Perkins 900 Series Instruction manual

i
Perkins 900 Series
Models CP and CR
WORKSHOP MANUAL
3 cylinder, naturally aspirated, and turbocharged diesel
engines for agricultural and industrial use
Publication, TPD 1345, Issue 3.
© Proprietary information of Perkins Engines Company Limited 2000, all rights reserved.
The information is correct at the time of print.
Published in June 2001 by Technical Publications.
Perkins Engines Company Limited, Peterborough, PE1 5NA, England.
This document has been printed from SPI². Not for Resale

ii
Chapters
1 General information
2 Specifications
3 Cylinder head assembly
4 Piston and connecting rod assemblies
5 Crankshaft assembly
6 Timing case and drive assembly
7 Cylinder block assembly
8 Engine timing
9 Aspiration system
10 Lubrication system
11 Fuel system
12 Cooling system
13 Flywheel and housing
14 Electrical equipment
15 Auxiliary equipment
16 Special tools
The following pages contain a detailed table of contents
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Workshop Manual, TPD 1345E, issue 3 iii
900 Series
Contents
1 General information
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...1
Engine views . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...2
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...3
Safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...4
Engine lift equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...6
Viton seals . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...7
POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... ...8
2 Specifications
Data and dimensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .11
Thread sealant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .28
Standard torque tensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .29
Special torque tensions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .30
Compression test data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .33
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iv Workshop Manual, TPD 1345E, issue 3
900 Series
3 Cylinder head assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35
Rocker cover
Operation 3-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36
Rocker assembly
Operation 3-2 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
Operation 3-3 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
Operation 3-4 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41
Operation 3-5 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42
Valve tip clearances
Operation 3-6 To check and to adjust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43
Valve springs
Operation 3-7 To change the valve springs, with the cylinder head fitted . ... ... ... ... ... 44
Cylinder head assembly
Operation 3-8 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46
Operation 3-9 To fit the cylinder head ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47
Operation 3-10 To tighten the cylinder head setscrews and fasteners .. ... ... ... ... ... ... 50
Operation 3-11 To fit ancillary components ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52
Valves and valve springs
Operation 3-12 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 54
Operation 3-13 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 55
Operation 3-14 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 56
Valve guides
Operation 3-15 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 57
Operation 3-16 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 58
Operation 3-17 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 59
Cylinder head
Operation 3-18 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 60
Operation 3-19 To correct a valve seat with a valve seat cutter ... ... ... ... ... ... ... ... ... 61
Operation 3-20 To fit a valve seat insert ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 62
4 Piston and connecting rod assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 63
Big end bearing
Operation 4-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 64
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Workshop Manual, TPD 1345E, issue 3 v
900 Series
Operation 4-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .65
Operation 4-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .65
Piston and connecting rod assembly
Operation 4-4 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .66
Operation 4-5 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .67
Operation 4-6 To check the piston height above the cylinder block .. ... ... ... ... ... ... ... .69
Operation 4-7 To check the height grade of a piston ... ... ... ... ... ... ... ... ... ... ... ... ... .70
Operation 4-8 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .71
Operation 4-9 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .72
Piston rings
Operation 4-10 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .73
Operation 4-11 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .75
Connecting rod
Operation 4-12 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .76
Small end bush
Operation 4-13 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .76
5 Crankshaft assembly
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .77
Crankshaft pulley
Operation 5-1 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .78
Rear oil seal assembly
Operation 5-2 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .79
Operation 5-3 To renew the rear oil seal ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .80
Thrust washers
Operation 5-4 To check crankshaft end-float ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .81
Operation 5-5 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .82
Operation 5-6 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .83
Main bearings
Operation 5-7 To remove (crankshaft in position) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... .85
Operation 5-8 To fit (crankshaft in position) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .86
Operation 5-9 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .86
Crankshaft
Operation 5-10 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .87
Operation 5-11 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .88
Operation 5-12 To inspect . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .89
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vi Workshop Manual, TPD 1345E, issue 3
