項目   零配件號碼         新件號   描述  

    1   CH10287    1   CH10287    栓塞         

    2   T406205    1   T406205    密封O型圈       

    3   CH10285    1   CH10285    栓塞         

    4   T409314    1   T409314    密封O型圈       

    5   CH10287    1   CH10287    栓塞         

    6   CH10146    1   CH10146    密封O型圈

    項目   零配件號碼         新件號   描述  

    1   CH11512    1   CH11512    CYL 蓋 ASSY          圈

    項目   零配件號碼         新件號   描述  

    2   CH11353    1   CH11353    密封墊 - 搖臂室蓋       

    3   CH10955    15  CH10955              

    項目   零配件號碼         新件號   描述  

    1   CH12792    1   CH12792    曲軸組合         

    1   CH11986    1   CH12792    曲軸組合         

    6   CH11379    1   CH11379    密封墊 -前油封          

    7   KRP3122    1   KRP3122    曲軸瓦       

    7   KRP3118    1   KRP3122    曲軸瓦       

    (7) KRP3116/025   1   KRP3116/025   曲軸瓦 -U/S         

    (7) KRP3116/050   1   KRP3116/050   曲軸瓦 -U/S         

    (7) KRP3117/025   1   KRP3117/025   曲軸瓦 -U/S         

    (7) KRP3117/050   1   KRP3117/050   曲軸瓦 -U/S         

    (7) CV11001    1   CV11001    要點殼軸承        (-)0.63 MM

    (7) CV11002    1   CV11002    要點殼軸承        (-)0.127 MM

    (7) CV11003    1   CV11003    要點殼軸承        (+)0.63 MM

    (7) CV11004    1   CV11004    要點殼軸承        (+-)0.63 MM

    8   KRP3206    1   KRP3206    止推片       

    項目   零配件號碼         新件號   描述  

    2      1      曲軸         

    3   CH12793    1   CH12793    曲軸傳動機構(gòu)        

    4   CH10653    1   CH10653    合釘         

    5   CH10652    1   CH10652    銷              

    項目   零配件號碼         新件號   描述  

    2      1      曲軸         

    3   CH11687    1   CH12793    曲軸傳動機構(gòu)        

    4   CH10653    1   CH10653    合釘         

    5   CH10652    1   CH10652    銷              

    項目   零配件號碼         新件號   描述  

    1   CH11988    1   CH11988    凸輪軸       

    2   CH10587    1   CH10587    密封O型圈       

    3   CH10588    1   CH10588    端蓋         

    4   CH10589    3   CH10589    公制的螺旋       

    項目   零配件號碼         新件號   描述  

       CH10221    5   CH10221    栓塞         

       CH10657    2   CH10657    密封O型圈       

       CH10658    2   CH10658    合釘         

       CH10663    1   CH10663    栓塞         

       CH10664    1   CH10664    栓塞         

       CH10667    1   CH10667    密封O型圈       

    1   CH10662    1   CH10662    間隔器       

    1   CH11398    1   CH11398    密封墊       

    2      1      密封墊       

    3      1      密封墊       

    4   CH10661    1   CH10661    合釘         

    5   CH10656    1   CH10656    合釘         

    6   CH10659    1   CH10659    合釘         

    7   CH10660    1   CH10660    密封O型圈       

    8   CH10658    2   CH10658    合釘         

    9   T400206    2   T400206    栓塞         

    9   CH10666    2   CH10666    栓塞             

    項目   零配件號碼         新件號   描述  

    1   T400909    1   T400909    曲軸箱       

    1   CH12546    1   檢查歷史   曲軸箱       

    1   T400208    1   檢查歷史   曲軸箱       

    1   T400208    1   檢查歷史   曲軸箱       

    6   CH11180    6   CH11180    氣缸襯套         

    7   CH10673    6   CH10673    帶        

    8   CH10674    6   CH10674    密封墊 -油       

    9   CH10677    6   CH10677    密封墊 -油       

    10  CH11179    6   CH11179    密封墊 -油              

    項目   零配件號碼         新件號   描述  

    2      1      缸體         

    3      1      軸承蓋       

    4   T400209    14  T400209    螺拴         

    5   CH10672    14  CH10672    墊圈                    

    項目   零配件號碼         新件號   描述  

    8   CH10679    14  CH10679    螺拴         

    8   CH11180    6   CH11180    氣缸襯套         

    項目   零配件號碼         新件號   描述  

    2      1      缸體         

    3   CH11180    1   CH11180    氣缸襯套         

    4   CH10673    6   CH10673    帶        

    4      14     螺拴         

    5   CH10674    6   CH10674    密封墊 -油       

    6   CH10677    6   CH10677    密封墊 -油       

    7   CH11179    6   CH11179    密封墊 -油       

    8      7      軸承蓋       

    9   T400209    14  T400209    螺拴         

    9      14     螺拴         

    10  CH10672    14  CH10672    墊圈                

    項目   零配件號碼         新件號   描述  

       CH10567    1   CH10567    螺拴         

    1   CH10594    1   CH10594    承接器       

    2   CH10581    1   CH10581    扣環(huán)         

    3   CH10004    2   CH10004    滾珠軸承         

    4   CH10592    1   CH10592    燃料噴射泵傳動機構(gòu)         

    5   CH10583    3   CH10583    螺拴         

    5   CH10541    4   CH10255    墊圈         

    6   CH10593    3   CH10593    墊圈         

    7   CH10550    3   CH10550    螺拴         

    8   CH10255    4   CH10255    墊圈         

    9   CH10590    1   CH10590    密封O型圈       

    10  CH10798    1   CH10798    螺帽         

    11  CH12764    1   CH12764    圖釘                    

    項目   零配件號碼         新件號   描述  

    1   CH12695    3   CH12695    搖桿軸       

    1   CH10685    3   CH12695    搖桿軸       

