Motor Perkins GN65770N

GN65770N
gn65770n
404D-22
2008/04/01
The information given within this parts book was correct at the time of printing and is subject to change without
notice. Always refer to your local Perkins outlet for the latest information. Only fully trained personnel should carry out servicing of engines. Before working on any engine always refer to the correct user service and maintenance
manual.
Always refer to your local Perkins outlet before purchasing any parts
Subject to any existing rights of third parties, the information given in this document is the property of Perkins Engines Limited and should not be copied, in whole or part, without the prior written consent of the Company.
Contents
1.
Introduction
Pg. 4
2.
How To Use Your Parts Book
Pg. 4
3.
Engine Breakdown
Pg. 5
4.
Symbol Descriptions
Pg. 9
5.
Parts Lists & Illustrations
Pg. 11
6.
Parts Index
Pg. 128
Introduction
The build list of your engine, found on the front page of this parts book, provides a unique
reference to the components fitted to your engine; therefore this parts book is only applicable to
this particular engine
Always quote your build list and engine serial number when contacting your Perkins outlet.
How to use your Parts Book

This parts book has been designed to provide you with all the information you need to identify
parts to service your engine. There are several features within the book to make it easy to find
the parts you require.
Front Page
This lists your build list number and the date of publication of this book
Symbol Descriptions
Provides a quick reference guide to the symbols used within the book.
Engine Breakdown
Use this to identify all the major sections of your engine and the relevant pages within the book.
Parts Lists & Illustrations
This section shows each major section of your engine broken down into individual part numbers
along with an associated illustration for identifying the parts you require.
The illustrations used in this parts book are representational only and should only be used for
identification purposes.
For fitting instructions please refer to your engine Service Manual.
Parts Index
Using either the part number or description of the part you require this section will help you
locate the page within the Parts Lists & Illustrations section where the part appears.
Engine Breakdown
Section
Page
Section
Page
Level 1 - Service
AAAAAAGN
11
Relief Valve
ACPG0004
37
Level 2 - Repair
AAAAAAGN
13
Timing Case
ADPG0016
39
Level 3 - Overhaul
AAAAAAGN
15
Timing Case
ADPG0016
41
Cylinder Block
ACPG0004
17
Timing Case
ADPG0016
43
Cylinder Block
ACPG0004
19
Timing Case
ADPG0016
45
Crankshaft, Pistons & Connecting Rods

ACPG0004
21
Timing Case
ADPG0016
47

ACPG0004
23
Camshaft & Gears

ADPG0016
49
Rear End Oil Seal

ACPG0004
25
Fuel Injection Pump

AFPG0016
51
Cylinder Head
ACPG0004
27
High Pressure Fuel Pipes

AFPG0016
53
Cylinder Head
ACPG0004
29
Atomisers
AFPG0016
55
Rocker Shaft Assembly

ACPG0004
31
Fuel Leak-Off Pipe

AFPG0016
57
Oil Pump
ACPG0004
33
Flywheel Housing
CDPG0001
59
Pipes
ACPG0004
35
Flywheel & Starter Ring

DDPG0000
61
Page 5
Engine Breakdown
Section
Page
Section
Page
Starter Motor
EDPG0001
63
Fan
MDPG0003
89
Pulleys
FBPG0001
65
Fan Drive
MEPG0017
91
Sump
GBPG0001
67
Alternator
NDPG0002
93
Dipstick & Filler Tube

GBPG0001
69
Drive Belt & Tensioner

NEPG0001
95

GBPG0001
71
Front End Drive Output

QCPG0001
97
Sump
GCPG0001
73
Cylinder Head Cover

TBPG0002
99
Filler
HBPG0000
75
Cylinder Head Cover

TBPG0002
101
Oil Filter
JBPG0000
77
Feed Pipes
TBPG0002
103
Oil Filter
JCPG0000
79
Exhaust Manifold
UBPG0002
105
Front End Drive Input

KBPG0001N
81
Exhaust Manifold
UDPG5503
107
Water Pump
LBPG0003
83
Lift Pump
VBPG0006
109
Thermostat & Housing

LBPG0003
85
Fuel Filter
VBPG0006
111
Water Outlet & Inlet

LDPG0001
87
Page 6
Engine Breakdown
Section
Page
Pipework & Connections

VBPG0006
113
Cold Start System

WDPG0000
115
Engine Lifting Eyes

XBPG0000
117
Throttle & Stop Controls

ZAPG0002
119
Instrumentation
ZJPG0000
121
Instrumentation
ZLPG0002
123
Electrical Wiring & Fittings

