Kenr6238 00

KENR6238-00
November 2006
Specifications
4006 TRS Gas and 4008 TRS Gas
Industrial Engines
SG6 (Engine)
SG8 (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 premature failures, product damage, personal injury or
death.
KENR6238
3
Table of Contents
Table of Contents
Specifications Section
Engine Design .....................................................
Spark Plug ............................................................
Fuel Lines .............................................................
Camshaft .............................................................
Valve Cover ..........................................................
Valve Mechanism .................................................
Cylinder Head ......................................................
Cylinder Head Valves ...........................................
Turbocharger .......................................................
Exhaust Elbow .....................................................
Exhaust Manifold .................................................
Aftercooler ...........................................................
Inlet Manifold .......................................................
Engine Oil Pump ..................................................
Engine Oil Filter Base ..........................................
Engine Oil Cooler .................................................
Engine Oil Pan .....................................................
Crankcase Breather (If equipped) .........................
Water Pump (If equipped) .....................................
Auxiliary Water Pump (If equipped) ......................
Water Temperature Regulator (If equipped) .........
Cylinder Block ......................................................
Crankshaft ...........................................................
Connecting Rod ...................................................
Connecting Rod Bearing Journal .........................
Main Bearing Journal ............................................
Piston and Rings ..................................................
Piston Cooling Jet .................................................
Cylinder Liner .......................................................
Camshaft Bearings ..............................................
Gear Group (Front) ...............................................
Housing (Front) .....................................................
Vibration Damper and Pulley ...............................
Flywheel ...............................................................
Flywheel Housing ................................................
Engine Lifting Bracket ...........................................
Belt Tension Chart ...............................................
Alternator .............................................................
Electric Starting Motor .........................................
Coolant Temperature Switch .................................
Detonation Sensor ................................................
4
5
5
5
6
7
7
8
9
10
10
10
11
11
14
14
16
17
17
18
19
20
21
22
23
23
23
24
25
25
26
27
27
28
28
29
29
29
30
30
30
Index Section
Index ..................................................................... 31
4
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i02586289
Engine Design
g01207434
Illustration 2
Eight cylinder
(A) Inlet valves
(B) Exhaust valves
Table 2
4008 Engine Specifications

Rated rpm
g01216853
Illustration 1
Cylinders and arrangement
1500
In-line eight cylinder
Six cylinder
Bore
160 mm (6.3 inch)
(A) Inlet valves

(B) Exhaust valves
Stroke
190 mm (7.5 inch)
Displacement
Table 1
4006 Engine Specifications

Rated rpm
1500
Cylinders and arrangement
In-line six cylinders
Bore
160 mm (6.3 inch)
Stroke
190 mm (7.5 inch)
Displacement
22.9 L (1397.4 in3)
Compression ratio
Aspiration
Rotation (flywheel end)
Aspiration
Rotation (flywheel end)
12:1
Turbocharged
Counterclockwise
Inlet valve lash (cold)
0.40 mm (0.01 inch)
Exhaust valve lash (cold)
0.40 mm (0.01 inch)
Firing order
1,4,7,6,8,5,2,3
12:1
Turbocharged
Counterclockwise
Inlet valve lash (cold)
0.40 mm (0.01 inch)
Exhaust valve lash (cold)
0.40 mm (0.01 inch)
Firing order
Compression ratio
30.56 L (1864.88 in3)
1,5,3,6,2,4
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i02600366
Spark Plug
i02589553
Camshaft
End play of a camshaft ................... 0.10 to 0.25 mm

(0.004 to 0.01 inch)
Maximum permissible end play of a worn
camshaft ................................. 0.30 mm (0.012 inch)
g01301435
Illustration 3
Typical example
The gap on the spark plug (1) should be set to

