2206 Service Manual

KENR6907
May 2008
Systems Operation
Testing and Adjusting
2206-E13 Industrial Engine
TGB (Engine)
TGD (Engine)
TGF (Engine)
This document has been printed from SPI. Not for Resale
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as
DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by NOTICE labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this

product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury or
death.
KENR6907 3
Table of Contents
Table of Contents Charging System - Test ........................................ 54

Electric Starting System - Test .............................. 54
Systems Operation Section Index Section
General Information ................................................ 4 Index ..................................................................... 55

Electronic Control System Components ................. 6
Fuel System ........................................................... 8
Air Inlet and Exhaust System ............................... 12
Lubrication System .............................................. 14
Cooling System .................................................... 15
Basic Engine ......................................................... 18
Electrical System ................................................. 19
Testing and Adjusting Section

Belt Tension Chart ................................................ 23
Fuel System
Fuel System - Inspect ........................................... 24
Air in Fuel - Test .................................................... 24
Electronic Unit Injector - Adjust ............................. 25
Electronic Unit Injector - Test ................................ 26
Finding Top Center Position for No. 1 Piston ........ 26
Fuel Quality - Test ................................................. 27
Fuel System - Prime ............................................. 28
Fuel System Pressure - Test ................................. 29
Gear Group (Front) - Time .................................... 30
Air Inlet and Exhaust System

Air Inlet and Exhaust System - Inspect ................. 31
Turbocharger - Inspect .......................................... 32
Exhaust Temperature - Test .................................. 34
Engine Crankcase Pressure (Blowby) - Test ........ 34
Engine Valve Lash - Inspect/Adjust ...................... 35
Lubrication System
Engine Oil Pressure - Test .................................... 37
Excessive Bearing Wear - Inspect ........................ 39
Excessive Engine Oil Consumption - Inspect ....... 39
Increased Engine Oil Temperature - Inspect ........ 40
Cooling System
Cooling System - Check (Overheating) ................ 41
Cooling System - Inspect ...................................... 42
Cooling System - Test ........................................... 43
Water Temperature Regulator - Test ..................... 45
Water Pump - Test ................................................ 46
Basic Engine
Piston Ring Groove - Inspect ................................ 47
Connecting Rod Bearings - Inspect ...................... 47
Main Bearings - Inspect ........................................ 47
Cylinder Block - Inspect ........................................ 47
Cylinder Liner Projection - Inspect ........................ 48
Flywheel - Inspect ................................................. 50
Flywheel Housing - Inspect ................................... 51
Vibration Damper - Check .................................... 53
Electrical System
Battery - Test ......................................................... 54
4 KENR6907
Systems Operation Section

i02769236
General Information
The following model views show the 2206-13 Engine

features. Due to individual applications, your engine
may appear different from the illustrations.
g01405969
Illustration 1
Typical example
Left side engine view
(1) Connection for the breather (4) Secondary fuel filter (7) Crankshaft damper
(2) Electronic control module (ECM) (5) Primary fuel filter (8) Oil filler
(3) Fuel priming pump (6) Fuel pump
KENR6907 5
g01405970
Illustration 2
Typical example
Right side engine view
(9) Water temperature regulator housing (12) Turbocharger (15) Oil cooler
(10) Alternator (13) Oil filter (16) Exhaust manifold
(11) Water pump (14) Oil drain plug
Starting the Engine Cold mode operation varies the fuel injection amount
for white smoke cleanup. Cold mode operation also
The Electronic Control Module (ECM) will varies the timing for white smoke cleanup. The
automatically provide the correct amount of fuel that engine operating temperature is usually reached
is necessary to start the engine. If the engine fails before the walk-around inspection is completed.
to start in 30 seconds, the starter switch should be
released. The starting motor should be allowed to
cool for 30 seconds before being used again.
Cold Mode Operation

The ECM will set the cold start strategy when the
coolant temperature is below 20 C (68 F).
Cold mode operation will be deactivated when any of

the following conditions have been met:
Coolant temperature reaches 20 C (68 F).

The engine has been running for twelve minutes.
6 KENR6907
i02769284
Electronic Control System

Components
g01402324
Illustration 3
(1) Engine coolant temperature sensor (4) Atmospheric pressure sensor (7) Fuel temperature sensor
(2) Intake manifold pressure sensor (5) Secondary position sensor (Camshaft) (8) Primary position sensor (Crankshaft)
(3) Intake manifold air temperature sensor (6) Engine oil pressure sensor (9) Electronic control module (ECM)
The electronic control system is integrally designed The engine uses the following types of electronic
into the engines fuel system and the engines air components:
inlet and exhaust system in order to electronically
control the fuel delivery and the injection timing. The Inputs
electronic control system provides increased timing
control and fuel air ratio control in comparison to Controls
conventional mechanical engines. Injection timing
is achieved by precise control of injector firing time, Outputs
and engine rpm is controlled by adjusting the firing
duration. The Electronic Control Module (ECM) An input component is one that sends an electrical
energizes the solenoid in the unit injector in order to signal to the ECM. The signal that is sent varies in
start the injection of fuel. Also, the ECM de-energizes one of the following ways:
the unit injector solenoids in order to stop injection
of fuel. Refer to Systems Operation, Testing and Voltage
Adjusting, Fuel System for a complete explanation
of the fuel injection process. Frequency
KENR6907 7
Pulse width
The variation of the signal is in response to a change
in some specific system of the equipment. The
ECM sees the input sensor signal as information
about the condition, environment, or operation of the
equipment.
A electronic control module (ECM) receives the

input signals. Electronic circuits inside the control
component evaluate the signals from the input
components. These electronic circuits also supply
electrical energy to the output components of the
system. The electrical energy that is supplied to
the output components is based on predetermined
combinations of input signal values.
An output component is one that is operated by a

control module. The output component receives
electrical energy from the control component. The
output component uses that electrical energy in one
of two ways. The output component can use that
electrical energy in order to perform work. The output
component can use that electrical energy in order to
provide information.
8 KENR6907
i02769330
Fuel System
g01282152
Illustration 4
Fuel system schematic
(1) Fuel return line (5) Fuel cooler (9) Fuel transfer pump
(2) Electronic unit injectors (6) Fuel tank (10) Fuel temperature sensor
(3) Fuel gallery (7) Secondary fuel filter
(4) Fuel priming pump (8) Primary fuel filter
The fuel supply circuit is a conventional design for Note: The inlet fuel temperature to the fuel transfer
engines with electronic unit injection. A fuel tank (6) pump must not exceed 79 C (175 F) when the
is used to store the fuel prior to use by the engine. A engine has reached normal operating temperature.
primary fuel filter/water separator (8) is placed into Fuel temperatures above 79 C (175 F) will reduce
the fuel supply circuit in order to remove large debris the life of the fuel transfer pump check valves. The
from the fuel. This debris may have entered the fuel efficiency and the engine power output are
fuel tank during fueling. The debris may have also reduced when the fuel temperature increases from
entered the fuel tank through the vent for the fuel 30 C (86 F) to 70 C (158 F).
tank. The primary filter element also separates water
from the fuel. The water is collected in the bowl at the
bottom of the primary fuel filter/water separator.
KENR6907 9
Fuel from the tank (6) flows to the fuel filter base. The fuel exits the fuel gallery and returns to the fuel
The fuel filter base contains the primary fuel filter filter base. A pressure regulating valve is located in
and the secondary fuel filter. The fuel flows through the fuel filter base. The pressure regulating valve
cored passages in the fuel filter base. The fuel regulates the pressure for the fuel system. A sufficient
priming pump (4) is mounted on the fuel filter base. amount of back pressure is maintained in the system
The fuel priming pump is used in order to manually in order to ensure a continuous availability of fuel to
pump the fuel into the fuel system after the system, the electronic unit injectors. The fuel flows from the
or parts of the system have been drained. The fuel fuel filter base to the fuel cooler (5). The fuel flows
priming pump is used in order to refill the fuel system from the fuel cooler (5) back to the tank (6).
after air has been introduced into the system. For
more information on priming the fuel system, refer Fuel System Electronic Control
to Systems Operation, Testing and Adjusting, Fuel
System - Prime. Circuit
As the fuel flows through cored passages in the fuel
filter base, the fuel is directed into the primary fuel
filter (8). Fuel flows out of the fuel filter and returns
to the passages in the fuel filter base. Prior to exiting
the fuel filter base, the fuel temperature is sampled
by the fuel temperature sensor (10). The signals
that are generated by the sensors are used by the
engine control in order to monitor the condition of the
engines components.
The fuel flows from the fuel filter base to the fuel
transfer pump (9). The fuel transfer pump (9) is a gear
type pump with fixed clearances. The fuel transfer
pump (9) incorporates an internal relief valve that g00451841
protects the fuel system from extreme pressure. In Illustration 5
the case of extreme pressure, fuel is redirected back Electronic governor
to the inlet of the fuel transfer pump (9). An outlet (1) Signals to the electronic unit injectors
check valve is used in order to prevent pressurized (2) Fuel injection control
fuel leakage back through the pump. The fuel transfer (3) Fuel position
(4) Electronic governor
pump (9) is located in the front of the engine. The fuel (5) Desired rpm
transfer pump (9) is driven by the front gear train. (6) Coolant temperature
(7) TC for No. 1 cylinder
The fuel flows from the fuel transfer pump (9) to the (8) FRC fuel position
(9) Rated fuel position
secondary fuel filter (7). The fuel is filtered in order (10) FCR maps
to remove small abrasive particles that will cause (11) Torque maps
premature wear to fuel system components. The fuel (12) Engine speed/timing sensor
flows from the secondary fuel filter (7) to the fuel filter (13) Engine speed/timing signals interpreter
base. (14) Engine rpm
(15) Coolant temperature sensor
(16) Boost pressure sensor
The fuel is then directed from the fuel filter base (17) Boost pressure
through the fuel return line (1) to fuel manifold (3) that
runs the length of the cylinder head. A continuous The injection pump, the fuel lines, and the nozzles
flow of fuel is supplied to the electronic unit injectors that are used in the traditional Perkins diesel engines
(2) in order to perform the following tasks: have been replaced with an electronically controlled,
mechanically actuated electronic unit injector in each
Supply fuel for injection cylinder. A solenoid on each injector controls the
amount of fuel that is delivered by the injector. An
Remove excessive heat from the injectors. Electronic Control Module (ECM) sends a signal to
each injector solenoid in order to provide complete
Remove air that may accumulate in the fuel control of the engine.
system.
10 KENR6907
Fuel Injection Electronic Unit Injector Mechanism

The ECM controls the amount of fuel that is injected
by varying the signals that are sent to the injectors.
The ECM sends a high voltage signal to the solenoid
in order to energize the solenoid. The injectors
will inject fuel only while the injector solenoid is
energized. By controlling the timing and the duration
of the voltage signal, the ECM can control injection
timing and the amount of fuel that is injected.
The ECM sets certain limits on the amount of fuel that

can be injected. FRC is a limit which controls the
amount of air and of fuel for the purpose of emission
control. This limit is based on the boost pressure.
When the ECM senses a higher boost pressure, the
ECM increases the FRC limit. Rated Fuel Pos is
a limit that is based on the horsepower rating of the
engine. This is similar to the rack stops and to the
torque spring on a mechanically governed engine.
Rated Fuel Pos provides horsepower and torque
curves for a specific engine family and for a specific
engine rating. All of these limits are programmed g01092960
Illustration 6
into the ECM by the factory. These limits are not
programmable by the service technician. Typical examples of Electronic Unit Injector fuel systems.
(1) Adjusting nut
Injection timing depends on three factors: the engine (2) Rocker arm assembly
(3) Unit injector
speed (rpm), the engine load, and the operational (4) Pushrod
conditions of the engine. The ECM determines the
top center position of No. 1 cylinder from the signal The unit injector pressurizes the fuel. The correct
that is provided by the engine speed/timing sensor. amount of fuel is then injected into the cylinder block
The ECM decides when the injection should occur at precise times. The ECM determines the injection
relative to the top center position. The ECM then timing and the amount of fuel that is delivered. The
provides the signal to the electronic unit injector at unit injector is operated by a camshaft lobe and a
the desired time. rocker arm. The camshaft has three camshaft lobes
for each cylinder. Two lobes operate the inlet and
exhaust valves, and the other lobe operates the
unit injector mechanism. Force is transferred from
the unit injector lobe on the camshaft through the
lifter to the pushrod (4). The force of the pushrod
is transferred through rocker arm assembly (2) and
to the top of the unit injector. The adjusting nut (1)
allows setting of the unit injector adjustment. Refer to
Systems Operation/Testing and Adjusting, Electronic
Unit Injector - Adjust for the correct setting of the
unit injector adjustment.
KENR6907 11
Electronic Unit Injector As the electronic unit injector mechanism transfers

