small end
bush machining. If a new connecting rod is fitted, ensure that it is of the correct length grade,
13 see Operation 4-11.

4 Lubricate the gudgeon pin bosses with clean engine lubricating oil and push in the gudgeon pin
04 towards the circlip. If the gudgeon pin is a tight fit in the piston, heat the piston to 40/50 C
10 (100/120 F) before the gudgeon pin is fitted.
5 Fit a new circlip in the groove in the other gudgeon pin boss. Ensure that it fits correctly in the
groove.
6 Fit the piston rings, see Operation 4-8.
E N G I N E – 1 1 0 4 C – 4 4
To check the length of a connecting rod Operation 4-11
A partially finished small end bush, which can be fitted to the original connecting rod and machined
to obtain the correct length grade is available, see Operation 4-14. Specialist equipment and
personnel with the correct training are needed to machine the partially finished small end bush.
Connecting rod kits are also available with the small end bush fitted and machined to obtain the
correct connecting rod grade.
! • It is important that the piston does not contact the cylinder head. Ensure that
the piston height above the cylinder block is correct.
• Ensure that the connecting rods are fitted in the correct cylinder. Record the
position of the connecting rod and its relevant cylinder when it is removed from
the engine.
13
To ensure that the piston height above the cylinder block is correct, the engine may have up to 04
six length grades (F to L) of connecting rods fitted. 11
Identification of the length grade is by a letter or colour which is marked on the side of each
connecting rod (A1). The letter F is the longest grade of connecting rod and letter L is the shortest
grade. The difference between grades is 0,046 mm (0.0018 in).
If the grade letter or colour on the side of the connecting rod cannot be seen, the length can be
checked by the measurement of the dimension (X) shown in (A). Before the length of the connecting
rod is measured, ensure that the bores of the big end and the small end are square and parallel,
see Operation 4-13. The length is checked with the big end bearing removed and the original
small end bush fitted. The dimensions for each grade are listed in the table below:
Grade letter Colour code Length (mm)

F Red 165,728/165,761
G Orange 165,682/165,715
H White 165,637/165,670
J Green 165,591/165,624
K Purple 165,545/165,578
L Blue 165,499/165,532
E N G I N E – 1 1 0 4 C – 4 4
PISTON AND PISTON RINGS
1 Check the piston for wear and other damage.

2 Check that the piston rings are free to move in their grooves and that the rings are not broken.
3 Remove the piston rings, see Operation 4-7, and clean the piston ring grooves and the piston
rings.
Note :
Engine models RG, RH, RJ, and RK, have pistons that have a tapered top groove and the piston
13 ring is wedge shaped. The top piston ring clearance cannot be checked by this method.
4 Fit new piston rings in the grooves and check for wear of the grooves with feeler gauges (A).
Compare the piston ring clearance in the groove to that given for new components in the relevant
04 Data and dimensions for the "Pistons and piston cooling jets" on page 17, and renew the piston
12 if necessary.
5 Clean all carbon from the top of the cylinder bore. Fit each piston ring in the top part of the
cylinder bore and measure the ring gap with feeler gauges (B). The coil spring must be removed
from the oil control ring when the gap of this piston ring is measured.
The piston ring gaps for new components are given in the relevant Data and dimensions for
the "Piston rings" on page 17.
E N G I N E – 1 1 0 4 C – 4 4
CONNECTING ROD
1 Check the small end bush for wear or for other damage and renew it, if necessary.
Note :
Connecting rod kits are available with a new small-end bush fitted and finished to the correct
grade, see Operation 4-11 to identify the correct connecting rod grade.
A partially finished small end bush, which can be fitted to the original connecting rod and machined
to obtain the correct length grade is also available, see Operation 4-14.
2 Check the connecting rod for distortion. Refer to the relevant Data and dimensions for the
"Connecting rods and big end bearings" on page 18 to identify the correct mandrel size.
13
Note : 04
The large and small end bores must be square and parallel with each other within the limits of 13
+/- 0,25 mm (0.010 in) measured 127 mm (5.0 in) each side of the connecting rod axis on a test
mandrel. With the small end bush fitted, the limits are reduced to +/- 0,06 mm (0.0025 in).
3 Check the fit of the gudgeon pin in the small end bush and check the gudgeon pin for wear,
refer to the relevant Data and dimensions for the "Gudgeon pins and small end bushes" on
page 18.
E N G I N E – 1 1 0 4 C – 4 4
PARTIALLY FINISHED SMALL END BUSH
Note :
For details on how to change the partially finished small end bush, contact your nearest Perkins
Dealer/Distributor for advice.
13
04
14
E N G I N E – 1 1 0 4 C – 4 4
PISTON COOLING JETS
To remove
Release the setscrew (A1) and remove the piston cooling jet assembly.
Note :
The crankshaft is removed in (A) to show clearly the piston cooling jet.
To fit
1 Check that the spring loaded valve moves
freely against spring pressure in the valve
assembly and that the jet tube is not
13
damaged. Renew piston cooling jets as
necessary.
04
2 Fit the piston cooling jet; ensure that the 15
valve is fitted correctly in the locating hole in
the cylinder block.
3 Fit the setscrew (A1) and tighten to 9 Nm (7
lbf ft) 0,9 kgf m.
To check the jet alignment Operation 4-16
Note :
Ensure that the end of a 1,70 mm (0.067 in)
diameter rod is round, to prevent damage to
the piston cooling jet bore.
Carefully insert a 1,70 mm (0.067 in) diameter
rod, of 300 mm (11.8 in) in length, into the jet.
If a suitable rod is not available, reduce the end
of a thicker rod to 1,70 mm (0.067 in) diameter
for a length of 16,00 mm (0.630 in).
When the rod is inserted into the jet it must
extend out of the top of the cylinder within the
area shown in (A).
Replace the piston cooling jet, as necessary.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
CRANKSHAFT ASSEMBLY
GENERAL DESCRIPTION
The crankshaft is forged from chromium molybdenum steel and has five main journals. There is
a large flange at the rear of the crankshaft to which the flywheel is fitted.
End-float and thrust movements are controlled by two split 360o thrust washers on both sides of
the centre main bearing.
The main bearings have steel backs with an aluminium/tin bearing material, and main bearing caps
are made of cast iron or spheroidal graphite iron.
The timing ring is an interference fit onto the machined surface of the web. The timing ring is
fitted behind the crankshaft palm and is located by a dowel.
The rear end oil seal is made from a PTFE material and is an integral part of the pressed steel
13
housing, which is fitted to the cylinder block. 05
The crankshaft pulley (A2) is held in position by a plain thrust block (A3) and three setscrews 1
(A4). The nose (A1) of the crankshaft and the pulley is serrated for location.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
CRANKSHAFT PULLEY
To remove
1 Remove the fan drive belt(s), see Operation 14-3.
2 Remove the three setscrews (A4) which hold the pulley and remove the setscrews, the thrust
block (A3) and the pulley (A2).
3 Clean the components and check for damage. Renew damaged components as required.
4 Check the area of the seal contact on the pulley for wear. If there is excessive wear a wear
sleeve can be fitted, see Operation 5-3.
13 To fit
1 Put the pulley (A2) in position on the crankshaft nose (A1). Lubricate lightly the threads of the
05 setscrews (A4) with clean engine lubricating oil. Fit the thrust block (A3) and the setscrews (A4)
2 and tighten the setscrews to 115 Nm (85 lbf ft) 11,8 kgf m.
2 Check each setscrew again to ensure that they are still to the correct torque.
3 Fit the drive belt(s), see Operation 14-3.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
REAR END OIL SEAL ASSEMBLY
To remove and to fit the rear end oil seal assembly Operation 5-2
! The new rear end oil seal assembly includes a plastic protection sleeve (A2) that
is fitted to the inside of the seal. This sleeve is to protect the oil seal from
damage when it is fitted to the crankshaft palm (A1). The plastic sleeve must
remain inside the seal until the assembly is fitted. When the assembly is fitted,
the plastic sleeve will be pushed out of the oil seal and the assembly. The plastic
sleeve must be discarded after the assembly is fitted. The seal of the new rear
end oil seal assembly is pre-waxed, there is no need to lubricate the palm or the
seal before it is fitted. 13
Note :
• The oil seal for the rear end oil seal assembly cannot be renewed, if the seal is faulty, the
05
3
complete assembly must be renewed.
• If the crankshaft palm has a wear groove caused by the old oil seal assembly, a wear sleeve
must be fitted to the crankshaft palm before the new assembly is fitted, see Operation 5-3.
• An alignment tool is needed to fit the rear end oil seal assembly, see page 82.
• The rear end oil seal cannot be used again and must be replaced if removed.
To remove
1 Remove the drive components from the rear end of the engine.
2 Remove the flywheel, see Operation 13-1 and the flywheel housing, see Operation 13-3.
3 Remove the Torx screws from the rear end oil seal housing and remove the assembly.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
To fit
! To prevent contamination of the oil seal surface, keep the new assembly packed
until required for use.
Note :
The rear end oil seal cannot be used again and must be replaced if removed.
1 Ensure that the crankshaft palm (A1), the rear face of the cylinder block and the bridge piece
are dry, free from dirt, and that there are no rough metal edges. Do not use a lubricant on
either the crankshaft palm, or on the rear end oil seal, as the seal is pre-waxed.
2 Remove the new rear end oil seal assembly (A3) from its pack. Ensure that the plastic sleeve
(A2) supplied with the rear end oil seal is square within the rear end oil seal. The plastic
protection sleeve must be in place when the seal is fitted to the crankshaft palm, this will prevent
13 the seal being damaged when fitted.

3 Place the rear end oil seal over the crankshaft palm and engage the plastic protection sleeve
(B1) onto the crankshaft palm (A1).
05 4 With the plastic protection sleeve engaged on the crankshaft palm, push the rear end oil seal
4 assembly evenly and smoothly onto the crankshaft palm until it is against the cylinder block.
The plastic protection sleeve will be pushed out of the assembly (C).
Continued
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
5 Discard the plastic sleeve.

6 Rotate the rear end oil seal (D3) to align the holes in the rear end oil seal assembly with the
holes in the cylinder block rear face and the cylinder block bridge piece.
7 Loosely fit the Torx screws (D5).
8 Place the seal alignment tool (D4), see page 82, onto the crankshaft palm and over the rear
end oil seal housing to align the rear end oil seal to the crankshaft palm.
Note :
• Ensure that the two rubber locating pins are correctly located into the cylinder block.
• Ensure that there is no distortion of the rubber dust lip and that is in full contact with crankshaft
palm. If there is distortion, discard the seal and replace with a new seal.
9 Tighten setscrews 1, 2, 3, 4, 5, 6, 7, and 10 in the sequence shown in (E) to 22 Nm (16 lbf
ft) 2,2 kgf m.
10 Remove the alignment tool and tighten the remaining Torx screws 8 and 9 in sequence (E)
to 22 Nm (16 lbf ft) 2,2 kgf m.
13
11 Fit the flywheel, see Operation 13-1 and the flywheel housing, see Operation 13-3. 05
12 Fit the drive components to the rear end of the engine.
5
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
Alignment tool
The alignment tool (F) must be manufactured locally to the following specifications :
1 Outer surface (F1) to be knurled
2 Remove all sharp edges
3 To be made from material EN 32, harden 0,5 mm deep.
13 = =
05 ˚ ˚x
6
Note :
All dimensions are in millimetres.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
To remove and to fit a wear sleeve Operation 5-3
Consumable products
POWERPART Liquid gasket 21820518
To remove
1 Remove the rear end oil seal, see Operation 5-2.
2 With a sharp tool mark a deep line along the length of the sleeve.
3 Insert a suitable thin blade between the crankshaft palm and the sleeve next to the marked line.
The wear sleeve will separate along the marked line.
4 Remove the wear sleeve. Use a suitable cleaner to remove any sealant from the crankshaft
palm.
13
To fit 05
1 Ensure that the crankshaft palm is dry and free from oil, dirt and sealant. 7
2 Remove any rough areas from the crankshaft palm surface.
3 Apply a small continuous bead of sealant (A2), that does not harden, to the inner surface of
the wear sleeve 5,0 mm (0.197 in) from the flange end of the sleeve (A1).
! The wear sleeve must be fitted within five minutes of applying the sealant.
4 Ensure that the crankshaft is fully forward in the engine.
5 Place the wear sleeve onto the crankshaft palm (B3), use the tool (B1) that is supplied with the
new wear sleeve and a suitable hammer, to force the wear sleeve (B2) over the crankshaft
palm leaving a gap (B5) of 0,4/0,6 mm (0.016/0.024 in).
6 Remove the tool and measure the gap (B5) between the wear sleeve flange and the cylinder
block in two places 180¡Æapart. The correct gap is 0,4/0,6 mm (0.016/0.024 in).
7 After the wear sleeve has been fitted, check and remove any rough metal edges from the
crankshaft palm and the wear sleeve.
8 Fit a new rear end oil seal, see Operation 5-2.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
THRUST WASHERS
To check crankshaft end-float Operation 5-4
The axial movement of the crankshaft is

controlled by thrust washers fitted both sides of
the centre main bearing (A).
13
05
8
The end-float can be checked with a feeler gauge between a thrust washer and the crankshaft
(B), or with a dial test indicator on one end of the crankshaft to check the movement (C).
If the end-float is more than the tolerance given in the relevant Data and dimensions for the
"Crankshaft" on page 19, thrust washers which are 0,019 mm (0.0075 in) oversize can be fitted.
The oversize thrust washers can be fitted to one or to both sides of the main bearing. They are
fitted instead of the standard size washer, to reduce the end-float to the factory tolerances.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
1 Drain the lubricating oil and remove the lubricating oil sump, see Operation 10-4.
2 If necessary, remove the lubricating oil pump, see Operation 10-9, or remove the balancer unit,
see Operation 5-15.
3 Release the setscrews of the centre main
bearing and remove the main bearing cap
complete with the lower halves of the thrust
washers.
4 Use a suitable tool (A1) made of a soft
material to push each of the upper halves of
the thrust washers from their recesses.
Where necessary, move the crankshaft to the
front or to the rear to loosen a tight washer.
13
05
9
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
1 Lubricate the thrust washers with clean engine lubricating oil.
! Factory built engines have an upper shell bearing that has an lubricating oil slot
(C1) that is fitted to the number one crankshaft journal. The remaining upper shell
bearings have a lubricating oil holes (C2). For service all upper shell bearings will
be replaced with bearings that have the lubricating oil slot (C1).
2 Slide each of the upper halves of the thrust washers into their recesses in the cylinder block.
Ensure that the sides of the thrust washers that have the grooves (A1) are against the crankshaft.
3 Fit the lower half thrust washers to the main bearing cap with the location tags in their recesses.
13 4 Ensure that the location thimbles (B2) are fitted correctly in the main bearing cap or in the
cylinder block.
5 Ensure that the bearing is fitted correctly in the cap and that the bearing and the crankshaft
05 journal are clean. Lubricate the bearing with clean engine lubricating oil.
10 6 Fit the cap with the location tags of both halves of the shell bearings to the same side (B1),
ensure that the plain bearing shell is fitted to the lower bearing cap (B).
7 Tighten the main bearing setscrews to 245 Nm (181 lbf ft) 25,0 kgf m.
8 Ensure that the crankshaft turns freely. If the thrust washers have been removed and fitted,
check the crankshaft end-float, see Operation 5-4.
9 If necessary, fit the lubricating oil pump, see Operation 10-10, or fit the balancer unit, see
Operation 5-15.
10 Fit the lubricating oil sump, see Operation 10-5, and fill the sump to the correct level with
lubricating oil of an approved grade, refer to Chapter 5 in the User’s Handbook.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
MAIN BEARINGS
To remove (with the crankshaft in position) Operation 5-7
! Ensure that the tops of the main bearing caps are stamped with their relevant
position number. Keep the bearings with their relevant caps.
Note :
• If more than one set of main bearings are to removed then identify, and keep each pair as a set.
• If the rear main bearing cap is to be removed with the crankshaft in position, the flywheel, the
flywheel housing, the rear end oil seal assembly and the bridge piece will have to be removed.
1 Drain the lubricating oil and remove the
sump, see Operation 10-4.
13
2 Remove all necessary components to get 05
access to the specific bearing cap. 11
3 Release the setscrews of the bearing cap
and remove the bearing cap. Remove the
lower half of the shell bearing from the cap.
4 With a suitable tool (A1), push the upper half
of the shell bearing from the side opposite to
the location tag (A2) to remove the bearing
tag from its recess (A3) in the bearing
housing. Carefully rotate the crankshaft to
release the bearing from its housing.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
To fit (with the crankshaft in position) Operation 5-8
1 Clean the upper half of the shell bearing and lubricate the bearing surface with clean engine
lubricating oil.
! Only the upper half of the bearing has lubrication holes and must be fitted to the
cylinder block.
2 Fit the plain end of the upper half of the bearing between the crankshaft journal and the side
of the bearing housing which has the recess for the location tag. Slide the bearing into its
housing until the tag on the bearing is fitted correctly in its recess in the housing.
3 Clean the lower half of the bearing and the cap, lubricate the bearing surface with clean engine
13 lubricating oil.
4 Fit the bearing into the cap with the tag of the bearing fitted correctly in the recess in the cap.
5 Ensure that the location thimbles (A2) are fitted correctly to the cap or to the cylinder block. Fit
05 the bearing cap with the location tags of both bearings on the same side (A1).
12 6 Inspect the setscrews for damage and for distortion and renew them if necessary. Lightly lubricate
the setscrew threads with clean engine lubricating oil. Fit the setscrews and tighten the setscrews
to 245 Nm (181 lbf ft) 25,0 kgf m.
7 Ensure that the crankshaft turns freely. If
the thrust washers have been removed
and fitted, check the crankshaft end-float,
see Operation 5-4.
8 Fit all the components which were removed
for access to the main bearing cap.
9 Fit the lubricating oil sump, see Operation
10-5, and fill the sump to the correct level
with lubricating oil of an approved grade,
refer to Chapter 5 in the User’s Handbook.
1 Inspect the bearings for wear and for other damage. If a bearing is worn or damaged, renew
both halves of the shell bearings and check the condition of the other bearings.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
CRANKSHAFT
Note :
If the crankshaft is to be renewed, it may be necessary to change the grade of the connecting
rods, see Operation 4-11. This will occur if the correct piston height above the block face cannot
be maintained with the original piston and connecting rod assemblies, see Operation 4-6.
! Use lift equipment or obtain assistance to lift heavy engine components such as
the flywheel, flywheel housing and the crankshaft.
1 Before the engine is removed from the vehicle or from the machine, drain the lubricating oil and
the coolant.
13
3 Remove the fan, see Operation 12-8, the drive belts, see Operation 14-3, the fan drive pulley
05
13
and housing, see Operation 12-9 and the coolant pump, see Operation 12-4.
4 Remove the fuel injection pump:
• For Bosch VP30 fuel injection pumps, see Operation 11-9.
• For Bosch EPVE fuel injection pumps, see Operation 11-11.
• For Delphi DP210 fuel injection pumps, see Operation 11-13.
5 Remove the crankshaft pulley, see Operation 5-1.
6 Remove the alternator and its mounting bracket, see Operation 14-4.
7 Remove the exhauster if fitted, see Operation 15-5.
8 Remove the timing case cover, see Operation 6-1.
9 Remove the timing gears and the timing case, see Chapter 6, Timing case and drive assembly.
10 Remove the flywheel, see Operation 13-1, and the flywheel housing, see Operation 13-3.
11 Remove the rear end oil seal housing, see Operation 5-2.
12 Remove the lubricating oil pump, see Operation 10-9, or remove the balancer unit, see
Operation 5-15.
13 Remove the bridge piece.
! The engine should be upside down before the fasteners for the crankshaft are
removed. If the engine cannot be turned upside down support the crankshaft
before the fasteners are removed.
14 Remove the caps of the connecting rods. Keep the bearings and caps together. Remove the
bolts of the connecting rods and carefully push the pistons towards the top their bores, see
Operation 4-4.
15 Ensure that the tops of the main bearing caps are stamped with their relevant position number.
Remove the main bearing caps, the lower half of the shell bearings and the upper and lower thrust
washers. Keep the bearings with their relevant caps, see Operation 5-5 and Operation 5-7.
16 Lift out the crankshaft. Remove the upper half of the bearings and keep each bearing with its
relevant lower half and cap.
! If a timing ring is fitted to the crankshaft ensure that is protected from damage
and is correctly stored.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
Consumable products
POWERPART Silicone adhesive 21826038
1 Ensure that all lubricating oil passages are clean and free from restriction.
2 Clean the main bearing housings and the upper half of the bearings. Fit the shell bearings with
the location tags fitted correctly in their recesses. Lubricate the bearings with clean engine
lubricating oil.
3 Ensure that the main journals of the crankshaft are clean. Put the crankshaft in position on the
13 upper bearings.
4 Clean and lubricate the upper halves of the thrust washers and slide them into their recesses
on both sides of the bearing housing. Ensure that the slotted sides of the thrust washers are
05 towards the crankshaft, see Operation 5-6.
14
5 Clean the bearing caps and the lower half of the bearings. Fit the bearings to the caps with
the location tags fitted correctly in their recesses. Lubricate the bearings with clean engine
lubricating oil.
6 Clean the lower halves of the thrust washers and lubricate them with clean engine lubricating
oil. Fit the thrust washers on both sides of the bearing cap for the centre main bearing.
7 Check that the location thimbles for the main bearing caps are fitted correctly in the caps or in
the cylinder block. Fit the bearing caps in their correct positions with the location tags of the
bearings on the same side.
8 Fit the setscrews to the main bearing caps and tighten them to 265 Nm (196 lbf ft) 27,0 kgf m.
Continued
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
9 Clean the bridge piece and the location areas for the bridge piece in the cylinder block. Use a
straight edge (A2) to ensure that the bridge piece is in line with the rear face of the cylinder
block. Tighten the bridge piece cap screws (A1) to 16 Nm (12 lbf ft) 1,6 kgf m.
Note :
The maximum protrusion for the bridge piece
(C2) to the cylinder block (C1) is 0/-0,075 mm
(0/-0.0029 in) (C3).
10 When the bridge piece is in position, inject
POWERPART Silicone adhesive into the
groove (B2) at each end of the bridge piece.
Continue to inject adhesive until the groove
is completely full and the adhesive leaves
the lower groove (B1) at the front and rear
of the bridge piece.
13
05
15
11 Fit the connecting rod caps, see Operation 4-2. Rotate the crankshaft two turns to ensure free
movement.
12 Fit the lubricating oil pump, see Operation 10-10, or fit the balancer unit, see Operation 5-15.
13 Fit the rear end oil seal housing, see Operation 5-2.
14 Fit the flywheel housing, see Operation 13-3, and the flywheel, see Operation 13-1.
15 Fit the timing case and the timing gears, see Chapter 6, Timing case and drive assembly.
16 Fit the timing case cover, see Operation 6-2.
17 Fit the exhauster if removed, see Operation 15-5.
18 Fit the alternator and its mounting bracket, see Operation 14-4.
19 Fit the crankshaft pulley, see Operation 5-1.
20 Fit the fuel injection pump:
• For Bosch VP30 fuel injection pumps, see Operation 11-10.
• For Bosch EPVE fuel injection pumps, see Operation 11-12.
• For Delphi DP210 fuel injection pumps, see Operation 11-14.
21 Fit the coolant pump, see Operation 12-5, the fan drive pulley and housing, see Operation 12-
9, the drive belts, see Operation 14-3, and the fan, see Operation 12-8.
22 Fit the lubricating oil sump, see Operation 10-5.
23 After the engine has been installed, fill the lubricating oil sump to the correct level with an
approved oil, refer to Chapter 5 in the User¡¯s Handbook.
24 Fill the cooling system. Copyrighted Material
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
Check the crankshaft for wear and other damage. The maximum permissible wear and ovality on
the crankshaft journals and crank pins is 0,04 mm (0.0016 in).
The main journals and the crank pins of standard size crankshafts can be machined to 0,25 mm
(0.010 in), 0,50 mm (0.020 in) or 0,75 mm (0.030 in) undersize on diameter, see "Crankshaft
overhaul" on page 19.
Special undersize bearings are available.
13
05
16
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
CRANKSHAFT TIMING RING
! Ensure that suitable protective clothing is worn.

! • Apply heat to the timing ring only to reduce the risk of damage to the crankshaft
• Carefully remove the timing ring, do not damage the crankshaft palm oil seal face.
1 Remove the crankshaft from the cylinder block, see Operation 5-10.
Note :
If a “speedi sleeve” (wear sleeve) has been fitted to service the crankshaft palm seal diameter,
the shoulder of this sleeve must be removed to give clearance for the timing ring.
13
2 Support the crankshaft in a vertical position 05
with the crankshaft palm at the bottom. 17
3 Apply heat to the timing ring (A1) with a
flame. The temperature of the timing ring
must not exceed 270 C (518 F). When heat
is applied to the timing ring, the ring will fall
off the crankshaft web.
4 Discard the old timing ring after it has been
allowed to cool safely.
5 Do not remove the timing ring locating dowel
(A2) from the crankshaft web unless the
locating dowel is damaged.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
! Ensure that suitable protective clothing is worn.
! • Apply heat to the timing ring evenly to reduce the risk of damage and distortion
to the timing ring (A1)
• Carefully fit the timing ring, do not damage the crankshaft palm oil seal face.
1 Ensure that the timing ring bore, and the crankshaft timing ring location shoulder, are both clean
and free from any rough metal edges.
2 If the locating dowel (A2) was removed press a new locating dowel into the hole in the crankshaft
web. Ensure that the locating dowel is at the bottom of the hole.
13 3 Support the crankshaft in a vertical position
with the crankshaft palm at the top.
4 Heat the timing ring (A1) in an oven to a
05 temperature of between 207 /250 C (405
18
/482 F). With the timing ring bore chamfer
and relief groove towards the crankshaft web,
and the dowel hole aligned with the dowel,
immediately fit the timing ring. Ensure that
the timing ring is fitted fully against the
crankshaft web shoulder.
5 Allow the timing ring to cool safely.
6 Fit the crankshaft to the cylinder block, see
Operation 5-11.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
BALANCER UNIT
Consumable products
To remove
1 Drain the lubricating oil from the sump and remove the sump, see Operation 10-4.
2 Set the piston of the number 1 cylinder to TDC, see Operation 8-1.
3 Insert the timing pin (C1) into the balancer, ensure that the timing pin is fully located in the
drive shaft.
13
! The weight of the unit is approximately 25 kg (55 lb).
05
19
4 Provide a support for the balancer unit before release of the setscrews from the engine.
5 Release the setscrews and carefully remove the balancer unit.
To fit
1 Ensure that the contact faces of the cylinder
block and of the balancer unit are clean and
that the thimble (A1) and the dowel (A2) are
fitted correctly to the cylinder block or to the
balancer unit.
2 Set the piston of the number 1 cylinder to
TDC, see Operation 8-1.
3 Fit two suitable M10 guide studs into
positions (B1).
Continued
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
4 Insert the timing pin (D1) into balancer, ensure that the timing pin is fully located in the drive
shaft and that the balancer weights are pointing away from the cylinder block.
5 Carefully fit the balancer unit onto the two M10 guide studs in the cylinder block, check that
the balancer unit is fitted correctly on the thimble and the dowel. Ensure that the idler and
crankshaft gears are in mesh. Fit two setscrews in the centre positions of the balancer frame,
then tighten the setscrews to 54 Nm (40 lbf ft) 5,5 kgf m.
6 Remove the two M10 guide studs and fit the
four remaining setscrews in their correct
position. Tighten the setscrews to 54 Nm (40
lbf ft) 5,5 kgf m.
7 Rotate the crankshaft through two turns to
ensure that it is free to rotate.
13 8 Fit the lubricating oil sump, see Operation

10-5, and fill the sump to the correct level
with lubricating oil of an approved grade,
05 refer to Chapter 5 in the User’s Handbook
20 TPD 1477.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
To dismantle (oil pump) Operation 5-16
1 Remove the balancer from the engine, see Operation 5-15.

2 To prevent movement of the drive shaft. Put a suitable flat distance piece in position between
the balancer weights.
3 Release the setscrew and remove the idler gear assembly (A).
Note :
Keep the components together as an assembly.
4 Release the nut of the lubricating oil pump gear and remove the nut. Using a suitable 2 legged
puller locate the puller arms on the back of the gear (B1) and remove the lubricating oil pump
gear from the shaft.
5 Release the four setscrews (C1) from the lubricating oil pump cover plate and remove the cover.
6 Inspect the lubricating oil pump, see Operation 5-18.
13
7 Dismantle the lubricating oil relief valve, see Operation 10-12. 05
21
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
To assemble (oil pump) Operation 5-17
Consumable products
POWERPART Threadlock and nutlock 21820117
1 Assemble the lubricating oil relief valve, see Operation 10-12.
2 Fit the four setscrews (A1) to the lubricating oil pump cover plate and tighten to 26 Nm (19 lbf ft)
2,6 kgf m.
3 Fit the lubricating oil pump gear and nut, gradually tighten to 95 Nm (70 lbf ft) 9,7 kgf m.
13 Note :
Ensure that the flats on the thrust washer (B2) are aligned.
4 If necessary, renew the idler gear. Lubricate the bush with clean engine lubricating oil. Fit the
05 hub into the bush and fit the thrust washer onto the rear of the hub. Ensure that the threads
22 of the setscrew are clean and dry. Fit the setscrew through the assembly and apply a small
amount of POWERPART Threadlock and nutlock to the thread. Fit the assembly to the front of
the balancer unit . Tighten the setscrew to 26 Nm (19 lbf ft) 2,6 kgf m.
5 Check the end-float of the idler gear with a feeler gauge between the front face of the idler
gear and the hub. Check the backlash between the idler gear and the drive shaft gear. Refer
to the Data and dimensions for "Balancer unit" on page 21.
6 Fit the suction tube and the joint and tighten the setscrews, if removed.
7 Remove the distance piece from the balancer weights.
8 Fit the balancer to the engine, see Operation 5-15.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT ASSEMBLY
Note :
If any part is worn enough to have an effect on the performance of the oil pump, the complete
oil pump must be renewed.
1 Remove the setscrews and remove the cover of the oil pump.
2 Remove the outer rotor and clean thoroughly all the parts. Check for cracks and any other
damage.
3 Fit the outer rotor and check the outer rotor to body clearance (A), refer to the Data and
dimensions for the "Lubricating oil pump" on page 25.
4 Check the inner rotor to outer rotor clearance (B), refer to the Data and dimensions for the
"Lubricating oil pump" on page 25.
5 Check the rotor end-float with a straight edge and a feeler gauge. For all the above clearances,
13
refer to the Data and dimensions for the "Lubricating oil pump" on page 25.
6 Lubricate the inner and outer rotor with clean engine lubricating oil. Clean the top face of the
05
oil pump and the inner face of the cover. Fit the cover. Tighten the setscrews to 28 Nm (21 23
lbf ft) 2,9 kgf m.
E N G I N E – 1 1 0 4 C – 4 4
TIMING CASE AND DRIVE ASSEMBLY
GENERAL DESCRIPTION
The timing case is made of either aluminium or cast iron.

The cast iron timing case is used to mount two power take-off units.
The timing gears are made of steel. There are two different types of steel camshaft gear and
upper idler gear.
One for heavy duty and one for light duty. A power take-off is available on either the left hand
side, or the right hand side or on both sides of the timing case. Some engines have an idler gear
with a roller bearing.
The drive from the crankshaft gear passes through an idler gear to the camshaft gear and to the
gear of the fuel injection pump. The drive from the crankshaft gear also passes through a lower
13
idler gear to the gear of the lubricating oil pump. The coolant pump is driven by the gear of the 06
fuel injection pump. The camshaft and the fuel injection pump run at half the speed of the 1
crankshaft.
In (A) the electronic fuel pump gear is fitted. In (B) the mechanical fuel pump gear is fitted.
The timing case contains the front oil seal.
E N G I N E – 1 1 0 4 C – 4 4
TIMING CASE COVER
Note :
• To assist with access to the timing case
cover, the fan drive can be removed, see
Operation 12-9.
• The timing case cover can be removed with
the crankshaft pulley fitted.
13 1 Remove the coolant pump, see Operation 12-4.

2 Remove the setscrews and the cover (A1),
together with the joint.
06 3 Remove the joint from the cover and discard
2 the joint.
E N G I N E – 1 1 0 4 C – 4 4
1 Clean the joint faces of the timing case and cover.

2 The new joint must be aligned by the three joint dowels (A1). The joint dowels are a push fit
into the cover (A2).
3 Fit two temporary studs (B1) through the timing case and into the cylinder block.
4 Remove the timing pins, if fitted.
5 Fit the cover to timing case and loosely fit the setscrews.
6 Loosely fit the coolant pump, see Operation
12-5. 1
7 Tighten the cover setscrews (C2) and coolant
pump fasteners (C1) together to 22 Nm (16
lbf ft) 2,2 kgf m
8 Fill the cooling system, refer to Chapter 4 of
2
13
User’s Handbook, TDP 1477. 06
9 If removed fit the crankshaft pulley, see 3
Operation 5-1.
10 Fit the fan drive, see Operation 12-9.
A R1342
E N G I N E – 1 1 0 4 C – 4 4
MECHANICAL FUEL PUMP GEAR
Special tools
Crankshaft timing pin 27610211
Camshaft timing pin 27610212
Rocker assembly tools 27610227
! • These procedures must only be carried out by a person with the correct training.
13 • The pump timing can be reset on the engine, see Operation 8-4.
• The timing pins are a push fit. Do not use excessive force to fit the pins.
06 • The engine is pin timed at TDC, do not use the pins as a locking device when
repairs are carried out on the engine.
4
Note :
• The fuel pump gear can be removed with the
crankshaft pulley fitted.
• It is recommend to help rotate the crankshaft,
that the glow plugs are removed, see Operation
14-10.
1 Rotate the crankshaft to TDC, see Operation 8-1.
2 Remove the rocker assembly, see Operation 3-4.
! The backlash must be removed from all

the gears before the fuel injection pump
is locked. Failure to do so will make
the fuel pump timing incorrect.
3 Apply pressure counter clockwise by hand to
the fuel pump gear (A2), to remove back lash
from the gears (B1), then lock the fuel injection
pump.
Continued
E N G I N E – 1 1 0 4 C – 4 4
4 To lock the Bosch EPVE pump shaft, ensure

the backlash is removed. Loosen the locking
screw (C2) and remove the washer (C1).
Tighten the locking screw (C2) to 31 Nm (23
lbf ft)3,1 kgf m.
5 Release the nut (E2) and fit a suitable two
legged puller (E3). Tighten the puller until the
gear is released.
6 Remove the puller (E3) and the nut (E2).
Remove the gear (E1).
1
13
2 06
5
E N G I N E – 1 1 0 4 C – 4 4
Special tools
Crankshaft timing pin 27610211 Camshaft timing pin 27610212
! • These procedures must only be carried out my a person with the correct training.
• The drive shaft of the pump must not be turned without the locking screw released,
as this will damage be the drive shaft.
• The engine is pin timed at TDC, do not use the pins as a locking device when
13 repairs are carried out on the engine.
1 Clean and check the fuel pump gear and renew if damaged. Clean the fuel injection pump
06 tapered shaft (A1).
6 2 Check the engine is set to TDC, see Operation 8-1.
3 Fit the gear (A2) onto the tapered shaft (A1). Check that the fuel pump gear is correctly in
mesh with the idler gear.
4 Fit the washer and nut (B1) and tighten by hand.
! The backlash must be removed before the fuel injection pump is released. Failure to
do so will make the fuel pump timing incorrect.
5 Apply pressure counter clockwise by hand (B2) to the fuel pump gear to remove the backlash
from all the gears (C1). Tighten the nut (B1) to 24 Nm (18 lbf ft) 2,4 kgf m.
Continued
E N G I N E – 1 1 0 4 C – 4 4
6 Release the locked fuel pump shaft.

• To release the Bosch EPVE pump shaft, ensure the backlash is removed. Loosen the locking
screw (D2) and fit the washer (D1). Tighten the locking screw (D2) to 12 Nm (9 lbf ft) 1,2 kgf m.
13
06
7 Tighten the nut (B1) to 88 Nm (65 lbf ft) 9,0 kgf m. 7
8 Remove the two timing pins.
9 Check the fuel injection pump gear end-float (F1) and the backlash (G1), see "Timing case and
drive assembly" on page 22.
10 Lightly lubricate each gear with clean engine lubricating oil.
12 Fit the glow plugs, see Operation 14-10.
E N G I N E – 1 1 0 4 C – 4 4
ELECTRONIC FUEL PUMP GEAR
Special tools
• If the hub nut (A3) is loosened the fuel injection pump timing will be lost and the
13 fuel injection pump will have to be removed and sent to your nearest Perkins
Dealer/Distributor to be reset.
06 • The timing pins are a push fit and must not be forced into place.
8 • The engine is pin timed at TDC, do not use the pins as a locking device when
Note :
The fuel pump gear can be removed with the crankshaft pulley fitted.
1 Rotate the crankshaft to obtain TDC see, Operation 8-1.
2 Set the Bosch VP30 fuel injection pump timing, see Operation 8-2.
3 With all three timing pins fitted (A1), remove the setscrews (A2) and the hardened washers from
the gear.
4 Remove the gear (B1) from the hub (B2).
E N G I N E – 1 1 0 4 C – 4 4
Note :
The fuel pump gear will only fit correctly in one position.
1 Clean and check the fuel pump gear (A1) for damage and renew if necessary. Clean the fuel
injection pump hub (A3).
2 If the timing pin (A2) has been removed, rotate the hub (A3) until the slot in the hub is aligned
with the hole in the pump body. Insert the timing pin through the slot into the hub (A3) and
fully into the body of the fuel injection pump. 13
3 With all three timing pins fitted, fit the fuel pump gear (A1) over the timing pin (A2) and onto
the hub (A3). 06
4 Loosely fit the flat hardened washers and setscrews (B3). 9
! To ensure that the engine is correctly timed, backlash must be removed from all
the gears.
5 Apply pressure counter clockwise by hand (B1) to the fuel pump gear (B2), to remove the
backlash.
6 Tighten the setscrews (B3) to 22 Nm (16 lbf ft) 2,2 kgf m.
7 Remove the timing pins.
8 Check the fuel pump gear end-float and backlash, see "Timing case and drive assembly" on
page 22.
9 Lightly lubricate each gear with clean engine lubricating oil.
E N G I N E – 1 1 0 4 C – 4 4
IDLER GEAR AND HUB
Note :
• There are two types of idler gear and hub. One gear is bushed and the other is fitted with roller
bearings. This gear is the heavy duty idler gear. To remove the heavy duty idler gear assembly,
the plate (A2) is removed and fitted as part of the gear assembly. To dismantle the assembly,
see Operation 6-10.
• When the idler gear is to be removed, it is good practice to mark the plate (A2) and the idler
gear, to help align the parts when they are to be assembled.
13 1 Remove the fuel pump gear; for the mechanical fuel pump gear, see Operation 6-3, and for the
electronic fuel pump gear, see Operation 6-5.
06 2 Remove the rocker assembly, see Operation 3-4.
10 3 Remove the three setscrews (A1) and the plate (A2) from the idler gear. Remove the gear and
the hub assembly (B1) from the recess (D1) in the cylinder block. The hub assembly (B1) must
be moved forward and lifted over the front oil seal housing (B2).
4 Slide the hub (C2) out of the gear (C1).
1
2
A R1498
E N G I N E – 1 1 0 4 C – 4 4
Special tools
Fuel pump timing pin 27610032
! • The hub assembly must be aligned correctly to the plate (B2) and the cylinder
block to allow the gear to be lubricated.
• The marked teeth (A2) on the idler gear must be assembled to the hub so that
they face to the front.
• The marked teeth (A2) on the idler gear must not be used as timing marks.
13
06
11
Note :
To fit the heavy duty idler gear assembly the plate (B2) is fitted as part of the gear assembly.
The plate will be marked with the word TOP, ensure this is facing the front of the engine this is
to allow the gear assembly to be fitted correctly. To assemble the heavy duty idler gear, see
Operation 6-11.
1 Clean and check the hub and gear for damage, renew if necessary.
2 Check the engine timing, see Operation 8-1.
Continued
E N G I N E – 1 1 0 4 C – 4 4
3 Lubricate the hub with clean lubricating engine oil and fit the gear to the hub. Rotate the hub
in the gear to align the oil way to the top.
4 Fit the hub assembly (C1) over the front oil seal housing (C2) and into mesh with crankshaft
gear and camshaft gear. Check that the hole (D1) is towards the cylinder head.
5 Align the plate (E2) to the three holes in the
hub. Fit the setscrew (E3).
6 With the hub assembly fitted, tighten evenly
the three setscrews (E3) to 44 Nm (32 lbf)
4,5 kgf m.
7 Check the end float (E1) and back lash, see
"Timing case and drive assembly" on page 22.
8 Fit the mechanical fuel pump gear, see
13 Operation 6-4, or the electronic fuel pump

gear, see Operation 6-6.
06
12
E N G I N E – 1 1 0 4 C – 4 4
To remove and fit idler gear bushes Operation 6-9
! If the bushes in the idler gear are to be renewed, the backlash between the camshaft
gear and the idler gear, and between the idler gear and the fuel pump gear must be
accurate.
If the bushes are to be changed, remove them with a suitable puller. If a puller is not available,
machine off the face of one of the bushes and press them out. Press in new bushes and machine
the bores to get the correct clearance on the hub. The gear must have the correct backlash.
Machine the faces to get the correct end clearance.
When assembled, the idler gear backlash between the crank gear and idler gear must be checked
in four positions. Rotate the crankshaft clockwise viewed from the front, and check the backlash
between the two gears every 90 , see "Timing case and drive assembly" on page 22. 13
06
13
E N G I N E – 1 1 0 4 C – 4 4
HEAVY DUTY IDLER GEAR ASSEMBLY
1 Remove the setscrew (A2), and the plate (A3) from the assembly.
2 Press the hub (A11) out of the bearing housing (A8).
3 Remove the circlip (A4) and the thrust washer (A5) from the gear (A6). Slide the bearing housing
(A8) with the rollers (A7) out of the gear (A6).
Note :
With the removal of the bearing from the gear, the rollers (A7) will become loose.
13 4 Remove the circlip (A10) and the thrust washer (A9).
06
14
E N G I N E – 1 1 0 4 C – 4 4
Consumable products
! • The bearing and the hub must be fitted so that the marked teeth of the heavy
duty idler gear are to the front.
• The new bearing assembly has a sleeve fitted, to hold the needle roller bearing
securely. The sleeve must not be removed before the bearing assembly is fitted
into the gear. If the sleeve is removed from the bearing assembly before the
bearing is fitted, the bearing rollers will become loose.
13
• The hub assembly must be aligned correctly to the plate (A3) and the cylinder 06
block to allow the gear to be lubricated. 15
• If a used bearing assembly is dismantled and the rollers become loose, a new
bearing assembly must be fitted.
1 Clean all parts and check for wear and damage, renew as necessary.
2 Fit the circlip (A10) into the back face of the gear (A6), slide the thrust washer (A9) into the
front face of the gear bore (A1).
3 Align the new bearing assembly with the sleeve to the front face (A1) of the gear bore, push
the bearing assembly out of the sleeve and into the gear bore.
4 Fit the thrust washer (A5) and the circlip (A4). Lightly lubricate the bearing with clean engine
lubricating oil.
5 Press the gear assembly onto the hub (A11).
Note :
If the old setscrew (A2) is to be used, apply POWERPART Threadlock and nutlock.
6 Fit the plate (A3) and the setscrew (A2) to the gear assembly. Rotate the plate (A3) until the
three holes in the plate are aligned correctly to the three holes in the hub (A11). The plate (A3)
will be marked with the word TOP, ensure this is facing the front of the engine. Tighten the
setscrew (A2) to 9 Nm (7 lbf ft) 0,9 kgf m.
E N G I N E – 1 1 0 4 C – 4 4
CAMSHAFT GEAR
! The engine is pin timed at TDC, do

not use the pins as a locking device
when repairs are carried out on the
engine.
1 Remove the idler gear, see Operation 6-7.
2 Remove the camshaft timing pin.
13 3 Remove the setscrew (A1), with its washer,
and remove the gear from the camshaft.
Ensure that the key in the camshaft is not
06 lost.
16
To fit
Note :
The camshaft timing pin is a push fit into the timing case. The camshaft gear will rotate a small
amount when the pin is fitted. This is to allow the assembly of the gears and removal of the
backlash from the gears when needed, with the timing pin fitted.
1 Clean and check the camshaft gear and camshaft key for wear and damage, renew if necessary.
2 Ensure that the camshaft key is fitted correctly.
3 Fit the camshaft gear to the camshaft with the marked teeth towards the front and the keyway
correctly aligned with the key. If necessary, lightly hit the gear with a soft face hammer to
engage the key into the keyway. Fit the camshaft timing pin. If the camshaft needs to be rotated,
remove the rocker assembly, see Operation 3-4.
4 Fit the washer and setscrew (A1) to the gear and tighten the setscrew to 95 Nm (70 lbf ft) 9,7
kgf m.
5 Fit the idler gear, see Operation 6-8.
E N G I N E – 1 1 0 4 C – 4 4
FRONT OIL SEAL
Consumable products
Three legged puller 27610230
To remove the oil seal from the timing case fitted to the engine
! The oil seal is made of “Viton”, see the safety precautions for "Viton seals" on
page 8. 13
! The oil seal housing must not be damaged when the oil seal is removed.
06
1 Remove the crankshaft pulley, see Operation 5-1. 17
2 Thoroughly clean the area around the oil seal housing.
3 Fit the legs (A2) of the puller under the oil seal and lock into position.
4 Fit a suitable distance piece (A1) between the crankshaft and the puller.
5 Remove the oil seal from the housing.
6 Discard the oil seal.
Note :
If the timing case is removed from the engine,
the seal can be removed from the timing case.
Use a suitable adaptor to press the seal out of
the timing case. Ensure that the timing case is
supported correctly, and that excessive pressure
is not used to remove the seal, this can damage
or distort the case.
E N G I N E – 1 1 0 4 C – 4 4
Special tools
Crankshaft front oil seal replacer 21825577 Pressure plate for use with 21825577 21825578
Fastener plate for use with 21825577 21825580 Adaptor for use with 21825577 27610217
To remove the oil seal from the timing case fitted to the engine
! The oil seal (A6) is made of “Viton”, see the safety precautions for "Viton seals"
on page 8.
13 ! • New timing case oil seals have a sleeve (A5) fitted to protect the oil seal. Do not
remove the sleeve until the crankshaft pulley is to be fitted. Discard the new oil
06 seal if the sleeve (A5) is not fitted.
18 • Damage may be done to the seal if the correct tool is not used.
• It is important that only genuine Perkins parts are used. The use of a seal that is
not a genuine Perkins part may damage the engine and will affect the warranty.
• Do not lubricate the oil seal or the oil seal housing.
1 Clean the oil seal housing and check for damage, renew if necessary.
2 Check the crankshaft pulley seal face for wear. To repair the pulley, see Operation 6-15.
3 Assemble the oil seal tool. Fit the fastener plate (A7) to the front of the crankshaft.
4 Assemble the nut (A1) and the pressure plate (A2) onto the threaded bar (A3).
5 Align the seal (A6) and the sleeve (A5) to the front of the oil seal housing (A8).
6 Fit the adaptor (A4) onto the sleeve (A5).
7 Put the pressure plate assembly onto the adaptor (A4) and tighten the threaded bar (A3) onto
the fastener plate (A7). Check the alignment of the assembly and the oil seal to the oil seal
housing.
8 Fit a rod through the hole in the end of the threaded bar to prevent movement of the bar when
the nut is tightened. Tighten the nut (A1) to push the seal into the housing. Tighten until contact
is made with the bottom face of the oil seal housing.
9 Remove the replacer tool.
10 Turn and pull the sleeve (A5) counter clockwise, to remove the sleeve from the oil seal.
11 Fit the crankshaft pulley immediately see, see Operation 5-1.
E N G I N E – 1 1 0 4 C – 4 4
To fit the oil seal with the timing case removed

1 Clean the oil seal housing and check for damage, renew if necessary.
2 Check the crankshaft pulley for damaged. To repair the pulley, see Operation 6-15.
3 Check that the new oil seal has the sleeve protector fitted.
4 Align the oil seal to the oil seal housing. Do not lubricate the oil seal or the housing.
5 With a suitable tool, press the oil seal into the housing until contact is made with the bottom
face of the housing.
6 Fit the timing case, see Operation 6-17.
7 When the front timing case cover is fitted, turn and pull the sleeve protector counter clockwise,
to remove the sleeve from the seal.
8 Fit the crankshaft pulley immediately, see Operation 5-1.
13
06
19
E N G I N E – 1 1 0 4 C – 4 4
To fit a wear sleeve Operation 6-15
To renew a worn or damaged crankshaft pulley, a wear sleeve (A2) is fitted over the spigot (A1).
1 Remove the crankshaft pulley, see Operation 5-1.
Note :
Full instructions and a special tool to fit the wear sleeve are in each service kit.
2 Fit the wear sleeve, in accordance with the manufacturer¡¯s instructions. It is not necessary to
remove the flange (A3) of the wear sleeve after it has been fitted. A new front oil seal (A4)
must be used when a wear sleeve is fitted.
13
06
20
E N G I N E – 1 1 0 4 C – 4 4
TIMING CASE
Special tools
Note :
It is not necessary to remove the alternator, if the belts and the link setscrew are removed. The
alternator can be rotated away from the timing case.
13
1 Drain the lubricating oil and coolant. 06
2 Remove the fan drive, see Operation 12-9. 21
3 If not previously removed, remove the crankshaft pulley, see Operation 5-1.
4 If required remove the alternator, see Operation 14-4.
6 Remove the fuel injection pump:
• For Bosch fuel injection pumps, see Operation 11-9 or Operation 11-11.
• For the Delphi DP210 fuel injection pump, see Operation 11-13.
7 Remove the coolant by-pass, see Operation 12-13.
8 Remove the PTO, if fitted see Operation 15-2.
9 Remove the crankshaft timing pin and the camshaft timing pin.
10 Remove the camshaft gear, see Operation 6-12.
11 Remove the timing case oil seal if a new oil seal is to be fitted, see Operation 6-13.
12 Remove the internal setscrews (A1) and the outer setscrews (A2) of the timing case.
13 Remove the timing case from the cylinder block. Remove the upper joint (B1) from the timing
case, and the lower joint from the cylinder block.
14 Discard all old joints.
E N G I N E – 1 1 0 4 C – 4 4
Special tools
POWERPART Retainer 21820608
Alignment tool 27610216
Note :
13 If a new timing case is to be fitted, it may be necessary to fit blanking plugs. Apply POWERPART
retainer, part number 21820608, to the blanking plug bore. This plug must be fitted into the timing
case before the case is fitted to the engine.
06 1 Clean and check the timing case for damage, renew if necessary.
22 2 Check that the camshaft thrust washer is fitted correctly. Fit the lower timing case joint (A1)
onto the cylinder block.
3 Fit two temporary studs (A2) to the cylinder block.
4 Fit the upper timing case joint (B1) to the timing case (B2).
Contineud
E N G I N E – 1 1 0 4 C – 4 4
5 Fit the alignment tool (C2) into the block, and secure in place.
6 Fit the timing case (C1) over the alignment tool (C2) and onto the cylinder block. Fit the
setscrews into the timing case and tighten by hand.
7 Align the timing case (D2) to the cylinder block (D1).
Note :
To seal the lubricating oil sump joint, ensure that the bottom of the timing case is correctly aligned
with the bottom of the cylinder block before the setscrews are tightened. The alignment of the
bottom face of the timing case (D2) and the cylinder block (D1) must not exceed ¡¾ 0,05 mm
(0.002 in).
8 Tighten the setscrews to 22 Nm (16 lbf ft) 2,2 kgf m, and check the alignment (C3) of the
timing case face to the cylinder block face, adjust if necessary.
9 Fit the coolant by-pass, see Operation 12-13.
10 Fit the lubricating oil sump, see Operation 10-5.
11 Fit the camshaft gear, see Operation 6-12.
13
12 Fit the idler gear, see Operation 6-8. 06
13 Fit the fuel injection pump:
23
• For Bosch fuel injection pumps, see Operation 11-10 or, see Operation 11-12.
• For the Delphi DP210 fuel injection pump, see Operation 11-14.
15 Fit the coolant pump, see Operation 12-5.
Note :
The coolant pump setscrews should be tightened together with the timing case cover setscrews.
16 Fit a new oil seal to the timing case, see Operation 6-14.
18 If removed fit the alternator, see Operation 14-4.
19 Fit the fan drive, see Operation 12-9.
20 When the engine is fitted into the application, fill the lubricating oil sump to the correct level
and with the correct grade of engine lubricating oil, see Operation 10-5. Fill the cooling system
to the correct level, and with the recommended POWERPART Antifreeze, see User’s Handbook
TPD 1477.
E N G I N E – 1 1 0 4 C – 4 4
CRANKSHAFT GEAR
To remove
1 Remove the timing case, see Operation 6-16.
2 The crankshaft gear is a transition fit on the crankshaft. It may slide off easily or, if it is a tight
fit and the gear is to be renewed, it may be necessary to remove the crankshaft , to remove
the gear safely, see Operation 5-10.
To fit
13 ! Do not use a flame to heat the gear, as this can cause local damage.
1 The gear (A1) can fit easily, or it may be
06 necessary to heat the gear before it will fit
24 onto the crankshaft. If the gear is to be
heated, heat the gear in an oven to not more
than 200 (392 ). If an oven is not
available, heat the gear in coolant which is
at its boiling point.
2 Align the keyway in the gear to the key in
the crankshaft.
3 Fit the gear (A1) with the shoulder (A2)
facing outwards.
E N G I N E – 1 1 0 4 C – 4 4
CAMSHAFT AND TAPPETS
1 Remove the timing case, see Operation 6-16.

