Perkins Engine 4006, 4008 Service Manual

TSL4184E

May 1998

User’s

Handbook

Perkins 4006 and 4008 Diesel

4006

4008

WARNING

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS MENTIONED IN THIS MANUAL.

IMPROPER OPERATION OR MAINTENANCE PROCEDURES COULD RESULT IN A SERIOUS ACCIDENT OR DAMAGE TO THE EQUIPMENT CAUSING INJURY OR DEATH.

NON-COMPLIANCE WITH THESE INSTRUCTIONS AND THOSE INCLUDED IN THE INSTALLATION MANUAL TSL4068 MAY INVALIDATE THE WARRANTY OFFERED WITH THE ENGINE.

MAKE QUITE CERTAIN THAT THE ENGINE CANNOT BE

STARTED IN ANY WAY BEFORE UNDERTAKING ANY MAINTENANCE, PARTICULARLY IN THE CASE OF AUTOMATICALLY STARTING GENERATING SETS.

4006/8 Diesel, May 1998

INTRODUCTION

The purpose of this Manual is to enable the operator to carry out routine servicing of the engine.

Before undertaking any work on the engine the appropriate section in the Workshop Manual should be read fully and completely understood prior to starting work.

The information contained within the manual is based on such information as was available at the time of going to print. In line with Perkins Engines (Stafford) Limited policy of continual development and improvement that information may change at any time without notice. The engine user should therefore ensure that he has the latest information before starting work.

The instructions contained in this manual will, provided that they are correctly carried out, ensure the safe operation of the equipment.

Users are respectfully advised that it is their responsibility to employ competent persons to operate, maintain and service the equipment in the interest of safety.

Certain overhaul operations are impracticable without the use of special tools, and those operators who are not equipped to undertake major repairs are urged to consult their Perkins distributor.

When not working on the engine, ensure that all covers, blank flanges, doors, etc., are refitted to openings to prevent the ingress of dirt, etc.

Please quote the engine type and serial number with all your enquiries. This will help us to help you. The type and serial number are on a plate fitted to the crankcase.

If any doubt exists regarding the installation, use or application of the engine, the Installation Manual should be consulted for further advice contact Applications Department at Perkins Engines (Stafford) Ltd.

Oil change intervals may be changed according to operating experience by agreement with Perkins Engines (Stafford) Limited and subject to oil analysis being carried out at regular intervals.

Please note that this 4000 Series manual also covers SE engines dispatched from the factory from 1 March 1996. A table of equivalent engine designations is given on page 2.

PERKINS COMPANIES
Perkins Group of Companies	Perkins International - North America	Moteurs Perkins SA
Perkins Engines (Peterborough) Ltd.	12025 Tech Center Drive,	Parc de Reflets - Paris Nord II,
Frank Perkins Way, Eastfield,	Livonia, Michigan 48150,	165 Avenue du Bois de la Pie, BP 40064,
Peterborough, PE1 5NA, England.	U.S.A.	95913 Roissy CDG Cedex, France
Tel.: [phone]	Tel.: [phone]	Tel.: [phone]
Telex: 32501 PERKEN G	Fax: [phone]	Fax: [phone]
Fax: [phone]

	Perkins Engines Latin America Inc
Perkins Engines (Shrewsbury) Ltd.	999 Ponce de Leon Boulevard,
Lancaster Road, Shrewsbury,	Suite 710, Coral Gables,
SY1 3NX, England.	Florida 33134, U.S.A.
Tel.: [phone]	Tel.: [phone]
Telex: 35171/2 PESL G	Telex: 32501 PERKEN G
Fax: [phone]	Fax: [phone]

Perkins Engines (Stafford) Ltd.	Perkins Engines Australia Pty Ltd
Tixall Road, Stafford, ST16 3UB, England.	Suite 2, 364 Main Street, Mornington
Tel.: [phone]	3931, Victoria, Australie.
Telex: 36156 PERKEN G	Tel.: [phone]
Fax: [phone]	Telex: 30816
	Fax: [phone]
Perkins Powerpart Distribution Centre

Perkins Engines (Far East) Pte Ltd.

39 Tuas Avenue 13,

Singapour 638999.