0.25 mm (0.01 inch).
g01296497
Tighten the spark plug (1) to the following

torque. ............................................. 50 Nm (37 lb ft)
Illustration 4
Note: Do not use any sealing compounds on the

thread of the spark plug.
(1) Diameter of the camshaft

journal ............................... 91.933 to 91.960 mm
(3.6194 to 3.6205 inch)
i02625313
Fuel Lines
Typical example
(2) The height of the inlet and the exhaust

lobes ............................. 78.58 mm (3.0937 inch)
Service limit of the height of the inlet and the exhaust
lobes ..................................... 78.1 mm (3.0748 inch)
Maximum worn clearance of bearing
journal ....................................... 0.25 mm (0.01 inch)
Table 3
Required Tools
Tool
Part Number
21820122
Part Description
Pipeseal and Primer
Qty
1
Apply Tooling (A) to the threads of the fuel pipes.
6
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i02588566
Valve Cover
Illustration 5
g01300953
(3) Tighten the setscrews to the following

torque. ...................................... 50 Nm (37 lb ft)
Illustration 7
g01296136
Typical example
Tighten the capscrews (1) in the sequence

that is shown in illustration 8 to the following
torque. ............................................. 70 Nm (52 lb ft)
Tighten the fasteners (2) that secure the rocker shaft
to the following torque. .................. 120 Nm (88 lb ft)
Tighten the capscrews (3) that secure the rocker
cover to the following torque. .......... 20 Nm (15 lb ft)
Illustration 6
g01300954
Note: The arms are shimmed in order to allow an

end play of 0.25 to 0.50 mm (0.0098 to 0.0197 inch).
(4) Tighten the allen head screw to the following
torque. ...................................... 68 Nm (50 lb ft)
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Diameter of the rocker arm bore

.... 25.031 to 25.051 mm (0.9855 to 0.9863 inch)
Clearance
Maximum clearance of both the rocker arm
bores. ............................ 0.089 mm (0.0035 inch)
The service limit for both rocker arm
bores ............................... 0.17 mm (0.0067 inch)
Diameter of the rocker shaft ... 24.962 to 24.987 mm
(0.9828 to 0.9837 inch)
Torque for the adjuster for the bridge piece ... 35 Nm
(26 lb ft)
i02586794
Cylinder Head
Illustration 8
g01296338
Typical example
Table 4
Required Tools
i02601996
Valve Mechanism
Illustration 9
Tool
Part Number
Part Description
PBC (Poly Butyl
Cuprysil) grease
Qty
1
g01302323
Typical example
(1) Locknut
Torque for the locknut ............... 50 Nm (37 lb ft)
(2) Rocker arm bores
Illustration 10
g01295090
Typical example
8
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Apply Tooling (A) to the cylinder head bolts. Tighten

the cylinder head bolts in the sequence that is shown
in illustration 10. Tighten the cylinder head bolts.
Refer to table 5 for the correct torques.
Diameter of the valve guide ..... 11.090 to 11.120 mm

(0.4366 to 0.4378 inch)
Table 5
Maximum worn clearance of the valve

stem ...................................... 0.20 mm (0.0079 inch)
Sequence
Torque
Finger tight
135 Nm (100 lb ft)
270 Nm (200 lb ft)
540 Nm (400 lb ft)
718 Nm (530 lb ft)
Clearance
Maximum worn clearance of the valve

guide ..................................... 0.20 mm (0.0079 inch)
The service limit for the valve stem .......... 0.109 mm
(0.0043 inch)
The service limit for the valve guide ......... 0.066 mm
(0.0026 inch)
Tighten the capscrew that secures the bush for the

spark plug to the following torque. ............... 135 Nm
(100 lb ft)
(3) Length of inlet valve .............. 169.6 to 169.9 mm

(6.6772 to 6.6890 inch)
i02589171
(3) Length of exhaust valve ........ 169.5 to 170.0 mm

(6.6732 to 6.6929 inch)
Cylinder Head Valves
(4) Inlet valve head ...................... 52.8 to 52.92 mm

(2.0787 to 2.0835 inch)
(4) Exhaust valve head .............. 52.00 to 52.12 mm
(2.0472 to 2.0520 inch)
The valve spring may be used on the inlet valve

or the exhaust valve. When the valve springs are
replaced the valve springs must be replaced in pairs.
Table 6
The minimum load for the

valve spring
The length of the installed

valve spring
400 Nm (295 lb ft)
42.54 mm (1.6748 inch)
Illustration 11
g01296347
Typical example
(1) Valve face angle ............................... 30 degrees