the force to the top of the electronic unit injector,
spring (1) is compressed and plunger (4) is driven
downward. This action displaces fuel through the
valve in solenoid valve assembly (3), and into the
return manifold to the fuel tank. As the plunger travels
downward, the passage in barrel (5) is closed by the
outside diameter of the plunger. The passages within
body (10) and along check valve (11) to the injector
tip already contain fuel for injection. After the passage
in the plunger barrel is closed, the injector is ready for
injection at any time. The start of injection relies on
the software in the Electronic Control Module (ECM).
When the solenoid valve assembly is energized

from a signal across solenoid connection (2), the
valve closes and fuel pressure is elevated in the
injector tip. Injection begins at 34500 1900 kPa
(5000 275 psi) as the force of spring (8) above
spacer (9) is overcome. The check valve begins
to lift from the valve seat. The pressure continues
to rise as the plunger cycles through a full stroke.
After the correct amount of fuel has been discharged
into the cylinder, the ECM removes the signal to the
solenoid connection. The solenoid valve assembly
is de-energized and the valve in the solenoid valve
assembly is opened. The high pressure fuel is then
dumped through the spill port and into the fuel return
manifold. The fuel is then returned to the fuel tank.
The check valve in the injector tip seats as the
pressure in the tip decreases.
The duration of injection meters the fuel that is

consumed during the fuel injection process. Injection
duration is controlled by the governor logic that is
g00984466
programmed into the ECM.
Illustration 7
Electronic unit injector As the camshaft lobe rotates past the point of
(1) Spring maximum lobe lift, the force on top of the electronic
(2) Solenoid connection to the Electronic Control Module (ECM) unit injector is removed and the spring for the injector
(3) Solenoid valve assembly mechanism is allowed to expand. The plunger returns
(4) Plunger assembly
(5) Barrel
to the original position. This uncovers the fuel supply
(6) Seal passage into the plunger barrel in order to refill the
(7) Seal injector pump body. The fuel at low pressure is again
(8) Spring allowed to circulate through the fuel injector body.
(9) Spacer
(10) Body
After circulating through the fuel injector body, the
(11) Check valve fuel flows out of the spill port. This continues until the
solenoid valve assembly is re-energized for another
Fuel at low pressure from the fuel supply manifold injection cycle.
enters the electronic unit injector at the fill port
through drilled passages in the cylinder head.
12 KENR6907
i02769479 Air is forced from the aftercooler into inlet manifold

(1). The air flow from the inlet port into the cylinders
Air Inlet and Exhaust System is controlled by inlet valves.
g00615497
Illustration 9
g01046036 Air inlet and exhaust system
Illustration 8
(2) Aftercooler core
Air inlet and exhaust system schematic
(4) Exhaust outlet
(1) Inlet to the engine (5) Turbine side of turbocharger
(2) Aftercooler core (6) Compressor side of turbocharger
(3) Inlet air line (8) Exhaust manifold
(4) Exhaust outlet from turbocharger (9) Exhaust valve
(5) Turbine side of turbocharger (10) Inlet valve
(6) Compressor side of turbocharger (11) Air inlet
(7) Air cleaner
Each cylinder has two inlet valves (10) and two
The engine components of the air inlet and exhaust exhaust valves (9) in the cylinder head. The inlet
system control the quality of air and the amount of valves open on the inlet stroke. When the inlet valves
air that is available for combustion. The components open, compressed air from the inlet port within the
of the air inlet and exhaust system are the following inlet manifold is pushed into the cylinder. The inlet
components: valves close when the piston begins the compression
stroke. The air in the cylinder is compressed and the
Air cleaner fuel is injected into the cylinder when the piston is
near the top of the compression stroke. Combustion
Turbocharger begins when the fuel mixes with the air. The force of
combustion pushes the piston on the power stroke.
Aftercooler The exhaust valves open and the exhaust gases
are pushed through the exhaust port into exhaust
Cylinder head manifold (8). After the piston finishes the exhaust
stroke, the exhaust valves close and the cycle begins
Valves and valve system components again.
Piston and cylinder Exhaust gases from the exhaust manifold flow
into the turbine side of turbocharger (5). The high
Exhaust manifold temperature exhaust gases cause the turbocharger
turbine wheel to turn. The turbine wheel is connected
The turbocharger compressor wheel pulls inlet air to the shaft that drives the compressor wheel.
through the air cleaner and into the air inlet. The air Exhaust gases from the turbocharger pass through
is compressed and this causes the air to become hot. exhaust outlet (4), through a muffler, and through an
The air flows through aftercooler core (2) and the exhaust stack.
temperature of the compressed air lowers. This helps
to provide increased horsepower output. Aftercooler
core (2) is a separate cooler core that is mounted in
front of the engine radiator. The engine fan causes
ambient air to move across both cores. This cools the
turbocharged inlet air and the engine coolant.
KENR6907 13
Turbocharger Valve System Components
g00291085
Illustration 10
Turbocharger
(4) Air inlet
(5) Compressor housing
(6) Compressor wheel
(7) Bearing
(8) Oil inlet port
(9) Bearing g01086490
Illustration 11
(10) Turbine housing
(11) Turbine wheel (1) Rocker arm
(12) Exhaust outlet (2) Pushrod
(13) Oil outlet port (3) Valve bridge
(14) Exhaust inlet (4) Valve spring
(5) Valve
(6) Lifter
Turbocharger (3) is mounted to exhaust manifold (2)
of the engine. All of the exhaust gases go from the The valve system components control the flow of
exhaust manifold through the turbocharger. inlet air into the cylinders and out of the cylinders
during engine operation. The valve mechanism also
The exhaust gases enter the turbocharger and the operates the fuel injector.
turbine wheel is turned. Because the turbocharger
turbine wheel is connected by a shaft to the The camshaft must be timed to the crankshaft in
turbocharger compressor wheel, the turbine wheel order to get the correct relation between the piston
and the compressor wheel turn at very high speeds. movement and the valve movement.
The rotation of the compressor wheel pulls clean
air through the compressor housing air inlet. The The camshaft has two camshaft lobes for each
action of the compressor wheel blades causes a cylinder. The lobes operate the inlet and exhaust
compression of the inlet air. This compression allows valves. As the camshaft turns, lobes on the camshaft
a larger amount of air to enter the engine. With more cause lifters (6) to move pushrods (2) up and down.
air in the engine, the engine is able to burn more fuel. Upward movement of the pushrods against rocker
The overall effect is an increase in power. arms (1) results in downward movement (opening) of
valves (5).
Bearing (7) and bearing (9) in the turbocharger use
engine oil that is under pressure for lubrication. The Each cylinder has two inlet valves and two exhaust
lubrication for the bearings flows through oil inlet port valves. The valves are actuated at the same time by
(8) and into the inlet port in the center section of the a valve bridge (3). Valve springs (4) close the valves
turbocharger cartridge. The oil exits the turbocharger when the lifters move down.
through oil outlet port (13). The oil then returns to
the engine oil pan through the oil drain line for the
turbocharger.
14 KENR6907
i02843427
Lubrication System
g01417920
Illustration 12
Lubrication system schematic
(1) Piston cooling jets (6) Oil filter bypass valve (11) Oil cooler bypass valve
(2) Main oil gallery in cylinder block (7) Main bearings (12) Engine oil cooler
(3) Engine pressure sensor (8) Signal line (13) Oil pan sump
(4) Oil flow to valve mechanism (9) Primary engine oil filter (14) High pressure relief valve
(5) Camshaft journals (10) Engine oil pump (15) Oil pump bypass valve
KENR6907 15
i02769599
Cooling System
Coolant Flow
g01417942
Illustration 13
Right side view of engine
(9) Primary engine oil filter
(10) Engine oil pump
(12) Engine oil cooler
The lubrication system supplies 110 C (230 F)

filtered oil at approximately 275 kPa (40 psi) at rated Illustration 14
g01085911
engine operating conditions. Oil pump bypass valve Cooling system schematic
(15) is controlled by the engine oil manifold pressure,
(1) Cylinder head
rather than the oil pump pressure. The engine oil (2) Expansion tank
manifold pressure is independent of the pressure (3) Return manifold
drop that is caused by the engine oil filter and the (4) Cylinder liners
engine oil cooler. (5) Temperature regulator housing
(6) Radiator
(7) Water pump
Oil cooler bypass valve (11) maintains the engine oil (8) Engine oil cooler
temperature to 110 C (230 F). High pressure relief
valve (14), which is located in the filter base, protects Note: Use Perkins ELC in an Air to Air Aftercooler
the filters and other components during cold starts. System. Refer to Operation and Maintenance
The opening pressure of the high pressure relief Manual, Fluid Recommendations for further
valve is 695 kPa (100 psi). The opening pressure of information. This keeps the temperature range of the
the oil filter bypass valve is 170 kPa (25 psi). Engine coolant high enough for efficient performance.
oil pressure sensor (3) is part of the engine protection
system. The water pump is gear-driven. The water pump is
located on the right hand side of the engine. The
The turbocharger cartridge bearings are lubricated by water pump supplies the coolant for the engine
the oil supply line from the main oil gallery, and the oil cooling system. The coolant is supplied to the
drain line returns the oil flow to the sump. following components:
Cylinder head (1)

Cylinder liners (4)
Engine oil cooler (8)
Air compressor (not shown)
Coolant conditioner element (not shown)
16 KENR6907
g01413806
Illustration 15
(3) Return manifold (7) Water pump
(5) Temperature regulator housing (8) Engine oil cooler
Water pump (8) pulls the coolant from the bottom of

radiator. The water pump is located on the right hand
side of the front timing gear housing.
The water pump impeller rotates at 1.17 times the

engine speed. The water pump is driven by an idler
gear. The idler gear is turned by the crankshaft
gear. The water pump shaft is supported by two ball
bearings. One ball bearing is located in the water
pump housing. The other ball bearing is located in the
front timing gear housing. The water pump impeller
face is open. The impeller is made out of cast iron.
The rear cover is an aluminum die casting. The water
pump seal is a cartridge seal that is located on the
inlet side of the water pump in order to provide good
water flow around the seal for cooling.
KENR6907 17
The coolant is pumped through engine oil cooler Temperature Regulator Housing
(9). The coolant then flows to the supply manifold.
The supply manifold, which is located in the cylinder
block, distributes coolant around the upper portion
of the cylinder liners. At each cylinder, the coolant
flows from the cylinder liner to the cylinder head.
The cylinder head is divided into single cylinder
cooling sections. In the cylinder head, the coolant
flows across the center of the cylinder and across
the injector seat boss. At the center of the cylinder,
the coolant flows around the injector sleeve over
the exhaust port. The coolant then exits into return
manifold (3). The return manifold collects the
coolant from each cylinder and the return manifold
directs the flow to temperature regulator housing
(5). When the coolant temperature regulator is
in the closed position, the coolant flows through
the coolant temperature regulator. This allows the
coolant to flow directly back to the water pump for
recirculation by bypassing the radiator. When the
coolant temperature regulator is in the open position,
the coolant is directed through the radiator and back
to the water pump inlet. g01085915
Illustration 16
Section view of the temperature regulator housing
Supply Manifold (1) Temperature regulator housing
(2) Coolant temperature sensor
Cooling is provided for only the portion of the cylinder
liner above the seal in the cylinder block. The coolant The coolant temperature regulator is a full flow
enters the cylinder block at each cylinder through bypass type that is used to control the outlet
slits in the supply manifold. The supply manifold is temperature of the coolant. When the engine is
an integral casting in the cylinder block. The coolant cold, the coolant temperature regulator is in the
flows around the circumference of the cylinder liner closed position. This allows the coolant to flow
and into the cylinder head through a single drilled through the coolant temperature regulator from the
passage for each liner. The coolant flow is split at return manifold. This allows the coolant to bypass
each cylinder liner so that 60 percent flows around the radiator. The coolant goes directly to the water
the cylinder liner and the remainder flows directly to pump for recirculation. As the coolant temperature
the cylinder head. increases, the coolant temperature regulator begins
to open directing some of the coolant to the radiator
and bypassing the remainder to the water pump inlet.
At the full operating temperature of the engine, the
coolant temperature regulator moves to the open
position. This allows all the coolant flow to be directed
to the radiator. The coolant then goes to the water
pump. This route provides the maximum heat release
from the coolant. A vent line is recommended from
the manifold to the radiator overflow tank in order to
provide venting for the cooling system.
18 KENR6907
i02773143 Cylinder liners (1) are seated on a ridge (4) in the

middle of the cylinder wall between the crankcase
Basic Engine and the coolant jacket. The ridge is created by a
counterbore in the cylinder block. The cylinder liners
have a lip (2) which rests on the ridge. The seals of
the coolant jacket are located in the upper regions
Cylinder Block and middle regions of the cylinder liners. The lower
barrier uses a D-ring seal (3) that is located above the
The cylinder block is a unique design with a deep seating surface of the cylinder liner. The upper barrier
counterbore that supports the cylinder liner. The is the head gasket which is above the coolant jacket.
cylinder block also forms the coolant jacket. Two
oil manifolds are provided in the cylinder block for The cylinder block has seven main bearings in order
engine lubrication. The manifold on the lower right to support the crankshaft. Each main bearing cap is
side of the cylinder block provides oil to the following fastened to the cylinder block with two bolts.
components:
Pistons, Rings, and Connecting
Piston cooling jets
Rods
Crankshaft bearings
The high compression ratio of the engine requires
Oil filter base the use of steel one piece pistons.
The manifold on the upper left side of the cylinder The pistons have three rings:
block provides oil to the following components:
Compression ring
Camshaft bearings
Intermediate ring
Valve mechanism
Oil ring
The manifold on the right supplies oil to the manifold
on the left. The oil travels through the cut above the The rings are located in grooves in the piston. The
number one main bearing and the cut above the rings seal the crankcase from the combustion gases
number four main bearing. and the rings also provide control of the engine
oil. The design of the compression ring is a barrel
face with a plasma face coating. The design of the
intermediate ring is a tapered shape and a chrome
finish. The oil ring is double railed with a coil spring
expander. The oil ring has a ground profile and a
chrome finish.
The connecting rod is a conventional design. The

cap is fastened to the shank by two bolts that are
threaded into the shank. Each side of the small end
of the connecting rod is machined at an angle of
12 degrees in order to fit within the piston cavity.
This allows a larger surface area on the piston, and
connecting rod in order to minimize bearing load.
Crankshaft
The crankshaft converts the linear motion of the
pistons into rotational motion. The crankshaft drives
a group of gears (front gear train) on the front of the
engine. The front gear train provides power for the
Illustration 17
g00762739 following components:
Camshaft
Water pump
KENR6907 19
Engine oil pump Vibration Damper