Tel.: [phone]

Fax: [phone]

	Frank Perkins Way,		Motori Perkins SpA
	Northbank Industrial Park, Irlam,		Via Socrate. 8,22070 Casnate
	Manchester, M44 5PP, England.		Con Bernate (Como), Italie.
	Tel.:	[phone]	Tel.:	031 56 46 25 / 031 56 46 33
	Specifications Help Desk		Telex: 380658 PERKIT I
	Tel.:	[phone]	Fax:	031 24 90 92 / 031 56 41 45
	Fax:	[phone]	Perkins Motoren GmbH
	Specifications Help Desk
	Tel.:	[phone]	D-63801 Kleinostheim,
	Telex: 32501 PERKEN G		Saalackerstrasse 4, Allemagne.
			Tel.:	(49) (6027) 5010
			Fax:	(49) (6027) 501130

In addition to the above companies, there are Perkins Distributors in most countries. Perkins Engies (Peterborough) Limited or one of the above companies can provide distributor handbooks Publication No. 1407/4/97

Publication TSL4184

Published by the Technical Publications Department, Stafford. © 1998 Perkins Engines (Stafford) Limited.

4006/8 Diesel, May 1998

1

INTRODUCTION

PERKINS ENGINES (STAFFORD) ENGINE DESIGNATIONS

4000 SERIES AND SE SERIES

EQUIVALENT TERMS

4000 SERIES	SE SERIES
4006TG	6SET
4006TWG	6SETCR
4006TWG3	6SETCR3
4006TAG1	6SETCA1
4006TAG2	6SETCA2
4006TAG3	6SETCA3
4006TEG	6SETCW
4008TWG2	8SETCR2
4008TAG	8SETCA
4008TAG1	8SETCA1
4008TAG2	8SETCA2

2	4006/8 Diesel, May 1998

		CONTENTS
		PAGE
INTRODUCTION & LIST OF PERKINS COMPANIES WORLDWIDE		1
ENGINE DESIGNATIONS		2
PHOTOGRAPHS		INSERTS
BRIEF DESCRIPTION OF THE 4006/8 DIESEL ENGINES		4
GENERAL INFORMATION		5-6
DIESEL ENGINE DATA		7-11
TORQUE SETTINGS		12-14
LUBRICATING OIL RECOMMENDATIONS		15-16
COOLANT, CORROSION INHIBITORS, ANTI-FREEZE		17
FUEL SPECIFICATION		18
OPERATING INSTRUCTIONS
PREPARATION FOR INITIAL START		19
BATTERIES		19
PRIMING THE LUBRICATION SYSTEM		20
FILLING COOLING SYSTEM		20
PRIMING THE FUEL SYSTEM		21
INSTRUMENT PANEL (ENGINE MOUNTED)		22-24
EXHAUST TEMPERATURE GAUGE (ENGINE MOUNTED)		24
NORMAL STARTING PROCEDURE		25
ENGINE SHUTDOWN		25
LIGHT LOAD OPERATION AND STANDBY GENERATING SETS		26
MAINTENANCE PROCEDURES		27-44
PREVENTITIVE MAINTENANCE		45-46
FAULT TRACING CHART		47
WIRING DIAGRAM CAV STARTER, WITH REPEATER RELAY		48
WIRING DIAGRAM CAV STARTER, WITHOUT REPEATER RELAY		49
WIRING DIAGRAM CAV STARTER WITH REPEATER RELAY
FOR REMOTE OR AUTOMATIC START		50
WIRING DIAGRAM ENGINE WITHOUT REPEATER (MANUAL START)		51
WIRING DIAGRAM PRESTOLITE STARTER WITH REPEATER RELAY		52
WIRING DIAGRAM PRESTOLITE STARTER WITHOUT REPEATER RELAY		53
WIRING DIAGRAM WITH HEINZMANN GOVERNOR AND PRESTOLITE
STARTER FOR MANUAL OR AUTOMATIC START		54
4006/8 SERIES ENGINE LUBRICATING OIL DIAGRAM	TP376	INSERT
4006/8TG AND 4006/8TAG SERIES ENGINE FRESH
WATER CIRCULATION DIAGRAM	TP377	INSERT
4006/8TWG SERIES ENGINE FRESH WATER CIRCULATION
DIAGRAM (RADIATOR COOLED)	TP378	INSERT
4006/8TWG SERIES ENGINE FRESH WATER CIRCULATION
DIAGRAM (HEAT EXCHANGER)	TP379	INSERT
4006/8TEG (FRESH & RAW WATER)	TP380	INSERT
4006/8 SERIES ENGINE FUEL DIAGRAM	TP294	INSERT

4006/8 Diesel, May 1998

3

4006TWG3

4006TG

4006TAG3

4008TAG2

BRIEF DESCRIPTION OF THE 4006/8 DIESEL ENGINES

4006TG 6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler in engine cooling circuit.