900 Series
6 Timing case and drive assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 91
Timing case cover
Operation 6-1 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 92
Operation 6-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 93
Front oil seal
Operation 6-3 To remove and to fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 94
Idler gear and hub
Operation 6-4 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 95
Operation 6-5 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 96
Fuel pump gear
Operation 6-6 To remove a gear from a tapered shaft .. ... ... ... ... ... ... ... ... ... ... ... ... 98
Operation 6-7 To fit a gear to a tapered shaft ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 99
Operation 6-8 To remove a gear fitted to a hub . ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 100
Operation 6-9 To fit a gear to a hub ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 101
Camshaft gear
Operation 6-10 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 103
Operation 6-11 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 104
Crankshaft gear
Operation 6-12 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 105
Timing case
Operation 6-13 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 106
Operation 6-14 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 107
Camshaft
Operation 6-15 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 109
7 Cylinder block assembly
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 111
Cylinder block
Operation 7-1 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 112
Operation 7-2 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 113
Operation 7-3 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 114
Cylinder liner
Operation 7-4 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 115
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Workshop Manual, TPD 1345E, issue 3 vii
900 Series
Operation 7-5 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...119
8 Engine timing
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...121
Engine timing
Operation 8-1 To set the engine to top dead centre (TDC) ... ... ... ... ... ... ... ... ... ... ...122
Operation 8-2 To check the valve timing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...123
Operation 8-3 To check the locking angle of the fuel injection pump timing . ... ... ... ...124
Operation 8-4 To check the timing of pin-timed fuel injection pumps ... ... ... ... ... ... ...126
9 Aspiration system
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...127
Turbocharger
Operation 9-1 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...128
Operation 9-2 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...130
Turbocharger faults .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...132
Closed breather system
Operation 9-3 To renew the engine breather valve ... ... ... ... ... ... ... ... ... ... ... ... ... ...134
Open breather system
Operation 9-4 General information ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...135
Operation 9-5 To clean .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...136
Operation 9-6 To renew ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...137
Breather separator
Operation 9-7 To renew the engine oil separator .. ... ... ... ... ... ... ... ... ... ... ... ... ... ...138
10 Lubrication system
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...139
Lubrication system flow diagram ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...140
Filter canister
Operation 10-1 To renew .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...141
Filter head
Operation 10-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...142
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viii Workshop Manual, TPD 1345E, issue 3
900 Series
Canister type lubricating oil cooler
Operation 10-3 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 143
Sump
Operation 10-4 To remove . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 144
Operation 10-5 To fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 145
Operation 10-6 To remove a sump retained by clamps . ... ... ... ... ... ... ... ... ... ... ... .. 148
Operation 10-7 To fit a sump retained by clamps .. ... ... ... ... ... ... ... ... ... ... ... ... ... .. 150
Oil strainer and suction pipe assembly
Operation 10-8 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 154
Operation 10-9 To inspect and to correct .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 155
Lubricating oil pump
Operation 10-10 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 156
Operation 10-11 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 157
Operation 10-12 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 159
Relief valve . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 160
Operation 10-13 To dismantle and to assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 160
Operation 10-14 To inspect ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 161
11 Fuel system
General description ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 163
Fuel filter
Operation 11-1 Fuel filter types .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 166
Operation 11-2 To renew the element type filter ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 167
Operation 11-3 To renew the quick release type filter ... ... ... ... ... ... ... ... ... ... ... ... .. 168
Atomisers
Operation 11-4 Atomiser faults .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 169
Operation 11-5 To remove atomisers retained by a clamp ... ... ... ... ... ... ... ... ... ... .. 170
Operation 11-6 To fit atomisers retained by a clamp . ... ... ... ... ... ... ... ... ... ... ... ... .. 171
Operation 11-7 To remove atomisers retained by a gland nut ... ... ... ... ... ... ... ... ... .. 172
Operation 11-8 To fit atomisers retained by a gland nut ... ... ... ... ... ... ... ... ... ... ... .. 173
Fuel lift pump
Operation 11-9 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 174
Operation 11-10 To dismantle ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 175
Operation 11-11 To assemble ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 176
Operation 11-12 To test . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 177
Delphi fuel injection pumps