    2   T400223    12  T400223    搖臂組合         

    2   CH11165    12  T400223    搖臂組合         

    3   CH12701    12  CH12701    螺旋         

    3   CH11162    12  檢查歷史   螺旋         

    3   CH11916    12  檢查歷史   螺旋         

    4   T400403    12  T400403    螺帽         

    4   CH10688    12  T400403    螺帽         

    4   CH12697    12  T400403    螺帽         

    5   CH10229    12  CH10229    密封O型圈       

    6   CH12702    12  CH12702    樞        

    6   CH10689    12  CH12702    鈕扣         

    6   CH12510    12  CH12702    樞        

    7   CH12831    12  CH12831    結(jié)軸塊       

    7   CH10680    12  CH12831    結(jié)軸         

    8   T400224    6   T400224    搖臂組合         

    8   CH11161    6   T400224    搖臂組合         

    8   CH12698    6   T400224    搖臂組合         

    9   CH11076    6   CH11076    螺旋         

    10  CH11077    6   CH11077    螺帽         

    11  CH11079    6   CH11079    密封O型圈       

    12  CH11078    6   CH11078    鈕扣         

    13  CH10566    4   CH10566    螺拴             

Lubricati on

System

Engine Oil Pressure - Test

i02571670

The engine oil pressure may be checked

electronically by using the electronic service tool.

The engine oil pressure can be measured with the

electronic service tool. Refer to Troubleshooting for

information on the use of the electronic serv ice tool.

Measuring Engine Oil Pressure

Work carefully around an engine that is running.

Engine parts that are hot, or parts that are moving,

can cause personal injury.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE

Illustration 34

Oil gallery plug

(1) Plug

g00977330

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

1.

Install Tool (A) into the oil gallery plugs (1).

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before open-

ing any compartment or disassembling any compo-

nent containing fluids.

Dispose of all fluids according to local regulations and

mandates.

Table 14

Tool (A) measures the oil pressure in the system.

Note: Engine oil pressure to the camshaft and main

bearings should be checked on each side of the

cylinder block at oil gallery plugs (1).

2. Start the engine. Refer to Operation and

Maintenance Manual, “Refill Capacities and

Rec ommendations” for the recommendations of

engine oil.

3. Rec ord the value of the engine oil pressure when

the engine is at operating temperature 100 °C

(212 °F).

The minimum engine oil pressure should be

approximately 275 to 414 kPa (40 to 59 psi).

4. Compare the recorded engine oil pressure with

the oil pressure indicators on the instrument panel

and the engine oil pressure that is displayed on

the electronic service tool.

5. An engine oil pressure indicator that has a defect

or an engine oil press ure sensor that has a defect

can give a false indication of a low oil pressure or

a high oil pressure. If there is a notable difference

between the engine oil pressure readings make

necessary repairs.

This document has been printed from SPI². Not for Resale

38

Testing and Adjusting Section

KENR6231

6.

7.

If low engine oil pressure is determined, refer to

“Reasons for Low Engine Oil Pressure”.

If high engine oil pressure is determined, refer to

“Reason for High Engine Oil Pressure”.

2.

Engine oil that is contaminated with fuel or coolant

will cause low engine oil pressure. High engine

oil level in the crankcase can be an indication

of contamination. Determine the reason for

contamination of the engine oil and make the

necessary repairs. Replace the engine oil with the

approved grade of engine oil. Refer to Operation

Reasons

Pressure

for

Low

Engine

Oil

and Maintenance Manual, “Engine Oil” for the

recommendations of engine oil.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before open-

ing any compartment or disassembling any compo-

nent containing fluids.

Dispose of all fluids acc ording to local regulations and

mandates.

• Engine oil level is low. Refer to Step 1.

• Engine oil is contaminated. Refer to Step 2.

Step 3.

Step 4.

screen. Refer to Step 5.

• The engine oil pump is faulty. Refer to Step 6.

to Step 7.

1. Check the engine oil level in the crankcase. The

oil level can possibly be too far below the oil pump

supply tube. This will cause the oil pump not to

have the ability to supply enough lubrication to the

engine components. If the engine oil level is low

add engine oil in order to obtain the correct engine

oil level. Refer to Operation and Maintenance

Manual, “Engine Oil” for the recommendations of

engine oil.

NOTICE

Perkins oil filters are manufactured to Perkins speci-

fications. Use of an oil filter that is not recommended

by Perkins c ould result in severe damage to the en-

gine bearings, crankshaft, etc., as a result of the larger

waste particles from unfiltered oil entering the engine

lubricating system. Only use oil filters recommended

by Perkins.