4006TWG 6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler and charge air cooler in engine cooling circuit.

4006TWG3 Up-rated version of the 4006TWG.

6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler and charge air cooler in engine cooling circuit.

4006TAG1 6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler in engine cooling circuit and air cooled charge air cooler in radiator.

4006TAG2 Up-rated version of the 4006TAG1.

6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler in engine cooling circuit and air cooled charge air cooler in radiator.

4006TAG3 Up-rated version of the 4006TAG2.

6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler in engine cooling circuit, and air cooled charge air cooler in radiator.

4006TEG 6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler in engine cooling circuit, and water cooled charge air cooler with raw water pump in separate cooling circuit.

4008TWG2 8 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler and charge air cooler in engine cooling circuit.

8 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with 4008TAG jacket water cooled oil cooler in engine cooling circuit and air cooled

charge air cooler in radiator.

4008TAG1 Up-rated version of the 4008TAG.

8 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler in engine cooling circuit and air cooled charge air cooler in radiator.

4008TAG2 Up-rated version of the 4008TAG1.

8 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler in engine cooling circuit and air cooled charge air cooler in radiator.

4	4006/8 Diesel, May 1998

GENERAL INFORMATION

SAFETY

Engine lift equipment

Use only the lift equipment which is designed for the engine.

Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder head, flywheel housing, crankshaft and flywheel.

Check the engine lift brackets for security before the engine is lifted.

Asbestos joints

Some joints and gaskets contain compressed asbestos fibres see Warning label Fig. 1 in a rubber compound or in a metal outer cover. The 'white' asbestos (Chrysotile) which is used is a safer type of asbestos and the danger of damage to health is extremely small.

Contact with asbestos particles normally occurs at joint edges or where a joint is damaged during removal, or where a joint is removed by an abrasive method.

To ensure that the risk is kept to a minimum, the procedures given below must be followed when an engine which has asbestos joints is dismantled or assembled.

●Work in an area with good ventilation.

●Do NOT smoke.

●Use a hand scraper to remove the joints - do NOT use a rotary wire brush.

●Ensure that the joint to be removed is wet with oil or water to contain any loose particles.

●Spray all asbestos debris with water and place it in a closed container which can be sealed for safe disposal.

Dangers from used engine oils

Prolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. The oil also contains potentially harmful contaminants which may result in skin cancer.

Adequate means of skin protection and washing facilities should be readily available.

Fig. 1

The following is a list of 'Health Protection Precautions', suggested to minimise the risk of contamination.

1.Avoid prolonged and repeated contact with used engine oils.

2.Wear protective clothing, including impervious gloves where applicable.

3.Do not put oily rags into pockets.

4.Avoid contaminating clothes, particularly underwear, with oil.

5.Overalls must be cleaned regularly.

Discard unwashable clothing and oil impregnated footwear.

6.First aid treatment should be obtained immediately for open cuts and wounds.

7.Apply barrier creams before each period of work to aid the removal of mineral oil from the skin.

8.Wash with soap and hot water, or alternatively use a skin cleanser and a nail brush, to ensure that all oil is removed from the skin. Preparations containing lanolin will help replace the natural skin oils which have been removed.

9.Do NOT use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing the skin.

10.If skin disorder appears, medical advice must be taken.

11.Degrease components before handling if practicable.

12.Where there is the possibility of a risk to the eyes, goggles or a face shield should be worn. An eye wash facility should be readily available.

4006/8 Diesel, May 1998

5

GENERAL INFORMATION

Environmental protection

There is legislation to protect the environment from the incorrect disposal of used lubricating oil. To ensure that the environment is protected, consult your Local Authority who can give advice.

Viton seals

Some seals used in engines and in components fitted to engines are made from Viton.

Viton is used by many manufacturers and is a safe material under normal conditions of operation.

If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes.

If it is necessary to come into contact with components which have been burnt, ensure that the precautions which follow are used:

Practical Information To clean components

It is important that the work area is kept clean and that the components are protected from dirt and other debris. Ensure that dirt does not contaminate the fuel system.

