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GN65770N gn65770n
404D-22 2008/04/01
The information given within this parts book was correct at the time of printing and is subject to change withoutnotice. Always refer to your local Perkins outlet for the latest information. Only fully trained personnel should car-ry out servicing of engines. Before working on any engine always refer to the correct user service and maintenancemanual.
Always refer to your local Perkins outlet before purchasing any parts
Subject to any existing rights of third parties, the information given in this document is the property of Perkins En-gines Limited and should not be copied, in whole or part, without the prior written consent of the Company.
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Contents
1. Introduction Pg. 4
2. How To Use Your Parts Book Pg. 4
3. Engine Breakdown Pg. 5
4. Symbol Descriptions Pg. 9
5. Parts Lists & Illustrations Pg. 11
6. Parts Index Pg. 128
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The build list of your engine, found on the front page of this parts book, provides a uniquereference to the components fitted to your engine; therefore this parts book is only applicable tothis particular engine
Always quote your build list and engine serial number when contacting your Perkins outlet.
This parts book has been designed to provide you with all the information you need to identify parts to service your engine. There are several features within the book to make it easy to findthe parts you require.
Front PageThis lists your build list number and the date of publication of this book
Symbol Descriptions
Provides a quick reference guide to the symbols used within the book.
Engine Breakdown
Use this to identify all the major sections of your engine and the relevant pages within the book.
Parts Lists & Illustrations
This section shows each major section of your engine broken down into individual part numbersalong with an associated illustration for identifying the parts you require.
The illustrations used in this parts book are representational only and should only be used for identification purposes.
For fitting instructions please refer to your engine Service Manual.
Parts Index
Using either the part number or description of the part you require this section will help youlocate the page within the Parts Lists & Illustrations section where the part appears.
Introduction
How to use your Parts Book
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Engine Breakdown
Page 5
Section Page
Level 1 - Service
AAAAAAGN
11
Level 2 - RepairAAAAAAGN
13
Level 3 - OverhaulAAAAAAGN
15
Cylinder Block
ACPG0004
17
Cylinder Block ACPG0004
19
Crankshaft, Pistons & Connecting RodsACPG0004
21
Crankshaft, Pistons & Connecting Rods
ACPG0004
23
Rear End Oil SealACPG0004
25
Cylinder HeadACPG0004
27
Cylinder Head
ACPG0004
29
Rocker Shaft AssemblyACPG0004
31
Oil PumpACPG0004
33
Pipes
ACPG0004
35
Relief Valve
ACPG0004
37
Timing CaseADPG0016
39
Timing CaseADPG0016
41
Timing Case
ADPG0016
43
Timing CaseADPG0016
45
Timing CaseADPG0016
47
Camshaft & Gears
ADPG0016
49
Fuel Injection PumpAFPG0016
51
High Pressure Fuel PipesAFPG0016
53
Atomisers
AFPG0016
55
Fuel Leak-Off PipeAFPG0016
57
Flywheel HousingCDPG0001
59
Flywheel & Starter Ring
DDPG0000
61
Section Page
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Engine Breakdown
Page 6
Starter Motor
EDPG0001
63
PulleysFBPG0001
65
SumpGBPG0001
67
Dipstick & Filler Tube
GBPG0001
69
Dipstick & Filler TubeGBPG0001
71
SumpGCPG0001
73
Filler
HBPG0000
75
Oil FilterJBPG0000
77
Oil FilterJCPG0000
79
Front End Drive Input
KBPG0001N
81
Water PumpLBPG0003
83
Thermostat & HousingLBPG0003
85
Water Outlet & Inlet
LDPG0001
87
Section Page
Fan
MDPG0003
89
Fan DriveMEPG0017
91
AlternatorNDPG0002
93
Drive Belt & Tensioner
NEPG0001
95
Front End Drive OutputQCPG0001
97
Cylinder Head CoverTBPG0002
99
Cylinder Head Cover
TBPG0002
101
Feed PipesTBPG0002
103
Exhaust ManifoldUBPG0002
105
Exhaust Manifold
UDPG5503
107
Lift PumpVBPG0006
109
Fuel FilterVBPG0006
111
Section Page
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Engine Breakdown
Page 7
Pipework & Connections
VBPG0006
113
Cold Start SystemWDPG0000
115
Engine Lifting EyesXBPG0000
117
Throttle & Stop Controls
ZAPG0002
119
InstrumentationZJPG0000
121
InstrumentationZLPG0002
123
Electrical Wiring & Fittings
ZPPG0001
125
Fuel Pre-Lift PumpZVPG0001
127
Section Page
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Engine Breakdown
Page 8
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Page 9
Symbols and Notes
Symbol Description
A From Engine Number
B Upto Engine Number
C Repairs and ReplacesD See Appropriate Section - Reference Number
E Alternative
F Order
G Remanufactured Part
H New for Old Part
I Number of Teeth
J Thickness
K Bottom
L Top
M Left Hand
N Right Hand
O Reference for Detailed Breakdown
P Other Service Options Available
Q Cylinder Number
R See History Section
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Level 1 - Service Plate A
AAAAAAGN
Page 10
Recommended stocking and service listsPerkins provides Recommended stocking and service lists, for Distributor use whenrecommending parts stocks for Dealers, preferred customers (eg fleets) etc. These listsare based on agreed workshop capability and are at three distinct levels:Level 1 - ServiceThe Level 1 workshop has the ability to perform basic non-intrusive maintenance onPerkins engines.Listes recommandes pour le stock et la maintenancePerkins fournit des listes recommandes pour le stock et la maintenance afin d'aider leDistributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont
bases sur le niveau technique des Ateliers avec trois niveaux distincts :Niveau 1- MaintenanceL'atelier de niveau 1 est capable d'executer l'entretien de base des moteurs Perkins (sansdemontage).Empfohlene Lagerbestands- und ServicelistenPerkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche dieVertragshndler verwenden knnen, um Hndlern und Kunden (z.B. Fuhrparks) einenbestimmten Ersatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbartenWerkstattfhigkeiten, welche in die folgenden drei Stufen unterteilt werden:Stufe 1 - ServiceWerksttten der Stufe 1 knnen grundlegende und einfache Wartungsarbeiten anPerkins-Motoren ohne Spezialwerkzeug durchfhren.Listas de servicio y de stock recomendadasPerkins proporciona Listas de servicio y de stock recomendadas, para que las use elDistribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientespreferidos (por ejemplo, flotas), etc. Estas listas se basan en capacidad del talleracordada y se dividen en tres niveles diferentes:Nivel 1 - ServicioEl taller del Nivel 1 puede llevar a cabo un mantenimiento no intrusivo en los motores