3. If the engine oil bypass valves are held in the

open position, a reduc tion in the oil pressure can

be the result. This may be due to debris in the

engine oil. If the engine oil bypass valves are

stuck in the open position, remove each engine

oil by pass valve and clean each bypass valve

in order to correct this problem. You must also

clean each bypass valve bore. Install new engine

oil filters. New engine oil filters will prevent more

debris from causing this problem. For information

on the repair of the engine oil bypass valves, refer

to Disassembly and Assembly, “Engine Oil Filter

Base - Disassemble”.

4. An oil line or an oil passage that is open, broken,

or disconnected will cause low engine oil pressure.

An open lubrication system could be caused by

a piston cooling jet that is missing or damaged.

Determine the reason for an open lubrication

system of the engine and make the necessary

repairs.

Note: The piston cooling jets direct engine oil toward

the bottom of the piston in order to cool the piston.

This also provides lubrication for the piston pin.

Breakage, a restriction or incorrect installation of the

piston cooling jets will cause seizure of the piston.

5. The inlet screen of the oil pickup tube for the

engine oil pump can have a restriction. This

restriction will cause cavitation and a loss of

engine oil pres sure. Check the inlet screen on

the oil pickup tube and remove any material that

may be restricting engine oil flow. Low engine oil

pressure may also be the result of the oil pickup

tube that is drawing in air. Check the joints of the

oil pickup tube for cracks or a damaged O-ring

seal. Remove the engine oil pan in order to gain

access to the oil pickup tube and the oil screen.

Refer to Disassembly and Assembly, “Engine Oil

Pan - Remove and Install” for more information.

This document has been printed from SPI². Not for Resale

KENR6231

39

Testing and Adjusting Section

6.

7.

Check the following problems that may occur to

the engine oil pump.

a. Air leakage in the supply side of the oil pump

will also cause cavitation and loss of oil

pressure. Check the supply side of the oil pump

and make necessary repairs. For information

on the repair of the engine oil pump, refer to

Disassembly and Assembly, “Engine Oil Pump

- Remove”.

b. Oil pump gears that have too much wear will

cause a reduction in oil pressure. Repair the

engine oil pump. For information on the repair

of the engine oil pump, refer to Disassembly

and Assembly, “Engine Oil Pump - Remove”.

Excessive clearance at engine bearings will

cause low engine oil pressure. Check the

engine components that have excessive bearing

clearance and make the necessary repairs.

NOTICE

Perkins oil filters are manufactured to Perkins speci-

fications. Use of an oil filter that is not recommended

by Perkins c ould result in severe damage to the en-

gine bearings, crankshaft, etc., as a result of the larger

waste particles from unfiltered oil entering the engine

lubricating system. Only use oil filters recommended

by Perkins.

i02553373

Excessive  Bearing  Wear -

Inspect

When some components of the engine show bearing

wear in a short time, the cause can be a restriction in

an oil passage.

Reason

for High

Engine

Oil

An engine oil pressure indicator may show that there

is enough oil pressure, but a component is worn

Pressure

NOTICE

due to a lack of lubrication. In such a case, look at

the passage for the oil supply to the component.

A restriction in an oil supply passage will not allow

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened

component life.

NOTICE

Care must be taken to ensure that fluids are contained

during performance of inspection, maintenance, test-

ing, adjusting and repair of the product. Be prepared to

collect the fluid with suitable containers before open-

ing any compartment or disassembling any compo-

nent containing fluids.

Dispose of all fluids according to local regulations and

mandates.

Engine oil pressure will be high if the engine oil

bypass valves become stuck in the closed position

and the engine oil flow is restricted. Foreign matter

in the engine oil system could be the cause for the

restriction of the oil flow and the movement of the

engine oil bypass valves. If the engine oil bypass

valves are stuck in the closed position, remove

each bypass valve and clean each bypass valve in

order to correct this problem. You must also clean

each bypass valve bore. Install new engine oil

filters. New engine oil filters will prevent more debris

from causing this problem. For information on the

repair of the engine oil filter bypass valve, refer to

Disassembly and Assembly, “Engine Oil Filter Base -

Disassemble”.

enough lubrication to reach a component. This will

result in early wear.

i02553374

Excessive  Engine  Oil

Consumption - Inspect

Engine Oil Leaks on the Outside of

the Engine

Check for leakage at the seals at each end of the

crankshaft. Look for leak age at the gasket for the

engine oil pan and all lubrication system connections.

Look for any engine oil that may be leaking from

the crankcase breather. This can be caused by

combus tion gas leakage around the pistons. A dirty

crankcase breather will cause high pressure in the

crankcase. A dirty crankcase breather will cause the

gaskets and the seals to leak.

Engine  Oil  Leaks  into  the

Combustion Area of the Cylinders

Engine oil that is leaking into the combustion area of

the cylinders can be the cause of blue s moke. There

are several possible way s for engine oil to leak into

the combustion area of the c ylinders:

• Leaks between worn valve guides and valve stems

This document has been printed from SPI². Not for Resale

40

Testing and Adjusting Section

KENR6231

•

•

•

•

•

Worn components or damaged components

(pistons, piston rings, or dirty return holes for the

engine oil)

Incorrect installation of the compression ring and/or

the intermediate ring

Leaks past the seal rings in the turbocharger shaft

Overfilling of the crankcase

Wrong dipstick or guide tube

Excessive consumption of engine oil can also

result if engine oil with the wrong viscosity is used.