Air compressor The force from combustion in the cylinders and from
driveline components will cause the crankshaft to
Fuel transfer pump twist. This is called torsional vibration. If the vibration
is too great, the crankshaft will be damaged. Driveline
Accessory drive components can excite torsional stress. This stress
will cause damage to components. The vibration
The crankshaft is held in place by seven main damper limits the torsional vibrations to an acceptable
bearings. The oil holes and the oil grooves in the amount in order to prevent damage to the crankshaft.
shell of the upper bearing supply oil to the connecting
rod bearings. The oil holes for the connecting rod The viscous vibration damper is installed on the front
bearings are located at the following main bearing of the crankshaft. The viscous vibration damper has
journals: 2, 3, 5, and 6. a weight in a case. The space between the weight
and the case is filled with a viscous fluid. The weight
Hydrodynamic seals are used at both ends of the moves in the case in order to limit the torsional
crankshaft to control oil leakage. The hydrodynamic vibration.
grooves in the seal lip move lubrication oil back into
the crankcase as the crankshaft turns. The front
i02773144
seal is located in the front housing. The rear seal is
installed in the flywheel housing. Electrical System
Camshaft
Grounding Practices
Correct grounding for the machine electrical system
and engine electrical systems is necessary for
correct machine performance and reliability. Improper
grounding will result in uncontrolled electrical circuit
paths and unreliable electrical circuit paths.
Uncontrolled engine electrical circuit paths can result

in damage to main bearings, crankshaft bearing
journal surfaces, and aluminum components.
To ensure correct functioning of the application and

Illustration 18
g00762808 engine electrical systems, an engine-to-frame ground
strap with a direct path to the negative battery post
The camshaft has three lobes at each cylinder in must be used. This may be provided by way of a
order to operate the unit injector, the exhaust valves, starting motor ground, a frame to starting motor
and the inlet valves. Seven bearings support the ground, or a direct frame to engine ground.
camshaft. The camshaft is driven by an idler gear
that is turned by the crankshaft in the front gear An engine-to-frame ground strap must be used in
train. Each bearing journal is lubricated from the oil order to connect the grounding stud of the engine
manifold in the cylinder block. A thrust pin that is to the frame of the application and to the negative
located at the rear of the block positions the camshaft battery post.
through a circumferential groove. The groove is
machined at the rear of the camshaft. Timing of the
camshaft is accomplished by aligning marks on the
crankshaft gear, idler gear, and camshaft gear with
each other.
The injector lobe on the camshaft has a modified

profile. The modified profile produces multiple
injections.
20 KENR6907
Unlike many electronic systems of the past, this

engine is tolerant to common external sources of
electrical noise. Buzzers that use electrical energy
can cause disruptions in the power supply. If buzzers
are used anywhere on the machine, the engine
electronics should be powered directly from the
battery system through a dedicated relay. The engine
electronics should not be powered through a common
power bus with other keyswitch activated devices.
Engine Electrical System

The electrical system has the following separate
circuits:
Charging
Starting (If equipped)
Accessories with low amperage
g01407491
Illustration 19 The charging circuit is in operation when the engine
(1) Starting motor to engine block is running. An alternator makes electricity for the
(2) Starting motor to battery negative charging circuit. A voltage regulator in the circuit
controls the electrical output in order to keep the
The engine must have a wire ground to the battery. battery at full charge.
Ground wires or ground straps should be combined The starting circuit is activated only when the start
at ground studs that are only for ground use. All of switch is activated.
the grounds should be tight and free of corrosion.
All of the ground paths must be capable of carrying Charging System Components
any likely current faults. An AWG #0 or larger wire is
recommended for the grounding strap to the cylinder Alternator
head.
The alternator is driven by a belt from the crankshaft
The engine alternator should be battery ground pulley. This alternator is a three-phase, self-rectifying
with a wire size that is capable of managing the full charging unit, and the regulator is part of the
charging current of the alternator. alternator.
The alternator design has no need for slip rings

NOTICE
and the only part that has movement is the rotor
When boost starting an engine, the instructions in Op-
assembly. All conductors that carry current are
eration and Maintenance Manual, Engine Starting
stationary. The following conductors are in the circuit:
should be followed in order to correctly start the en-
gine.
Field winding
This engine is equipped with a 24 volt starting system.
Only equal voltage for boost starting should be used. Stator windings
The use of a higher voltage will damage the electrical
system. Six rectifying diodes
The Electronic Control Module (ECM) must be dis- Regulator circuit components
connected at the J1/P1 and J2/P2 locations before
welding on the application.
The engine has several input components which are

electronic. These components require an operating
voltage.
KENR6907 21
The rotor assembly has many magnetic poles that

look like fingers with air space between each of the
opposite poles. The poles have residual magnetism.
The residual magnetism produces a small magnetic
field between the poles. As the rotor assembly
begins to turn between the field winding and the
stator windings, a small amount of alternating current
(AC) is produced. The AC current is produced in the
stator windings from the small magnetic field. The
AC current is changed to direct current (DC) when
the AC current passes through the diodes of the
rectifier bridge. The current is used for the following
applications:
Charging the battery g00425518

Illustration 20
Supplying the accessory circuit that has the low Typical alternator components
amperage (1) Regulator
(2) Roller bearing
(3) Stator winding
Strengthening the magnetic field (4) Ball bearing
(5) Rectifier bridge
The first two applications use the majority of the (6) Field winding
current. As the DC current increases through the (7) Rotor assembly
field windings, the strength of the magnetic field is (8) Fan
increased. As the magnetic field becomes stronger,
more AC current is produced in the stator windings. Starting System Components
The increased speed of the rotor assembly also
increases the current and voltage output of the
alternator.
Starting Solenoid
The voltage regulator is a solid-state electronic

switch. The voltage regulator senses the voltage in
the system. The voltage regulator switches ON and
OFF many times per second in order to control the
field current for the alternator. The alternator uses
the field current in order to generate the required
voltage output.
NOTICE
Never operate the alternator without the battery in the
circuit. Making or breaking an alternator connection
with heavy load on the circuit can cause damage to
the regulator.
g00317613
Illustration 21
Typical starting solenoid
22 KENR6907
When two sets of solenoid windings are used, the

windings are called the hold-in winding and the
pull-in winding. Both sets of windings have the same
number of turns around the cylinder, but the pull-in
winding uses a wire with a larger diameter. The wire
with a larger diameter produces a greater magnetic
field (1). When the start switch is closed, part of the
current flows from the battery through the hold-in
windings. The rest of the current flows through the
pull-in windings to the motor terminal. The current
then flows through the motor to ground. Solenoid
(2)is fully activated when the connection across the
battery and the motor terminal is complete. When
solenoid (2) is fully activated, the current is shut
g00425521
off through the pull-in windings. At this point, only
Illustration 22 the smaller hold-in windings are in operation. The
Typical starting motor components hold-in windings operate for the duration of time that
(1) Field is required in order to start the engine. Solenoid (2)
(2) Solenoid will now draw less current from the battery, and the
(3) Clutch heat that is generated by solenoid (2) will be kept at
(4) Pinion
(5) Commutator an acceptable level.
(6) Brush assembly
(7) Armature
The starting solenoid (2) is an electromagnetic switch

that performs the following basic operations:
The starting solenoid (2) closes the high current

starting motor circuit with a low current start switch
circuit.
The starting solenoid (2) engages the pinion of the

starting motor (4) with the ring gear.
Solenoid (2) has windings (one or two sets) around

a hollow cylinder. A plunger that is spring loaded is
inside the cylinder. The plunger can move forward
and backward. When the start switch is closed and
electricity is sent through the windings, a magnetic
field (1) is made. The magnetic field (1) pulls the
plunger forward in the cylinder. This moves the shift
lever in order to engage the pinion drive gear with the
ring gear. The front end of the plunger then makes
contact across the battery and motor terminals of
solenoid (2). Next, the starting motor begins to turn
the flywheel of the engine.
When the start switch is opened, current no longer

flows through the windings. The spring now pushes
the plunger back to the original position. At the same
time, the spring moves the pinion gear away from
the flywheel.
KENR6907 23

Section

i02773145
Belt Tension Chart
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Belt Tension Gauge 1
Table 2
Fan Drive Belt Tension Chart

Gauge Reading
Size of Belt Top Width of Belt
Initial Belt Tension(1) Used Belt Tension(2)
5 VX 16 mm (0.629 inch) 868 N (195 lb) 800 N (180 lb)
Measure the tension of the belt that is farthest from the engine.
(1) Initial Belt Tension refers to a new belt.
(2) Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.
Install Tooling (A) at the center of the longest free

length of belt and check the tension on the belt.
Check and adjust the tension on the tightest belt.
To adjust the belt tension, refer to Disassembly and
Assembly, Belt Tightener - Install.
Note: When the belts are replaced, always replace

the belts as a set.
Table 3
Alternator Belt Tension Chart
Gauge Reading
Size of Belt Top Width of Belt
Initial Belt Tension(1) Used Belt Tension(2)
3 VX 9.7 mm (0.381 inch) 400 N (89.9240 lb) 267 N (60.0243 lb)
Measure the tension of the belt that is farthest from the engine.
(1) Initial Belt Tension refers to a new belt.
(2) Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.
Install Tooling (A) at the center of the longest free

length of belt and check the tension on the belt.
Check and adjust the tension on the tightest belt.
To adjust the belt tension, refer to Disassembly and
Assembly, Alternator - Install.
24 KENR6907
Fuel System Elbows

Relief valves
i02773147
Check valves
Fuel System - Inspect
Observe the fuel flow during engine cranking.
Look for air bubbles in the fuel. If there is no fuel
in the sight gauge, prime the fuel system. Refer to
A problem with the components that send fuel to System Operation, Testing and Adjusting, Fuel
the engine can cause low fuel pressure. This can System - Prime for more information. If the engine
decrease engine performance. starts, check for air in the fuel at varying engine
speeds. When possible, operate the engine under
1. Check the fuel level in the fuel tank. Ensure that the conditions which have been suspect of air in
the vent in the fuel cap is not filled with dirt. the fuel.
2. Check all fuel lines for fuel leakage. The fuel lines
must be free from restrictions and faulty bends.
Verify that the fuel return line is not collapsed.
3. Install a new fuel filter.
4. Cut the old filter open with a suitable filter cutter.

Inspect the filter for excess contamination.
Determine the source of the contamination. Make
the necessary repairs.
5. Service the primary fuel filter (if equipped).
6. Operate the hand priming pump (if equipped).