Perkins.Elenco parti consigliate ad uso stock ed assistenzaPerkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza;ci per soddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengonoin considerazione la capacit operativa concordata con lofficina e sono distinti in tre livelliLivello 1 - AssistenzaIl livello 1 prevede che lofficina sia in grado di operare in maniera basilare sui motoriPerkins.
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Level 2 - Repair Plate A
AAAAAAGN
Page 12
Recommended stocking and service lists
Perkins provides Recommended stocking and service lists, for Distributor use whenrecommending parts stocks for Dealers, preferred customers (eg fleets) etc. These lists arebased on agreed workshop capability and are at three distinct levels:Level 2 - RepairThe Level 2 workshop has the ability to perform maintenance service,and inspection service onPerkins engines.Listes recommandes pour le stock et la maintenancePerkins fournit des listes recommandes pour le stock et la maintenance afin d'aider leDistributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont bases surle niveau technique des Ateliers avec trois niveaux distincts :
Niveau 2 - Maintenance & reparationL'atelier de niveau 2 est capable dexecuter toutes les oprations d'entretien, la reparation descomposants externes (demarreur, alternateur,etc) et le diagnostic pour les problmes touchant l'electroniqueEmpfohlene Lagerbestands- und ServicelistenPerkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshndlerverwenden knnen, um Hndlern und Kunden (z.B. Fuhrparks) einen bestimmtenErsatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbartenWerkstattfhigkeiten, welche in die folgenden drei Stufen unterteilt werden:Stufe 2 - Reparatur Werksttten der Stufe 2 knnen Instandsetzungs- und Inspektionsarbeiten an Perkins-Motorendurchfhren.Listas de servicio y de stock recomendadasPerkins proporciona Listas de servicio y de stock recomendadas, para que las use elDistribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientes preferidos(por ejemplo, flotas), etc. Estas listas se basan en capacidad del taller acordada y se dividen entres niveles diferentes:Nivel 2 - ReparacinEl taller de Nivel 2 puede llevar a cabo el servicio de mantenimiento y el servicio de inspeccin
en los motores Perkins.Elenco parti consigliate ad uso stock ed assistenzaPerkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ci persoddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono inconsiderazione la capacit operativa concordata con lofficina e sono distinti in tre livelli :Livello 2 - RiparazioneNel livello 2 lofficina in grado di svolgere la manutenzione e di fare controlli diassistenza sui motori Perkins.
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Level 3 - Overhaul Plate A
AAAAAAGN
Page 14
Recommended stocking and service listsPerkins provides Recommended stocking and service lists, for Distributor use when recommending partsstocks for Dealers, preferred customers (eg fleets) etc. These lists are based on agreed workshop capabilityand are at three distinct levels:Level 3 - Overhaul.The Level 3 workshop has the ability to perform complete service work on Perkins engines. Can repair andfully overhaul engine, including engine test. Can perform all levels of electronics diagnosis and applicationrelated faults.Listes recommandes pour le stock et la maintenancePerkins fournit des listes recommandes pour le stock et la maintenance afin d'aider le Distributeur dans sesconseils aux Agents, aux clients habituels, etc.. Ces listes sont bases sur le niveau technique des Ateliersavec trois niveaux distincts :Niveau 3 - Maintenance, reparation & refection L' atelier de niveau 3 est capable de couvrir toutes les oprations d'entretien des moteurs Perkins. Il peutaussi rparer et entirement refaire des moteurs ainsi que les tester. Il est capable d'effectuer un diagnosticpour les problmes touchant l'electronique et aux applications.Empfohlene Lagerbestands- und ServicelistenPerkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshndler verwendenknnen, um Hndlern und Kunden (z.B. Fuhrparks) einen bestimmten Ersatzteilbestand zu empfehlen. DieseListen basieren auf den vereinbarten Werkstattfhigkeiten, welche in die folgenden drei Stufen unterteiltwerden:Stufe 3 - berholungWerksttten der Stufe 3 knnen umfassende Servicearbeiten an Perkins-Motoren durchfhren. Sie knnen
Motoren reparieren und komplett berholen und auerdem Motorprfungen durchfhren. Sie knnenumfassende elektronische Diagnoseprfungen durchfhren und anwendungsspezifische Strungenuntersuchen.Listas de servicio y de stock recomendadasPerkins proporciona Listas de servicio y de stock recomendadas, para que las use el Distribuidor alrecomendar stocks de repuestos a los Distribuidores, a los clientes preferidos (por ejemplo, flotas), etc. Estaslistas se basan en capacidad del taller acordada y se dividen en tres niveles diferentes:Nivel 3 - Reparacin generalEl taller de Nivel 3 puede llevar a cabo un trabajo de servicio completo en los motores Perkins. Puedereparar y reacondicionar completamente un motor, incluyendo probar el motor. Puede llevar a cabo todos los
niveles de diagnstico electrnico y las fallas relacionadas con la aplicacin.Elenco parti consigliate ad uso stock ed assistenzaPerkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ci per soddisfare lerichieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono in considerazione la capacit operativaconcordata con lofficina e sono distinti in tre livelli :Livello 3 - RevisioneNel livello 3 lofficina in grado di svolgere lavori di assistenza completi sui motori Perkins. E in grado diriparare e svolgere una revisione completa del motore, incluso le prove. Pu anche effettuare diagnosi sullelettronica a tutti i livelli e sui relativi difetti nelle applicazioni.