Operation 11-13 General description . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 178
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Workshop Manual, TPD 1345E, issue 3 ix
900 Series
Operation 11-14 To remove the Delphi locked pump ... ... ... ... ... ... ... ... ... ... ... ... ...178
Operation 11-15 To fit the Delphi locked pump . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...180
Operation 11-16 To remove the Delphi pin-timed pump ... ... ... ... ... ... ... ... ... ... ... ...181
Operation 11-17 To fit the Delphi pin-timed pump ... ... ... ... ... ... ... ... ... ... ... ... ... ...183
Operation 11-18 To adjust . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...185
Operation 11-19 To eliminate air from the fuel system . ... ... ... ... ... ... ... ... ... ... ... ...187
Operation 11-20 To remove .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...190
Operation 11-21 To fit ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...191
Operation 11-22 To eliminate air from the fuel system . ... ... ... ... ... ... ... ... ... ... ... ...193
12 Cooling system
Cooling system flow diagram .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...196
Thermostat ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...197
Operation 12-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...197
Operation 12-2 To test .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...198
How to fill the cooling system
Operation 12-3 To fill and vent the system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...199
Coolant pump
Operation 12-4 To remove ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...200
Operation 12-5 To fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...201
Operation 12-6 To dismantle . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...202
Operation 12-7 To assemble . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...203
Fan
Operation 12-8 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...206
13 Flywheel and flywheel housing
General description .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...207
Flywheel
Operation 13-1 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...208
Ring gear
Operation 13-2 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...209
Flywheel housing
Operation 13-3 To remove and to fit . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...210
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xWorkshop Manual, TPD 1345E, issue 3
900 Series
14 Electrical equipment
Operation 14-1 To check the drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 212
Operation 14-2 To adjust the drive belt tension . ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 213
Operation 14-3 To remove and to fit the drive belts ... ... ... ... ... ... ... ... ... ... ... ... ... .. 214
Operation 14-4 To remove and to fit the alternator ... ... ... ... ... ... ... ... ... ... ... ... ... .. 215
Operation 14-5 To maintain the alternator . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 216
Alternator fault diagnosis . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 217
Operation 14-6 To remove and to fit .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 219
Operation 14-7 To maintain the brush gear and the commutator .. ... ... ... ... ... ... ... .. 220
Operation 14-8 To test on the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 220
Starting aid
Operation 14-9 To remove and to fit a fuelled starting aid . ... ... ... ... ... ... ... ... ... ... .. 222
Operation 14-10 To check the fuelled starting aid . ... ... ... ... ... ... ... ... ... ... ... ... ... .. 223
15 Auxiliary equipment
Not used . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 225
16 Special tools
List of special tools .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 227
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Workshop Manual, TPD 1345E, issue 3 1
1
900 Series
General information 1
Introduction
This Workshop Manual has been designed to provide assistance in the service and overhaul of Perkins 900
Series engines. For overhaul procedures the assumption is made that the engine is removed from the
application.
The engine conforms with USA (EPA/CARB) stage 1 and EEC stage 1 emissions legislation for agricultural
and industrial applications.
Read and remember the "Safety precautions" on page 4. They are given for your protection and must be used
at all times.
Most of the general information which is included in the User’s Handbook (Chapters 1 to 6) has not been
repeated in this workshop manual and the two publications should be used together.
The details of some operations will be different according to the fuel injection pump that is fitted. The specific
pump type used can be found by reference to the manufacturer’s identification plate on the pump body.
Generally, the type of pump fitted is as shown below.
lDelphi - DP200 Series
lStanadyne - DB4
When reference is made to the "left" 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 tools is given in Chapter 16, Special tools.
Reference to the relevant special tools is also made at the beginning of each operation.
Original setscrews or studs used in holes that are open to the inside of the engine, have a sealant that is
applied by the manufacturer. If the setscrew or stud is to be used again, the threads must be cleaned and a
suitable sealant should be used on the threads. POWERPART recommended consumable products are listed
on page 8. Reference to the relevant consumable products are made at the beginning of each operation.
Data and dimensions are included in Chapter 2, Specifications.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: 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.
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2Workshop Manual, TPD 1345E, issue 3
900 Series
Engine views
C0004/1
C0002
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Workshop Manual, TPD 1345E, issue 3 3
900 Series
Engine identification
The 900 Series is a 3 cylinder, water cooled, direct injection, diesel engine for industrial and agricultural
applications. The complete engine family consists of both turbocharged and naturally aspirated models.
The engine number is stamped on a label (A2) fastened to the left side of the cylinder block.
The two letters at the beginning of the engine number are the code letters for the engine type.