If excessive resistance is felt, inspect the fuel
pressure regulating valve. If uneven resistance
is felt, test for air in the fuel. Refer to Systems
Operation, Testing and Adjusting, Air in Fuel -
Test for more information.
7. Remove any air that may be in the fuel system. g01096678

Illustration 23
Refer to Systems Operation, Testing and
Adjusting, Fuel System - Prime. (1) A steady stream of small bubbles with a diameter of
approximately 1.60 mm (0.063 inch) is an acceptable amount
of air in the fuel.
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch)
i02773148 are also acceptable if there is two seconds to three seconds
Air in Fuel - Test intervals between bubbles.
(3) Excessive air bubbles in the fuel are not acceptable.
3. If excessive air is seen in the sight gauge in the

fuel return line, install a second sight gauge at
This procedure checks for air in the fuel. This the inlet to the fuel transfer pump. If a second
procedure also assists in finding the source of the air. sight gauge is not available, move the sight gauge
from the fuel return line and install the sight gauge
1. Examine the fuel system for leaks. Ensure that at the inlet to the fuel transfer pump. Observe
the fuel line fittings are properly tightened. Check the fuel flow during engine cranking. Look for air
the fuel level in the fuel tank. Air can enter the bubbles in the fuel. If the engine starts, check for
fuel system on the suction side between the fuel air in the fuel at varying engine speeds.
transfer pump and the fuel tank.
If excessive air is not seen at the inlet to the fuel
2. Install a suitable fuel flow tube with a visual sight transfer pump, the air is entering the system after
gauge in the fuel return line. When possible, install the fuel transfer pump. Proceed to Step 6.
the sight gauge in a straight section of the fuel line
that is at least 304.8 mm (12 inches) long. Do not
install the sight gauge near the following devices
that create turbulence:
KENR6907 25
If excessive air is seen at the inlet to the fuel i02799187

transfer pump, air is entering through the suction
side of the fuel system. Electronic Unit Injector - Adjust
To avoid personal injury, always wear eye and face

protection when using pressurized air.
4. Pressurize the fuel tank to the recommendations

of the OEM in order to avoid damage to the fuel
tank. Check for leaks in the fuel lines between
the fuel tank and the fuel transfer pump. Repair
any leaks that are found. Check the fuel pressure
in order to ensure that the fuel transfer pump is
operating properly. For information about checking
the fuel pressure, see System Operation, Testing
and Adjusting, Fuel System Pressure - Test.
5. If the source of the air is not found, disconnect

the supply line from the fuel tank and connect an
external fuel supply to the inlet of the fuel transfer
pump. If this corrects the problem, repair the fuel
tank or the stand pipe in the fuel tank.
g01126970
6. If the injector sleeve is worn or damaged, Illustration 24
combustion gases may be leaking into the fuel Injector Mechanism
system. Also, if the O-rings on the injector sleeves (1) Rocker arm
are worn, missing, or damaged, combustion gases (2) Adjustment screw
may leak into the fuel system. (3) Locknut
Follow the procedure in order to adjust your electronic

unit injectors:
1. Put the No. 1 piston at the top center position

on the compression stroke. Refer to Systems
Operation/Testing and Adjusting, Finding Top
Center Position for No. 1 Piston.
a. Cylinder 3, 5, and 6 can be adjusted with

cylinder 1 at TC compression stroke.
b. Loosen the jam nut.
c. Turn the adjustment screw until the screw

makes contact with the electronic unit injector.
d. Turn the adjustment screw through 180

degrees in a clockwise direction.
e. Tighten the jam nut to a torque of 55 10 Nm

(41 7 lb ft).
2. Rotate the engine in the normal operating direction

by 360 degrees. Cylinder 1 will now be on TC
exhaust stroke.
a. Cylinder 1, 2, and 4 can be adjusted with

cylinder 1 at TC exhaust stroke.
b. Loosen the jam nut.
26 KENR6907
c. Turn the adjustment screw until the screw 5. Remove the suspect unit injector and check the
makes contact with the electronic unit injector. unit injector for signs of exposure to coolant. Refer
to Disassembly and Assembly, Electronic Unit
d. Turn the adjustment screw through 180 Injector - Remove. Exposure to coolant will cause
degrees in a clockwise direction. rust to form on the injector. If the unit injector
shows signs of exposure to coolant, remove the
e. Tighten the jam nut to a torque of 55 10 Nm injector sleeve and inspect the injector sleeve.
(41 7 lb ft). Refer to Disassembly and Assembly, Electronic
Unit Injector Sleeve - Remove. Replace the
injector sleeve if the injector sleeve is damaged.
i02773150
Check the unit injector for an excessive brown
Electronic Unit Injector - Test discoloration that extends beyond the injector tip. If
excessive discoloration is found, check the quality
of the fuel. Refer to Systems Operation, Testing
and Adjusting, Fuel Quality - Test. Replace the
This procedure assists in identifying the cause for seals on the injector and reinstall the injector.
an injector misfiring. Perform this procedure only Refer to Disassembly and Assembly, Electronic
after performing the Cylinder Cutout Test. Refer to Unit Injector - Install. Also refer to Disassembly
Troubleshooting for more information. and Assembly, Electronic Unit Injector Sleeve -
Install.
1. Check for air in the fuel, if this procedure has
not already been performed. Refer to Systems 6. If the problem is not resolved, replace the suspect
Operation, Testing and Adjusting, Air in Fuel - injector with a new injector.
Test.
i02793631
Finding Top Center Position

Electrical shock hazard. The electronic unit injec- for No. 1 Piston
tor system uses 90-120 volts.
2. Remove the valve cover and look for broken Table 4

parts. Repair any broken parts or replace any
broken parts that are found. Inspect all wiring to Required Tools
the solenoids. Look for loose connections. Also Tool Part Number Part Description Qty
look for frayed wires or broken wires. Ensure
that the connector for the unit injector solenoid A CH11148 Engine turning tool 1
is properly connected. Perform a pull test on B CVT0015 Adapter 1
each of the wires. Refer to Troubleshooting,
Electrical Connectors - Inspect. Inspect the posts C 27610286 Timing pin 1
of the solenoid for arcing. If arcing or evidence
of arcing is found, remove the cap assembly.
Refer to Disassembly and Assembly, Electronic
Unit Injector - Remove. Clean the connecting
posts. Reinstall the cap assembly and tighten
the solenoid nuts to a torque of 2.5 0.25 Nm
(22 2 lb in). Refer to Disassembly and Assembly,
Electronic Unit Injector - Install.
3. Check the valve lash setting for the cylinder of the

suspect unit injector. Refer to Systems Operation,
Testing and Adjusting, Engine Valve Lash -
Inspect/Adjust.
4. Ensure that the bolt that holds the unit injector is

tightened to the proper torque. If necessary, loosen
the bolt that holds the unit injector and tighten the
bolt to a torque of 55 10 Nm (40.6 7.4 lb ft).
KENR6907 27
4. The inlet and exhaust valves for the No. 1

cylinder are fully closed if No. 1 piston is on the
compression stroke and the rocker arms can be
moved by hand. If the rocker arms cannot be
moved and the valves are slightly open, the No. 1
piston is on the exhaust stroke.
Note: When the actual stroke position is identified,

and the other stroke position is needed, remove
Tooling (C) from the hole in the flywheel. Then turn
the flywheel by 360 degrees in the direction of normal
engine rotation and reinstall Tooling (C) into the hole
in the flywheel.
Note: Never turn the engine by the crankshaft

vibration damper. The crankshaft vibration damper is
a precision part. Major engine failure may be caused
by damage to the crankshaft vibration damper.
i02773153
Fuel Quality - Test
Ensure that all adjustments and repairs are performed

by authorized personnel that have had the correct
g01395098 training.
Illustration 25
(1) Flywheel housing
(2) Timing hole plug
Use the following procedure to test for problems
(3) Cover bolt regarding fuel quality:
(4) Cover
1. Determine if water and/or contaminants are
1. Remove two bolts (3) and remove cover (4) from present in the fuel. Check the water separator (if
flywheel housing (1) in order to open the turning equipped). If a water separator is not present,
hole. proceed to Step 2. Drain the water separator, if
necessary. A full fuel tank minimizes the potential
2. Insert Tooling (B) into the timing hole (2). for overnight condensation.
The timing hole is located approximately
127 to 152 mm (5.0 to 6.0 inch) above the turning Note: A water separator can appear to be full of fuel
hole for Tooling (A) in the flywheel housing. Use when the water separator is actually full of water.
Tooling (A) in order to turn the engine flywheel.
Turn the flywheel in the direction of engine 2. Determine if contaminants are present in the
rotation. The direction of engine rotation is fuel. Remove a sample of fuel from the bottom
counterclockwise, as the engine is viewed from of the fuel tank. Visually inspect the fuel sample
the flywheel end. Turn the flywheel until Tooling for contaminants. The color of the fuel is not
(C) engages with the hole in the flywheel. necessarily an indication of fuel quality. However,
fuel that is black, brown, and/or similar to sludge
Note: If the flywheel is turned beyond the point of can be an indication of the growth of bacteria or
engagement, the flywheel must be turned in the oil contamination. In cold temperatures, cloudy
direction that is reverse of normal engine rotation. fuel indicates that the fuel may not be suitable for
Turn the flywheel by approximately 30 degrees. Then operating conditions.
turn the flywheel in the direction of normal rotation
until Tooling (C) engages with the hole in the flywheel. Refer to Operation and Maintenance Manual,
This procedure removes the play from the gears Fluid Recommendations for more information.
when the No. 1 piston is at the top center position.
3. Remove the valve mechanism cover from the

engine.
28 KENR6907
3. If fuel quality is still suspected as a possible

cause to problems regarding engine performance,
disconnect the fuel inlet line, and temporarily
operate the engine from a separate source of
fuel that is known to be good. This will determine
if the problem is caused by fuel quality. If fuel
quality is determined to be the problem, drain the
fuel system and replace the fuel filters. Engine
performance can be affected by the following
characteristics:
Cetane number of the fuel

Air in the fuel
Other fuel characteristics
i02788192
Fuel System - Prime
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
g01394181
Illustration 26
NOTICE
Typical example
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon- 3. Loosen the union of the pipe for the fuel(1).
nected fuel system component.
Note: Do not remove the union completely. Open the
union enough to allow the air that is trapped in the
Note: This procedure is most common when the cylinder head to be purged from the fuel system.
engine has run out of fuel.
4. Unlock and operate the hand priming pump (2).
1. Turn the ignition switch to the OFF position. Use a suitable container to collect excess fuel.
2. Fill the fuel tank(s) with clean diesel fuel. 5. Tighten the union of the pipe for the fuel (1).
6. Operate the hand priming pump until a strong

pressure is felt on the pump. Push the priming
pump plunger inward. Tighten the plunger by hand
and start the engine.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for 30
seconds before cranking the engine again.
7. If the engine will not start, allow the starting motor

to cool for 30 seconds. Repeat steps 3 to 6 in
order to operate the engine.
8. Continue to eliminate air from the fuel system if

these events occur:
KENR6907 29
The engine starts, but the engine does not run Stuck fuel pressure regulating valve in the fuel
evenly. transfer pump
The engine starts, but the engine continues to Pinched fuel return line
misfire or smoke.
9. Run the engine with no load until the engine runs

Checking Fuel Pressure
smoothly. Table 5
Required Tools
i02788197
Fuel System Pressure - Test A - Pressure Gauge 1
Low Fuel Pressure

Low fuel pressure can cause low power. Low fuel
pressure can also cause cavitation of the fuel
which can damage the fuel injectors. The following
conditions can cause low fuel pressure:
Plugged fuel filters

Debris in the check valves for the fuel priming
pump
Debris in the pressure regulating valve

Partially open check valve
Sticking or worn fuel pressure regulating valve in
the fuel transfer pump
Severe wear on return fuel pressure regulating

valve in the fuel filter base
Worn gears in the fuel transfer pump

Pinched fuel lines or undersized fuel lines
g01394979
Illustration 27
Old fuel lines that have a reduced interior diameter Typical example
that was caused by swelling
To check the fuel transfer pump pressure, remove
Fuel lines with deteriorating interior surfaces the hose assembly (1). Install a pressure gauge, and
start the engine.
Pinched fuel line fittings or undersized fuel line
fittings
Fuel Pressure Readings
Debris in the fuel tank, fuel lines, or fuel system
components that create restrictions The typical fuel pressure of the engine at operating
temperature can vary. When the engine is under
load, the fuel pressure can be 550 kPa (80 psi).
High Fuel Pressure
The performance of the unit injector deteriorates
Excessive fuel pressure can cause fuel filter gaskets when the fuel pressure drops below 241 kPa (35 psi).
to rupture. The following conditions can cause high Low power complaints and erratic operation can
fuel pressure: occur in this situation. Check for a plugged fuel filter
or air in the fuel lines as possible causes for these
Plugged orifices in the fuel pressure regulating complaints before replacing fuel system components.
valve
30 KENR6907
i02788237 Note: The electronic injection timing must be

calibrated after reassembly of the front gear train.
Gear Group (Front) - Time Refer to Troubleshooting, Engine Speed/Timing
Sensor - Calibrate.
g01126079
Illustration 28
Front Gear Group
(1) Camshaft gear and timing reference ring
(2) Timing marks
(3) Idler gear
(4) Crankshaft gear
The basis for correct fuel injection timing and valve

mechanism operation is determined by the timing
reference ring and the alignment of the front gear
group. The timing reference ring is located on the end
of the camshaft. The timing reference ring is used to
measure crankshaft rotation. During installation of
the front gear, timing marks (2) on idler gear (3) must
be in alignment with the timing marks on crankshaft
gear (4) and the timing marks on camshaft gear (1).
Refer to Disassembly and Assembly, Gear Group