3 Remove the rocker assembly and the push rods, see Operation 3-4.
4 With the engine upside down, remove the camshaft thrust washer (A1) and carefully remove
the camshaft (B).
5 Remove the tappets.
6 Inspect the camshaft and the tappets for wear and other damage, also inspect the camshaft
bush. Renew the components as necessary. 13
06
25
E N G I N E – 1 1 0 4 C – 4 4
1 Ensure that all components are clean and are lubricated with clean engine lubricating oil.
2 With the engine upside down, fit the tappets into position.
3 Carefully fit the camshaft.
4 Fit the camshaft thrust washer (A2). Ensure
that it is fitted correctly onto the hollow dowel
(A1).
5 Turn the engine the right way up.
7 Check that the camshaft end-float is within
13 the limits, see "Camshaft" on page 22.

8 Fit the push rods.
06 10 Adjust the valve tip clearance, see Operation
26 3-7.
E N G I N E – 1 1 0 4 C – 4 4
GENERAL DESCRIPTION
The cylinder block is made of high duty cast iron with an integral crankcase. The sides of the
cylinder block extend below the crankshaft centre line to give added strength. The cylinder block
provides full length support for the cylinder bores.
All bores are honed with silicon carbide tools to a controlled finish to ensure long life and low oil
consumption.
A bush is fitted in the cylinder block for the front camshaft journal and the other camshaft journals
run directly in the block.
Note : 13
Your Perkins Dealer/Distributor has specialist equipment and personnel with the correct training to
repair worn cylinder bores. 07
1
E N G I N E – 1 1 0 4 C – 4 4
CYLINDER BLOCK
Note :
• If the cylinder block is to be renewed, it may be necessary to change the grade of the connecting
rods, see the table in Operation 4-11. This will occur if the correct piston height above the block
face cannot be maintained with the original piston and connecting rod assemblies, see Operation
4-6.
• All of the components that need to be removed for access to the cylinder block are referred to
in the procedure below. As a result some of the stages within operations may be repeated.
13 1 Ensure that all engine fluids are drained.
2 Remove the ECM, if fitted, see Operation 14-13, the wiring harness, and the speed and timing
07 sensor, if fitted, see Operation 14-16.
2 3 Remove the VLPM, if fitted, see Operation 14-14.
4 Remove the lubricating oil cooler, see Operation 12-10.
5 Remove the lubricating oil filter head, see Operation 10-3.
6 Remove the cylinder head, see Operation 3-9.
7 Remove the crankshaft, see Operation 5-10.
8 Remove the piston and the connecting rod assemblies, see Operation 4-4.
9 Remove the camshaft, see Operation 6-19.
10 Remove the piston cooling jets, if fitted, see Operation 4-15.
E N G I N E – 1 1 0 4 C – 4 4
Consumable products
1 Clean thoroughly the new cylinder block. Ensure that all the oil passages are clean and free
from debris.
2 Remove the threaded plugs from the old cylinder block and clean the threads. Seal the threads
with POWERPART Threadlock and nutlock, and fit the threaded plugs into the new cylinder
block.
3 Fit the piston cooling jets, see Operation 4-15.
4 Fit the crankshaft, see Operation 5-11. Do not fit the lubrication oil sump at this time.
13
5 Fit the piston and connecting rod assemblies, see Operation 4-5.
6 Fit the camshaft, see Operation 6-20.
07
3
7 Fit the lubricating oil filter housing, see Operation 10-3.
8 Fit the lubricating oil cooler, see Operation 12-11.
9 Fit the ECM, if removed, see Operation 14-13, the wiring harness, and the speed and timing
sensor, if removed, see Operation 14-16.
10 Fit the VLPM, if removed, see Operation 14-14.
11 Install the engine into the vehicle or machine.
13 Fill the lubricating oil sump to the correct level with an approved lubricating oil.
E N G I N E – 1 1 0 4 C – 4 4
1 Clean the internal passages for the coolant

and the oil.
2 Check the cylinder block for cracks and for
other damage.
3 Check the camshaft bush for wear. If the
bush is to be renewed, use a suitable
adaptor to press it out of the bore. Ensure
that the lubricating oil hole in the new bush
(A1) will be towards the front of the engine
13 when fitted. Press in the new bush with the

oil hole on the same side and aligned with
the oil hole in the block until the front end of
07 the bush is aligned with the face of the
4 recess.
E N G I N E – 1 1 0 4 C – 4 4
CYLINDER BORE
To ensure the best performance during the life of the engine it is important that worn or damaged
cylinder bores are re-bored and re-honed.
The condition of a cylinder bore is decided by:
• The amount and location of any polished areas
• Wear
• Damage to the bore wall.
Note :
It will not be necessary to re-bore/re-hone if:
13
• The honed finish can still be clearly seen. 07
• The engine performance and oil consumption are acceptable. 5
To check the condition of a cylinder bore
1 Inspect the bore surface for cracks and deep scratches.
2 Check the bore wall for areas where the honed finish has been polished away. Check especially
the area around the top of the bore just below the carbon ring. In this area, thrust from the top
piston ring is at its maximum.
! • Do not use "Flex-hone" to repair cylinder bores.
• New oversized piston and rings must be fitted when the cylinder bore is re-
bored/re-honed.
• An engine can have high oil consumption with very little wear of the bores, if
the surfaces of the bores are glazed.
• Specialist training and equipment are needed to machine the finish of a cylinder
bore.
E N G I N E – 1 1 0 4 C – 4 4
ENGINE TIMING
ENGINE TIMING
GENERAL DESCRIPTION
To ensure that the 1100 Series 4 cylinder engines have an accurate system of timing, the engines
are pin timed.
This system will set the engine so that number one piston is at top dead centre (TDC) on the
compression stroke.
To reach the accurate fuel injection needed for engines to conform to emissions legislation, the
latest fuel injection pumps operate at a static timing of TDC.
It is important that fuel injection timing is accurate to conform to emissions legislation. Always use
Operation 8-1 to obtain TDC on the compression stroke of number one cylinder. 13
! • If the hub nut (A1) is loosened the Bosch VP30 fuel injection pump timing will be
lost and the fuel injection pump will have to be removed and sent to your nearest
08
Perkins Dealer/Distributor to be reset. 1
• The Delphi DP210 nut (B1) must not be released until TDC on the compression
stroke is set, the backlash is removed from the fuel injection pump gear and the
fuel pump shaft is locked. If the nut (B1) is loosened before TDC on the
compression stroke is set and the fuel pump shaft is locked the fuel pump timing
will be lost. The pump will have to be removed and sent to your nearest Perkins
Dealer/Distributor to be reset.
• The Bosch EPVE nut (B1) must not be released until TDC on the compression
stroke is set, the backlash is removed from the fuel injection pump gear and the
fuel pump shaft is locked. If the nut (B1) is loosened before TDC on the
compression stroke is set and the fuel pump shaft is locked, the fuel pump timing
will be lost. To adjust the fuel pump timing see, Operation 8-4.
E N G I N E – 1 1 0 4 C – 4 4
ENGINE TIMING
ENGINE TIMING
To set number 1 piston to TDC on the compression stroke Operation 8-1
Special tools
Crankshaft timing pin 27610211 Camshaft timing pin 27610212
! • This procedure must only be carried out by a person with the correct training.
13 • The timing pins are a push fit. Do not use excessive force to fit the pins.
• Do not use the pins as a locking device when repairs are carried out on the engine.
08 • The timing pins must be removed before the timing case cover is fitted. Failure to
2 do so will damage the engine.
• The marks on the timing gears are not to be use as timing marks. The marks
indicate the front of the gear only.
Continued
E N G I N E – 1 1 0 4 C – 4 4
ENGINE TIMING

2 Remove the glow plugs, see Operation 14-10.
3 Remove the timing case cover see, Operation 6-1.
Note :
The crankshaft timing pin can be inserted with the crankshaft pulley still fitted.
4 To set the No 1 piston to TDC on the correct stroke, rotate the crankshaft in the normal direction
of rotation until the intake valve (A7) of number 4 cylinder has just opened and the exhaust
valve (A8) of the same cylinder has not closed completely.
5 Carefully rotate the crankshaft in the normal direction of rotation. Align the hole in the crankshaft
with the hole in the cylinder block and the timing case (B1). Insert the crankshaft timing pin
through the timing case and the cylinder block. Push the pin fully into the hole in the crankshaft
web.
6 Insert the camshaft timing pin, through the
hole in the camshaft gear (B2) and into the
13
body of the timing case. With the two timing 08
pins fitted the engine is set at TDC number 1 2 3 4 5 6 7 8 3
one on the compression stroke.
Note :
The camshaft timing pin is a push fit into the
timing case. The camshaft gear can rotate a
small amount when the pin is fitted. This is to
allow the assembly of the gears and removal
of the backlash from the gears, with the timing A R1181
pins fitted.
7 Remove the timing pin from each gear.
E N G I N E – 1 1 0 4 C – 4 4
ENGINE TIMING
To check the timing of the Bosch EPVE fuel injection pump Operation 8-3
Consumable products
Bosch EPVE fuel pump timing adaptor 27610248
! This procedure must only be carried out by a person with the correct training.
1 Rotate the crankshaft to obtain TDC, see Operation 8-1.

2 Remove the high pressure fuel pipes from the fuel injection pump.
3 Remove the plug (A1) and washer from the rear of the fuel pump and fit the Bosch EPVE fuel
13 pump timing adaptor (B1), and a suitable dial gauge (B2). Set the dial gauge to indicate
approximately 3,0 mm.
4 Slowly rotate the crankshaft, counter-clockwise from the front of the engine, until the dial gauge
08 indicates that the plunger of the fuel injection pump is at the bottom of its stroke. Set the dial
4 to zero.
5 Slowly rotate the crankshaft clockwise, until the crankshaft timing pin can be pushed into the
crankshaft web. With the engine set at TDC, check the reading on the dial gauge.
Fuel injection pump with the code ER has a plunger lift of 1,55 mm (0.061in).
6 If the fuel pump timing is correct, remove the dial gauge and the Bosch EPVE fuel pump timing
adaptor. Fit a new washer and the plug. Tighten the plug to 29 Nm (21 lbft) 2,9 kgf m.
7 If the fuel injection pump timing is to be adjusted, see Operation 8-4.
8 Fit the high pressure fuel pipes to the fuel injection pump.
9 Eliminate the air from the fuel system, see Operation 11-8.
1 2
A R1540 B R1571
E N G I N E – 1 1 0 4 C – 4 4
ENGINE TIMING
To adjust the timing of the Bosch EPVE fuel injection pump Operation 8-4
Consumable products
! • This procedure must only be carried out by a person with the correct training.
• Do not turn the fuel injection pump with the pump shaft locked.

2
3
4
Remove the rocker assembly, see Operation 3-4.
Remove the high-pressure fuel pipes from the fuel injection pump.
Remove the plug and washer from the rear of the fuel pump and fit the Bosch EPVE fuel pump
13
timing adaptor (A1) and a suitable dial gauge (A2). Set the dial gauge to indicate approximately 08
3,0 mm. 5
5 Remove the timing pins.
6 Rotate the crankshaft slowly counter-clockwise and then clockwise, until the needle of the dial
gauge indicates that the plunger of the fuel injection pump is at the bottom of its stroke. Set
the dial to zero.
7 Rotate the crankshaft slowly clockwise, until the needle of the dial gauge indicates the required
plunger lift, see Operation 8-3.
8 To lock the Bosch EPVE pump shaft, loosen the locking screw (B2) and remove the washer
(B1). Tighten the locking screw (B2) to 31 Nm (23 lbf ft) 3,1 kgf m. Ensure that the needle of
the dial gauge has not moved.
2
2
A R1571 B R1395
Continued
E N G I N E – 1 1 0 4 C – 4 4
ENGINE TIMING
9 Remove the Bosch mechanical fuel pump gear, see Operation 6-3.
Note :
• There no key fitted into the keyway (C1).
• If the fuel injection pump is on the correct stroke, the keyway (C1) is towards the outlet (D1).
11 Fit the fuel pump gear, see Operation 6-4.
12 Ensure that the needle of the dial gauge has not moved. Remove the dial gauge and the
Bosch EPVE fuel pump timing adaptor (A1). Fit a new washer and tighten the plug (E1) to 29
Nm (21 lbf ft) 2,9 kgf m.
14 Fit the high pressure fuel pipes.
13 15 Fit the timing case cover, see Operation 6-2.

08
6
1
C R1573
E R1540
E N G I N E – 1 1 0 4 C – 4 4
ENGINE TIMING
To check the valve timing Operation 8-6
Note :
Do not fit the timing case cover, the glow plugs or the rocker cover at this stage.
1 Set the piston of number 1 cylinder to TDC on the compression stroke, see Operation 8-1.
2 Mark the pulley at TDC, set a temporary pointer to the mark.
3 For naturally aspirated engines :
• Set the valve tip clearance of number 1 cylinder intake valve to 0,589 mm (0,023 in) and No
1 exhaust valve to 0,698 mm (0.027 in).
4 For turbocharged engines :
• Set the valve tip clearance of number 1 cylinder intake valve to 1,220 mm (0.048 in) and No
1 exhaust valve to 1,302 mm (0.051 in).
5 Rotate the crankshaft, clockwise from the front, until the push rod of number 1 cylinder intake
13
valve is just loose and the push rod for number 1 exhaust valve is equally loose. In this position,
check if the mark on the crankshaft pulley or damper is within +/- 2.5¡Æ of the temporary pointer.
08
Use the formula below to find the measurement which is equal to 2.5 on the pulley or damper. 7
CxP
360
C = circumference of pulley or damper
P = 2.5 degrees
6 If the timing is more than 2.5 out of position, the timing gears are likely not to be in correct
mesh.
Note :
• One tooth on the camshaft gear is equivalent to 18 mm (0.62in) at the circumference of a pulley
of 200 mm (7.87 in) diameter.
• One tooth on the camshaft gear is equivalent to 16 mm (0.70 in) at the circumference of a
pulley of 170 mm (6.69 in) diameter.
7 Rotate the crankshaft, clockwise from the front, until the intake valve of the rear cylinder has
just opened, and the exhaust valve has just closed. Set the valve tip clearance of the intake
valve of No 1 cylinder to 0,20 mm (0.008 in). Set the valve tip clearance of the exhaust valve
of No 1 cylinder to 0,45 mm (0.018 in).
8 Fit the timing case front cover, see Operation 6-2.
11 Remove the temporary pointer from the timing case and the timing mark from the pulley.
E N G I N E – 1 1 0 4 C – 4 4
ASPIRATION SYSTEM
ASPIRATION SYSTEM
To remove and to fit the breather pipe Operation 9-5
To remove
1 Release the hose clip and remove the hose from the breather pipe assembly.
2 Release the two fasteners (A2) and pull the breather pipe assembly (A1) out of the rocker cover.
3 Remove the “O” ring (A3).
4 Remove the joint (A4) and the two fasteners (A2) from the breather pipe assembly.
13
09
1
5 Clean all the components and discard all joints and “O” rings.
Continued
E N G I N E – 1 1 0 4 C – 4 4
ASPIRATION SYSTEM
To fit
1 Fit the new joint (B4) into the breather pipe housing.
2 Push the two fasteners (B2) into the breather pipe assembly.
3 Fit a new “O” ring (B3) to the breather pipe assembly and lubricate the ¡°O¡± ring with clean
lubricating engine oil.
4 Push the breather pipe assembly into the rocker cover and tighten the fasteners to 9 Nm (7 lbf ft)
0,9 kgf m.
5 Fit the breather hose and tighten the clip to 5 Nm (4 lbf ft) 0,5 kgf m.
13
09
2
E N G I N E – 1 1 0 4 C – 4 4
ASPIRATION SYSTEM
ASPIRATION SYSTEM
To remove and to fit the breather pipe Operation 9-6
To remove
1 Release the two fasteners (A2) and pull the breather pipe assembly (A1) out of the rocker cover.
2 Remove the “O” ring (A3).
3 Remove the joint (A4) and the two fasteners (A2) from the breather pipe assembly.
4 Clean all the components and discard all joints and “O” rings.
13
09
3
Continued
E N G I N E – 1 1 0 4 C – 4 4
ASPIRATION SYSTEM
To fit
1 Fit the new joint (B4) into the breather pipe housing.
2 Push the two fasteners (B2) into the breather pipe assembly.
3 Fit a new “O” ring (B3) to the breather pipe assembly and lubricate the “O” ring with clean
lubricating engine oil.
4 Push the breather pipe assembly into the rocker cover and tighten the fasteners to 9 Nm (7 lbf ft)
0,9 kgf m.
5 Fit the breather hose and tighten the clip to 5 Nm (4 lbf ft) 0,5 kgf m..
13
09
4
E N G I N E – 1 1 0 4 C – 4 4
ASPIRATION SYSTEM
CLOSED ENGINE BREATHER
To clean and to renew Operation 9-7
Note :
For details on how to change the closed crankcase breather and element, contact your nearest
Perkins Dealer/Distributor for advice.
13
09
5
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
LUBRICATION SYSTEM
GENERAL DESCRIPTION
Pressure lubrication is supplied by a rotor type pump which is driven through an idler gear from
the crankshaft gear. The pump has an inner rotor and an outer rotor which are off-set to each
other. There is a an interference fit between the inner rotor and the drive shaft. When the pump
rotates, the space between the lobes which are in mesh increases to cause a suction to fill the
space and the a decrease to create a pressure increase.
Lubricating oil from the sump passes through a strainer and pipe into the suction side of the pump.
The pump delivers the oil to the cylinder block.If a oil cooler is fitted the oil is transferred to and
from the oil cooler by a internal passage in the cylinder block. The oil is transferred by the oil
pump frame to the oil filter passage in the cylinder block. If a oil cooler is not fitted the oil is
13
transferred directly to the oil filter passage. 10
Then relief valve is integral with the pump and re-circulates the excess oil directly back to oil 1
pump inlet. The lubricating oil passes through the oil filter and directly back to the main pressure
rail which drilled the full length of the left side of the cylinder block.
From the pressure rail, lubricating oil passes to the main bearings of the crankshaft and through
passages in the crankshaft to the big end bearings. The pistons and the cylinder bores by the oil
jets which are attached the main pressure rail.
Lubricating oil passes from the main bearings through passages in the cylinder block to the journals
of the camshaft. The front camshaft bearings feeds oil through a drilling in the cylinder block and
cylinder head to the rocker shaft. The oil passes through the centre of the rocker shaft to the
rocker levers. The rocker pads, valve stems, cam lobes and the tappets are splash lubricated.
The hub of the idler gear is lubricated by oil from the end pressure rail and the timing gears are
splash lubricated.
The lubricating oil for turbochargers is delivered by an external pipe from a tapping on the side
of the cylinder block above the right hand side of filter face. The oil returns from the turbocharger
down another extended drain pipe into the side of the cylinder block from a connection on the
right side of the cylinder block, or filter head, through an external pipe to the turbocharger. The
oil passes through the turbocharger and returns through a pipe to the sump.
Top mounted turbochargers are fed from the filter head, or from a connection on the right hand
side of the engine.
These engines are fitted with piston cooling jets that are connected to the oil pressure rail and
spray lubricating oil inside the pistons to keep them cool.
Key to the oil flow diagram on page 158.
1 Suction pressure to the lubrication oil pump.
2 Main engine lubrication oil pressure.
3 Reduced engine lubrication oil pressure.
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
LUBRICATION SYSTEM FLOW DIAGRAM
13
10
2
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
FILTER CANISTER
To renew (canister type oil filter) Operation 10-1
! Discard the used canister, and lubricating oil in a safe place and in accordance
with local regulations.
• The canister contains a valve and a special tube to ensure that lubricating oil does
not drain from the filter, when the lubricating oil is changed. Ensure that the correct
perkins POWERPART canister is used.
• Ensure that the application is on a level surface to ensure an accurate reading on
the dipstick.
1 Put a suitable container below the lubricating oil filter.
13
2 Remove the filter canister with a strap wrench. Ensure that the adaptor is secure in the filter 10
head. Discard the canister. 3
3 Clean the filter head.
4 If the filter canister is mounted vertically position (A) add clean engine lubricating oil to the new
canister. Allow the oil enough time to pass
through the filter element.
5 Lubricate the top of the canister seal (A1)
with clean engine lubricating oil.
6 Fit the new canister and tighten by hand only.
Do not use a strap wrench.
7 Remove the container and discard the old
lubricating oil.
8 Operate the engine and check for leakage
from the filter. When the engine has cooled,
check the oil level on the dipstick and add
more oil into the sump, as necessary.
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
To renew (element type oil filter) Operation 10-2
! Discard the used element and lubricating oil in a safe place and in accordance
with local regulations.
! Ensure that the application is on a level surface to ensure an accurate reading on
the dipstick.
1 Put a suitable container below the lubricating oil filter.
Note :
On the horizontal filter assembly the drain plug (A2) is in the filter head and should not be removed.
13 2 Remove the drain plug (A2) together with the seal and drain the lubricating oil.
3 Fit a 1/2” square drive ratchet into the recess (A1) and remove the filter casing (A3). Discard
the old filter element.
10 4 Clean the filter casing and replace the seal (B2). Fit a new seal to the drain plug and fit the
4 plug finger tight.
5 Fit the new filter element (B1) into the casing and rotate the element to locate it into position.
6 If the filter casing is in vertically mounted position (A), add clean engine lubricating oil to the
filter casing. Allow the oil enough time to pass through the filter element.
7 Lubricate the seal (B2) with clean engine lubricating oil. Fit the casing (A3) into the filter head
(A4).
8 Tighten the casing (A3) to 25 Nm (18 lbf ft) 2,5 kgf m.
9 Tighten the drain plug to 12 Nm (9 lbf ft) 1,2 kgf m.
10 Remove the container and discard the old lubricating oil.
11 Operate the engine and check for leakage from the filter. When the engine has cooled, check
the oil level on the dipstick and add more oil into the sump, as necessary.
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
FILTER HEAD
Consumable products
To remove
! If a balancer is fitted, the oil filter head must only be mounted on the left hand of
the engine.
1 Put a tray under the filter head to contain spilt lubricating oil.
13
2 Remove the filter canister, see Operation 10-1 or Operation 10-2. 10
3 Remove the setscrews and remove the filter head (A2) (B2) from the cylinder block. Discard 5
the joint (A1) (B1).
4 Clean the joint face (A1) (B1) of the filter head and the cylinder block.
To fit
1 Ensure that all joint surfaces are clean and free from damage.
2 Fit a new joint to the filter head, the joint is fitted dry.
Note :
The setscrews for securing the filter head have a sealant (MEAS) applied by the manufacturer to
the first 13,0 mm (0.50 in) of the threads. If the setscrews are used again, the sealant must be
removed from the male and female threads and POWERPART Threadlock and nutlock applied to
the first 13,0 mm (0.50 in) of the setscrew threads.
3 Fit the filter head to the cylinder block. Gradually and evenly tighten the setscrews.
4 Fit the new filter canisters, see Operation 10-1 or Operation 10-2.
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
SUMP
! • Discard the used lubricating oil in a safe place and in accordance with local
regulations.
• Before the sump is removed, especially with the cast iron version, ensure that
the sump is fully supported before the setscrews are removed.
1 Operate the engine until it is warm.
13 2 Stop the engine, remove the sump drain plug

(A1) and its ‘O’ ring, and drain the oil. Where
necessary, remove the dipstick and the
10 dipstick tube, see Operation 10-6.
6 3 Provide a support for the sump and remove
the setscrews and, if relevant, the two nuts
which fasten the sump to the timing case.
Lower the sump and remove and discard the
joint.
4 Wash the sump with an approved cleaning
fluid, ensure all the cleaning fluid is removed.
Clean the flange face of the sump and of the
cylinder block.
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
Special tools
POWERPART Threadlock and nutlock 21820117 POWERPART Silicone rubber sealant 1861108
Note :
• If either the cylinder block bridge piece, and / or the timing case, have just been fitted then fit
the sump before any bridge piece / timing case sealant has been allowed to cure.
• If the sump only is to be fitted, then any old surface sealant from either the cylinder block bridge
piece, and / or the timing case, should be removed and renewed.
1 Remove any old sealant from the cylinder block bridge piece, timing case, and cylinder block
joint surfaces.
13
2 Ensure that the joint faces of the cylinder block and the sump are both free from dirt and 10
damage. 7
Continued
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
3 Insert four alignment studs into holes (A1).

4 Apply a bead of POWERPART Silicone rubber sealant to the joints between the cylinder block
and the timing case (C1), and the cylinder block and the bridge piece (B2).
Note :
Handle the sump joint with care as rubber-sealing bead can be easily damaged.
5 Place the joint onto the cylinder block over the alignment studs and ensure that all of the fixing
holes align correctly.
6 Place the sump onto the cylinder block over the alignment studs.
Note :
The setscrews for securing the sump have a sealant (MEAS) applied by the manufacturer to the
13 first 13,0 mm (0.50 in) of the threads. If the setscrews are used again, the sealant must be
removed from the male and female threads and POWERPART Threadlock and nutlock applied to
the first 13,0 mm (0.50 in) of the setscrew threads.
10 7 Loosely fit the setscrews into all of the available holes by hand.
8 8 Remove the alignment studs and fit the remainder of the setscrews.
9 Tighten the four setscrews (D1) to 22 Nm (16 lbf ft) 2,2 kgf m.
10 Tighten the remaining setscrews to 22 Nm (16 lbf ft) 2,2 kgf m.
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
11 Fit the drain plug, if necessary fit a new

‘O’ ring, and tighten to 34 Nm (25 lbf ft)
3,5 kgf m.
12 Fill the sump to the mark (E2) on the
dipstick with new engine lubricating oil of an
approved grade, see User’s Handbook TPD
1477.
13
10
9
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
DIPSTICK TUBE
Consumable products
POWERPART Threadlock and Nutlock 21820117
1 Remove the dipstick tube M16 gland nut and remove the tube from the sump.
2 Clean the gland nut and the thread in the sump of all old sealant.
13 3
4
5
Ensure that the rubber seal is fitted to the dipstick tube assembly.
Apply POWERPART Threadlock and Nutlock to the threads of the gland nut.
Fit the dipstick tube to the sump in the correct position, tighten the gland nut to 18 Nm (14 lbf ft) 1,8
10 kgf m.
10
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
OIL STRAINER AND SUCTION PIPE
The oil strainer is an integral part of the suction pipe. No regular service is necessary but wash
the strainer when it is removed.
To remove
1 If not already removed; remove the lubricating
oil sump, see Operation 10-4.
2 Remove the setscrews from the flange of the
suction pipe. Remove the suction pipe and
strainer. Remove the old joint. Clean the
flange face of the oil pump and the suction
13
pipe. 10
To fit 11
1 Fit the suction pipe to the oil pump together
with a new joint. Tighten the setscrews (A1).
2 Fit the lubricating oil sump, see Operation
10-5.Continued
1 Wash the assembly in an approved cleaning fluid and dry it thoroughly.

2 Check the pipe, the strainer and the welded joints for cracks and other damage.
3 If a component is damaged, renew as necessary.
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
LUBRICATING OIL PUMP ASSEMBLY
! Discard the used lubricating oil in a safe place and in accordance with local
regulations.
1 If not already removed; remove the lubricating
oil sump, see Operation 10-4.
2 Remove the setscrews (A1) and remove the
oil pump assembly.
13
10
12
1 Fill the oil pump assembly with clean engine lubricating oil. Fit the oil pump assembly to the
cylinder block, ensure that the dowel (A1) and the thimble (A2) are correctly located, then tighten
the setscrews to 22 Nm (16 lbf ft) 2,2 kgf m.
2 Check the idler gear for wear and other damage. If the gear is damaged, it must only be
renewed as an assembly. The assembly consists of an idler gear, an idler shaft and a front
plate.
3 Check that there is backlash between the oil pump idler gear and the crankshaft gear (B).
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
Note :
For all the clearances, refer to the Data and dimensions for the "Lubrication system" on page 25.
1 Remove the setscrews and remove the cover of the oil pump.
2 Remove the outer rotor and clean all the parts. Check for cracks and any other damage.
3 Fit the outer rotor, and check the outer rotor to body clearance (A).
4 Check the inner rotor to outer rotor clearance (B).
5 Check the rotor end-float with a straight edge and a feeler gauge.
6 Lubricate the inner and outer rotor with clean engine lubricating oil. Clean the top face of the
oil pump and the inner face of the cover. Fit the cover. Tighten the setscrews to 28 Nm (21
lbf ft) 2,9 kgf m.
13
10
13
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
RELIEF VALVE
To remove and to fit the relief valve of the balancer Operation 10-12
To remove
1 Remove the plug that retains the relief valve (A1). Remove the spring and valve (B).
To fit
1 Ensure the relief valve is clean.
2 Place the relief valve and spring into the balancer.
3 Tighten the plug for the relief valve (A1) to 22 Nm (16 lbf ft) 2,2 kgf m.
13
10
14
E N G I N E – 1 1 0 4 C – 4 4
LUBRICATION SYSTEM
To remove and to fit the relief valve of the lubricating oil pump Operation 10-13
! Do not change the operation pressure of the relief valve by a method other than
the installation of new components.
To remove
1 Remove the plug which fastens the relief valve (A1), and remove the spring and valve (B).
To fit
1 Ensure the relief valve is clean.
2 Place the valve spring and relief valve into the lubricating oil pump.
3 Tighten the plug for the relief valve (A1) to 22 Nm (16 lbf ft) 2,2 kgf m.
13
10
15
To inspect the relief valve of the lubricating oil pump/balancer Operation 10-14
! Do not change the operation pressure of the relief valve by a method other than
the installation of new components.
1 Check the spring for wear and other damage and, if possible, check the load necessary to
compress the spring to its fitted length, refer to the Data and dimensions for "Oil pressure relief
valve (oil pump)" on page 25 or "Oil pressure relief valve (balancer)" on page 25.
2 Check the plunger for wear and other damage and ensure that it slides easily in the bore of
the relief valve.
3 Check the body and the end plug for wear and other damage.
4 Renew worn or damaged components.
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
FUEL SYSTEM
GENERAL DESCRIPTION
! • The fuel injection equipment must only be checked by personnel who have had the
correct training
• If a fuel injection pump is returned for repair, or under warranty, then all of the
fuel ports must be closed with a plastic blanking cap to prevent the entry of water
and dirt into the pump. If these blanking caps are not fitted then the warranty will
be affected.
• A new fuel injection pump will be supplied with the pump shaft in the locked
position. The drive shaft of the pump must not be turned without the spacer (B2)
13
in position under the locking screw (B1). 11
The 1100 Series four cylinder engines are 1
used for industrial, construction and
agricultural applications and use three
different types of fuel injection pump :
• Bosch EPVE (B)
These fuel injection pumps conform to
emissions legislation.
Continued
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
Bosch EPVE (E) fuel injection pump has locking

screws which lock the shaft. It is important that
the locking screw is released and the pump
shaft is free to turn when the pump is fitted to
the engine.
The electronic fuel lift pump and fuel filter are

a single assembly. The maximum no-load
speed is shown on the emissions data plate
fitted to various positions on the side of the
cylinder block, see "Engine identification" on
page 3.
13 The atomisers, which are of the valve covered
orifice (VCO) type, have nozzles with five holes.
11 The atomisers inject fuel in a very fine spray
2 into the combustion chamber in the top of each
piston.
The atomisers are set in the factory and are
not serviceable, they must be checked in
accordance with the preventive maintenance
schedules in the User’s Handbook.
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
COLD START ADVANCE UNIT (KSB)
Bosch EPVE (A) fuel injection pump has a cold start advance unit that holds the timing of the
pump in an advanced position when the engine is cold.
! It is important that the electrical connections to the sender unit are connected
correctly. Failure of the KSB to operate correctly could result in damage to the
engine as the timing will be fully advanced for normal operation.
The sender unit, is on the rear of the timing case on the left side of the engine.
With the engine cold, the sender unit energises to advance the pump timing for the cold start
operation of Bosch fuel injection pumps.
Note :
13
The wiring diagrams on the following page
show the sender unit position when the engine
11
is cold. 3
To ensure that the engine conforms to

emissions legislation, it is important that the
electrical connections of the engine cold start
advance unit are fitted correctly before the
engine is operated.
Continued
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
Wiring diagrams for the cold start advance unit fitted to Bosch EPVE injection pumps are shown
in the illustrations (A), and (B) respectively. For easy identification the cables are shown in circles
on the illustrations.
The amperage of each of the cables is listed in the cable identification table below. The
identification numbers for the electrical components are shown in triangles. Refer to the component
identification list to find a component.
13
11
4
Cable identification(1) Component identification(2)

Cable (Number) Current (Amperes) Component Description
1 3 1 Fuel injection pump
2 3 2 Engine stop solenoid
3 6 3 Sender unit
4 3 4 Start switch
5 3 5 Cold start advance unit
(1) For numbers shown in circles
(2) For numbers shown in triangles
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
TYPICAL FUEL SYSTEM
The position of the fuel system components may vary from application to application, this
information is provided for training purposes only.
Fuel from the tank passes to the electric lift pump/filter (A4). Fuel leaves the lift pump (A3) under
pressure to the fuel injection pump (A6).
The fuel injection pump has a self-vent pipe to remove air from the fuel system back into the fuel
tank through a connection on the connector block. The fuel in the injection pump also lubricates
and cools the pump. The amount of fuel and the fuel injection timing is controlled by the Engine
Control Module (ECM).
The fuel injection pump increases the fuel pressure and injects high-pressure fuel at the correct
time and sequence through pipes to the atomisers (A1).
13
11
5
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
FUEL FILTER ASSEMBLY
To renew Operation 11-1
! • The combustible material of some components of the engine (for example certain
seals) can become extremely dangerous if it is burned. Never allow this burnt
material to come into contact with the skin or with the eyes, see "Viton seals" on
page 8 for safety precautions.
• Discard the used element and fuel oil in a safe place in accordance with local
regulations.
• If the fuel level in the tank is higher than the fuel lift pump, the supply and return
13 fuel line valves must be turned off before servicing or repairs are made. If the fuel
line valves are not turned off, fuel will flow through the system.
• Ensure that the starter switch is in the OFF position before any service or repairs
11 are made to the fuel system. If the lift pump has power, fuel will be released.
6
! • It is important that only genuine Perkins parts are used. The use of an element
that is not a genuine Perkins part may damage the fuel injection pump.
• The pre-filter canister and main filter elements must be renewed at the same time.
• Do not allow dirt to enter the fuel system. Before a connection is disconnected,
clean the area around the connection. After a component has been disconnected,
fit a suitable cover to all open connections.
1 Place a suitable container below the fuel filter assembly to retain spilled fuel oil.
2 Thoroughly clean the outside surfaces of the fuel filter assembly. Open the drain tap (A1) at
the bottom of the filter casing to drain the fuel from the filter.
3 Use a strap wrench to loosen the filter casing. Remove the casing and element from the fuel
filter head.
4 To remove the filter element from the casing; Press down on the filter element (B1), against
the spring pressure, and rotate the element to the left to release it from the filter casing (B4).
5 Put the new filter element inside the casing and press the element down against the spring
pressure. Rotate the element to the right to lock the element into the casing.
6 Fit a new seal (B3) to the casing and lightly lubricate the seal face with clean fuel oil.
7 Check that the thread (B2) on the inside of the element is not damaged.
8 Fit the filter assembly to the fuel filter head and tighten by hand until the filter assembly contacts
the filter head. Tighten the assembly a further 1/8 of a turn by hand. Do not use a strap wrench.
9 Close the drain tap (A1) and remove the container.
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
ATOMISERS
To identify a faulty atomiser Operation 11-2
Regular maintenance of the atomisers is not necessary. The atomiser should be renewed and not
cleaned, and renewed only if an atomiser fault occurs. The major problems that may indicate that
new atomisers are needed are listed below :
• Engine will not start or is difficult to start
• Not enough power
• Engine misfires or runs erratically
• High fuel consumption
• Black exhaust smoke
• Engine knocks or vibration
13
• Excessive engine temperature.
11
! • If your skin comes into contact with high-pressure fuel, obtain medical assistance 7
immediately.
• Keep away from moving parts during engine operation. Some moving parts
cannot be seen clearly while the engine runs.
To find the defective atomiser, release the atomiser cover setscrews (A1) and remove the atomiser
cover (A2), run the engine at fast idle.
Release and tighten the union nuts (B1) of the high-pressure fuel pipe at each atomiser, one at
a time. Do not loosen the union nut more than half a turn. When the union nut of the defective
atomiser is released, it has little or no effect on the engine speed.
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
! • Atomisers must be removed and fitted by a person with the correct training.
• Do not allow dirt to enter the fuel system. Before a connection is disconnected,
clean thoroughly the area around the connection. After a component has been
disconnected, fit a suitable cover to all open connections.
1 Release the atomiser cover setscrews (A1) and remove the atomiser cover (A2).
2 Remove the fuel leak-off pipe from the connection (C2).
3 Remove the union nuts of the high-pressure pipe from the atomiser (C1) and from the fuel
injection pump. Do not bend the pipe. If necessary, remove the pipe clamps. Fit a plastic cap
13 to cover the fuel inlet connection.

4 Remove the setscrew (C3) from the clamp (C4) and remove the atomiser and its seat washer
from the recess in the cylinder head.
11
8 ! Remove and discard the seat washer (B1). If the original seat washer remains in the
recess for the atomiser, the nozzle protrusion will be incorrect when a new seat washer
is added.
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
1 Put the new seat washer (A2) into the seat recess in the cylinder head.
2 Ensure that the atomiser seal (A1) is not damaged. Apply a small amount of clean engine oil
to the seal.
! The atomiser must be fitted so that the two leak-off connections (B2) point away
from the cylinder head towards the intake manifold.
3 Place the atomiser (B1) into the recess in the cylinder head.
4 Fit the clamp (B4), tighten the setscrew (B3) for the clamp to 27 Nm (20 lbf ft) 2,8 kgf m.
! Do not tighten the union nuts of the high-pressure pipes to more than the
recommended torque value. If there is a leakage from the union nut, ensure that
the pipe is correctly aligned with the atomiser inlet. Do not tighten the atomiser
13
union nut more, as this can cause a restriction at the end of the pipe. This can
affect the fuel delivery.
11
9
5 Remove the plastic cap and fit the high-pressure fuel pipe. Tighten the union nuts to 27 Nm
(20 lbf ft) 2,8 kgf m.
6 If removed earlier, fit the high pressure fuel pipe clamps.
7 Fit the fuel leak-off pipes to the connectors (B2).
8 Operate the engine and check for leakage of fuel and that there is no air in the system.
9 Stop the engine. Refit the atomiser cover and tighten the setscrews, see Operation 3-1.
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
FUEL LIFT PUMP AND FILTER ASSEMBLY
! Do not allow dirt to enter the fuel system. Before a connection is disconnected,
clean thoroughly the area around the connection. After a component has been
disconnected, fit a suitable cover to all open connections.
To remove
1 Disconnect the fuel pipes from the electric fuel lift pump and filter assembly.
2 Drain the electric fuel lift pump and filter assembly, see Operation 11-1.
13 3 Remove the setscrew (A2) and the spacer from the support bracket (A3) for the fuel pipes.
4 Remove the setscrews (A1) and rubber washers. Remove the electric fuel lift pump and filter
assembly.
11
10 To fit
Note :
Ensure that new rubber washers are fitted to the setscrews and the cylinder block before the
electric fuel lift pump and filter assembly is fitted.
1 Fit the setscrews (A1) and new rubber washers
to the fuel lift pump and filter assembly.
2 Fit the spacer and the setscrew (A2) to the
support bracket (A3) for the fuel pipe.
3 Fit the fuel pipes to the fuel lift pump and
filter assembly.
4 Eliminate any trapped air from the fuel system,
see Operation 11-8.
1
5 Operate the engine and check for leakage of

fuel and that there is no air in the system.
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
To test Operation 11-6
1 Remove the two outlet fuel pipes from the electric fuel lift pump and filter assembly, make note
of the location of the pipes to ensure that the pipes are fitted correctly.
2 Connect two suitable rubber hoses to the outlet pipes (feed to fuel infection pump and return
to the fuel tank), and place into a three litre measuring cylinder.
3 Operate the engine until a consistent flow of fuel is running from the outlet pipe of the fuel
injection pump.
Note :
The return pipe to the fuel tank will have a slower flow than the feed pipe from the fuel injection
pump.
4
5
The combined flow of both pipes should be at a rate of two litres/per minute as a minimum.
If the flow is less than two litres/per minute, replace the electric fuel lift pump and filter assembly.
13
6 Connect the electric fuel lift pump outlet pipes in the correct position. 11
7 Operate the engine and check for leakage of fuel and that there is no air in the system. 11
To test pressure regulator Operation 11-7
1 Remove the fuel lift pipe from the fuel injection pump, fit a suitable pipe with a pressure test
point and connect a 0-80 kPa (0-12 lbf/in2) 0-0,8 kgf/cm2 pressure gauge.
2 Operate the engine at idle for two minutes to allow any trapped air to be removed.
3 The reading on the pressure gauge should be as below:
• Bosch EPVE = 31 kPa (4.49 lbf/in2) 0,31 kgf/cm2 at idle, and rated speed 31 kPa (4.49
lbf/in2) 0,31 kgf/cm2
4 The combined flow of both pipes should be at a rate of two litres/per minute as a minimum.
5 Connect the fuel lift pipe to the fuel injection pump. Operate the engine at idle for two minutes.
Note :
If the fuel lift pump and filter assembly does not meet the above specifications check for the
following; that all the electrical connections are fitted, there are no leaks in the pipes and
connections, that the seal on the drain tap does not leak and that the ¡°O¡± ring for the canister
to the lift pump does not leak.
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
AIR IN THE FUEL SYSTEM
If air enters the fuel system, it must be removed before the engine can be started.
Air can enter the system if :
• The fuel tank is drained during normal operation
• The low-pressure fuel pipes are disconnected
• A part of the low-pressure fuel system leaks during engine operation
• A fuel system component such as a filter element, or a fuel pump, has been installed during a
service
• The high pressure fuel pipes have been disconnected.
13 To remove Operation 11-8
11
12 ! • Do not operate the engine until the air is eliminated from the fuel injection pump.
• After the air is eliminated, operate the engine at low idle for two minutes.
The Delphi DP210 fuel injection pump will eliminate air automatically when the start key is turned
to the RUN position for three minutes.
The Bosch VE and the VP30 fuel injection pumps will not eliminate air automatically.
1 Release the atomiser cover setscrews and remove the atomiser cover, see Operation 3-1.
2 Turn the start key to the RUN position for three minutes, then return the key to the OFF position.
3 Loosen the high pressure pipes (A1) at the atomisers.
4 Operate the starter motor until fuel free from air comes from the connections.
5 Tighten the connections to 30 Nm (22 lbf ft) 3,0 kgf m.
6 Start the engine and check for leaks.
7 Fit the atomiser cover and tighten its setscrews, see Operation 3-1.
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
BOSCH EVPE FUEL INJECTION PUMP
General description
! A new fuel injection pump will be supplied with the pump shaft in the locked
in position under the locking screw (B1).
Bosch EPVE fuel injection pumps have a drive gear fastened to the shaft of the pump.
An ‘O’ ring (A3) is fitted into a groove in the pump flange. This ‘O’ ring is fitted instead of a joint
between the pump flange and the timing case.
13
11
13
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
1 Disconnect the battery.

2 Set the engine to TDC number 1 cylinder
compression stroke, see Operation 8-1.
3 Lock the pump shaft; To lock the fuel
injection pump shaft loosen the locking screw
(A2) and remove the spacer (A1). Tighten the
locking screw (A2) to 31 Nm (23 Ibf ft) 3,1
kgf m.
! Use a second spanner to prevent

13 movement of the high pressure outlet
on the pump when the union nut for
each high pressure pipe is released.
11
14 4 Remove the low pressure and the high
pressure fuel pipes from the pump.
! Do not rotate the crankshaft when

the pump is not on the engine.
5 Remove the fuel pump gear, see Operation
6-3.
Note :
Remove the KSB electrical connections.
6 Remove the setscrew from the fuel pump
support bracket (B1).
7 Remove the setscrews and washers that
secure the fuel pump and remove the pump.
8 Discard the fuel pump ‘O’ ring (C3).
E N G I N E – 1 1 0 4 C – 4 4
FUEL SYSTEM
! • The engine must be set to TDC number 1 cylinder compression stroke before
the pump is fitted, see Operation 8-1.
• A new fuel injection pump is supplied with the pump shaft in the locked
position. The drive shaft of the pump must not be turned without the spacer
(A2) in position under the locking screw (A1).
• Do not rotate the crankshaft when the pump is not on the engine.
1 Fit a new ‘O’ ring (A3) to the pump flange.

Lightly lubricate the ‘O’ ring with clean engine
lubricating oil. Put the pump into position in
the timing case and fit the three washers and
13
setscrews, then tighten the setscrews to 25
11
15
2 Loosely fit the setscrew (B1) of the support
bracket. Ensure that force is not applied to
the fuel injection pump.
! The fuel pump gear must be fitted to

the engine before the crankshaft is
rotated.
5 Tighten the setscrew (B1) of the support
bracket to 44 Nm (32 lbf ft) 4,4 kgf m. Ensure
that force is not applied to the fuel injection
pump.
! • Do not tighten the union nuts of the

high-pressure pipes more than the
recommended torque tension. If
there is a leakage from the union
nut, ensure that the pipe is correctly
aligned with the pump outlet. Do not tighten the pump union nut more, as this can
cause a restriction at the end of the pipe. This can affect the fuel delivery.
• Use a second spanner to prevent movement of the high pressure outlet on the pump
when the union nut for each high pressure pipe is tightened.
6 Fit the low pressure and the high pressure fuel pipes to the pump. Tighten the high pressure
pipe union nuts to 27,5 Nm (21 lbf ft) 2,8 kgf m.
8 Fit the KSB electrical connection.
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
COOLING SYSTEM
GENERAL DESCRIPTION
Coolant from the bottom of the radiator passes through the centrifugal coolant pump that is fitted
onto the front of the timing case, to assist the flow of the coolant through the system.
The coolant pump is gear driven by the fuel injection pump gear.
An integral oil cooler, if fitted, has an aluminium cover with a five or seven plate element. The oil
cooler has no external pipes and is fitted to the left side of the cylinder block.
From the pump, the coolant passes through a passage in the timing case to the coolant jacket
in the top left side of the cylinder block. The coolant continues to the rear of the cylinder block
where some of the coolant passes into the lubricating oil cooler, if one is fitted. Some of the
13
coolant passes around the element of the integral cooler and then to the rear of the cylinder block. 12
The coolant then passes from the rear of the cylinder block and into the cylinder head. The coolant 1
leaves the cylinder head at the front and passes into the thermostat housing.
If the thermostat is closed, the coolant goes directly through a by-pass to the inlet side of the
coolant pump. If the thermostat is open, the thermostat closes the by-pass and the coolant passes
to the top of the radiator.
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
COOLANT FLOW DIAGRAM
13
12
2
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
THERMOSTAT
Consumable products
Thermostat tool 27610226
Note :
Engines are fitted with a single thermostat (A). Identification of the thermostat is by the nominal
temperature which is stamped on the by-pass valve.
1 Drain the coolant in the cooling system to a level below the thermostat position and disconnect
13
the top hose from the coolant outlet connection.
2 Release the two setscrews (A1) and remove the thermostat housing from the cylinder head.
12
3 Remove the “O” ring and discard.
3
4 Press down on the thermostat using the thermostat tool (B1) and rotate the thermostat to release
it from the housing (B2).
5 Remove the thermostat from the housing.
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
Special tools Consumable products
Thermostat tool 27610226 POWERPART Red rubber grease 21820221
1 Clean the thermostat housing. Ensure that the grooves for the spring retainers and the seat for
the “O” ring are free of debris.
2 Ensure that the jiggle pins (A1) in the thermostat are both free to move.
3 Lubricate a new “O” ring (B1) with POWERPART Red rubber grease before it is fitted. Fit “O”
ring. Place the thermostat (C1) in position in the housing (C3).
13 4 Use the thermostat tool (D1) to push and rotate the thermostat to engage the spring retainers
into the grooves in the housing (C2) and (C4).
5 Fit the thermostat assembly to the cylinder head and tighten the setscrews.
12 6 Connect the top hose and fill the cooling system.
4
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
To test Operation 12-3
Note :
Do not remove the thermostat from the housing to test.
1 Place the thermostat and the housing in a suitable container filled with coolant.
2 Heat the coolant gradually. Use a thermometer to check the temperature at which the valve
starts to open and at which it is fully open. For the correct operating temperatures, refer to the
Data and dimensions for "Thermostat" on page 26.
! If the thermostat does not operate correctly, it must be renewed. Do not try to adjust
the settings.
13
12
5
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
COOLANT PUMP
Note :
Identification of the coolant pump is by the part number that is cast onto the coolant pump body.
1 Drain the cooling system and disconnect the

hose at the inlet connection of the coolant
pump.
2 Remove the nine setscrews in (A) which
13 retain the coolant pump and remove the

coolant pump.
3 Remove and discard the joint.
12
6
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
Consumable products
1 Ensure that all joint faces are clean.
2 Check the drive gear of the coolant pump for wear or other damage. If the gear is damaged,
the pump must be renewed.
3 Fit two suitable guides (A1), fit a new joint (A2).
4 Fit the pump (B1) onto the guides and into the timing case cover with its gear in mesh with
the gear of the fuel injection pump.
Note :
13
The setscrews that retain the coolant pump have a sealant (MEAS) applied by the manufacturer 12
to the first 13,0 mm (0.50 in) of the threads. If the setscrews are used again, the sealant must 7
be removed from the male and female threads and POWERPART Threadlock and nutlock applied
to the first 13,0 mm (0.50 in) of the setscrew threads.
5 Fit and lightly tighten the seven setscrews which retain the pump to the cover of the timing
case. The pump is a tight fit in the cover,
but can be pulled into position if the
setscrews for the pump are gradually and
evenly tightened.
6 Remove the guides and fit the remaining
setscrews.
7 Tighten all the setscrews (C) on the coolant
pump to 22 Nm (16 lbf ft) 2,2 kgf m.
8 Connect the hose to the inlet connection of
the coolant pump and fill the cooling system.
9 Operate the engine and check for leakage.
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
1 Remove the setscrews, (A1) the cover and the joint. Discard the joint.
2 To remove the impeller (B3) from the pump shaft; drill twelve 6,35 mm (0.25 in) holes between
the existing holes at equal distance around the impeller. Drilling these holes will break pieces
off the impeller (B3) to allow the 2 legged puller to be correctly fitted.
3 The impeller can be removed by using a suitable two legged puller attached to the back of the
impeller (B1). Tighten the centre setscrew (B2) of the puller until the impeller is removed. Discard
the impeller.
13
12
8
Continued
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
! Do not damage the sealing face of the coolant seal housing during removal of the seal.
4 To remove the coolant seal (C4), it will be necessary to break the seal and use an extractor
to remove the centre sleeve of the seal from the body of the shaft. This will loosen the grip of
the seal on the shaft. To remove the body of the seal, drill three 3,175 mm (0.125 in) holes
through the top of the coolant seal 120 apart. Fit three 25,4 mm (1.00 in) self-tapping screws.
Insert a suitable lever through the coolant inlet of the pump body and gradually and evenly
apply the lever under the head of each self-tapping screw to remove the seal. Discard the seal.
! Do not damage the sealing face of the oil seal housing during removal of the seal.
5 Remove and discard the circlips (C6) (C7).