An example of an engine number is:
CP12345U123456A
Further information about the engine number system can be found in the User’s Handbook
If you need parts, service or information for your engine, you must give the complete engine number to your
Perkins 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 distributor.
Other identification labels fitted to the engine include:
lAn emissions legislation label (A3) fitted to the side of the cylinder block
lA label (A1), fitted to the fuel injection pump, with the fuel injection pump part number.
If a short engine has been fitted in service, two engine serial numbers and a TPL number are stamped on the
engine serial number pad (B3).
Examples of the serial numbers are shown in (B).
If parts for the short engine are needed in service, use the serial number (B4). If parts that were moved from
the original engine to the short engine are needed, use the serial number (B1) and the TPL number (B2).
Code letters Engine type
CP Three cylinder, naturally aspirated
CR Three cylinder, turbocharged
4
1
23
B
A0045
CP12345U123456A
CP39770 TPL No212
21
3
A
A0043
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4Workshop Manual, TPD 1345E, issue 3
900 Series
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.
lDo not fill the engine with lubricating oil above the mark on the dipstick (see Operation 10-1/B1) or damage
could occur to the engine.
lIf the lubrication system has been drained, the rocker gear and the camshaft reservoir must be lubricated
before the engine is started or damage could occur to the engine.
lOnly use these engines in the type of application for which they have been designed.
lDo not change the specification of the engine.
lDo not smoke when you put fuel in the tank.
lClean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
lDo not put fuel in the tank while the engine runs (unless it is absolutely necessary).
lDo 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).
lDo not make adjustments that you do not understand.
lEnsure that the engine does not run in a location where it can cause a concentration of toxic emissions.
lOther persons must be kept at a safe distance while the engine or auxiliary equipment is in operation.
lDo not permit loose clothing or long hair near moving parts.
Warning! Keep away from moving parts during engine operation.Some moving parts cannot be seen clearly
while the engine runs.
lDo not operate the engine if a safety guard has been removed.
lDo not remove the filler cap of the cooling system while the engine is hot and while the coolant is under
pressure, because dangerous hot coolant can be discharged.
lDo not use salt water or any other coolant which can cause corrosion in the closed circuit of the cooling
system.
lDo 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.
lDisconnect the battery terminals before a repair is made to the electrical system.
lOnly one person must control the engine.
lEnsure that the engine is operated only from the control panel or from the operators position.
lIf your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
lDiesel 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.
lDo not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets of clothing.
lDiscard used lubricating oil in a safe place to prevent contamination.
lEnsure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is
started.
lUse extreme care if emergency repairs must be made in adverse conditions.
lThe 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, refer to "Viton seals" on page 7.
lRead and use the instructions relevant to lift equipment, refer to "Engine lift equipment" on page 6.
Continued
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Workshop Manual, TPD 1345E, issue 3 5
900 Series
lAlways 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.
lDo not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately
lTurbochargers operate at high speeds 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.
lDo 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.
lFit only genuine Perkins parts.
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6Workshop Manual, TPD 1345E, issue 3
900 Series
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 313 Kg (690 lbs) minimum capacity is used.
Before the engine is lifted:
lAlways use engine lift equipment of the approved type and of the correct capacity to lift the engine. It is
recommended that lift equipment of the type shown 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
lCheck 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
lTo prevent damage to the rocker cover, ensure that there is clearance between the hooks and the rocker
cover.
lUse lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder
head, flywheel housing, crankshaft and flywheel.
A
A0044
1
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Workshop Manual, TPD 1345E, issue 3 7
900 Series
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:
Warnings!
lEnsure that the components have cooled.
lUse Neoprene gloves and discard the gloves safely after use.
lWash the area with calcium hydroxide solution and then with clean water.
lDisposal 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 clean water or
with calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.
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1
8Workshop Manual, TPD 1345E, issue 3
900 Series
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 Easy Flush
Cleans the cooling system. Part number 21825001.
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.
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 Retainer (oil tolerant)
To retain components that have an interference fit, but is in contact with oil. Part number 21820603.
POWERPART Retainer (high strength)
To retain components which have an interference fit. Part number 21820638.
POWERPART Safety cleaner
General cleaner in an aerosol container. Part number 21820128.
Continued
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Workshop Manual, TPD 1345E, issue 3 9
900 Series
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 which 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 which seals joints. Part number 1861117.
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