(Front) - Remove and Disassembly and Assembly,
Gear Group (Front) - Install.
Note: If timing reference ring (1) is installed backward

the engine will not start.
Check for proper alignment of the camshaft gear and

timing reference ring (1) on the camshaft assembly.
Inspect the key between the timing reference ring
and the camshaft gear. Check the teeth on the timing
ring. The teeth should not be defaced. The teeth
should have sharp clean edges and the teeth should
be free of contaminants.
KENR6907 31
Air Inlet and Exhaust

System
i02788810
Air Inlet and Exhaust System

- Inspect
A general visual inspection should be made to the air

inlet and exhaust system. Make sure that there are
no signs of leaks in the system.
Table 6
Required Tools
- Differential Pressure
A 1
Gauge
Air Inlet Restriction

There will be a reduction in the performance of the
engine if there is a restriction in the air inlet system.
1. Inspect the engine air cleaner inlet and ducting

in order to ensure that the passageway is not
blocked or collapsed.
2. Inspect the engine air cleaner element. Replace

a dirty engine air cleaner element with a clean
engine air cleaner element.
3. Check for dirt tracks on the clean side of the

engine air cleaner element. If dirt tracks are
observed, contaminants are flowing past the
engine air cleaner element and/or the seal for the
engine air cleaner element.
Hot engine components can cause injury from

burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
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.
4. Use Tooling (A) for this test.
32 KENR6907
g01417906
Illustration 29
Air inlet piping
(1) Air Cleaner (2) Test location (3) Turbocharger
a. Connect the vacuum port of the differential i02788812

pressure gauge to test location (2). Test
location (2) may be located anywhere along the Turbocharger - Inspect
air inlet piping after air cleaner (1) but before
turbocharger (3).
b. Leave the pressure port of the differential

pressure gauge open to the atmosphere.
Hot engine components can cause injury from
c. Start the engine. Run the engine at full load. burns. Before performing maintenance on the
engine, allow the engine and the components to
d. Record the value. cool.
e. Compare the result from step 4.d to the

appropriate values that follow.
The air flow through a used engine air cleaner Personal injury can result from rotating and mov-
may have a restriction. The air flow through a ing parts.
plugged engine air cleaner will be restricted to some
magnitude. In either case, the restriction must not be Stay clear of all rotating and moving parts.
more than the following amount:
Never attempt adjustments while the machine is
Maximum restriction ........ 6.2 kPa (25 in of H2O) moving or the engine is running unless otherwise
specified.
The air flow through a new engine air cleaner element
must not have a restriction of more than the following The machine must be parked on a level surface
amount: and the engine stopped.
Maximum restriction ........ 3.7 kPa (15 in of H2O)
KENR6907 33
4. Inspect the compressor and the compressor

NOTICE wheel housing for oil leakage. An oil leak from
Keep all parts clean from contaminants. the compressor may deposit oil in the aftercooler.
Drain and clean the aftercooler if you find oil in
Contaminants may cause rapid wear and shortened the aftercooler.
component life.
a. Check the oil level in the crankcase. If the oil
level is too high, adjust the oil level.
NOTICE
Care must be taken to ensure that fluids are contained b. Inspect the air cleaner element for restriction. If
during performance of inspection, maintenance, test- restriction is found, correct the problem.
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- c. Inspect the engine crankcase breather. Clean
ing any compartment or disassembling any compo- the engine crankcase breather or replace
nent containing fluids. the engine crankcase breather if the engine
crankcase breather is plugged.
Dispose of all fluids according to local regulations and
mandates. d. Remove the oil drain line for the turbocharger.
Inspect the drain opening. Inspect the oil drain
Before you begin inspection of the turbocharger, line. Inspect the area between the bearings of
be sure that the inlet air restriction is within the the rotating assembly shaft. Look for oil sludge.
specifications for your engine. Be sure that the Inspect the oil drain hole for oil sludge. Inspect
exhaust system restriction is within the specifications the oil drain line for oil sludge in the drain
for your engine. Refer to Systems Operation, Testing line. If necessary, clean the rotating assembly
and Adjusting, Air Inlet and Exhaust System - shaft. If necessary, clean the oil drain hole. If
Inspect. necessary, clean the oil drain line.
The condition of the turbocharger will have definite e. If Steps 4.a through 4.d did not reveal the
effects on engine performance. Use the following source of the oil leakage, the turbocharger has
inspections and procedures to determine the internal damage. Replace the turbocharger.
condition of the turbocharger.
Inspection of the Turbine Wheel
Inspection of the Compressor and the Compressor and the Turbine Housing
Housing
Remove the air piping from the turbine housing.
Inspection of the Turbine Wheel and the Turbine
Housing
Inspection of the Compressor and

the Compressor Housing
Remove air piping from the compressor inlet.
1. Inspect the compressor wheel for damage from a

foreign object. If there is damage, determine the
source of the foreign object. As required, clean
the inlet system and repair the intake system.
Replace the turbocharger. If there is no damage,
go to Step 3.
2. Clean the compressor wheel and clean the

compressor housing if you find buildup of foreign
material. If there is no buildup of foreign material,
go to Step 3.
3. Turn the rotating assembly by hand. While you

turn the assembly, push the assembly sideways . g00763164
Illustration 30
The assembly should turn freely. The compressor Typical example
wheel should not rub the compressor housing. (1) Turbine Housing
Replace the turbocharger if the compressor wheel (2) Turbine Wheel
rubs the compressor wheel housing. If there is no (3) Turbocharger
rubbing or scraping, go to Step 4.
34 KENR6907
1. Inspect the turbine for damage by a foreign object. i02788813

If there is damage, determine the source of the
foreign object. Replace turbocharger (3). If there Exhaust Temperature - Test
is no damage, go to Step 2.
2. Inspect turbine wheel (2) for buildup of carbon and

Table 7
other foreign material. Inspect turbine housing (1)
for buildup of carbon and foreign material. Clean Required Tools
turbine wheel (2) and clean turbine housing (1) if
you find buildup of carbon or foreign material. If
there is no buildup of carbon or foreign material, A - Infrared Thermometer 1
go to Step 3.
When the engine runs, the temperature of an exhaust
3. Turn the rotating assembly by hand. While you manifold port can indicate the condition of a fuel
turn the assembly, push the assembly sideways. injection nozzle.
The assembly should turn freely. Turbine wheel (2)
should not rub turbine wheel housing (1). Replace A low temperature indicates that no fuel is flowing to
turbocharger (3) if turbine wheel (2) rubs turbine the cylinder. An inoperative fuel injection nozzle or
housing (1). If there is no rubbing or scraping, go a problem with the fuel injection pump could cause
to Step 4. this low temperature.
4. Inspect the turbine and turbine housing (1) for oil A very high temperature can indicate that too much
leakage. Inspect the turbine and turbine housing fuel is flowing to the cylinder. A malfunctioning
(1) for oil coking. Some oil coking may be cleaned. fuel injection nozzle could cause this very high
Heavy oil coking may require replacement of temperature.
the turbocharger. If the oil is coming from the
turbocharger center housing go to Step 4.a. Use Tooling (A) to check exhaust temperature.
a. Remove the oil drain line for the turbocharger.
Inspect the drain opening. Inspect the area i02788814
between the bearings of the rotating assembly
shaft. Look for oil sludge. Inspect the oil drain Engine Crankcase Pressure
hole for oil sludge. Inspect the oil drain line
for oil sludge. If necessary, clean the rotating
(Blowby) - Test
assembly shaft. If necessary, clean the drain
opening. If necessary, clean the drain line.
Table 8
b. If crankcase pressure is high, or if the oil drain
Required Tools
is restricted, pressure in the center housing
may be greater than the pressure of turbine Part
housing (1). Oil flow may be forced in the wrong Tool Number Part Name Quantity
direction and the oil may not drain. Check the -
A Pressure Gauge 1
crankcase pressure and correct any problems.
c. If the oil drain line is damaged, replace the oil Damaged pistons or rings can cause too much
drain line. pressure in the crankcase. This condition will cause
the engine to run rough. There will be more than the
d. Check the routing of the oil drain line. Eliminate normal amount of fumes (blowby) rising from the
any sharp restrictive bends. Make sure that crankcase breather. The breather can then become
the oil drain line is not too close to the engine restricted in a very short time, causing oil leakage
exhaust manifold. at gaskets and seals that would not normally have
leakage. Blowby can also be caused by worn valve
e. If Steps 4.a through 4.d did not reveal the guides or by a failed turbocharger seal.
source of the oil leakage, turbocharger (3) has
internal damage. Replace turbocharger (3). Install Tooling (A) to the most convenient location on
the output tube for the crankcase breather or the
breather hose. The pressure for the engine blowby
should be 0.25 kPa (1 inch of H2O).
KENR6907 35
Note: Do not use the data alone to determine if the Table 9

engine should be overhauled. Other indicators such Inlet Valves Exhaust Valves
as high oil consumption, low power, hard starting,
and excessive fuel consumption must be considered. Valve Lash 0.38 0.08 mm
0.64 0.08 mm
(Stopped (0.015 0.003
(0.025 0.003 inch)
After a new engine is used for a short time, the Engine) inch)
blowby can decrease as the rings are seated. New TC
engines should be checked for blowby during all Compression 1-2-4 1-3-5
maintenance checks. As the piston rings and cylinder Stroke
walls wear, the blowby will gradually increase.
TC Exhaust
3-5-6 2-4-6
The blowby on a worn engine may be two times or Stroke(1)
more than the blowby of a new engine and may Firing Order 1-5-3-6-2-4(2)
indicate the need for an overhaul. (1) 360 from TC compression stroke
(2) The No. 1 cylinder is at the front of the engine.
i02788818
If the measurement is not within this range, an
Engine Valve Lash - adjustment is necessary. Refer to Valve Lash
Inspect/Adjust Adjustment for the proper procedure.
Valve Lash Adjustment
To prevent possible injury, do not use the starter

to turn the flywheel.
Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-
suring valve clearance.
This engine uses high voltage to control the fuel

injectors. g00935559
Illustration 31
Disconnect electronic fuel injector enable circuit Cylinder and valve location
connector to prevent personal injury. (A) Exhaust valves
(B) Inlet valves
Do not come in contact with the fuel injector ter-
minals while the engine is running. Use the following procedure to adjust the valve lash:
1. Put the No. 1 piston at the top center position

Note: Valve lash is measured between the rocker on the compression stroke. Refer to Systems
arm and the valve bridge. All measurements and Operation, Testing and Adjusting, Finding Top
adjustments must be made with the engine stopped Center Position for No. 1 Piston.
and the valves fully closed.
Table 10
Valve Lash Check Compression
Stroke for No. Inlet Valves Exhaust Valves
An adjustment is NOT NECESSARY if the 1 Piston
measurement of the valve lash is in the acceptable 0.38 0.08 mm 0.64 0.08 mm
range in Table 9. Valve Lash (0.015 0.003 (0.025 0.003
inch) inch)
Cylinders 1-2-4 1-3-5
2. Adjust the valve lash according to Table 10.
36 KENR6907
a. Lightly tap the rocker arm with a soft mallet. d. Tighten the adjustment locknut to a torque
This will ensure that the lifter roller seats of 30 7 Nm (22 5 lb ft). Do not allow
against the camshafts base circle. the adjustment screw to turn while you are
tightening the adjustment locknut. Recheck
b. Loosen the adjustment locknut. the valve lash after tightening the adjustment
locknut.
c. Place the appropriate feeler gauge between
rocker arm and the valve bridge. Then, turn 5. Remove the timing bolt from the flywheel after all
the adjustment screw in a clockwise direction. adjustments to the valve lash have been made.
Slide the feeler gauge between the rocker arm Reinstall the timing cover.
and the valve bridge. Continue turning the
adjustment screw until a slight drag is felt on Refer to Systems Operation, Testing and Adjusting,
the feeler gauge. Remove the feeler gauge. Electronic Unit Injector - Adjust.
d. Tighten the adjustment locknut to a torque

of 30 7 Nm (22 5 lb ft). Do not allow
the adjustment screw to turn while you are
tightening the adjustment locknut. Recheck
the valve lash after tightening the adjustment
locknut.
Note: If necessary, adjust the electronic unit injectors

on cylinders 3, 5 and 6. Refer to Systems Operation,
Testing and Adjusting, Electronic Unit Injector -
Adjust for the correct procedure.
3. Remove the timing pin. Turn the flywheel by 360

degrees in the direction of engine rotation. This
will put the No. 6 piston at the top center position
on the compression stroke. Install the timing pin.
Table 11
Compression
Stroke for No.6 Inlet Valves Exhaust Valves
Piston
0.38 0.08 mm 0.64 0.08 mm
Valve Lash (0.015 0.003 (0.025 0.003
inch) inch)
Cylinders 3-5-6 2-4-6
4. Adjust the valve lash according to Table 11.
a. Lightly tap the rocker arm with a soft mallet.