Engine oil with a thin viscosity can be caused by fuel

leakage into the crankcase or by increased engine

temperature.

Increased

Engine

Oil

i02553375

Temperature

- Inspect

If the oil temperature is high, then check for a

restriction in the oil pas sages of the oil cooler. A

restriction in the oil cooler will not cause low oil

pressure in the engine.

Determine if the oil cooler bypass valve is held in the

open position. This condition will allow the oil to pass

through the v alve instead of the oil cooler. The oil

temperature will increase.

Refer to Operation and Maintenance Manual, “Refill

Capacities” for the correct lubricating oil.

This document has been printed from SPI². Not for Resale

KENR6231

41

Testing and Adjusting Section

Cooling

System

i02553376

5.

Check the sending unit. In some conditions, the

temperature sensor in the engine sends signals

to a sending unit. The sending unit converts these

signals to an electrical impulse which is used by a

mounted gauge. If the sending unit malfunctions,

Cooling

System - Check

the gauge can show an incorrect reading. Also if

the electric wire breaks or if the electric wire shorts

(Overheating)

Above normal coolant temperatures can be caused

by many conditions. Use the following procedure

to determine the cause of above normal coolant

temperatures:

Personal injury can result from escaping fluid un-

der pressure.

If a pressure indication is shown on the indicator,

push the release valve in order to relieve pressure

before removing any hose from the radiator.

1. Check the coolant level in the cooling system.

Refer to Operation and Maintenance Manual,

“Cooling System Coolant Level - Check”. If the

coolant level is too low, air will get into the cooling

system. Air in the cooling system will cause a

reduction in coolant flow and bubbles in the

coolant. Air bubbles will keep coolant away from

the engine parts, which will prevent the transfer of

heat to the coolant. Low coolant level is caused by

leaks or incorrectly filling the radiator.

2. Check the mixture of antifreeze and water. Refer

to Operation and Maintenance Manual, “Fluid

Recommendations”. If the coolant mixture is

incorrect, drain the s ystem. Put the correct mixture

of water, antifreeze and coolant conditioner in the

cooling system.

3. Check for air in the cooling system. Air can enter

the cooling system in different ways. The most

common causes of air in the cooling system

are not filling the cooling system correctly and

combustion gas leakage into the cooling system.

Combustion gas can get into the system through

ins ide cracks, a damaged cylinder head, or a

damaged cylinder head gasket. Air in the c ooling

system c auses a reduction in coolant flow and

bubbles in the coolant. Air bubbles keep coolant

away from the engine parts, which prevents the

transfer of heat to the coolant.

4. Check the water temperature gauge. A water

temperature gauge which does not work correctly

will not show the correct temperature. Refer

to Systems Operation, Testing and Adjusting,

“Cooling System - Inspect”.

6.

7.

8.

9.

out, the gauge can show an incorrect reading.

Check the radiator.

a. Check the radiator for a restriction to coolant

flow. Check the radiator for debris, dirt, or

deposits on the inside of the radiator core.

Debris, dirt, or deposits will restrict the flow of

coolant through the radiator.

b. Check for debris or damage between the fins

of the radiator core. Debris between the fins

of the radiator core restricts air flow through

the radiator core. Refer to Systems Operation,

Testing and Adjusting, “Cooling System -

Inspect”.

c. Ensure that the radiator size is adequate for

the application. An undersized radiator does

not have enough area for the effective release

of heat. This may cause the engine to run

at a temperature that is higher than normal.

The normal temperature is dependent on the

ambient temperature.

Check the filler c ap. A pressure drop in the

radiator can cause the boiling point to be lower.

This can cause the cooling system to boil. Refer

to Systems Operation, Testing and Adjusting,

“Cooling System - Tes t”.

Check the fan and/or the fan shroud.

a. The fan must be large enough to send air

through most of the area of the radiator core.

Ensure that the size of the fan and the position

of the fan are adequate for the application.

b. The fan shroud must be the proper size and

the fan shroud must be positioned correctly.

Ensure that the size of the fan shroud and the

position of the fan shroud are adequate for the

application.

If the fan is belt driven, check for loose drive belts .

A loose fan drive belt will cause a reduction in the

air flow across the radiator. Check the fan drive

belt for proper belt tension. Adjust the tension of

the fan drive belt, if necessary. Refer to Sys tems

Operation, Testing and Adjusting, “Belt Tension

Chart”.

This document has been printed from SPI². Not for Resale

42

Testing and Adjusting Section

KENR6231

10. Check the coolin, g system hoses and clamps.

Damaged hoses with leaks can normally be seen.

Hoses that have no visual leak s can soften during

operation. The soft areas of the hose can become

kinked or crushed during operation. These areas

of the hose can cause a restriction in the coolant

flow. Hoses become soft and/or get cracks

after a period of time. The inside of a hose can

deteriorate, and the loose particles of the hose

can cause a restriction of the coolant flow. Refer

to Operation and Maintenance Manual, “Hoses

and Clamps - Inspect/Replace”.

11. Check for a restriction in the air inlet system.

A restriction of the air that is coming into the

engine can cause high cylinder temperatures.