6 Put the impeller end of the pump body face
down on a suitable press. Press the drive
gear end of the shaft through the gear (C10)
and the pump body until the shaft (C3) and
13
ball bearing assembly (C8) are released from 12
the pump. Discard the bearing and the shaft.
9
The gear will also be released through the
side of the housing.
7 Inspect the gear for wear or other damage
and renew it, if necessary.
down on a press and use a suitable mandrel
to engage the outer face of the oil seal (C11).
Press out the oil seal and discard it.
9 With the impeller end of the pump body face
down on a press, use a suitable mandrel to
engage the outer race of the needle roller
bearing (C9). Press out the bearing and
discard it.
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
! It is important that all of the components in the kit for the coolant pump are used.
1 Clean thoroughly the inside of the pump body, the bearing bores and the counterbore for the
coolant seal. These bores and their chamfers must be clean and free of corrosion.
2 Put the gear end of the pump body face down on a press. Use a suitable mandrel to engage
the outer face of the oil seal and press in until the bottom face of the oil seal is level with the
face of the gear housing.
3 With the gear end of the pump body face
down on a press, position the drive gear into
the correct position. Use a suitable adaptor
13 to press the drive shaft through the oil seal
and into drive gear so that there is a 1,5 mm
(0.060 in) gap between the drive gear and
12 the top face of the drive gear pocket.
10
4 Use a suitable adaptor to press the bearing
(A8) onto the drive shaft, until it is against its
shoulder.
down on a press. Fit the new circlip (A6),
with the bevel edge away from the oil seal
to retain the bearing assembly in the body of
the pump. Fit the circlip (A7) to the drive
shaft to retain the bearing assembly to the
drive shaft of the pump.
6 Turn the pump over and press the needle
roller bearing (A9) into the bearing housing
until the end of the bearing is level with or
0,5 mm (0.020 in) below the top of the
housing.
Continued
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
! Do not lubricate the coolant seal (B4). The coolant seal must not be contaminated
with oil or grease. If the coolant seal is held by hand, it should be held by the
edge of the outside flange.
A tool (C) can be manufactured to press the new seal into position. The tool should be made of
a suitable material to the dimensions shown below :
A 54,0 mm (2.125 in) E 44,0 mm (1.732 in)
B 6,0 mm (0.236 in) F 18,00 mm (0.708 in)
C 10,0 mm (0.393 in) G 54,00 mm (2.125 in)
D 48,0 mm (1.889 in)
7 Turn the pump over onto the gear end and with the widest end of the coolant seal towards the
oil seal, push the seal onto the shaft until it is in contact with the coolant seal counterbore.
Ensure that the seal is square with the bore and with a suitable adaptor press the seal into the
counterbore, until the outer flange is in contact with the pump body. Continue to apply force for
13
approximately ten seconds to ensure that the seal remains in position.
8 Press the impeller onto the shaft so that it is level with the top of the drive shaft.
12
9 Fit a new cover joint and fit the cover. Fit the setscrews and tighten to 22 Nm (16 lbf ft) 2,2 11
kgf m.
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
FAN
To remove
Remove the locknuts and remove the fan from the studs. The fan extension and the pulley can
now be removed from the studs, if fitted.
To fit
Clean thoroughly the rear of the fan where the fan fits onto the fan extension. Ensure that all
paint is removed from this area. Fit the pulley onto the studs, and fit the fan extension, if removed.
13 Clean the front face of the fan extension. Fit the fan and the locknuts, refer to the Data and
dimensions for "Special torques for setscrews and nuts" on page 31.
12
12
FAN DRIVE
To remove
1 Loosen the pivot fasteners of the alternator and the fasteners of the alternator adjustment link.
Remove the drive belt(s), see Operation 14-3.
2 Release the locknuts and remove the fan, see Operation 12-8. Remove the fan extension, if
fitted, and the pulley.
3 Check the end-float of the drive shaft. If it is more than 0,25 mm (0.010 in), the fan drive
assembly must be renewed.
4 Release the setscrews and remove the fan drive.
To fit
1 Fit the fan drive and tighten the setscrews to 44 Nm (33 lbf ft) 4,5 kgf m.
2 Fit the fan, see Operation 12-8.
3 Fit the belt(s) and adjust the tension, see Operation 14-3 and Operation 14-2.
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
LUBRICATING OIL COOLER
1 Drain the cooling system.

2 Place a suitable container under the oil
cooler.
Note :
Do not remove setscrews (A1), as these setscrews
hold the oil cooler element to the cover.
3 Release the setscrews that retain the oil
cooler to the cylinder block.
13
4 Remove the oil cooler and the joint.
12
13
1 Renew the joint, ensure that all the joint

faces are clean.
2 Fit the oil cooler.
3 Fit all the setscrews and tighten to the correct
torque.
5 Check the oil level on the dipstick (A1). Refill
to the correct level with new lubricating oil of
an approved grade, refer to the User’s
Handbook TPD 1477.
6 Operate the engine and check for leakage of
coolant or oil.
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
To dismantle and to assemble Operation 12-12
To dismantle
1 Remove the oil cooler from the cylinder block, see Operation 12-10.
2 Remove the four setscrews (A1) from the oil cooler and remove the cooler element.
! Do not allow compressed air to contact your skin. If compressed air enters your
skin, obtain medical help immediately.
3 Clean the element and check for cracks. If a solution is used to clean the outside of the element,
ensure that this does not enter the element. Check that there are no restrictions to the flow of
lubricating oil through the element of the oil cooler. If the inside of the element needs to be
13 cleaned, use a solvent which is suitable for copper. Dry the element with low pressure air and
then flush it with clean engine lubricating oil.
To assemble
12 1 Renew the joints (B1) on the flanges of the element.
14 2 Fit the element to the cover and tighten the setscrews (A1) to the correct torque.
3 Fit the oil cooler, see Operation 12-11.
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
To remove and to fit a coolant by-pass pipe Operation 12-12
Consumable products
POWERPART Red rubber grease 21820221
To remove
1 Remove the two setscrews (A1).
2 Carefully pull the coolant by-pass pipe from the cylinder head.
3 Remove and discard the “O” rings.
To fit
1 Fit new “O” rings (B1) and (B2) and lubricate with POWERPART Red rubber grease.
2 Carefully fit by-pass pipe into the cylinder head, ensure that the “O” ring is correctly fitted.
13
3 Fit the two setscrews (A1) and tighten to the correct torque. 12
15
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
Special tools
Spanner for flange nut of the
21825964 Timing pin 27610032
• A new fuel injection pump will be supplied with the pump shaft in the locked
13 position. The drive shaft of the pump must not be turned without the spacer
(A2) in position under the locking screw (A1). Before the crankshaft is turned, or
the pump is fitted, put the spacer into position under the locking screw to
12 ensure that the pump drive shaft is released.
16
2 Lightly lubricate the ‘O’ ring with clean engine
lubricating oil. Fit the pump into position in
setscrews.
Continued
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
3 Loosely fit the setscrew (C1) of the support bracket. Ensure that force is not applied to the fuel
injection pump.
4 Put the fuel pump gear onto the hub of the fuel pump. The setscrews (B4) for the fuel pump
gear should be in the centre of the slots to allow for the removal of backlash. Loosely fit the
setscrews.
5 Insert the timing pin (B5) through the hole (B3) of the fuel pump gear and the slot of the hub
(B2) until it can be pushed fully into the hole (B1) in the body of the fuel injection pump. If the
timing pin cannot be pushed into the pump body, check that the engine is correctly set at TDC
on the number 1 cylinder, see Operation 8-1.
6 Carefully turn the gear counter-clockwise by hand to remove the backlash between the idler
gear and the fuel pump gear. Do not rotate the crankshaft or the fuel injection pump shaft.
Tighten the setscrews for the fuel injection pump gear to 28 Nm (20 lbf ft) 2,8 kgf m.
7 Remove the timing pin.
9 Tighten the setscrew (C1) of the support bracket to 44 Nm (32 lbf ft) 4,4 kgf m. Ensure that
13
force is not applied to the fuel injection pump. 12
17
1
2
B A1665/1
Continued
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
! • Do not tighten the union nuts of the high-pressure pipes more than the
recommended torque tension. If there is a leakage from the union nut, ensure
that the pipe is correctly aligned with the pump outlet. Do not tighten the pump
union nut more, as this can cause a restriction at the end of the pipe. This can
affect the fuel delivery.
• Use a second spanner to prevent movement of the high pressure outlet on the
pump when the union nut for each high pressure pipe is tightened.
11 Fit the electrical connector to the fuel pump;
to fit the electrical connector, push the
13 connector fully into the socket on the fuel

pump, to lock the connector to the fuel
pump push in the locking clamp (D). Ensure
12 that the connector pins are not damaged.
18 12 Connect the battery.
13 Eliminate air from the fuel system, see
Operation 11-8.
14 Operate the engine and check for leakage
of fuel and that there is no air in the system.
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
BOSCH EVPE FUEL INJECTION PUMP
General description
! A new fuel injection pump will be supplied with the pump shaft in the locked
in position under the locking screw (B1).
Bosch EPVE fuel injection pumps have a drive gear fastened to the shaft of the pump.
An ‘O’ ring (A3) is fitted into a groove in the pump flange. This ‘O’ ring is fitted instead of a joint
between the pump flange and the timing case.
13
12
19
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
1 Disconnect the battery.

2 Set the engine to TDC number 1 cylinder
compression stroke, see Operation 8-1.
3 Lock the pump shaft; To lock the fuel
injection pump shaft loosen the locking screw
(A2) and remove the spacer (A1). Tighten the
locking screw (A2) to 31 Nm (23 Ibf ft) 3,1
kgf m.
! Use a second spanner to prevent

13 movement of the high pressure outlet
on the pump when the union nut for
each high pressure pipe is released.
12
20 4 Remove the low pressure and the high
pressure fuel pipes from the pump.
! Do not rotate the crankshaft when

the pump is not on the engine.
5 Remove the fuel pump gear, see Operation
6-3.
Note :
Remove the KSB electrical connections.
6 Remove the setscrew from the fuel pump
support bracket (B1).
7 Remove the setscrews and washers that
secure the fuel pump and remove the pump.
8 Discard the fuel pump ‘O’ ring (C3).
E N G I N E – 1 1 0 4 C – 4 4
COOLING SYSTEM
• A new fuel injection pump is supplied with the pump shaft in the locked
position. The drive shaft of the pump must not be turned without the spacer
(A2) in position under the locking screw (A1).
• Do not rotate the crankshaft when the pump is not on the engine.

Lightly lubricate the ‘O’ ring with clean engine
lubricating oil. Put the pump into position in
13
setscrews, then tighten the setscrews to 25
12
21
2 Loosely fit the setscrew (B1) of the support
bracket. Ensure that force is not applied to
the fuel injection pump.
! The fuel pump gear must be fitted to

the engine before the crankshaft is
rotated.
5 Tighten the setscrew (B1) of the support
bracket to 44 Nm (32 lbf ft) 4,4 kgf m. Ensure
that force is not applied to the fuel injection
pump.
! • Do not tighten the union nuts of the

high-pressure pipes more than the
recommended torque tension. If
there is a leakage from the union
nut, ensure that the pipe is correctly
aligned with the pump outlet. Do not tighten the pump union nut more, as this can
cause a restriction at the end of the pipe. This can affect the fuel delivery.
• Use a second spanner to prevent movement of the high pressure outlet on the pump
when the union nut for each high pressure pipe is tightened.
8 Fit the KSB electrical connection.
E N G I N E – 1 1 0 4 C – 4 4
GENERAL DESCRIPTION
The steel flywheel is fitted with a hardened starter ring. The starter rings have either 115 or 126
teeth.
The flywheel housing is normally made of cast iron, but certain flywheel housings are made of
aluminium alloy.
FLYWHEEL
13
13
1
! The flywheel is heavy. Use lift equipment or get help to assist with the lift
operation before removal of the flywheel fasteners.
To remove
1 Remove two opposite setscrews from the flywheel. Fit temporarily two guide to ensure that the
flywheel can be removed and fitted safely.
2 Remove the remainder of the setscrews and washers and remove the flywheel.
3 Check the flywheel and ring gear for damage and renew, if necessary.
To fit
1 Ensure that the location faces of the crankshaft and the flywheel are clean and free from damage.
2 Fit a hardened steel washer to each of the ten setscrews. Fit the flywheel over the guide studs
and secure in place with eight of the setscrews. Do not fully tighten the setscrews. Tighten the
setscrews, see "Specific torque values" on page 31.
3 Remove the temporary studs and fit the remaining two setscrews. Tighten the setscrews, see
"Specific torque values" on page 31.
4 Check the flywheel run-out with a dial test indicator (A). This must be less than 0,30 mm (0.012
in) total indicator reading.
5 Check the alignment of the flywheel face (B). The error in alignment must not be more than
0,03 mm (0.001 in) total indicator reading for every 25 mm (1.0 in) of the flywheel radius from
the crankshaft axis to the indicator plunger. During this check, keep the crankshaft pressed
toward the front of the engine to remove the effect of crankshaft end-float.
E N G I N E – 1 1 0 4 C – 4 4
RING GEAR
To remove
! Wear eye protection and suitable protective clothing during this operation.
Before the ring gear is removed, check the position of the chamfer on the teeth. To remove the
ring gear use a hammer and a chisel to break the ring. Ensure that the flywheel is not damaged
during this operation.
13 To fit
The ring gear is heated onto the flywheel. When a new gear is to be fitted, ensure that it is not
heated to more than 250 C (480 F). Ensure that the chamfer on the teeth of the gear is in the
13 correct direction.
2
E N G I N E – 1 1 0 4 C – 4 4
FLYWHEEL HOUSING
! The flywheel housing is heavy, use lift equipment or get help to assist with the lift
operation before removal of the flywheel housing fasteners.
To remove
1 Remove the starter, see Operation 14-7, and the flywheel, see Operation 13-1.
2 Release the housing setscrews and with a soft face hammer, hit carefully the housing to remove
it from the dowels.
To fit
1 Ensure that the rear face of the cylinder block and the faces of the housing are clean and free
13
from damage. Ensure that the location dowels are fitted correctly. If a felt seal is fitted to the 13
rear flange of the sump, renew the seal. 3
2 Fit the housing onto the dowels and lightly tighten the setscrews.
3 Check the housing concentricity with a dial test indicator (A). The run-out limit is given in the
relevant Data and dimensions for the "Flywheel and housing" on page 27. If any adjustment is
necessary, it must be made on the housing and the concentricity checked again.
4 Tighten the setscrews to the torque recommended in "Specific torque values" on page 31.
5 Check the housing alignment (B). The maximum tolerance is given in the relevant Data and
dimensions for the "Flywheel and housing" on page 27. Any necessary adjustment must be
made on the housing and not on the cylinder block.
6 Fit the flywheel, see Operation 13-1 and the starter motor, see Operation 14-7.
E N G I N E – 1 1 0 4 C – 4 4
GENERAL
! Many of the operations in this chapter should be done only by a person who has
had training to Level 2 , in 1100 Series Electronic Engine Diagnostics , or greater.
Note :
It may be necessary to refer to the TIPSS EST User Manual for more details.
ALTERNATORS
13
General description 14
The Denso A115i 12 volt and the A127i 12 volt and 24 volt alternators are driven from the 1
crankshaft pulley by double belts. The diodes, resistors and the brushes are fitted inside a cover
to protect them against dirt and moisture. Fans are included within the alternator casing to cool
and protect the alternator.
These alternators have solid state regulators fitted within the rear cover. The regulators are sealed
and repair is not possible.
For any repairs to the alternator consult your nearest Perkins Dealer/Distributor.
! • Do not disconnect the battery while the engine is in operation. This will cause a
voltage surge in the alternator charge system which will immediately cause
damage to the diodes or to the transistors.
• Do not disconnect an electrical wire before the engine is stopped and all
electrical switches are in the off position.
• Do not cause a short circuit by the connection of electrical wires to the wrong
terminals. The correct electrical wire must be connected to the correct terminal.
A short circuit or wrong connection, which gives reverse polarity, will
immediately cause permanent damage to the diodes and to the transistors.
• Do not connect a battery into the system until it has been checked for the
correct polarity and voltage.
• Do not check for current flow with a spark contact as damage can be caused to
the transistors.
E N G I N E – 1 1 0 4 C – 4 4
To check the drive belts Operation 14-1
1 Check the belts for wear and damage and renew, if necessary, in pairs.
2 Check the belt tension. Check/adjust the tension on both belts. To ensure maximum belt life, it
is recommended that a belt tension gauge is used. Fit the gauge (A1) at the centre of the
longest free length and check the tension. If a Burroughs gauge is used, the correct tension is
535 N (120 lbf) 54 kgf. If the tension is equal to, or less than 250 N (56 lbf) 25 kgf on either
belt, adjust both belts to 535 N (120 lbf) 54 kgf, see Operation 14-2.
13
14
2
E N G I N E – 1 1 0 4 C – 4 4
To adjust drive belt tension Operation 14-2
1 Loosen the pivot fastener (A1) of the alternator and the fasteners of the adjustment link (A2)
and (B1).
2 Change the position of the alternator to give the correct tension. Tighten the adjustment link
fasteners, and then tighten the pivot link fasteners. If there are two pivot fasteners, tighten the
front fastener and then the rear fastener.
3 Check the belt tension again to ensure that it is still correct, see Operation 14-1.
13
14
3
To adjust drive belt tension Operation 14-3
The drive belts are supplied as a set and must be renewed as a set.
1 Loosen the pivot fastener (A1) of the alternator and the adjustment link fasteners (A2) and (B1).
2 Release all of the tension from the belts and remove the belts.
3 Fit the new belts and adjust the tension, see Operation 14-2. The belt tension must be checked
again after the first 1000 km (600 miles) or 20 hours of operation.
E N G I N E – 1 1 0 4 C – 4 4
To remove and to fit the alternator Operation 14-4
To remove
! Ensure that the battery earth connection has been removed before any alternator
connection is removed.
1 Disconnect the electrical connection.
2 Release all the belt tension and remove the belts, see Operation 14-3.
3 Remove the adjustment link from the alternator and remove the pivot bolts. Make a note of the
position of the washers and distance pieces to ensure that they are fitted correctly. Remove the
alternator.
13 To fit
1 Put the alternator in position and assemble loosely the pivot fasteners and the adjustment link
and its fasteners. Ensure that the washers and the distance pieces are fitted in their correct
14 positions and that the alternator pulley is aligned to the crankshaft pulley within ¡¾ 2,4 mm
4 (0.094 in).
2 Fit the drive belts and adjust the drive belt tension, see Operation 14-2.
3 Connect the electrical connection.
4 If all of the work is complete, connect the battery earth connection.
To maintain Operation 14-5
1 Ensure that the drive belts are not worn and that the belt tension is correct, see Operation 14-1.
2 Keep the alternator clean. To clean the alternator, use a material which is damp with kerosene
or a special fluid used for this purpose. Ensure that the fluid does not enter the cover of the
alternator.
3 Ensure that air can pass easily over the casing to keep it cool.
E N G I N E – 1 1 0 4 C – 4 4
Fault diagnosis for the alternator Operation 14-6
The alternator is designed in such a way that a flow of current (indicated by no light at the warning
lamp or a reading shown on an ammeter) shows that the system is in correct operation. If the
system is in correct operation, no open circuit, voltage or current output checks need to be done
on the installation unless :
• The warning lamp does not show when the alternator is stationary and the switch is in the “ON”
position, or it shows a light when the alternator is in operation
• No charge current is shown on the ammeter
• The battery is discharged
• The battery is hotter than normal which is an indication of loss of voltage control.
If one or more of the above symptoms occur, the procedure indicated below should be applied. 13
Normal operation :
1 Ensure that the engine has stopped and that the ignition switch is in the “OFF” position.
14
5
2 Check that the battery voltage is correct, either 12V to 12.8 V (12V system), or 24V to 25.6V
(24V system). Check the condition of the battery if the voltage is not correct.
3 Turn the ignition switch to the “ON” position and check that the ignition warning lamp is
illuminated.
4 Start the engine and operate it at a fast idle. Check that the ignition warning lamp is now
extinguished.
5 Switch on an electrical load, such as the vehicle lights, and increase the engine to its maximum
speed.
6 The battery voltage should now rise to either 13.5V (12V system), or 27V (24V system).
7 Switch off the applied electrical load and the battery voltage should rise to either 14V (12V
system) or 28V (24V system).
Continued
E N G I N E – 1 1 0 4 C – 4 4
If the warning lamp is not illuminated when the ignition switch is in the “ON” position:
1 Check that the battery voltage is correct, (see the description for Normal operation), with the
ignition switch in the “OFF” position.
Note :
Refer to the basic charging circuit illustration (A).
2 Check that the voltage at alternator terminal “B+” (A8) to earth is the same as the battery
voltage. If it is not, the cables and wires may be damaged or disconnected. Check the
connections at the alternator (A7) and at the battery (A2). Check for cable continuity. Check for
earth continuity between the alternator casing and the alternator brackets.
3 Check the ignition warning lamp bulb (A4) and renew if necessary.
4 With the ignition switch (A3) in the “On” position, check the voltage between the alternator “D+”
13 terminal (A5) and earth. If this voltage is greater than 2V then the alternator is faulty. Renew
the alternator, see Operation 14-4.
If the warning light continues to be illuminated when the alternator is in operation:
14
6 1 Set the ignition switch to the On position.
2 Start and run the engine at a fast idle speed. Measure the voltages between the alternator
terminal B+ (A8) and earth, and between alternator terminal D+ (A5) and earth. The voltages
should be between 13V and 15V (12V system) and between 26V and 30V (24V system). If the
voltages are not within this range then the alternator is faulty. Renew the alternator, see
Operation 14-4.
3 Increase the engine to its maximum, switch on an electrical load (A1) such as the vehicle lights,
and measure the voltages between the alternator terminal B+ (A8) and earth, and the alternator
terminal D+ (A5) and earth. The voltages should be between 13V and 15V (12V system) and
26V to 30V (24V system). If these values are correct then the fault is within the charging system
circuit. Check that the cables and connections are all correct. If the voltages are still incorrect
then the alternator is faulty. Renew the alternator, see Operation 14-4.
Key to the basic charging circuit illustration (A).
1 Applied electrical load.
2 Battery.
3 Ignition switch.
4 Ignition warning light.
5 Alternator terminal D+ .
6 Alternator terminal W .
7 Alternator.
8 Alternator terminal B+ .
E N G I N E – 1 1 0 4 C – 4 4
STARTER MOTORS
General description
The Dense P95RL (12 volt) is operated by a solenoid and have roller clutch drives. The solenoid
engages the starter drive in two operations to ensure that the motor gets its maximum torque only
when the starter motor is engaged fully with the flywheel. The clutch prevents rotation of the
armature at high speed if the starter is held in the engaged position.
! Always disconnect the battery terminals before the removal of any component of
the electrical system. 13
! Care must be taken to avoid damage to the engine speed and timing sensor fitted
14
to the cylinder block (A) when a starter motor is removed from, or fitted to, the
7
left side of the engine.
Note :
The starter motor may be fastened to the flywheel housing by either setscrews or studs and nuts.
To remove
1 Disconnect the starter motor cables.
2 Remove the fasteners and remove the starter motor.
To fit
Note :
The starter motors may have an O ring fitted to the starter motor flange. Check the condition
of the O ring and renew, if necessary.
1 Check that the starter motor is free from faults, oil and grease.
2 Clean the flange face of the starter motor and
the face of the flywheel housing.
3 Fit the starter motor and tighten the M10
setscrews or nuts to a torque of 44 Nm (33
lbf ft) 4,5 kgf m.
4 Connect the starter motor cables.
E N G I N E – 1 1 0 4 C – 4 4
To maintain the brush gear and the commutator Operation 14-8
Repairs to the starter motor are not recommended. Your Perkins Dealer/Distributor has specialist
equipment and personnel with the correct training to repair your starter motor.
To test on the engine Operation 14-9
Ensure that the battery is fully charged.
13 Turn on the lights and operate the starter switch. If no lights are fitted to the machine, connect
a voltmeter across the battery terminals and operate the starter switch.
If the starter does not operate but the lights keep their power, or there is no voltage drop across
14 the battery, check the switch and all the connections and wires. Slow action of the starter can be
8
caused by faulty connections.
E N G I N E – 1 1 0 4 C – 4 4
STARTING AID
General description
The starting aid for the 1100 Series four cylinder engines consists of a set of glow plugs, one on
each cylinder. The glow plugs are fitted in the cylinder head near the atomisers. The tip of the
glow plugs reaches into the combustion chamber in the piston crown.
The glow plugs are operated electrically, usually through the start switch. When the glow plugs
are energised, their tips become very hot and improve the combustion process during cold start
conditions.
To remove and to fit a glow plug Operation 14-10 13

To remove
14
1 Disconnect the glow plugs power supply cable. 9
2 Remove the four nuts (A1) that fasten the bus-bar, remove the bus-bar.
3 With a suitable socket, loosen, then remove the glow plugs.
To fit
1 Ensure that the threads of the glow plugs and
the cylinder head holes are clean.
2 Fit the glow plugs into the correct holes in
the cylinder head, then gradually tighten to
18 Nm (13 lbf ft) 1,8 kgf m.
3 Fit the bus-bar and the four nuts, tighten the
nuts to 2 Nm (1.5 lbf ft) 0,2 kgf m.
4 Connect the glow plugs power supply cable.
E N G I N E – 1 1 0 4 C – 4 4
To check the glow plugs’ power supply continuity Operation 14-11
1 Disconnect the glow plugs’ power supply cable and the bus-bar.
2 Apply one probe of a multi-meter, that can check continuity, to the terminal of the glow plug
and apply the other probe to a suitable earth. If the continuity is correct the multi-meter will give
an audible signal. If there is no audible signal, renew the glow plug. Repeat this check for all
of the glow plugs.
Note :
If a multi-meter is not available the following procedure can be used.
1 Connect a 12V test lamp between the positive terminal of the battery and earth to check that
the lamp will light.
13 2 Connect the test lamp between the terminal of the glow plug, that is furthest away from the
power supply, and earth.
3 Operate the control switch, the test lamp should be illuminated if the power supply is correct.
14 4 Disconnect the cables at each glow plug.
10 5 Connect the test lamp to the positive terminal of the battery and to the terminal of a glow plug.
The lamp will be illuminated if the continuity is correct. If the test lamp is not illuminated, renew
the glow plug.
6 When all of the glow plugs have been checked, connect the bus-bar to the glow plugs and
reconnect the power supply cable.
To check the operation of the glow plug Operation 14-12
1 Disconnect the glow plugs’ power supply cable and the bus-bar.
2 Connect a 50-0-50 ammeter between the power supply cable and the terminal of a glow plug.
3 Connect a voltmeter between the glow plug terminal and the earth.
4 Engage the control switch and check the readings of the ammeter and the voltmeter:
• 12 volt Beru glow plugs.
With a 12 volt supply, there is an immediate initial current of 30 amperes, that becomes
approximately 21 amperes for each glow plug. This will reduce to approximately 14 amperes
after 8 seconds, 10 amperes after 20 seconds and reach 9 amperes after 60 seconds.
• 24 volt Beru glow plugs.
With a 24 volt supply, the initial current is approximately 12 amperes for each glow plug, that
becomes approximately 8.5 amperes after 8 seconds, 7 amperes after 20 seconds and reach 6
amperes after 60 seconds.
Note :
If the ammeter reading is low, or there is no reading, renew the glow plug. If there is no voltmeter
reading, check the switch and the power supply cable.
When all of the glow plugs have been checked, remove the ammeter and the voltmeter and
connect the power supply cable. Check that the glow plugs are correctly fitted.
E N G I N E – 1 1 0 4 C – 4 4
To remove and to fit a temperature sensor. Operation 14-18
There are two temperature sensors fitted to the engine. One sensor is fitted to the cylinder head
(A1) for the coolant temperature and one sensor is fitted to the intake manifold (B1) for the air
intake temperature.
To remove
! Before the coolant temperature sensor is removed from the cylinder head, ensure
that the coolant is drained to a level that is below the sensor or the cylinder head.
1 Disconnect the connector from the sensor.
2 With a suitable spanner, loosen then remove the sensor from the cylinder head or the intake
manifold.
3 Discard the O ring.
13
14
11
Continued
E N G I N E – 1 1 0 4 C – 4 4
To fit
1 Ensure that the threads of the sensor and the threads in the cylinder head or the intake manifold
are clean and free from damage.
2 Fit a new ‘O’ ring (E1) to the sensor.
Note :
The O rings for the temperature sensors are black.
3 Fit the sensor to the cylinder head (C1) and the induction manifold (D1), tighten the sensor to
20 Nm (15 lbf ft) 2,1 kgf m.
4 Check that the connector seal is in place, that it is clean and is not damaged. Renew the seal
if it is damaged, see Operation 14-19.
5 Carefully fit the electrical connector to the sensor to ensure that the connector pins are not bent
13 during this operation.

6 Lightly pull the harness connector to ensure that it is locked to the sensor connector.
14
12
E N G I N E – 1 1 0 4 C – 4 4
WIRING HARNESS
! • Repairs to the wiring harness should not be carried out unless directed by the
Diagnostic Manual.
• If a wiring harness is returned under warranty, the MIC connector must be
covered with a plastic blanking cap to prevent the entry of water and dirt into
the unit. If this blanking cap is not fitted then the warranty may be affected.
Note :
A repair kit is available for all wiring harness repairs.
There are three main options for wiring harness repair, these are:
1 Renew the complete wiring harness.
2 Renew the pins or sockets, complete with wires attached.
3 Renew the connector, complete with wires attached.
13
Repairs that are difficult, or may take a long time to repair, should not be carried out. It may be 14
more cost effective to renew the wiring harness.
13
New connector pins and sockets are supplied with a short wire attached. The end of the wire
must be crimped to the wiring harness, see Operation 14-21.
New connectors are supplied complete with pins or sockets and short wires attached. The ends
of these wires must be crimped to the wiring harness, see Operation 14-21.
The tables below show a list of repair options that are recommended for each of the connectors
and the main wiring harness :
Sensor connector
Description Repair
Remove the connector pins from the body and
Damage to the connector body
fit to a new connector body
Remove the damaged connector pin or socket
Damage to the connector pins or sockets
and fit a new connector pin or socket
Damage to the connector body and the
Renew the complete connector
connector pins or sockets
Diagnostic connector
Note :
If several connector pins are damaged, it is recommended that the complete connector is renewed.
Description Repair
Remove the connector pins from the body and
Damage to the connector body
fit to a new connector body
Remove the damaged connector pin and fit a
Damage to a connector pin
new connector pin
Damage to the connector body and the
Renew the complete connector
connector pins
Continued
E N G I N E – 1 1 0 4 C – 4 4
Fuel injection pump connector

Repairs to the fuel injection pump connector are not recommended because specialist equipment
and personnel with the correct training are necessary. It is more cost effective to renew the wiring
harness.
Wiring harness
Note :
If several wires are damaged, it is more cost effective to renew the wiring harness.
Description Repair
Cut wire Use a crimp to join the wires together
Remove the damaged section of wire, replace
13 Damage to wire insulation only with a new section of wire and crimp to the
original wires
14 Damage to wire by corrosion

Remove the damaged section of wire, replace
with a new section of wire and crimp to the
14 original wires
Damage to the harness outer cover Repair with tape
! • Do not bend the wires directly from the rear of the connector (A1) as distortion
of the rear seal will result, and this will allow water to enter the connector.
E N G I N E – 1 1 0 4 C – 4 4
To repair a sensor connector. Operation 14-19
To repair a sensor connector, the body can be renewed, individual pins and sockets can be
renewed or the connector complete with wires attached can be renewed.
The connectors (A) have locking wedges that are pushed into the connectors to lock the pins or
sockets in position.
Sensor Connector types
Male connectors (A1).
Female connectors (A2).
Connector pin (A3) with wire connected.
Connector socket (A4) with wire connected.
13
14
15
E N G I N E – 1 1 0 4 C – 4 4
To remove a connector from a sensor or another connector
! • Do not use tools to separate the two parts of a sensor connector (A), because
damage to the lockingmechanism may result.
• Do not pull on the wires to separate a sensor connector.
1 Before a connector is removed from a sensor, or from another connector, ensure that the
connector and the local area are clean, free from dirt, oil and grease.
2 For a male and female sensor / harness
connectors; hold the connector in two hands
and press the locking mechanism (A1) until
it releases. Hold the locking mechanism down
and lightly pull the two parts of the connector
13 until they separate.

For a pressure or temperature sensor; hold the
locking mechanism (A2) or (A3) down and
14
lightly pull on the connector until it separates
16
from the sensor.
To remove a pin from a male connector

1 To remove the locking wedge from a male connector, insert a small thin screwdriver blade
between the locking wedge and the connector body. Lightly lift the locking wedge off the
connector body. Put the locking wedge in a safe place so that it can be fitted later.
2 Release the connector pin locking mechanism and lightly pull the wire out of the connector.
To remove a socket from a female connector
1 To remove the locking wedge from a female connector, use thin long-nose pliers, hold the pliers
firmly in one hand and lightly pull the female connector until the locking wedge is removed. Put
the locking wedge in a safe place so that it can be fitted later.
2 Release the connector socket locking mechanism and lightly pull the wire out of the connector.
To insert a pin or socket into a sensor connector
1 Hold the wire of the pin or socket that is to be inserted into the connector approximately 25,4
mm (1.0 inch) behind the contact crimped area.
2 Hold the connector with the rear seal towards you.
3 Push the pin or socket fully into the connector seal.
4 When all contacts are in position, insert the locking wedge and push it into place.
Note :
For locking wedges that have an arrow, the arrow must be fitted towards to the connector locking
mechanism.
5 To connect a new wire or connector to the wiring harness, see Operation 14-21.
E N G I N E – 1 1 0 4 C – 4 4
To repair a Diagnostic, a ECM, or a MIC connector Operation 14-20
It is recommended that if several pins need to be replaced, or if the connector body is damaged,
it may be cost effective to renew the harness.
To remove a pin or a socket from a connector
Note :
• The procedure is the same for the Diagnostic, ECM and MIC connectors.
• The tool required to remove the contact pins or sockets from these connectors is supplied in
the wiring harness repair kit.
1 Before a connector pin or socket is removed from a connector, ensure that the connector and
the local area are clean, free from dirt, oil and grease.
2 Carefully fit the removal tool (A2) onto the wire (A1) that is attached to the pin (B1) or the 13
socket to be removed.
3 Carefully push the removal tool (C1) along the wire and into the seal of the connector. 14
4 Carefully push the removal tool (B2) fully into the connector to release the connector locking 17
mechanism (B3).
5 With the removal tool (B2) fully engaged onto the pin or the socket, carefully withdraw the pin
or the socket (B1) with the removal tool.
! After the repair of Diagnostic, ECM and MIC connectors, ensure that the seals are
fitted and are correctly in position as damage to the connector body can result if
they are not.
E N G I N E – 1 1 0 4 C – 4 4
To insert a pin or socket into a connector.
! • Do not bend the wires directly from the rear of the connector as distortion of the
rear seal will result, and this will allow water to enter the connector. (See illustration
on page 245).
• Ensure that all ECM and MIC connector holes that are not used by a wire to a
socket or a pin, are closed by a blanking plug to ensure a waterproof seal. The
blanking plugs must be inserted into the connector so that the head of the blanking
plug is pushed against, but not into, the connector end seal. (See illustration on
page 245).
Note :
• The procedure is the same for Diagnostic,
13 ECM and MIC connectors.

• New pins and sockets are supplied with a
short length of wire fitted.
14 • Any pin or socket holes that are not used in
18 the connector must have blanking plugs fitted.
1 Hold the wire (D1) approximately 25,4 mm
(1.0 inch) behind the pin or socket.
2 Hold the connector with the rear of the
connector towards you.
3 Push the pin or socket (E1) or socket through
the connector rear seal.
4 Push the pin or socket (F2) into the
connector until the pin or socket is against
the locking mechanism (F1).
5 Push the pin or socket (F3) until the locking
mechanism (F4) is in position behind the pin
or socket.
6 Carefully pull on the wire to test that the pin
or socket is locked in position. If the pin or
socket pulls out of the connector, repeat the
procedure from stage 1.
! After the repair of Diagnostic, ECM

and MIC connectors, ensure that the
seals are fitted and are correctly in
position as damage to the connector
body can result if they are not.
E N G I N E – 1 1 0 4 C – 4 4
To connect a new wire or connector to the wiring harness Operation 14-21
! Do not solder the wires to the wiring harness. The wires must be correctly crimped.
Note :
• Connector sleeves that are supplied in the wiring harness repair kit have a heat-shrink cover
that has sealant applied to the inner surface.
• The new pins, sockets, and complete connectors that are supplied in the wiring harness kit, all
have short wires connected to them.
1 Cut the original wire to give the correct length when the new wire is connected.
2 Remove the insulation from the end of the wires that are to be joined.
3 Put the wires (A2) into the connector sleeve (A) and using a crimping tool, crimp the middle
area (A1).
4 Apply enough heat to the heat-shrink part of the connector (A3) to seal the wires inside the
13
connector sleeve. 14
Note : 19
If more than one wire is to be crimped to the wiring harness the connector sleeves (B1) must be
fitted at different lengths from the connector.
E N G I N E – 1 1 0 4 C – 4 4
AUXILIARY EQUIPMENT
AUXILIARY EQUIPMENT
GENERAL DESCRIPTION
The power take-off (PTO) adaptor provides a means to use the engine power to operate auxiliary
equipment.
The idler gear drives the splined shaft of the adaptor.
13
15
1
E N G I N E – 1 1 0 4 C – 4 4
AUXILIARY EQUIPMENT
ADAPTOR FOR A HYDRAULIC PUMP OR A STEERING PUMP
To remove
1 Remove the Allen screws (A1) and remove the
adaptor assembly from the rear of the timing
case.
2 Remove the setscrews (A8) and the rear
cover (A10).
3 Check the gear (A4), the spline drive and the
13 bearings (A3 and A9) for wear and damage,
renew the components if necessary.
15 To fit
2 1 Fit a new ‘O’ ring (A7) in its recess in the
housing (A6) and lightly lubricate it with clean
engine lubricating oil. Lubricate the bearings
(A3) and (A9) with clean engine lubricating
oil. Fit the rear cover (A10) and fit the
adaptor assembly to the timing case and
tighten the cap screws.
E N G I N E – 1 1 0 4 C – 4 4
AUXILIARY EQUIPMENT
1 Remove the circlip (A5). Provide a support

for the flange face of the housing (A6). Use
a suitable adaptor on the front bearing (A9)
to press the gear and bearings out of the
housing.
2 Remove the bearings (A3 and A9) from the
gear (A4) with a suitable puller.
13
15
3
E N G I N E – 1 1 0 4 C – 4 4
AUXILIARY EQUIPMENT
Consumable products
POWERPART Retainer (oil tolerant) 21820603
1 Apply a narrow ring of POWERPART Retainer (oil tolerant) to the outer surface of the front
bearing (A9) in the position shown (A2). Provide a support for the front face of the housing.
Use a suitable adaptor on the outer race of the bearing to press the front bearing onto the
shoulder in the housing. Remove any excess retainer.
13 2 Apply a narrow ring of POWERPART

Retainer (oil tolerant) to the inner surface of
the front bearing (A9) in the position shown
15 (A2). Provide a support for the bearing. With
4 the small diameter of the gear (A4) toward
the bearing, press the gear into the bearing
until the gear is against its shoulder.
3 Apply a narrow ring of POWERPART
Retainer (oil tolerant) to the outer surface
and to the inner surface of the rear bearing
(A3) in the positions shown (A2). Ensure that
the support is under the front bearing. Use
a suitable adaptor on the outer ball race of
the bearing to press the bearing into the
housing and onto the shoulder on the gear
(A4). Remove any excess retainer. Fit the
circlip (A5) into its groove in the housing.
4 Check the backlash between the power take-
off gear and the idler gear. The backlash is
0,11/0,17 mm (0.004/0.007 in).
E N G I N E – 1 1 0 4 C – 4 4
AUXILIARY EQUIPMENT
EXHAUSTER
To remove
1 Disconnect the lubricating oil and vacuum pipes from the exhauster and fit covers to the open
ends of the pipes.
2 Release the setscrews and remove the exhauster.
To fit
1 Ensure that the joint faces of the exhauster and the timing case are clean and renew the joint.
Fit the exhauster to the timing case and tighten the setscrews.
2 Remove the covers from the open ends of the pipes and connect the oil pipe and the vacuum
pipe to the exhauster.
13
15
5
E N G I N E – 1 1 0 4 C - 4 4
SPECIAL TOOLS
SPECIAL TOOLS
These tools are available through your nearest Perkins Dealer/Distributor. If you cannot obtain the
correct tool locally contact :
The Perkins Service Department, Peterborough, PE1 5NA, England, UK. Tel 01733 583000, Fax
01733 582240, Telex 32501 PERKEN G.
13
16
1
E N G I N E – 1 1 0 4 C - 4 4
SPECIAL TOOLS
LIST OF SPECIAL TOOLS
Part number Part number Illustration
Remover / replacer for valve guides (main tool).

21825478
Reference number PD.1D.
13 21828479
Adaptor for use with 21825478.
Reference number PD.1D-13.
16
2
Inlet and outlet valve guide adaptor for

27610234
use with 21825478.
Bosch EPVE fuel pump timing adaptor.

27610248
Reference number.
Gauge for piston height, valve depth and

21825496 cylinder liner flange; for use with 21825617.
Reference number PD.41D.
Fastener plate for use with 21825577.

21825580
Reference number PD.170-3.
Replacer tool for seal of timing case cover

21825577 (main tool).
Reference number PD.170.
E N G I N E – 1 1 0 4 C - 4 4
SPECIAL TOOLS
Pressure plate for use with 21825577.

21825578
27610217
Adaptor for front seal for use with 21825577.
Reference number.
13
16
3
Replacer tool for pistons.

21825491
Dial gauge for use with 21825496.

21825617
Valve spring compressor.

21825666
Reference number PD.6118B.
Stud adaptor for use with 21825666.

21825931
27610235 Setscrew adaptor for use with 21825666.s
E N G I N E – 1 1 0 4 C - 4 4
SPECIAL TOOLS
Angle gauge to tighten cylinder head setscrews.

21825607
Reference number PD.198. (MS.1531).
13
16 Combined reamer/cutters and handle for
4 27610030 valve guides and 30 valve seat inserts.
Reference number.
27610227 Rocker assembly tools.
Timing pin for balancer drive shaft.

27610225
Reference number.
Timing case alignment tool.

27610216
Reference number.
Thermostat fitting and removal tool.

27610226
Reference number.
E N G I N E – 1 1 0 4 C - 4 4
SPECIAL TOOLS
Camshaft gear timing pin.

27610212
Reference number.
27610211
Crankshaft timing pin.
Reference number..
13
16
5
Bosch VP30 fuel injection pump timing pin.

27610032
Reference number.
Three legged puller.

27610230
Reference number.
UKMK0662 Wiring harness repair kit
ENGINE–GM V6
(FOR LPG) 15
• 15 – 01 ENGINE REMOVAL AND REPLACEMENT
• 15 – 02 4.3 LITER V6 ENGINE REPAIR PROCEDURES
• 15 – 03 COOLING SYSTEM
E N G I N E – V 6
ENGINE REMOVAL AND REPLACEMENT
ENGINE REMOVAL
The following procedures describe the steps

necessary to remove the engine. A hoist capable
of lifting he overhead guard, counterweight, and
engine is required.
• Remove the overhead guard.
• Remove the driver’s seat and any electrical wires

mounted to the seat support.
• Remove the clamshell hood.
15
• Remove counterweight. See the procedures for
01
removing the counterweight in Group 70. 1
• Disconnect battery leads at battery and re-move

the battery. Disconnect horn wires.
• Remove floor plates. Remove top and side body

sheet metal.
• Drain radiator and remove radiator hoses to

engine and to filler neck bracket.
E N G I N E – V 6
• Remove transmission oil cooling lines at ra

diator.
• Remove the radiator.
15
01
2
• Remove the engine oil cooler and hose.
• Remove the air cleaner and air cleaner hoses

and clamps.
E N G I N E – V 6
• Remove the main pump inlet fitting assembly, inlet

hose, and stiffener.
• Remove heat shield from the the muffler and

manifold.
• Remove the muffler and tail-pipe.
• Remove the exhaust pipe and heat shield wrap.
15
01
3
• Remove accelerator control at carburetor throttle

lever.
• Remove the fuel line that goes from fuel pump to

fuel tank in frame.
• Remove the oil line from transmission.

• Remove and tag all wire harness leads to engine
components.
Coil the wire harness and tie it out of the way
to prevent damage when the engine is re-moved.
E N G I N E – V 6
• Connect OSHA-approved overhead chain to the

engine lifting brackets.
• Remove the engine mount bolts and dampen-
ers.
• Remove the engine flywheel housing to trans-

mission fasteners.
• Remove the cover plate of flywheel housing.

Unbolt the torque converter drive plate from the Cover plate & hole
engine flywheel through the top hole.
15
• Carefully separate engine from transmission by
01 moving the engine away from the trans-
4 mission. Lift engine out of truck. Use prybars
if necessary to assist in separating engine from
transmission; do not use unnecessary or
excessive force.
Note :
Do not pry on the torque converter. Nicks
and scratches can cause fatigue and leaks.
E N G I N E – V 6
ENGINE REPLACEMENT
The following procedures explain replacement of the

engine. A hoist capable of lifting the overhead
guard, counterweight, and engine is required.
Note :
The following procedures assume the torque
convertor is in the transmission.
• Begin lowering the engine into frame using the

hoist and chains hooked into enginelifting brackets.
Put engine mounting dampeners in place on
frame-mounting surfaces.
• Remove top cover on flywheel housing. Check

alignment of torque converter and flywheel
ensuring that torque converter rotates freely.
Cover plate & hole 15
• Insert engine-mounting bolts and tighten to a
01
5
torque of 23-27 lbf·ft (32–36 N·m).
• Insert transmission case-to-engine bolts.

Torque engine-to-transmission bolts to 24-27 lbf·ft
(33-37 N·m).
• Use hole on the flywheel housing to replace the

torque converter drive plate to engine flywheel
bolts and tighten to a torque of 19 to 21 lbf·ft (25-
28 N·m).
• Tighten fasteners to a torque of 24-27 lbf·ft (33-

37 N·m).
E N G I N E – V 6
• Replace all wires on correct components on

engine and remove all identification tags.
• Replace the oil line on the transmission.
• Replace the fuel line on the fuel pump.
15 • Connect the accelerator control at the

carburetor throttle lever.
01
6
• Install the exhaust pipe and heat shield wrap.