This will ensure that the lifter roller seats
against the camshafts base circle.
b. Loosen the adjustment locknut.
c. Place the appropriate feeler gauge between

rocker arm and the valve bridge. Then, turn
the adjustment screw in a clockwise direction.
Slide the feeler gauge between the rocker arm
and the valve bridge. Continue turning the
adjustment screw until a slight drag is felt on
the feeler gauge. Remove the feeler gauge.
KENR6907 37
Lubrication System
i02788819
Engine Oil Pressure - Test
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 service 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 g00977330

Illustration 32
component life. Oil gallery plug
(1) Plug
NOTICE
Care must be taken to ensure that fluids are contained 1. Install Tool (A) into the oil gallery plugs (1).
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to Note: Engine oil pressure to the camshaft and main
collect the fluid with suitable containers before open- bearings should be checked on each side of the
ing any compartment or disassembling any compo- cylinder block at oil gallery plugs (1).
nent containing fluids.
2. Start the engine. Refer to Operation and
Dispose of all fluids according to local regulations and Maintenance Manual, Fluid Recommendations
mandates. for the correct engine oil.
3. Record the value of the engine oil pressure when

Table 12
the engine is at operating temperature 100 C
Required Tools (212 F).
Part
Tool Number Part Name Quantity The minimum engine oil pressure should be
approximately 275 to 414 kPa (40 to 59 psi).
A - Pressure Gauge 1
4. Compare the recorded engine oil pressure with
Tool (A) measures the oil pressure in the system. 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 pressure 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.
6. If low engine oil pressure is determined, refer to

Reasons for Low Engine Oil Pressure.
38 KENR6907
7. If high engine oil pressure is determined, refer to 2. Engine oil that is contaminated with fuel or
Reason for High Engine Oil Pressure. coolant will cause low engine oil pressure. High
engine oil level in the crankcase can be an
indication of contamination. Determine the reason
Reasons for Low Engine Oil for contamination of the engine oil and make
Pressure the necessary repairs. Replace the engine oil
with the approved grade of engine oil. Refer
NOTICE to Operation and Maintenance Manual, Fluid
Keep all parts clean from contaminants. Recommendations for the correct engine oil.
Contaminants may cause rapid wear and shortened NOTICE

component life. Perkins oil filters are manufactured to Perkins speci-
fications. Use of an oil filter that is not recommended
by Perkins could result in severe damage to the en-
NOTICE
gine bearings, crankshaft, etc., as a result of the larger
Care must be taken to ensure that fluids are contained waste particles from unfiltered oil entering the engine
during performance of inspection, maintenance, test- lubricating system. Only use oil filters recommended
by Perkins.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. 3. If the engine oil bypass valves are held in the
open position, a reduction in the oil pressure can
Dispose of all fluids according to local regulations and be the result. This may be due to debris in the
mandates. engine oil. If the engine oil bypass valves are
stuck in the open position, remove each engine
oil bypass valve and clean each bypass valve
Engine oil level is low. Refer to Step 1. in order to correct this problem. You must also
clean each bypass valve bore. Install new engine
Engine oil is contaminated. Refer to Step 2. oil filters. New engine oil filters will prevent more
debris from causing this problem. For information
The engine oil bypass valves are open. Refer to on the repair of the engine oil bypass valves, refer
Step 3.
to Disassembly and Assembly, Engine Oil Filter
Base - Disassemble.
The engine lubrication system is open. Refer to
Step 4.
4. An oil line or an oil passage that is open, broken,
or disconnected will cause low engine oil pressure.
The oil pickup tube has a leak or a restricted inlet An open lubrication system could be caused by
screen. Refer to Step 5.
a piston cooling jet that is missing or damaged.
Determine the reason for an open lubrication
The engine oil pump is faulty. Refer to Step 6. system of the engine and make the necessary
repairs.
Engine Bearings have excessive clearance. Refer
to Step 7.
Note: The piston cooling jets direct engine oil toward
1. Check the engine oil level in the crankcase. The the bottom of the piston in order to cool the piston.
oil level can possibly be too far below the oil pump This also provides lubrication for the piston pin.
supply tube. This will cause the oil pump not to Breakage, a restriction or incorrect installation of the
have the ability to supply enough lubrication to the piston cooling jets will cause seizure of the piston.
engine components. If the engine oil level is low
add engine oil in order to obtain the correct engine 5. The inlet screen of the oil pickup tube for the
oil level. Refer to Operation and Maintenance engine oil pump can have a restriction. This
Manual, Fluid Recommendations for the correct restriction will cause cavitation and a loss of
engine oil. engine oil pressure. 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.
KENR6907 39
6. Check the following problems that may occur to

the engine oil pump. NOTICE
Perkins oil filters are manufactured to Perkins speci-
a. Air leakage in the supply side of the oil pump fications. Use of an oil filter that is not recommended
will also cause cavitation and loss of oil by Perkins could result in severe damage to the en-
pressure. Check the supply side of the oil pump gine bearings, crankshaft, etc., as a result of the larger
and make necessary repairs. For information waste particles from unfiltered oil entering the engine
on the repair of the engine oil pump, refer to lubricating system. Only use oil filters recommended
Disassembly and Assembly, Engine Oil Pump by Perkins.
- Remove.
b. Oil pump gears that have too much wear will i02788840
cause a reduction in oil pressure. Repair the
engine oil pump. For information on the repair Excessive Bearing Wear -
of the engine oil pump, refer to Disassembly
and Assembly, Engine Oil Pump - Remove. Inspect
7. Excessive clearance at engine bearings will
cause low engine oil pressure. Check the
engine components that have excessive bearing When some components of the engine show bearing
clearance and make the necessary repairs. 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
Pressure is enough oil pressure, but a component is worn
due to a lack of lubrication. In such a case, look at
the passage for the oil supply to the component.
NOTICE
A restriction in an oil supply passage will not allow
Keep all parts clean from contaminants.
enough lubrication to reach a component. This will
result in early wear.
Contaminants may cause rapid wear and shortened
component life.
i02788843
NOTICE Excessive Engine Oil

Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Consumption - Inspect
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. Engine Oil Leaks on the Outside of
Dispose of all fluids according to local regulations and the Engine
mandates.
Check for leakage at the seals at each end of the
crankshaft. Look for leakage at the gasket for the
Engine oil pressure will be high if the engine oil engine oil pan and all lubrication system connections.
bypass valves become stuck in the closed position Look for any engine oil that may be leaking from
and the engine oil flow is restricted. Foreign matter the crankcase breather. This can be caused by
in the engine oil system could be the cause for the combustion gas leakage around the pistons. A dirty
restriction of the oil flow and the movement of the crankcase breather will cause high pressure in the
engine oil bypass valves. If the engine oil bypass crankcase. A dirty crankcase breather will cause the
valves are stuck in the closed position, remove gaskets and the seals to leak.
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 Engine Oil Leaks into the
filters. New engine oil filters will prevent more debris Combustion Area of the Cylinders
from causing this problem. For information on the
repair of the engine oil filter bypass valve, refer to Engine oil that is leaking into the combustion area of
Disassembly and Assembly, Engine Oil Filter Base - the cylinders can be the cause of blue smoke. There
Disassemble. are several possible ways for engine oil to leak into
the combustion area of the cylinders:
Leaks between worn valve guides and valve stems
40 KENR6907
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.
i02788844
Increased Engine Oil

Temperature - Inspect
If the oil temperature is high, then check for a

restriction in the oil passages 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 valve instead of the oil cooler. The oil
temperature will increase.
Refer to Operation and Maintenance Manual, Refill

Capacities for the correct lubricating oil.
KENR6907 41
Cooling System 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
i02788847 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
(Overheating) the electric wire breaks or if the electric wire shorts
out, the gauge can show an incorrect reading.
6. Check the radiator.

Above normal coolant temperatures can be caused
by many conditions. Use the following procedure a. Check the radiator for a restriction to coolant
to determine the cause of above normal coolant flow. Check the radiator for debris, dirt, or
temperatures: 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

Personal injury can result from escaping fluid un- of the radiator core. Debris between the fins
der pressure. of the radiator core restricts air flow through
the radiator core. Refer to Systems Operation,
If a pressure indication is shown on the indicator, Testing and Adjusting, Cooling System -
push the release valve in order to relieve pressure Inspect.
before removing any hose from the radiator.
c. Ensure that the radiator size is adequate for
the application. An undersized radiator does
1. Check the coolant level in the cooling system.
not have enough area for the effective release
Refer to Operation and Maintenance Manual,
of heat. This may cause the engine to run
Cooling System Coolant Level - Check. If the
at a temperature that is higher than normal.
coolant level is too low, air will get into the cooling
The normal temperature is dependent on the
system. Air in the cooling system will cause a
ambient temperature.
reduction in coolant flow and bubbles in the
coolant. Air bubbles will keep coolant away from
7. Check the filler cap. A pressure drop in the
the engine parts, which will prevent the transfer of
radiator can cause the boiling point to be lower.
heat to the coolant. Low coolant level is caused by
This can cause the cooling system to boil. Refer
leaks or incorrectly filling the radiator.
to Systems Operation, Testing and Adjusting,
Cooling System - Test.
2. Check the mixture of antifreeze and water. Refer
to Operation and Maintenance Manual, Fluid
8. Check the fan and/or the fan shroud.
Recommendations. If the coolant mixture is
incorrect, drain the system. Put the correct mixture
a. The fan must be large enough to send air
of water, antifreeze and coolant conditioner in the
through most of the area of the radiator core.
cooling system.
Ensure that the size of the fan and the position
of the fan are adequate for the application.
3. Check for air in the cooling system. Air can enter
the cooling system in different ways. The most
b. The fan shroud must be the proper size and
common causes of air in the cooling system
the fan shroud must be positioned correctly.
are not filling the cooling system correctly and
Ensure that the size of the fan shroud and the
combustion gas leakage into the cooling system.
position of the fan shroud are adequate for the
Combustion gas can get into the system through
application.
inside cracks, a damaged cylinder head, or a
damaged cylinder head gasket. Air in the cooling
9. If the fan is belt driven, check for loose drive belts.
system causes a reduction in coolant flow and
A loose fan drive belt will cause a reduction in the
bubbles in the coolant. Air bubbles keep coolant
air flow across the radiator. Check the fan drive
away from the engine parts, which prevents the
belt for proper belt tension. Adjust the tension of
transfer of heat to the coolant.
the fan drive belt, if necessary. Refer to Systems
Operation, Testing and Adjusting, Belt Tension
4. Check the water temperature gauge. A water
Chart.
temperature gauge which does not work correctly
will not show the correct temperature. Refer
to Systems Operation, Testing and Adjusting,
Cooling System - Inspect.
42 KENR6907
10. Check the cooling system hoses and clamps. 14. Check the water temperature regulator. A water
Damaged hoses with leaks can normally be seen. temperature regulator that does not open, or
Hoses that have no visual leaks can soften during a water temperature regulator that only opens
operation. The soft areas of the hose can become part of the way can cause overheating. Refer to
kinked or crushed during operation. These areas Systems Operation, Testing and Adjusting, Water
of the hose can cause a restriction in the coolant Temperature Regulator - Test.
flow. Hoses become soft and/or get cracks
after a period of time. The inside of a hose can 15. Check the water pump. A water pump with a
deteriorate, and the loose particles of the hose damaged impeller does not pump enough coolant
can cause a restriction of the coolant flow. Refer for correct engine cooling. Remove the water
to Operation and Maintenance Manual, Hoses pump and check for damage to the impeller. Refer
and Clamps - Inspect/Replace. to Systems Operation, Testing and Adjusting,
Water Pump - Test.
11. Check for a restriction in the air inlet system.
A restriction of the air that is coming into the 16. Check the air flow through the engine
engine can cause high cylinder temperatures. compartment. The air flow through the radiator
High cylinder temperatures cause higher than comes out of the engine compartment. Ensure
normal temperatures in the cooling system. Refer that the filters, air conditioner, and similar items
to Systems Operation, Testing and Adjusting, Air are not installed in a way that prevents the free
Inlet and Exhaust System - Inspect. flow of air through the engine compartment.
a. If the measured restriction is higher than the 17. Check the aftercooler. A restriction of air flow
maximum permissible restriction, remove the through the air to air aftercooler (if equipped) can
foreign material from the engine air cleaner cause overheating. Check for debris or deposits
element or install a new engine air cleaner which would prevent the free flow of air through
element. Refer to Operation and Maintenance the aftercooler.
Manual, Engine Air Cleaner Element -
Clean/Replace. 18. Consider high outside temperatures. When
outside temperatures are too high for the rating
b. Check for a restriction in the air inlet system of the cooling system, there is not enough of a
again. temperature difference between the outside air
and coolant temperatures.
c. If the measured restriction is still higher than
the maximum permissible restriction, check the 19. Consider high altitude operation. The cooling
air inlet piping for a restriction. capacity of the cooling system goes down as
the engine is operated at higher altitudes. A
12. Check for a restriction in the exhaust system. pressurized cooling system that is large enough to
A restriction of the air that is coming out of the keep the coolant from boiling must be used.
engine can cause high cylinder temperatures.
i02788851
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
Cooling System - Inspect
the exhaust system for a restriction. Refer to
Systems Operation, Testing and Adjusting, Air
Inlet and Exhaust System - Inspect. Cooling systems that are not regularly inspected are
the cause for increased engine temperatures. Make
b. If the measured restriction is higher than the a visual inspection of the cooling system before any
maximum permissible restriction, there is a tests are performed.
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 Personal injury can result from escaping fluid un-
expansion tank. A restriction of the shunt line der pressure.
from the radiator top tank to the engine water
pump inlet will cause a reduction in water pump If a pressure indication is shown on the indicator,
efficiency. A reduction in water pump efficiency push the release valve in order to relieve pressure
will result in low coolant flow and overheating. before removing any hose from the radiator.
KENR6907 43
1. Check the coolant level in the cooling system.