High cy linder temperatures cause higher than

normal temperatures in the cooling system. Refer

to Systems Operation, Testing and Adjusting, “Air

Inlet and Exhaust System - Inspect”.

a. If the measured restriction is higher than the

maximum permissible restriction, remove the

foreign material from the engine air cleaner

element or install a new engine air cleaner

element. Refer to Operation and Maintenance

Manual, “Engine Air Cleaner Element -

Clean/Replace”.

b. Check for a restriction in the air inlet system

again.

c. If the measured restriction is still higher than

the maximum permissible restriction, check the

air inlet piping for a restriction.

12. Check for a restriction in the exhaust system.

A restriction of the air that is coming out of the

engine can cause high cylinder temperatures.

a. Make a visual inspection of the exhaust system.

Check for damage to exhaust piping or for a

damaged muffler. If no damage is found, check

the exhaust system for a restriction. Refer to

Systems Operation, Testing and Adjusting, “Air

Inlet and Exhaust System - Inspect”.

b. If the measured restriction is higher than the

maximum permissible restriction, there is a

restriction in the exhaust system. Repair the

exhaust system, as required.

13. Check the shunt line, if the shunt system is

used. The shunt line must be submerged in the

expansion tank. A restriction of the shunt line

from the radiator top tank to the engine water

pump inlet will cause a reduction in water pump

efficiency. A reduction in water pump efficiency

will result in low coolant flow and overheating.

14. Chec k the water temperature regulator. A water

temperature regulator that does not open, or

a water temperature regulator that only opens

part of the way can cause overheating. Refer to

Systems Operation, Testing and Adjusting, “Water

Temperature Regulator - Test”.

15. Check the water pump. A water pump with a

damaged impeller does not pump enough coolant

for correct engine cooling. Remove the water

pump and check for damage to the impeller. Refer

to Systems Operation, Testing and Adjusting,

“Water Pump - Test”.

16. Chec k the air flow through the engine

compartment. The air flow through the radiator

comes out of the engine compartment. Ensure

that the filters, air conditioner, and similar items

are not installed in a way that prevents the free

flow of air through the engine compartment.

17. Chec k the aftercooler. A restriction of air flow

through the air to air aftercooler (if equipped) can

cause overheating. Check for debris or deposits

which would prevent the free flow of air through

the aftercooler.

18. Cons ider high outside temperatures. When

outside temperatures are too high for the rating

of the cooling system, there is not enough of a

temperature difference between the outside air

and coolant temperatures.

19. Cons ider high altitude operation. The cooling

capacity of the cooling system goes down as

the engine is operated at higher altitudes. A

pressurized cooling s ystem that is large enough to

keep the coolant from boiling must be used.

i02553378

Cooling System - Inspect

Cooling systems that are not regularly inspected are

the cause for increased engine temperatures. Make

a visual inspection of the cooling system before any

tests are performed.

Personal injury can result from escaping fluid un-

der pressure.

If a pressure indication is shown on the indicator,

push the release valve in order to relieve pressure

before removing any hose from the radiator.

This document has been printed from SPI². Not for Resale

KENR6231

43

Testing and Adjusting Section

1.

2.

Check the coolant level in the cooling system.

Refer to Operation and Maintenance Manual,

“Cooling System Coolant Level - Check”.

Check the quality of the coolant. The coolant

should have the following properties:

• Color that is similar to new coolant

• Odor that is similar to new coolant

• Free from dirt and debris

If the coolant does not have these properties,

drain the sy stem and flush the system. Refill

the cooling system with the correct mixture of

water, antifreeze, and coolant conditioner. Refer

to Operation and Maintenance Manual, “Fluid

Illustration 35

Boiling point of water

g00921815

3.

Recommendations”.

Look for leak s in the system.

Remember that temperature and pressure work

together. When a diagnosis is made of a cooling

system problem, temperature and pressure must be

checked. Cooling system pressure will have an effec t

on the cooling system temperature. For an example,

Note: A small amount of coolant leak age across

the surfac e of the water pump seals is normal. This

leakage is required in order to provide lubrication for

this type of seal. A hole is provided in the water pump

housing in order to allow this coolant/seal lubric ant

to drain from the pump housing. Intermittent leakage

of small amounts of coolant from this hole is not an

indication of water pump seal failure.

4. Ensure that the air flow through the radiator does

not have a restriction. Look for bent core fins

between the folded cores of the radiator. Also, look

for debris between the folded cores of the radiator.

5. Inspect the drive belts for the fan.

6. Check for damage to the fan blades.

7. Look for air or combustion gas in the cooling

system.

8. Inspect the filler cap, and check the surface that

seals the filler cap. This surface must be clean.

i02553379

Cooling System - Test

This engine has a pres sure type cooling system. A

pressure type cooling system has two advantages.

The cooling system can be operated in a safe manner

at a temperature higher than the normal boiling point

(steam) of water.

This type of system prevents cavitation in the water

pump. Cavitation is the forming of low pressure

bubbles in liquids that are caused by mechanical

forces. It is difficult to create a pocket of air in this

type of cooling system.

refer to Illustration 35. This will show the effect of

pressure on the boiling point (steam) of water. This

will also show the effect of height above s ea level.

Personal injury can result from hot coolant, steam

and alkali.