• Install the muffler and tail pipe.
• Install the muffler and manifold heat shields.
E N G I N E – V 6
• Install the main pump inlet fitting assembly using

a new gasket; install the inlet hose and stiffener.
Fill the oil sump to the correct level.
• Install the air cleaner and air cleaner hoses and

clamps. Ensure that all connections are tight and
do not leak.
15
01
7
• Install the radiator.
• Install the engine oil cooler and hoses.
E N G I N E – V 6
• Connect the transmission oil-cooling lines at the

radiator.
• Connect engine cooling lines to the radiator; fill

the radiator to the correct level.
15
01 • Install front and rear floor plates.
8 • Install seat support and top hood.
• Attach electrical leads to the horn.
• Install the battery and connect the battery
leads.
• Install the counterweight and tighten bolt to a

torque of 350-400 lbf-ft (650-800N·m).
! WARNING
Use caution when replacing the coun-
terweight. Keep all body parts away;
use prybars to manuever the counter-
weight into exact mounting position.
E N G I N E – V 6
• Install sheet metal.
• Replace the overheadguard. Insert and tighten

fasteners to a torque of 50-55 lbf·ft (65-75 N·m).
15
01
9
E N G I N E – V 6
4.3 LITER V6 ENGINE REPAIR PROCEDURES
! NOTICE
Always use the correct fastener in the correct location. Use the correct fastener part
number to replace a fastener. If the correct fastener part number is not available, a
fastener of equal size and strength may be used. Do not use a fastener that is stronger
when the correct fastener part number is not available in the following applications:
• Some bolts are designed to permanently stretch, and if a stronger fastener is used, the part will
not be tightened correctly. These permanently stretching bolts will be called out. The correct part
number fasteners must be used to replace this type of fastener because there is no available
equivalent.
• Other bolts are designed to break if over tightened to prevent part damage. Using a stronger
fastener may cause part damage to occur.
Fasteners that need to be replaced when removed will be called out. Fasteners that require thread
lockers or thread sealant will be called out The correct tightening specification and sequence must
be used when installing fasteners. Part or system damage may occur if the above instructions are
15
not followed.
02
1
Use only a razor blade type scraper on engine component surfaces. Use extreme care so sealing
surfaces are not scratched. Do not use any other method or technique to remove gasket material
except where indicated. Do not use abrasive pads, sand paper or power tools to remove gasket
material except where indicated. These techniques will produce fine grit that the oil filter will not
be able to remove from the oil this grit is abrasive and has been known to cause internal
engine damage.
E N G I N E – V 6
GENERAL DESCRIPTION
ENGINE CONSTRUCTION
The 4.3L (262 CID) engine is a liquid-cooled 90-degree V6 type with overhead valves, cast-iron
block, cylinder heads, and cast-iron balance shaft.
CYLINDER BLOCK
The cylinder block has 6 cylinders arranged in a “V” shape with 3 cylinders in each bank.
Starting at the front of the engine, cylinders in the right bank are numbered l-3-5 and cylinders
in the left bank are numbered 2-4-6 (when viewed from the front of the engine). The firing order
of the cylinders is 1-6-5-4-3-2. The cylinders are encircled by coolant jackets.
CYLINDER HEADS
15 The cylinder heads have one intake and one exhaust valve for each cylinder. A spark plug is
located between the valves in the side of the cylinder head. The valve guides are integral and
02 the rocker arms are retained on individual threaded in Studs.
2
CRANKSHAFT
The crankshaft is supported by four main bearing inserts. The number four bearing at the rear
of the engine is the end thrust bearing. The bearings are retained by bearing caps that are
machined with the block for proper alignment and clearances.
CAMSHAFT
The camshaft is supported by four full round, sleeve type bearings. A sprocket on the crankshaft
drives a timing chain which in turn drives the camshaft through a sprocket.
PISTONS AND CONNECTING RODS
The pistons are made of cast aluminum alloy using two compression rings and one oil control
ring. piston pins are offset 1.58750 mm (0.0625 in.) toward the major thrust side (right side) to
reduce piston slap as the connecting rod travels from one side of the piston to the other side
after a stroke. The pins are a press fit in the connecting rod and a floating fit in the piston.
BALANCE SHAFT
A cast-ductile balance shaft is mounted in the crankcase above and in-line with the camshaft
for enhanced engine smoothness under all operating conditions. A camshaft gear drives the gear
attached to the balance shaft. The front end of the balance shaft is supported by a ball bearing
and the opposite end uses a sleeve bearing.
E N G I N E – V 6
VALVE TRAIN
The valve train is a ball pivot type. Motion is transmitted from the camshaft through the hydraulic
lifter and pushrod to the rocker arm.The rocker arm pivots on its ball and transmits the camshaft
motion to the valve. The hydraulic valve lifters with roller followers keep all parts
of the valve train in constant contact. Each lifter acts as an automatic adjuster and maintains zero
lash in the valve train and eliminates the need for periodic valve adjustment.
INTAKE MANIFOLD
A cast-aluminum intake manifold is used that has an exhaust gas recirculation (EGR) port cast into
it for the mixture of exhaust gases with the fuel and air mixture.
15
02
3
E N G I N E – V 6
15
02
4
E N G I N E – V 6
1. Oil Pump Shaft Extension 122. Retainer

2. Oil Pump Body 123. Oil Pump Bolt
5. Pump Cover 124. Spring Stop Plug
6. Pressure Regulator valve 125. Nut
7. Pressure Regulator Valve Spring 126. Gasket
8. Spring Stop Retaining Pin 127. Oil Fan Drain Plug
10. Pickup Screen and Pipe 128. Oil Pan Stud
70. Oil Pan Gasket 129. Bolt
71. Oil Pan Reinforcement 130. Clip
72. Oil pan 131. Bolt
80. seal Retainer Screw 132. Main Bearing Cap Bolt
81. Seal Retainer Nut 133. Groove Pin
82. Seal Retainer 134. Engine Flywheel
83. Seal Retainer Stud 135. Flywheel Bolt
84. Seal Retainer Gasket 136. Lower Main Bearing Insert
87. Camshaft Retainer 137. Crankshaft Front Oil seal
88. Camshaft Retainer Screw 138. Torsional Damper
90. Seal 139. Groove Pin
91. Gasket 140. Timing Pointer
92. Oil Fitter Adapter 141. Bolt
93. Bolt 142. Front Cover
100. Main Bearing Cap 143. Front Cover Gasket
101.
102.
103.
Crankshaft
Oil Filter
Piston Rings
144.
145.
146.
Upper Main Bearing Insert
Woodruff key
Dowal Pin
15
104. Piston 148. Canshaft
105. Connecting Rod 149. Coolant Pump Gasket 02
106. Connecting Rod Bearing 150. Bolt 5
107. Connecting Rod Cap 151. Coolant Pump
108. Connecting Rod Nut 152. Crankshaft Sprocket
109. Plug 153. Bolt
110. Knock Sensor 154. Camshaft sprocket
111. Plug 155. Timing Chain
112. Expansh Cup Plug 156. Camshaft Bearing
113. Plug 157. Expansion Plug
114. Engine Block 156. Oil Level Indicator Tube
115. Plug 159. Oil Level Indicator
116. Water Jacket Plug 160. Bolt
121. Dowel Pin 161. Piston Pin
E N G I N E – V 6
15
02
6
E N G I N E – V 6
20. Valve Stem Key 165. Coolant Outlet Gasket

21. Inlet Valve Spring Cap 166. Thermostat
22. Valve Stem Oil Shield 167. Vacuum Fitting
23. Valve Stem Oil Seal (O-Ring) 168. Engine Coolant
24. Inlet Valve Stem Seal Temperature, sensor
26. Valve Spring with Damper 169. Bolt
27. Inlet Valve 170. Intake Manifold
28. Exhaust Valve Rotator 171. Oil Pressure Sensor
29. Exhaust Valve 172. Oil Pressure Fitting
40. Lifter Restrictor Retainer Bolt 173. E.G.R. Valve Gasket
41. Lifter Restrictor Retainer 174. E.G.R. Valve
42. Rocker Arm Nut 175. Bolt
43. Rocker Arm Ball 176. Intake Manifold Gasket
44. Rocker Arm 177. Nut
45. Push Rod 176. Power Booster
46. VaIve Lifter Guide (Restrictor) Vacuum Pipe
47. Lifter 179. Exhaust Manifold
48. Flat Washer 180. Fower Booster Vacuum
50. Cylinder Head Bolt Pipe Fitting
51. Spark Plug 181. Plug
52. Coolant Temperature Sensor 182. Coolant Temperature Sensor
53. Drain Plug 183. Crankcase Ventilation Valve
54.
60.
61.
Cylinder Head Gasket
Heat Shield
Washer
184.
185.
186.
Oil Filler Cap
Oil Filler Tube
Bolt
15
62. Exhaust ManifoId Lock 700. Rocker Arm Cover Bolt
63. Bolt/Stud 701. Rocker Arm Cover 02
162. Stud 702. Rocker Arm Cover Gasket 7
163. Bolt 704. Crankcase Vent Tube Grommet
164. Coolant Outlet 705. Crankcase Vent Valve Grommet
E N G I N E – V 6
ENGINE LUBRICATION
Figures 15-02-8 and 15-02-9 page.

Lubrication schematics are shown in figures of 15-02-8 and 15-02-9 page. The gear type oil
pump is driven from the distributor shaft, which is gear driven from the camshaft. Oil is drawn
into the oil pump through a pickup screen and pipe.
Pressurized oil is routed to the oil filter. In case of excessive oil pressure, a bypass valve is
provided. Filtered oil flows into the main gallery and then to the camshaft, balance shaft rear
bearing, and crankshaft bearings.
The valve lifter oil gallery supplies oil to the valve lifters. Oil flows from the hydraulic lifters
through the hollow pushrods to the rocker arms. Oil firorn overhead drains back to the crankcase
through oil drain holes.
The timing chain is drip fed from the fi-ont camshaft bearing. The pistons and piston pins are
lubricated by oil splash.
15
02
8
E N G I N E – V 6
A.
B.
C.
Regulator Valve (Shown in Open Position)
Suction
Oil Pressure Switch
15
D.
E.
Valve Lifter Gallery
Main Oil Gallery
02
F. Bypass Valve 9
Front View
Front View Rearview

Showing Path of Oil to Timing Chain Showing Main Gallery, Oil Filter and
Crankshaft Oil Feed
E N G I N E – V 6
GENERAL INFORMATION
STATEMENT ON CLEANLINESS AND CARE
• An engine is a combination of many machined, honed, polished, and lapped surfaces with very
fine tolerances.
• Whenever valve train components, cylinder head, cylinder, crankshaft, or connecting rod
components are removed for service, they should be retained in order. At the time of installation,
they should be installed in the same locations and with the same mating surfaces as when
removed.
• Any time the air cleaner or TBI unit is removed, the intake opening must be covered.This will
protect against the entrance of foreign material which could follow the intake passage into the
cylinder and cause extensive damage when the engine is started.
• When any internal engine parts are serviced, care and cleanliness are important. A liberal
coating of engine oil should be applied to friction areas during assembly to protect and lubricate
the surfaces on initial operation. Throughout this section, it should be understood that proper
15 cleaning and protection of machined surfaces and friction areas is part of the repair procedure.
This is considered standard shop practice even if not specifically stated.
02 ! Important
10
Use of RTV sealer and anaerobic gasket eliminator
Two types of sealer are commonly used in the engines covered by this manual. These are RTV
sealer and anaerobic “gasket eliminator” sealer.
It is important that these sealers be applied properly and in their proper place to prevent oil
leaks. The two types of sealers are not interchangeable. Use the sealer recommended in the
procedure.
• RTV (room temperature vulcanization) sealer is used where a nonrigid part is assembled to a
rigid part. Common examples are oil pans and rocker covers.
• Anaerobic gasket ehminator hardens in the absence of air. This sealer is used where two rigid
parts (such as castings) are assembled together. When two rigid parts am disassembled and
sealer or gasket is readily noticeable, the parts were probably assembled using gasket
eliminator.
USING RTV SEALER
• Do not use RTV when extreme temperatures are expected, such as exhaust manifold, head
gasket or where gasket eliminator is specified.
• When separating components sealed with RTV, use a rubber mallet and “bump” the part
sideways to shear the RTV sealer. “Bumping” should be done at bends or reinforced areas to
prevent distortion of parts. RTV is weaker in shear (lateral) strength than in tensile (verti-cal)
strength.
! NOTICE
Attempting to pry or pull components apart may result in damage to the part.
E N G I N E – V 6
• Surfaces to be resealed must be clean and dry. Remove all traces of oil and RTV with a
chlorinated solvent (GM P/N 1050454 or equivalent). Do not use petroleum cleaners such as
mineral spirits. They leave a film onto which RTV will not stick.
• Apply RTV to one of the clean surfaces. Use abead size as specified in the procedure. Run the
bead to the inside of any bolt holes. Do not allow the sealer in any blind threaded holes, as it
may prevent the bolt from seating properly or cause damage when the bolt is tightened.
• Assemble while RTV is still wet (within 3 minutes). Do not wait for RTV to skin over.
• Torque bolts to specitications. Do not over-torque.
USING ANAEROBIC GASKET ELIMINATOR
• Clean surfaces to be resealed with a chlorinated solvent (GM P/N 1050454 or equivalent) to
remove all oil, grease, and old material.
• Apply a continuous bead of gasket eliminator to one flange.
• Spread the bead evenly with your finger to get a uniform coating on the complete flange.
• Assemble parts in the normal manner and torque immediately to specifications.
15
02
! Important 11
Anaerobic sealed joints that are partially torqued and allowed to cure more than five
minutes may result in incorrect shimming of the joint.
REPLACING ENGINE GASKETS
! CAUTION
Composite type gaskets are used in some areas of the engine assembly. These gaskets
have a thin metal core. Use caution when removing or handling composite gaskets to
help avoid personal injury.
THREAD REPAIR
Tools Required
General purpose thread repair kits are available commercially.
Damaged threads may be reconditioned by drilling out, rethreading, and installing a suitable thread
insert. Copyrighted Material
E N G I N E – V 6
! CAUTION
Wear safety glasses to avoid eye damage.
• Determine size, pitch, and depth of damaged thread. If necessary, adjust stop collars on
cutting tool and tap to required depth.
! Important
Refer to the kit manufacturer’s instructions regarding the size of drill and tap to be
used.
• Drill out damaged thread.

• Tap hole. Lubricate tap with light engine oil. Clean the thread.
! Important
Avoid buildup of chips. back out the tap every few turns and remove chips.
15
• Thread the thread insert into the mandrel of the installer.
Engage the tang of the insert on the end of the mandrel.
• Lubricate the insert with light engine oil (except when installing in aluminum) and install.
02 ! Important
12 When correctly installed, the insert should be flush to one turn below the surface.
• If the tang of the insert does not break off when backing out the installer, break the tang
off with a drift
DISASSEMBLY OF ENGINE
TOOLS AND SHOP EQUIPMENT
A clean well-lit work area should be available. other necessary equipment includes: a suitable
parts cleaning tank, compressed air supply, trays to keep parts and fasteners organized, and
au adequate set of hand tools.
An approved engine repair stand will aid the work and help prevent personal injury or component
damage.
Special tools are listed and illustrated throughout this section with a complete listing at the end
of the section. These tools (or their equivalents) are specially designed to quickly and
safely accomplish the operations for which they are intended.
The use of these special tools will also minimize possible damage to engine components.
Some precision measuring tools are required for inspection of certain critical components. Torque
wrenches are necessary for the correct assembly of various parts.
E N G I N E – V 6
ACCESSORY REMOVAL
The various procedures in this manual assume that the engine accessories have been removed.
These accessories may include one or more of the following:
• Hydraulic Pump
• Generator
• Air Conditioning Compressor
• Cooling Fan
• Distributor
• TBI unit
It is beyond the scope of this section to cover in detail the many different accessory installations.
Refer to the appropriate service manual section for this information.
Diagrams of emissions and vacuum hose routings, wiring harness routing, accessory drive belt
layout, etc. should be found before removing accessories.
CLEANING
15
02
It is important that the engine be as clean as possible to prevent dirt from entering critical areas 13
during disassembly.
Remove the engine accessories before cleaning, to provide better access to the engines exterior
surfaces. After removing the TBI unit, distributor, etc., cover the openings with tape to
prevent the entry of contaminants.
Methods used to clean the engine will depend on the means which are available. Steam cleaning,
pressure washing, or solvent cleaning am some of the acceptable methods. AIlow
the engine to dry thoroughly before beginning any work.
DRAINING THE ENGINE
Remove or Disconnect
• Oil pan drain plug and washer.
! Important
Allow the oil to drain into a proper container.
• Oil filter.
• Coolant drain plug and or knock sensor from the block
! Important
Allow the coolant to drain from the block into a proper container.
E N G I N E – V 6
Install or Connect
! NOTICE
Refer to “Notice” on page 1.
• 0il pan drain bo1t.
Tighten
Drain plug to 25 N ·m (18 lbs. ft).
• Coolant drain plug and or knock sensor into the block.
Tighten
Coolant drain plug or knock sensor to 14 N ·m (124 lbs. in.).
EGR VALVE REMOVAL
15 Remove or Disconnect
• Bolts.
• EGR valve.
02 • Gasket.
14
EXHAUST MANIFOLD REMOVAL
• Exhaust manifold bolts, washers, and tab washers.
• Heat shields.
• Exhaust manifold.
COOLANT PUMP REMOVAL
• coolant pump bolts.
• coolant pump.
• Gaskets.
ROCKER ARM COVER REMOVAL
• Rocker arm cover bolts(1).
• Rocker arm covers (2).
• Gaskets.
INTAKE MANIFOLD REMOVAL
• Intake manifold bolts.
• Intake manifold. Intended for CLARK dealers only
• Gaskets. Do not sell or distribute
E N G I N E – V 6
VALVE TRAIN COMPONENT REMOVAL
19. Bolt
20. Retainer
21. Nuts
22. Balls
23. Rocker Arm
24. Pushrods
25. Restrictor
26. Hydraulic Lifter
15
! Important 02
Store all reusable components in an exact order so they can be reassembled in the same 15
position from which they were removed.
• Rocker arm nuts (21), balls (22), and rocker arms (23).
• Push rods (24).
• Bolt (19).
• Guide assembly (20).
• Hydraulic lifters (26).
! Important
Remove the lifters one at a tune and place them in an organizer rack
CYLINDER HEAD REMOVAL
• Engine lift bracket.
• Cylinder head bolts.
• Cylinder heads.
• Head gaskets.
E N G I N E – V 6
TORSIONAL DAMPER REMOVAL
Tool Required
J 23523-E Torsional Damper Puller
! NOTICE
02 The inertial weight section of the torsional damper is assembled to the hub with a
16 rubber sleeve. The removal procedures must be followed (with the proper tools) or
movement of the inertia weight section of the hub will destroy the tuning of the
torsional damper and the engine timing reference.
• Torsional damper bolt.

• Torsional damper using J 23523-E.
• Crankshaft key.
E N G I N E – V 6
15
02
17
A. Sealer
70. Gasket, Oil Pan
72. Pan, Oil
125. Nut, Oil Pan
128. Stud, Oil Pan
129. Bolt, Oil Pan
130. Clip
34. Nut
36. Stud
36. Key
37. Gear, Balance Shaft Drive
38. Sprocket, Crankshaft
39. Bolt
40. Sprocket, Camshaft
41. Chain, Timing
E N G I N E – V 6
OIL PAN REMOVAL
• Oil pan nuts (125).
• Oil pan bolts (129).
• Clips (130) and studs (128).
• Reinforcements.
• Oil pan (72).
• Gasket (70).
OIL PUMP REMOVAL
• Oil pump to main bearing cap bolt.
• Complete oil pump assembly.
• Shaft extension.
15 FLYWHEEL REMOVAL
18 • Flywheel bolts.
• Flywheel.
FRONT COVER REMOVAL
• Front cover bolts.
• Front cover.
• Front cover gasket.
TIMING CHAIN AND CAMSHAFT SPROCKET REMOVAL
Check timing chain free play. If the timing chain

can be moved back and forth in excess of
1.58750 mm (0.625 in.), make a note that the
timing chain should be replaced during
assembly.
• Camshaft sprocket bolts (39) and nut (34).

• Camshaft sprocket (40) and timing chain (41)
together.
E N G I N E – V 6
! Important
The sprocket has a light interference fit on the camshaft.
Tap the sprocket on its lower edge to loosen it.
CAMSHAFT REMOVAL
Tool Required:
5825-A Crankshaft Gear Remover
• Balance shaft drive gear stud (35).

• Balance shaft drive gear (37).
• Crankshaft sprocket (38), if necessary. Use 5825
(fig-ure 13).
• Camshaft retainer bolts and camshaft retainer.
• Camshaft.
! Important
15
Install three 7.9375 mm (0.3125 in.- 18 pitch) bolts 100 ~ 125 mm (3.937 in. - 4.921 in.)02
long into the camshafts threaded holes. Use these bolts to handle the camshaft. 19
E N G I N E – V 6
BALANCE SHAFT REMOVAL
42. Driven Gear

43. Retainer
46. Bearing
46. Plug
47. Balance Shaft
46. Bolt
49. Bolt
15
02 Tools Required:
38834 Balance Shaft Bearing Service
20 Kit 26941 Bearing Remover
1. Bolt (49).
2. Driven gear (42).
3. Retainer bolts (48).
4. Retainer (43).
5. Balanceshaft(47)using a soft faced hammer(above figure).
6. Balance shaft rear bearing (45) using 38834 and 26941.
! Important
The balance shaft with front bearing are serviced as an assembly.
Use only the correct tools for bearing and shaft installation.
Inspect the balance shaft driven gear and the drive gear for nicks and burrs.
PISTON AND CONNECTING ROD REMOVAL
Tools Required :
Copyrighted Material 5239 Guide Set
Intended for CLARK dealers only 24270 Ridge Reamer
E N G I N E – V 6
• Ridge or deposits from the upper end of the
cylinder bores as follows:
a. Rotate the crankshaft until the piston is at
BDC.
b. Place a cloth on top of the piston.
c. Perform the cutting operation with 24270.
d. Rotate the crankshaft until the piston is at
TDC.
e. Remove the cloth and cuttings.
f. Repeat this procedure for each piston.
• Mark the cylinder numbers on the tops of each piston.
! Important
Marking them from the front to the rear, with the engine in an upright position and
viewed from the front :
– The right bank is numbered l-3-5.
– The left bank is numbered 2-4-6.
• Check the connecting rod and cap for identification marks.

15
02
! Important 21
Mark the parts if required.
Marking them from the front to the rear, with the engine
in an upright position and viewed tiom the front:
– The right bank is numbered l-3-5.
– The left bank is numbered 2-4-6.
Store the connecting rod, bearings and cap together as
mating parts, so they may be reassembled in the same position from which they were
removed.
• connecting rod cap.

• Connecting rod and piston.
! Important
Attach 5239 to the connecting rod bolts (figure 20 page below and right).
Use the long guide rod of 5239 to push the connecting rod and piston out of the bore
through the top of the engine.
• Connecting rod beatings.
E N G I N E – V 6
CRANKSHAFT REAR OIL SEAL REMOVAL
! NOTICE
When removing the crankshaft rear oil
sesl,be careful to not damage the
crankshaft sealing surface. A minor
scratch can cause a major oil leak.
• Crankshaft rear oil seal. Insert a screwdriver

into the notches provided in the seal retainer
and pry the seat out (figure right).
15 CRANKSHAFT REAR OIL SEAL RETAINER REMOVAL
22
• Screws (50) and nuts (51).
• Seal retainer (52).
• Gasket (54).
CRANKSHAFT REMOVAL
Inspect
• Check the main bearing caps for location markings.
Mark the caps if necessary. The caps must be returned to their original locations during
assembly.
1. Main bearing cap bolts.
2. Main bearing caps and lower main bearing inserts.
3. Crankshaft from the cylinder block with extreme care, taking care to avoid damage to
crankshaft journals and thrust flange surfaces.
4. Upper main bearing inserts.
E N G I N E – V 6
MAIN BEARING REMOVAL (WITHOUT REMOVING CRANKSHAFT)
Tool required:
8080 Main Bearing Remover/Installer
Inspect
• Check the main bearing caps for location
markings.
Mark the caps if necessary. The caps must be
returned to their original locations during
assembly.
1. Main bearing cap bolts.
2. Main bearing caps
3. Lower main bearing inserts from the main bearing caps.
4. Upper main bearing inserts.
a. Insert 8080 into the crankshaft oil hole (figure above).
b. Rotate the crankshaft to turn the upper main bearing insert out of the block.
15
02
23
CLEANING, INSPECTION, AND REPAIR
! NOTICE
Carefully remove all gasket material from the part using a plastic or wood scraper. Use
Loctite brand “Chisel Gasket Remover” (P/N 79040), Permatex brand “Gasket Remover”
(F/N 4MA) or equivalent. Follow all safety recommendations and directions that are on
the can.
Do not use any other method or technique to remove gasket material. from a part Do not use
abrasive pads, sand paper or power tools to clean gasket surfaces. These methods of cleaning
can damage the part Abrasive pads also produce a fine grit that the oil filter cannot remove from
the oil. This grit is abrasive and has been known to cause internal engine damage.
! NOTICE
If the engine is damaged internally and needs to be rebuilt, make sure all foreign material
is completely flushed out of the cooling system/oil cooler system (if equipped). Failure
to flush out the debris can result in damage to the rebuilt engine.
E N G I N E – V 6
15
02
24
64. Plug, oil pressure crossover hole 115. Plug, engine block coolant drain hole
65. Plug, oil pressure crossover hole 147. Plug, oil gallery hole
111. Plug, oil gallery hole 157. Plug, oil gallery hole
113. Plug, oil gallery hole
Engine Block Coolant Drain and Oil Gallery Plugs
A solvent tank large enough to hold the larger engine parts will be needed as well as various
bristle brushes and gasket scrapers. A source of compressed air will also be helpful in the
cleaning operations.
Special tools are listed and illustrated throughout this section with a complete listing at the end
of the section. These tools (or their equivalents) are specially designed to quickly and safely
accomplish the operations for which they are intended. They should not be used in operations
for which they are not designed. These special tools, when they are properly used, will also
minimize possible damage to engine.
Some precision measuring tools are required for inspection of certain critical components. These
include micrometers, torque wrenches, feeler gages, dial indicator set, etc. The inspection work,
when performed with the proper methods and tools, is most important.
The rebuilt engine cannot be expected to perform properly if the parts are worn beyond
acceptable limits are reused.
E N G I N E – V 6
CYLINDER BLOCK
• Oil pressure fitting and sensor.

• Coolant drain plugs.
• Oil filter adapter bolts.
• Oil filter adapter and gasket
• Camshaft and balance shaft cup plugs (89).
• Front oil gallery cup plugs (86).
• Rear oil gallery plugs (87,88, and 90).
Clean
• Sealing material from mating surfaces.

• Boil cylinder block in caustic solution.
- Flush with clean water or steam.
• Cylinder bores.
• Threaded holes.
15
• Oil galleries and passages.
• Scale deposits from coolant passages.
02
• Spray or wipe cylinder bores and machined surfaces with engine oil. 25
Inspect
1. All expansion plugs for lack of fit or leakage.

2. Valve lifter bores for deep scratches and deposits.
3. Cracks in the block.
- Cylinder walls.
- Coolant jackets.
- Engine mount bosses.
- Main bearing webs.
4. Main bearing bores and caps.
- All main bearing bores should be rounded and uniform in ID at all of the bearing supports.
- The area were the main bearing inserts contact the main bearing bore should be smooth.
- if a main bearing cap is found to be damaged, replace the cap and linebore the block.
E N G I N E – V 6
5. Cylinder head mounting surface for flatness,

using a precision straight edge and feeler
gage (figure right).
- Set the straight edge on the sealing surface
to be inspected.
- Take the feeler gage and at various
locations, check the gap between the
straight edge and the sealing surface.
- If the gap is greater thau 0.05 mm (0.002
in.) within 152 mm (6 in.) at any sealing
location, the block must be replaced.
- If the gap is found to be less than 0.05mm(0.002in.) at any sealing location and a cause
for leakage is suspected, then the minor irregularities may be carefully machined from the
block.
6. Oil pan, timing cover, and intake manifold mounting surfaces for nicks. Minor irregularities
may be cleaned up with a flat file.
15 CYLINDER BORE
02 Inspect
26 • Cylinder bores for scoring or other damage.
• Cylinder bore taper and out-of-round.
MEASURING CYLINDER BORE TAPER

AND OUT-OF-ROUND
Tool requiredz
58087 Cylinder Bore Gage (or equivalent)
! Important
If one or more cylinder bores are rough, scored or worn beyond limits, it will be
necessary to smooth or true up such bores to fit new pistons.
No attempt should be made to cut down oversize pistons to fit cylinder bored as this
will destroy the surface treatment and affect the weight. The smallest possible oversize
pistons should be used and the cylinder bores should be honed to size for proper
clearances.
• Refer to “Specifications” for tolerances.

• Set the gage so the thrust pin must be forced in about 7 mm (l/4 in.) to enter the gage in
the cylinder bore.
• Center the gage in the cylinder and turn the dial to “0”.
E N G I N E – V 6
• Carefully work the gage up and down to determine

taper and turn it to different points around the
cylinder wall to determine the out-of-round
condition. Measure the bore both parallel to and
at right angles to the engine centerline. Measure
at the top, middle, and bottom of the bore and
note the readings.
• Recondition the cylinder bore as necessary, as
outlined later.
CYLINDER BORE RECONDITIONING
• Measure the cylinder bore for out of round and

taper as
• Measure
outlined previously.
for wear at the top of the bore (point
15
“A”) and at the bottom (point “B”).
02
27
• Cylinder bores can be measured by setting the

cylinder gage dial at zero in the cylinder at the
point of desired measurement. Lock the dial
indicator at zero before removing from the
cylinder, and measure across the gage contact
points with an outside micrometer, with the gage
at the same zero setting when removed from the
cylinder (figure right).
E N G I N E – V 6
• If the cylinders are found to exceed the specified out-of-round or taper, honing or boring will
be necessary. Any cylinders that were found to have less than 0.13 mm (0.005 in.) wear or
taper may not entirely clean up when fitted to a high limit piston. If it is desired to entirely
clean up the bore in these cases, it will be necessary to rebore for an oversize piston. If more
than 0.13 mm (0.005in.)taper or wear,they should be bored and honed to the smallest oversize
that will permit complete resurfacing of all cylinders.
• Fine vertical scratches made by ring ends will not, by themselves, cause excessive oil
consumption; therefore, honing to remove them is unnecessary.
• Make sure the honing stones are clean, sharp, and straight Move the hone slowly up and
down to produce a 46 to 66 degree crosshatch pattern. Clean the bore thoroughly with soap
and water.Dry and rub in clean engine oil,then re-measure.
• If honing is not required, the cylinder bores should be cleaned with a hot water and detergent
wash. Apply clean engine oil to the bore after cleaning.
BORING
• Before the honing or re-boring operation is started, measure all new pistons with the micrometer
15 contacting at points exactly 90 degree from the piston pin centerline.
Some pistons must be measured at a specified distance from the piston crown. Refer to the
02 proper section for additional instructions. Then select the smallest piston for the first fitting. The
slight variation usually found between pistons in a set may provide for correction in case the
28
first piston is fitted too loose.
• Before using any type of boring bar, the top of the cylinder block should be filed to remove
any dirt or burrs. This is very important. If not checked, the boring bar may be tilted which
would result in the rebored cylinder wall not being at right angles of the crankshaft.
• The instructions furnished by the manufacturer of the equipment being used should be carefully
followed.
• When reboring cylinders, all crankshaft bearing caps must be in place and tightened to the
proper torque to avoid distortion of the bores in the final assembly. Always make sure the
crankshaft is out of the way of the boring cutter when boring each cylinder.
Crankshaft bearings and other internal parts must be covered or taped to protect them during
the boring or honing operation.
• When taking the final cut with a boring bar, leave 0.025 mm (0.001 in.) on the diameter for
finish honing to give the required position to the cylinder clearance specifications. (The honing
or boring operation must be done carefully so the specified clearance between pistons, rings,
and cylinder bores is maintained).
HONING
1. When honing the cylinders, follow the hone manufacturer’s recommendations for use, cleaning,
and lubrication during honing. Use only clean, sharp stones of the proper grade for the amount
of material to be removed. Dull, dirty stones cut unevenly and generate excessive heat. When
using coarse or medium grade stones, use care to leave sufficient metal so that all stone
marks may be removed with the fine stones used for finishing to provide proper clearance.
2. Occasionally, during the honing operation, the cylinder bore should be thoroughly cleaned and
the piston selected for the individual cylinder checked for correct fit.
3. When honing to eliminate taper in the cylinder, full strokes of the hone in the cylinder should
be made in addition to checking measurement
Copyrighted Material at the top, middle and bottom of the bore
repeatedly. Intended for CLARK dealers only
E N G I N E – V 6
! NOTICE
Handle the pistons with care and do not attempt to force them through the cylinder until
the cylinder has been honed to the correct size as the piston can be distorted through
careless handling.
4. When finish honing a cylinder bore to fit a piston, the hone should be moved up and down at
a sufficient speed to obtain very fine uniform surface finish marks in a crosshatch pattern at
the specified angle of 45” to 65’.
5. The finish marks should be clean but not sharp,free from imbedded particles and torn or folded
metal.
6. By measuring the piston to be installed at the sizing point specified in the propersection, and
adding the average of the clearance specification, the finish hone cylinder measurement can be
determined. It is important that the block and the piston be measured at room tempemture.
7. It is of the greatest importance that refinished cylinder bores are trued up to have the less
than specified out-of-roundtaper. Each bore must be final honed to remove all stone or cutter
marks and provide a smooth surface.
15
8. Refer to “Specifications” in the proper section piston to bore clearance tolerances.
9. After final honing and before the piston is check for fit, clean the bores with hot water and
detergent. Scrub with a stiff bristle brush and rinse thoroughly with hot water. It is essential
that a good cleaning operation be performed. If any of abrasive material is allowed to remain 02
in the cylinder bores, it will wear the new rings and cylinder bores in addition to the bearings
29
lubricated by contaminated oil. After washing, the dry bore should then be brushed clean with
a power-driven fiber brush.
10. Permanently mark the piston for the cylinder which it has been fitted.
11. Apply clean engine oil to each bore to prevent rusting.
! NOTICE
For steps 2,4,5, and 6, refer to “Notice” on page 1.
Install or Connect
1. Front oil gallery plugs (86).
! Important
Coat plug outside diameter with sealant (GM P/N 1052080) or equivalent.
2. Rear oil gallery plugs (87,88, and 90).
Tighten
• Plug (87) to 30 N·m (22 lbs. ft.).
• Plug (88) to 40 N·m (30 lbs. ft).
• Plug (90) to 40 N·m (30 lbs. ft.).
3. Camshaft and balance shaft cup plugs (89) to proper depth.
! Important
Coat plug outside diameter with sealant (GM P/N 1052080) or equivalent.
E N G I N E – V 6
4. Oil filter adapter, gasket, and bolts.
Tighten
• Bolts to 22 N·m (16 lbs. ft.).
5. Coolant drain plugs.
Tighten
• Plugs to 20 N·m (15 lbs. ft.)
6. Oil pressure fitting and sensor.
Tighten
• Fitting to 11 N·m (97 lbs. in.) plus tmn for alignment if necessary.
PISTON DISASSEMBLY
15 ! NOTICE
The connecting rod, bearing and cap need to be stored together as mating parts, so
02 they may be reassembled in the same position from which they were removed.
30
1. Upper compression ring

2. Lower compression ring
3. Expander
4. Upper rall
5. Lower Rail
E N G I N E – V 6
Tool Required:
J 24086-B Piston Pin Remover and Jnstaller
1. Piston rings. In most cases,the rings should be
discarded and replaced with new ones at
assembly.
2. Connecting rod bearing inserts. If the inserts are
to be reused, place them in a rack so they may
be reinstalled in their original connecting rod and
cap.
3. Piston pin.
• Place the piston/connecting rod on support fixture
J2408620. Make sure the connecting rod is fully
supported.
• Press out the piston pin.
Clean
1. Piston.
15
• Remove all varnish and carbon deposits. Do not 02
use a wire brush 31
• Remove the carbon from the ring grooves.
• Oil control ring groove holes.
Inspect
1. Piston pin bore in the piston and connecting rod.

Check for scuffing, burrs, etc.
2. Piston for scratches wear, etc.
3. Connecting rod for cracks, nicks, etc. If a
suitable jig is available, check the connecting rod
for a bent or twisted condition.
4. Piston.
• Ring land for cracking, wear, etc.
• Ring grooves for burrs, nicks, etc.
• Skirts and pin bosses for cracking.
• Skirts for scuffing.
5. Connecting rod bearing inserts for scratches or
deep pitting.
MEASURING PISTON PIN TO PISTON

CLEARANCE
Measure
1. Piston pin diameter. Check against

“Specifications.” Copyrighted Material
E N G I N E – V 6
2. Piston pin to piston clearance.

• Measure the piston pin hole diameter.
• Subtract the piston pin diameter from the piston
pin hole diameter to obtain the clearance.
• Replace the piston and piston pin if the
clearance exceeds specifications. The piston
and piston pin are a matched set and not
available separately.
PISTON SELECTION
1. Check the used piston to cylinder bore

clearance.
Measure
15 • Cylinder bore diameter Use a telescoping bore

gage, located 63.5 mm (2.5 in.) below the top
of the cylinder bore.
02 • Piston diameter. Measure the piston skirt at a
32
right angle to the piston pin, at the centerline
of the piston pin.
• Subtract the piston diameter from the cylinder
bore diameter to determine piston to bore
clearance.
• Refer to “Specifications” in the proper section.
Determine if the piston clearance is in the
acceptable range.
2. If the used piston is not acceptable, deter-
mine it a new piston will fit the cylinder bore.
3. If a new piston does not bring the clearance
within tolerances, the cylinder bore must be
reconditioned.
4. Mark the piston to identify the cylinder for
which it was fitted.
E N G I N E – V 6
PISTON ASSEMBLY
ASSEMBLING THE PISTON AND CONNECTING ROD
Tool Required
J 24086-B Piston Pin Remover and Installer Set
Install or Connect
1. Piston and connecting rod.

• The valve cutouts in the piston crown must be opposite the connecting rod bearing tangs.
• Lubricate the piston pin holes in the piston and connecting rod with engine oil.
• Install the pin guide to hold the piston and connecting rod together. Be sure to use the proper
pin guide. Refer to the instructions supplied with the tool.
2. Piston pin.
• Insert the piston pin into the piston pinhole.
• Place the assembly on the support fixture.
• Adjust the piston pin installer (J24086-9) to the correct length, using the letter number scale on
15
the installer adjuster. This is necessary to ensure that the piston pin is pressed into the piston
to the correct depth. Refer to the instructions supplied with the tool for the proper setting.
02
• Lock the adjuster in place with the lock ring. 33
! NOTICE
After the installer hub bottoms on the
support assembly, do not exceed, 35,000
kPa (5,000 psi) pressure, as this could cause
damage to the tool.
• Place the adjuster in the support future. Press the

piston pin into place (until the adjustable installer
bottoms in the support fixture).
• Remove the piston and connecting rod assembly
from the tool and check the piston for freedom of
movement on the piston pin.
A. Press Ram
B. Adjustable Installer J24096-9
C. Support Fixture J24096-20
D. Connecting Rod Support J24096-l 1
E. Pin Guide
F. Lock Ring
G. Adjuster
H. Number Scale
E N G I N E – V 6
INSTALLING THE PISTON RINGS
Measure
1. Ring end gap as follows:

• Select rings comparable in size to the piston
being Used.
• Slip the compression ring into the cylinder bore
and press it down about 6.35mm (0.250 in.)
above ring travel.
Make sure the ring is square with the cylinder
wall.
• Measure the space or gap between the ends
of the ring with a feeler gage.
• Refer to “Specifications” in the proper section
for correct gap.
15 • If the gap between the ends of the ring is not

as specified, remove the ring and try another
for fit.
02
34 Inspect
1. Ring fit as follows:

• Fit each compression ring to the piston on
which it is going to be used.
• Slip the outer surface of the top and second
compres-sion ring into the respective piston
ring groove, to make sure that the ring is free.
If binding occurs at any point, the cause should
be determined. If binding is caused by the ring
groove, correct by depressing the groove with
a fine cut file. If the binding is caused by a
distorted ring, try a new ring.
E N G I N E – V 6
Assemble
! NOTICE
All compression rings are marked on the upper side of the ring. When installing the
compression rings, make sure the Marked side is toward the top of the piston
! NOTICE
The oil control rings are three piece types,consisting of two rails and an expander.
1. Expander.
2. Lower rail.
3. upper rail.
4. Upper compression ring.
5. Lower compression ring.
• Flex all rings to make sure they are free. If binding occurs at any point the cause should be
determined. If binding is caused by the ring groove, correct by dressing the groove with a fine
cut file. If binding is caused by a distorted ring, try a new ring.
– Ring gaps must be 180° apart.
15
– Rail gaps must be 180° apart.
02
Measure 35
• Ring clearance. Use a feeler gage. Compare with

“Specifications” in the proper section.
E N G I N E – V 6
NTAKE AND EXHAUST MANIFOLDS
Clean
• Mating surfaces on intake manifold and cylinder

head.
• Excessive carbon buildup in the exhaust
passages of the intake manifold.
• Scale and deposits from the coolant passages
of the intake manifold.
• EGR passage of excessive carbon deposits.
Inspect
• Manifolds for cracks, broken flanges, and
15 gasket surface damage.

• Alignment of manifold flanges. Use a straight
edge and feeler gage. If the flanges do not
02 align, the manifold is warped and should be
36 replaced.
CAMSHAFT
! Important
Do not attempt to repair the camshaft, replace it if damaged.
Whenever the camshaft is replaced, a new set of lifters must also he installed.
Inspect
• Bearing surfaces and lobes for wear

• Sprocket.
• Keyway and threads.
– Galling
– Gouges
– Overheating
• Camshaft journal diameters, Refer to “Engine
Specifications” in the back of this section for
proper diameters.
E N G I N E – V 6
CAMSHAFT BEARINGS
CAMSHAFT BEARING REPLACEMENT
Inspect
• Camshaftbearings for scratches,pits, or loose fit in
their bores. Replace the camshaft bearings if
necessaty.
Tool Required
J 6098-01 Camshaft Bearing Remover and Installer
A. Bearing Tool C. Nut
1. Rear camshaft plug. B. Pilot D. Puller Screw
2. Inner camshaft bearings. Use J 6098-01.
• Insert the pilot into the front camshaft bearing bore.
• Slide the puller screw, with the nut and washer, through the pilot.
• Insert the bearing tool into the inner camshaft bearing bore with the shoulder of the tool against
15
the bearing.
• Hold the puller screw with a wrench.Turn the nut with a second wrench to pull the camshaft
02
bearing from its bore. 37
• Repeat this procedure to remove the remaining inner camshaft bearings. Note that the rear inner
bearing must be removed with the pilot fitted into the rear camshaft bearing.
3. Outer camshaft bearing. Use J 6098-01.
• Assemble the bearing tool and driver handle.
• Drive the outer camshaft bearings out of the block.
Clean
• Camshaft bearing bores in the block
Install or Connect
Tool Required
J 6098-01 Camshaft Bearing Remover andInstaller
A. Bearing Tool B. Driver Handle
E N G I N E – V 6
! NOTICE
The outer camshaft bearings must be installed first. These bearings serve as guides
for the pilot, and help center the inner bearings during the installation process.
! NOTICE
Besure to fit the correct cam bearing into the bore. The cam bearing bores vary in
size.
1. Outer camshaft bearings. Drive the bearings

into place using J 6098–01.
! Important
Make sure the camshaft bearing hole (or
holes) align with the oil hole (or holes)
in the block. On some engines, the oil
holes may be difficult to see. If so, use
a piece of 2 mm rod to check alignment.
15 Check camshaft bearing oil hole alignment
02
2. Inner camshaft bearing. Use tool J 6098-01.
38
• Assemble the tool with the pilot engaged in the front bearing and the pilot flange against
the front face of the block.
• Slide the puller screw, with nut and washer, through the pilot.
• Place the new bearing on the bearing tool. Hold the bearing tool and bearing against the
bearing bore.
Align the bearing oil hole with the oil hole in the block.
• Thread the puller screw into the bearing tool enough to hold the tool and bearing in place.
Holding the puller screw with a wrench, turn the nut with a second wrench to pull the
camshaft bearing into place.
• Holding the puller screw with a wrench, turn the nut with a second wrench to pull the
camshaft into place.
• Remove the puller screw, pilot, and bearing tool.
! Important
Make sure the camshaft bearing hole (or holes) align with the oil hole (or holes) in
the block. If it is difficult to see the alignment, use a piece of brass rod as described
in step 1.
3. Camshaft rear plug.

• Coat a new camshaft plug with sealer (Loctite #592 or equivalent).
• Install the plug flush to 0.80 mm (0.03125 in) deep.
E N G I N E – V 6
TIMING CHAIN AND SPROCKETS
Inspect
• Sprockets for chipped teeth and wear.

– Excessively worn sprockets will rapidly wear a new chain.
• Timing chain for damage.
– An excessively worn chain will rapidly wear a new set of sprockets.
CRANKSHAFT SPROCKET REPLACEMENT
Tool Required~
5825-A Crankshaft Sprocket Puller
5590 Crankshaft Sprocket installer
1. Crankshaft sprocket using 5825–A.
15
2. Key (if necessary). 02
J5825–A
39
Install or connect
1. Key (if removed).
2. Crankshaft sprocket using 5590.
J5590
Installing the crankshaft sprocket
E N G I N E – V 6
FRONT COVER
Clean
• Old gasket from the gasket surfaces.
Inspect
• Front cover for damage, dents, or cracks.
1. Oil seal from the front cover.
• Pry the seal out with a large screwdriver.
• Be careful not to distort the front cover.
Install or Connect
Tool Required:
15 J 35468 Front Cover Aligner aud Oil Seal
Installer
02
40 1. New seal so that the open end of the seal
is toward the inside of the cover.
• Support the cover at the seal area.
• Drive the seal into position with 35468.
Lubricate the seal with engine oil before
installing the torsional damper.
Installing oil seal (Cover removed)
COOLANT PUMP
Clean
• All gasket mating surfaces. Be sure old gasket material is removed and free of oil or other
foreign materials.
! NOTICE
Do not immerse the pump in solvent. The solvent may enter the pump’s permanently
lubricated bearings and cause premature bearing failure.
Inspect
• Coolant pump shaft for rotation and end play. The shaft and fan hub should turn straight and
smoothly. If the hub wobbles or the shaft is noisy or feels “lumpy” when turned, replace the
coolant pump. If the shaft end play exceeds 0.381 mm (0.015 in), replace the coolant pump.
• Coolant pump body at the drain (weep) hole. Slight staining around the weep hole is normal.
Replace the coolant pump only if coolant is dripping from the weep hole while the engine is
running or while the system is pressurized.
E N G I N E – V 6
OIL PAN AND ROCKER ARM COVERS
Clean
• Parts in solvent. remove all sludge and varnish.
• Old gaskets from the gasket surfaces.
Inspect
• Rubber grommets and parts on the rocker arm cover for deterioration.
• Oil pan for rock damage or cracks.
• Oil pan baffle for lack of fit.
• Drain plug threads for stripping.
OIL PUMP
1. Shaft Extension (1).
! Important
15
• Do not remove pickup pipe and screen unless replacement is required. 02
• The pickup pipe has a press fit in to the pump cover. 41
• Do not remove the screen from the pipe. The pickup screen and pipe are serviced as
a complete assembly only.
2. Pickup pipe and screen (10).

3. Screws (9).
4. Pump cover (5).
! Important
Mark where the idler gear (4) and drive gear (3) mesh together, so they can be reinstalled
with the same gear teeth indexed.
5. Idler gear (4) and drive gear (3).

6. Retaining pin (8).
7. Pressure regulator spring (7).
8. Pressure regulator valve (6).
1. Shaft extension
2. Pump body
3. Drive gear and shaft
4. Idler gear
5. Pump cover Oil pump components
6. Pressure regulator valve
7. Pressure regulator spring
8. Retaining pin
9. Screws
10. Pickup screen and pipe Intended for CLARK dealers only
E N G I N E – V 6
Clean
• All parts in clean solvent and dry them with compressed air.
Inspect
• Pump body (2) for cracks, wear, or other damage.
• Inside of the cover (5) for cracks and wear that would permit oil to leak past the ends of the
gears.
• Gears (3 and 4) for wear.
• Drive gear and shaft (3) for lack of fit in the pump body (2).
• The pump gears, cover, and body are not serviced separately.
If any of the parts are damaged or worn, the entire oil pump assembly must be replaced.
• Pickup screen and pipe (10) for damage to the screen or loose fit of the pipe.
• Pressure regulator valve (6) for fit. The regulator valve should slide freely in its bore without
sticking or binding.
15 Install or Connect
02 Tool Required
42 21882 Rickup Tube and Screen Installer.
J21882
1. Pressure regulator valve (6) into the pump
cover.
2. Pressure regulator spring (7) into the pump
cover.
3. Retaining pin (8) into the pump cover.
4. Drive gear and shaft (3) into the pump body.
5. Idler gear (4) into the pump body.
Installing the oil pump screen

! Important
Match together the index marks on the
two gears made during disassembly.
6. Pump cover (5).
! NOTICE
Refer to “Notice” on page 15–02–1.
7. Screws (9).
E N G I N E – V 6
Tighten
• Screws to 9 N·m (80 lbs·in)
Inspect
• With the shaft extension (1) installed on the pump, turn the drive shaft by hand to check for
smooth operation.
! NOTICE
Be careful of twisting, shearing, or collapsing the pipe when installing it to the pump.
A damaged pipe can cause lack of lubrication and engine failure.
8. Pickup screen and pipe.

• If the pickup screen and pipe assembly was removed, it should be replaced with a new part.
Loss of press fit condition could result in an air leak and loss of oil pressure.
• Mount the oil pump in a soft-jawed vise.
• Apply sealer to the end of the pipe.
• Tap the pickup screen and pipe into place, using 21882 and a hammer.
• The pump screen must be parallel with the bottom of the oil pan when installed.
15
9. Oil pump drive shaft and connector (1).
02
43
VALVE TRAIN COMPONENTS
• Store all reusable components in an exact order, so they may be reassembled in the same position
from which they were removed.
PUSHRODS, ROCKER ARMS, BALLS, AND NUTS
Clean
• All parts in clean solvent and dry them with compressed air.
• Make sure the oil passages through the pushrods are clear.
Inspect
• Rocker arms and balls at their mating surfaces. These surfaces should be free from wear or
damage.
• Rocker arm areas that contact the valve stems and the socket areas that contact the ends of
the pushrods. These areas should be free of wear or damage.
• Rocker arm nuts.
• Pushrod ends for scoring, roughness, or bends.
– Roll the pushrod on a flat surface to determine its straightness. If the rod is bent, the rod will
not roll freely. Replace if necessary.
E N G I N E – V 6
HYDRAULIC LIFTERS
The type of hydraulic lifters used in this engine are the roller type. Hydraulic litters are serviced
only as an assembly. No internal parts are available.
! Important
• Service is limited to a disassembly and cleaning. Discard any valve lifter(s) that are
worn.
• Whenever the camshaft needs to be replaced, a new set of hydraulic lifters must also
be installed.
CYLINDER HEAD
DISASSEMBLY
Tool required
15 J 8062 Valve Spring Compressor

J8062
Remove or disconnect
02
44 1. Valve keepers (67).
• Compress the springs with 8062 (figure 46).
• Remove the keepers (67).
• Remove J 8062.
2. Intake valve components.

• Cap (68).
• Shield (69). Compressing the valve springs
• Seal (71).
• Damper (72).
• Spring (73).
3. Exhaust valve components.

• Rotator (75)
• Shield (69).
• Seal (71).
• Damper (72).
• Spring (73).
67. Valve keeper 73. Spring

68. Cap 74. Intake valve
Valves and components
69. Shield 75. Rotator
70. O–ring seal 76. Exhaust valve
71. Seal
! Important
• Place the valves (74 and 76) in an organizer rack so they can be replaced in their
original position at reassembly.
E N G I N E – V 6
CLEANING AND INSPECTION
Clean
Tools Required
J 8089 Wire brush
J 8101 Valve Guide Cleaning Tool
• Carbon from the combustion chambers. Use J 8089.