(2) Valve stem diameter ...... 11.0109 to 11.0236 mm
(0.4335 to 0.4340 inch)
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i02598986
Turbocharger
Illustration 12
g01300955
Typical example
(1) Tighten the capscrews to the following

torque. ...................................... 70 Nm (52 lb ft)
Tighten the capscrews for the oil feed pipe to the
following torque. .............................. 50 Nm (37 lb ft)
10
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i02599007
Exhaust Elbow
Illustration 13
i02601282
Aftercooler
g01300991
Illustration 14
g01301904
Typical example
Typical example
(1) Tighten the nut to the following torque. .... 11 Nm

(97 lb in)
(1) Tighten the bolts to the following torque. .. 27 Nm

(20 lb ft)
1. Use a soft faced hammer to tap the outer edge of

the clamp at three points. Refer to illustration 13.
2. Tighten the clamp.
3. Repeat the procedure until no movement is
obtained.
i02600535
Exhaust Manifold
Tighten the setscrews to the following

torque. ............................................. 70 Nm (52 lb ft)
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i02601271
Inlet Manifold
Illustration 15
g01301907
Illustration 16
g01301893
Typical example
Typical example
Tighten the fasteners (2), (3), (4) and (5) to the


(37 lb ft)
Tighten the retaining bolts (not shown) to the

i02590290
Engine Oil Pump
Type ............................. Gear-driven differential rotor

Number of lobes
Inner rotor ......................................................... 4
Outer rotor ........................................................ 5
12
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Place a straight edge across the rotors. Use a feeler

gauge (3). Measure the gap between the rotors and
the end face of the oil pump body. Refer to illustration
18.
Thickness of the joint for the oil pump
cover ..... 0.229 to 0.254 mm (0.0090 to 0.0100 inch)
Under compression, the joint for the pump cover may
be 0.05 to 0.08 mm (0.0020 to 0.0031 inch). This will
occur when the bolts are secured.
Illustration 17
g01296785
Typical example
(1) Maximum clearance of the outer rotor to the

body .............................. 0.127 mm (0.0050 inch)
(2) Maximum clearance of the outer rotor to the
body .............................. 0.178 mm (0.0070 inch)
Illustration 19
g01296789
Typical example
(4) End play of the rotors on the drive shaft to pump

body and pump cover ............... 0.08 to 0.15 mm
(0.0031 to 0.0059 inch)
Illustration 18
g01296788
Typical example
KENR6238
Illustration 20
13
g01296790
Illustration 22
g01296798
Typical example
Typical example
Tighten the bolts (5), (6) and (7) to the following

torque. ............................................. 28 Nm (21 lb ft)
Tighten the bolts (9), (10) and (11) to the following

torque. ............................................. 50 Nm (37 lb ft)
Illustration 21
g01296793
Typical example

(21 lb ft)
14
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i02590641
Engine Oil Filter Base
g01296944
Illustration 23
Typical example
Tighten the setscrews for the pipe (1) to the following

torque. ............................................. 50 Nm (37 lb ft)

torque. ...................................... 50 Nm (37 lb ft)
Tighten the setscrews (2) for the oil filter base to the

torque. ...................................... 50 Nm (37 lb ft)
i02599048
Engine Oil Cooler
Illustration 24
g01301061
Typical example
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15
Illustration 25
g01301083
Typical example

torque. ...................................... 50 Nm (37 lb ft)
(4) Tighten the pipe to the following
torque. ............ 173 to 206 Nm (128 to 152 lb ft)
torque. ...................................... 50 Nm (37 lb ft)
torque. ...................................... 50 Nm (37 lb ft)
16
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i02599018
Engine Oil Pan
g01301001
Illustration 26
Typical example
(1) Oil pan
(2) Dipstick
(3) Fasteners
(4) Suction pipe
(5) Drain plugs
(3) Tighten the fasteners to the following

torque. ...................................... 40 Nm (30 lb ft)
Tighten the setscrews (not shown) that secure
the oil pan (1) to the cylinder block to following
torque. ............................................. 54 Nm (40 lb ft)
Tighten the gland nut (not shown) for the dipstick (2)
to the following torque. .................... 18 Nm (13 lb ft)
(5) Tighten the drain plugs to the following
torque. ...................................... 68 Nm (50 lb ft)
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i02586813
Closed Breather System
Crankcase Breather
(If equipped)
Open Breather
Illustration 28
g01296937
Typical example
(1) Clips
(2) Bowl
Secure the clips (1) in the correct positions.