Refer to Operation and Maintenance Manual,
Cooling System Coolant Level - Check.
2. 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 system and flush the system. Refill g00921815
the cooling system with the correct mixture of Illustration 33
water, antifreeze, and coolant conditioner. Refer Boiling point of water
to Operation and Maintenance Manual, Fluid
Recommendations. Remember that temperature and pressure work
together. When a diagnosis is made of a cooling
3. Look for leaks in the system. system problem, temperature and pressure must be
checked. Cooling system pressure will have an effect
Note: A small amount of coolant leakage across on the cooling system temperature. For an example,
the surface of the water pump seals is normal. This refer to Illustration 33. This will show the effect of
leakage is required in order to provide lubrication for pressure on the boiling point (steam) of water. This
this type of seal. A hole is provided in the water pump will also show the effect of height above sea level.
housing in order to allow this coolant/seal lubricant
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.
Personal injury can result from hot coolant, steam
and alkali.
4. Ensure that the air flow through the radiator does
not have a restriction. Look for bent core fins
At operating temperature, engine coolant is hot
between the folded cores of the radiator. Also, look
and under pressure. The radiator and all lines
for debris between the folded cores of the radiator.
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
5. Inspect the drive belts for the fan.
Remove filler cap slowly to relieve pressure only
6. Check for damage to the fan blades.
when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
7. Look for air or combustion gas in the cooling
system.
Cooling System Conditioner contains alkali. Avoid
contact with skin and eyes.
8. Inspect the filler cap, and check the surface that
seals the filler cap. This surface must be clean.
The coolant level must be to the correct level in order
to check the coolant system. The engine must be
i02788878
cold and the engine must not be running.
Cooling System - Test After the engine is cool, loosen the pressure cap
in order to relieve the pressure out of the cooling
system. Then remove the pressure cap.
This engine has a pressure type cooling system. A
pressure type cooling system has two advantages. The level of the coolant should not be more than
The cooling system can be operated in a safe manner 13 mm (0.5 inch) from the bottom of the filler pipe. If
at a temperature higher than the normal boiling point the cooling system is equipped with a sight glass,
(steam) of water. the coolant should be to the proper level in the sight
glass.
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.
44 KENR6907
Checking the Filler Cap Seal

Table 13 Surface for seal
Required Tools
Remove any deposits that are found on these
Tool Part Number Part Description Qty items, and remove any material that is found on
A GE50031 Pressurizing Pump 1 these items.
2. Install the filler cap onto Tooling (A).

One cause for a pressure loss in the cooling system
can be a damaged seal on the radiator filler cap. 3. Look at the gauge for the exact pressure that
opens the filler cap.
4. Compare the gauge reading with the opening

pressure that is listed on the filler cap.
5. If the filler cap is damaged, replace the filler cap.
Testing The Radiator And Cooling

System For Leaks
Table 14
Required Tools
g01096114
Illustration 34
A GE50031 Pressurizing Pump 1
Typical schematic of filler cap
(1) Sealing surface of both filler cap and radiator
Use the following procedure in order to check the
cooling system for leaks:

and alkali.
At operating temperature, engine coolant is hot and alkali.
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or At operating temperature, engine coolant is hot
steam. Any contact can cause severe burns. and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
Remove filler cap slowly to relieve pressure only steam. Any contact can cause severe burns.
enough to touch with your bare hand. Remove filler cap slowly to relieve pressure only
Cooling System Conditioner contains alkali. Avoid enough to touch with your bare hand.
Cooling System Conditioner contains alkali. Avoid
To check for the amount of pressure that opens the
filler cap, use the following procedure:
1. After the engine is cool, loosen the filler cap slowly
1. After the engine cools, carefully loosen the filler and allow pressure out of the cooling system.
cap. Slowly release the pressure from the cooling Then remove the filler cap from the radiator.
system. Then, remove the filler cap.
2. Ensure that the coolant level is above the top of
Carefully inspect the filler cap. Look for any the radiator core.
damage to the seals and to the sealing surface.
Inspect the following components for any foreign 3. Install Tooling (A) onto the radiator.
substances:
4. Take the pressure reading on the gauge to 20 kPa
(3 psi) more than the pressure on the filler cap.
Filler cap
KENR6907 45
5. Check the radiator for leakage on the outside. Coolant temperature can also be read on the display
screens of the Electronic Service Tool.
6. Check all connection points for leakage, and
check the hoses for leakage.
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 Illustration 35
g01096115
Table 15 Typical example

(1) Water manifold assembly
Required Tools
Tool Part Number Part Description Qty Remove a plug from water manifold assembly (1).
- Install Tooling (A) in the open port:
A Thermometer 1
A temperature indicator of known accuracy can also
be used to make this check.
Personal injury can result from escaping fluid un- Start the engine. Run the engine until the temperature
der pressure. reaches the desired range according to the test
thermometer. If necessary, place a cover over part of
If a pressure indication is shown on the indicator, the radiator in order to cause a restriction of the air
push the release valve in order to relieve pressure flow. The reading on the water temperature indicator
before removing any hose from the radiator. should agree with the test thermometer within the
tolerance range of the water temperature indicator.
i02788898
Making contact with a running engine can cause Water Temperature Regulator
rotating parts. - Test
Check the accuracy of the water temperature

indicator or water temperature sensor if you find Personal injury can result from escaping fluid un-
either of the following conditions: der pressure.
If a pressure indication is shown on the indicator,

The engine runs at a temperature that is too hot, push the release valve in order to relieve pressure
but a normal temperature is indicated. A loss of
coolant is found. before removing any hose from the radiator.
The engine runs at a normal temperature, but a 1. Remove the water temperature regulator from the
hot temperature is indicated. No loss of coolant is engine.
found.
46 KENR6907
2. Heat water in a suitable container until the

temperature is 98 C (208 F).
3. 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.
4. Keep the water at the correct temperature for ten

minutes.
5. 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.
i02788939
Water Pump - Test
Table 16 g01417901
Illustration 36
Required Tools Typical example
Tool Part Number Part Description Qty (1) Port
(2) Water manifold
A GE50033 Pressure Gauge 1
Perform the following procedure in order to determine
if the water pump is operating correctly:
1. Remove one plug from port (1).

Making contact with a running engine can cause
2. Install Tooling (A) in port (1).
rotating parts.
3. Start the engine. Run the engine until the
coolant is at operating temperature. Refer to
Specifications, Water Temperature Regulator for
further information.
4. Note the water pump pressure. The water pump

pressure should be 100 to 125 kPa (15 to 18 psi).
KENR6907 47
Basic Engine Connecting rod bearings are available with smaller

inside diameters than the original size bearings.
These bearings are for crankshafts that have been
i02788973 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
Inspect the Piston and the Piston correct procedure.
Rings
i02801041
1. Check the piston for wear and other damage.
Main Bearings - Inspect
2. Check that the piston rings are free to move in the
grooves and that the rings are not broken.
Main bearings are available with smaller inside
Inspect the Clearance of the Piston diameters than the original size bearings. These
Ring bearings are for crankshafts that have been ground.
1. Remove the piston rings and clean the grooves If necessary, replace the main bearings. Refer
and the piston rings. to Disassembly and Assembly, Crankshaft Main
Bearings - Remove and Install for the correct
2. Fit new piston rings in the piston grooves. procedure.
3. Check the clearance for the piston ring by placing i02801042

a suitable feeler gauge between the piston groove
and the top of piston ring. Refer to Specifications, Cylinder Block - Inspect
Piston and Rings for the dimensions.
Inspect the Piston Ring End Gap

1. Clean all of the coolant passages and the oil
1. Clean all carbon from the top of the cylinder bores. passages.
2. Place each piston ring in the cylinder bore just 2. Check the cylinder block for cracks and damage.
below the cylinder ring ridge.
3. The top deck of the cylinder block must not be
3. Use a suitable feeler gauge to measure piston machined. This will affect the depth of the cylinder
ring end gap. Refer to Specifications, Piston and liner flange and the piston height above the
Rings for the dimensions. cylinder block.
Note: The coil spring must be removed from the oil 4. Check the front camshaft bearing for wear. Refer
control ring before the gap of the oil control ring is to Specifications, Camshaft Bearings for the
measured. 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
i02799220 oil hole in the new bearing faces the front of the
block. The oil hole in the bearing must be aligned
Connecting Rod Bearings - with the oil hole in the cylinder block. The bearing
Inspect 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.
48 KENR6907
i02846965 Table 18
Cylinder Liner Projection - Specifications
Inspect Liner Projection

0.06 to 0.18 mm
( 0.0024 to 0.0071 inch)
Maximum Variation in
0.050 mm (0.0020 inch)
Each Liner
Table 17
Maximum Average
Required Tools Variation Between 0.08 mm (0.0031 inch)
Adjacent Liners
Maximum Variation
- Clamp bolt (M16 x 2 0.100 mm (0.0040 inch)
A 6 Between All 6 Liners
mm)
B GE50006 Clamp washer 6
9. If a liner does not meet the recommended cylinder
C GE50007 Clamp washer 6 liner projection specification, check the following
parts:
Cylinder liner
D GE50002 1
projection tool
The depth of the cylinder block bore should be
100.00 0.03 mm (3.937 0.001 inch).
1. Clean the cylinder liner flange and the cylinder
block surface. Remove any nicks on the top of the The liner flange should be 100.12 0.03 mm
cylinder block (1). (3.942 0.001 inch).
2. Install the cylinder liners to the cylinder block If the dimensions for the liner flange do not
without seals or bands. Ensure that the cylinder match the specifications, replace the liner. Then
liners are installed to the original positions. repeat the liner projection measurements. If the
dimensions for the depth of the cylinder block
bore do not match the specifications, replace the
cylinder block. Then repeat the liner projection
measurements.
g01456150
Illustration 37
3. Install Tooling (B) and Tooling (C) to Tooling (A).

Install Tooling (A) around the liner (2). Refer to
illustration 37.
4. Tighten the clamp bolts to a torque of 14 Nm

(10 lb ft).
5. Use Tooling (D) to measure the cylinder liner

projection at "A", "B", "C" and "D". Refer to
illustration 38.
6. Record the measurements for the cylinder.
7. Repeat steps 3 to 6 for each cylinder.
8. Add the four readings for each cylinder. Divide the

sum by four in order to find the average.
KENR6907 49
g00443044
Illustration 38
50 KENR6907
i02801049 Bore Runout (Radial Eccentricity)

Flywheel - Inspect of the Flywheel
Table 20
Required Tools
Face Runout (Axial Eccentricity) of Tool Part Number Part Description Qty
the Flywheel 21825617 Dial Gauge 1
A
Table 19 - Magnetic Base 1
Required Tools
21825617 Dial Gauge 1
A
- Holder 1
g01278054
Illustration 40
Typical example
1. Install Tooling (A). Refer to illustration 40.
2. Set the dial indicator to read 0.0 mm (0.00 inch).

g00286049
Illustration 39
Typical example 3. Turn the flywheel at intervals of 45 degrees and
read the dial indicator.
1. Install Tooling (A). Refer to illustration 39. Always
put a force on the crankshaft in the same direction 4. Take the measurements at all four points. The
before the dial indicator is read. This will remove difference between the lower measurements and
any crankshaft end clearance. the higher measurements that are performed at
all four points must not be more than 0.15 mm
2. Set the dial indicator to read 0.0 mm (0.00 inch). (0.006 inch) for the maximum permissible face
runout (radial eccentricity) of the flywheel.
3. Turn the flywheel at intervals of 45 degrees and
read the dial indicator.
4. 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.
KENR6907 51
If you use 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.
1. Install Tooling (A) to the flywheel so the anvil of the

dial indicator will contact the face of the flywheel
housing. Refer to illustration 42.
2. Use a rubber mallet and tap the crankshaft toward

the rear before the dial indicator is read at each
point.
g00286058
Illustration 41
Flywheel clutch pilot bearing bore
5. To find the runout (eccentricity) of the pilot bearing

bore, use the preceding procedure.
6. The runout (eccentricity) of the bore for the pilot

bearing in the flywheel must not exceed 0.13 mm
(0.005 inch).
i02801085
Flywheel Housing - Inspect Illustration 43

g00285932
Checking face runout of the flywheel housing
3. Turn the flywheel while the dial indicator is set at