At operating temperature, engine coolant is hot

and under  pressure. The radiator and all lines

to heaters or the engine contain hot coolant or

steam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is cool

enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid

contact with skin and eyes.

The coolant level must be to the correct level in order

to check the coolant sys tem. The engine must be

cold and the engine must not be running.

After the engine is cool, loosen the pressure cap

in order to relieve the pressure out of the cooling

sys tem. Then remove the pressure c ap.

The level of the coolant should not be more than

13 mm (0.5 inch) from the bottom of the filler pipe. If

the cooling system is equipped with a sight glass,

the coolant should be to the proper level in the sight

glass.

This document has been printed from SPI². Not for Resale

Testing and Adjusting Section

KENR6231

Checking the Filler Cap

Table 15

•

•

Seal

Surface for seal

One cause for a pressure loss in the cooling system

can be a damaged seal on the radiator filler cap.

2.

3.

4.

5.

Remove any deposits that are found on these

items, and remove any material that is found on

these items.

Install the filler cap onto Tooling (A).

Look at the gauge for the exact pressure that

opens the filler cap.

Compare the gauge reading with the opening

pressure that is listed on the filler cap.

If the filler cap is damaged, replace the filler c ap.

Testing The Radiator And Cooling

System For Leaks

Table 16

Illustration 36

Typical schematic of filler cap

(1) Sealing surface of both filler cap and radiator

g01096114

Use the following procedure in order to check the

cooling system for leaks:

Personal injury can result from hot coolant, steam

and alkali.

At operating temperature, engine coolant is hot

and under  pressure. The radiator and all lines

to heaters or the engine contain hot coolant or

steam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is cool

enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid

contact with skin and eyes.

To check for the amount of pressure that opens the

filler cap, use the following procedure:

1. After the engine cools, carefully loosen the filler

cap. Slowly release the pressure from the cooling

system. Then, remove the filler cap.

Carefully inspect the filler cap. Look for any

damage to the seals and to the sealing surface.

Inspect the following components for any foreign

substances:

• Filler cap

Personal injury can result from hot coolant, steam

and alkali.

At operating temperature, engine coolant is hot

and under  pressure. The radiator and all lines

to heaters or the engine contain hot coolant or

steam. Any contact can cause severe burns.

Remove filler cap slowly to relieve pressure only

when engine is stopped and radiator cap is cool

enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid

contact with skin and eyes.

1. After the engine is cool, loosen the filler cap slowly

and allow pressure out of the cooling system.

Then remove the filler cap from the radiator.

2. Ensure that the coolant level is above the top of

the radiator core.

3. Install Tooling (A) onto the radiator.

4. Take the pressure reading on the gauge to 20 kPa

(3 psi) more than the pressure on the filler cap.

This document has been printed from SPI². Not for Resale

45

Testing and Adjusting Section

5.

6.

Check the radiator for leakage on the outside.

Check all connection points for leakage, and

check the hoses for leakage.

Coolant temperature can also be read on the display

screens of the Electronic Service Tool.

The cooling system does not have leakage only if the

following conditions exist:.

• You do not observe any outside leakage.

• The reading remains steady after five minutes.

The inside of the cooling system has leakage only if

the following conditions exist:

• The reading on the gauge goes down.

• You do NOT observe any outside leakage.

Make any repairs, as required.

Test For The Water Temperature

Gauge

Table 17

Illustration 37

Typical example

(1) Water manifold assembly

g01096115

Personal injury can result from escaping fluid un-

der pressure.

If a pressure indication is shown on the indicator,

push the release valve in order to relieve pressure

before removing any hose from the radiator.

Remove a plug from water manifold assembly (1).

Install Tooling (A) in the open port:

A temperature indicator of known accuracy can also

be used to make this check.

Start the engine. Run the engine until the temperature

reaches the desired range according to the test

thermometer. If necessary, place a cover over part of

the radiator in order to cause a restriction of the air

flow. The reading on the water temperature indicator

should agree with the test thermometer within the

tolerance range of the water temperature indicator.

Making contact with a running engine can cause

burns from hot parts and can cause injury from

rotating parts.

When working on an engine that is running, avoid

contact with hot parts and rotating parts.

Check the accuracy of the water temperature

Water Temperature

- Test

i02553380

Regulator

indicator or water temperature sensor if you find

either of the following conditions:

• The engine runs at a temperature that is too hot,

but a normal temperature is indicated. A loss of

coolant is found.

• The engine runs at a normal temperature, but a

hot temperature is indicated. No loss of coolant

is found.

Personal injury can result from escaping fluid un-

der pressure.

If a pressure indication is shown on the indicator,

push the release valve in order to relieve pressure

before removing any hose from the radiator.

1. Remove the water temperature regulator from the

engine.

This document has been printed from SPI². Not for Resale

46

Testing and Adjusting Section

KENR6231

2.

3.

4.

5.

Heat water in a suitable container until the

temperature is 98 °C (208 °F).

Hang the water temperature regulator in the

container of water. The water temperature

regulator must be below the surface of the water

and away from the sides and the bottom of the

container.

Keep the water at the correct temperature for ten

minutes.

After ten minutes, remove the water temperature

regulator. Ensure that the water temperature

regulator is open.