i02599562
Illustration 27
Typical example
(1)
(2)
(3)
(4)
(5)
Wing nut
Cover
Filter elements
Breather body
Dowel
g01224945
Water Pump
(If equipped)
Tighten the wing nut (1) finger tight.
Illustration 29
g01301219
Typical example
18
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(1) Tighten the nut to the following torque. .. 230 Nm

(170 lb ft)
g01301220
Illustration 30
Typical example

torque. ...................................... 50 Nm (37 lb ft)
torque. ...................................... 25 Nm (18 lb ft)
i02600365
Auxiliary Water Pump

(If equipped)

(37 lb ft)
Illustration 31
g01301431
Typical example

(21 lb ft)
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19
i02586838
Water Temperature Regulator

(If equipped)
Illustration 32
g01301432
Typical example
(2) Tighten the nut to the following torque. .. 250 Nm

(184 lb ft)
Tighten the retaining nuts (not shown) to the following
torque. ............................................. 56 Nm (41 lb ft)
The maximum angle of rotation between the inlet
housing and outlet housing is 30 degrees.
Illustration 33
g01240519
Typical example
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Outlet hose
Cover
Joint
Water temperature regulator
Housing
Setscrew
Nut
(7) Nut
Tighten the nuts that fasten the cover to the
following torque. ....................... 50 Nm (37 lb ft)
(4) Water temperature regulator
Opening temperature ................ 71 C (159.8 F)
Full opening temperature ............. 85 C (185 F)
20
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i02601303
Cylinder Block
Note: Ensure that the crankshaft can rotate freely.
6 Cylinder Engines
Tighten the cap bolts to the torque values in table 7.
Tighten the cap bolts in the sequence that is shown
in illustration 35.
Table 7
Illustration 34
Sequence
Torque
Finger tight
135 Nm (100 lb ft)
270 Nm (200 lb ft)
540 Nm (400 lb ft)
783 Nm (580 lb ft)
g01315956
Typical example
Distance from top of crankcase to center of the main

bearing bore ............................ 540.00 to 540.15 mm
(21.2598 to 21.2657 inch)
Illustration 35
g01309554
The depth of the cylinder bore of the cylinder

block ..... 15.12 to 15.20 mm (0.5953 to 0.5984 inch)
8 Cylinder Engines
Distance from bottom of crankcase to center of main

bearing bore ........................ 152.375 to 152.425 mm
(5.9990 to 6.0010 inch)
Tighten the cap bolts to the torque values in table 7.

Tighten the cap bolts in the sequence that is shown
in illustration 36.
Bore in new cylinder liner .... 160.000 to 160.025 mm

(6.2992 to 6.3002 inch)
Use the following procedure in order to install the
main bearing cap bolts.
1. Apply clean engine oil to the threads of the main
bearing cap bolts.
2. Install the main bearing caps with the locating tabs
in correct alignment with the recess in the cylinder
block. Install the main bearing cap bolts.
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21
i02588517
Crankshaft
The temperature of the gear for installation on the

crankshaft ........................................ 250 C (482 F)
g01309557
Illustration 36
Tighten the side capscrews to the torque values in

table 8. Tighten the capscrews in the sequence that
is shown in illustration 37.
Table 8
Sequence
Torque
Finger tight
135 Nm (100 lb ft)
270 Nm (200 lb ft)
Illustration 37
g01309560
22
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g01296099
Illustration 38
Typical example
(1) Diameter of main bearing