Before a component is removed from the engine, clean around the component and ensure that all openings, disconnected hoses and pipes are sealed.

Remove, clean and inspect each component carefully. If it is usable, put it in a clean dry place until needed. Ball and roller bearings must be cleaned thoroughly and inspected. If the bearings are usable, they must be flushed in low viscosity oil and protected with clean paper until needed.

Before the components are assembled, ensure that the area is free from dust and dirt as possible. Inspect each component immediately before it is fitted, wash all pipes

●Ensure that the components have and ports and pass dry compressed air

cooled.

through them before connections are made.

●Use Neoprene gloves and discard the Use suitable gloves for protection when

gloves safely after use.

●Wash the area with a calcium hydroxide solution and then with clean water.

components are degreased or cleaned with trichloroethylene, white spirit, etc.

Degreasing solutions which are basically

●Disposal of gloves and components trichloroethane are not recommended which are contaminated, must be in

accordance with local regulations.

If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or with a calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.

6	4006/8 Diesel, May 1998

DIESEL ENGINE DATA

For full technical data please refer to the Product Information Manual. Type: Water-cooled, turbocharged, charge cooled, industrial diesel engine.

RANGE	4006		4008
Cycle		4 stroke
No. of cylinders	6		8
Configuration		In-Line
Bore		160 mm
Stroke		190 mm
Total swept volume	22.92 litres		30.561 litres
Compression ratio		13.6:1
Rotation	Anti-clockwise looking on flywheel end
Firing order	1-5-3-6-2-4		1-4-7-6-8-5-2-3
Cylinder numbering	Cylinder 1 furthest from flywheel
Valve clearances
Inlet and exhaust (cold)		0,40 mm (0.016”)
Valve dia (mm)		48 (early engine)
Inlet and exhaust	52 (later and uprate engines)
Valve setting		See Page 43
Valve timing	See Workshop Manual Section U
Injection timing	See Engine Number plate
Piston speeds	Engine r/min		m/s (ft/min)
	1000		6.33 (1247)
	1200		7.60 (1496)
	1500		9.50 (1870)
	1800		11.40 (2244)

TYPICAL COOLING SYSTEM

	Approved coolants				See Page 17
	Water capacity (block only)		36 litres (8 gal)			48 litres (10.5 gal)
	Total water capacity	Litres		Gals	Spec	Litres	Gals	Spec.
	Engine with tropical radiator	106		23.3	TG	135	29.7	TAG
		110		24.2	TAG1	145	31.9	TAG1
		110		24.2	TAG2	145	31.9	TAG2
		125		27.5	TAG3	48	10.6	TWG2*
		106		23.3	TWG
		130		28.6	TWG3
		46		10.1	TEG**
*	Engine only
** Engine with heat exchanger
	Engine shut down temperature				96°C
	Max water temperature into engine	To be determined from heat dissipated & water flow
				through each particular engine model
	Thermostat opening temperature				71°C
	System pressure				0.5 to 0.7 bar

4006/8 Diesel, May 1998

7

DIESEL ENGINE DATA

FUEL SYSTEM

		4006		4008
Approved fuels		See page 18
Relief valve setting		276 kPa (40 lb/in²)
Injector nozzle pressure		225-235 atm
Injection equipment		Lucas-Bryce unit injector
Filtre/water separator		Spin-on expendable canister(s)
Fuel lift pump		Maximum suction lift 2 metres
Fuel flow		13.4 litres/min. (3 gpm) @ 1800 r/min
	GOVERNORS
Type		Electronic		Electronic
Type		Hydraulic		Hydraulic
LUBRICATION SYSTEM
Recommended oil		See page 15
Type of system		Wet sump, external engine mounted oil pump
Total oil capacity (oil cooler and filter)		122.7 litres (27 gal)		165.5 litres (36.5 gal)
Sump capacity (dipstick) Min.		90.7 litres (20 gal)		127 litres (27.9 gal)
Sump capacity (dipstick) Max.		113.4 litres (25 gal)		154 litres (33.9 gal)
Min. oil pressure (rated speed) to bearings		200 kPa (28 lb/in²)
Crankcase pressure		25 mm water gauge
Max. oil temperature to bearings		105°C
Lubricating oil filter		disposable canister type
INDUCTION SYSTEM
Air cleaner		Single air cleaner		Twin air cleaners
		Twin air cleaners (Uprate)
Type (paper element)		S551A
Max. Air intake depression		381 mm H2O (28 mm Hg)
Air restriction Indicator setting		380 mm H2O
Turbocharger		Garrett (x1)		(x2)
		(x2 uprate only)