• Valve guides. Use J 8101.
• Valve stems and heads on a wire wheel.
• Carbon and old gasket from the cylinder head gasket surface.
J8089
J8101
15
02
45
Cleaning the combustion chambers Cleaning the valve guides
Inspect
• Cylinder head for cracks in the exhaust ports, combustion chambers, or external cracks to the
coolant chamber.
Gasket surfaces should be free of damage.
• Valves for burning, pitting, or warpage. Refer to “Valve Grinding.”
• Check the valve stems for scoring or excessive wear. Stems must not be bent.
• Rocker arm studs for wear, damage, or improper fit.
• Valve seats for pitting or other damage. Grind or reface as needed.
• Rotators. The rotators should rotate smoothly without binding
E N G I N E – V 6
Measure
Tools required
J8001 Dial Indicator (or equivalent)
J9666 Valve spring tester
1. Valve stem to guide bore clearance.
! NOTICE:
Excessive valve stem to guidebore
clearance will cause excessive oil
consumption and may cause valve
break–age. Insufficient clearance will
result in noisy and sticky functioning of
the valve and disturb the engine’s
smoothness.
15
02 Measuring stem-to-bore clearance
46
• Clamp a dial indicator (J 8001 or equivalent)
on one side of the cylinder head rocker arm
cover gasket rail.
• Locate the indicator so movement of the
valve stem from side to side (crosswise to
the head) will cause direct movement of the
indicator stem. The indicator stem must
contact the side of the valve stem just above
the valve guide bore.
• Drop the valve head about 1.6 mm (0.0625
in) off the valve seat.
Measuring valve spring tension
• Move the stem of the valve from side to side
using light pressure to obtain a clearance
reading. If clearance exceeds specifications,
it will be necessary to ream the valve guide
bores for oversize valves as outlined later in
this manual.
3. Valve spring length. Replace the spring if the

length is not as specified.
Intended for CLARK dealers only Measuring valve spring length
E N G I N E – V 6
REPAIR
Valve Grinding
Pitted valves must be refaced to the proper angle.
Valve stems that show excessive wear, or valves
that are warped excessively must be replaced.
When an excessively warped valve head is refaced,
a knife edge will be ground on part or all of the
valve head due the amount of metal that must be
removed to completely reface. Knife edges lead to
breakage, burning, preignition due to heat localizing
on this knife edge.
If the edge of the valve head is less than 0.80 mm
(0.032 in) after grinding, replace the valve.
Valve head measurement
Several different types of equipment are available for refacing valves. The recommendation of the
manufacturer of the equipment being used should be carefully followed to attain the proper results.
Refer to “Specifications” for valve face angle specifications.
15
02
Valve Seat Grinding 47
Reconditioning the valve seats is very important because the seating of the valves must be perfect
for the engine to deliver the power and performance built into it.
Another important factor is the cooling of the valve head. Good contact between each valve and
its will ensure that heat will be properly carried away.
Several different types of equipment are available for reseating valve seats. The recommendations
of the manufacturer of the equipment being used should be carefully followed to attain proper
results.
Regardless of what type of equipment is used, it is essential that valve guide bores be free from
carbon or dirt to ensure proper centering of the pilot in the guide. Refer to “Specifications” for valve
seat angle specifications.
Reaming Valve Guides

The valve guides used in this engine are simply
holes bored in the cylinder head Therefore, the
valve guides are not replaceable.
If the valve stem-to-bore clearance (as measured

previously in this manual) is excessive, the valve
guides should be reamed and a valve with an
oversize stem installed.
Intended for CLARK dealers onlyReaming the valve guides
E N G I N E – V 6
Available oversize valves are as follows (nominal dimensions are given):
• INTAKE : 0.08 mm (0.003 in)

0.38 mm (0.015 in)
0.76 mm (0.030 in)
• EXHAUST : 0.08 mm (0.003 in)
0.38 mm (0.015 in)
Select a reamer that will provide a straight, clean bore through the guide’s entire length. Reamer
availability is as follows (sixes given are nominal):
•J 5830–l 0.08 mm (0.003 in) oversize

•J 6621 0.13 mm (0.005 in) oversize
•J 5830–2 0.38 mm (0.015 in) oversize
•J 5830–3 0.76 mm (0.030 in) oversize
These reamers (except J 6621) also available in Reamer Set J 5830-02.
15 ROCKER ARM STUD REPLACEMENT

02 The 4.3L engine has screw-in rocker arm studs with positive stop shoulders. You must follow
48 the replacement procedures outlined below under “Screw-In Studs.” No valve adjustment is
necessary. When the valve train requires service, you simply tighten the rocker arm nuts to 27
N·m (20 lbs·ft).
Tools Required
J 5802–01 Rocker Arm Stud Remover
J 6880 Rocker Arm Stud Installer
E N G I N E – V 6
1. Rocker arm stud by unscrewing using J 5802-01.
! NOTICE
Refer to ‘Notice” on page 15–02–1.
Install or connect
1. Rocker arm stud using J 6880.
Tighten
• Rocker arm stud to 47 N·m (35 lbs·ft).
A J6880
15
02
49
Removing rocker arm stud Installing rocker arm stud
A. Nut
B. Flat Washer
E N G I N E – V 6
ASSEMBLY
Install or connect
1. Insert the valves(74 and 76) into the proper valve guides until the face of the valve contacts
the valve seat.
2. Seal (71) (intake valves only).
• Install the seal (71) over the valve stem.
• Hold the valve (74) against the valve seat.
• Push the seal (71) down the valve stem until it bottoms out against the head.
3. Springs (73) and dampers (72).
4. Shields (69).
5. Cap (68) or rotator (75).
! Important
Compress the valve spring using 8062, enough so the lower valve stem groove can
be seen clearly.
15 6. O–ring seal (70) onto the valve stem’s lower

groove, making sure the seal (70) is flat and
02 not twisted.
50 • Apply a small amount of grease to the area
of the upper valve stem groove.
• Assemble the two valve keepers into the
upper groove using the grease to hold them
in place.
• Release the compressor tool 8062, making
sure the valve keepers stay in place.
• Repeat the preceding steps on the Checking the valve seals
remaining valves.
Inspect
• O–ring seals for leakage.
– Place the suction cup supplied with 23738-A over the shield.
– Connect 23738–A to the suction cup and apply a vacuum.
– Watch the vacuum pump gage, no air should be able to leak past the seal.
– If the seal will not hold a vacuum, it may have been damaged or improperly installed.
– Repeat the preceding steps on the remaining valves.
Measure
• Valve spring installed height of each spring as follows :
1. Use an arrow thin scale. A cut away scale may be helpful.

2. From the top of the shim or the spring to the top of the shield.
3. If this measurement exceeds the amount given in “Engine Specifications,” install valve spring
seat shims, approximately 1.58750 mm (0.0625 in) thick, between the spring and cylinder head.
NEVER shim the spring so as to give an installed height under the specified amount.
E N G I N E – V 6
THERMOSTAT AND COOLANT OUTLET
1. Bolts.
2. Stud.
3. Coolant outlet.
4. Gasket.
5. Thermostat (with gasket).
Inspect
• Coolant outlet for cracks.
Install or Connect
1. Thermostat
2. New gasket.
3. Coolant outlet.
! NOTICE:
15
02
4. Bolt. 51
5. Stud
Tighten
• Bolts to 28 N·m (21 lbs·ft).
• Stud to 28 N·m (21 lbs·ft).
TORSIONAL DAMPER
Inspect
• Torsional damper weight for signs of shifting on the hub.
Replace as needed. Area of the torsional damper hub shaft that contacts the front crankshaft seal
for roughness or nicks. Replace the damper if this condition exists. If damper is replaced, new
balance weights of the same size must be installed on the new damper in the same location as
the old damper.
E N G I N E – V 6
CRANKSHAFT AND BEARINGS
Some engines may have rear main bearings that are 0.2032mm (0.008 in) wider than standard
across the thrust faces.
The crankshaft on these engines can be identified by 0.2032mm (0.008 in) stamped on the rear
counterweight.
Clean
• Crankshaft with solvent.
– Do not scratch the bearing journals.
– Remove all sludge from the oil passages with compressed air.
• Main bearing inserts.
– Wipe free of oil with a soft cloth.
Inspect
• Crankshaft for cracks.
15 – Use the magnaflux method, if available.

– Crankpins, main bearing journals and thrust surfaces scoring, nicks or damage caused by
lack of lubrication.
02 – Main bearing inserts for scoring or other damage.
52
Measure
• Main bearing and connecting rod journal diameters.
Compare with “‘Engine Specifications”
• Main bearing and connecting rod journals for taper and out-of-round.
• Maximum journal taper is 0.025 mm (0.001 in)
• Maximum out-of-round is 0.05 mm (0.002 in)
• Crankshaft run-out.
– Mount the crankshaft in V-blocks or between centers.
– Use a dial indicator.
– If the main journals are misaligned, the crankshaft is bent and must be replaced. The main
bearings must also be replaced at the same time.
• Grind or replace the crankshaft if necessary. In
general, the lower inserts (except the #1
bearing) show the greatest wear and distress
from fatigue. Upon inspection, if a lower insert
is suitable for reuse, it can be assumed that
the upper insert is also satisfactory. If a lower
insert shows evidence of wear or damage, both
the upper and lower inserts must be replaced.
Micrometer
Measuring the crankshaft journals
E N G I N E – V 6
ASSEMBLY OF THE ENGINE
Prior to assembly
The importance of cleanliness during the assembly procedure cannot be overstressed. Dirt will cause
premature wear of the rebuilt engine. Lubricate all moving parts lightly with engine oil or engine
assembly lubricant (unless otherwise specified) during assembly. This will provide initial lubrication
when the engine is started.
CRANKSHAFT AND MAIN BEARING INSTALLATION
Main bearings are of the precision insert type and do not use shims for adjustment. If clearances
are excessive, both upper and lower bearing inserts will be required. Service bearings are available
in standardize and 0.0254 mm (0.001 in), 0.0508 mm (0.002 in), 0.2286 mm (0.009 in), 0.254
mm (0.010 in) and 0.508 mm (0.020 in) undersize.
Selective fitting of both rod and main bearing inserts is necessary in production to obtain close
tolerances. For this reason you may find one half of a standard insert with one half of a 0.0127
mm (0.0005 in) undersize insert which will decrease the clearance 0.0127 mm (0.0005 in) from
using a full standard bearing.
15
Some engines may have rear main bearings that are 0.2032mm (0.008 in) wider than standard
02
across the thrust faces. If there rear main bearings are replaced, they must have the proper 53
distance between thrust faces to obtain proper distance between thrust faces to obtain proper
crankshaft end play.
INSPECTING CRANKSHAFT END PLAY
Install or Connect
! NOTICE
For steps 4 and 6, refer to “Notice” on page 15–02–1.
1. Upper main bearing inserts to the block.
! Important
If any undersized bearings are used, they must be fitted to the proper journals.
2. Crankshaft
Feeler gage
3. Lower main bearing inserts to the main bearing
caps.
Copyrighted MaterialMeasuring crankshaft end play

E N G I N E – V 6
MEASURING MAIN BEARING CLEARANCE
The simplest, most accurate way to measure main bearing clearance is with the use of gaging
plastic. This wax-like material compresses evenly between the bearing and journal surfaces
without damaging them. proceed as follows :
Clean
• All oil from the crankshaft journal and main bearing inserts.
Install or connect
1. Main bearing insert sand crankshaft.
2. Gaging plastic. Place gaging plastic
• Begin with the rear main bearing. parallel to crankshaft
• Wipe the oil from the crankshaft journal and
the lower main bearing insert.
• Place a piece of gaging plastic the full width
15 of the lower bearing insert (parallel to the

crankshaft) on the journal. Do not rotate the
crankshaf while the gaging plastic is between
02 the bearing and journal.
54
Placing the gaging plastic on the
bearing journal
3. Main bearing cap and bolts.
! NOTICE
Tighten
• Bolts to Specification.
• Main bearing cap. DO NOT REMOVE THE GAGING PLASTIC FROM THB JOURNAL OR
LOWER MAIN BEARING INSERT.
Measure
• Gaging plastic as follows:
– The flattened gaging plastic will be found
adhering to either the lower bearing insert or
journal.
– On the edge of the gaging plastic envelope
there is a graduated scale. Without removing
the gaging plastic, measure its compressed
width (at the widest point) with the Measure widest
point of gaging
graduations on the gaging plastic envelope.
plastic with
graduated scale
Intended for CLARK dealers only Measuring the gaging plastic
E N G I N E – V 6
– If the flattened gaging plastic tapers to ward the middle or ends, there is a difference in
clearance indicating taper, low spot or other irregularity of the bearing or journal. Be sure to
measure the journal with a micrometer if the flattened gaging plastic indicates more than 0.001 in.
difference.
– Normally main bearing journals wear evenly and are not out-of-round. However, if a bearing is
being fitted to an out-of-round journal, be sure to fit to the maxi-mum diameter of the journal.
If the bearing is fitted to the minimum diameter and the journal is excessively out-of-round,
interference between the bearing and the journal will result in rapid bearing failure.
– If the bearing clearance is within specifications, the bearing is satisfactory. lf the clearance is
not within specifications, replace the bearing. Always replace upper and lower inserts as a unit.
– A standard or undersize bearing may produce the proper clearance. Refer to the proper section
for bearing availability. If not, it will be necessary to regrind the crankshaft journal for use with
the next undersize bearing. After selecting a new bearing, recheck the clearance.
– Remove the flattened gaging plastic.
– Perform the preceding steps on the remaining main bearings.
MEASURING CONNECTING ROD BEARING CLEARANCE
Connecting rod bearings are of the precision insert type and do not use shims for adjustment. DO
15
NOT FILE RODS OR ROD CAPS. If clearances are found to be excessive, a new bearing (both 02
upper and lower halves) will be required. The simplest, most accurate way to measure connecting 55
rod bearing clearance is with the use of plastic gaging plastic.
This wax-like material compresses evenly between the bearing and journal surfaces without
damaging then. Proceed as follows:
Clean
• All oil from the crankshaft journal and connectingrod bearing inserts.
Install or Connect
1. Connecting rod with the upper connecting rod bearing insert to the crankshaft bearing journal.
2. A piece of gaging plastic the length of the bearing (parallel to the crankshaft) on the journal.
The plastic gage should be placed in the middle of the upper and lower bearing insert Bearings
are eccentric and false readings could occur if placed elsewhere.
! Important
If a bearing is being fitted to an out-of round
crankpin, be sure to fit the maximum Place gaging
diameter of the crankpin. If the bearing is plastic paralledl to
fitted to the minimum diameter and the crankshaft
crankpin is excessively out-of-round,
interference between the bearing and the
crankpin will result in rapid bearing failure.
Copyrighted MaterialPlacing the gaging plastic on the

connecting rod journal
E N G I N E – V 6
3. Connecting rod cap with the lower connecting rod bearing insert. DO NOT TURN THE
CRANKSHAFT WITH THE GAGING PLASTIC INSTALLED.
4. Connecting rod cap nuts.
! NOTICE
Refer to ‘Wotice” on page 15–02–1.
Tighten
• Nuts to “Specifications.” Refer to the proper section.
! Important
The gaging plastic will be found sticking to either the journal or lower connecting rod
bearing insert Do not remove it at this time.
Measure
• Gaging plastic at its widest point using the Measure
15 scale on the gaging plastic envelope.

• If the clearance exceeds specifications, select
a new, correct size, connecting rod bearing and
widest point
of gaging
plastic with
graduated
02 remeasure the clearance. scale
56 • A standard or undersize bearing may produce
the proper clearance. Refer to the proper
section for bearing availability.
Measuring the gaging
• Do not attempt to use shims or file the bearing to obtain the needed clearance.
• If the clearance cannot be brought to within specifications, recondition or replace the crankshaft.
1. Gaging plastic.
! Important
Apply engine oil to the main bearing inserts.
4. Main bearing caps (except rear cap) and bolts to the block.
Tighten
• Main bearing cap bolts (except mar cap) to 110 N·m (81 lbs·ft).
5. Rear main bearing cap.

6. Rear main bearing cap bolts.
E N G I N E – V 6
Tighten
• Rear main bearing cap bolts to 14 N·m (124 lbs·in).
Measure
• Crankshaft end play, as follows:

– Firmly thrust the crankshaft first rearward then forward. This will line up the rear main bearing
and crankshaft thrust surfaces.
Tighten
• The rear main bearing cap bolts to 110 N·m (81 Ibs·ft).
Measure
• With the crankshaft wedged forward, measure at the front end of the rear main bearing with a
feeler gage (figure 60). The proper clearance is 0.0635–0.4572 mm (0.0025–0.018 in).
15
02
! Important 57
• If correct end play cannot be obtained, be certain that the correct size rear main bearing
has been installed.
• Production engines may have rear main bearings that are 0.2032 mm (0.008 in) wider
across the thrust faces than standard.
Inspect
• Crankshaft for binding. Try turning the crankshaft to check for binding. If the crankshaft does not
turn freely, loosen the main bearing cap bolts one pair at a time until the tight bearing is located.
Burrs on the bearing cap, foreign matter between the insert and the block or the bearing cap, or
a faulty insert could cause a lack of clearance at the bearing.
Tighten
• All main bearing cap bolts to 110 N·m (81 lbs·ft).
E N G I N E – V 6
CRANKSHAFT REAR OIL SEAL RETAINER INSTALLATION
Clean
• Gasket surfaces on the block and seal retainer.
InstaIl or connect
1. New gasket (54) to the block.
! Important
It is not necessary to use sealant to hold
the gasket in place.
2. Seal retainer (52).

3. Screws (50) and nuts (51).
! NOTICE
15 Refer to “Notice” on page 15–02–1.
Crankshaft rear oil seal retainer
Tighten A. Rear of Block 52. Retainer

02 50. Screw 53. Stud
58 • Screws and nuts to 15 N·m (11 lbs·ft). 51. Nut 54. Gasket
E N G I N E – V 6
CRANK SHAFT REAR OIL SEAL INSTALLATION
Tool Required:
35621 Seal Installer
Install or Connect
1. Crankshaft rear oil seal.
• Lubricate the inner and outer diameter of the
seal with engine oil.
• Install the seal on 35621.
• Position 35621 against the crankshaft. Thread
the attaching screws into the tapped holes in
the crankshaft.
• Tighten the screws securely with a screwdriver.
This will ensure that the seal is installed
squarely over the crankshaft.
J35621
• Turn the handle until it bottoms.
• Remove 35621.
Installing the crankshaft rear oil seal
15
CAMSHAFT INSTALLATION
02
59
Camshaft and components
34. Nut 38. Sprocket, crankshaft

35. Stud 39. Bolt
36. Key 40. Sprocket, camshaft
37. Gear, balance shaft drive 41. Chain, timing
E N G I N E – V 6
Install or Connect
! Important
• Coat camshaft lobes and journals with a high quality engine oil supplement (GM
Engine Gil Supplement or equivalent).
• Apply engine oil supplement (GM P/N 1052367), or equivalent to all the teeth on the
distributor drive gear.
1. Two or three 7.9375 mm (0.3125 in – 18 pitch)

bolts 100 – 125 mm (3.937 in – 4.921 in) long
into the camshaft threaded holes. Use these
bolts to handle the camshaft threaded holes.
Use these bolts to handle the camshaft.
2. Camshaft to the engine. Handle the camshaft
carefully to prevent damage to the camshaft
bearings.
15
02 ! NOTICE Installing camshaft
60 Refer to “Notice” on page 15–02–1.
3. Camshaft retainer and retainer bolts.
Tighten
• Bolt to 14 N·m (124 lbs·in).
BALANCE SHAFT INSTALLATION
! NOTICE
For steps 3,4, and 6, refer to “Notice” on page 15–02–1.
Tools Required :
38834 Balance Shaft Bearing Service Kit
36996 Balance Shaft Installer
8092 Driver Handle
36660 Torque/Angle Meter
E N G I N E – V 6
15
02
61
Installing balance shaft and components
42. Driven Gear 47. Balance Shaft

43. Retainer 46. Bolt
46. Bearing 49. Bolt
46. Plug
Install or Connect
1. Balance shaft rear bearing (45) using 38834.
2. Balance shaft (47) into block using 36996 and 8092.
• Dip the front balance shaft bearing into clean engine oil before assembly.
• Retaining ring on balance shaft front bearing must be seated on case.
3. Install balance shaft bearing retainer (43) and bolts (48).
Tighten
• Balance shaft retainer bolts (48) to 14 N·m (124 lbs·in).
• Balance shaft driven gear (42) and bolt (49).
Tighten
• Balance shaft driven gear bolt (49) to 20 N·m (15 lbs·ft) plus an additional turn of 35 degrees
using 36660.
E N G I N E – V 6
! Important
• Rotate balance shaft (47) by hand to make sure there is clearance between the balance
shaft (47) and retainer (43). If balance shaft (47) does not rotate freely, check to be
sure retaining ring on front bearing is seated on case.
• Turn the camshaft so, with the balance shaft drive gear temporarily installed, the
timing mark on the drive gear is straight up.
• With the balance shaft drive gear removed, turn the balance shaft so the timing mark
on the driven gear points straight down.
5. Balance shaft drive gear (37) onto camshaft.
! Important
Make sure the timing marks on the balance shaft drive gear and driven gear line.
6. Balance shaft drive gear bolt.
Tighten
15 • Bolt to 16 N·m (12 lbs·ft).
02
62
E N G I N E – V 6
TIMING CHAIN AND SPROCKET INSTALLATION
Install or Connect
1. Camshaft sprocket and timing chain.
! Important
• Line up the tuning marks on the camshaft
sprocket and crankshaft sprocket.
• The number 4 cylinder is at top dead center
of the compression stroke with the timing
marks in this position.
Camshaft–to–crankshaft timing marks
2. Camshaft sprocket bolts (39) and nut (34). 15

Tighten 02
• Camshaft sprocket bolts (39) and nut (34) to 28 N·m 63
FRONT COVER INSTALLATION
! NOTICE
1. Front cover gasket to the front cover.

• Use gasket cement to hold the gasket in place.
2. Front cover to the engine.
! NOTICE
3. Front cover bolts.
Tighten
• Front cover to block bolts to 14 N·m (124 lbs·in).
E N G I N E – V 6
TORSIONAL DAMPER INSTALLATION
Tool Required :
39046 Torsional Damper Ruller and Installer
Install or Connect
1. Crankshaft key (if removed).
! NOTICE :
The inertial weight section of the
torsional damper is assembled to the hub
with rubber type material. The correct
installation procedures with the proper
tool) must be followed or movement of
the inertial weight section of the hub will
destroy the tuning of the torsional
15 damper.
2. Stud (item A.,) to the crankshaft. Thread the

02 stud fully into the tapped hole in the
Installing the torsional damper
64 crankshaft.
3. Torsional damper over the end of the stud. Align the key way in the torsional damper shaft
with the crankshaft
4. Bearing, washer, and nut.
• Turn the nut to pull the vibration damper into place.
• Remove the tool.
! NOTICE :
5. Torsional damper bolt and washer.
Tighten
• Bolt to 95 N·m (70 lbs·ft).
E N G I N E – V 6
PISTON AND CONNECTING ROD INSTALLATION
CONNECTING ROD BEARING SELECTION
Tools required :
5239 Connecting Rod Guide Set
8037 Ring Compressor
36660 Torque/Angle Meter
Connecting rod bearings are of the precision insert type and do not use shims for adjustment. DO
NOT FILE RODS OR ROD CAPS.
! Important
• If clearances are excessive, install a new bearing. Service bearings are available in standard
size and 0.050 mm (0.002 in), 0.254 mm (0.010 in), 0.508 mm (0.020 in), undersize for use
with new and used standard size crankshafts.
• Lubricate the cylinder walls lightly with engine oil.
• Make sure the piston is installed in the matching cylinder. 15
02
Install or connect 65
1. connecting rod bearings.
• Make sure that the bearing inserts are of the
proper size.
• Install the bearing inserts in the connecting rod
and connecting rod cap.
• Lubricate the bearings with engine oil.
Guiding the connecting rod
2. Piston and connecting rod into the proper bore.

• With the connecting rod cap removed, install
5239 onto the connecting rod bolts
• Locate the piston ring end gaps. Lubricate the
piston and rings with engine oil.
A. Oil ring rail gaps

B. 2nd compression ring gap
C. Notch In piston
D. Oil ring spancer gap Piston ring end gap location
(Tang in hole or slot with arc)
E. Top compression ring gap
E N G I N E – V 6
• Without disturbing the ring end gap location,

install 8037 over the piston.
• The piston must be installed so that the
notch in the piston faces the front of the
engine.
• Place the piston in its matching bore. The
connecting rod bearing tang slots must be
on the side opposite the camshaft. Using
light taps with a hammer handle, tap the
piston down into its bore. Guide the
connecting rod to the crankpin with 5239.
Hold the ring compressor against the block
until all rings have entered the cylinder bore.
• Remove 5239 from the connecting rod bolts. Installing the piston
! Important
Each connecting rod and bearing cap should be marked, beginning at the front of the
15 engine. Cylinders 1, 3, and 5 are the right bank and 2, 4, and 6 are the left bank
(when viewed from the front of the engine). The numbers on the connecting rod and
bearing cap must be on the same side when installed in the cylinder bore. If a
02 connecting rod is ever transposed from one block or cylinder to another, new
66 connecting rod bearings should be fitted and the connecting rod should be numbered
to correspond with the new cylinder number.
! NOTICE
3. Connecting rod cap with bearing insert and nut.
Tighten
• Connecting rod bolt nuts to 27 N·m (20 lbs·ft).
• Connecting rod bolt nuts an additional 70° using 36660.
Measure
• Connecting rod side clearance. The proper
clearance is 0.15–0.35 mm (0.006–0.014 in).
Measuring connecting rod side clearance

E N G I N E – V 6
OIL PUMP INSTALLATION
Install or Connect
1. Oil pump to the engine.
• Align the slot in the oil pump shaft with the tang on the distributor shaft
• The oil pump should slide easily into place.
• No gasket is used.
! NOTICE:
2. Oil pump to main bearing cap bolt.
Tighten
• Oil pump to main bearing cap bolt to 88 N · m (65 lbs· f t )
OIL PAN INSTALLATION

15
02
! Important 67
Apply RTV (GM P/N 12346141) or equivalent
to the front cover to block joint and to the
crankshaft rear retainer seal to block joint.
Apply the sealant about 25 mm (1.00 in) in
both directions from each of the four
comers.
1. Oil pan gasket (27) to the block.

2. Oil pan (29) to the gasket (27).
3. Reinforcements (28). Oil pan sealant
E N G I N E – V 6
! NOTICE
4. Oil pan clips, bolts (83), nuts (82), and studs (84).
15
02
68
Oil pan and components
Tighten
• Bolts (83) and studs (84) to 11 N·m (97 lbs·in).
• Four corner nuts (82) to 23 N·m (17 lbs·ft).
E N G I N E – V 6
CYLINDER HEAD INSTALLATION
INSTALL OR CONNECT
Clean
• Gasket surfaces on the block and cylinder head.
1. Head gasket.
! Important
• Do not use sealer on composition gaskets.
• Place the gasket over the block dowel pins.
2. Cylinder head Carefully guide the cylinder head into place over the dowel pins and gasket.
! NOTICE
15
3. Cylinder head bolts. Coat threads of the cylinder
head bolts with sealing compound (GM P/N
02
69
1052080) or equivalent and install finger-tight.
Cylinder head bolt tightening sequence

Tighten
• Cylinder head bolts in three steps.
– The first sequence to 34 N·m (25 lbs·ft).
– The second sequence to 61 N·m (45 lbs·ft).
– Final torque sequence to 90 N·m (65 lbs·ft).
4. Engine lift bracket.
E N G I N E – V 6
VALVE TRAIN COMPONENT INSTALLATION
Install or connect
! Important
• Replace all hydraulic lifters, change the engine oil and filter and add GM Engine oil
supplement to the engine oil whenever a new camshaft is installed.
• Lubricate the hydraulic lifter bodies and feet with engine oil supplement.
15
02
70
1. Hydraulic lifters to the block
2. Guide assembly.
Valve train components
Tighten
• Guide assembly bolts to 16 N·m (12 lbs·ft).
3. Pushrods.
• Seat the pushrods into the socket of the hydraulic lifters.
• Coat mating surfaces of the rocker arms (23) and balls (22) with engine oil supplement (GM
P/N 1052367) or equivalent.
• Rocker arms (23) with balls (22) on to the proper stud
• Rocker arm nuts (21) on to the studs.
! Important
• Align the push rod into the rocker arm while tightening rocker arm nut (21).
• No lash adjustment is needed.
VALVE ADJUSTMENT
The 4.3L engine has screw-in rocker arm studs with positive stop shoulders, no valve adjustment
is necessary. When the valve train requires service, you simply tighten the rocker arm nuts to
27 N · m (20 lbs · ft). Copyrighted Material
E N G I N E – V 6
INTAKE MANIFOLD INSTALLATION
INSTALL OR CONNECT
1. Gaskets to the cylinder head with the port blocking plates facing the rear of the engine.
2. RTV to the front and rear sealing surfaces on the block.
Apply a 4.76250 mm (0.1875 in) bead of RTV or equivalent to the front and rear of the block
as shown in figure. Extend the bead 12.7000 mm (0.500 in) up each cylinder head to seal
and retain the gaskets.
3. Intake manifold to the engine.
! NOTICE
4. Intake manifold bolts.
Tighten
• Intake manifold bolts to 47 N·m (35 lbs·ft) using the tightening sequence shown in next page.
15
• Retorque, intake manifold bolts using the tightening sequence shown in next page.
02
71
Intake Mainfold and components
E N G I N E – V 6
Intake manifold bolt tightening sequence
15 ROCKER ARM COVER INSTALLATION
02 Install or connect
72
1. Rocker arm cover (2 or 3).
2. New gasket.
! NOTICE
Tighten
• Rocker arm cover bolts (1) to 10 N·m
(90 lbs·in).
Rocker arm cover and components
E N G I N E – V 6
EXHAUST MANIFOLD INSTALLATION
15
Exhaust mainfolds and components
02
73
Install or Connect
1. Exhaust manifold.
2. Heat shield (60).
! NOTICE
3. Exhaust manifold bolts (63), washers (61), and tab washers (62).
Tighten
• Bolts on center exhaust tube to 36 N·m (26 Ibs·ft).
• Bolts on front and rear exhaust tubes to 28 N·m (20 lbs·ft).
• Bend the tab washers over the heads of all bolts.
EGR VALVE INSTALLATION
Install or Connect
1. New gasket.
2. EGR valve.
! NOTICE
3. Bolts. Copyrighted Material

E N G I N E – V 6
Tighten
• Bolts to 22 N·m (16 lbs·ft).
FLYWHEEL INSTALLATION
Install or Connect
1. Flywheel.
! NOTICE
2. Flywheel bolts.
Tighten
• Bolts to 100 N·m (74 lbs · ft).
15 COOLANT PUMP INSTALLATION

02
74 Install or Connect
1. Gaskets.
2. Coolant pump.
! NOTICE
3. Coolant pump bolts.
Tighten
• Coolant pump bolts to 40 N·m (30 Ibs·ft).
ENGINE ACCESSORY INSTALLATION
Install the engine accessories (distributor, oil filter, generator, etc.) as directed in the proper on-
vehicle Truck Service Manual. Connect all vacuum hoses and electrical equipment
the same way as removed.
E N G I N E – V 6
ENGINE SET–UP AND TESTING
After overhaul, turn the engine over manually and inspect for any unusual noises or evidence that
parts are binding. If parts are binding disassemble engine to determine the source.
1. lnstall oil filter.

2. Fill the crankcase with the proper quantity and grade of engine oil.
! Important
If a new camshaft or hydraulic lifters were installed, add engine oil supplement to the
engine oil.
3. Fill the cooling system with the proper quantity and grade of coolant.
! Important
• Whenever the cooling system is serviced or drained for service procedures, 2 coolant
sealant pellets, or equivalent, must be added to the cooling system.
• The pellets must be added to the radiator or the pressurized coolant reservoir. Pellets
must be crushed prior to installation.
15
• Do not place pellets into a non-pressurized coolant recovery reservoir. On these systems, 02
the pellets must be added to the radiator. 75
• The sealant pellets may leave a film on the sides of pressurized and non-pressurized
coolant recovery reservoirs. This film is normal.
4. Crank the engine several times. Listen for any unusual noises or evidence that parts are binding.
5. Use the proper on-vehicle Truck Service Manual or Emission Control Label for specifications on
ignition timing adjustment.
6. Start the engine and listen for unusual noises.
7. Run the engine speed at about 1000RPM until the engine is at operating temperature.
8. Listen for sticking lifters and other unusual noises.
9. Check for oil and coolant leaks while the engine is running.
E N G I N E – V 6
SPECIFICATIONS
CMP40/45/50SL
SF35/40/45L
GENERAL DATA
Type V6
Displacemeni 4.3L (262 C.l.D.)
Bore 101.600 mm (4.00 in)
Stroke 88.392 mm (3.48 in)
Compression ratio 9.10 to 1
Firing order 1–6–5–4–3–2
Oil pressure (Minimum HOT) 41 kpa (6psi)–1000 rpm–124 kPa(18 psi) / 2000 rpm
CYLINDER BORE
Diameter 101.618–101.643 mm (0.001 in)
15 Out of
round
Production
Service limit
0.025 mm (0.001 in) Maximum
0.051 mm (0.002 in) Maximum
02 Thrust side 0.0125 mm (0.005 in) Maximum
Production
76 Taper Relief side 0.025 mm (0.001 in) Maximum
Service limit 0.025 mm (0.001 in) Maximum
PISTON
Clearance Production 0.018–0.061 mm (0.0007–0.0024 in)
PISTON RING
Top 0.030–0.081 mm (0.0012–0.0032 in)
Groove Production
Second 0.030–0.081 mm (0.0012–0.0032 in)
Compression
clearance
Top 0.254–0.508 mm (0.010–0.020 in)

Production
Cap Second 0.254–0.635 mm (0.010–0.025 in)

Groove Production 0.051–0.178 mm (0.002–0.007 in)
clearance Serive limit 0.202 mm (0.008 in) Maximum
Oil
Gap Production 0.381–1.397 mm (0.015–0.055 in)
Service limit 1.651 mm (0.065 in)
PISTION PIN
Diameter 23.546–23.553 mm (0.9270–0.9273 in)
Clearance Production 0.005–0.018 mm (0.0002–0.0007 in)
in piston Service limit 0.025 mm (0.001 in) Maximum

Fit in rod 0.020–0.041
Intended for CLARK dealers only mm (0.0008–0.0016in) Interference
E N G I N E – V 6
CMP40/45/50SL
SF35/40/45L
EXHAUST MANIFOLD
Surface flatness 0.254 mm mm (0.010 in) Maximum
INLET MANIFOLD
Surface flatness 0.254 mm mm (0.010 in) Maximum
CYLINDER HEAD
Surface flatness 0.102 mm mm (0.004 in) Overall
BALANCE SHAFT
Front bearing journal diameter 54.986–55.001 mm (2.1648–2.1654 in)
Rear bearing joumal diameter 38.085–38.100 mm (1.4994–1.500 in)
Rear bearing joumal clearance 0.025–0.091 mm (0.001–0.0036 in)
CRANKSHAFT
Diameter
#1
#2, #3
62.189–62.212 mm (2.4482–2.4493 in)
62.182–62.205 mm (2.4481–2.4490 in)
15
#4 62.177–62.200 mm (2.4479–2.4488 in) 02
Main journal Production 0.005 mm (0.0002 in) Maximum 77
Taper
Serv. limit 0.025 mm (0.001 in)
Out of Production 0.054 mm (0.0002 in) Maximum
round Serv. limit 0.025 mm (0.001 in) Maximum

#1 0.020–0.051 mm (0.0008–0.0020 in)
Production #2, #3 0.028–0.058 mm (0.0011–0.0023 in)

Main bearing #4 0.043–0.081 mm (0.0017–0.0032 in)
clearance #1 0.025–0.038 (0.0010 mm–0.0015 in)
Service
#2, #3 0.025–0.038 (0.0010 mm–0.0015 in)
limit
#4 0.064–0.089 (0.0025 mm–0.0018 in)
Crankshaft end play 0.127–0.457 (0.0025 mm–0.0018 in)
Crankshaft runout 0.025 mm (0.001 in) Maximum
Diameter 57.117–57.142 mm (2.2487–2/2497 in)
Production 0.0127 mm (0.0005 in)
Taper
Crankpin Serv. limit 0.025 mm (0.001 in)
Out of Production 0.013 mm (0.0005 in)
roung Serv. limit 0.025 mm (0.001 in)
Rod bearing Production 0.033–0.089 mm (0.0013–0.0035 in)
clearance Service Limit 0.076 mm (0.0030 in)
Rod side clearance 0.381–1.168 mm (0.015–0.046 in)
E N G I N E – V 6
CMP40/45/50SL
SF35/40/45L
CAMSHAFT
Intake 5.893–5.994 mm (0.232–0.236 in)
Lobe lift
Exhaust 6.528 mm (0.257 in)
Jourmal diameter 47.452–47.478 mm (1.8682–1.8692 in)
End play 0.102–0.305 mm (0.004–0.012 in)
VALVE SYSTEM
Lifter Hydraulic
Rocker arm ratio 1.50 to 1
Valve lash (Inake & Exhaust) Torque rocker arm nut to 27 N·m (20lbs·ft)
Face angle (Intake & Exhaust) 45°
Seat angle (Intake & Exhaust) 46°
15 Seat runout (Intake & Exhaust)
Seat width
Intake
0.051 mm (0.002in) Maximum
0.889–1.524 mm (0.035–0.060 in)
02 Exhaust 1.575–2.363 mm (0.062–0.093 in)

78 Production Int. & Exh. 0.025–0.069 mm (0.0010–0.0017 in)
Stem
Intake High limit production + 0.025 mm (0.001 in)
clearance Service
Exhaust High limit production + 0.025 mm (0.002 in)
Free length 51.562 mm (2.03 in)
Valve spring Closed 338–374N @43.18 mm (76–84 lbs.@1.70 in)

Pressure
(outer) Open 863–916N @31.75 mm (194–206 lbs.@1.25 in)
Installed height 42.926 @43.434 mm (1.690–1.710 in)
Valve sprg. Free length 47.244 mm (1.86 in)
damper Approximate no. of coils 4
E N G I N E – V 6
FASTENER TIGHTENING SPECIFICATIONS
Item N·m lb · ft lb · in
Balance shaft drive gear retaining bolt 6 12 –
Balance Gear driven gear bolt (torque plus a 35° turn) 20 15 –
Balance shaft retainer bolt 14 – 124
Camshaft sprocket bolts 28 21 –
Camshaft thrust plate screws 14 – 124
Connecting rod bolt nuts (torque plus a 70° turn). 27 20 –
Coolant outlet bolts 28 21 –
Coolant pump bolts 40 30 –
Crankshaft rear oil seal retainer screws and nuts 15 11 –
Cylinder head bolts (in sequence) 90 65 –
EGR valve bolt 22 16 –
Engine block drain plug
Exhaust manifold bolts
20 15 – 15
Center two bolts 36 26 –
02
79
All other bolts 28 20 –
Flywheel bolts 100 74 –
Flywheel housing bolts 44 32 –
Front cover bolts 14 – 124
Hydraulic lifter guide assembly 16 12 –
Intake manifold bolts (in sequence) 47 35 –
Main bearing cap bolts 110 81 –
Oil filter adapter bolts 22 16 –
Oil gallery plug, left rear 40 30 –
Oil gallery plug, right rear 40 30 –
Oil gallery plug, left side rear 30 22 –
Oil pan bolts 11 – 97
Oil pan drain plug 25 18 –
Oil pan nuts 23 17 –
Oil pan studs to oil seal retainer or engine block 23 17 –
Oil pressure fitting 11 – 97
Oil pump bolt 88 65 –
Oil pump cover bolts 9 – 80
Rocker arm cover bolts 10 – 90
Rocker arm nuts 27 20 –
Rocker arm stud 47 35 –
Torsional damper bolt Intended for CLARK dealers only 95 70 –
E N G I N E – V 6
COOLING SYSTEM
COOLING SYSTEM
TROUBLESHOOTING
CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION
Temperature ligth 1. Transmission cooler or 1. Check cooler and lines

comes on frequently. lines blocked. for blockage. Flush
2. Transmission cooler cooler and lines. If
defective. problem not corrected,
replace cooler or
defective lines.
2. Replace transmission
cooler. Flush system.
Transmission fluid 1. Transmission oil cooler 1. Check engine coolant for

loss (no signs). portion of radiator leaking transmission fluid
into cooling system. contamination. Repair or
replace cooler. 15
03
Rough idle 1. Coolant temperature 1. Replace themostate. 1
(engine misfiring) below normal due to
incorrect or defective
thermostat.
Excessive blue/white 1. Coolant temperature 1. Replace themostate.

exhaust smoke below normal due to
incorrect or defective
thermostat.
Engine overheating 1. Low coolant level. 1. Check coolant. Fill as

2. Radiator pressure cap required. Check for
defective. leaks.
3. Inadequate air flow to 2. Replace radiator
radiator. pressure cap.
4. Radiator fins plugged. 3. Check operation of fan.
5. Radiator clogged. If defective, replace fan.
6. Scale or deposits in 4. Blow debris from
cooling system radiator fins.
7. Radiator defective. 5. Drain and flush radiator.
8. Thermostat incorrect or 6. Drain and flush cooling
de fective. system.
9. Collapsed radiator 7. Repair or replace
hose(e). radiator.
10. Water pump defective. 8. Replace thermostat.
9. Replace hose(s)
10. Replace water pump
Engine lubricating 1. Oil cooler core leaking. 1. Check for oil in coolant. If
oil loss. Copyrighted Material found, check and replace
Intended for CLARK dealers only oil cooler core.
POWER TRAIN 20
• 20–01 GENERAL INFORMATION
• 20–02 DRIVE AXLE
• 20–03 POWERSHIFT TRANSMISSION
P O W E R T R A I N
GENERAL INFORMATION
GENERAL INFORMATION
The transaxle assembly consists of a common drive axle fitted with either a powershift
transmission or a manual shift transmission.
This manual describes the disassembly and assembly procedure of the axle and each
transmission separately rather than by transaxle assemblies.
! CAUTION
Cleanliness is of extreme importance in the servicing, repair and overhaul of this unit.
Before attempting any repairs, thoroughly clean the exterior housing to prevent the
possiblity of dirt entering the unit.
POWERSHIFT UNIT
FEATURES
The torque delivered by the engine is multiplied by the torgue converter to a maximum of 2.23
times. This force is then transmitted through the transaxle which consists of a powershift
transmission, differential, axle shafts and final drives.
The transaxle design eliminates the need for driveshafts which provides a compact drive
mechanism enhancing machined manoeuverability and load handling capabilities. 20
The powershift transmission offers ease of operation and most importantly reduces operator
fatigue. 01
1
P O W E R T R A I N
GENERAL INFORMATION
STRUCTURE
10
12
6
11
13 5
4
3
14
8
7
20
1
01
2
1. Torque converter
2. Control valve
3. Forward 1st valve
4. Forward 2nd valve
5. Reverse 1st valve
6. Reverse 2nd valve
7. Reverse 1st clutch pack
8. Reverse 2nd clutch pack
9. Transmission charging pump
10. Parking brake
11. Differential gear
12. Reduction gear
13. Service brake
14.forFinal
Intended CLARKreduction gear
dealers only
P O W E R T R A I N
GENERAL INFORMATION
OPERATING PRINCIPLES AND FUNCTIONS
• Sequence of power flow
Engine Torque converter Transmission Reduction gear assembly
Axle shaft Final drive Driving wheel
• The torque converter is a type of fluid coupling that transmits the power absorbed from the
engine. It is composed of an impeller connected to the crankshaft, the turbine connected to
the converter output shaft, and the stator which changes the direction of fluid between them.
As the load from outside is increased, slippage will occur between the impeller and turbine so
the rotational speed of the turbine will approch 0 (what is called “stall”). At this time, the torque
ratio will increase a maximum of 2.23 times.
• The powershift transmision provides a reduction ratio of 1.77 for 1st gear and 1.00 for 2nd
gear. The hydraulically actuated clutch packs provide a smooth transmission of power to the
final drives.
• The differential assembly consists of the bevel pinion/ring gear set and the differential gear
set. The power delivered from the transmission reduced by the pinion/ring gear set, and then
transmitted to the left/right axle shaft by the differential gear set.
• The final reduction of the power transmitted to the axle shaft occurs in the planetary unit of
20
each axle hub.
01
• The parking brake is installed between the transmission output shaft and the axle assembly 3
input shaft. The service brake installed in the axle hub is a wet multi disc type. Therefore
regardless of working conditions the braking mechanism is not adversely affected.
P O W E R T R A I N
GENERAL INFORMATION
MAIN SPECIFICATION
Classification Specification
Rated input 81 hp
Rated input rotational speed 2700 rpm
Max. input torque 30 kgf·m
Gear shifting step Forward/Reverse 2nd
Gear shifting method Clutch pack
Gear shifting means Direct
Increasing
the speed
Forward
Gear shifting pattern
Reverse
Decreasing
the speed
20 Service brake Hydraulic wet multi disc

Parking brake Mechanical drum brake
01
1st 30.395
4 Total Forward
2nd 17.132
reduction
1st 30.395
ratio Reverse
2nd 17.132
Total weight 440 kg
Kind CLARK OIL#2776236
Transmission Capacity 13 l
Replacing period Initial 50hr, after every 1000hr
Oil
Kind Total T/M DA 80W/90, TORQUE FLUID 56,#2776236
Axle Capacity 9l
Replacing period Initial 50hr., after every 1000hr.
P O W E R T R A I N
DRIVE AXLE
DRIVE AXLE
DISASSEMBLY
• Remove the magnetic plug in each axle hub

and drain the oil.
• Remove the magnetic plug on the center axle

housing and drain the oil.
20
02
1
• Remove the capscrews and lock washers for

hub the assembly.
! Warning
The hub assembly is heavy, support it
with a sling and crane that are in good
condition and of adequate load rating.
• Remove the hub assembly with a crane.

! Warning
Match mark the hub flange and the axle
housing flange prior to disassembly.
P O W E R T R A I N
DRIVE AXLE
• Remove the axle shaft.

! CAUTION
The length of right and left is different.
Pay attention to it.
• The lengths of shafts are different. Take a
mark on the shaft for assembly.
• Remove the hexagon socket capscrews and

lock washers from the differential carrier.
20
02 • Separate the differential carrier assembly and
2 axle housing assembly.
DISASSEMBLY AND ASSEMBLY OF AXLE HOUSING ASSEMBLY
Disassembly
• Remove the air breather.
P O W E R T R A I N
DRIVE AXLE
• Remove the plug.
• Remove the brake bleeder screw.
20
02
3
• Remove the brake line fitting.
• Remove the brake piston return spring and

spring locking ring.
Push each spring inward with the plunger,
reach through the center of the piston into the
housing and unhook the spring from the lock
ring located behind the flange.
P O W E R T R A I N
DRIVE AXLE
• Remove the brake piston, then pull out the lock

ring.
• Remove the 1st square ring.
20
02
4
• Remove the 2nd square ring.
Assembly
• Apply grease onto both new square rings, and
install carefully so they do not twist.
P O W E R T R A I N
DRIVE AXLE
• Insert the lock ring into the housing behind the

flange.
• Insert the brake piston.

! CAUTION
Take care to prevent the square rings
from being pushed out of the grooves.
• To install the piston return springs, reach

throught the center of the piston into the
housing, pick up and hold the lock ring in place
then push each spring inward and hook it onto
the lock ring as shown. Ensure that each
spring is securely locked into the slot in the
end of the plunger.
20
02
5
• Install the copper washer onto the brake line

fitting and tighten it.
! CAUTION
If the copper washer isn't installed
properly, the brake will not work due to
brake oil leakage.
P O W E R T R A I N
DRIVE AXLE
• Apply Loctite #569 onto the brake bleeder

screw fitting and tighten it.
• Supply air to the brake line fitting and check

the operating condition of the brake piston.
20
02
6
• Apply Loctite #569 onto the air breather and
tighten it.
• Tighten the drain plug.
P O W E R T R A I N
DRIVE AXLE
DISASSEMBLY AND ASSEMBLY OF HUB
Disassembly
• Remove the disc carrier gear.
• Pull out the snap ring with snap ring pliers.

Disassemble the sun gear and disc carrier.
20
02
7
• Remove the retaining ring.
• Remove the brake plate.
P O W E R T R A I N
DRIVE AXLE
• Remove the friction brake discs and steel

discs.
• Remove the plate cover capscrews of the

wheel flange and remove the plate.
20
02
8
• Remove the lock plate hexagon socket
capscrews.
• Remove the lock plate.
P O W E R T R A I N
DRIVE AXLE
• Remove the bearing adjusting nut.
• Remove the center adjusting spacer.
• Disassemble the wheel flange hub.
20
02
9
• Remove the O–ring.
• Remove the bearing and wheel studs from the

flange. (Remove the studs only if required.)
P O W E R T R A I N
DRIVE AXLE
• Remove the carrier shaft/planetary from the

ring gear hub.
• Remove the bearing with a proper puller.
20
02
10
• Remove the planetary pins, gears and thrust
washers.
• Remove the bearings.
P O W E R T R A I N
DRIVE AXLE
• Remove the thrust washer.

disassemble the bearing hub assembly and
ring gear.
20
02
11
• Remove the oil seal.
P O W E R T R A I N
DRIVE AXLE
• Remove the bearing race with a proper puller.
Assembly (Refer to “Clean and Check”)

• Insert the bearing race into the hub housing.
20
02
12
• Insert a new oil seal into hub the housing.
• Insert the retaining ring.
P O W E R T R A I N
DRIVE AXLE
• Apply Loctite #518 onto the ring gear.
• Install the bearing assembly hub to the ring

gear.
! CAUTION
After applying Loctite #518, install the
hub assembly immediately.
20
02
13
• Tighten the capscrews.
15.5 ± 0.7 kgf·m (112±5 lbf·ft)
• Insert the thrust washer into the carrier

shaft / planetary.
P O W E R T R A I N
DRIVE AXLE
• Insert the bearings into the planetary gears.

! CAUTION
Apply gear oil to each bearing.
• Install the thrust washers to both sides of the

planetary gears.
20
02
14
• Install the planetary gears into the carrier shaft
and insert the pins.
! CAUTION
Position the groove of the pin end toward
the center of the carrier shaft.
• Press–fit the bearinng onto the carrier shaft by

pressing on the inner race.
P O W E R T R A I N
DRIVE AXLE
• Put the carrier shaft/planetary into the ring gear

hub assembly.
• Press–fit the bearing onto the wheel flange

hub.
20
02
15
• Press–fit the wheel studs into the wheel hub
flange.
• Install the spherical spacer for dual rims onto

the wheel stud.
P O W E R T R A I N
DRIVE AXLE
• Apply grease onto the O–ring and insert it into

the flange.
• Apply grease onto the oil seal lip of the

bearing hub housing.
• Put the wheel flange hub into the bearing hub
20 assembly.
! CAUTION
Handle carefully, do not damage the oil
02 seal.
16
• Put the spacer into the wheel flange hub.
• Tighten the bearing clearance adjusting nut.

! CAUTION
Tighten the adjusting to obtain a rolling
torque of : 3 kgf·m (22 lbf·ft)
– Tighten the adjusting nut :

28 kgf·m (202 lbf·ft)
– Loosen the adjusting nut by one revolution
retighten : 7 kgf·m (50Intended
lbf·ft) and then dealers only
for CLARK
loosen it again by one notch. Do not sell or distribute
P O W E R T R A I N
DRIVE AXLE
• Install the lock plate.

(If necessary loosen or tighten the ring nut
slightly to align the lock plate.)
• Tighten the hexagon socket capscrews.

: 8.7 ± 0.2 kgf·ft (63 ± 2 lbf·ft)
20
02
17
• Apply liquid gasket onto the flange cover and
install it.
• Tighten the capscrews.

: 3.3 ± 0.2 kgf·ft (24 ± lbf·ft)
P O W E R T R A I N
DRIVE AXLE
• Tighten the oil drain plug.
• Install the inner brake plate.
20
02
18
• Alternately Install the friction brake discs and
the steel discs.
• Install the outer brake plate.

! Select the thickness of the plate so that
the stroke of brake piston is 1.3 mm.
– Selecting method for thickness of plate
• Assemble the standard plate with thickness of

4mm.
• Measure the distance between axle housing
flange surface and pistion surface Copyrighted
:C Material
P O W E R T R A I N
DRIVE AXLE
• Measure the distance between ring gear flange B

surface of axle hub assembly and assembling A
surface : B C
• Measure the distance bewteen assembled plate S
surface and assembling surface : A
• The thickness of plate, t, is as follows :
t =C –(B –A) –1.3+4.0
• Insert the retaining ring.

! Ensure that the ring is completely seated.
20
02
19
• Assemble the sun gear and brake disc carrier,
and insert the snap ring.
• Put the brake disc carrier assembly into the

hub assembly.
! CAUTION
Do not exert excessive force, rotate the
carrier gear slowly to align the disc teeth.
P O W E R T R A I N
DRIVE AXLE
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL CARRIER ASSEMBLY
Disassembly
• Remove the parking brake drum.
• Remove the snap ring.
20
02
20
• Remove the hexagon socket capscrews for the

parking brake.
• Remove the parking brake assembly.
P O W E R T R A I N
DRIVE AXLE
• Remove the cover.
20
02
21
• Remove the capscrew, and remove the locking

plate on each differential cap.
P O W E R T R A I N
DRIVE AXLE
• Remove the capscrews and the differential

caps.
! CAUTION
Mark the position of each differential cap
before disassembling.
• Remove the bearing adjusting nuts.
20
02
22
• Remove the differential assembly.
• Remove the bearings with a proper puller.
P O W E R T R A I N
DRIVE AXLE
• Remove the capscrews holding the bevel ring

gear.
! CAUTION
Remove the bevel ring gear only if it is
to be replaced!
The ring gear and pinion gear must be
replaced as a set.
• Remove the bevel gear.
20
02
23
• Spread the lock tab of the lock washer.
• Loosen the lock nut and remove it.
P O W E R T R A I N
DRIVE AXLE
• Remove the lock washer.
• Remove the bearing.
20
02
24
• Remove the bevel pinion assembly.
• Remove the pinion bearing.
P O W E R T R A I N
DRIVE AXLE
20
02
• Remove the shim.
25
! CAUTION
Measure the thickness of shim.
Assembly
• Press–fit the bearing race.
! CAUTION
Ensure that the bearing race is comp-
letely seated.
P O W E R T R A I N
DRIVE AXLE
• Install the shim.
• Selecting method for thickness of the shim.