journal ............................... 120.57 to 120.59 mm
(4.7468 to 4.7476 inch)
Clearance between a new bearing and the
journal ... 0.089 to 0.152 mm (0.0035 to 0.0060 inch)
Maximum permissible clearance between the bearing
and journal .......................... 0.203 mm (0.0080 inch)
Diameter of main bearing
bore ..................................... 120.675 to 120.726 mm
(4.7510 to 4.7530 inch)
(2) Diameter of connecting rod bearing
journal ............................ 117.993 to 118.013 mm
(4.6454 to 4.6462 inch)
Clearance between a new bearing and the
journal ... 0.073 to 0.127 mm (0.0029 to 0.0050 inch)
Maximum clearance between a new bearing and the
journal ................................. 0.203 mm (0.0080 inch)
Crankshaft end play ........................ 0.13 to 0.48 mm
(0.0051 to 0.0189 inch)
The maximum permissible end play with used
bearings ................................ 0.53 mm (0.0209 inch)
Refer to Specifications, Connecting Rod Bearing

Journal and Specifications, Main Bearing Journal
for more information about the crankshaft journals.
i02586868
Connecting Rod
Table 9
Undersized Connecting Rod Bearing

0.25 mm (0.010 inch)
0.51 mm (0.020 inch)
Note: Lubricate the threads of the setscrews with

clean engine oil before installation.
Tighten the setscrews for the connecting rod to the
Tighten the setscrews for the connecting rod for an
additional 60 degrees.
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23
Bore in connecting rod for small end

bearing .................................... 71.425 to 71.450 mm
(2.8120 to 2.8130 inch)
Bore of the small end bearing for the connecting
rod ..... 63.551 to 63.576 mm (2.5020 to 2.5030 inch)
Bore for the big end bearing shells in the connecting
rod ....................................... 123.000 to 123.025 mm
(4.8425 to 4.8435 inch)
Distance between parent
bores ....................................... 335.94 to 336.06 mm
(13.2260 to 13.2307 inch)
Maximum permissible wear of the main bearing

journals ............................... 0.040 mm (0.0016 inch)
Radius of the fillet of the main bearing
journals ..... 3.68 to 3.69 mm (0.1448 to 0.1452 inch)
Width of new main bearing
journal ..................................... 35.235 to 35.165 mm
(1.3872 to 1.3844 inch)
The shell for the main bearings

Thickness at center of the shells .. 2.083 to 2.089 mm
(0.0820 to 0.0823 inch)
Maximum worn clearance for the small end

bearing .................................. 0.15 mm (0.0059 inch)
Width of the main bearing shells .. 31.62 to 31.88 mm

(1.244 to 1.255 inch)
End play on the connecting rod ...... 0.16 to 0.36 mm

(0.0063 to 0.0142 inch)
Maximum clearance between the bearing shell and

the main bearing journals ... 0.203 mm (0.0080 inch)
i02601232
Connecting Rod Bearing

Journal
i02601241
Piston and Rings
Refer to Specifications, Crankshaft for information

on the undersize crankshaft journals.
The diameter of the connecting rod bearing
journal .................................. 117.993 to 118.013 mm
(4.6454 to 4.6462 inch)
Maximum permissible wear of a bearing journal on a
new connecting rod ............ 0.203 mm (0.0080 inch)
Undersize bearing shell ...... 0.254 mm (0.0100 inch)
Undersize bearing shell ...... 0.508 mm (0.0200 inch)
Width of the connecting rod bearing
journals ................................... 37.962 to 38.038 mm
(1.4946 to 1.4976 inch)
Radius of the fillet of the connecting rod bearing
journals ......... 3.68 to 3.96 mm (0.145 to 0.156 inch)
i02601231
Main Bearing Journal

Illustration 39
g01301943
Typical example
The diameter of the main bearing

journal ..................................... 120.57 to 120.59 mm
(4.7468 to 4.7476 inch)
(1) Top compression ring

The shape of the top compression
ring .................................................... rectangular
24
Width of top compression ring ................ 4.5 mm