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Level 3 - Overhaul Plate A
AAAAAAGN
Page 15
Item Part No. References Qty. Description Notes
1 1 LEVEL 3 - OVERHAUL
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Cylinder Block Plate A
ACPG0004
Page 16
1
18 19
20
21
12
13
11
14
8
5
3
9
2
15
10
17
7
16
6
22
4
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Cylinder Block Plate A
ACPG0004
Page 17
Item Part No. References Qty. Description Notes
1 1 CYLINDER BLOCK (A)
2 198466940 4 PLUG3 198466010 3 PLUG4 198466020 2 PLUG5 064210025 2 PLUG6 064210040 3 PLUG7 064210040 1 PLUG8 064210040 1 PLUG9 198466920 3 PLUG
10 198517222 P 1 BUSH11 042309017 1 NEEDLE BEARING12 042309018 1 NEEDLE BEARING13 040106203 1 BALL BEARING
14 064100045 1 PLUG15 165296220 1 SHAFT16 012110635 1 STUD17 012110660 1 STUD18 010109441 3 STUD19 030500612 2 DOWEL20 030500616 2 DOWEL21 030501025 2 DOWEL22 030309005 2 PIN
Service Options
10 198517226 J (-)0.25MM 1 BUSH
10 198517229 J (-)0.50MM 1 BUSH
Footnotes
(A) SERVICE BY COMPLETE ENGINE
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Cylinder Block Plate B
ACPG0004
Page 18
1
2
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Cylinder Block Plate B
ACPG0004
Page 19
Item Part No. References Qty. Description Notes
1 165996590 1 GASKET - TIMING CASE
2 011310612 2 SCREWHistory
a.4 U65166580 1 PLATE
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Crankshaft, Pistons & Connecting Rods Plate A
ACPG0004
Page 20
16
21
22
9
10
15
30
18
12
24
8
14
2029
23
17
11
27
28
67
5
3
32
33
1
2
26
31
4
25
19
13
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Crankshaft, Pistons & Connecting Rods Plate A
ACPG0004
Page 21
Item Part No. References Qty. Description Notes
1 115256990 1 CRANKSHAFT ASSEMBLY
2 F 115256990 1 CRANKSHAFT ASSEMBLY3 115276270 1 CRANKSHAFT GEAR 4 030509020 1 KEY5 199266210 1 THRUST WASHER 6 199266200 1 THRUST WASHER 7 199266200 1 THRUST WASHER 8 110156360 Q 1 1 HOLDER 9 F 110156360 1 CAP
10 F 110156360 1 CAP11 030500612 2 DOWEL12 010109406 2 SCREW13 011511070 1 SCREW
14 110156370 Q 2 1 HOLDER 15 F 110156370 1 CAP16 F 110156370 1 CAP17 030500612 2 DOWEL18 010109406 2 SCREW19 011511070 1 SCREW20 110156380 Q 3 1 HOLDER 21 F 110156380 1 CAP22 F 110156380 1 CAP23 030500612 2 DOWEL24 010109406 2 SCREW25 011511070 1 SCREW26 110156390 Q 4 1 HOLDER 27 F 110156390 1 CAP28 F 110156390 1 CAP29 030500612 2 DOWEL30 010109406 2 SCREW31 010700860 2 BOLT32 U5MB0025 P 1 MAIN BEARING KIT33 U5ME0030 1 BIG END BEARING KIT
Service Options
32 U5MB0025A J (-) 0.25MM 1 MAIN BEARING KIT
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Crankshaft, Pistons & Connecting Rods Plate B
ACPG0004
Page 22
5
6
9
12
4
8
7
3 2
1
10
11
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Crankshaft, Pistons & Connecting Rods Plate B
ACPG0004
Page 23
Item Part No. References Qty. Description Notes
1 115017491 4 PISTON AND RING KIT
2 F 115017491 1 PISTON3 115107970 1 PISTON RING KIT4 115026330 4 CON ROD ASSEMBLY5 F 115026330 1 ROD6 F 115026330 1 CAP7 198517265 1 SMALL END BUSH8 115176140 2 CON ROD BOLT9 020109120 2 CON ROD NUT
10 115326220 4 GUDGEON PIN11 036500028 4 CIRCLIP12 036500028 4 CIRCLIP
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Rear End Oil Seal Plate A
ACPG0004
Page 24
1
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Rear End Oil Seal Plate A
ACPG0004
Page 25
Item Part No. References Qty. Description Notes
1 050209083 1 SEAL - REAR END OIL (A,B)
Footnotes
(A) SEE SERVICE BULLETIN NO.195
(B) ALSO ORDER WEAR SLEEVE - 29990037
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Cylinder Head Plate A
ACPG0004
Page 26
220
14
13
19
17
11
7
8
3
18
12
10
16
1
9
15
4
6
5
2122
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Cylinder Head Plate A
ACPG0004
Page 27
Item Part No. References Qty. Description Notes
1 111011030 1 CYLINDER HEAD ASSEMBLY
2 F 111011030 1 CYLINDER HEAD3 064210010 3 PLUG4 064210018 7 CAP5 064210025 3 PLUG6 064210025 3 PLUG7 064210030 1 CAP8 064210030 1 CAP9 120166380 4 INTAKE VALVE
10 TPN646 4 VALVE SEAT INSERT11 120406070 4 SEAL - VALVE STEM (A)12 198216700 4 VALVE SPRING13 120186080 4 CAP
14 120226070 4 VALVE COLLET15 120176380 4 EXHAUST VALVE16 TPN645 4 VALVE SEAT INSERT17 120406050 4 SEAL - VALVE STEM (B)18 198216700 4 VALVE SPRING19 120186080 4 CAP20 120226070 4 VALVE COLLET21 120216041 4 VALVE SPRING CAP22 120216041 4 VALVE SPRING CAP