8	4006/8 Diesel, May 1998

			DIESEL ENGINE DATA
	EXHAUST SYSTEM
		4006		4008
Manifold type		Dry		Dry
Exhaust outlet flange (non uprate)		Vertical (single)		Vertical (single) Option
(uprate)		Vertical (single) Option		Vertical (twin)
		Vertical (twin)
Mating flange (non uprate)		1 x 8" Table "D" BS4		1 x 10" Table "D"
(uprate)		1 x 10" Table "D"		2 x 6" Table "D"
		2 x 6" Table "D" Option
Max. exhaust back pressure		See Product Information Manual
Max. exhaust temperature		See Product Information Manual
	FLYWHEEL
SAE size		14"		18"
	FLYWHEEL HOUSING
SAE size		0		0
	CRANKSHAFT
Max. overhung weight on rear bearing		1000 kg
Tuning plate		1 x 14.6"		-
T.V. damper (non uprate)		1 x 14"		2 x 20"
(uprate)		1 x 18"

NOTE: Subject to a torsional vibration investigation different T.V. dampers may be fitted

4006/8 Diesel, May 1998

9

DIESEL ENGINE DATA

TYPICAL DRY WEIGHT

	4006	4008
Dry weight (engine)	2295 kg 4006TG	3120 kg 4008TAG
	2320 kg 4006TAG1/2	3250 kg 4008TAG1/2
	2340 kg 4006TWG	3325 kg 4008TWG2
	2420 kg 4006TEG
	2400 kg 4006TAG3
	2340 kg 4006TWG3
Dry weight (engine and tropical radiator)	2636 kg 4006TG	3730 kg 4008TAG
	2761 kg 4006TAG1/2	4360 kg 4008TAG1/2
	2477 kg 4006TWG1/2
	3010 kg 4006TAG3
	2790 kg 4006TWG3
Dry weight (engine and heat exchanger)	2560 kg 4006TEG	3462 kg 4008TWG2

	HOLDING DOWN BOLT HOLES
Bolt size (engine feet)			20 mm
No. off				6
		ELECTRICAL SYSTEM
Voltage				24
Alternator type			PRESTOLITE (BUTEC) A3024 with internal regulator
Alternator output (amps)			30 at a stabilised output of 28 volts
Starter motor type			PRESTOLITE/BUTEC		MS7/3A
			MS1/105
No. of teeth (gear ring)				190
No. of teeth (starter motor)				12
Battery capacity cold cranking amps			540 (each battery)		600 (each battery)
to IEC Standard at 0°C (32°F)
Battery (lead acid) 24 V			(2 x 12V) Total 143 Ah		(2 x 12V) Total 178 Ah

10	4006/8 Diesel, May 1998

DIESEL ENGINE DATA

PROTECTION EQUIPMENT

Before resetting protection equipment, it must be established whether special settings (for that individual engine) have been specified in the engine sales contract. This is particularly important with ALL high water temperature settings.

Standard settings for protection equipment are as follows:

	4006	4008
Shutdown switches	Alarm	Shutdown
High Oil temperature	105°C	110°C
Low oil pressure	2.06 bar (30 lb/in²)	1.93 bar (28 lb/in²)
Hight water temperature
71°C Thermostat	91°C	96°C

Caution: The above standard settings do not supersede any settings specified in the engine sales contract.

Overspeed

15% (on 1500 rev/min)

7% (on 1800 rev/min)

AIR STARTING

Air starter pressure	30 bar
Compressed air supply	17 bar
Type	Ingersoll-Rand Type SS350
Type	GALI A25

	INSTRUMENT PANEL (ENGINE MOUNTED)
		Normal Operation
Oil pressure		Between 300-560 kPa (42.6-80 lb/in²)
Oil temperature		Between 80-90°C (176-194°F)
Water temperature		Between 65-85°C (149-185°F)
Exhaust temperature		See Product Information Manual
Boost pressure		See Test Certificate

COOLANT JACKET HEATING

Heater	1 x 2 kW	1 x 4 kW

4006/8 Diesel, May 1998

11

TORQUE SETTINGS

WARNING	IT IS ESSENTIAL THAT THE CORRECT LENGTH OF SCREW OR
	BOLT IS USED. INSUFFICIENT LENGTH MAY RESULT IN THE

THREAD BEING STRIPPED, WHEREAS TOO LONG A THREAD MAY RESULT IN BOTTOMING IN A BLIND HOLE, OR CATCHING ON ADJACENT COMPONENTS.

