Perkins 900 Series CP/CR Engine

Tools: Feeler gauges

1. Check clearance with feeler gauges between top of valve stem and rocker lever, engine hot or cold.
2. Rotate crankshaft until inlet valve of number 1 cylinder has just opened and exhaust valve has not closed completely.
3. Check/adjust clearance of valve number 3 and number 6.
4. Set valves of number 2 cylinder as above, check/adjust valve number 2 and number 5.
5. Set valves of number 3 cylinder, check/adjust valve number 1 and number 4.
6. Fit rocker cover and tighten cap nuts to 30 Nm metal cover or 20 Nm plastic cover.

Tools: Locking pin for crankshaft 21836001

1. Remove rocker cover.
2. Loosen atomiser clamp setscrews or gland nuts.
3. Rotate crankshaft clockwise from front until inlet valve has just closed.
4. Insert locking pin into hole below slot in backplate.
5. Continue rotating crankshaft clockwise slowly until pin enters hole in flywheel.
6. Engine is now set at TDC number 1 cylinder, compression stroke.
7. Remove pin and fit rocker cover.

Tools: Timing pin 27610033, Locking pin for crankshaft 21836001

1. Remove cover for fuel injection pump gear.
2. Set piston of number 1 cylinder to TDC on compression stroke.
3. Insert timing pin through slot in fuel pump gear and hole in hub.
4. Push pin fully into recess in body of fuel pump; if fully inserted timing is correct.
5. If timing pin cannot be pushed into pump body, check engine is correctly set at TDC.
6. If engine set correctly but pin does not fit, fuel pump must be removed and set by specialist.
7. Remove timing pin and fit gear cover.

Tools: 0-70 kPa (0-10 lbf/in2) pressure gauge

1. Disconnect fuel outlet pipe; fit 0-70 kPa pressure gauge to outlet.
2. Release connection at gauge and operate priming lever to eliminate air.
3. Operate starter motor for 10 seconds with stop control in stop position.
4. Note maximum pressure. If less than 42/70 kPa, repair or renew pump.
5. Check rate pressure reduces to half maximum; if less than 30 seconds, repair or renew pump.
6. Remove gauge and connect outlet pipe.
7. Release vent screw on filter head and operate priming lever until fuel free of air; tighten.
8. Connect engine stop solenoid.

Tools: Thumb pressure

1. Loosen pivot fasteners of alternator and fasteners of adjustment link.
2. Change position of alternator to give correct tension.
3. Tighten adjustment link fasteners then pivot link fasteners.
4. Check belt tension again.

⚠ Damage to fuel injection pump, battery and starter motor can occur if starter motor used excessively.

1. Loosen vent plug on filter head of pre-filter, if fitted.
2. Operate priming lever of fuel lift pump until fuel free of air comes from banjo bolt; tighten.
3. Loosen banjo bolt on top of filter head; operate priming lever until fuel free of air; tighten.
4. Loosen union nut at fuelled starting aid; operate priming lever until fuel free of air; tighten.
5. Loosen high-pressure connections at two atomisers.
6. Operate starter motor until fuel free of air comes from high-pressure pipe connections.
7. Tighten high-pressure pipe connections to 22 Nm (16 lbf ft) 2,2 kgf m.
8. Operate engine at low idle for minimum five minutes.

⚠ Do not remove filler cap while engine hot and system under pressure.

1. Remove filler cap carefully.
2. Fill cooling system until coolant reaches bottom of filler tube.
3. If vent screw fitted in cylinder head, loosen it.
4. When coolant free from air flows from vent point, tighten vent screw.
5. If brass thermostat fitted horizontally, loosen vent screw on top until just tight.
6. When coolant free from air flows, tighten thermostat vent screw.
7. Remove filler cap and add coolant to bottom of filler tube; fit cap.
8. Start engine, operate at 1750 rev/min for two minutes, stop and allow to cool.
9. Repeat venting and filling until all air is eliminated.

⚠ Discard used canister and fuel in safe place.

1. Clean outside surfaces of fuel filter assembly.
2. Drain fuel from filter if drain tap fitted.
3. Hold bottom cover; release setscrew through filter head.
4. Lower bottom cover; remove and discard element.
5. Clean inside surfaces of filter head and cover.
6. Renew seals and O ring; lightly lubricate with clean fuel.
7. Put bottom cover under new element; hold element squarely to filter head.
8. Engage and tighten setscrew.
9. Eliminate air from fuel filter.

Tools: Strap wrench

1. Put tray under filter. Clean outside surfaces.
2. Use strap wrench to loosen canister; remove and discard canister.
3. Ensure adaptor is secure in filter head; clean inside filter head.
4. Add clean engine lubricating oil to new canister.
5. Lubricate seal on top of canister with clean engine oil.
6. Fit new canister and tighten by hand until seal contacts head, then further 1/2 to 3/4 turn.
7. Ensure sump has oil. Operate starter until oil pressure obtained.
8. Start engine, check for leakage, stop, after 15 minutes check oil level.

⚠ Specialist training and equipment needed to machine partially finished liner.

Tools: Hydraulic press 0-24 tonne, Stepped adaptor 27610024, Depth gauge 21825496, Dial gauge 21825617

1. Dismantle cylinder block and inspect.
2. Bore and hone cylinders to parent bores and machine chamfer.
3. Clean parent bore with Loctite Safety Cleaner.
4. Apply Loctite 640 to complete parent bore except 25 mm band top and bottom.
5. Clean new liner and dry with lint-free cloth.
6. Put block below press; engage liner with external chamfer towards bottom.
7. Put 0.010 mm stepped adaptor into top of liner.
8. Press in liner slowly until adaptor contacts block face.
9. Measure liner height at four points immediately.
10. Fit new piston rings.
11. Assemble cylinder block.

1. Disconnect fuel pipes from fuel lift pump.
2. Release setscrews, remove lock plates and remove fuel lift pump.
3. Ensure camshaft eccentric is in minimum lift position before fitting.
4. Clean joint face and fit lift pump with new joint.
5. Fit lock plates and setscrews; tighten to 22 Nm (16 lbf ft) 2,2 kgf m.
6. Connect fuel pipes.
7. Release vent screw on fuel filter head and operate priming lever until fuel free of air.
8. Tighten vent screw; operate engine and check for leakage.

⚠ Do not tighten cylinder head fasteners again with engine hot or after limited service.

Tools: Angle gauge 21825607

1. Tighten setscrews 1-8 in sequence to 70 Nm (52 lbf ft) 7,1 kgf m.
2. Repeat step 1 to ensure all setscrews are at correct torque.
3. Tighten further by 60° (1 flat) in correct sequence.
4. Tighten setscrews a further 60° (1 flat) in correct sequence.
5. Tighten fasteners 9-12 in sequence to 50 Nm (37 lbf ft) 5,1 kgf m.
6. Repeat step 7 to ensure fasteners are at correct torque.
7. Tighten fasteners 9-12 further by 60° (1 flat) in correct sequence.