– Measure the dimension of “C”.
Example) Mesausred dimension, “C” : 148.0 mm
– Assume the theoretical distance of bevel
pinion as 117.4mm Refer to the pinion value
marked on end of bevel pinion.
Marked value : – 0.1
Actual assembling distance,
20 “R”=117.4–0.1=117.3mm
– Measured dimension of bearing width,
“B”=28mm
02
26
– Perform the following calculation to get the
shim thickness, “S”.
Dimension “C” 148.0 mm
Dimension “R” –117.3 mm
Bearing width “B” –28.0 mm
Dimension “S” 2.7 mm

! CAUTION
Ensure that the bearing race and shim
are completely seated.
P O W E R T R A I N
DRIVE AXLE
• Press the bearing onto the bevel pinion gear

shaft.
• Install the bevel pinion assembly in the

differential carrier
20
02
27
• Heat the bearing and insert it onto the bevel
pinion gear shaft.
• Install the lock washer.
P O W E R T R A I N
DRIVE AXLE
• Tighten the lock nut.

Rolling torque of bearing : 120~130 N·cm
(10~12 in·lbs).
• Crimp the lock washer so the lock nut can not

be loosened.
20
02
28
• Install the bevel gear to the differential unit.
• Apply Loctite #242 onto the capscrews and

tighten in a criss–cross pattern.
: 6.5 ± 0.7 kgf·m (47 ± 5 lbf·ft)
! CAUTION
Replace the capscrews every time that
they are removed.
P O W E R T R A I N
DRIVE AXLE
• Install the differential assembly bearings.
• Install the differential unit assembly.
20
02
29
• Install the adjusting nuts.
• Put the differential caps into their specified

position, and tighten the capscrews.
: 11.3 ± 1.1 kgf·m (81 ± 8 lbf·ft)
! Confirm the direction of left and right of

differential cap.
P O W E R T R A I N
DRIVE AXLE
• Screw in the adjusting nuts to obtain an

approx. backlash of the bevel gear set without
preload-ing the roller bearings. Backlash :
0.13~0.18 mm (0.005~007 in)
Check the rotating torque of the pinion and
differential. Tighten nut on opposite side to the
bevel gear to obtain a 50–70 N·cm(4~6 in·lbs)
higher rotating torque than on the pinion.
• Install the locking plate to each differential cap

and tighten the capscrew.
: 3.3 ± 0.3 kgf·m (24 ± 2 lbf·ft)
Brush a small amount of prussian bluing on 3
or 4 adjacent teeth of the bevel gear. Rotate
the pinion several revolutions in each direction
until tooth contact marks are visible.
– To change the contact pattern, adjust the
pinion underhead bearing shim pack.
20 – A change to gear backlash will change the

gear tooth contact.
– A change to the gear tooth contact will change the gear backlash.
02 If the contact pattern is correct remove the bluing from the gears.
30
• Apply Loctite #569 onto the plug and install it

to the cover.
• Apply Loctite #RC/609 onto the outer diameter

of the oil seal and press–fit it into the cover.
P O W E R T R A I N
DRIVE AXLE
• Assemble the cover.
• Install the brake assembly.
20
02
31
• Tighten the hexagon socket capscrews.
: 8.7 ± 0.3 kg·m (63 ± 2 lbf·ft)
Apply Loctite #242.
• Install the retaining ring with snap ring pliers.
P O W E R T R A I N
DRIVE AXLE
• Install the brake drum
DISASSEMBLY AND ASSEMBLY OF DIFFERENTIAL CASE ASSEMBLY
Disassembly
• Remove the capscrews and spring washer
maching the cases.
20
02
32
• Remove the case-rh
• Remove the side gears and thrust washers.
P O W E R T R A I N
DRIVE AXLE
• Remove the spider assembly.
• Remove the differential gears and thrust washers onto the spider pin.
• Remove the side gears and thrust washers.

20
02
33
Assembly
• Install the side gear and thrust washer into the
case-lh
P O W E R T R A I N
DRIVE AXLE
• Install the differential gears and thrust washers

onto the spider pin.
• Install the spider assembly.
• Install the side gear and thrust washer.
20
02
34
• Install the case-lh.
! CAUTION
Do concurrence the assembly mark for
case assemble.
• Apply Loctite #242 onto the capscrew and

install spring washer and capscrew.
P O W E R T R A I N
DRIVE AXLE
• Tighten thr capscrews in a cross-cross pattern.

: 6.5 ± 0.7 kgf·m (47 ± 5 lbf·ft)
ASSEMBLY OF THE DRIVE AXLE
• Install the differential carrier assembly to the

axle housing.
20
02
35
• Apply Loctite #242 onto the hexagon socket
capscrews thread portion and tighten.
: 24.5 ± 1 kgf·m (177 ± 7 lbf·ft)
• Install the spacer (thickness : 7 mm) onto the

axle shaft end.
! CAUTION
Install the spacer with the chamfer of the
inner diameter facing the axle shaft.
P O W E R T R A I N
DRIVE AXLE
• Install the spacer (thickness : 8 mm) onto the

opposite axle shaft end.
! CAUTION
Install the spacer with the chamfer of the
inner diameter facing the axle shaft.
• Insert the axle shaft into the axle housing.
! CAUTION
• Insert the long splined side to the
differential.
• The length of axle shaft is different
between left and right, so install the
long shaft into right side.
20 • Apply Loctite #518 onto the surface of hub

assembly.
02
36
• Install the hub assembly.
! CAUTION
Align the match marks made prior to disassembly. Assemble with the oil drain plug
towards the ground.
P O W E R T R A I N
DRIVE AXLE
• Apply Loctite #242 onto the hexagon socket

capscrew thread portion and tighten.
: 24.5 ±1 kgf·m (177±7 lbf·ft)
• Install the dowel pin.
20
02
37
P O W E R T R A I N
POWERSHIFT TRANSMISSION
DISASSEMBLY
Cleanlines is essential in all work, therefore read the Transmission Maintenance guide prior to
conducting any repairs.
• Remove the magnetic plug of the transmission

case to drain the oil completely.
! CAUTION
If the oil isn't drained completely, oil will
be leaked when disassembling the torque
converter.
• Disassemble the torque converter from the

transaxle.
20
03
1
DISASSEMBLY AND ASSEMBLY OF

TORQUE CONVERTER
Disassembly
• Remove the drive plate and flexible plate.

gear.
P O W E R T R A I N
Assembly
• Install the flexible plate and drive plate to
torque converter.
20
03
2
• Apply Loctite #242 onto the thread portion of
the capscrews and tighten.
: 5.6 ± 0.5 kgf·m (40 ± 4 lbf·ft)
• Insert the O–ring into the gear.
P O W E R T R A I N
• Install the gear to the torque converter.
• Apply Loctite #242 onto the thread portion of

the hexagon socket capscrews and tighten.
20
03
3
• Remove the cover.
• Remove the snap pin and clevis pin.
P O W E R T R A I N
• Remove the cable fork and nut.
• Remove the cable assembly by loosening the

cable locking nut.
20
03
4
• Remove the stud nuts and separate the
transmission and drive axle assembly.
DISASSEMBLY OF THE TRANSMISSION ASSEMBLY
• Remove the nut and solenoid coil.
P O W E R T R A I N
• Roosen the hydraulic hose coupling and

remove hydraulic hose.
• Roosen the hydraulic hose coupling and

remove hydraulic hose.
20
03
5
• Roosen the hydraulic fitting.

transmission control valve assembly.
Quantity capscrew : 21EA
P O W E R T R A I N
• Remove the gasket.
• Remove the hydraulic fitting.
20
03
6
• Remove the hexagon head capscrew and oil
filter assembly.
• Loosen the clamps and remove the hose.
P O W E R T R A I N
• Remove the connector.
• Remove the capscrews, flange and O–ring.
20
03
7
• Remove the strainer.
• Remove the the hexagon head capscrew,

pump and gasket.
P O W E R T R A I N
• Remove the thermo sensor.
• Remove the oil dipstick.
20
03
8
• Remove the dipstick pipe.

bracket.
P O W E R T R A I N
• Remove the plugs and copper washer.
20
03
9
• Remove the needle roller bearing.
• Remove the plug, O–ring, spring and ball.
P O W E R T R A I N
• Remove the air breather.
• Remove the capscrews and inspection cover.
20
03
10
• Remove the capscrews.
• Remove the pump drive gear assembly.
P O W E R T R A I N
• Remove the capscrews and separate the torque

converter housing from the transmission.
DISASSEMBLY AND ASSEMBLY OF THE PUMP DRIVE GEAR
Disassembly
20
03
11
• Remove the retaining ring with snap ring pliers.
• Remove the gear assembly.
P O W E R T R A I N
• Remeve the bearing from the flange cover.
• Remeve the bearing from the drive gear.
20
03 Assembly
12
• Install the bearing in the drive gear.
• Install the gear assembly.
P O W E R T R A I N
• Install the bearing in the flange cover.
• Insert the retaining ring with snap ring pliers.
20
03
13
• Insert the O–ring.
• Remove the screws and air breather plate.
P O W E R T R A I N
• Remove the capscrews and stator hub

assembly.
• Remove the bushing.
20
03
14
• Remove the piston ring.
P O W E R T R A I N
• Remove the capscrew and remove the idler

shaft.
20
03
15
• Remove the idler gear assembly.
P O W E R T R A I N
• Remove the bearings and inner spacer.
• Remove the bearing races.
20
03
16
• Remove the outer spacer.
P O W E R T R A I N
• Remove the stator hub assembly and bearing

with a proper puller.
• Remove the bearing races with a proper puller.
20
03
17
• Remove the O–rings.
• Remove the shaft assemblies (3 pcs).
P O W E R T R A I N

flange cover.
20
03
18
covers.
• Remove the gaskets.
P O W E R T R A I N
• Remove the spacer shim.
! CAUTION
Measure the thickness of the shim and
confirm the position to be assembled.
20
03
19
• Remove the spacer shims.
! CAUTION
Measure the thickness of the shims and
confirm the position to be assembled.
• Remove the capscrews and remove the oil

guide baffle.
P O W E R T R A I N
• Remove the bearings (3 pcs) from the trans-

mission case.
CLUTCH PACK ASSEMBLIES
INPUT SHAFT SUB ASSEMBLY(REVERSE) LAY SHAFT SUB ASSEMBLY(FORWARD)
20
03
20
1. SHAFT-INPUT 12. PLATE-REACTION

2. CLUTCH PISTON 13. RING-RETAINING
3. SEAL-OUTER 14. WASHER-THRUST
4. SEAL-INNER 15. GEAR ASSY-LOW
5. PLUG-BALL 16. GEAR-HIGH
6. SPRING-RETURN 17. BEARING-NEEDLE
7. PISTON-BALANCE 18. WASHER-THRUST
8. SEAL-BALANCE 19. BEARING-T/ROLLER
9. RING-RETAINING 20. RING-PISTON
10. PLATE-END 21. GUIDE-SPRING
11. PLATE-FRICTION 22. BALL-STEEL
P O W E R T R A I N
Disassembly and assembly of the input(reverse) and lay(forward) shaft clutch units.
The input shaft and the lay shaft each utilize a low speed(1st) clutch and a high speed (2nd)
clutch.
The low speed clutch units are identical as are the high speed clutch units. Therefore the
following disassembly and assembly procedure is described on the basis of the clutch units
rather than by the individual shaft assembly.
Disassembly of low speed (1st) clutch unit

• Remove the oil seal ring of clutch the input
shaft.
20
03
21
• Remove the front bearing with proper puller.
P O W E R T R A I N
• Remove lock ball.
! CAUTION
Pay attention not to miss it.
• Remove the 1st gear assembly.
20
03
22
P O W E R T R A I N
! CAUTION
MARK the position prior to removal.
• Remove the outer end plate.
20
03
23
• Remove the clutch friction discs (5pcs) and
steel plate (4pcs).
• Remove the inner end plate.
P O W E R T R A I N
• Remove the retaining ring and balance piston.
• Remove the spring.
20
03
24
• Remove the spring guide.
• Remove the clutch piston by blowing air into

the hydraulic supply passage.
P O W E R T R A I N
• Remove the piston inner oil seal.
! CAUTION
Note the direction of the oil seal lip to
aid in reassembly.
• Remove the piston outer oil seal.
! CAUTION
aid in reassembly.
20
Disassembly of high speed (2nd) clutch 03
25
• Remove the oil seal ring of the clutch shaft.
• Remove the rear bearing with a proper puller.
P O W E R T R A I N
• Remove the lock ball.
! CAUTION
Pay attention not to miss it.
20
03
26
• Remove the 2nd gear.
P O W E R T R A I N
! CAUTION
Mark the position prior to removal.
20
03
27
• Remove the outer end plate.
• Remove the clutch friction discs (5pcs) and

steel plate (4pcs).
P O W E R T R A I N
• Remove the inner end plate.
• Remove the retaining ring and spring stopper.
20
03
28
• Remove the springs.
• Remove the spring guide.
P O W E R T R A I N
• Remove the clutch piston by blowing air into

the hydraulic supply passage.
• Remove the piston inner oil seal.
! CAUTION
aid in reassembly.
20
03
29
• Remove the piston outer oil seal.
! CAUTION
aid in reassembly.
Assembly of low speed 1st clutch

• Press–fit the ball–plug.
! CAUTION
• Quantity : 2EA
• set the ball into the shaft seat, then
strike the jig to press-fit the ball.
• Use the proper jig for this procedure.
P O W E R T R A I N
• Insert the oil seal into the outer diameter of

piston clutch.
! CAUTION
Install the oil seal as shown in the
illustration.
• Insert the oil seal into the inner diameter of

piston clutch.
! CAUTION
illustration.
20
03
30
• Position the taper of the oil seal outer diameter
and inner diameter as shown.
• Apply transmission oil (CLARK OIL #2776236)
onto the oil seal when assembling.
• Install the clutch piston.
P O W E R T R A I N
• Insert the spring guide.
• Install the spring.
20
03
31
• Install the piston so the springs are seated well
into the groove of the spring stopper.
• Press the piston with a jig, and install the

retaining ring.
! CAUTION
Press untill the sound of the retaining
ring seating is heard.
P O W E R T R A I N
• Remove the jig and confirm that the retaining

ring is seated well into the groove.
• For check the oil leakage, blowing air into the

hydraulic supply passage of 1st clutch pack.
20
03
32
• Install the inner end plate.
• Install the clutch friction discs
! CAUTION
• When installing, apply transmission oil
(CLARK OIL #2776236).
• Assembly quantity : 5EA
P O W E R T R A I N
• Install the disc plates.
! CAUTION
• When assembling the clutch pack install
a friction disc, then alternate steel and
friction discs. The last disc installed is
friction.
• Install the outer end plate.
20
03
33
• Install the retaining ring.
! CAUTION
• When assembling, measure the
thickness of retaining ring.
• Install the ring according to the location
mark made prior to disassembly.
• After assembling, measure the clearance

between the end plate and ring, and select the
thickness of ring so that the clearance
becomes 1.8 mm 2.0 mm.
P O W E R T R A I N
• Install the thrust washer.
• Press–fit the bearing into the 1st gear

assembly.
! CAUTION
• When assembling, place the bearing at
1mm inside from gear side face.
(CLARK OIL #2776236).
20
03
34
• Install the 1st gear assembly.
! CAUTION
Match the gear and disc spline teeth, and
ensure that the gear is fully engaged.
• Install the lock ball.
P O W E R T R A I N
! CAUTION
• Pay attention to the assembling
direction.
• Face the oil grove toward the gear
needle bearing.
• Press–fit the bearing.
! CAUTION
After press–fitting, confirm there is no
clearance between clutch shaft end and
bearing side face.
20
03
35
• Install the oil seal ring onthe clutch only input
shaft.
Assembly of high speed 2nd clutch
• Insert the oil seal into the outer diameter of

piston clutch.
! CAUTION
illustration.
P O W E R T R A I N
• Insert the oil seal into the inner diameter of

piston clutch.
! CAUTION
illustration.
• Position the taper of the oil seal outer diameter

and inner diameter as shown.
• Apply transmission oil (CLARK OIL #2776236)
onto the oil seal when assembling.
20
03
36
• Install the clutch piston.
• Insert the spring guide.
P O W E R T R A I N
• Install the piston so the springs are seated well

into the groove of the spring stopper.
20
03
37
• Press the piston with a jig, and install the
retaining ring.
! CAUTION
Press untill the sound of the retaining
ring seating is heard.
• Remove the jig and confirm that the retaining

ring is seated well into the groove.
P O W E R T R A I N
• For check the oil leakage, blowing air into the

hydraulic supply passage of 2nd clutch pack.
• Install the inner end plate.
20
03
38
• Install the clutch friction discs.
! CAUTION
(Clark 0:1 #2776236).
• Install the disc plates.
! CAUTION
• When assembling the clutch pack install
a friction disc, then alternate steel and
friction discs. The last disc installed is
friction.
P O W E R T R A I N
• Install the outer end plate.
• Install the retaining ring.
! CAUTION
• When assembling, measure the
thickness of retaining ring.
• Install the ring according to the location
mark made prior to disassembly.
20
03
39
• After assembling, measure the clearance
between the end plate and ring, and select the
thickness of ring so that the clearance
becomes 1.8mm ~ 2.0 mm.
P O W E R T R A I N
Press–fit the bearing into the 2nd gear.
! CAUTION
• When assembling, place the bearing at
1mm inside from gear side face.
(CLARK OIL #2776236).
• Install the 2nd gear.
! CAUTION
Match the gear and disc spline teeth, and
ensure that the gear is fully engaged.
20
03
40
• Install the lock ball.
! CAUTION
• Pay attention to the assembling
direction.
• Face the oil grove toward the gear
needle bearing.
P O W E R T R A I N
! CAUTION
clearance between clutch shaft end and
bearing side face.
• Install the oil seal ring of clutch shaft.

Quantity : 3EA
20
03
41
DISASSEMBLY AND ASSEMBLY OF THE OUPUT SHAFT
Disassembly
• Remove the front bearing with a proper puller.
P O W E R T R A I N
• Remove the bearing with a proper puller.
• Remove the 1st output gear.
20
03
42
• Remove the flat key.
Assembly
• Press–fit the flat key.
P O W E R T R A I N
• Press–fit the 1st gear.
! CAUTION
After press–fitting, confirm the clearance
to shaft side face.
• Press–fit the output shaft front bearing.
! CAUTION
After press–fitting, confirm that there is
no clearance between gear side face and
bearing side face.
20
03
• Press–fit the output shaft rear bearing. 43
! CAUTION
After press–fitting, confirm that there is
no clearance between gear side face and
bearing side face.
ASSEMBLY OF TRANSMISSION
• Install the oil guide baffle and tighten the spring

washers and capscrews.
: 1.4 ± 0.14 kgf·m (10 ±1 lb·ft)
P O W E R T R A I N
• Press–fit the dowel pin for case positioning.

Quantity : 2EA
• Tighten the oil plug
! CAUTION
• Apply Loctite #569 onto the plug.
• Quantity : 4EA
20
03
44
• Install the bearing outer spacer to the idler gear.
! CAUTION
A spacer constitutes a set with a bearing,
so take care not to mixed it with another
spacer.

Quanity : 2EA
! CAUTION
There must be no clearance the between
bearing race and the spacer face.
P O W E R T R A I N
• Install the bearing and inner spacer.
• Install the idler gear assembly to the idler shaft

bore of the torque converter case.
20
03
45
• Install the O–ring to the idler shaft.
• Install the idler shaft, and apply Loctite #242

onto the capscrew thread portion and tighten
it.
: 15.5 ± 0.7 kgf·m (112 ± 5 lb·ft)
P O W E R T R A I N
• Install the air breather plate and apply Loctite

#242 onto the screws.
: 0.3 ± 0.03 kgf·m (26 ± 3 lb·ft)
• Install the pump flange assembly and gasket to

the torque converter case.
! CAUTION
Apply Loctite #518 sparingly onto the
contacting surface of the flange and
case.
20
03
46
• Apply Loctite #242 onto the capscrews thread
portion and tighten it.
: 6.5 ± 0.7 kgf·m (47 ± 5 lb·ft)
• Install the oil seal.
! CAUTION
Apply Loctite #RC/609 onto the outer
diameter of the oil seal and apply grease
onto the lip.
P O W E R T R A I N
• Install the O–ring.
! CAUTION
When assembling, seat it onto the flange
face of the case.
• Press–fit the ball plug.
! CAUTION
When assembling the ball plug, using the
jig hit the ball outer diameter first to
insert it into the hole, and then hit the
jig again to press–fit the ball.
20
03
47
• Install the piston ring, ensure that it is properly
hooked.
• Press–fit the bushing.
P O W E R T R A I N
• Install the stator hub assembly, and apply

Loctite #242 onto the capscrew thread portion
and tighten it.
: 11.3 ± 1.1 kgf·m (82 ± 8 lb·ft)
! CAUTION
clearance between the housing seat and
the bearing.
20
03
48
! CAUTION
the bearing.
! CAUTION
the bearing.
P O W E R T R A I N
• Insert the O–ring onto the plug, and install it

to the torque converter case.
• Install the steel ball.
20
03
49
• Fit the O–ring onto the plug, install, and tighten

securely.
P O W E R T R A I N
• Install the air breather.
! CAUTION
Apply Loctite #569 onto the air breather
thread portion.
• Install the cover and tighten the bolt.

: 3.3 ± 0.2 kgf·m (24 ± 2 lb·ft)
• Install the bearing to the input shaft and lay
20 shaft and output shaft bores.
03
50
• Install the shaft assemblies (3EA) to the

transmission case.
• Install the O–rings.
! CAUTION
The O–ring must be seated well into the
groove.
P O W E R T R A I N
• Install the gasket and then install the torque

converter case assembly to the transmission
case.
! CAUTION
Apply Loctite #5699 sparingly onto the
contacting surfaced of the flange and
case.
• Appply Loctite #242 onto the capscrew thread

portion and tighten.
: 11.3 ±1.1 kgf·m (82 ± 8 lb·ft)
Quantity : 14EA
20
03
51
• Select the proper shim and install it to the
bearing surface of input shaft and lay shaft.
– Calculating method of shim thickness
Select the proper shims enough to push
the bearings and install them to the
bearing surface.
Install cover without gasket to T/M
housing surface and tighten bolts with 1.3
kgf.m.
Turn each shaft over 3times clockwise
and counterclockwise.
Remove cover and turn carefully shaft 1time clockwise and counterclockwise.
Measure the depths("A")from T/M housing surface to bearing surface 2points as 180
P O W E R T R A I N
If the difference of measurement is over B

0.1 , have to do repeatedly from to A
until the difference of measurement is below

0.01~0.03 .
Measure the stepped difference("B") of cover
to be assembled.
The compressed thickness of gasket is 0.5 .
The thickness of shims is calculated as below
formula
A(Average)-B(Average)+0.5(gasket thickness)
-0.1(end play) = Thickness of Shims
• Apply Loctite #569 onto the plug and install.

Tighten securely.
20
03
52
• Install the gasket.
• Install the cover assembly.
! CAUTION
Be very careful not to damage the oil
seal ring of the shaft when assembling.
P O W E R T R A I N
• Install the lock washers and hexagon socket

capscrews, apply Loctite #242 onto the thread
: 7.6 ± 0.3 kgf·m (60 ± 2 lb·ft)
! CAUTION
After assembly turn shafts, shafts have
to be turned smoothly.
If the shafts are not turned smoothly,
repeat the assembly procedure from
'calculating method of shim thickness'.
• Select the proper shim and install it to the

bearing surface of output shaft.
– Calculating method of shim thickness
Select the proper shims enough to push

the bearings and install them to the
bearing surface.
20
Install cover without gasket to T/M 03
housing surface and tighten bolts with 1.3 53
kgf.m.
Turn each shaft over 3times clockwise
A B
counterclockwise.
Remove cover and turn carefully shaft
1time clockwise and counterclockwise.
Measure the depths("A")from T/M housing
surface to bearing surface 2points as 180
If the difference of measurement is over
0.1 ,have to do repeatedly from to
until the difference of measurement is below
0.01~0.03 .
Measure the stepped difference("B") of cover
to be assembled.
The thickness of shims is calculated as
below formula
A (Average) - B (Average) - 0.1 (end play)
= Thickness of Shims
P O W E R T R A I N
• Press–fit the oil seal.
! CAUTION
Apply Loctite #RC/609 onto the outer
diameter of the oil seal.
• Install the lock washers and hexagon socket

: 7.6 ± 0.3 kgf·m (60 ± 2 lb·ft)
! CAUTION
After assembly turn shafts, shaft has to
be turned smoothly.
If the shaft is not turned smoothly,
20 repeat the assembly procedure from

'calculating method of shim thickness'.
03
54
• Install the spring pin.
• Install the valve gasket.
P O W E R T R A I N
• Install the valve assembly.
• Install the spring washer and socket head

: 4.4 ± 0.2 kgf·m (32 ± 2 lb·ft)
Quantity : 20EA
20
03
55
• Insert the O–ring onto the connector and
tighten securely.
• Install the gasket on the pump assembly.
P O W E R T R A I N
• Install the pump assembly and gasket.
• Install the spring washer onto each bolt, and

apply Loctite #242 onto the thread portion and
tighten it.
: 4.4 ± 0.2 kgf·m (32 ± 2 lb·ft) : 5EA
8.7 ± 0.3 kgf·m (63 ± 2 lb·ft) : 1EA
20
03
56
• Install the filter and apply Loctite #242 onto
the thread portion and tighten it.
: 4.4 ± 0.2 kgf·m (32 ± 2 lb·ft)
• Fit the O–ring onto the connector, install and

tighten securely.
P O W E R T R A I N
• Install the strainer.
• Insert the O–ring into the flange.
20
03
57
• Install the flange to the transmission case,
apply Loctite #242 onto the hexagon socket
capscrews and tighten.
: 8.7 ± 0.3 kgf·m (63 ± 2 lb·ft)
• Fit the O–ring onto the connector, install it to

the pump assembly, and tighten securely.
P O W E R T R A I N
• Install the clamps on the hose.
! CAUTION
• Remove any foreign material inside the
hose.
• Ensure that the inner and outer casings
are not damaged.
• Install the hose, ensure that it is the correct

length and not distored.
Tighten the clamps.
20
03
58
• Install the hose assembly.
Insure that the hose is not kinked due to a
misaligned fitting.
• Install the hose assembly.

Insure that the hose is not kinked due to a
misaligned fitting.
P O W E R T R A I N
• Fit the O–ring onto the thermo sensor, install

it in the transmission case, and tighten
securely.
• Install the dipstick tube.
! CAUTION
Apply Loctite #RC/609 onto the thread
20
03
59
• Install the oil dipstick.
• Install the cable bracket, and tighten the

hexagon socket capscrews.
P O W E R T R A I N
• Fit the copper gasket onto the plug, install

and tighten the plug securely.
• Fit the O–ring onto the magnetic plug, and

install it in the transmission case.
20
03
60
• Fit the O–ring onto the connector, install and
tighten securely.
! CAUTION
Install direction of connector is a
upwards
Fit the O–ring onto the plug, install and tighten

securely.
DISASSEMBLY AND ASSEMBLY OF THE CONTROL VALVE
Disassembly
Preparation :
• Dismantle the control valve in a clean environment.
• Use only clean solvent to wash the parts.
• Replace scored parts.
• Replace all O–rings and seals.
• Oil all sliding parts prior to assembly.
• Tighten capscrews and plugs to specified
Intended torque.
for CLARK dealers only
P O W E R T R A I N
• Remove the retaining nut and solenoid coil.
• Remove the ball valve cartridge.
20
03
61
• Remove the plug and O–rings.
• Remove the connector.
P O W E R T R A I N
• Remove the plug onto the accumulator case.
• Remove the plug onto the body case.
20
03
62
• Lubricating pressure control valve : remove the
plug, O–ring, and lube spool.
• Torque converter pressure control valve :

remove the cap and converter spool.
P O W E R T R A I N
• Regulating pressure control valve : remove the

cap and regulator spool.
• Lubricating pressure control valve : remove the

capscrew, cap, O–ring, seats, and spring.
20
03
63
• Torque converter pressure control valve :
remove the capscrew, cap, O–ring, seats, and
spring.
• Regulating pressure control valve : remove the

! CAUTION
Do not mix–up the springs in the valve
body.
P O W E R T R A I N
• Roosen cap assembly and nut.
• Remove the inching cylinder assembly.
20
03
64
• Remove the piston assembly into the inching
cylinder assembly.
• Remove the oil seal and wear ring.
P O W E R T R A I N
• Remove the capscrew and spring washer.
• Remove the accumulator assembly.
20
03
65
• Remove the rod assembly, piston washer,
inching spring, and inching spool.
• Remove the modulator spring and spool.
P O W E R T R A I N
• Remove the stop pin, springs, spool retaining

ring, washer, and O–ring of modulating
accumulators.
• Remove the springs and O–ring of inching.
20
03
66
• Remove the spring pins and plugs onto the
valve case.
Assembly
• Install the plugs and spring pins.

Quantity : plug → 4EA
spring pin → 2EA
P O W E R T R A I N
• Install the springs and O–ring, the portion of

inching into the accumulator case.
• Install the stop pin, springs, spool retaining

ring, washer, and O–ring the portion of
modulating accumulator into the accumulator
case.
20
03
67
• Install the modulator spring and spool into the
valve body case.
• Install the rod assembly, piston washer, inching

spring, and inching spool into the valve body
case.
P O W E R T R A I N
• Install the accumulator assembly.
• Install the capscrew and spring washer and

tighten the hexagon head capscrew.
: 2.3 ± 0.5 kgf·m (17 ± 3 lbf·ft)
20
03
68
• Install the oil seal and wear ring.
! CAUTION
Make the small end of oil seal outer
diameter toward the cone type of the
inching piston.
• Insert the piston assembly into the inching

cylinder housing assembly.
P O W E R T R A I N
• Install the inching cylinder assembly.
• Install the cap assembly and nut.
20
03
69
• Adjut the portion air breather is upward using
nut.
• Regulating pressure control valve : Install the

P O W E R T R A I N
• Torque converter pressure control valve : Install

the capscrew, spring washer, cap, O–ring,
seats, and spring.
• Lubricating pressure control valve : Install

capscrew, spring washer, cap, O–ring, seats,
and spring.
20
03
70
• Regulating pressure control valve : Install
capscrew, spring washer, cap and regulator
spool.
• Torque converter pressure control valve : Install

the capscrew, spring washer, cap and
converter spool.
P O W E R T R A I N
• Lubricating pressure control valve : Install the

plug, O–ring, and lube spool.
• Install the plug onto the body case and tighten.
20
03
71
• Install the plug onto the accumulator case and
tighten.
• Install the connector.
P O W E R T R A I N
• Install the plug and O–rings.
• Install the ball valve cartridge.

Quantity : 4 EA
: 3.5 kgf·m
20
• Install the retaining nut and solenoid coil.
03 Quantity : 4 EA
72 : 0.5~0.7 kgf·m
MOUNTING THE TRANSMISSION TO THE AXLE

• Apply Loctite #242 on to the thread and
tighten stud bolt.
P O W E R T R A I N
• Align the transmission assembly and drive axle

assembly.
• Install the lock washers and nuts.

: 17.9 ± 1.8 kgf·m (129 ±13 lbf·ft)
20
03
73
• Install the parking brake cable.
• Tighten the cable locking nut.
P O W E R T R A I N
• Tighten the nut and yoke.
• Insert the clevis pin into the yoke, and lock

with a snap pin.
20
03
74
• Install the cover and tighten the capscrews.
• Install the torque converter assembly.
P O W E R T R A I N
• Measure the distance between the torque

converter housing flange and the drive plate.
– The proper dimension is 66 mm.
REPLACING OF TRANSMISSION OIL FILTER

• Remove the filter canister.
20
03
75
• Remove the filter element.
• Replace a new element.
P O W E R T R A I N
• Install the ball case.
20
03
76
P O W E R T R A I N
TRANSMISSION MAINTENANCE GUIDE
CLEANING AND INSPECTION
CLEANING
Clean all parts thoroughly using solvent type cleaning fluid. It is recommended that parts be
immersed in cleaning fluid and moved up and down slowly until all old lubricant and foreign
material is dissolved and parts are thoroughly cleaned.
! CAUTION
Care should be exercised to avoid skin rashes, fire hazards and inhalation of vapors
when using solvent cleaners.
Bearings
Remove bearings from cleaning fluid and strike larger side of cone flat against a block of wood
to dislodge solidified particles of lubricant. Immerse again in cleaning fluid to flush out particles.
Repeat above operation until bearings are thoroughly clean. Dry bearings using moisture free
compressed air. Be careful to direct air stream across bearing to avoid spinning. Do not spin
20
bearings when drying. Bearings may be rotated slowly by hand to facilitate drying process.
Housings
Clean interior and exterior of housings, bearing caps, etc. thoroughly. Cast parts may be cleaned 03
in hot solution tanks with mild alkali solutions providing these parts do not have ground or 77
polished surfaces. Parts should remain in solution long enough to be thoroughly cleaned and
heated. This will aid the evaporation of the cleaning solution and rinse water. Parts cleaned in
solution tanks must be thoroughly rinsed with clean water to remove all traces of alkali. Cast
parts may also be cleaned with steam cleaner.
! CAUTION
Care should be exercised to avoid skin rashes and inhalation of vapors when using
alkali cleaners :
All parts cleaned must be thoroughly dried immediately by using moisture–free compressed air
or soft, lintless absorbent wiping rags free of abrasive materials such as metal filings, contamin-
ated oil or lapping compound.
Inspection
The importance of careful and thorough inspection of all parts cannot be overstressed.
Replacement of all parts showing indicaiton of wear or stress will eliminate costly and avoidable
failures at a later date.
Bearings
Carefully inspect all rollers, cages and cups for wear, chipping or nicks to determine fitness of
bearings for further use. Do not replace a bearing cone or cup individually without replacing the
mating cup or cone at the same time. After inspection,
Copyrighted dip bearings in clean light oil and wrap
Material
in clean lintless cloth or paper to protect them until installed.only
Intended for CLARK dealers
P O W E R T R A I N
Oil Seals, Gaskets and Retaining Rings

Replacement of spring load oil seals, “O” rings, metal sealing rings, gaskets and snap rings is
more economical when unit is disassembled than premature overhaul to replace these parts at
a future time. Further loss of lubricant through a worn seal may result in failure of other more
expensive parts of the assembly. Sealing members should be handled carefully, particularly when
being installed. Cutting, scratching, or curling under of a seal lip seriously impairs its efficiency.
Apply a thin coat of permatex No. 2 on the outer diameter of the oil seal to assure an oil tight
fit into the retainer. When assembling new metal type sealing rings, they should be lubricated
with a coat of grease to stabilize rings in their grooves for ease of assembly of mating members.
Lubricate all “O” rings and seals with recommended type Automatic Transmission Fluid before
assembly.
Gears and Shafts

If magna–flux process is available, use process to check parts. Examine teeth on all gears
carefully for wear, pitting, chipping, nicks, cracks or scores. If gear teeth show spots where case
hardening is worn through or cracked, replace with new gear. Small nicks maybe removed with
suitable hone. Inspect shafts and quills to make certain they are not sprung, bent, or splines
twisted, and that shafts are true.
Housing, Covers, etc.
20 Inspect housings, covers and bearing caps to be certain they are thoroughly cleaned and that
mating surfaces, bearing bores, etc., are free from nicks or burrs. Check all parts carefully for
evidence of cracks or condition which would cause subsequent oil leaks or failures.
03
78
LUBRICATION
RECOMMENDED LUBRICANTS FOR SHI POWERSHIFT TRANSMISSIONS AND

TORQUE CONVERTERS
TYPE OF OIL See Lube Chart.

CAPACITY Consult Operator’s Manual on applicable machine model for system
capacity. Torque Converter, Transmission and allied hydraulic system
must be considered as a whole to determine capacity.
CHECK PERIOD Check oil level DAILY with engine running at 700–800 RPM and oil
temperature at 82~93°C (180~200°F).
! It is recommended that filter elements be changed after 50 and

100 hours of operation on new and rebuilt or repaired units.
(a) Drain transmission and remove sump screen. Clean screen thoroughly
and replace, using new gaskets.
(b) Drain oil filters, remove and discard filter elements. Clean filter shells
and install new elements.
(c) Refill transmission to LOW mark.
(d) Run engined at 700–800 RPM and add oil to bring level to LOW
mark. When oil temperature is hot 82~93°C(180~200°F) make final
oil Intended
level check. BRINGdealers
for CLARK OIL only
LEVEL TO FULL MARK.
P O W E R T R A I N
SERVICING MACHINE AFTER TRANSMISSION OVERHAUL
The transmission, torque converter, and its allied hydraulic system are important links in the
drive line between the engine and the wheels. The proper operation of either unit depends
greatly on the condition and operation of the other ; therefore, whenever repair or overhaul of
one unit is performed, the balance of the system must be considerred before the job can be
considered completed.
After the overhauled or repaired transmission has been installed in the machine, the oil cooler,
and connecting hydraulic system must be thoroughly cleaned. This can be accomplished in
several manners and a degree of judgment must be exercised as to the method employed.
The following are considered the minimum steps to be taken :
• Drain engine system thoroughly.
• Disconnect and clean all hydraulic lines. Where feasible, hydraulic lines should be removed
from machine for cleaning.
• Replace oil filter elements, cleaning out filter cases thoroughly.
• The oil cooler must be thoroughly cleaned. The cooler should be “back flushed” with oil and
compressed air until all foreign material has been removed. Flushing in direction of normal oil
flow will not adequately clean the cooler. If necessary, cooler assembly should be removed
from machined for cleaning, using oil, compressed air and steam cleaner for that purpose. DO
NOT use flushing compounds for cleaning purposes.
• On remote mounted torque converters remove drain plug from torque converter and inspect
interior of converter housing, gears, etc. If presence of considerable foreign material is noted,
it will be necessary that converter be removed, disassembled and cleaned thoroughly. It is
realized this entails extra labor ; however, such labor is a minor cost compared to cost of
20
difficulties which can result from presence of such foreign material in the system. 03
• Reassemble all components and use only type oil recommended in lubrication section. Fill
79
transmission through filler opening until fluid comes up to LOW mark on transmission dipstick.
Run engine two minutes at 700~800 RPM to prime torque converter and hydraulic lines.
Recheck level of fluid in transmission with engine running at idle (700–800 RPM).
Add quantity necessary to bring fluid level to LOW mark on dipstick. Recheck with hot oil
(180–200°F).
Bring oil level to FULL mark on dipstick.
• Recheck all drain plugs, lines, connections, etc., for leaks and tighten where necessary.
MEASURING TORQUE CONVERTER STALL
• Start engine and run at low idle.

• Put the directional lever in Forward or Reverse, and speed control lever in the highest speed
range.
• Using the brake, stop the machine and measure the engine speed when the engine reaches
high idle.
Do not run at stall speed for more than 30 seconds, and do not let the torque converter oil
temperature rise above 120°C (248°F).
! Block the tires.
P O W E R T R A I N
HIGH STALL SPEED

Causes of high stall speed :
• Slipping clutch.
• Cavitating converter.
In general, when the stall speed is high, there is a problem in the converter and transmission
circuit, and it will be necessary to troubleshoot the system. There is no mystery to solving
problems, there is only good sense that begins with “LOOK FOR THE OBVIOUS FIRST.”
LOW STALL SPEED

Causes of low stall speed :
• Plugged air cleaners.
• Accelerator linkage not functioning properly.
• High altitudes.
• Dirty fuel filters.
• Restriction in the exhaust.
• Faulty injectors or nozzles.
• Incorrect fuel adjustment.
• Low compression.
In general, when the stall speed is low, there is a problem in the engine that must be corrected
before further checks can be made in the transmission and converter circuit, or in the hydraulic
20 circuit.
TROUBLESHOOTING
03
80 The following data is presented as an aid to locating the source of difficulty in a malfunctioning
unit. lt is necessary to consider the torque converter charging pump, transmission, oil cooler,
and connecting lines as a complete system when running down the source of trouble since the
proper operation of any unit therein depends greatly on the condition and operations of the
others. By studying the principles of operation together with data in this section, it may be
possible to correct any malfunction which may occur in the system.
TROUBLESHOOTING PROCEDURE BASICALLY CONSISTS OF TWO CLASSIFICATIONS :
MECHANICAL AND HYDRAULIC.
Mechanical checks
Prior to checking any part of the system from a hydraulic standpoint, the following mechanical
checks should be made :
• A check should be made to be sure the accelerator control lever linkage is properly connected
and adjusted at all connecting points.
• Check the transmission electric shift control unit, solenoid valves and related electrical wiring.
If transmission engagement is not correct, the problem may be in the control valve assembly.
P O W E R T R A I N
HYDRAULIC CHECKS
Before checking on the torque converter, transmission, and allied hydraulic system for pressures
and rate of oil flow, it is essential that the following preliminary checks be made :
Check oil level in transmission. This should be done with oil temperatures of 82~93°C
(180~200°F) DO NOT THESE CHECKS WITH COLD OIL. To bring the oil temperature to this
specification it is necessary to either work the machine or “stall” out the converter. Where the
former means is impractical, the latter means should be employed as follows :
Engage shift lever in forward and high speed and apply brakes. Accelerate engine half to
three–quarter throttle.
Hold stall until desired converter outlet temperature is reached.
! CAUTION
Full throttle stall speeds for an excessive length of time will overheat the converter.
CAUSE REMEDY
LOW CLUTCH PRESSURE 1. Low oil level 1. Fill to proper level.
2. Clutch pressure regulating 2. Clean valve spool and
valve spool stuck open. housing.
3. Faulty charging pump. 3. Replace pump.
4. Broken or worn clutch shaft 4. Replace sealing rings.
or piston sealing rings.
5. Clutch piston bleed valve
stuck open.
5. Clean bleed valves
thoroughly. 20
LOW PRESSURE OF 1. Low oil level 1. Fill to proper level.
CHARGING PUMP 2. Suction screen plugged. 2. Clean suction screen 03
OUTPUT 3. Air leaks at pump intake 3. Tighten all connections or 81
hose and connections or replace hose if necessary.
collapsed hose.
4. Defective oil pump. 4. Replace pump.
OVERHEATING 1. Worn oil sealing rings. 1. Remove, disassemble, and

rebuild converter assembly.
2. Worn oil pump. 2. Replace.
3. Low oil level. 3. Fill to proper level.
4. Pump suction line taking air. 4. Check oil line connections
and tighten securely.
NOISY CONVERTER 1. Worn oil pump. 1. Replace.

2. Worn or damaged bearings. 2. A complete disassembly will be necessary
3. Worn converter to determine what bearing is faulty.
3. Replace
LACK OF POWER 1. Low engine RPM at 1. Tune engine, check governor.

converter stall.
2. See “Overheating” and make 2. Make corrections as
same checks. explained in “Overheating”.
P O W E R T R A I N
PRESSURE AND CHECK PORTION AND OIL FILLING PORT

1. PORT “A”
Main pressure supplied to the control valve by charging pump
Specification : 20 ±1 kg/cm2 (285±14 psi)
2. PORT “B”
Main pressure supplied to the clutch pack when shifting to forward 1st
Specification : 17.5 ±1 kg/cm2 (250 ±14 psi)
3. PORT “C”
Main pressure supplied to the clutch pack when shifting to forward 2nd
4. PORT “D”
Main pressure supplied to the clutch pack when shifting to reverse 1st
5. PORT “E”
Main pressure supplied to the clutch pack when shifting to reverse 2nd
Specification : 17.5 ± 1 kg/cm2 (250 ± 14 psi)
20 6. PORT “F”
Torque converter relief pressure
Specification : 3~7.5 kg/cm2 (42~106 psi)
03
82 7. PORT “G”
Pressure supplied to the lubricating line of each shaft of transmission
Specification : 0.5~3kg/cm2 (7~43 psi)
8. PORT “H”
Transmission oil level gauge
9. PORT “J”
Transmission oil filter assembly
10. PORT “K”

Transmission oil filling port
11. PORT “L”

Drive axle oil filling port
12. As shifting to each step, the remaining pressure of other shift step shall be less than
1 kg/cm2 (14 psi).
P O W E R T R A I N
J K
C
Reverse 2nd solenoid valve
B
Reverse 1st solenoid valve
Forward 2nd solenoid valve
Forward 1st solenoid valve

20
F H A G 03
83
P O W E R T R A I N
MAINTENANCE STANDARD
TRANSMISSION GEAR BOX SHAFT UNIT
1 10 5 11 8 11 9 1
20 6
7
03
84
2 3 4
P O W E R T R A I N
Unit : mm
Content Remark
No. Inspecting point Tolerance Standard Limit
Standard dimension
Shaft Hole clearance clearance
Clearance of Outer + 0.025 – 0.013 – 0.063 ~

62 –
both bearings diameter 0 – 0.038 – 0.013
1 of input, lay
shaft Inner + 0.038 + 0.013 – 0.038 ~
29.987 –
diameter + 0.025 0 0.012

62 –
rear bearing of diameter 0 – 0.038 – 0.013
2 output shaft
Inner + 0.038 + 0.013 – 0.038 ~
31.75 –
diameter + 0.025 0 – 0.012
Clearance of Outer 0 – 0.041 – 0.076 ~

73.431 –
front bearing of diameter – 0.016 – 0.076 – 0.057
3 output shaft
Inner + 0.021 0 – 0.033 ~ Replace
41.275 –
diameter + 0.002 – 0.012 – 0.002
4
Clearance of oil
seal of output
shaft
Outer
diameter
58
+ 0.35
+ 0.15
+ 0.046
0
– 20
Inner
40
0
– – 03
diameter – 0.052
85
Clearance of Outer – 0.008 – 0.040 ~
45 ± 0.007
needle bearing diameter – 0.033 – 0.015
5 of 1st, 2nd
gear Inner – 0.009
35 – –
diameter – 0.025
Backlash of 1st
6 0.10~0.25 (0.004~0.010 in.)
gear set
Backlash of
7 0.10~0.25 (0.004~0.010 in.)
2nd gear set
Backlash of
8 forward/reverse 0.10~0.25 (0.004~0.010 in.)
gear set
Thickness of 3.95~4.00 (min. 3.15)

9
washer (0.155~0.157 in) (min. 0.124 in)
Thickness of
10 3.95~4.00 (min. 3.15)
washer
Moving distance 1.8~2.0

11
of clutch pack (0.071~0.079 in)
P O W E R T R A I N
CHARGING PUMP DRIVING UNIT
5 2 4 1 6 7 3
Unit : mm
Content Remark
20 No. Inspecting point

Standard dimension
Tolerance
Shaft Hole
Standard
clearance
Limit
clearance

03 idler bearing diameter
59.131
0 – 0.038 – 0.003
–
86 1
Inner 0 + 0.013 – 0.055 ~
31.75 –
diameter – 0.013 0 – 0.013
Clearance of Outer + 0.022
85 – – –
bearing of diameter – 0.013
2 charging pump
Inner + 0.013 Replace
driving shaft 45 – – –
diameter + 0.002
Clearance of Outer + 0.35 + 0.063 – 0.35
150 –
oil seal of diameter + 0.15 0 – 0.087
3 charging pump
Inner 0
driving gear 130 – – –
diameter – 0.1
Clearance
between idler
4 0.10~0.25 (0.004~0.010 in.)
gear and
driving gear
Tightening
5 5.8~7.2 kgf·m (42~52 lbf·ft)
torque of bolt
Tightening
6 10.2~12.4 kgf·m (74~90 lbf·ft) Retighten
torque of bolt
Tightening
7 Copyrighted
5.8~7.2Material
kgf·m (42~52 lbf·ft)
torque of bolt Intended for CLARK dealers only
P O W E R T R A I N
DIFFERENTIAL GEAR REDUCTION UNIT
11 4 3 2 5 7 1 10 9 8 6 20
03
87
P O W E R T R A I N
(Unit : mm)
Content Remark
Standard dimension
Clearance of Outer + 0.025 + 0.025 – 0.025 ~

82.931 –
side bearing diameter 0 0 + 0.025
1 of differential
Inner + 0.089 + 0.013 + 0.038 ~
gear assembly 45.6182 –
diameter + 0.051 0 + 0.089

90 –
front bearing diameter – 0.020 – 0.059 – 0.004
2 of bevel pinion
Inner + 0.029 0 – 0.041 ~
gear 50 –
diameter + 0.009 – 0.012 – 0.009

84 –
rear bearing diameter – 0.020 – 0.059 – 0.004
3 of bevel pinion
Inner + 0.029 0 – 0.041 ~ Replace
gear 50 –
diameter + 0.009 – 0.012 – 0.009
20 4
Clearance of
oil seal of
cover
Outer
diameter
58 –
+ 0.046
0
–
03 Inner
40
0
– –
diameter – 0.062
88
Backlash of
5 0.13~0.18 (0.005~0.007 in)
bevel gear set
Working torque
6 of bevel gear 0.08~0.34 kgf·m (7~29 lbf·in)
set
Backlash of
7 differential 0.0~0.36 (0.0~0.014 in)
gear set
Front vibration
8 of bevel gear max. 0.1 (0.004 in)
set
Tightening
9 5.8~7.2 kgf·m (42~52 lbf·ft)
torque of bolt
Tightening
10 10.2~12.4 kgf·m (73~89 lbf·ft) Retighten
torque of bolt
Tightening
11 8.5~9.0 kgf·m (61~65 lbf·ft)
torque of bolt
P O W E R T R A I N
HUB REDUCTION UNIT
9 10 7 5 8 4
20
03
89
3 2 1 11 6
P O W E R T R A I N
Unit : mm
Content Remark
Standard dimension

140 –
hub inner diameter – 0.025 – 0.068 – 0.003
1 bearing
Inner + 0.035 0 – 0.055 ~
90 –
diameter + 0.013 – 0.020 – 0.013

155 –
hub outer diameter – 0.025 – 0.068 – 0.003
2 bearing
Inner + 0.035 0 – 0.055 ~
100 –
diameter + 0.013 – 0.020 – 0.013
Clearance of Outer + 0.065

180 – – –
hub oil seal diameter 0
3
Inner 0
155 – – –
diameter – 0.1
20 4
Backlash of
planetary gear
and sun gear
0.10~0.25 (0.004~0.010 in) Replace
03
Backlash of
90
5 planetary gear 0.10~0.25 (0.004~0.010 in)
and sun gear
Clearance
1.5~1.7 (max. 1.9)
6 between piston
(0.060~0.067 in) (max 0.075 in)
and plate
Clearance
between washer
7 0.7~1.1 (0.028~0.043 in)
and planetary
gear
Limit thickness
8 1.0 (0.039 in)
of washer
Tightening
9 torque of hub 1~3 kg·m (7~22 lbf·ft)
bearing
Tightening Retighten
10 10.2~12.4 kgf·m (74~90 lbf·ft)
torque of bolt
Tightening
11 16.1~19.7 kgf·m (116~142 lbf·ft)
torque of bolt
STEERING SYSTEM 30
• 30–01 FUNCTION AND MAINTENANCE
• 30–02 STEERING UNIT
• 30–03 PRIORITY VALVE
S T E E R I N G S Y S T E M
FUNCTION AND MAINTENANCE
OUTLINE
• The oil from hydraulic tank (6) is sent to priority valve (2) by steering pump (5).
• When the steering wheel is turned ; the movement is transmitted via the steering column shaft
to steering unit (1), which activates priority valve (2).
• The distribution of the oil flow through the priority valve is controlled by the “LS” signal from
30
the steering unit. 01
• The oil flow necessary for steering flows through priority valve “CF” port to the steering unit
1
then to the steering cylinder.
The oil not required for the steering, flows to the main control valve through “EF” port of the
priority valve.
• When the steering wheel is not operated all the oil from steering pump (5) flows to the main
control valve, except for 0.5 l /min. which flows to the steering unit to provide an immediate
response when the steering wheel is operated.
NEUTRAL POSITION
• When the steering wheel is not operated, the neutral position springs of steering unit (1) return
the sleeve to a neutral position in relation to the spool. The spool is centered on the pin
secured in the sleeve.
• Under this condition oil from steering pump (5) flows to “P” port of priority valve (2).
Since the ports to the steering cylinder are closed in steering unit (1) pilot pressure “PP” signals
priority valve (2) and all the oil (except for 0.5 l /min.) from the steering pump flows through the
“EF” port to the main control valve.
OPERATING PRINCIPLE DURING LEFT/RIGHT TURN
• When the steering wheel is turned left/right, the spool within steering unit (1) spline–fitted to
the steering column shaft will rotate in a left/right–hand direction.
• Oil from steering pump (5) flows to “P” port of priority valve (2). The position of the valve spool
is determined when the pressure difference between the front and rear orifices is balanced with
the spool spring force.
• The high pressure oil flows through “CF” port of the priority valve to steering unit (1). The flow
is directed through the steering unit to the steering cylinder according to the rotational direction
of the steering wheel. Oil flow to the steering cylinder is in proportion to the angular rotation
of the steering wheel.
• Return oil from the left/right cylinder chamber flows through “T” port of the steering unit to
tank.
• The progression of this operation articulates the machine in the desired direction.
SPECIFICATION
CMP40/45D/50SD CMP40/45L/50SL
SF35/40/45D SF35/40/45L
Displacement (cc/rev) 160 140
Relief pressure (kg/cm2(psi)) 140 (2000) 110 (1570)
30
01
2
STEERING UNIT
CONSTRUCTION
30
01
3
1. Steering Column 7. Cardan shaft

2. Neutral position springs 8. Stator
3. Housing 9. Rotor
4. Check valve 10. Pin
5. Spool 11. Gerotor
6. Sleeve
FUNCTION
Breakdown of functions according to sub–assembly
ROTARY VALVE BANK
• Three positions : Neutral Position

Right hand feed position
Left hand feed position
• In neutral position it has the following function
– Lock steering cylinder power supply (no reaction)
– Lock steering unit set power supply
• In feed position (right or left hand)
– It directs the oil from the pump to the gerotor set.
– It directs the oil from gerotor set towards the steering cylinder and the cylinder return flow
towards the tank.
GEROTOR SET
• Delivers an oil flow proportional to steering wheel turning motion.