(0.1772 inch)
The clearance between a new top compression
ring and the piston groove in a new
piston ..................................... 0.075 to 0.115 mm
(0.0030 to 0.0045 inch)
Ring gap ..................................... 0.5 to 0.75 mm
(0.0197 to 0.0295 inch)
Note: When you install a new top compression ring,
make sure that the word TOP is facing the top of
the piston.
KENR6238
Piston pin
Diameter of a new piston
pin ..................................... 63.492 to 63.500 mm
(2.4997 to 2.5000 inch)
i02601233
Piston Cooling Jet
(2) Intermediate compression ring

The shape of the intermediate compression
ring ....................................... Internal bevel in the
bottom edge with a tapered face
Width of intermediate compression ring .. 3.5 mm
(0.1378 inch)
The clearance between a new intermediate
compression ring and the piston groove in a new
piston .... 0.05 to 0.1 mm (0.0020 to 0.0039 inch)
Ring gap ................................... 0.50 to 0.75 mm
(0.0197 to 0.0295 inch)
Note: When you install a new intermediate
compression ring, make sure that the word TOP is
facing the top of the piston.
(3) The oil control ring
Width of oil control ring ..... 6.0 mm (0.2362 inch)
The clearance between a new oil control ring and
the groove in a new piston ........ 0.05 to 0.09 mm
(0.0020 to 0.0035 inch)
Ring gap ................................... 0.50 to 0.75 mm
(0.0197 to 0.0295 inch)
Illustration 40
g01301857
Typical example
(1) Tighten the setscrew to the following

torque. ...................................... 50 Nm (37 lb ft)
Note: The oil control ring is a two-piece ring that is

spring loaded. A pin is used in order to hold both
ends of the spring of the oil control ring in position.
The ends of the spring of the oil control ring must be
installed opposite the end gap of the oil control ring.
Note: Ensure that the ring end gaps of the piston
rings are spaced 120 degrees from each other.
Piston
Width of top groove in the piston .. 4.59 to 4.565 mm
(0.1807 to 0.1797 inch)
Width of second groove in new
Width of third groove in new
KENR6238
25
i02601367
Cylinder Liner
Illustration 41
i02589510
Camshaft Bearings
g01301991
The dimension (1) relative to the face of the

crankcase and the ring groove is 2.07 to 2.20 mm
(0.0815 to 0.0866 inch).
Illustration 42
g01296480
Typical example
The diameter of the installed camshaft

bearing .................................... 92.131 to 92.093 mm
(3.6272 to 3.6257 inch)
The maximum worn clearance of the camshaft
bearing .................................. 0.25 mm (0.0098 inch)
26
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i02600480
Gear Group (Front)
Idler gear end play with roller

bearings .................................... 0.10 to 0.75 mm
(0.0039 to 0.0295 inch)
(2) Camshaft gear
Tighten the setscrews for the camshaft gear to
the following torque. .............. 150 Nm (110 lb ft)
(3) Crankshaft gear
Bore diameter of crankshaft gear
........ 51.00 to 51.03 mm (2.0079 to 2.0091 inch)
Outside diameter of crankshaft
hub .................................... 51.021 to 51.002 mm
(2.0087 to 2.0079 inch)
Clearance of gear on
crankshaft ......................... 0.020 to +0.020 mm
(0.0008 to +0.0008 inch)
Backlash values
Backlash between the idler gear (1) and the oil
pump gear (4) ....................... 0.125 to 0.375 mm
(0.0049 to 0.0148 inch)
Illustration 43
g01301569
Gear Train
(1)
(2)
(3)
(4)
Idler gear
Camshaft gear
Crankshaft gear
Oil Pump Gear
(1) Idler gear and hub