NOTE: * Bolt and threads must be lubricated with clean engine oil.

** Cylinder head bolts to be lubricated under the heads, under the washers and on the threads with P.B.C. (Poly-Butyl-Cuprysil) grease. Important: See Section R10 in the Workshop Manual before fitting. All other bolt threads only to be lubricated with clean

engine oil. Care must be taken not to oil the heads and faces.
TORQUE SETTINGS
CYLINDER HEAD GROUP	lbf.ft		Nm
Cylinder head bolt ** (early type)	M24	550	750
Cylinder head bolt ** (later (waisted) type)	M24	530	723
Rocker shaft bolt/nut	M16	90	120
Rocker adjuster nut inlet/exhaust	M12	35	50
Rocker adjuster nut pump/injector	M14	50	70
Rocker box bolt	M10	35	50
Air manifold bolt	M10	35	50
Exhaust manifold bolt	M10	50	70
Turbocharger V-band clamp nuts	M8	8	11
CRANKCASE AND CRANKSHAFT GROUPS
* Main bearing bolt	M24	580	783
Side bolts (main bearing caps)	M16	124	168
Bolts sump to crankcase	M10	40	57
* Connecting rod bolt	M16	210	285
Viscous damper botls (4006/8 series)	M12	120	160
Flywheel bolts	M16	250	340
Front drive adaptor bolts	M16	250	340
Balance weight bolt	M16	250	340
Front crankshaft pulley bolt	M16	250	340
Piston cooling jet bolt	M10	7	10
Flywheel housing bolt	M10	35	50
Crankcase side bolts	M16	200	270

12	4006/8 Diesel, May 1998

TORQUE SETTINGS

	LUBRICATING OIL PUMP		lbf.ft	Nm
	Bolts, pump housing to gearcase plate	M10	35	50
	Thin nut, gear to drive shaft	M24	175	237
	CAMSHAFT GROUP
	Camshaft gear bolt	M12	110	150
	Camshaft thrust plate bolt	M10	35	50
	Camshaft follower housing bolt	M10	35	50
	Idler gear hub bolts	M10	35	50
	WATER PUMP
	Water pump gear nut	M24	170	230
	Water header to oil cooler bolts	M10	35	50
	Water header to gearcase bolts	M10	35	50
	Raw water pump gear securing nut, dry thread	M35	18	244
	ENGINE FEET
	Engine feet to base frame bolts	M20	350	475
	Engine feet to cushion feet bolts	M16	160	215
	Engine feet to gearcase and suspension plate bolt	M10	35	50
	GOVERNOR
	Control shaft mounting plate bolt	M10	35	50
	FAN DRIVE	1/
	Fan driven pulley taper lock bush screws		35	50
		2" BSW
	Fan driven pulley taper lock bush screws	5/	65	90
		8" BSW
	ALTERNATOR	3/
	Drive pulley taper lock bush nuts		15	20
		8" BSW
	FUEL PUMP/INJECTORS
	Injector capscrew clamp to cylinder head, early
	engines	M10	50	70
	Injector capscrew clamp to cylinder head, later
	engines	M12	70	95
	Injector nozzle nut to holder	M27	150	203
	Fuel pump control linkage screw	2BA	6	8
	Unit injector control lever capscrews	M5	6	8
	FLEXIBLE COUPLING (HOLSET)	M12 or 1/2" UNC
	Flexible coupling cover screw		90	129
	Coupling driving flange screws (coupling size 2.15)	M12 or 1/2" UNC	90	129

4006/8 Diesel, May 1998

13

TORQUE SETTINGS

GENERAL TORQUE LOADINGS

The following torque loadings are general for metric coarse threads for grade 8.8 steel and do not supersede the figures quotes above.

Thread size (mm)	lbf.ft	Nm
8	18	25
10	35	50
General Note:
M10-12.9 steel	50	70
These are based to BS 3692.

14	4006/8 Diesel, May 1998