• Ensures steering hydraulic servo–assistance.
• Functions as a hand pump when the pump has no flow (safety), however steering wheel
operating force is very heavy.
Operation of the rotary valve bank is connected to the gerotor set by the cardan shaft. Each
30 of these components fulfils specific functions which are put into motion by turning the steering
wheel.
01 DESCRIPTION
4
The steering unit device consists of a rotary valve bank spool (5), sleeve (6) and gerotor set (8),
(9) flanged to main housing (3).
The steering column (1) drives spool (5) ; inside sleeve (6) and these two parts turn at ± 8° in
relation to each other.
These parts are positioned at an angle by means of neutral position springs (2). When the
steering wheel is not turned (Neutral position), the springs return the sleeve to a neutral position
in relation to the spool.
The cardan shaft (7) is integral with sleeve (6) by pin (10) with stator (8) and rotor (9).
Steering check valve (4) enables the steering cylinder return flow to be reinjected direct for power
supplying the device (closed circuit).
During normal operation the valve is closed.
OPERATION
RIGHT–HAND TURNING
When the steering wheel is turned, selector

spool (5) turns in relation to feed sleeve (6) ;
pin (10) which is tightly secured in sleeve (6),
goes through spool (5) via a hole with a
diameter larger than that of the pin.
This enables the spool to rotate on either side
by 8°. As a result of this, the cylinder feed lines
open progressively, the return ports to the tank
close and the oil is directed towards gerotor
set (11) which directs the oil towards the steering
cylinder. The volume of fluid discharged is in
direct proportion to the angular movement of the
steering wheel. As from 8° the spool and sleeve
turn at the same speed and constitute a follow-
up system.
If the steering is no longer activated, the center-
ing springs push feed sleeve (6) to a neutral
position. The oil from the pump is once again
channelled towards the tank and the cylinder
chambers are locked.
NEUTRAL POSITION
30
01
The spool and sleeve are centered in relation to
5
each other by the springs. Aligned ports channel
the oil from the pump to the tank (centre open).
The cylinder ports are closed (no reaction), so if
the steering axle strikes an obstacle, no repercu-
ssions are felt at the steering wheel.
MANUAL CONTROL
As soon as an operating fault arises upstream

of the device (engine shut-down during travel,
damage to component, burst pipe), the gerotor
set is automatically converted to a manual emer-
gency pump which ensures closed circuit power-
supply of the steering cylinder.
When the steering wheel is turned, the selector spool turns too. When it reaches 8°, the pin
drives the feed sleeve and the gerotor set by means of the cardan shaft. Under these conditions,
the steering unit operates as a manual pump and discharges the oil towards the steering cylinder.
Pressure depends on the torque exerted by the operator on the steering wheel.
TIMING GEROTOR ASSY.
• Before disassembling for checking, mark the position of the various components.
• When reassembling :
– Position feed ports facing you.
– Mount the gears (1–2) so that the position of one of the rotor (1) teeth (4) corresponds to
that shown in relation to the slot of the cardan shaft (3).
If this timing is not observed, steering tends to turn automatically in the reverse direction to that
of the steering wheel (operates as a motor).
30
01
6
CHECKING AND ADJUSTING RELIEF PRESSURE
The steering system relief pressure is adjusted by the relief valve in the steering unit, specification
140 kgf/cm2 (1992 psi). If the relief pressure setting is higher than specification it can cause defects
of the hydraulic hoses, tear the steering cylinder seal, and cause damage to the steering shaft
link. If the relief pressure setting is lower than specification, excessive force is required to turn
the steering wheel.
CHECK
! Loosen the oil filler cap on the hydraulic tank and operate the steering wheel several
times to release the pressure in the hydraulic circuit.
1. Engage the parking brake and put the transmission into neutral.
2. Block the driving wheels.
3. Remove the plug (PT 1/8" ) from the fitting on the steering cylinder.
4. Install the hydraulic pressure gauge 0~350 kg/cm2 (0°~5000 psi)
5. Start the engine and run at high idle.
6. Turn the steering wheel and measure the pressure when the relief valve is actuated.
ADJUSTMENT
• Remove plug
30
01
7
• Adjust the pressure.

– Specification : 140 kgf/cm2 (1992 psi)
– To increase : turn clockwise
– To decrease : turn counter–clockwise
TROUBLESHOOTING
Steering systems with load sensing
Fault Possible cause Remedy
Steering wheel is • Insufficient oil pressure. • Check the oil pressure.

heavy to turn. ➀ pump drive defective. ➀ Replace pump drive.
➁ Pump is worn out. ➁ Replace pump.
• Pressure relief valve is stuck in • Repair or clean pressure relief

open position or setting valve. Adjust the valve to the
pressure is too low. correct pressure.
• Priority valve spool stuck. • Clean or replace valve.
• Too much friction in the • Grease/repair axle knuckle pins,

mechanical parts of the steering cylinder pins, steering
steering system. column bearings.
Check the hydraulic cylinder for
malfunction.
Constant steering • Leaf springs without spring • Replace leaf springs.

is necessary for force or broken.
straight travel. • Spring in relief valve broken. • Replace relief valve.
(“Snake–like driving”) • Gerotor assy worn. • Replace gerotor assy.
• Cylinder scored or piston seals • Replace defective parts.
30 worn.
Neutral position of • Steering column and steering • Align the steering column with
01 steering wheel unit out of alignment. steering unit.
8 can not be obtained, • Too little or no end play • Adjust the end play and if
i.e. there is a between steering column and necessary, shorten the splined
tendency towards steering unit input shaft. shaft.
“motoring”. • Pinching between inner and • Dismantle the steering unit and
outer spools. repair as required.
“Motoring” effect. • Leaf springs are stuck or • Replace leaf springs.

The steering wheel broken and therefore have
can turn on its own. reduced spring force.
• Inner and outer spools sticking • Dismantle the steering unit and
possibly due to dirt. clean/repair as required.
Backlash • Cardan shaft fork worn or • Replace cardan springs.

broken.
• Leaf springs without spring • Replace leaf springs.
force or broken.
• Worn splines on the steering • Replace steering
column. column/shaft.
Shimmy–abnormal • Air in the steering cylinder. • Bleed steering system, remedy

vibration of steering cause of air ingression.
wheel. • Worn axle knuckles or steering • Replace worn parts.
cylinder pins.
• Leaking relief valve and • Repair/replace relief valve,
anticavitation valves or broken anticavitation valves.
valve springs. Replace the springs.
Steering wheel can be • Oil is needed in the tank. • Fill with clean oil and bleed the
turned continuously system.
without articulating the • Steering cylinder worn. • Replace or repair cylinder.
steering axle wheels. • Gerotor set worn. • Replace gerotor set.
• Spacer across cardan shaft • Install spacer.
missing.
Steering wheel can be • One or both anticavitation valves • Clean or replace defective
turned slowly in one leaking. valves.
or both direction • Relief valve leaking. • Clean or replace defective
without articulating the valve.
axle wheels.
Steering is too slow • Insufficient oil supply to steering • Replace pump.

and heavy when unit, pump defective.
trying to turn quickly. • Relief valve setting too low. • Adjust valve to correct setting.
• Relief valve sticking owing to dirt.
• Check valve in emergency
• Clean the valve.
• Clean or replace the check 30
steering unit stuck open allowing valve.
pressure to return to tank.
01
(if equipped) 9
Heavy kick–back in • Incorrect setting of cardan shaft • Correct setting as shown in

steering wheel in both and gerotor set. service manual.
directions.
Turning the steering • Hydraulic hoses for the steering • Reverse the hoses.
wheel articulates the cylinder have been interchanged.
axle wheels in the • Incorrect assembly of cardan • Reassemble correctly
opposite direction. shaft and gerotor.
Hard point when • Pump output low. • Check pump flow.

starting to turn the • Relief valve set pressure to low. • Inspect relief valve and adjust.
steering wheel. Replace the valve if defective.
• Cross–over relief valve set
pressure to low. (if equipped)
• Priority valve spool orifice blocked. • Clean spool orifice.
• Oil is too thick (cold). • Let motor run until oil is warm.
Leakage at either input • Shaft defective. • Replace shaft seal, see service
shaft, end cover, manual.
gerotor set, housing or • Screws loose. • Tighten screws (3 ± 0.3 kgf · m).
ports. • Washers or O–rings defective. • Replace washers or O–rings.
30
01
10
STEERING UNIT
STEERING UNIT
TOOLS
• Holding tool.
• Assembly tool for O–ring and kin–ring.
• Assembly tool for cardan shaft.

30
02
1
• Assembly tool for dust seal.
STEERING UNIT
• Torque wrench 0~7 kgf·m (0~50 lbf·ft)

13 mm socket (12 point).
6, 8 and 12 mm hexagon sockets.
12 mm screwdriver.
2 mm screwdriver.
13 mm box end wrench.
6, 8 and 12 mm hexagon L wrench.
Plastic hammer.
Tweezers.
The tools listed are not available from
SAMSUNG.
DISASSEMBLY
In repair, keep all parts clean.

Be sure the steering unit is thoroughly cleaned
and free of dirt and debris prior to disassembly.
• Place the steering unit in the holding tool and

remove the screws in the end cover (6–plus
one special screw).
30 • Remove the end cover, sideways.
02
2
• Lift the gerotor set (with spacer if fitted) off the

unit. Take out the two O – rings
STEERING UNIT
• Remove cardan shaft.
• Remove distributor plate.
• Screw out the threaded bushing over the check

valve. 30
02
3
• Remove O – ring.
STEERING UNIT
• Shake out the check valve ball (φ 8 mm).

Shake out the two anticavitation check valve
balls. (if equipped)
• Take care to keep the cross pin in the sleeve

and spool horizontal. The pin can be seen
through the open end of the spool. Press the
spool inwards and the sleeve, ring, bearing
races and needle bearing will be pushed out
of the housing together.
30 • Take the ring, bearing races and needle

bearing from sleeve and spool. The outer (thin)
bearing race can sometimes “stick” in the
02 housing, therefore check that it has come out.
4
• Press out the cross pin. Use the special screw

from the end cover
STEERING UNIT
• A small mark has been made with a pumice

stone on both the spool and sleeve close to
one of the slots for the neutral position
springs (see drawing).
If the mark is not visible, remember to leave
a mark of your own on sleeve and spool
before the neutral position springs are
disassembled.
• Carefully press the spool out of the sleeve.
• Press the neutral position springs out of their

slots in the spool. 30
02
5
• Remove dust seal O–ring / kin–ring.
STEERING UNIT
• Screw out the plug using an 8 mm hexagon L

wrench. Remove seal washers.
• Unscrew the relief set screw using an 8 mm

hexagon L wrench.
30 • Shake out the spring and piston. The valve

seat is bonded into the housing and cannot be
removed.
02
6
• The pressure relief valve is now disassembled.
STEERING UNIT
ASSEMBLY
Before assembly clean all parts very carefully, replace all seals and O–rings, and lubricate all
parts with hydraulic oil.
• Assemble spool and sleeve.
! When assembling spool and sleeve, only one of two possible ways of positioning the
spring slots is correct. There are three slots in the spool and three holes in the sleeve
at the end of the spool / seeve opposite to the end with spring slots. Place the slots
and holes opposite each other so that parts of the holes in the sleeve are visible
through the slots in the spool.
• Place the two flat neutral position springs in

the slot.
Place the curved springs between the flat ones
and press them into place.
• Line up the spring set.

30
02
7
• Guide the spool into the sleeve. Make sure that

spool and sleeve are placed correctly in
relation to each other.
STEERING UNIT
• Press the springs together and push the neutral

position springs into place in the sleeve.
• Line up the springs and center them.
30 • Guide the ring down over the sleeve.
! The ring should be able to rotate free of

02 the springs.
• Fit the cross pin into spool / sleeve.
STEERING UNIT
• Fit bearing races and needle bearing as

illustrated.
Assembly pattern for standard bearings.

– Outer bearing race 1 ;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;; ;;;;;;;
– Needle bearing
– Inner bearing race ∗ (thicker) ;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
2
– Spool ;;;;;;; ;;;;;;;
;;;;;;;
;;;;;;; ;;;;;;;
;;;;;;;
– Sleeve 3
• Turn the steering unit until the bore is

horizontal. Guide the outer part of the assembly 30
tool into the bore for the spool / sleeve.
02
9
• Grease O–ring and Kin–ring with hydraulic oil

and place them on the tool.
STEERING UNIT
• Hold the outer part of the assembly tool in the

bottom of the steering unit housing and guide
the inner part of the tool completely to the
bottom.
• Press and turn the O–ring / Kin–ring into

position in the housing.
30 • Draw the inner and outer parts of the assembly

tool out of the steering unit bore, leaving the
guide from the inner part in the bore.
02
10
• With a light turning movement, guide the spool

and sleeve into the bore.
! Fit the spool set holding the cross pin

horizontal.
STEERING UNIT
• The spool set will push out the assembly tool

guide. The O–ring and Kin–ring are now in
position.
• Turn the steering unitil the bore is vertical

again. Put the check valve ball into the hole
indicated by the arrow.
• Screw the threaded bushing lightly into the

check valve bore. The top of the bushing must 30
lie just below the surface of the housing.
02
11
• Grease the O–ring with mineral oil approx.

viscosity 500cst at 20°C.
STEERING UNIT
• Place the distributor plate so that the channel

holes match the holes in the housing.
• Guide the cardan shaft down into the bore so

that the slot is parallel with the connection
flange.
30 • Place the cardan shaft as shown so that it is

held in position by the mounting fork.
02
12
• Lubricate the two O–rings with mineral oil

approx. viscosity 500cst at 20°C and place
them in the two grooves in the gerotor assy.
Fit the gerotor assembly on the cardan shaft.
STEERING UNIT
• Fit the rotor and cardan shaft so that a tooth

base in the rotor is positioned in relation to the
shaft slot as shown. Turn the stator so that the
seven through holes match the holes in the
housing.
• Fit the spacer, if any.
• Place the end cover in position.

30
02
13
• Fit the special screw with washer and place it

in the hole shown.
STEERING UNIT
• Fit the six screws with washers and insert

them. Cross–tighten all the screws evenly in
several stages.
: 3 ± 0.3 kgf·m (22 ± 2 lbf·ft)
• Place the dust seal ring in the housing.

The dust seal ring must be placed only after
the pressure relief valve has been fitted.
30 • Fit the dust seal ring in the housing using

special tool and a plastic hammer.
02
14
• Press the plastic plugs into the connection

ports. Do not use a hammer!
STEERING UNIT
• Fit the piston.
• Fit the spring.
• Screw in the relief set screw with an 8 mm

hexagon L wrench. Adjust the pressure setting 30
on a test bench or in the vehicle.
02
15
• Install the plug with dust seal into the housing

using an 8 mm hexagon L wrench.
: 5.1 ± 1 kgf·m (37 ± 7 lbf·ft)
PRIORITY VALVE
PRIORITY VALVE
TOOLS
• Open–end spanner 27 mm.

Multigrip pliers.
Nylon pin.
Hexagon L wrench 5, 8 and 10 mm.
These tools are not available from SAMSUNG.
DISASSEMBLY
• Screw out the PP plug using the open–end

spanner. Remove the O–ring.
• Screw out the LS plug using the open–end

30
spanner. Remove the O–ring. 03
1
• Take out the spring.
PRIORITY VALVE
• Press out the spool using the nylon pin.
ASSEMBLY
• The illustration shows the external PP spool

and external PP plug. The external PP plug
can only be used with the external PP spool.
30 • Guide the spool into the bore. Use the nylon

pin to centre the spool in the bore.
03
2
• Guide the spring and LS plug into the bore.

Remember the O–ring.
PRIORITY VALVE
• Screw in the PP plug (with O–ring) and LS

plug (27 mm open–end spanner).
: 6 kgf·m (43 lbf·ft)
30
03
3
BRAKE SYSTEM 40
• 40–01 GENERAL
• 40–02 ADJUSTMENTS
• 40–03 BLEEDING BRAKE
• 40–04 REMOVAL/INSTALLATION
• 40–05 BRAKE VALVE
B R A K E S Y S T E M
GENERAL
GENERAL
FEATURES
The fork lift is equipped with a hydraulic over hydraulic brake system consisting of a hydraulic
booster type brake valve and axle wheel end multi wet disc service brakes.
The hydraulic booster type brake valve and the enclosed multi wet disc brakes provide high
braking performance regardless of working conditions.
OPERATING PRINCIPLE AND FUNCTIONS
Brake rod Brake line
Brake pedal Brake valve Brake assembly
Hydraulic line Hydraulic line
Hydraulic pump Hydraulic tank
The principle of actuation is as follows :

When the brake pedal is operated, push rod (1) of the brake valve power assist section (3)
pushes pistons (5, 7) thereby forcing the brake oil from the master cylinder section (18) to the
wheel end brake pistons applying the multi wet disc brakes.
40
As the pedal is depressed the hydraulic power assist return circuit through the brake valve is
blocked and the pressurized oil from the brake pump acts on the large diameter of piston (7),
01
thereby exerting greater force on the brake oil displaced by the master cylinder. This generates 1
high braking pressures with minimal brake pedal effort, enhancing over all brake performance.
The brake pump circuit is protected by a relief valve built into the brake valve assembly.
INCHING OPERATION (Powershift transmission)
The inching system allows the transmission directional clutch pack to slip so that travel speed
and lift speed can be independent.
An electric sensor mounted on the inching pedal bracket sends a signal to the transmission to
regulate the pressure acting on the directional clutch pack when the inching pedal is operated.
The first portion of the inching pedal stroke activates the inching function, then the remaining
stroke operates the brake system. Both pedals are mounted
Copyrighted Material on a common shaft and the inching
pedal interlocks with the brake pedal.
ADJUSTMENT
ADJUSTMENT
BRAKE PEDAL AND INCHING PEDAL HEIGHT AND FREEPLAY
• Recommended height and freeplay of the brake

pedal and inching pedal .
Freeplay
7~10mm
155mm
! CAUTION
Incorrect pedal stroke adjustment can cause transmission overheating.
• Block the wheels and release the parking brake.

• Fully depress the inching pedal to maximum stroke.
• Put the transmission directional control lever in neutral position.
• Accelerate the engine RPM to maximum.
• Shift the directional control lever to Forward. If the engine RPM decreases, the inching pedal
stroke must be adjusted.
! Be prepared for the vehicle to move !

• Turn the start key to “OFF”, apply the parking brake, and adjust the pedal stop bolt (A,B) about
6mm. Start the engine and repeat above procedure.
• If the engine RPM decreases, check the inching valve for the transmission.
40
PARKING BRAKE 02
1
The parking brake unit installed on the transmission output shaft, is operated by mechanical
force of the toggle type parking brake lever.
• Check if the parking brake works properly when
you apply and release repeatedly. Release
• Recommended applying force range :
15~30 kgf (33~66 lbf). Lock
BLEEDING BRAKE
BLEEDING BRAKE
The purpose of bleeding the brake system is to remove any air trapped in the hydraulic circuit
which can cause spongy brakes and brake fading.
SERVICE BRAKES
! CAUTION
Use hydraulic oil in the service brake system.
• Fill the brake reservoir with hydraulic oil, and maintain full level during the bleeding procedures.
• Install a clear vinyl hose onto the axle wheel end bleeder screw and place the other end in
a container.
• Depress the brake pedal several times to build up the circuit pressure.
• While depressing the pedal loosen the bleeder screw and observe the flow of hydraulic oil for
air bubbles.
• Close the bleeder screw while the brake pedal is still depressed.
• Repeat the procedure until there are no air bubbles in the flow of hydraulic oil.
• Then bleed the opposite wheel end brake assembly.
• When the air bleeding is completed, fill the brake reservoir.
! Two workers are required for this operation ; one depresses the pedal and the other
bleeds the system.
40
03
1
REMOVAL / INSTALLATION
REMOVAL / INSTALLATION OF MASTER

CYLINDERS AND PEDAL ARRANGEMENT.
The brake system is divided into 3 parts as follows :

1. Brake and inching pedal arrangement
2. Brake master cylinder
3. Inching master cylinder
! CAUTION
Before disassembling the brake system, shut off the engine, engage the parking brake
and block the wheels.
BRAKE AND INCHING PEDAL ARRANGEMENT
1. To remove the pedal arrangement remove 1 2

split pins (6, 9) and clevis pins (7, 8) connec-
6
ting the pedal rods to the brake master 7
cylinder and master cylinder. 3
2. Remove mounting bolts (2, 4pcs) for the
bracket and remove the pedal assembly.
3. Remove pedal rod (3) from brake pedal 9
8
bracket (1). 10
4. Installation is the reverse order of removal. 5
BRAKE MASTER CYLINDER (VALVE)
1. To remove the brake master cylinder discon-

40
nect the hydraulic hose and brake tube from 04
the master cylinder. 1
brake master cylinder bracket.
3. Remove split pin (3) and clevis pin (2).
4. Remove split pin (6) and remove hub rod (5).
5. Remove mounting bolts (4, 3pcs) and remove
brake master cylinder (7).
6. Installation is the reverse order of removal.
REMOVAL / INSTALLATION
INCHING MASTER CYLINDER
1. To remove the inching master cylinder,

disconnect the hose from the brake fluid 9
reservoir and remove the tube to the inching 8
slave cylinder. 7
3
4
inching master cylinder bracket. 5
3. Remove split pin (9) and clevis pin (8).
4. Remove clevis (7) and inching rod (5).
5. Remove mounting bolts (4, 2pcs) and remove 1
inching master cylinder (1).

6. Installation is the reverse order of removal.
40
04
2
BRAKE VALVE
BRAKE VALVE
DISASSEMBLY
• Remove the brake valve from the fork lift as previously described.
• Separate the master cylinder unit and the power assist unit by removing the 2 capscrews and
the plain washers.
ASSEMBLY
• Install the spacer between the sections (if

fitted).
• Assemble the master cylinder unit and the
power assist unit with the 2 capscrews and the
plain washers.
: 3.04~3.46 kgf·m (22~25 lbf·ft)
DISASSEMBLY AND ASSEMBLY OF POWER ASSIST UNIT
DISASSEMBLY
• Disassemble the brake valve from the fork lift as previously described. Drain the oil from the
assembly.
• Disassemble the master cylinder section from the power assist section by removing cap
40
screws (23, 2pcs) and plain washers (22, 2pcs). 05
• When disassembling the master cylinder section, leave piston (7) and spring (16) in the power 1
assist section.
• Remove O–ring (17), filler plug (21) and gasket (20) from cylinder housing (18).
• Remove plug (29), cage (27), taper spring (26), ball (25) and O–ring (24) from cylinder housing
(18).
• Remove spring (16) and piston (7) from booster housing (3).
• Remove cups (8, 9, 10) and piston ring (6) from piston (7).
• Remove plug (15), spring (13), shim (12) and piston (11) from booster housing (3). Pay attention
to the number of shims removed from the housing. Remove O–ring (14) from plug (15).
BRAKE VALVE
• Remove push rod (1) and boot (2) from booster housing (3).
• Remove piston (5) through the larger diameter bore of booster housing (3).
Remove cup (4) from piston (5).
ASSEMBLY
! CAUTION
Use only hydraulic oil for the power assist unit and master cylinder.
Lubricate the rubber components of repair kit with hydraulic oil for each section before
assembling.
• Clean all the parts before assembling.
• Install new cup (4) onto piston (5), and insert it into the larger diameter bore of booster
housing (3). Pay attention to the direction of cup. The piston must contact the bottom of the
housing.
• Install push rod (1) and a new boot (2) to booster housing (3).
• Install new O–ring (14) onto plug (15).
• Install piston (11), shim (12), spring (13) and plug (15) to booster housing (3).
! Confirm that the number of shims installed is the same as removed. Tighten the plug
securely.
• Install new piston ring (6) and new cups (8, 9, 10) onto piston (7). Pay attention to the direction
and sequence of cups.
• Insert piston (7) into booster housing (3) with care. Then install spring (16) to booster housing (3)
around piston (7).
• Insert new O–ring (28) onto plug (29).
• Install new O–ring (24), new ball (25), new taper spring (26), new cage (27) and plug (29) to
cylinder housing (18).
! When installing cage (27), confirm that spring (26) is aligned properly and located in
40 place. The smaller end of taper spring (26) should be against the side of ball (25).
• Install new gasket (20), filler plug (21) and new O–ring (17) to the cylinder housing.
05 • Assemble the master cylinder section with plain washers (22, 2pcs) and capscrews (23, 2pcs).
: 3.04~3.46 kgf·m (22 ~ 25 lbf·ft)
2
• Install the brake valve in the machine. Connect the push rod and the hydraulic lines. Perform
the air bleeding according to the relevant procedure.
BRAKE VALVE
29
28
27
26 21
25
24
20
19
18
17
23 16
22 15
14
1312
11
10
9
8
6
5
4
2
40
1
05
3
1. Push rod 11. Piston 21. Filler plug

2. Boot 12. Shim 22. Plain washer
3. Booster housing 13. Spring 23. Capscrew
4. Cup 14. O–ring 24. O–ring
5. Piston 15. Plug 25. Ball
6. Piston ring 16. Spring 26. Spring
7. Piston assembly 17. O–ring 27. Cage
8. Cup 18. Cylinder housing 28. O–ring
9. Cup 19. Bleeder screw 29. Plug
10. Cup 20. Gasket
BRAKE VALVE
BLEEDING PROCEDURES
! CAUTION
Use the recommended hydraulic oil only and do not re–use the oil. Top off the oil
level after bleeding.
PRESSURE BLEEDING (BRAKE SYSTEM)
• Fill the master cylinder and pressure bleeder with hydraulic oil as specified.
• Connect the pressure bleeder to the master cylinder reservoir and regulate the pressure to
2.1kgf/cm2 (30psi) maximum.
• Do not operate the brake pedal.
• Install a clear vinyl hose on the master cylinder bleeder screw (19) and place the other end
in a container.
• Open the bleeder screw and bleed the air from the system. When the flow of hydraulic oil is
free of air bubbles close the bleeder screw.
• Install a clear vinyl hose on the wheel end brake assembly bleeder screw farthest from the
master cylinder, and place the other end in a container.
• Open the bleeder screw and bleed the air from the system. When the flow of hydraulic oil is
free of air bubbles close the bleeder screw.
• Repeat the procedure to bleed the opposite brake assembly.
• Remove the pressure bleeder and test the brakes. If the brakes feel spongy, check the system
for leaks and repeat the air bleeding procedures.
40
05
4
HYDRAULIC SYSTEM 50
• 50–01 MAIN PUMP (DIESEL)
• 50–02 AUXILIARY PUMP (DIESEL)
• 50–03 MAIN CONTROL VALVE
• 50–04 HYDRAULIC CYLINDERS
• 50–05 W SERIES HYDRAULIC GEAR PUMP (LPG)
H Y D R A U L I C S Y S T E M
MAIN PUMP
SPECIFICATION
1. Bolt
2. Washer–spring
3. Cover–end
4. O–ring
5.
Backing ring
6.
7. Seal–lobe
8. Bushing
9. Bushing
10. Body
11. Gear–driven
12. Shaft–drive
13. Flange
14. Seal–lip
15. Dowel–hollow
Specification DIRECTION OF ROTATION

Pump Model 2PL158
Theoretical Displacement
Max Continuous
49.35 cm3/rev (3.01 in3/rev)
210 bar
50
Pressure P1 (3045 psi)
01
Maximum Speed At
2600 rev/min 1
Pressure P1
Minimum Speed At
500 rev/min
Pressure P1
Rotation When Viewed
Anti–clockwise
on end of Driveshaft
Approx Weight 7.7 kg (16.9 lbs)
Operating Temperature Continuous 0°C to 80°C
Cold start –20°C
Range Max intermittent 100°C
Shaft Seal Type Single nitrile Copyrighted Material
MAIN PUMP
DISASSEMBLY
! CAUTION :
• Do not use excessive force to remove pump parts.
• Be very careful not to damage the machined surfaces.
• Handle the gears as a set, due to wear patterns and close tolerances the same teeth
must mesh when reassembling.
• To install the bushings use a press or a bushing driver.
• Use a soft faced hammer to assemble pump parts.
DISASSEMBLY
• Secure the pump in a vise with the driving

shaft facing downward. Remove the capscrews
(8pcs).
! Match mark all mating sections prior to

disassembly.
! Use soft material jaw liners i.e copper or

lead
• Remove the end cover bolt, O–ring, back–up

ring and bushing lobe seal as shown in the
figure.
50
01
2
MAIN PUMP
• Remove the flange using a plastic hammer.

Don't strike with excessive force.
• Remove the snap ring from the flange.
• Secure the flange in a vice and remove the

shaft seal with a driver.
! Do not score the flange.
50
01
• Disassemble the O–ring, back–up ring and 3
bushing lobe seal from the pump body, as
shown in the figure.
MAIN PUMP
• Remove the front bushings by tapping the

backside of the drive shaft with a plastic
hammer.
! Mark each bushing to denote its location

within the pump body prior to removal.
• Remove the rear bushings by lightly tapping

the driven gear through the rear of the pump
body.
ASSEMBLY
• Install the rear bushings in the body.
! Ensure the bushings are in the correct

location.
The “C” shape of the bushing should
mate with the flat in the pump body.
50
01
• Install the O–ring, back–up ring and bushing
4
lobe seal in backside, and put the end cover
on the bottom.
MAIN PUMP
• Install the gear set into the body.
! Lubricate the gear set and bushings prior

to installing.
• Insert the shaft seal with a press. Apply

hydraulic oil onto the seal housing to aid the
installation.
• Install the snap ring into the flange.
50
01
• Insert the upper bushings in the body, and 5
install the O–ring, back–up ring and bushing
lobe seal.
MAIN PUMP
• Install the flange to the body, mating it with

the dowel pin. Confirm that the O–ring,
back–up ring and bushing lobe seal are in
place.
• Install the end cover bolts (8pcs) :

5 ± 0.3 kgf·m (36 ± 2 lbf·ft)
Confirm that O–ring, back–up ring and bushing
seal are in place.
ASSEMBLING THE BUSHING LOBE SEAL AND BACKING RING
50
01
6
MAIN PUMP
The bushings should be replaced if there is

INSPECTION AND any general scoring or fine scoring with a
ASSESSMENT matt appearance or tearing of the surface
material. Often there is a witness where the
Each component should be thoroughly tips of the opposing gears have wiped an
cleaned, carefully examined and assessed for overlap resembling a half moon shape. There
suitability of re–use. Below is a guide for must be no noticeable wear step as it is
inspecting the various components. critical that the bushing side face is
completely flat to the gear side face.
BODY
The bearing liners are acceptable providing
Inspect the body bore cut–in where both
that they are not scored or show other
gears wipe into the body.
damage. The general outside area of the
The body can only be re–used if the 'cut–in' bushing should not show any prominent signs
is bright and polished in appearance and the of wear.
depth does not exced.
0.05~0.1 mm (0.002~0.004 in).
GEARS
The gear side faces should be examined for
The body should be replaced if the surface bruising or scoring. Often operation on
is scored, has a matt appearance or shows contaminated fluid shows scoring between the
signs that the tip of the gears have dug in root of the gear and the journal undercut,
and torn away the surface material. which leaves a wear step. If a wear step can
The body should be inspected to ensure that be felt by drawing a sharp pointed tool across
there is no superficial damage which may the surface from the undercut outwards
adversely affect performance or sealing. Pay towards the tip of the gear, then the gear set
particular attention to the port threads and must be replaced.
body 'O' ring seal recesses. The gear teeth should then be carefully
examined to ensure that there are no signs
MOUNTING FLANGE of bruising or pitting.
AND END COVER The journal bearing surfaces should be
The inner surfaces should be inspected to completely free from scoring or bruising. The
ensure that there is no unusual wear or surface should appear highly polished and
scoring in the regions where the body 'O' smooth to touch.
rings and backing rings contact, which could
Examine the area where the shaft seal lips
result in external leakage.
run on the drive shaft, this shows up as a
Check the shaft seal recess for scoring or
damage that could result in oil leakage
polished ring or rings. If a noticeable groove
can be felt or there is scoring the shaft 50
around the outer diameter of the shaft seal. should be replaced.
Replacement shaft seals can be refitted with
01
Provided the drive shaft is not damaged from
loctite hydraulic sealant to overcome slight 7
the drive–coupling and the gears have not
damage in this area.
been harmed as described above, then the
BUSHINGS gears can be re-used. If, however, the gears
are damaged they must be replaced as a
The side faces which abut the gears should
matched pair.
be perfectly flat showing no sign of scoring.
Characterstically there are bright polished As a matter of good practice, when pumps
areas on this surface caused by loading have been dismantled, all the seals should
against the gear side faces, which is often beMaterial
Copyrighted replaced. It is most important that only the
more pronounced on the low pressure side. genuine
Intended for CLARK dealers seals
only are used.
AUXILIARY PUMP
SPECIFICATION
Pump model JINSUNG
Displacement 10.2 cc/rec (0.622 cu.in/rev)
Rated pressure 245 kgf/cm2 (3500 psi)
Max. Speed 3000 rpm.
Rotation
STRUCTURE
1. Shaft cover
2. Bushing
3. Gear housing
4. Port cover
5. Bushing
6. Gear set
7. Thrust plate
8. Channel seal
9. Square seal
10.
11.
Lip seal
Dowel pin
50
12. Bolt 02
13. Washer
1
AUXILIARY PUMP
TROUBLESHOOTING
Trouble Probable cause Remedy

Driven in the wrong direction of The drive direction must be changed
Pump not rotation. immediately to prevent seizure.
delivering Coupling or shaft sheared or Inspect auxiliary driveshaft and pump
fluid. disengaged. input shaft.
Replace the necessary parts.
Fluid intake pipe in reservoir Check all strainers and filters for dirt and
restricted. sludge. Clean if necessary.
Fluid viscosity too heavy to pick up Completely drain the system. Add new
prime. filltered fluid of the proper viscosity.
Air leaks at the intake, pump not Check the inlet connections to determine
priming. where air is being drawn in. Tighten any
loose connections. See that the fluid in
the reservoir is above the intake pipe
opening. Check the minimum drive speed
which may be too slow to prime the
pump.
Relief valve stuck open. Inspect and clean the relief valve.
Relief valve spring broken. Replace relief valve assembly.
Damaged internal pump parts. Disassemble and inspect gears, thrust
plates, seals and pump body.
Repair or replace pump.
System relief valve set too low. Use a pressure gauge to correctly adjust
Insufficient
the relief valve.
pressure
build–up. Loss of flow from pump. Worn pump parts.
Damaged inlet or pressure line.
Pump intake partially blocked. Service the intake strainers. Check the
Pump
fluid condition and, if necessary, drain and
making
50 noise.
flush the system. Refill with clean fluid.
Air leaks at the intake or shaft seal Check the inlet connections and seal to
causing cavitation. (Oil in reservoir determine where air is being drawn in.
02 would probably be foamy). Tighten any loose connections and
2 replace the seal if necessary. See that
the fluid in the reservoir is above the
intake pipe opening.
Pump drive speed too slow or too Operate the pump at the recommended
fast. speed.
Auxiliary driveshaft misalignment. Check if the shaft seal bearing or other
parts have been damaged. Replace any
damaged parts. Realign the coupled
Intended for CLARK dealers onlyshafts.
AUXILIARY PUMP
Trouble Probable cause Remedy

External Shaft seal leakage. Damaged or worn seal.
leakage. Damaged or worn bushings.
Damaged shaft seal housing bore or
sealing area of output shaft grooved.
Replace parts as required.
Leakage between pump sections. Damaged O–rings or damaged surfaces
in O–ring groove.
Replace parts as required.
START–UP
Whenever it is possile to do so, fill the pump ports with system hydraulic fluid. This will make
it easier for the pump to prime when it is first started.
Self Priming : With a minimum drive speed of 600 RPM, a pump should prime immediately.
Failure to prime within a short length of time may result in damage due to lack of lubrication.
Inlet lines must be tight and free from air leaks. However, it may be necessary to loosen a
fitting on the outlet side of the pump to purge entrained air.
No load starting : These pumps are designed to startup with no load on the pressure ports.
They should never be started against a load or a closed center valve.
50
02
3
AUXILIARY PUMP
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY
1. Clean the pump thoroughly prior to disassembly.
2. Secure the pump in a vise with the drive shaft facing downward.
∗ Use soft material jaw liners, i.e copper or lead.
3. Scribe marks on shaft cover, gear housing and port cover prior to dismantling.
4. Remove capscrews and port cover. Use a soft faced hammer to loosen the cover.
5. Remove the square seal and channel seal.
6. Remove the thrust plate and gear set.

! Prior to removal mark the driving gear and driven gear so as to mesh to same teeth
when reassembling.
7. Remove the gear housing from the shaft cover.
8. Remove the lip seal from the shaft cover.

! Do not score the shaft cover seal bore.
ASSEMBLY
1. Inspect all parts for damage and wear, replace as required.

! Lubricate all parts prior to installation.
2. Install a new lip seal in the shaft cover.
! Use a proper driver to install the seal, make sure the lip faces to the inside of the
pump.
3. Install square seals to the gear housing.
4. Install the gear housing to the shaft cover.
5. Install the channel seals to the thrust plates.
6. Install a thrust plate with the seal against the shaft cover.
50 ! Do not use force to install it, hold the thrust plate level and slide it into position in
the gear housing.
02 ! Install the thrust plates with the alignment marks (grooves) on the outlet side of the
gear housing.
4
∗ Also note that the seal is shaped like a “3”, ensure the open side of “3” faces the inlet
port.
7. Install the gear set.

! Be sure to align/mesh the marked teeth.
8. Install the thrust plate with the seal facing the port cover.
9. Install the port cover and capscrews

ISO 32 – 17 ± 0.5 kgf·m (122Material
Copyrighted ± 4 lbf·ft)
Plain washer – 19.6
Intended kgf·m
± 0.1for (142 dealers
CLARK ± 1 lbf·ft)
only
AUXILIARY PUMP
INSPECTION AND ASSESSMENT
Each component should be thoroughly cleaned, carefully examined and assessed for suitability
of re–use. Below is a guide for inspecting the various components.
GEAR HOUSING
• Inspect the body bore cut–in where both gears

wipe into the body.
The body can only be re–used if the ‘cut–in’
is bright and polished in appearance and the
depth does not exceed 0.18mm (0.007 in).
If the length of the contact traces is a half of
the internal length of the gear hole, it is
normal.
The body should be inspected to ensure that
there is no superficial damage which may
adversely affect performance or sealing. Pay
particular attention to the port threads and
body ‘O’ ring seal recesses.
GEAR
• The gear teeth should be carefully examined to

ensure that there are no signs of bruising,
pitting or that a wear step can be felt.
The journal bearing surfaces should be
completely free from scoring or bruising. The
surface should appear highly polished and
smooth to touch.
Gear set should be changed if the φd size is
below φ23.887.
Examine the area where the shaft seal lips run
on the drive shaft, this shows up as a polished
ring or rings. If a noticeable groove can be felt
or there is scoring the shaft should be
replaced. 50
THRUST PLATE
02
5
• The surface of the thrust plate is coated with
a gray colored Teflon. In normal operation, a
soft trace is left at the point of gear contact
as shown in the figure.
A regular trace is not a problem, but any
irregular scratch or roughness felt by rubbing
with a finger nail, or if the thickness is less
than 4.894 mm (0.1927 in), the plate should be
replaced. Intended for CLARK dealers only
AUXILIARY PUMP
• If a hollow dowel pin is damaged it must be

replaced.
If a new pin is loose in the bore of the gear
housing, port cover or shaft cover, that part
must be replaced.
SEALS
All seals should be replaced in reassembly.
BUSHING
New bushings must be installed when the gear

set is replaced.
Always replace the bushings as a set.
50
02
6
MAIN CONTROL VALVE
STRUCTURE
The control valve is the open center type, designed for minimal internal oil leakage. The tilt
spool incorporates a tilt lock valve spool and a flow control valve plate is installed between the
lift and tilt valve sections to control attachment operating speed. Optional auxiliary valve sections
have adjustable relief valves ; a maximum of two sections may be added.
1. Input unit
2. Single acting unit (lift)
3. Double acting unit (tilt)
4. Output unit
5. O–ring
6. Square ring
7. Square ring
8. Nut
9. Plain washer
10. Bolt
11. Hexagon socket head bolt
12. Hinge hold
13. Hexagon socket head bolt
14. Cap
15. Back–up ring
16. Square ring
17. Spool
18. Spool
19.
20.
21.
Guide
Spring
Capscrew
50
22. Spool head 03
23. O–ring
24. Spring 1
25. Spool (tilt lock)
26. Plate
27. Relief valve
28. Plug
29. O–ring
30. Spring
31. Poppet
32. Plate (flow control)
33. O–ring
Copyrighted Material 34. Plug
Intended for CLARK dealers only 35. Back–up ring
MAIN CONTROL VALVE
SPECIFICATION
CMP40-50SD/L
Model SF35-45D/L
EATON
Main relief pressure kgf/cm (psi)
2
200~210 (2845~2987)
Relief type Vented cartridge
Spool type Cantype spring return
Rated Q’ty l /min (gpm) 144 (38)
TROUBLESHOOTING
Trouble Cause Remedy
– Dirt between valve housing and – Clean valve housing and spool.
spool sliding surface.
– Hydraulic oil contamination. – Replace hydraulic oil.
Spool sticking. – Return spring damage. – Replace spring.
– Valve housing deformation. – Loosen and retorque the bolts.
– Spool bent. – Replace valve housing and spool
assembly.
– Paint chip or dust in the seal. – Disassemble and wash the seal.
Leaking at – Loosened seal plate (hinge hold). – Wash the seal plate and tighten
spool seal. the capscrews.
– Seal damaged or worn. – Replace the seal.
– Worn valve housing and spool. – Replace valve housing and spool
Cylinder
assembly.
dropping in
– Cylinder bypassing internally. – Check the cylinder, replace the
neutral.
cylinder seals.
50 Cylinder drops – Damaged check valve poppet, – Replace the poppet or spring.
when control seat, or broken spring. – If the poppet seat is damaged
03 lever moves replace the valve housing.
2 from neutral
position to lift
position.
Mast tilts with – Scratched or worn tilt lock spool. – Replace tilt spool and tilt lock
engine off and valve spool assembly.
tilt control lever – Damaged tilt lock spring. – Replace spring.
pushed forward. – Oil leak at O–ring. – Replace O–ring.
MAIN CONTROL VALVE
Trouble Cause Remedy
– Damaged relief valve. – Replace relief valve assembly.

Cylinder speed – Blocked flow control valve plate. – Clean flow valve plate.
deficiency. – Dirt in relief valve. – Wash or replace the relief valve.
– Faulty hydraulic pump. – Refer to hydraulic pump section.
Mast waver – Scratched or worn tilt lock valve – Replace tilt lock spool and tilt
during forward spool. spool assembly.
tilt.
No lift / tilt – Dirt between valve and spool. – Disassemble and clean.
operation with – Faulty relief valve. – Adjust or replace relief valve.
engine running – Hydraulic pump defective. – Repair or replace pump.
and control
levers operated.
Control – Broken return spring. – Replace springs.

valve spool – Dirt or foreign particles lodged – Disassemble and clean.
does not between spool and housing.
return to – Bent spool. – Replace valve assembly.
neutral. – Misalignment of linkage. – Repair linkage.
Load can not – Low relief valve setting. – Adjust relief valve.
be lifted to – Hydraulic pump defective. – Repair or replace pump.
maximum – Mast rails binding. – Check rollers and cylinder racking,
height. repair as required.
– Worn or damage piston seals. – Replace piston seals.

Oil leak at top
– Scored cylinder wall. – Replace cylinder.
of lift cylinder.
– Plugged vent line. – Unplug vent line.
50
03
3
MAIN CONTROL VALVE
DISASSEMBLY
• Clean the main control valve thoroughly prior to disassembly.

• Keep parts in order as removed and do not mix the parts of the valve sections.
• Remove the nuts and bolts that hold the valve assembly together, then separate the sections.
• Remove the relief valve assembly from the input valve section.
• Remove the cap and hinge hold plate from the lift spool section.
• Remove the lift spool by tapping lightly on the end with a soft faced hammer.
• Remove all O–rings, back–up rings and seals.
• Remove the load check valve and flow control valve plate.
• Disassemble the tilt valve section following the above steps.
• Secure the tilt spool in a vise (use soft material jaw liners), unscrew the spool head and remove
the spring and tilt lock spool.
ASSEMBLY
• Install new back–up rings, O–rings and seals.

• Assemble in reverse order of disassembly.
• Ensure that the flow control valve plate is installed between the lift and tilt valve sections.
• Contol valve through bolts : 5 kgf·m (36 lbf·ft)
• Relief valve : 5 kgf·m (36 lbf·ft)
! To aid assembly apply a light coating of grease to all O–rings and seals to hold them
in place.
Lubricate the spools with hydraulic oil prior to assembly.
50
03
4
MAIN CONTROL VALVE
INSPECTION AND ASSESSEMENT
• Inspect valve spools and bores for burrs, nicks, scratches, paint or scoring.
If any damage is evident, provided the flaw is minor it may be polished with fine emery and
crocus cloth. However if the flaw is excessive the part must be replaced.
• Inspect the valve body for external damage, check all port threads and ensure the fittings,
plugs and relief valve do not bind.
• Inspect the valve sections for cracks.

The valve housing must be replaced as a complete assembly.
• Inspect the load check valve poppet seat for cracks, grooving or pitting.
The valve section must be replaced as a complete assembly since the poppet seat can not
be repaired.
• Inspect the spool return springs, ensure they are not corroded, cracked, bent or broken.
• Inspect the relief valve assembly for cracks, damaged or worn poppet and seat.
The relief valve must be replaced as an assembly.
50
03
5
MAIN CONTROL VALVE
ADJUSTING HYDRAULIC PRESSURE
∗ Measurement condition
• Coolant temperature : within operating range
• Steering position : Neutral
• Hydraulic temperature : 45~55°C (113~131°F)
• Engine speed : High idle
! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
! Operate the control levers several times to release the remaining pressure in the
hydraulic piping.
PRESSURE MEASUREMENT METHOD
• Stop the engine.

• Remove the plug (PT 1/8) attached to supply port fitting of the control valve and install the
pressure gauge adapter.
50
Pressure gauge 0~350 kg/cm3 (4979 psi)
03
6
MAIN CONTROL VALVE
• Start the engine, run at maximum speed, and operate control the control lever as follows, then
read the pressure gauge.
SPECIFICATION
Unit : kg/cm2 (psi)
Model CMP40D/LSF35D/L CMP45D/L

SF40D/L CMP50SD/SL
Lever
Litting 200 (2845) 210 (2987)
Forward tilting 200 (2845) 210 (2987)
Backward tilting 200 (2845) 210 (2987)
HYDRAULIC PRESSURE ADJUSTING METHOD
• Remove the valve cover to expose the relief valve.

• Loosen lock nut (2) and turn screw (1) to adjust.
∗ Adjust the screw as follows :
–To increase pressure, turn clockwise.
–To decrease pressure, turn counter–clockwise.
• Check again, and confirm the set pressure.
50
03
FX989
7
! When removing the hydraulic pressure gauge, release the pressure in the same way
as when installing the gauge.
HYDRAULIC CYLINDERS
HYDRAULIC CYLINDERS
LIFT CYLINDER
DISASSEMBLY
Prior to disassembly, thoroughly clean the exterior of the cylinder.

Remove the hydraulic oil from the cylinder by stroking the piston rod to force the oil out. When
overhauling the cylinder, ensure that contamination does not enter the cylinder. The smallest
particles are capable of severely damaging the hydraulic system.
• Hold the cylinder securely in a vise, do not use

excessive force.
• Remove the gland with a hook wrench.

Carefully pull the gland assembly from the
cylinder tube and slide it off the cylinder rod.
50
• After the gland is removed, pull the piston rod 04
assembly from the cylinder barrel. 1
HYDRAULIC CYLINDERS
• Remove the piston packing and wear ring from

the piston.
• Remove the retaining ring from the gland, and

remove the dust wiper, bushing, and rod
packing.
Remove O–ring and back–up ring.
INSPECTION
• Carefully wash all parts with clean solvent, and store in a clean place.
• Check whether the piston rod is damaged, minor scratches of the mirror surface can be repaired
with a fine oil stone. But it must be replaced in the case of deep score marks.
• Check whether the barrel is damaged. Replace in the case of deep scoring or other damage.
Check the threads for the gland and port fittings.
• Lightly coat all parts with hydraulic oil. If the parts are to be stored for a long time, cover
with a clean rag.
50
04
2
HYDRAULIC CYLINDERS
ASSEMBLY
• Install the new retaining ring, dust wiper,

bushing, and rod packing in the gland. Install
the new back–up ring and O–ring.
• Install the new packing and wear ring.
• Lightly lubricate the piston with hydraulic oil

and carefully push the piston rod into the
cylinder barrel.
50
04
• Lightly lubricate the gland assembly, then
3
screw the gland into the cylinder barrel with a
hook wrench. When tightening, don't damage
the seal.
: 60 ± 6 kgf·m (433 ± 43 lbf·ft)
★ Thoroughly test the cylinder for smooth

operation and oil leaks.
HYDRAULIC CYLINDERS
TILT CYLINDER
DISASSEMBLY

• Hold the cylinder securely in a vise, do not use

excessive force.
• Remove the gland with a hook wrench.

Carefully pull the gland assembly from the
cylinder tube and slide it off the cylinder rod.
50 • After the gland is removed pull the piston rod

04 assembly from the cylinder barrel.
4
HYDRAULIC CYLINDERS
• Remove the nut, and piston from the rod.