Tighten the setscrews for the idler gear to the
following torque. ....................... 50 Nm (37 lb ft)
Backlash between the oil pump gear (4) and the

crankshaft gear (3) ............... 0.125 to 0.375 mm
(0.0049 to 0.0148 inch)
Backlash between the idler gear (1) and the
crankshaft gear (3) ............... 0.125 to 0.375 mm
(0.0049 to 0.0148 inch)
Backlash between the camshaft gear (2) and the
idler gear (1) ......................... 0.125 to 0.375 mm
(0.0049 to 0.0148 inch)
Width of idler gear and split bearing

assembly .......................... 30.164 to 30.135 mm
(1.1876 to 1.1864 inch)
Inside diameter of idler gear bearings with
flanges .............................. 50.797 to 50.818 mm
(1.9999 to 2.0007 inch)
Outside diameter of idler gear
hub .................................... 50.716 to 50.737 mm
(1.9967 to 1.9975 inch)
Clearance of idler gear bearing on
hub .... 0.06 to 0.102 mm (0.0024 to 0.0040 inch)
Idler gear end play ........................ 0.1 to 0.2 mm
(0.0039 to 0.0079 inch)
Maximum permissible end play ............ 0.38 mm
(0.015 inch)
KENR6238
27
i02615714
Housing (Front)
Illustration 44
i02588325
Vibration Damper and Pulley
g01309677
Illustration 45
g01295953
Typical example
Typical example

torque. ...................................... 50 Nm (37 lb ft)
(1) Tighten the 12 mm fasteners to the following

torque. .................................. 163 Nm (120 lb ft)
(1) Tighten the 16 mm fasteners to the following
torque. .................................. 339 Nm (250 lb ft)
torque. .................................. 339 Nm (250 lb ft)
Tighten the fasteners (2) for the crankshaft adapter in
the sequence that is shown in illustration 46.
28
KENR6238
g01295959
Illustration 46
Illustration 47
i02600369
Flywheel
g01301445
i02600371
Flywheel Housing
Heat the flywheel ring gear to the following

temperature. .................................... 250 C (480 F)
Note: Do not use an oxyacetylene torch to heat the
flywheel ring gear.
Tighten the fasteners. Refer to table 10 for the correct
torque values. Refer to illustration 47 for the correct
torque sequence.
Table 10
Stage
Torque
Finger tight
135 Nm (100 lb ft)
337 Nm (249 lb ft)
Illustration 48
g01301449
Typical example
KENR6238
29
Setscrew
The output of the alternator .................... 30 Amp
(1) Tighten the setscrew to the following

torque. ................................ 50 Nm (37 lb ft)
i02624340
Engine Lifting Bracket
Tighten the fasteners that secure the engine lifting

bracket to a torque of 47 Nm (35 lb ft).
i02600376
Belt Tension Chart

Illustration 50
g01301498
Typical example
Alternator Drive Belts
(1) Tighten the screws to the following

torque. ...................................... 20 Nm (15 lb ft)
(55 lb ft)
Illustration 49
g01301469
Typical example
Apply a force of 15.6 Nm (11.5 lb ft) midway between

the two pulleys (2). Refer to illustration 49.
Illustration 51
i02600402
Alternator
g01301502
Typical example
Tighten the fasteners (3) and (4) to the following

torque. ............................................. 50 Nm (37 lb ft)
28 volt output
30
KENR6238
i02602028
i02601316
Electric Starting Motor
Detonation Sensor
Tighten the fasteners to the following

torque. ............................................. 95 Nm (70 lb ft)
Tighten the bolt that secures the sensor to the

Rated voltage ................................................ 24 volts
Tighten the bolts that retain the wiring rail to the

i02601250
Coolant Temperature Switch
Table 11
Required Tools
Tool
Part
Number
Part Description
Loctite 573
Illustration 52
Qty
1
g01301867
Typical example for the electro unit
The coolant temperature switch monitors the engine

coolant temperature. The switch may not be installed
on the engine. Apply Tooling (A) to the threads of
the nut (1).
KENR6238
31
Index Section
Index
A
Aftercooler ............................................................. 10
Alternator ............................................................... 29
Auxiliary Water Pump (If equipped) ....................... 18
Housing (Front)...................................................... 27
Important Safety Information ................................. 2

Inlet Manifold ......................................................... 11
Belt Tension Chart ................................................. 29