Replace the water temperature regulator if the

water temperature regulator is not open at the

specified temperature. Refer to Specifications,

“Water Temperature Regulator”.

i02553381

Making contact with a running engine can cause

burns from hot parts and can cause injury from

rotating parts.

When working on an engine that is running, avoid

contact with hot parts and rotating parts.

Perform the following procedure in order to determine

if the water pump is operating correctly:

1. Remove the plug from port (2).

2. Install Tooling (A) in port (2).

3. Start the engine. Run the engine until the coolant

is at operating temperature.

4. Note the water pump pres sure. The water pump

pressure should be 100 to 125 kPa (15 to 18 psi).

Water Pump -

Test

Table 18

Tool

A

Required Tools

Part Number     Part Description

GE50033    Pressure Gauge

Qty

1

Illustration 38

Typical example

(1) Water outlet

(2) Port

(3) Temperature regulator hous ing

(4) Water pump

(5) Port

g01033819

This document has been printed from SPI². Not for Resale

KENR6231

47

Testing and Adjusting Section

Basic

Engine

i02553382

Connecting rod bearings are available with s maller

inside diameters than the original size bearings.

These bearings are for crankshafts that have been

ground.

Piston

Ring Groove - Inspect

If necessary, replace the connecting rod bearings.

Refer to Disassembly and Assembly, “Connecting

Rod Bearings - Remove” and Disassembly and

Assembly, “Connecting Rod Bearings - Install” for the

correct procedure.

Inspect the Piston and the Piston

Rings

1. Check the piston for wear and other damage.

2. Check that the piston rings are free to move in the

grooves and that the rings are not broken.

Main

Bearings

- Inspect

i02553396

Inspect the Clearance of the Piston

Ring

1. Remove the piston rings and clean the grooves

and the piston rings.

2. Fit new piston rings in the piston grooves.

3. Check the clearance for the piston ring by placing

a suitable feeler gauge between the piston groove

and the top of piston ring. Refer to Specifications,

“Piston and Rings” for the dimensions.

Inspect the Piston Ring End Gap

1. Clean all carbon from the top of the cylinder bores .

2. Place each piston ring in the cylinder bore just

below the cylinder ring ridge.

3. Use a suitable feeler gauge to measure piston

ring end gap. Refer to Specifications, “Piston and

Rings” for the dimensions.

Note: The coil spring must be removed from the oil

control ring before the gap of the oil control ring is

measured.

i02553391

Connecting Rod Bearings -

Inspect

Main bearings are available with smaller inside

diameters than the original size bearings. These

bearings are for crankshafts that have been ground.

If nec essary, replace the main bearings. Refer

to Disassembly and Assembly, “Crankshaft Main

Bearings - Remove and Install” for the correct

procedure.

i02571419

Cylinder Block - Inspect

1. Clean all of the coolant passages and the oil

passages.

2. Check the cylinder block for cracks and damage.

3. The top deck of the cylinder block must not be

machined. This will affect the depth of the cylinder

liner flange and the piston height above the

cylinder block.

4. Check the front cams haft bearing for wear. Refer

to Specifications, “Camshaft Bearings” for the

correct specification of the camshaft bearing. If a

new bearing is needed, use a suitable adapter to

press the bearing out of the bore. Ensure that the

oil hole in the new bearing faces the front of the

block. The oil hole in the bearing must be aligned

with the oil hole in the cylinder block. The bearing

must be aligned with the face of the recess.

The connecting rod bearings fit tightly in the bore in

the rod. If the bearing joints are worn, check the bore

size. This can be an indication of wear because of

a loose fit.

This document has been printed from SPI². Not for Resale

48

Testing and Adjusting Section

KENR6231

Cylinder

Inspect

Liner

Projection

i02553404

-

Table 19

Note: The projection of the cylinder liner is measured

from the top of the cy linder liner to the top of the

spacer plate.

Illustration 39

Liner Projection Components

(1) Bolt

(2) Washer

(3) Washer

(4) Spacer plate

(5) Cylinder liner

(6) Block

g01096458

This document has been printed from SPI². Not for Resale

KENR6231

49

Testing and Adjusting Section

Illustration 40

g00443044

This document has been printed from SPI². Not for Resale

50

Testing and Adjusting Section

KENR6231

1.

2.

3.

4.

5.

6.

7.

8.

9.

Ensure that the top face of the cylinder block (6)

is clean. Install a new s pacer plate gasket and a

clean spacer plate.

Install the cylinder liners to the cylinder block

without seals or bands. Ensure that the cylinder

liners are installed to the original positions.

Install Tooling (B) and Tooling (C) to Tooling (A).

Refer to illustration 39.

Install Tooling (A) around the liner. Refer to

illustration 39.

Tighten the bolts (6) to a torque of 95 N·m (70 lb ft).

Use Tooling (D) to measure the cylinder liner

projection at "A", "B", "C" and "D". Refer to

illustration 40.

Record the measurements for the cylinder.

Repeat steps 3 to 7 for each cylinder.

Add the four readings for each cylinder. Divide the

sum by four in order to find the average.

Do not exceed the maximum liner projection of

0.152 mm (0.006 inch). The excessive liner projection

will contribute to cracking of the liner flange.

When the liner projection is correct, put a temporary

mark on the liner and the spacer plate. Set the liners

aside.