Footnotes
(A) INLET(B) EXHAUST
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Cylinder Head Plate B
ACPG0004
Page 28
2
3
1
5
4
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Cylinder Head Plate B
ACPG0004
Page 29
Item Part No. References Qty. Description Notes
1 P 1 GASKET - CYLINDER HEAD
2 111136480 14 SCREW3 111136490 4 SCREW4 012110655 2 STUD5 012110860 2 STUD
Service Options
1 111147711 J 1.2MM 1 GASKET - CYLINDER HEAD1 111147721 J 1.3MM 1 GASKET - CYLINDER HEAD
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Rocker Shaft Assembly Plate A
ACPG0004
Page 30
7
2
13
5
12
15
11
1
16
3
14
4
6
9
810
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Rocker Shaft Assembly Plate A
ACPG0004
Page 31
Item Part No. References Qty. Description Notes
1 120036821 1 ROCKER BOX
2 F 120036821 1 ROCKER BOX3 120316201 1 ROCKER SHAFT4 052109076 1 SEAL - O RING5 120356131 4 ROCKER ARM ASSEMBLY INLET6 120356141 4 ROCKER ARM ASSEMBLY EXHAUST7 198217170 3 ROCKER SHAFT SPRING8 199486220 8 ADJUSTING SCREW9 020109076 8 NUT
10 199280300 6 WASHER 11 120996130 1 SEAL - ROCKER BOX12 120456310 8 PUSHROD13 120116160 8 TAPPET
14 012109044 4 STUD15 023100010 4 NUT16 011310635 2 SCREW
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Oil Pump Plate A
ACPG0004
Page 32
9
6
11
8
4
3
2
14
7
15
12
10
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Oil Pump Plate A
ACPG0004
Page 33
Item Part No. References Qty. Description Notes
1 165026270 1 IDLER GEAR
2 F 165026270 1 IDLER GEAR 3 F 165026270 1 ROTOR 4 F 165026270 1 ROTOR 5 198517290 3 BUSH6 030509018 3 DOWEL7 198217760 1 SPRING8 140116220 1 COVER 9 P 1 SHIM
10 198216720 1 SPRING11 199236540 1 COLLAR 12 036800010 1 CIRCLIP14 199266270 1 THRUST WASHER
Service Options
9 199286150 J (+)0.10MM 1 SHIM9 199286160 J (+)0.15MM 1 SHIM9 199286170 J (+)0.20MM 1 SHIM9 199286180 J (+)0.50MM 1 SHIM
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Pipes Plate A
ACPG0004
Page 34
1
4
3
2
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Pipes Plate A
ACPG0004
Page 35
Item Part No. References Qty. Description Notes
1 140607020 1 OIL PIPE
2 198486780 1 BOLT3 140996260 1 WASHER 4 140996260 1 WASHER
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Relief Valve Plate A
ACPG0004
Page 36
1
2
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Relief Valve Plate A
ACPG0004
Page 37
Item Part No. References Qty. Description Notes
1 140036220 1 RELIEF VALVE
2 052109078 1 SEAL - O RING
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Timing Case Plate A
ADPG0016
Page 38
1
4
3
2
5
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Timing Case Plate A
ADPG0016
Page 39
Item Part No. References Qty. Description Notes
1 1 TIMING CASE (A)
2 165996630 1 GASKET - TIMING CASE3 011310640 7 SCREW4 011310660 4 SCREW5 023100006 1 NUT
Footnotes
(A) SEE FOLLOWING PARTS LIST FOR SERVICE COMPONENTS
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Timing Case Plate B
ADPG0016
Page 40
1
2
3
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Timing Case Plate B
ADPG0016
Page 41
Item Part No. References Qty. Description Notes
1 165106870 1 TIMING CASE
2 030300414 1 PIN3 198636160 1 SEAL - FRONT END OIL
History
a.052300850 1 SEAL - O RING110416290 1 BEARING HOLDER ASSEMBLY
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Timing Case Plate C
ADPG0016
Page 42
12
11
8
9
7
51
4
2
6
13
3
10
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Timing Case Plate C
ADPG0016
Page 43
Item Part No. References Qty. Description Notes
1 125616120 1 BRACKET
2 165996640 1 GASKET3 125156262 R a. 1 ARM4 198217870 1 SPRING5 052100070 1 SEAL - O RING6 198217750 1 SPRING7 023100008 1 NUT8 2315C039 1 SCREW9 2648A120 1 NUT
10 26420462 1 ANTI-TAMPER CAP11 2315C039 1 SCREW12 2318A207 1 NUT13 011310614 4 SCREW
History
a.3 125156261 1 ARM
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Timing Case Plate D
ADPG0016
Page 45
Item Part No. References Qty. Description Notes
1 125046613 R a. 1 CONTROL LEVER
2 125116221 1 SHAFT3 025100008 1 WASHER 4 131046560 1 SPEED SENSOR 5 020800010 1 NUT6 125306151 R b. 1 CONTROL LEVER 7 125116211 1 SHAFT8 024500006 1 NUT9 025100006 1 WASHER
10 198217880 1 SPRING11 031100004 1 PIN
History
a.1 125046612 1 CONTROL LEVER
b.6 125306150 1 CONTROL LEVER