ZPPG0001
125
Fuel Pre-Lift Pump

ZVPG0001
127
Page 7
Engine Breakdown
Page 8
Symbols and Notes

Symbol
Description
From Engine Number
Upto Engine Number
Repairs and Replaces
See Appropriate Section - Reference Number
Alternative
Order
Remanufactured Part
New for Old Part
Number of Teeth
Thickness
Bottom
Top
Left Hand
Right Hand
Reference for Detailed Breakdown
Other Service Options Available
Cylinder Number
See History Section
Page 9
Level 1 - Service
Plate A
AAAAAAGN
Recommended stocking and service lists

Perkins provides Recommended stocking and service lists, for Distributor use when
recommending parts stocks for Dealers, preferred customers (eg fleets) etc. These lists
are based on agreed workshop capability and are at three distinct levels:
Level 1 - Service
The Level 1 workshop has the ability to perform basic non-intrusive maintenance on
Perkins engines.
Listes recommandes pour le stock et la maintenance
Perkins fournit des listes recommandes pour le stock et la maintenance afin d'aider le
Distributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont
bases sur le niveau technique des Ateliers avec trois niveaux distincts :
Niveau 1- Maintenance
L'atelier de niveau 1 est capable d'executer l'entretien de base des moteurs Perkins (sans
demontage).
Empfohlene Lagerbestands- und Servicelisten
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die
Vertragshndler verwenden knnen, um Hndlern und Kunden (z.B. Fuhrparks) einen
bestimmten Ersatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbarten
Werkstattfhigkeiten, welche in die folgenden drei Stufen unterteilt werden:
Stufe 1 - Service
Werksttten der Stufe 1 knnen grundlegende und einfache Wartungsarbeiten an
Perkins-Motoren ohne Spezialwerkzeug durchfhren.
Listas de servicio y de stock recomendadas
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el
Distribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientes
preferidos (por ejemplo, flotas), etc. Estas listas se basan en capacidad del taller
acordada y se dividen en tres niveles diferentes:
Nivel 1 - Servicio
El taller del Nivel 1 puede llevar a cabo un mantenimiento no intrusivo en los motores
Perkins.
Elenco parti consigliate ad uso stock ed assistenza
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza;
ci per soddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono
in considerazione la capacit operativa concordata con lofficina e sono distinti in tre livelli
Livello 1 - Assistenza
Il livello 1 prevede che lofficina sia in grado di operare in maniera basilare sui motori
Perkins.
Page 10
Level 1 - Service
Plate A
AAAAAAGN
Item
1
Part No.
References
Qty.
1
Description
Notes
LEVEL 1 - SERVICE
Page 11
Level 2 - Repair
Plate A
AAAAAAGN

Perkins provides Recommended stocking and service lists, for Distributor use when
recommending parts stocks for Dealers, preferred customers (eg fleets) etc. These lists are
based on agreed workshop capability and are at three distinct levels:
Level 2 - Repair
The Level 2 workshop has the ability to perform maintenance service,and inspection service on
Perkins engines.
Perkins fournit des listes recommandes pour le stock et la maintenance afin d'aider le
Distributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont bases sur
le niveau technique des Ateliers avec trois niveaux distincts :
Niveau 2 - Maintenance & reparation
L'atelier de niveau 2 est capable dexecuter toutes les oprations d'entretien, la reparation des
composants externes (demarreur, alternateur,etc) et le diagnostic pour les problmes touchant
l'electronique
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshndler
verwenden knnen, um Hndlern und Kunden (z.B. Fuhrparks) einen bestimmten
Ersatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbarten
Werkstattfhigkeiten, welche in die folgenden drei Stufen unterteilt werden:
Stufe 2 - Reparatur
Werksttten der Stufe 2 knnen Instandsetzungs- und Inspektionsarbeiten an Perkins-Motoren
durchfhren.
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el
Distribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientes preferidos
(por ejemplo, flotas), etc. Estas listas se basan en capacidad del taller acordada y se dividen en
tres niveles diferentes:
Nivel 2 - Reparacin
El taller de Nivel 2 puede llevar a cabo el servicio de mantenimiento y el servicio de inspeccin
en los motores Perkins.
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ci per
soddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono in
considerazione la capacit operativa concordata con lofficina e sono distinti in tre livelli :
Livello 2 - Riparazione
Nel livello 2 lofficina in grado di svolgere la manutenzione e di fare controlli di
assistenza sui motori Perkins.
Page 12
Level 2 - Repair
Plate A
AAAAAAGN
Item
1
Part No.
References
Qty.
1
Description
Notes
LEVEL 2 - REPAIR
Page 13
Level 3 - Overhaul
Plate A
AAAAAAGN