Remove the piston packing and wear ring. 50-04-05-1,50-04-06-2
• Remove the retaining ring from the gland, and

remove the dust wiper, bushing and rod
packing.
INSPECTION
• Carefully wash all parts with clean solvent, and store in a clean place.
• Check whether the piston rod is damaged, minor scratches of the mirror surface can be repaired
with a fine oil stone. But it must be replaced in the case of deep score marks.
• Check whether the barrel is damaged. Replace in the case of deep scoring or other damage.
Check the threads for the gland and port fittings.
• Lightly coat all parts with hydraulic oil. If the parts are to be stored for a long time, cover
with a clean rag.
50
04
5
HYDRAULIC CYLINDERS
ASSEMBLY
• Install the new retaining ring, dust wiper,

bushing, and rod packing in the gland. Install
the new back–up ring and O–ring.
• Install the new packing and wear ring, install

the piston to the piston rod, and tighten the
nut.
: 80 ± 8 kgf·m (578 ± 58 lbf·ft)
• Lightly lubricate the piston with hydraulic oil

and carefully push the piston rod into the
cylinder barrel.
50
04
6 • Lightly lubricate the gland assembly, then
screw the gland into the cylinder barrel with a
hook wrench. When tightening, don't damage
the seal.
: 80 ± 8 kgf·m (578 ± 58 lbf·ft)
HYDRAULIC CYLINDERS
• Thoroughly test the cylinder for smooth

STEERING CYLINDER
DISASSEMBLY

• Make a match mark on the cylinder glands,

cylinder tube, and cylinder rod to correctly align
the parts for reassembly.
• Remove the nut on the cylinder tie rods, and

carefully extract each tie rod.
• Disassemble the gland from the cylinder tube

by tapping the cylinder gland with a soft faced
50
hammer (plastic mallet).
• Remove the gland, and pull the piston from the
04
cylinder tube. 7
• Remove all the seals and packing.
• Inspect the cylinder gland for damage.
HYDRAULIC CYLINDERS
• Confirm whether scratch marks or corrosion is

present inside the cylinder tube.
! A light honing is permissible.
• Check the piston rod and piston surface for

damage. If any damage is evident, provided the
flaw is minor it may be polished with fine
emery and crocus cloth. However if the flaw is
excessive the part must be replaced.
ASSEMBLY
• Install new seal in the cylinder gland and on

the piston rod assembly.
• Push the piston and the rod assembly into the
cylinder tube.
! Ensure that the match marks are aligned.
50
04
• Install the cylinder glands to the cylinder tube.
8
Confirm that the gland and tube mating
surfaces are not damaged, then install the
glands.
! Ensure that the match marks are aligned.
HYDRAULIC CYLINDERS
• Install the tie rods to the cylinder, and tighten

the nuts.
: 5.0 ± 0.5 kgf·m (36 ± 4 lbf·ft)
• Thoroughly test the cylinder for smooth

50
04
9
W SERIES HYDRAULIC GEAR PUMP
W SERIES GEAR PUMP
DOUBLE PUMP (1500 SERIES SHOWN)
50
05
1
TOOL REQUIRED
• Metric Socket Set

• Internal Snap Ring Pliers
• Shaft Seal Sleeve
• Torque Wrench-100 lb-ft capacity
DISASSEMBLY
Note :
The following general instructions also apply to multiple section gear pumps, the only extra parts
are the coupling between the drive shafts and the center distance plate which drivdes the two
pump sections. The repair procedure also applies to the “W” series Gear Motors.
1. It is very important to work in a clean work area when repairing hydraulic products. Plug
ports and wash exterior of pump with a proper cleaning solvent before continuing.
2. Remove port plugs and drain oil from pump.
3. Use a permanent marker pen to mark a line

across the mounting flange, gear housing and
end cover. This will assure proper reassembly
and rotation of pump.
4. Remove key from drive shaft if applicable.
5. Clamp mounting flange in a protected jaw

vise with pump shaft facing down.
50 6. Loosen the four metric hex head bolts.
05
7. Remove pump from vise and place on clean
2
work bench, remove the four hex head bolts
and spacers if applicable.
8. Lift and remove end cover.
9. Carefully remove gear housing and place on

work bench. Make sure the rear bearing block
remains on the drive and idler shafts.
10. Remove rear bearing block from drive and

idle shafts.
50
05
11. Remove idler shaft from bearing block. 3
12. Remove drive shaft from mounting flange.

There is no need to protect the shaft seal
as it will be replaced as a new item.
13. Remove the front bearing block.
14. Turn mounting flange over, with shaft seal

up, and remove the retaining ring with
proper snap ring pliers.
50
05 15. Remove the oil seal from mounting flange,
4 be careful not to mar or scratch the seal
bore.
16. Remove the dowel pins from the gear

housing. Do not lose pins.
17. Remove seals from both bearing blocks and

discard.
INSPECT PARTS FOR WEAR
1. Clean and dry all parts thoroughly prior to inspection.

It is not necessary to inspect the seals as they will be replaced as new items.
2. Check drive shaft spline for twisted or broken

teeth, check keyed drive shaft for broken or
chipped key way. No marks or grooves on
shaft in seal area, some discoloration of shaft
is allowable.
3. Inspect both the drive gear shaft and idler gear shafts at the bearing points and seal area
for rough surfaces and excessive wear.
4. Inspect gear face for scoring or excessive

50
wear. If the face edge fo gear teeth are
sharp, they will mill into the bearing blocks.
05
If wear has occurred, the parts are unusable. 5
5. Inspect bearing blocks for excessive wear or

scoring on the surface which are in contact
with the gears. Also inspect the bearings for
excessive wear or scoring.
6. Inspect the area inside the gear housing. It is normal for the surface inside the gear housing
to show a clean “wipe” on the inside surface on the intake side. There should not be
excessive wear or deep scratches and gouges.
GENERAL INFORMATION
It is important that the relationship of the mounting flange, bearing blocks and gear housing
correct. Failure to properly assemble this pump will result with little or no flow at rated pressure.
REVERSE SHAFT ROTATION OF PUMP
Note :
This pump is not bi–rotational, if the shaft rotation must be changed the following procedure
must be followed.
Reversing the shaft rotation of the “W” series gear pump may be accomplished by rotating, as
a group, the two bearing blocks and the gear housing 180° in relationship to the remaining parts
of the pump. This procedure will place the pressure port on the opposite side of the pump from
50 its original position.
05
6
REASSEMBLY
Note :
New seals should be installed upon reassembly of pump or motor. Refer to page 50–05–12 for
the necessary kit part numbers for the W–1500 pumps and motors.
1. Install new shaft seal in mounting flange with

part number side facing outboard. Press the
seal into the seal bore until the seal reaches
the bottom of the bore. Uniform pressure
must be used to prevent misalignment or
damage to the seal.
2. Install retaining ring in groove in seal bore of

mounting flange.
3. Place front and back bearing blocks on a

clean surface with the E-seal grooves facing
up. Apply a light coating of petroleum jelly in
the grooves. Also coat the E-seal and backup
50
with the petroleum jelly, this will help keep 05
the seals in place during reassembly.
7
4. Place the E-seals, flat side outward, into the

grooves in both bearing blocks. Follow by
carefully placing the backup ring, flat side out
ward, in the groove made by the E-seal and
the groove in the bearing block.
Note :
The backup ring in the W1500 pump is
symmetrical.
5. Place mounting flange, with shaft seal side down, on a clean flat surface.
6. Apply a light coating of petroleum jelly to the exposed face of the front bearing block.
7. Insert the drive end of the drive shaft through

the bearing block with the seal side down,
and the open side of the E-side pointing to
the intake side of the pump.
8. Install the seal sleeve over the drive shaft and carefully slide the drive shaft through the
shaft seal. Remove the seal sleeve from shaft.
9. Install the idler gear shaft in the remaining
50 position in the bearing block. Apply a light

coat of clean oil to the face of the drive and
idler gears.
05
8
10. Pick up the rear bearing block, with seal

side up and with open end of the E-seal
facing the intake side of the pump, place
over the drive and idler gear shafts.
11. Install two dowel pins in the holes in the mounting flange or two long dowel pins through
gear housing if pump is a multiple section pump.
12. To install the o-rings in the gear housing,

apply a light coating of petroleum jelly in the
grooves on both sides of the gear housing.
Also coat the new o-rings and install them
in the grooves.
13. Gently slide the gear housing over the rear

bearing block assembly, slide housing down
until the housing engages the dowel pins.
Press firmly in place with hands, do not
force or use any tool. Check to make sure
the intake port in the housing is on the
same side as the open end of the E-seal
50
and that the marked lines on the mounting
flange and gear housing are in alignment.
05
9
14. The surface of the rear bearing block should be slightly below the face of the gear housing.
If the bearing block sits higher then the rear face of the gear housing then the E-seal or
o-ring have shifted out of the groove. If this is the case, remove the gear housing and
check for proper seal installation.
15. Install the two remaining dowel pins in the

rear of the gear housing, if applicable, and
place the end cover over the back of the
pump.
16. Install the four spacers, if applicable, and

hex head bolts through the bolt holes in the
end cover, hand tighten.
17. Place mounting flange of the pump back in

the protected jawed vise and alternately
torque the bolts to the torque specifications
in the torque chart on page 50–05–12. All
torque figures are for “dry torque” bolts.
50
05 18. Remove pump from vise.
10 19. Place a small amount of clean oil in the inlet of the pump and rotate the drive shaft away
from the inlet one revolution. If the drive shaft binds, disassemble the pump and check for
assembly problems, then reassemble the pump.
20. The name plate located on the end cover

contains the build date code and the model
number. Please refer to this information
when corresponding with the J. S. Barnes
Service Department.
PLACING PUMP BACK INTO SERVICE
1. If shop test stand is available, the following procedure for testing rebuilt pumps is
recommended :
A. Mount pump on test stand making sure that the proper level of clean oil is available in
the reservoir. Check suction line for leaks and obstructions.
B. Start pump and run for three minutes at zero pressure.
C. Intermittently load pump to 500 P.S.I. for three minutes.
D. Intermittently load pump to 1000 P.S.I. for three minutes.
E. Intermittently load pump to 2000 P.S.I. for three minutes.
F. Remove pump from test stand and check for freeness of drive shaft. Check pump for signs
50
of external leakage. 05
11
2. If shop test stand is not available, the following procedure for testing rebuilt pumps is
recommended :
A. For engine driven pumps, mount pump on equipment and run pump at 1/2 engine speed
at zero pressure for three minutes.
B. By operating control valve, build pressure intermittently for three minutes.
C. Increase engine speed to full throttle and build pressure intermittently for three minutes.
D. Stop engine and check pump for external leaks.
E. For electric motor driven pumps, run pump at little or no load for three minutes, gradually
increase load on pump and cycle each succeeding load for three minutes. Check pump
for external leaks after break-in test.
PUMP SEAL KIT CHART
W-1500 Series Kit

Pump/Motor Description
W/35mm Shaft Seal
Single Pump 5200015
Double Pump 5200016
Triple Pump 5200017
Quad Pump 5200018
NOTE :
1500 Series Pumps manufactured from late 1996 use 35mm O.D. shaft seals, 1500 Series
Motors are not affected.
BOLT TORQUE CHART
Torque Values, Black Oxide Torque Values, Zinc Plated

Pump Series Thread Size
End Cover or Stator End Cover or Stator
W-1500 Metric 12 × 1.75 80-85 lb-ft / 108-115 N-m 68-73 lb-ft / 92.2-99.0 N-m
Bolts and flange threaded hole must be in dry, non-lubricated condition.
50
05
12
SINGLE OR DOUBLE PUMP TROUBLE SHOOTING
Pump Trouble Probable Cause Remedy

1. Pump does not develop full a. System relief valve set too a. Check system relief valve for
pressure. low or leaking. proper setting.
b. Oil viscosoty too low. b. Change to proper viscosity
c. Pump is worn out. oil.
c. Repair or replace pump.
2. Pump will not pump oil. a. Reservoir low or empty. a. Fill reservoir to proper level.
b. Suction strainer clogged. b. Clean suction strainer.
3. Noisy pump caused by a. Oil too thick. a. Change to proper viscosity.

cavitation. b. Oil filter plugged b. Clean filters.
c. Suction line plugged or too c. Clean line and check for
small. proper size.
4. Oil heating. a. Oil supply low. a. Fill reservoir to proper level.

b. Contaiminated oil. b. Drain reservoir and refill with
c. Setting of relief valve too clean oil.
high or too low. c. Set to correct pressure.
d. Oil viscosity too low. d. Drain reservoir and fill with
proper viscosity.
5. Foaming oil. a. Low oil level a. Fill reservoir to proper level.

b. Air leaking into suction line. b. Tighten fittings, check
c. Wrong kind of oil. condition of line.
c. Drain reservoir, fill with non-
forming oil.
6. Shaft seal leakage. a. Worn shaft seal. a. Replace shaft seal.

b. Worn shaft in seal area. b. Replace drive shaft and seal.
50
05
13
MAINTENANCE 60
• 60–01 MAST
– General
– Standard mast
– Full free lift mast
– Triple mast
• 60–02 OTHER COMPONENT

– Carriage
– Cylinder racking
– Lift chains
– Forks
– Counterweight
– Lifting, jacking and blocking
M A S T M A I N T E N A N C E
MAST
GENERAL
PRECAUTION
! Before performing any visual inspection or maintenance of the mast, carriage or forks,
strictly adhere to the following :
• Do not reach through the open areas of the mast.
• Do not walk or stand under raised forks.
• Use only hardwood blocks with square cut ends, that are not cracked or damaged.
• Ensure that all chains / slings and lifting equipment is in good condition and of
adequate load rating.
• Read the entire check and adjustment procedure before starting any maintenance or
service function.
Failure to comply with these warnings can result in severe injury.
VISUAL INSPECTION
A visual inspection should be conducted daily, however a thorough inspection of the mast
assembly must be done at a minimum of every 500 hours.
MAST
Check rail roller clearance and wear pattern.

Check mast for alignment, looseness and smoothness of operation.
Check mast mounting brackets and trunnions for loose bolts.
Check hydraulic hoses for leaks and interference with the mast.
CARRIAGE
Check rail to roller clearance.

Check fork bar notches for excessive wear and damage.
Check smoothness of operation.
CHAINS
Check
Check
for uniform tension.
for proper lubrication.
60
Check for corrosion, bent or cracked links. 01
Check chain mounting components for wear and damage. 1
CYLINDERS – LIFT, TILT
Check for seal leakage.

Check cylinder rods for nicks and scratches.
Check cylinder racking (uneven stroking of lift and tilt cylinder rods).
MAST
CLASSIFICATION ACCORDING TO MAST TYPE
STANDARD 2–STAGE MAST
Construction : An outer and inner rail with dual

lift cylinders.
Free lift : The distance that the carriage
can be raised before the inner
rail begins to lift. This distance
400–500 mm(16~20 in) is obtain-
ed by making the inner rail
shorter than the outer rail. The
carriage moves at twice the
speed of the lift cylinder rod.
FULL FREE LIFT 2–STAGE MAST
Construction : An outer and inner rail with dual

lift cylinders and a separate
larger diameter hydraulic cylinder
(primary) to raise the carriage.
Free lift : The distance from the lowest
carriage position to the top of the
mast. The inner rail does not
begin to lift until the carriage
reaches the top of the mast.
FULL FREE LIFT 3–STAGE MAST
Construction : An outer, intermediate and inner

rail with dual lift cylinders
(secondary) and a separate
larger diameter hydraulic cylinder
(primary) to raise the carriage.
The inner rail is raised via the lift
chains connected to the outer
rail. The action of these chains is
60 controlled by the lift cylinders

(secondary) attached to the
intermediate rail.
01 Free lift : The distance from the lowest carriage position to the top of the mast. The inner
2 rail does not begin to lift until the carriage reaches the top of the mast.
The carriage and the inner rail move at twice the speed of the intermediate rail.
FULL FREE LIFT MAST OPERATION :
Since the diameter of the primary cylinder is larger than the secondary cylinder and the load
on the secondary cylinders is greater by the
Copyrighted weight of the inner rail (intermediate rail–3 stage)
Material
primary cylinder and the carriage,
Intendedthe primarydealers
for CLARK cylinder
onlyextends first.
MAST
STANDARD MAST
REMOVING AND INSTALLING MAST
REMOVAL
• Park the fork lift in a suitable place, and set the steer wheels and the chassis in line.
• Apply the parking brake and remove the forks.
• Tilt the mast completely forward.
• Block the steering and driving wheels and turn
the key switch to “ OFF ”.
• Put a drain pan under the rails.
• Disassemble the hose connected between the
M.C.V and the regulator valve.
• Sling the outer rail at the center of the top tie
bar using an overhead crane.
(Before the mast is completely disassembled
from the fork lift, balance the weight so the rail
does not tilt.)
• Apply a small amount of tension by lifting with
the overhead crane.
• Remove the bolt and tilt cylinder mounting pin
on both sides. If the tension of the chain sling
Tilt cylinder mounting pin
hanging on the overhead crane is not applied,
the mast may fall forward at the last moment,
when the tilt mounting pin is removed.
Be especially careful, pay attention to safety.
• Remove the bolts of the trunnion bracket at the
mast lower mounting. Bolt
• Carefully move the mast forward from the fork Tilt cylinder yoke
lift with the overhead crane.
INSTALLATION
• Carry out the reinstalling of the mast in the

reverse order of removal.
• When reconnecting the hoses pay attention to
60
the installation direction of the flow limiting
valve and the flow regualtor valve.
01
3
! CAUTION
If the flow limiting valve is incorrectly Trunnion
installed, a hose failure will result in an bracket
: 24~29.4 kgf·m
uncontrolled drop of the carriage (174~213 lbf·ft)
Bolt
assembly, causing serious injury or Loctite#271
death.
MAST
TRUNNION BUSHING
To check the trunnion mounting

• Check for missing, broken, bent, or loose trunnion cap fasteners. Replace any damaged parts.
• Lift the mast 305–610 mm (1–2 ft) and tilt the mast fully forward.
• Check for trunnion bushing or cap wear by inserting a feeler gauge between the trunnion cap
and the axle mounting bushing surface.
• The gap should not exceed 0.75 mm (0.030 in.)
• If the gap exceeds specification the bushing or cap may need replacement.
FLOW LIMITING VALVE
The flow limiting valve is connected directly to one rail lift cylinder and the carriage lift cylinder
(Full free lift mast) to control the descent speed of the cylinder in the event that the flow
regulator valve malfunctions or a hydraulic hose ruptures.
Under normal descent speeds the pressure inside the cylinder and in the hose are approximately
equal. Therefore the flow limiting valve does not operate, and the flow regulator valve controls
the descent speed.
However if the flow regulator valve malfunctions or a hose ruptures, a pressure difference occurs
between the cylinder and the output side of the valve. The pressure in the valve pushes the
plunger in the valve, throttling the output port which reduces the descent speed.
! CAUTION
The valve must be installed with the arrow pointing away from the cylinder.
If installed in the reverse position the valve does not function.
1. O–ring
2. Nipple
3. Nipple stopper
4. Body
5. Spring
6. Plunger
60
01
4
MAST
FLOW REGULATOR VALVE
The flow regulator valve in the hydraulic circuit to the rail lift cylinders (secondary) and the
carriage lift cylinder (primary full free lift mast) is mounted on the mast assembly. This valve
regulates the flow rate of the return oil from the lift cylinders to control the descent speed of
the cylinders.
When the return circuit is activated the check valve in the flow regulator valve is closed by the
return oil and all return flow passes though the variable orifice, restricting the flow thereby
regulating the descent speed of the cylinders.
! CAUTION
The valve must be installed with the arrow pointing in the direction of flow to the
cylinder.
1. Housing
2. Tee
3. Valve
4. O–ring
60
01
5
MAST
CHECKING CARRIAGE AND MAST SHIM
• Park the fork lift where the forks can be lifted

to the maximum height.
• Apply the parking brake and set steer wheels
and chassis in line, then place wood blocks at
the front and rear of both steer wheels.
The tilt angle should be 0° and the forks
should be about 50 mm (2.0 in) below the
maximum height. Turn the key switch to “OFF”.
• Prepare a feeler gauge 0.5 mm (0.020 in), and
a “C” type clamp.
• To check the gap, catch one side bearing with

a “C” type clamp. Insert a block at the clamp Carriage
contact position to transmit the force equally to
the two bearings without damage and defor-
mation of the rail surface.
Inner
• Don’t exceed the tightening torque : rail Gauge
27 kgf·m. (195 lbf·ft)
• Put a feeler gauge 0.5 mm (0.020 in) between "C"
Clamp
the rail surface and the bearing surface on the
Block
opposite side tightened by the “C” type clamp.
• When a feeler gauge is not available, use a Gauge
shim of the same specification.
Outer
rail
! Be sure to check rail–to–roller clearance at the tightest point. If a 0.5 mm (0.020 in.)
feeler gauge goes in and a 1.0 mm (0.040 in.) does not, no shims are needed.
Gauge Bearing
60 "C" Clamp
01
6 Block
Gauge
Insert position
of gauge
MAST
CHECKING AND ADJUSTING CARRIAGE SIDE ROLLER
It is possible to check the clearance of upper

and lower end bearing of the carriage, but it is
impossible to check and adjust the middle and
side bearing. After checking the carriage upper
and lower end bearing clearance, check the
middle bearing and side roller as follows after
the carriage is disassembled.
• Disassemble the carriage.

• Check and adjust the carriage upper and lower bearing shims using a carpenter's same method
as described for the mast. Ensure that the side thrust roller does not interfere with checking
the clearance.
• Adjust the middle and side roller using a carpenter’s square, as shown.
• Set the square against the upper and lower bearing and adjust (shim) the middle bearing and
side roller to be in line with the vertical edge of the square.
ADJUSTING MAST SHIM
! This job must be done by a qualified technician.
DISASSEMBLY
To adjust the rail roller clearance the mast must 15(2)

16(2)
be partially disassembled as follows : 22(2)

21(4)
20(2)
17(2)
18(2)
• Remove the carriage from the mast.
29
32
(2)
3(2) 4(2)
32(2)
4(2)
33
60
6(2) 2
1
23(2)
7(2) 16(2)
8(4)
5(2)
a
a
10
9
30
01
25
31
7
36
37 14
13
12 (2)
28
MAST
• Place the drive wheels on blocks high enough

so that the lower end of the outer rail will clear
the floor by 153~203 mm (6~8 in).
• Apply the parking brake and block the steering
wheels.
• Tilt the mast to 0° vertical.
• Place a drain pan under the mast and remove

the tilt cylinder hydraulic hoses.
• Temporarily tie the lift cylinder supply hose to
the outer rail near the overhead guard to
minimize the loss of oil.
• Attach a sling to the inner rail top tie bar and

lift it approx. 203 mm (8 in).
• Place two blocks under the inner rail.
• Remove the bolts securing the lift cylinder rods
to the inner rail top tiebar.
• Remove the bolts securing the lift cylinder to
the outer rail support bracket.
• Remove the double nuts and rubber cushion.
• Raise the inner rail using an overhead crane.
• Remove the lift cylinder from the mast.
! When disassembling the lift cylinders, note the number of shims on the end of each
60 lift cylinder rod.
• Remove the blocks under the inner rail and

01 lower the inner rail slowly.
8
Now the outer rail and inner rail rollers will be
exposed.
• Take out the bearing and shim the rollers as
required.
! Take care that the number of shims

assembled at each side is the same if
possible. Intended for CLARK dealers only
MAST
SHIM INSTALLATION
• Gently pry the rollers off the posts. Pry at different points around the bearing to work it off.
• If the clearance check indicated an even number of shims needed, split the quantity evenly
between the rollers on either side of the rail.
• However if the clearance check indicated an odd number of shims needed, split the quantity
of shims so that the odd number are placed one side and the even number are on the opposite
side. i.e. 3 shims needed, place 2 on the left side roller and 1 on the right side roller.
• Check the rollers and replace if the bearings do not operate smoothly.
• Install the rollers on to the posts using a rubber mallet to firmly seat the roller against the
shims.
REASSEMBLY
• When the shim adjustment is completed, raise

the inner rail with the hoist crane.
• Install the lift cylinders. When fully seated in
the lower mount install the lower lock bracket.
• Install the shims which were removed from the
rod end of the lift cylinders when disassem-
bling, and secure each cylinder rod to the tie
bar with the capscrews.
! Use same quantity shims as removed

from each rod when disassembling.
• Tighten the cylinder clamp bracket and the rubber cushion bolt.
1~2 kgf·m (7~14 lbf·ft)
• Install the hydraulic hoses and sheaves.

• Install the lift chain assemblies.
• Install the carriage.
• Adjust the chain.
• Check the level of the hydraulic oil. Add if required.
• Confirm for interference by moving the mast up and down.
• Lift cylinder rod end lock capscrew :
side lock 6.5 kgf·m (47 lbf·ft)
end lock 26.7 kgf·m (193 lbf·ft) 60

01
9
MAST
FULL FREE LIFT MAST
Checking mast shim, carriage shim and adjusting carriage shim procedure is same as that of
the standard mast.
ADJUSTING MAST SHIM
This job must be done by a qualified technician.
DISASSEMBLY

• Apply the parking brake and place the drive
wheels on blocks high enough so that the
lower end of the outer rail will clear the floor
by 153~203 mm (6~8 in).
• Tilt the mast 0° vertical.
• Push the lift lever fully forward.
• Attach a sling to the top tie bar of the inner
rail.
• Place a drain pan under the primary cylinder
and disconnect the supply hose.
• Remove the bracket of hose sheave from the
free bar.
• Temporarily tie the supply hose to the upper
side of the outer rail to prevent the excessive
leakage.
! Temporarily tie both lift cylinders to the

outer rail.
• Disassemble the lift chains.

• Lower the inner rail slowly using overhead
crane so that the upper and lower rollers are
exposed.
60 • Take out the bearing and shim the rollers as

required.
01 ! Take care that the number of shims

10 assembled at each side is the same if
possible.
MAST
TRIPLE MAST
CHECKING MAST AND CARRIAGE SHIM
The procedure for checking the mast and carriage rail roller clearance is the same as that
described for the standard mast.
60
01
11
MAST
ADJUSTING MAST SHIM
DISASSEMBLY
To adjust the rail roller clearance the mast must be partially disassembled as follows:

• Lower the inner and intermediate rails completely.
• Place the drive wheels on blocks high enough so that the lower end of the outer rail will clear
the floor by 153~203 mm (6–8 in).
• Tilt the mast to 0° vertical. (Fig. 1)
• Place a drain pan under the mast and remove the hydraulic hoses, tubes and sheave
assemblies for the primary (centered mounted) cylinder and the lift cylinders.
(Match mark the hoses if removed from the “limiting valve”)
• Temporarily tie the lift cylinders supply hose to the outer rail.
! Temporarily tie both lift cylinders to the outer rail.

• Attach a sling to the top tie bar of the inner rail and lift it approximately 203 mm (8 in) above
the intermediate rail.
• Place two blocks under the inner rail, then lower it until the rail rests on the blocks.
• Remove the inner rail lift chain assemblies and the capscrews securing the cylinder rods to
the intermediate rail top tie bar.
• Attach the sling to both the inner rail and intermediate rail top tie bars.
• Raise the inner and intermediate rails, remove the two blocks previously installed and place a
1 m (3 ft) heavy wood block under the base of both the intermediate and inner rails. Ensure
that the block is large enough to hold both of the rail bases.
• As you raise the rails take note of the shims on the lift cylinder rods.
• Lower the inner and intermediate rails on to the block. Ensure they are firmly seated.
• Attach a sling to a lift cylinder and take up the slack.
• Remove the lower lock bracket from the lift cylinder, collapse the cylinder rod into the barrel
and carefully lift the cylinder out of the mast. (Fig. 2)
• Repeat the procedure and carefully remove the other lift cylinder.
• Attach a sling to both the inner and intermediate rail top tie bars, raise the rails, then remove
the support block and lower both rails to the floor. Ensure that both rails are on the floor.
• The intermediate rail lower rollers and outer rail upper rollers are now exposed, shim the rollers
as required. (Fig. 3)
• Attach a sling to the intermediate rail top tie bar, raise the rail and insert a 100 × 100 × 610
60 mm (4 × 4 × 24 in.) block between the upper or lower tie bars of the inner and intermediate rails.
• The intermediate rail upper rollers and inner rail lower rollers are now exposed, shim the rollers
01 as required. (Fig. 4)
12
MAST
Fig.¯1 Fig. 2
Fig. 3 Fig. 4
SHIM INSTALLATION
The procedure for removing the rollers and installing additional shims is the same as that
described for the standard mast.
REASSEMBLY
• Raise the intermediate rail and remove the block between the upper or lower tie bars of the
inner and intermediate rails.
• Lower the intermediate rail to the floor.
• Attach a sling to the top bar of both the inner and intermediate rails, then raise the rails 60
carefully guiding the lower rollers into position.
• Continue to raise both rails until a 1 m (3 ft) block can be placed under the base of both the 01
intermediate and inner rails. Ensure that the block is large enough to hold both of the rail 13
bases.
• Lower the inner and intermediate rails on to the block.
Ensure they are firmly seated. Install a safety chain from the inner and intermediate lower tie
bars to the outer rail top tie bar.
MAST
• Attach a sling to a lift cylinder and carefully position it in the mast.

• When fully seated in the lower mount install the lower lock bracket.
• Repeat the procedure and install the other lift cylinder.
• Raise the inner and intermediate rails, remove the safety chain and the support block.
• Carefully lower the rails, guide each lift cylinder rod into the intermediate rail top tie bar,
(do not forget to install the rod shims) and install capscrews to secure the cylinder rod.
26.7 kgf·m (193 lbf·ft)
• Raise both rails enough to place a block under the base of the inner rail, then lower the rails
until inner rail rests on the block.
• Install the lift chain assemblies and the hydraulic hoses and sheaves.
• Remove the support block from under the inner rail and lower the rail completely.
60
01
14
OTHER COMPONENT
CARRIAGE
The standard mast carriage and the full free lift mast carriage are very similar, the only difference
being that the full free lift carriage is operated by a center mounted hydraulic cylinder rather
than the rail lift cylinders.
REMOVAL
• Apply the park brake, place directional lever in neutral and block the steer wheels.
• Adjust the tilt angle of the mast to 0° vertical. (Fig.1)
• Raise the carriage 153~203 mm (6–8 in) then place a heavy pallet under the forks.
• Lower the carriage until the forks rest on the pallet, use two “C” clamps to clamp the forks
to the pallet. (Fig.1)
• On the standard mast continue to lower the lift cylinders until the chain tension is released.
• Turn the start switch to “OFF”
• On the full free lift mast continue to lower the center mounted (primary) cylinder until the chain
tension is released.
• Remove the carriage chain clevis pins from the chain anchors on the rear side of the carriage
(std. mast) or remove the clevis pins at the primary cylinder, pull the chain out of the sheaves
and lay them over the carriage (full free lift mast).
• Raise the inner rail until the carriage upper rollers are clear. (Fig. 2)
• Start the engine, release the park brake and slowly back away from the carriage. (Fig. 2)
60
02
1
OTHER COMPONENT
Fig. 1 Fig. 2
INSTALLATION
• Ensure that the carriage is securely clamped to the pallet.

• Slowly drive the fork lift up to the carriage assembly with the inner rail centered on the carriage.
• Raise the inner rail until it is high enough to clear the carriage upper rollers.
• Tilt the mast until it is at the same angle as the carriage assembly.
• Slowly move the fork lift forward until the inner rail is centered over the carriage rollers.
• Carefully lower the inner rail over the carriage rollers until the rail lift cylinders are completely
collapsed.
• Apply the parking brake, place directional lever in neutral, turn “OFF” the start switch and block
the steer wheels.
• Reinstall the lift chains. Always use new cotter pins.
CYLINDER RACKING
60 CHECKING
02
The phenomenon referred to as racking occurs when the stroke of the lift cylinders or the tilt
2
cylinders are not equal.
Lift cylinder racking–If lift cylinder racking occurs it can be felt when the rail reaches maximum
lift, since there is shock loading on one cylinder when it stops and the other cylinder continues
stroking.
Tilt cylinder Racking–If tilt cylinder racking occurs it can be visibly noticed when tilting reaches
maximum forward or backward position, since there is a twisting motion of the mast as one
Copyrighted
cylinder stops and the other continues Material
stroking.
OTHER COMPONENT
ADJUSTING
LIFT CYLINDER
• Raise the forks approximately 100 mm (4 in) off the floor.

• Check the tension of both chains, if necessary adjust so that the tension is equal.
• To adjust lower the carriage until the heel of the forks is 13 mm (1/2" ) off the floor. Adjust
each chain anchor until the carriage just starts to lift. Tightening torque of lock nut :
9.5 kgf·m (68 lbf·ft)
• Raise the lift cylinders to maximum stroke and check if both cylinder rods stop at the same
time.
• If racking occurs even after adjusting the chains, remove the cylinder rod of the lift cylinder
which stopped first (shorter stroke) from the rail tie bar, add shims and reinstall.
• Recheck for racking and adjust shimming if required.
• Tightening torque of cylinder rod end lock capscrew : 26.7 kgf·m (193 lbf·ft)
TILT CYLINDER
• Tilt the mast fully forward and fully backward and check it both cylinders start and stop at the
same time.
• If racking occurs adjust the cylinder with the longest stroke.
• Loosen the bolt clamping the rod end yoke and rotate the cylinder rod to shorten the stroke.
(Adjust forward tilt first.)
• When no racking is evident tighten the clamping bolt. 18.4 kgf·m (133 lbf·ft)
LIFT CHAINS
The lift chains are very important components in the mast assembly. The safe, efficient, reliable
transfer of lifting force from the hydraulic cylinders to the carriage (forks) depends on proper care
and periodic maintenance. To obtain maximum chain life, correct chain adjustment and regular
lubrication with the correct lubricant is essential.
LUBRICATING CHAIN
60
Inspect and lubricate the chains every 250 hours
with a quality chain spray lubricant or SAE 20 02
grade engine oil. 3
In adverse working conditions inspect and
lubricate every 50 hours. The lubricant must be
absorbed into the joint and between the links to
gain maximum chain life. Lubricating the outer
surface prevents rust and corrosion. (Fig. 1)
Intended for CLARK dealers only Fig. 1
OTHER COMPONENT
CHAIN FAILURES
Excessive chain overload particularly without

sufficient lubrication causes protruding pins and
crushed links. (Fig. 2)
Fig. 2
Cracked and broken links are a result of fatigue

caused by exceeding the rated capacity of the
equipment. (Fig. 3)
Insufficient or improper lubrication contributes to
this type of failure due to seized joints.
Fig. 3
• Wear
Replace the chain if the chain length is longer than the new chain length by 3% or more.
Always replace the two chains in a set for consistent lift operation.
• Rust (corrosion)
It is very important to protect the lift chain from corrosion whether the equipment is being used
or stored. The corrosion causes cracks in the chain, which reduce the rated capacity of the
lift chain.
60 • Fracture and crack

Chain fractures occur because of overloads that considerably exceed the rated capacity of the
02 equipment or by sudden impact loading. The most common reason for chain cracks is fatigue
4 failure. Replace with new chains when fractures or cracks are found. Always replace all chains
of the equipment at the same time.
• Seized joint
The joints of the lift chain must bend freely. A tight joint is caused by a bent pin and plate,
or rust. Do not repair a chain by cutting out a worn section and joining in a new piece.
OTHER COMPONENT
• Chain anchor/clevis bolt

Check wear, damage, and general condition of the chain anchors. If there is wear in the anchor
or damaged to the clevis bolt thread, replace the anchor assembly.
• Cleaning
It is preferable to clean the chains with a biodegradeable solvent, however if steam cleaned
do not use a caustic solution.
CHECKING CHAIN TENSION
• Place the mast at 0° vertical.

• Pick up a load and raise the forks approxi-
mately 153 mm (6 in).
• Push the chains forward and pull them
backward to check the amount of tension on
each chain.
• If one chain moves more than the other, lower
and adjust the chain anchor bolts for equal
tension on both chains.
• Raise the load and recheck the chain tension,
adjust if required.
• Chain anchor lock nut :
9.5 kgf·m (68 lbf·ft).
ADJUSTING LENGTH OF LIFT CHAINS
STANDARD AND FULL FREE LIFT 2–STAGE MAST
The standard mast has two chains, one on eash side of the mast anchored from the top tie
bar of the outer rail to the carriage.
The full free lift mast has two chains anchored from the base area of the primary cylinder (center
mounted on the inner rail) to the carriage.
• Ensure that the tires are inflated to specification.

• Pick up a rated load (to obtain maximum chain stretch).
• Set the tilt angle of the mast to 0° vertical.
60
• Lower the carriage and inner rail completely.
• Adjust the carriage chains so that the heel of each fork is approximately 13 mm (1/2" ) off the
02
floor. 5
• Recheck the chain tension.
• Check anchor lock nut : 9.5 kgf·m (68 lbf·ft ).
OTHER COMPONENT
FULL FREE LIFT TRI MAST
The full free lift 3–stage mast has four chains, 1 set anchored from the base of the inner rail
to the top tie bar of the outer rail, and the other set anchored from the base area of the primary
cylinder (center mounted) to the carriage.
• Ensure that the tires are inflated to specification.

• Pick up a rated load (to obtain maximum chain stretch).
• Set the tilt angle of the mast to 0° vertical.
• Lower the inner and intermediate rails completely.
• Adust the back chains so that the inner rail is 3.1mm (1/8" ) above the intermediate rail.
• Next adjust the carriage chains so that the heel of the forks is approximately 13 mm (1/2" ) off
the floor.
60
02
6
OTHER COMPONENT
FORKS
REMOVAL AND INSTALLATION
• Release the lock latch on the fork, then slide

the fork over the notch in the lower carriage
fork bar.
• Lift the end of the fork, the lower fork hanger

will separate from the lower carriage fork bar.
• Place a block of wood under the heel of the
fork.
• Press the end of the fork downward, the upper

fork hanger will disengage from the upper
carriage fork bar.
! CAUTION
When the fork disenages it is not
supported by the carriage and can fall to
the side.
60
02
7
Repeat the above procedure to detach the other fork.
Installing the forks is carried out in the reverse order of removal.
OTHER COMPONENT
INSPECTION
The forks should be inspected regularly to ensure component integrity.
VISUAL INSPECTION
• Fork Alignment : Compare fork arms to be sure they are straight, on the same plane (level),
and the same length.
• Fork Latch : Check for damage and holding ability.
• Fork Stops : Inspect the carriage fork stop for wear and or damage.
• Unusual Wear : Check for visible wear caused by improper operation or abuse.
• Physical Damage : Check for impact damage which could weaken the forks.
• Cracks : Inspect the forks for cracks at the heel, toe, and hanger areas.
FORK WEAR AND HEEL WEAR
Industrial Standards require that a fork be removed from service when the blade or heel thickness
is reduced by 10% from its original thickness.
• Use a pair of calipers (fork wear calipers are recommended) to gauge the thickness on an
unworn portion of the arm.
Move the calipers to the worn, heel area of the fork and make a measurement.
If the heel is 10% smaller than the arm, the load capacity could be reduced by 20%. A
3,500 kg (7700 lbs.) capacity fork with 10% wear can only safely handle 2,800 kg (6170 lbs.)
FORK FATIGUE
• Fatigue cracks normally start in the heel area or on the underside of the top hanger.
If cracks are found, the fork should be replaced. Dye penetrants or magnaflux can be used
for a more accurate inspection.
FORK ALIGNMENT
• Park the fork lift on a flat, even surface, tilt mast to vertical position, and set forks
60 25–50 mm (1–2 in) above the ground.

• Compare fork arms to be sure they are straight, on the same plane (level), and the same
length.
02 • Measure the distance from the fork tips to the ground. The height difference between the forks
tips should be no more than 3% of the fork length. For example, a 1070 mm (42 in) fork should
8
not vary more than 30.5 mm (1.2 in) up or down from its mate.
• If the fork tips are not aligned within the specified 3% difference, the cause of the problem
must be determined and corrected before returning the unit to service.
If replacement is necessary, always replace the forks in a set.
OTHER COMPONENT
FORK BENDING
Overloading, glancing blows against solid objects, or picking up loads unevenly can bend or twist
a fork. Use the following procedure to check for fork bending.
• Place a 50 ×100 × 6100 mm (2 × 4 × 24 in) wood block flat on the fork. Make sure the block is
not resting on the heel radius.
• Set a carpenter's square on the block against the fork shank.
• Check the fork 508 mm (20 in) above the blade to make sure it is not bent more than
14.5 mm (0.6 in) at the maximum.
• If blades are bent over the 14.5 mm (0.6 in) allowance they should be replaced as a set.
60
02
9
OTHER MAINTENANCE 70
• 70–01 COUNTERWEIGHT
• 70–02 LIFTING, JACKING AND BLOCKING
OTHER M A I N T E N A N C E
COUNTERWEIGHT
COUNTERWEIGHT
The counterweight should be inspected regularly to ensure that it is securely mounted and for
cracks, particularly around the mounting bolts and tow pin areas.
! CAUTION
Do not operate the fork lift without a counterweight or with loose mounting bolts.
Failure to comply can result in severe injury or death.
REMOVAL
! CAUTION
To lift the counterweight use wire ropes or chains that are certified and in good
condition and of adequate load rating and length.
! Stand clear of the counterweight as it is being hoisted, moved, or mounted.
• Install two eye bolts of adequate size and load

rating into the counterweight.
• Connect the lift chains or wire rope slings to

the eye bolts and using an overhead hoist of
sufficient lifting capacity slowly lift the chains
until the slack is removed.
70
01
1
COUNTERWEIGHT
• Remove the mounting capscrews, then raise

the counterweight from the fork lift frame.
• Slowly lower the counterweight on to a sturdy

pallet. As a precaution block the counterweight
to prevent it from shifting when the pallet is
moved.
INSTALLATION
Installing the counterweight is the reverse procedure of removal.
• Install the shims in the original position, or set

the counterweight on the frame and determine
the thickness of shims required (1).
• Remove the counterweight and install the
shims on the frame.
• Set the counterweight on the frame, and adjust
capscrew (2) to level the counterweight. Lock
the jam nut.
• Insert mounting capscrews (3) and install
washer (4) as required between the frame plate
70 and counterweight.
• Tighten mounting capscrews to specification.
01 Apply loctite #277 : 45–50 kgf·m (325~362 lbf·ft)
LIFTING, JACKING AND BLOCKING
! CAUTION
Do not raise the fork lift by jacking on the counterweight.
Only use a hydraulic jack that is certified, in good condition and of adequate load rating.
SAFE PARKING
Carry out the following procedures first before raising and blocking the machine.
• Park the fork lift on a hard flat surface such a as concrete floor without gaps or holes.
• Put the mast to the vertical position, and lower completely the forks or attachment.
• Put all control levers in neutral position and turn the start key to “OFF”.
• Engage the parking brake and block the wheels.
LIFTING THE DRIVING WHEELS
Use the mast to lift the driving wheels from the floor.
• Start the engine, and tilt the mast backward

completely. If needed, lift the mast a little for
2nd stage, and turn the start switch key to
“OFF”.
• Put a hardwood block 100 ×100 mm (4 × 4 in.)

below the mast rail. Set an iron plate approxi-
mately 6.4 mm (1/4″) thick on each wood block.
70
02
1
• Turn the start key to “ON”, and tilt the mast

forward completely.
Release the tilt control lever, and check the
gap between the drive wheels and floor.
• Turn the start key to “OFF”.
• Confirm that the support blocks under the mast

rails are securely positioned.
Steel plate
Wood block
• Carry out the above procedures in reverse order to remove the support blocks.
70
02
2
LIFTING THE STEERING WHEELS
PARK THE FORK LIFT SAFELY
• Install the jack under the rear part of the fork

lift frame.
! Do not install the jack under the counter-

weight.
• Raise the fork lift just enough to conduct

repairs.
• Place hardwood blocks under both sides of the
frame close to the steering wheels to ensure
maximum stability.
• Put an equal amount of blocking under each
side to keep the fork lift horizontal.
• The length of the blocking should be equal to
the width of the fork lift.
• Lower the fork lift to the blocks and confirm
machine stability prior to performing any
repairs.
When repairs are completed lower the steering wheels to the floor, by carrying out the
procedure in reverse order.
70
02
3
LIFTING THE ENTIRE FORK LIFT
! CAUTION
SIDE–TO–SIDE TIPOVER. When jacking the side be sure the mast is lowered fully and
do not raise one side of the fork lift more than about 50 mm (2 in) higher than the
other, to avoid tipping it over laterally.
END–TO–END TIPOVER. If the mast and transaxle are removed while the fork lift is
blocked up, it will tip backwards due to the heavy counterweight. Both mast and
counterweight must be removed before attempting to raise the fork lift for transaxle
removal. The back of the unit must be supported by blocking under the steer axle to
prevent movement.
The reverse is also true. If the counterweight is removed while the fork lift is up on
blocks, the weight of the mast and transaxle will cause it to tip on the front blocks
and fall forward.
• Place the jack under the side frame near the center of the fork lift. Get as close as possible
to the point of balance.
! CAUTION
Ensure that the jack is properly
positioned under the side frame.
• Carefully lift one side of the fork lift at a time,

to a maximum height 150 mm (6 in.)
! CAUTION
When raising the fork lift do not exceed
the point of stability.
The fork lift could tip over causing
serious injury or death.
70 • Place the blocks under the side frame close to

the driving wheels and steering wheels for
maximum stability.
02 • Lower the fork lift on to the blocks and move
4 the jack to the opposite side. Repeat the lifting
procedure.
• Use the same size blocks under each side, so
the fork lift will be level and have maximum
stability. Copyrighted Material
• When working on components other than the

drive axle or steering axle raise the fork lift and
put wheel cradles of adequate load rating and
stability under the wheels.
• Lower the fork lift in the reverse order of the lifting procedure.
To prevent side–to–side tipover, lower one side of the fork lift at a time by 50 mm (2 in) then
repeat the process on the opposite side.
70
02
5
CIRCUIT DIAGRAM 80
• 80–01 HYDRAULIC & ELECTRIC CIRCUIT DIAGRAM

– Electric circuit diagram (For DSL truck)
– Electric circuit diagram (For LPG truck)
– Electric circuit diagram (For LPG SECM)
– Hydraulic circuit diagram (For DSL truck)
– Hydraulic circuit diagram (For LPG truck)
C I R C U I T D I A G R A M
HYDRAULIC & ELECTRIC CIRCUIT DIAGRAM
ELECTRIC CIRCUIT DIAGRAM (FOR DSL TRUCK)

80
01
1
• CMP40D·CMP45D·CMP50SD
1. Battery
• SF35D·SF40D·SF45D
2. Cranking motor
3. Relay–3 point
4. Relay–start
5. Alternator
6. Slow blow fuse
7. Key switch
8. Induction heater
9. Fuse box ass’y
10. Stop/throttle ctrls
11. Panel Ass’y
12. Fuel sender
13. Water temp. sender
14. S/W–ENG.oil press
16. Parking brake sw
17. Rear work lamp
18. Licence lamp ass’y
19. T/sig. lamp
20. Head lamp
21. Combi. lamp
22. Column lever ass’y
23. Switch–brake stop
24. Flasher unit
25. Room lamp
27. T/M oil temp sw
28. Antenna
29. Cassette
30. T/M solenoid valve
31. Relay–horn
32. Horn switch
33. Horn
34. Relay–3 point
35. Back–up alarm
36. Beacon lamp
37. Heater switch
38. Heater
39. Wiper motor & brkt. ass’y
40. Washer pump
41. Speaker
ELECTRIC CIRCUIT DIAGRAM (FOR LPG TRUCK)

80
01
3
• CMP40L·CMP45L·CMP50SL
1. Battery
• SF35L·SF40L·SF45L
2. Cranking motor
3. Relay–3 point
4. Relay–start
5. Alternator
6. Slow blow fuse
7. Key switch
9. Fuse box ass’y
10. Distributer
11. Panel Ass’y
12. LPG press s/w
14. S/W–ENG oil press
17. Rear work lamp
19. T/sig. lamp
20. Head lamp
21. Combi. lamp
24. Flasher unit
25. Room lamp
27. T/M oil temp s/w
28. Cassette
29. Antenna
31. Relay–horn
32. Horn switch
33. Horn
34. Relay–3 point
35. Back–up alarm
36. Beacon lamp
37. Heater switch
38. Heater
40. Washer pump
41. Speaker
ELECTRIC CIRCUIT DIAGRAM (FOR LPG SECM)

80
01
5
1. Battery
2. Cranking motor
3. Relay–3 point
4. Relay–start
5. Alternator
6. Slow blow fuse
7. Key switch
9. Fuse box ass’y
10. Distributer
11. Panel Ass’y
12. LPG press s/w
14. S/W–ENG oil press
17. Rear work lamp
19. T/sig. lamp
20. Head lamp
21. Combi. lamp
24. Flasher unit
25. Room lamp
27. T/M oil temp s/w
28. Cassette
29. Antenna
31. Relay–horn
32. Horn switch
33. Horn
34. Relay–3 point
35. Back–up alarm
36. Beacon lamp
37. Heater switch
38. Heater
40. Washer pump
41. Speaker
HYDRAULIC CIRCUIT DIAGRAM (FOR DSL TRUCK)

80
01
7
• CMP40D·CMP45D·CMP50SD
• SF35D·SF40D·SF45D
HYDRAULIC CIRCUIT DIAGRAM (FOR LPG TRUCK)

80
01
9

Clark Service Manual-712

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Clark Service Manual-712

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SF35-45D/L

RATED CAPACITY : 3500~5000kg

Part No. 8034283

Manufactured by #40–1, Ungnam-Dong,

• 00–01 REVISION HISTORY

Revision Revision Revision Revision Revision

00–01–10 13–03–5 13–05–6 13–06–24

00 Revision Revision Revision Revision Revision

Revision Revision Revision Revision Revision

00 Revision Revision Revision Revision Revision

HOW TO READ THIS MANUAL

CHAPTER AND SECTION

Section number (01 : Structure and function)

Chapter number (10 : Engine)

For the revision status in this manual, refer to REVISION HISTORY.

Symbol Item Remarks

Special safety precautions are necessary when

Special technical precautions or other precautions for

Tightening Places that require special attention for the tightening

Places that require proper tools used in assembling

Adhesive Places to be applied with adhesive.

Lubricating Places where oil or lubricant must be added.

SAFETY CLOTHES AND HELMET

• Wear the specified work clothes in the correct manner.

00 PREPARE FOR EMERGENCIES

HANDLE FLUIDS SAFELY–AVOID FIRES

• Handle fuel with care it is highly flammable.

DISPOSE OF FLUIDS PROPERLY

• Improperly disposing of fluids can harm the

relevant environmental protection regulations

AVOID HARMFUL ASBESTOS DUST

00 PREPARATIONS FOR WORK

• Unexpected machine movement can cause

USE TOOLS PROPERLY

• Use a tool only for its designed application.

• Illuminate your work area adequately but safely.

• Hot coolant can burn you. Let it cool down.

AVOID HIGH-PRESSURE FLUIDS

• When raising heavy components, use a hoist or crane.

• When working on the battery, wear goggles or

• Keep sparks, lighted matches, and open flame

• Battery posts and cables touched by metal

• If water gets to the electrical system, abnormal

00 CAUTIONS DURING OPERATION

• Do not allow anyone to stand or walk under

NEVER RIDE ON FORKS

• Never use the forks to lift people.

ROTATING PARTS / ALIGNING HOLES

• Never touch rotating part such as the fan

PINCHING AND FALLING

• Do not use the mast as a ladder.

• Do not add air pressure immediately to the

• The tire must be inflated by trained personnel

! the fork lift is improperly operated.

cm 1 0.01 0.00001 0.3937 0.03281 0.01094 0.000006

m 100 1 0.001 39.37 3.2808 1.0936 0.00062

km 100000 1000 1 39370.7 3280.8 1093.6 0.62137

in 2.54 0.0254 0.000025 1 0.08333 0.02777 0.000015

ft 30.48 0.3048 0.000304 12 1 0.3333 0.000189

yd 91.44 0.9144 0.000914 36 3 1 0.000568

mile 160930 1609.3 1.6093 63360 5280 1760 1

Unit cm2 m2 km2 a ft2 yd2 in2

cm2 1 0.0001 – 0.000001 0.001076 0.000012 0.155000