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Timing Case Plate E
ADPG0016
Page 46
9
4
3
2
1
6
7
11
12
8
5
10
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Timing Case Plate E
ADPG0016
Page 47
Item Part No. References Qty. Description Notes
1 131046650 1 SCREW
2 F 131046650 1 BOLT3 020109177 1 NUT4 025100010 1 WASHER 5 198217910 1 SPRING6 198346160 1 RING7 131276440 1 ANTI-TAMPER CAP8 131466251 1 BOLT9 020109239 1 NUT
10 025100006 1 WASHER 11 064210012 1 CAP12 131466270 1 ANTI-TAMPER CAP
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Camshaft & Gears Plate A
ADPG0016
Page 49
Item Part No. References Qty. Description Notes
1 120026950 1 CAMSHAFT
2 F 120026950 1 CAMSHAFT3 034100508 1 WOODRUFF KEY4 120016240 1 CAMSHAFT GEAR 5 040109057 1 BALL BEARING6 199216320 1 SPACER 7 125256240 1 SLIDER 8 199566750 1 PLATE9 011310612 1 SCREW
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Fuel Injection Pump Plate A
AFPG0016
Page 50
3
4
6
5
1
2
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High Pressure Fuel Pipes Plate A
AFPG0016
Page 52
7
8
1
2
3
4
5
6
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High Pressure Fuel Pipes Plate A
AFPG0016
Page 53
Item Part No. References Qty. Description Notes
1 131507520 Q 1 1 FUEL INJECTION PIPE
2 131507530 Q 2 1 FUEL INJECTION PIPE3 131507540 Q 3 1 FUEL INJECTION PIPE4 131507550 Q 4 1 FUEL INJECTION PIPE5 199106021 3 CLAMP6 199106021 3 CLAMP7 010110625 3 SCREW8 023100006 3 NUT
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Atomisers Plate A
AFPG0016
Page 54
3
1
2
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Fuel Leak-Off Pipe Plate A
AFPG0016
Page 56
3
4
2
1
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Flywheel Housing Plate A
CDPG0001
Page 58
1
2
3
5
4
67
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Flywheel Housing Plate A
CDPG0001
Page 59
Item Part No. References Qty. Description Notes
1 110367570 1 BACKPLATE
2 011510816 10 SCREW3 011511220 2 SCREW4 010111030 2 BOLT5 020900010 2 NUT6 026200010 2 WASHER 7 027100010 2 WASHER
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Flywheel & Starter Ring Plate A
DDPG0000
Page 60
1
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Flywheel & Starter Ring Plate A
DDPG0000
Page 61
Item Part No. References Qty. Description Notes
1 010109341 6 BOLT
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Starter Motor Plate A
EDPG0001
Page 62
1
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Starter Motor Plate A
EDPG0001
Page 63
Item Part No. References Qty. Description Notes
1 185086600 1 STARTER MOTOR
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Pulleys Plate A
FBPG0001
Page 64
1
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Pulleys Plate A
FBPG0001
Page 65
Item Part No. References Qty. Description Notes
1 145336620 1 WATER PUMP PULLEY
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Sump Plate A
GBPG0001
Page 66
64
2
1
7
3
5
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Sump Plate A
GBPG0001
Page 67
Item Part No. References Qty. Description Notes
1 110708390 1 SUMP
2 110996920 1 GASKET - SUMP3 010109235 30 SCREW4 140406680 A U713161N 1 STRAINER 5 140987020 A U713161N 1 PIPE - OIL SUCTION6 052109076 1 SEAL - O RING7 011310612 2 SCREW
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Dipstick & Filler Tube Plate A
GBPG0001
Page 68
4
2
1
3
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Dipstick & Filler Tube Plate A
GBPG0001
Page 69
Item Part No. References Qty. Description Notes
1 198416690 1 DIPSTICK
2 110756490 1 DIPSTICK TUBE3 010109235 1 SCREW4 052100100 2 SEAL - O RING
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Dipstick & Filler Tube Plate B
GBPG0001
Page 70
4
3
2
1
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Dipstick & Filler Tube Plate B
GBPG0001
Page 71
Item Part No. References Qty. Description Notes
1 198436290 1 PLUG
2 052100100 1 SEAL - O RING3 052100100 1 SEAL - O RING4 011310612 1 SCREW
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Sump Plate A
GCPG0001
Page 73
Item Part No. References Qty. Description Notes
1 198736310 1 VALVE
2 025100016 1 WASHER 3 010109238 1 SCREW4 025100016 1 WASHER
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Filler Plate A
HBPG0000
Page 74
2
3
4
1
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Filler Plate A
HBPG0000
Page 75
