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Perkins 900 Series
Models CP and CR
WORKSHOP MANUAL
3 cylinder, naturally aspirated, and turbocharged diesel
engines for agricultural and industrial use
Publication, TPD 1345, Issue 3.
© Proprietary information of Perkins Engines Company Limited 2000, all rights reserved.
The information is correct at the time of print.
Published in June 2001 by Technical Publications.
Perkins Engines Company Limited, Peterborough, PE1 5NA, England.
i
This document has been printed from SPI². Not for Resale
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Table of Contents
Related Manuals for Perkins CP
Summarization of Contents
1 General Information
Introduction
Overview of the workshop manual for Perkins 900 Series engines.
Engine Identification
Details on how to identify the Perkins 900 Series engine number and labels.
Safety Precautions
Important safety guidelines for operating and servicing the engine.
Engine Lift Equipment
Guidance on using appropriate equipment for lifting engine components safely.
Viton Seals
Information and warnings regarding the handling of Viton seals, especially when burned.
POWERPART Recommended Consumable Products
List of recommended consumable products for engine service and maintenance.
2 Specifications
Data and Dimensions
Technical specifications and dimensions for basic engine data.
Thread Sealant
Recommendations for using sealant on setscrews and studs for engine assembly.
Standard Torque Tensions
Standard torque values for various types of fasteners used on the engine.
Special Torque Tensions
Specific torque values for setscrews and nuts in different engine assemblies.
Compression Test Data
Information and guidelines for performing engine compression tests.
3 Cylinder Head Assembly
General Description
Overview of the cylinder head assembly and its components.
Rocker Cover
Procedure for removing and fitting the rocker cover.
Rocker Assembly
Procedures for removing, dismantling, and inspecting the rocker assembly.
Valve Tip Clearances
Procedure for checking and adjusting valve tip clearances.
Cylinder Head Assembly
Procedures for removing and fitting the cylinder head assembly.
4 Piston and Connecting Rod Assembly
General Description
Overview of pistons, connecting rods, and their features.
Big End Bearing
Procedures for removing and fitting big end bearings.
Piston Rings
Procedures for removing, fitting, and inspecting piston rings.
5 Crankshaft Assembly
General Description
Overview of the crankshaft, its materials, and balance weights.
Crankshaft Pulley
Procedures for removing and fitting the crankshaft pulley.
Rear Oil Seal Assembly
Procedures for removing and fitting the rear oil seal assembly.
Main Bearings
Procedures for removing and fitting main bearings with the crankshaft in position.
Crankshaft
Procedures for removing and fitting the crankshaft, and checking its condition.
6 Timing Case and Drive Assembly
General Description
Overview of the timing case, gears, and their drive mechanism.
Timing Case Cover
Procedure for removing and fitting the timing case cover.
Front Oil Seal
Procedures for removing and fitting the front oil seal.
Timing Case
Procedure for removing and fitting the timing case.
7 Cylinder Block Assembly
General Description
Description of the cylinder block construction, liners, and camshaft journals.
Cylinder Block
Procedures for dismantling and inspecting the cylinder block.
Cylinder Liner
Procedure for fitting cylinder liners.
8 Engine Timing
General Description
Overview of engine timing gears and fuel injection pump timing.
To Set the Engine to Top Dead Centre (TDC)
Procedure for setting the engine to TDC on the compression stroke.
To Check the Valve Timing
Procedure for checking the engine valve timing.
9 Aspiration System
General Description
Overview of the turbocharger and its function.
Turbocharger
Procedures for removing and fitting the turbocharger.
Turbocharger Faults
Chart of common turbocharger problems and their possible causes.
Closed Breather System
Procedure for renewing the engine breather valve.
10 Lubrication System
General Description
Explanation of the engine lubrication system and oil flow.
Filter Canister
Procedure for renewing the oil filter canister.
Sump
Procedures for removing and fitting the engine sump.
Lubricating Oil Pump
Procedure for removing the lubricating oil pump.
11 Fuel System
Fuel Filter Types
Description of the two types of fuel filters used on the engine.
To Renew the Element Type Filter
Procedure for renewing the element type fuel filter.
Atomisers
Information on atomiser faults and how to identify a defective atomiser.
Fuel Lift Pump
Procedures for removing and fitting the fuel lift pump.
Delphi Fuel Injection Pumps
Procedures for removing and fitting Delphi fuel injection pumps.
To Adjust
Procedure for adjusting the fuel injection pump idle and maximum speeds.
To Eliminate Air from the Fuel System
Procedure for bleeding air from the fuel system.
12 Cooling System
General Information
Overview of the engine cooling system and coolant flow.
How to Fill the Cooling System
Procedure for filling and venting the cooling system.
Coolant Pump
Procedures for removing and fitting the coolant pump.
13 Flywheel and Flywheel Housing
General Description
Description of the flywheel and flywheel housing construction.
Flywheel
Procedures for removing and fitting the flywheel.
Flywheel Housing
Procedures for removing and fitting the flywheel housing.
14 Electrical Equipment
To Check the Drive Belts
Procedure for checking the condition and tension of drive belts.
To Remove and to Fit the Alternator
Procedures for removing and fitting the alternator.
Alternator Fault Diagnosis
Guide for diagnosing common alternator faults and their causes.
Starter Motors
Procedures for removing and fitting the starter motor.
Cold Starting System
General description of the cold starting system.
Starting Aid
Procedures for removing and fitting a fuelled starting aid.
15 Auxiliary Equipment
Not Used
This section is not used in this manual.
16 Special Tools
List of Special Tools
List of special tools available for engine service and maintenance.
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