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
WARNIN GS M E NTIONED IN THI S M A NUAL.

IMPROPER OPERATION OR MAINTENANCE PROCEDURES
COULD R ESULT IN A SERIOUS ACCIDE NT OR D AMAGE TO THE
EQUIPME NT CAUSING IN J URY 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 informationcontained withinthe 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 Engines (Peterborough) Ltd.

Frank Perkins W ay, Eastfield,
Peterborough, PE1 5NA, England.
Tel.: [phone]
Telex: 32501 PERKEN G
Fax: [phone]

Perkins Engines (Shrewsbury) Ltd.

Lancaster Road, Shrewsbury,
SY1 3NX, England.
Tel.: [phone]
Telex: 35171/2 PESL G
Fax: [phone]

Perkins Engines (Stafford) Ltd.

Tixall Road, Stafford, ST16 3UB, England.
Tel.: [phone]
Telex: 36156 PERKEN G
Fax: [phone]

Perkins Powerpart Distribution Centre

Frank Perkins Way,
Northbank Industrial Park, Irlam,
Manchester, M44 5PP, England.
Tel.: [phone]
Specifications Help Desk
Tel.: [phone]

Fax: [phone]
Specifications Help Desk
Tel.: [phone]

Telex: 32501 PERKEN G

Perkins International - North America

12025 Tech Center Drive,
Livonia, Michigan 48150,
U.S.A.
Tel.: [phone]
Fax: [phone]

Perkins Engines Latin America Inc

999 Ponce de Leon Boulevard,
Suite 710, Coral Gables,
Florida 33134, U.S.A.
Tel.: [phone]
Telex: 3 2501 PERKEN G
Fax: [phone]

Perkins Engines Australia Pty Ltd

Suite 2, 364 Main Street, Mornington
3931, Victoria, Australie.
Tel.: [phone]
Telex: 3 0816
Fax: [phone]

Motori Perkins SpA

Via Socrate. 8,22070 Casnate
Con Bernate (Como), Italie.
Tel.: [phone]
Telex: 380658 PERKIT I
Fax: [phone]

Perkins Motoren GmbH

D-63801 Kleinostheim,
Saalackerstrasse 4, Allemagne.
Tel.: (49) (6027) 5010
Fax: (49) (6027) 501130

Moteurs Perkins SA

Parc de Reflets - Paris Nord II,
165 Avenue du Bois de la Pie, BP 40064,
95913 Roissy CDG Cedex, France
Tel.: [phone]
Fax: [phone]

Perkins Engines (Far East) Pte Ltd.

39 Tuas Avenue 13,
Singapour 638999.
Tel.: [phone]

Fax: [phone]

In additiontothe above companies, thereare Perkins Distributorsin most countries. PerkinsE ngies (Peterborough) Limitedor
one of the above companies can provide distributor handbooks Publication No. 1407/4/97

Publication TSL4184
Publishedby the TechnicalPublicationsDepartment, Stafford.
© 1998 Perkins Engines (Stafford) L imited.

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

SAFETY
Engine lift equipment

Use onlythe 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.

GENERAL INFORMATION

Fig. 1

Asbestos joints

Some joints and gaskets contain
compressed asbestos fibres see Warning
labelFig.1in 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.

●

Useahandscrapertoremovethejoints

- do NOT use a rotary wire brush.

●

Ensure that the joint to be removed is
wet withoil or water tocontain any loose
particles.

●

Sprayall asbestos debriswithwater and
placeitinaclosedcontainerwhichcan
be sealed for safe disposal.

Dangers from used engine oils

Prolongedandrepeated contact withmineral
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 facilitiesshould be readilyavailable.

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 eachperiod
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

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm. Battery
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.

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:

●

Ensure that the components have
cooled.

●

Use Neoprene gloves and discard the
gloves safely after use.

●

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

●

Disposal of gloves and components
which are contaminated, must be in
accordance with local regulations.

Practical Information
To clean components

It is important that the workarea is keptclean
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 inspecteach component
carefully. If it is usable, put it in a clean dry
place until needed. Ball and roller bearings
mustbe cleanedthoroughlyand inspected.If
the bearings are usable, they must be
flushed in low viscosity oiland protected with
clean paper until needed.

Before the components are assembled,
ensurethat thearea is freefrom dustand dirt
as possible. Inspect each component
immediately before it is fitted, wash all pipes
and ports and pass dry compressed air
through them before connections are made.

Use suitable gloves for protection when
components are degreased or cleaned with
trichloroethylene, white spirit, etc.
Degreasing solutions which are basically
trichloroethane are not recommended

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.ofcylinders 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)

Inlet and exhaust
Valve setting See Page 43
Valve timing See Workshop M anual Section U
Injection timing See Engine Number plate
Piston speeds Engine r/min

1000
1200
1500
1800

48 (early engine)

52 (later and uprate engines)

m/s (ft/min)

6.33 (1247)

7.60 (1496)

9.50 (1870)

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**

*Engineonly
** Engine with heat exchanger

Engine shut down temperature 96°C
Max water temperature into engine
Thermostat opening temperature 71°C

System pressure 0.5 to 0.7 bar

To be determined from heat dissipated & water flow

through each particular engine model

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 H
Air restriction Indicator setting 380 mm H
Turbocharger

Garrett (x1)

(x2 uprate only)

O(28mmHg)

2

O

2

(x2)

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)
Mating flange (non uprate) 1 x 8" Table "D" BS4 1 x 10" Table "D"
(uprate)

Max. exhaust back pressure See Product Information Manual
Max. exhaust temperature See Product Information Manual

1 x 10" Table "D"

2 x 6" Table "D" Option

Vertical (twin)

2 x 6" Table "D"

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
No. of teeth (gear ring) 190

No. of teeth (starter motor) 12
Battery capacity cold cranking amps

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

PRESTOLITE/BUTEC

MS1/105

540 (each battery) 600 (each battery)

MS7/3A

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

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

Alarm Shutdown

Caution: Theabove standardsettingsdo not supersede anysettings specifiedin theengine

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 thethreads with P.B.C. (Poly-Butyl-Cuprysil) grease. Important:See SectionR10 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
Fan driven pulley taper lock bush screws

/

" BSW 35 50

2

5

/

" BSW 65 90

8

ALTERNATOR

3

Drive pulley taper lock bush nuts

/

" BSW 15 20

8

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 l inkage screw 2BA 6 8
Unit injector control lever capscrews M5 6 8

FLEXIBLE COUPLING (HOLSET)

1

Flexible coupling cover screw M12 or
Coupling driving flange screws (coupling size 2.15) M12 or

/

" UNC 90 129

2

1

/

" UNC 90 129

2

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

81825
10 35 50

General Note:

M10-12.9 steel 50 70
These are based to BS 3692.

14 4006/8 Diesel, May 1998