Item Part No. References Qty. Description Notes
1 198436350 1 OIL FILLER CAP
2 052100400 1 SEAL - O RING3 398430080 1 OIL FILLER CAP4 052100280 1 SEAL - O RING
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Oil Filter Plate A
JBPG0000
Page 76
1
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Oil Filter Plate A
JBPG0000
Page 77
Item Part No. References Qty. Description Notes
1 140517050 1 OIL FILTER
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Oil Filter Plate A
JCPG0000
Page 78
1
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Oil Filter Plate A
JCPG0000
Page 79
Item Part No. References Qty. Description Notes
1 140546020 1 CONNECTION
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Front End Drive Input Plate A
KBPG0001N
Page 80
3
2
1
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Front End Drive Input Plate A
KBPG0001N
Page 81
Item Part No. References Qty. Description Notes
1 U15397401 R a. 1 CRANKSHAFT PULLEY
2 020109086 1 NUT3 034100508 1 WOODRUFF KEY
History
a.1 115397400 1 CRANKSHAFT PULLEY
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Water Pump Plate A
LBPG0003
Page 83
Item Part No. References Qty. Description Notes
1 145010060 1 WATER PUMP
2 145996921 1 GASKET3 145537300 1 HOSE4 2481877 1 HOSE CLIP5 2481877 1 HOSE CLIP6 011310635 4 SCREW7 023100006 1 NUT
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Thermostat & Housing Plate A
LBPG0003
Page 85
Item Part No. References Qty. Description Notes
1 145046110 1 THERMOSTAT HOUSING
2 145206230 1 THERMOSTAT3 145996930 1 GASKET - THERMOSTAT HSG4 011310655 2 BOLT5 023100006 2 NUT6 064500030 1 PLUG7 064500060 1 PLUG
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Water Outlet & Inlet Plate A
LDPG0001
Page 86
2
1
3
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Water Outlet & Inlet Plate A
LDPG0001
Page 87
Item Part No. References Qty. Description Notes
1 145226320 1 CONNECTION
2 145996051 1 GASKET - THERMOSTAT HSG3 011510825 2 SCREW
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Fan Plate A
MDPG0003
Page 88
1
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Fan Plate A
MDPG0003
Page 89
Item Part No. References Qty. Description Notes
1 145306730 1 FAN
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Fan Drive Plate A
MEPG0017
Page 90
1
2
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Fan Drive Plate A
MEPG0017
Page 91
Item Part No. References Qty. Description Notes
1 145386390 1 PLATE
2 011310620 4 SCREW
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Alternator Plate A
NDPG0002
Page 93
Item Part No. References Qty. Description Notes
1 TPN766 1 ALTERNATOR
2 F TPN766 1 ALTERNATOR 3 3113E031 1 ALTERNATOR PULLEY4 TPN744 1 ALTERNATOR BRACKET5 2314H022 1 SCREW6 011510820 3 SCREW7 185727130 1 LEVER 8 011510825 1 SCREW9 026100008 1 WASHER
10 011510825 1 SCREW11 026109017 1 WASHER 12 023100008 1 NUT
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Drive Belt & Tensioner Plate A
NEPG0001
Page 94
1
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Drive Belt & Tensioner Plate A
NEPG0001
Page 95
Item Part No. References Qty. Description Notes
1 080109107 1 BELT
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Front End Drive Output Plate A
QCPG0001
Page 96
1
9
7
2
6
3
8
4
5
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Front End Drive Output Plate A
QCPG0001
Page 97
Item Part No. References Qty. Description Notes
1 U65166580 1 PLATE
2 110416290 1 BEARING HOLDER ASSEMBLY3 U65206791 1 COVER 4 052300850 1 SEAL - O RING5 052300850 1 SEAL - O RING6 U65206791 1 COVER 7 052300850 1 SEAL - O RING8 2314J017 2 SCREW9 2318A604 2 NUT
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Cylinder Head Cover Plate B
TBPG0002
Page 100
2
1
3
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Feed Pipes Plate A
TBPG0002
Page 102
2
1
3
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Feed Pipes Plate A
TBPG0002
Page 103
Item Part No. References Qty. Description Notes
1 165206810 1 COVER
2 3688A035 1 GASKET3 010109600 2 SCREW
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Exhaust Manifold Plate A
UBPG0002
Page 104
1
2
3
4
56
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Exhaust Manifold Plate A
UBPG0002
Page 105
Item Part No. References Qty. Description Notes
1 135617150 1 EXHAUST MANIFOLD