Note: Refer to Disassembly and Assembly, “Cy linder

Liner - Install” for the correct final installation

procedure for the cylinder liners.

i02553516

Flywheel - Inspect

Face Runout (Axial Eccentricity) of

the Flywheel

Table 21

Required Tools

Tool   Part Number     Part Description     Qty

A     21825617    Dial Indicator Group      1

Table 20

Note: If the liner projection changes around the liner,

turn the liner to a new position within the bore. If the

liner projection is not within specifications, move the

liner to a different bore. Inspect the top face of the

cylinder block.

If the cylinder liner projections are below 0.025 mm

(0.0010 inch) or 0.051 mm (0.0020 inch) corrective

action must be taken. A thinner spacer plate may

be used. The thinner spacer plate is available from

your Perkins distributor. The plates are 0.076 mm

(0.0030 inch) thinner than the original plate. The

Illustration 41

Checking face runout of the flywheel

g00286049

plates will increase the liner projection. Us e these

spacer plates to compensate for low liner projections

which are less than the 0.076 mm (0.0030 inch). Use

these spacer plates if inspection of the top face of

the cylinder block reveals no measurable damage

directly under the liner flanges but the average liner

projection is less than 0.076 mm (0.0030 inch).

1.

2.

Install Tooling (A). Refer to illustration 41. Always

put a force on the crankshaft in the same direction

before the dial indicator is read. This will remove

any crankshaft end clearanc e.

Set the dial indicator to read 0.0 mm (0.00 inch).

This document has been printed from SPI². Not for Resale

KENR6231

51

Testing and Adjusting Section

3.

4.

Turn the flywheel at intervals of 45 degrees and

read the dial indicator.

Take the measurements at all four points. The

difference between the lower measurements and

the higher measurements that are performed at

all four points must not be more than 0.15 mm

(0.006 inch), which is the maximum permissible

face runout (axial eccentricity) of the flywheel.

Bore

Runout (Radial Eccentricity)

of the Flywheel

Table 22

Required Tools

Tool   Part Number     Part Description

Qty

Illustration 43

Flywheel clutch pilot bearing bore

g00286058

A

21825617

Dial Indicator Group

1

5.

6.

To find the runout (ec centricity) of the pilot bearing

bore, use the preceding procedure.

The runout (eccentricity) of the bore for the pilot

bearing in the flywheel must not exceed 0.13 mm

(0.005 inch).

i02553531

Flywheel Housing - Inspect

Table 23

Illustration 42

Checking bore runout of the flywheel

1. Install Tooling (A). Refer to illustration 42.

g01278054

Face Runout (Axial Eccentricity) of

the Flywheel Housing

2.

3.

4.

Set the dial indicator to read 0.0 mm (0.00 inch).

Turn the flywheel at intervals of 45 degrees and

read the dial indicator.

Take the measurements at all four points. The

difference between the lower measurements and

the higher measurements that are performed at

all four points must not be more than 0.15 mm

(0.006 inch) for the maximum permissible face

runout (radial eccentricity) of the flywheel.

Illustration 44

Typical example

g00285931

If you us e any other method except the method that

is given here, always remember that the bearing

clearance must be removed in order to receive the

correct measurements.

This document has been printed from SPI². Not for Resale

52

Testing and Adjusting Section

KENR6231

1.

2.

Install Tooling (A) to the fly wheel so the anvil of the

dial indicator will contact the face of the flywheel

housing. Refer to illus tration 44.

Use a rubber mallet and tap the crankshaft toward

the rear before the dial indicator is read at each

point.

Illustration 47

Checking bore runout of the flywheel housing

g00285932

Illustration 45

Checking face runout of the flywheel housing

g00285932

3.

4.

Turn the flywheel while the dial indicator is set at

0.0 mm (0.00 inch) at location (A). Read the dial

indicator at locations (B), (C) and (D).

The difference between the lower measurements

and the higher measurements that are performed

at all four points must not be more than 0.38 mm

(0.015 inch), which is the maximum permissible

face runout (axial eccentricity) of the flywheel

Illustration 48

g00763974

housing.

Bore Runout (Radial Eccentricity)

of the Flywheel Housing

2.

While the dial indicator is in the position at location

(C) adjust the dial indicator to 0.0 mm (0.00 inch).

Push the crankshaft upward against the top of

the bearing. Refer to Illustration 48. Write the

measurement for bearing clearance on line 1 in

column (C).

Illustration 46

Typical example

g00285934

Note: Write the measurements for the dial indicator

with the correct notations. This notation is necessary

for making the calc ulations in the chart correctly.

3. Divide the measurement from Step 2 by two. Write

this number on line 1 in columns (B) and (D).

4. Turn the flywheel in order to put the dial indicator

at position (A). Adjust the dial indicator to 0.0 mm

(0.00 inch).

5. Turn the flywheel counterclockwise in order to

put the dial indicator at position (B). Write the

measurements in the chart.

6. Turn the flywheel counterclockwise in order to

put the dial indicator at position (C). Write the

1.

Install Tooling (A) to the fly wheel so the anvil of the

dial indicator will contact the bore of the flywheel

housing. Refer to illus tration 46.

measurement in the chart.

This document has been printed from SPI². Not for Resale