Alternator Drive Belts ......................................... 29
5
25
22
23
30
17
17
17
21
20
20
20
7
8
25
D
Detonation Sensor................................................. 30
P
Piston and Rings ................................................... 23
Piston ................................................................. 24
Piston Cooling Jet.................................................. 24
S
Spark Plug ............................................................. 5
Specifications Section ........................................... 4
T
Table of Contents................................................... 3
Turbocharger ......................................................... 9
V
E
Electric Starting Motor ...........................................
Engine Design .......................................................
Engine Lifting Bracket............................................
Engine Oil Cooler ..................................................
Engine Oil Filter Base............................................
Engine Oil Pan.......................................................
Engine Oil Pump....................................................
Exhaust Elbow.......................................................
Exhaust Manifold ...................................................
M
Main Bearing Journal............................................. 23
The shell for the main bearings.......................... 23
C
Camshaft ...............................................................
Camshaft Bearings ................................................
Connecting Rod.....................................................
Connecting Rod Bearing Journal...........................
Coolant Temperature Switch .................................
Crankcase Breather (If equipped) .........................
Closed Breather System ....................................
Open Breather ...................................................
Crankshaft ............................................................
Cylinder Block........................................................
6 Cylinder Engines.............................................
8 Cylinder Engines.............................................
Cylinder Head........................................................
Cylinder Head Valves ............................................
Cylinder Liner ........................................................
30
4
29
14
14
16
11
10
10
Valve Cover ........................................................... 6

Valve Mechanism .................................................. 7
Vibration Damper and Pulley................................. 27
W
Water Pump (If equipped) ..................................... 17
Water Temperature Regulator (If equipped) .......... 19
F
Flywheel ................................................................ 28
Flywheel Housing .................................................. 28
Fuel Lines .............................................................. 5
G
Gear Group (Front)................................................ 26
Copyright 2006 Perkins Engines Company Limited

All Rights Reserved
Printed in U.K.

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Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

4008 Engine Specifications

Cylinders and arrangement

160 mm (6.3 inch)

(A) Inlet valves

190 mm (7.5 inch)

4006 Engine Specifications

Cylinders and arrangement

In-line six cylinders

160 mm (6.3 inch)

190 mm (7.5 inch)

22.9 L (1397.4 in3)

Inlet valve lash (cold)

0.40 mm (0.01 inch)

Exhaust valve lash (cold)

0.40 mm (0.01 inch)

Inlet valve lash (cold)

0.40 mm (0.01 inch)

Exhaust valve lash (cold)

0.40 mm (0.01 inch)

30.56 L (1864.88 in3)

End play of a camshaft ................... 0.10 to 0.25 mm

The gap on the spark plug (1) should be set to

Tighten the spark plug (1) to the following

Note: Do not use any sealing compounds on the

(1) Diameter of the camshaft

(2) The height of the inlet and the exhaust

Apply Tooling (A) to the threads of the fuel pipes.

(3) Tighten the setscrews to the following

Tighten the capscrews (1) in the sequence

Note: The arms are shimmed in order to allow an

Diameter of the rocker arm bore

Apply Tooling (A) to the cylinder head bolts. Tighten

Diameter of the valve guide ..... 11.090 to 11.120 mm

Maximum worn clearance of the valve

135 Nm (100 lb ft)

270 Nm (200 lb ft)

540 Nm (400 lb ft)

718 Nm (530 lb ft)

Maximum worn clearance of the valve

Tighten the capscrew that secures the bush for the

(3) Length of inlet valve .............. 169.6 to 169.9 mm

(3) Length of exhaust valve ........ 169.5 to 170.0 mm

Cylinder Head Valves

(4) Inlet valve head ...................... 52.8 to 52.92 mm

The valve spring may be used on the inlet valve

The minimum load for the

The length of the installed

400 Nm (295 lb ft)

42.54 mm (1.6748 inch)

(1) Valve face angle ............................... 30 degrees

(1) Tighten the capscrews to the following

(1) Tighten the nut to the following torque. .... 11 Nm

(1) Tighten the bolts to the following torque. .. 27 Nm

1. Use a soft faced hammer to tap the outer edge of

Tighten the setscrews to the following

Tighten the fasteners (2), (3), (4) and (5) to the

(1) Tighten the bolts to the following torque. .. 50 Nm

Tighten the retaining bolts (not shown) to the

Engine Oil Pump