2 135996780 1 GASKET - EXHAUST MANIFOLD3 011510860 4 SCREW4 010310880 2 SCREW5 023100008 2 NUT6 027100008 2 WASHER
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Exhaust Manifold Plate A
UDPG5503
Page 107
Item Part No. References Qty. Description Notes
1 314990013 1 GASKET - EXHAUST
2 011510825 1 SCREW
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Lift Pump Plate A
VBPG0006
Page 109
Item Part No. References Qty. Description Notes
1 130506351 1 LIFT PUMP
2 2415A070 1 SEAL - O RING3 2314F003 2 SCREW
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Fuel Filter Plate A
VBPG0006
Page 110
2
7
5
6
8
4
1
3
11
9
10
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Fuel Filter Plate A
VBPG0006
Page 111
Item Part No. References Qty. Description Notes
1 130316190 1 FUEL FILTER HEAD
2 130366120 1 FUEL FILTER 3 130976260 1 BRACKET4 130976250 1 STAY5 010111035 2 BOLT6 026200010 2 WASHER 7 020900010 2 NUT8 027100010 2 WASHER 9 010310820 2 BOLT
10 023100008 2 NUT11 011510816 2 SCREW
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Pipework & Connections Plate A
VBPG0006
Page 112
1
8
9
2
12
5
10
7
13
6
4
11
3
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Cold Start System Plate A
WDPG0000
Page 114
4
1
3
2
65
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Cold Start System Plate A
WDPG0000
Page 115
Item Part No. References Qty. Description Notes
1 185366190 4 GLOWPLUG
2 F 185366190 1 GLOWPLUG3 F 185366190 1 NUT4 185376150 1 BAR 5 020100004 1 NUT6 027100004 1 WASHER
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Engine Lifting Eyes Plate A
XBPG0000
Page 116
2
3
4
1
-
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Engine Lifting Eyes Plate A
XBPG0000
Page 117
Item Part No. References Qty. Description Notes
1 195816100 1 LIFTING EYE
2 011510820 1 SCREW3 026100008 1 WASHER 4 195816100 1 LIFTING EYE
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Throttle & Stop Controls Plate A
ZAPG0002
Page 118
2
3
1
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Throttle & Stop Controls Plate A
ZAPG0002
Page 119
Item Part No. References Qty. Description Notes
1 U25416480 1 CONTROL LEVER
2 185206450 1 SOLENOID3 025100016 1 WASHER
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Instrumentation Plate A
ZJPG0000
Page 120
2
3
5
1
4
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Instrumentation Plate A
ZJPG0000
Page 121
Item Part No. References Qty. Description Notes
1 198486871 1 BANJO BOLT
2 140996260 1 WASHER 3 140996260 1 WASHER 4 064400010 1 PLUG5 1 ROCKER BOX ASSEMBLY
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Instrumentation Plate A
ZLPG0002
Page 122
1
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Instrumentation Plate A
ZLPG0002
Page 123
Item Part No. References Qty. Description Notes
1 385720500 1 WATER TEMPERATURE SENSOR
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Electrical Wiring & Fittings Plate A
ZPPG0001
Page 124
1
2
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Electrical Wiring & Fittings Plate A
ZPPG0001
Page 125
Item Part No. References Qty. Description Notes
1 20195 1 CONNECTION KIT
2 F 20195 3 CONNECTION
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Fuel Pre-Lift Pump Plate A
ZVPG0001
Page 126
2
1
3
5
6
4
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Fuel Pre-Lift Pump Plate A
ZVPG0001
Page 127
Item Part No. References Qty. Description Notes
1 130306380 1 PRE-FUEL FILTER ASSY
2 F 130306380 1 FUEL FILTER HEAD3 26560182 1 FUEL FILTER BOWL5 26560183 3 DRAIN PLUG4 130306360 1 FUEL FILTER 6 26560184 1 SEAL - O RING
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Parts Index
Page 128
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Page 129
Parts Index
Description Part No. Page
ADJUSTING SCREW 199486220 31
ALTERNATOR TPN766 93
ALTERNATORBRACKET
TPN744 93
ALTERNATORPULLEY
3113E031 93
ANTI-TAMPER CAP 131276440 47
131466270 47
26420462 43
ARM 125156261 43
125156262 43
BACKPLATE 110367570 59
BALL BEARING 040106203 17
040109057 49
BANJO BOLT 198486871 121
TPN731 113
BAR 185376150 115
BEARING HOLDERASSEMBLY
110416290 41, 97
BELT 080109107 95
BIG END BEARINGKIT
U5ME0030 21
BOLT 010109341 61
010111030 59
010111035 111
010310820 111
010700860 21
011310655 85
131466251 47
198486780 35
198487450 57
BRACKET 125616120 43
130976260 111
BREATHER VALVE 110566080 99
BUSH 198517222 17
198517226 17
198517229 17