Table 21 0.0 mm (0.00 inch) at location (A). Read the dial
Required Tools indicator at locations (B), (C) and (D).
Tool Part Number Part Description Qty 4. The difference between the lower measurements
21825617 Dial Gauge 1 and the higher measurements that are performed
A at all four points must not be more than 0.38 mm
- Holder (0.015 inch), which is the maximum permissible
face runout (axial eccentricity) of the flywheel
housing.
Face Runout (Axial Eccentricity) of
the Flywheel Housing Bore Runout (Radial Eccentricity)
of the Flywheel Housing
g00285931
Illustration 42
Typical example g00285934
Illustration 44
Typical example
52 KENR6907
1. Install Tooling (A) to the flywheel so the anvil of the 6. Turn the flywheel counterclockwise in order to
dial indicator will contact the bore of the flywheel put the dial indicator at position (C). Write the
housing. Refer to illustration 44. measurement in the chart.
7. Turn the flywheel counterclockwise in order to

put the dial indicator at position (D). Write the
measurement in the chart.
8. Add the lines together in each column.
9. Subtract the smaller number from the larger

number in column B and column D. Place this
number on line III. The result is the horizontal
eccentricity (out of round). Line III in column C is
the vertical eccentricity.
g00285932
Illustration 45
Checking bore runout of the flywheel housing
g00763974
Illustration 46
g00286046
Illustration 47
2. While the dial indicator is in the position at location
(C) adjust the dial indicator to 0.0 mm (0.00 inch). Graph for total eccentricity
Push the crankshaft upward against the top of (1) Total vertical eccentricity
the bearing. Refer to Illustration 46. Write the (2) Total horizontal eccentricity
(3) Acceptable value
measurement for bearing clearance on line 1 in (4) Unacceptable value
column (C).
10. Find the intersection of the eccentricity lines
Note: Write the measurements for the dial indicator (vertical and horizontal) in Illustration 47.
with the correct notations. This notation is necessary
for making the calculations in the chart correctly. 11. If the point of the intersection is in the Acceptable
range, the bore is in alignment. If the point of
3. Divide the measurement from Step 2 by two. Write intersection is in the Not acceptable range, the
this number on line 1 in columns (B) and (D). flywheel housing must be changed.
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.
KENR6907 53
i02801086
Vibration Damper - Check
g01401686
Illustration 48
(1) Vibration damper
(2) Crankshaft pulley
(1) Spacer for the pulley
(4) Bolts
Damage to the vibration damper or failure of the

vibration damper will increase vibrations. This will
result in damage to the crankshaft.
Replace the damper if any of the following conditions

exist:
The damper is dented, cracked, or fluid is leaking

from the damper.
The paint on the damper is discolored from

excessive heat.
The damper is bent.

The bolt holes are worn or there is a loose fit for
the bolts.
The engine has had a crankshaft failure due to

torsional forces.
NOTICE
Inspect the viscous vibration damper for signs of leak-
ing and for signs of damage to the case. Either of
these conditions can cause the weight to contact the
case. This contact can affect damper operation.
54 KENR6907
Electrical System To check for correct output of the alternator, refer to

Specifications.
i02801089 Before the start of on-engine testing, the charging

system and the battery must be checked according
Battery - Test to the following steps.
1. The battery must be at least 75 percent (1.225 Sp

Gr) of the full charge. The battery must be held
Most of the tests of the electrical system can be done tightly in place. The battery holder must not put
on the engine. The wiring insulation must be in good too much stress on the battery.
condition. The wire and cable connections must be
clean, and both components must be tight. 2. Cables between the battery, the starter, and the
engine ground must be the correct size. Wires
and cables must be free of corrosion. Wires and
cables must have cable support clamps in order to
Never disconnect any charging unit circuit or bat- prevent stress on battery connections (terminals).
tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an explo- 3. Leads, junctions, switches, and panel instruments
sion from the flammable vapor mixture of hydro- that have direct relation to the charging circuit
gen and oxygen that is released from the elec- provide correct circuit control.
trolyte through the battery outlets. Injury to per-
sonnel can be the result. 4. Inspect the drive components for the charging unit
in order to be sure that the components are free of
grease and oil. Be sure that the drive components
The battery circuit is an electrical load on the charging have the ability to operate the charging unit.
unit. The load is variable because of the condition of
the charge in the battery.
i02801092
NOTICE Electric Starting System - Test

The charging unit will be damaged if the connections
between the battery and the charging unit are broken
while the battery is being charged. Damage occurs
because the load from the battery is lost and because Most of the tests of the electrical system can be
there is an increase in charging voltage. High voltage done on the engine. The wiring insulation must be
will damage the charging unit, the regulator, and other in good condition. The wire and cable connections
electrical components. must be clean, and both components must be tight.
The battery must be fully charged. If the on-engine
test shows a defect in a component, remove the
i02813962 component for more testing.
Charging System - Test The starting system consists of the following four
components:
Keyswitch
Note: This procedure is only applicable if a charging
system is installed. Start relay
The condition of charge in the battery at each regular Starting motor solenoid
inspection will indicate whether the charging system
operates correctly. An adjustment is necessary when Starting motor
the battery is constantly in a low condition of charge
or a large amount of water is needed. Trouble with the starting system could be caused
by the battery or by charging system problems. If
Test the charging unit and the voltage regulator on the battery is suspect, refer to Troubleshooting,
the engine. Use wiring and components that are a Battery. If the starting system is suspect, refer to
permanent part of the system. This testing will give an Troubleshooting, Engine Will Not Crank.
indication of needed repair. After repairs are made,
perform a test in order to prove that the units have
been repaired to the original condition of operation.
KENR6907 55
Index Section
Index
A Excessive Bearing Wear - Inspect......................... 39
Excessive Engine Oil Consumption - Inspect........ 39
Air in Fuel - Test..................................................... 24 Engine Oil Leaks into the Combustion Area of the
Air Inlet and Exhaust System .......................... 12, 31 Cylinders .......................................................... 39
Turbocharger ..................................................... 13 Engine Oil Leaks on the Outside of the Engine.. 39
Valve System Components................................ 13 Exhaust Temperature - Test................................... 34
Air Inlet and Exhaust System - Inspect.................. 31
Air Inlet Restriction............................................. 31
F
B Finding Top Center Position for No. 1 Piston......... 26

Flywheel - Inspect.................................................. 50
Basic Engine.................................................... 18, 47 Bore Runout (Radial Eccentricity) of the
Camshaft............................................................ 19 Flywheel ........................................................... 50
Crankshaft.......................................................... 18 Face Runout (Axial Eccentricity) of the
Cylinder Block .................................................... 18 Flywheel ........................................................... 50
Pistons, Rings, and Connecting Rods ............... 18 Flywheel Housing - Inspect ................................... 51
Vibration Damper ............................................... 19 Bore Runout (Radial Eccentricity) of the Flywheel
Battery - Test ......................................................... 54 Housing ............................................................ 51
Belt Tension Chart ................................................. 23 Face Runout (Axial Eccentricity) of the Flywheel
Housing ............................................................ 51
Fuel Quality - Test.................................................. 27
C Fuel System....................................................... 8, 24
Electronic Unit Injector ........................................ 11
Charging System - Test ......................................... 54 Electronic Unit Injector Mechanism.................... 10
Connecting Rod Bearings - Inspect....................... 47 Fuel System Electronic Control Circuit ................ 9
Cooling System ............................................... 15, 41 Fuel System - Inspect............................................ 24
Coolant Flow ...................................................... 15 Fuel System - Prime .............................................. 28
Supply Manifold ................................................. 17 Fuel System Pressure - Test ................................. 29
Temperature Regulator Housing ........................ 17 Checking Fuel Pressure..................................... 29
Cooling System - Check (Overheating) ................. 41 Fuel Pressure Readings .................................... 29
Cooling System - Inspect....................................... 42 High Fuel Pressure ............................................ 29
Cooling System - Test............................................ 43 Low Fuel Pressure ............................................. 29
Checking the Filler Cap...................................... 44
Test For The Water Temperature Gauge ........... 45
Testing The Radiator And Cooling System For G
Leaks................................................................ 44
Cylinder Block - Inspect......................................... 47 Gear Group (Front) - Time..................................... 30
Cylinder Liner Projection - Inspect......................... 48 General Information................................................. 4
Cold Mode Operation........................................... 5
Starting the Engine .............................................. 5
E
Electric Starting System - Test............................... 54 I

Electrical System ............................................. 19, 54
Charging System Components .......................... 20 Important Safety Information ................................... 2
Engine Electrical System ................................... 20 Increased Engine Oil Temperature - Inspect ......... 40
Grounding Practices .......................................... 19
Starting System Components ............................ 21
Electronic Control System Components.................. 6 L
Electronic Unit Injector - Adjust ............................. 25
Electronic Unit Injector - Test................................. 26 Lubrication System .......................................... 14, 37
Engine Crankcase Pressure (Blowby) - Test ......... 34
Engine Oil Pressure - Test..................................... 37
Measuring Engine Oil Pressure ......................... 37 M
Reason for High Engine Oil Pressure ................ 39
Reasons for Low Engine Oil Pressure ............... 38 Main Bearings - Inspect......................................... 47
Engine Valve Lash - Inspect/Adjust ....................... 35
Valve Lash Adjustment ...................................... 35
Valve Lash Check .............................................. 35
P
Piston Ring Groove - Inspect................................. 47

Inspect the Clearance of the Piston Ring........... 47
Inspect the Piston and the Piston Rings ............ 47
Inspect the Piston Ring End Gap....................... 47
Systems Operation Section ..................................... 4
Table of Contents..................................................... 3
Testing and Adjusting ............................................ 23
Testing and Adjusting Section ............................... 23
Turbocharger - Inspect .......................................... 32
Inspection of the Compressor and the Compressor
Housing ............................................................ 33
Inspection of the Turbine Wheel and the Turbine
Housing ............................................................ 33
Vibration Damper - Check ..................................... 53
Water Pump - Test................................................. 46

Water Temperature Regulator - Test ..................... 45
2008 Perkins Engines Company Limited

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KENR6907

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Charging System - Test ........................................ 54

Systems Operation Section Index Section

General Information ................................................ 4 Index ..................................................................... 55

Testing and Adjusting Section

Air Inlet and Exhaust System

Systems Operation Section

The following model views show the 2206-13 Engine

Cold Mode Operation

Cold mode operation will be deactivated when any of

Coolant temperature reaches 20 C (68 F).

Electronic Control System

A electronic control module (ECM) receives the

An output component is one that is operated by a

Fuel Injection Electronic Unit Injector Mechanism

The ECM sets certain limits on the amount of fuel that

Electronic Unit Injector As the electronic unit injector mechanism transfers

When the solenoid valve assembly is energized

The duration of injection meters the fuel that is

i02769479 Air is forced from the aftercooler into inlet manifold

Turbocharger Valve System Components

The lubrication system supplies 110 C (230 F)

Cylinder head (1)

Water pump (8) pulls the coolant from the bottom of

The water pump impeller rotates at 1.17 times the

i02773143 Cylinder liners (1) are seated on a ridge (4) in the

The connecting rod is a conventional design. The

Engine oil pump Vibration Damper

Uncontrolled engine electrical circuit paths can result

To ensure correct functioning of the application and

The injector lobe on the camshaft has a modified

Unlike many electronic systems of the past, this

Engine Electrical System

The alternator design has no need for slip rings

The engine has several input components which are

The rotor assembly has many magnetic poles that

Charging the battery g00425518

The voltage regulator is a solid-state electronic

When two sets of solenoid windings are used, the

The starting solenoid (2) is an electromagnetic switch

The starting solenoid (2) closes the high current

The starting solenoid (2) engages the pinion of the

Solenoid (2) has windings (one or two sets) around

When the start switch is opened, current no longer

Testing and Adjusting

Testing and Adjusting

Belt Tension Chart

Fan Drive Belt Tension Chart

Install Tooling (A) at the center of the longest free

Note: When the belts are replaced, always replace

Install Tooling (A) at the center of the longest free

Fuel System Elbows

3. Install a new fuel filter.

4. Cut the old filter open with a suitable filter cutter.

5. Service the primary fuel filter (if equipped).

6. Operate the hand priming pump (if equipped).

7. Remove any air that may be in the fuel system. g01096678

3. If excessive air is seen in the sight gauge in the

If excessive air is seen at the inlet to the fuel i02799187

To avoid personal injury, always wear eye and face

4. Pressurize the fuel tank to the recommendations

5. If the source of the air is not found, disconnect