198517290 33
CAMSHAFT 120026950 49
CAMSHAFT GEAR 120016240 49
CAP 064210012 47
064210018 27
064210030 27, 27
120186080 27, 27
CIRCLIP 036500028 23, 23
036800010 33
CLAMP 199106021 53, 53
CLIP 067100015 113 , 113 ,113 , 113
COLLAR 199236540 33
CON RODASSEMBLY
115026330 23
CON ROD BOLT 115176140 23
CON ROD NUT 020109120 23
CONNECTION 131246240 113
140546020 79
145226320 87
Description Part No. Page
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Parts Index
Page 130
CONNECTION KIT 20195 125
CONTROL LEVER 125046612 45
125046613 45
125306150 45
125306151 45
U25416480 119
COVER 140116220 33
165206810 103
U65206791 97, 97
CRANKSHAFTASSEMBLY
115256990 21
CRANKSHAFTGEAR
115276270 21
CRANKSHAFTPULLEY
115397400 81
U15397401 81
CYLINDER HEADASSEMBLY
111011030 27
CYLINDER HEADCOVER
111217411 99
DIPSTICK 198416690 69
DIPSTICK TUBE 110756490 69
DOWEL 030500612 17, 21,21, 21, 21
030500616 17
030501025 17
030509018 33
DRAIN PLUG 26560183 127
EXHAUSTMANIFOLD
135617150 105
EXHAUST VALVE 120176380 27
Description Part No. Page
FAN 145306730 89
FUEL FILTER 130306360 127
130366120 111
FUEL FILTER BOWL 26560182 127
FUEL FILTER HEAD 130316190 111
FUEL INJECTIONPIPE
131507520 53
131507530 53
131507540 53
131507550 53
FUEL INJECTIONPUMP
131010080 51
FUEL PIPE 068209227 113
TPN673 113
GASKET 135996950 101
145996921 83
165996640 43
3688A035 103
GASKET - CYL.HEAD COVER
111996401 99
GASKET -CYLINDER HEAD
111147711 29
111147721 29
GASKET -EXHAUST
314990013 107
GASKET -EXHAUSTMANIFOLD
135996780 105
GASKET - SUMP 110996920 67
GASKET -THERMOSTAT HSG
145996051 87
Description Part No. Page
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Parts Index
Page 132
PLATE 145386390 91
199566750 49
U65166580 19, 97
PLUG 064100045 17
064210010 27
064210025 17, 27, 27
064210040 17, 17, 17
064400010 121
064500030 85
064500060 85
198436290 71
198466010 17
198466020 17
198466920 17
198466940 17
PRE-FUEL FILTERASSY
130306380 127
PUSHROD 120456310 31
RELIEF VALVE 140036220 37
RETAINING PLATE 110666210 99
RING 198346160 47
ROCKER ARMASSEMBLY
120356131 31
120356141 31
ROCKER BOX 120036821 31
ROCKER SHAFT 120316201 31
ROCKER SHAFTSPRING
198217170 31
SCREW 010109235 67, 69
Description Part No. Page
010109238 73
010109406 21, 21,21, 21
010109600 103
010110625 53
010310880 105
010700820 51
010800820 51
011310612 19, 49,67, 71
011310614 43
011310620 91, 101
011310635 31, 83
011310640 39, 99
011310660 39, 99
011510816 59, 111
011510820 93, 117
011510825 87, 93,93, 107
011510860 105
011511070 21, 21, 21
011511220 59
015600406 99
111136480 29
111136490 29
131046650 47
2314F003 109
2314H022 93
2314J017 97
Description Part No. Page
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Page 133
Parts Index
2315C039 43, 43
SEAL - FRONT ENDOIL
198636160 41
SEAL - INJECTOR 131426200 55
131426230 55
SEAL - O RING 052100070 43
052100100 69, 71, 71
052100280 75
052100400 75
052109076 31, 67
052109078 37
052300850 41, 97,97, 97
2415A070 109
26560184 127
SEAL - REAR ENDOIL
050209083 25
SEAL - ROCKERBOX
120996130 31
SEAL - VALVESTEM
120406050 27
120406070 27
SHAFT 125116211 45125116221 45
165296220 17
SHIM 131437490 51
131437500 51
131437510 51
131437520 51
131437530 51
Description Part No. Page
131437730 51
131437760 51
199286150 33
199286160 33
199286170 33
199286180 33
SLIDER 125256240 49
SMALL END BUSH 198517265 23
SOLENOID 185206450 119
SPACER 199216320 49
SPEED SENSOR 131046560 45
SPRING 198216720 33
198217750 43
198217760 33
198217870 43
198217880 45
198217910 47
STARTER MOTOR 185086600 63
STAY 130976250 111
STRAINER 140406680 67
STUD 010109441 17
012109044 31
012110635 17
012110655 29
012110660 17
012110860 29
SUMP 110708390 67
Description Part No. Page
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Parts Index
TAPPET 120116160 31
THERMOSTAT 145206230 85
THERMOSTATHOUSING
145046110 85
THRUST WASHER 199266200 21, 21
199266210 21
199266270 33
TIMING CASE 165106870 41
VALVE 198736310 73
VALVE COLLET 120226070 27, 27
VALVE SEATINSERT
TPN645 27
TPN646 27
VALVE SPRING 198216700 27, 27
VALVE SPRING CAP 120216041 27, 27
WASHER 025100006 45, 47
025100008 45, 57, 57
Description Part No. Page
140996260 35, 35,
121 , 121
140996270 99
199280300 31
2411156 113, 113 ,113
WATER PUMP 145010060 83
WATER PUMPPULLEY
145336620 65
WATERTEMPERATURESENSOR
385720500 123
WOODRUFF KEY 034100508 49, 81
Description Part No. Page