Perkins provides Recommended stocking and service lists, for Distributor use when recommending parts
stocks for Dealers, preferred customers (eg fleets) etc. These lists are based on agreed workshop capability
and are at three distinct levels:
Level 3 - Overhaul.
The Level 3 workshop has the ability to perform complete service work on Perkins engines. Can repair and
fully overhaul engine, including engine test. Can perform all levels of electronics diagnosis and application
related faults.
Perkins fournit des listes recommandes pour le stock et la maintenance afin d'aider le Distributeur dans ses
conseils aux Agents, aux clients habituels, etc.. Ces listes sont bases sur le niveau technique des Ateliers
avec trois niveaux distincts :
Niveau 3 - Maintenance, reparation & refection
L' atelier de niveau 3 est capable de couvrir toutes les oprations d'entretien des moteurs Perkins. Il peut
aussi rparer et entirement refaire des moteurs ainsi que les tester. Il est capable d'effectuer un diagnostic
pour les problmes touchant l'electronique et aux applications.
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshndler verwenden
knnen, um Hndlern und Kunden (z.B. Fuhrparks) einen bestimmten Ersatzteilbestand zu empfehlen. Diese
Listen basieren auf den vereinbarten Werkstattfhigkeiten, welche in die folgenden drei Stufen unterteilt
werden:
Stufe 3 - berholung
Werksttten der Stufe 3 knnen umfassende Servicearbeiten an Perkins-Motoren durchfhren. Sie knnen
Motoren reparieren und komplett berholen und auerdem Motorprfungen durchfhren. Sie knnen
umfassende elektronische Diagnoseprfungen durchfhren und anwendungsspezifische Strungen
untersuchen.
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el Distribuidor al
recomendar stocks de repuestos a los Distribuidores, a los clientes preferidos (por ejemplo, flotas), etc. Estas
listas se basan en capacidad del taller acordada y se dividen en tres niveles diferentes:
Nivel 3 - Reparacin general
El taller de Nivel 3 puede llevar a cabo un trabajo de servicio completo en los motores Perkins. Puede
reparar y reacondicionar completamente un motor, incluyendo probar el motor. Puede llevar a cabo todos los
niveles de diagnstico electrnico y las fallas relacionadas con la aplicacin.
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ci per soddisfare le
richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono in considerazione la capacit operativa
concordata con lofficina e sono distinti in tre livelli :
Livello 3 - Revisione
Nel livello 3 lofficina in grado di svolgere lavori di assistenza completi sui motori Perkins. E in grado di
riparare e svolgere una revisione completa del motore, incluso le prove. Pu anche effettuare diagnosi sull
elettronica a tutti i livelli e sui relativi difetti nelle applicazioni.
Page 14
Level 3 - Overhaul
Plate A
AAAAAAGN
Item
1
Part No.
References
Qty.
1
Description
Notes
LEVEL 3 - OVERHAUL
Page 15
Cylinder Block
Plate A
ACPG0004
14
22
13
18
19
8
20
6
3
2
11
12
16
17
21
15
10
9
Page 16
Cylinder Block
Plate A
ACPG0004
Item
Part No.
1
2 198466940
3 198466010
4 198466020
5 064210025
6 064210040
7 064210040
8 064210040
9 198466920
10 198517222
11 042309017
12 042309018
13 040106203
14 064100045
15 165296220
16 012110635
17 012110660
18 010109441
19 030500612
20 030500616
21 030501025
22 030309005
Service Options
10
10
198517226
198517229
References
J (-)0.25MM
J (-)0.50MM
Qty.
Description
1
4
3
2
2
3
1
1
3
1
1
1
1
1
1
1
1
3
2
2
2
2
CYLINDER BLOCK
PLUG
PLUG
PLUG
PLUG
PLUG
PLUG
PLUG
PLUG
BUSH
NEEDLE BEARING
NEEDLE BEARING
BALL BEARING
PLUG
SHAFT
STUD
STUD
STUD
DOWEL
DOWEL
DOWEL
PIN
1
1
BUSH
BUSH
Notes
(A)
Footnotes
(A)
SERVICE BY COMPLETE ENGINE
Page 17
Cylinder Block
Plate B
ACPG0004
2
1
Page 18
Cylinder Block
Plate B
ACPG0004
Item
Part No.
1
2
165996590
011310612
References
Qty.
Description
1
2
GASKET - TIMING CASE

SCREW
PLATE
Notes
History
a.
4
U65166580
Page 19
Plate A
ACPG0004
33
4
7
6
3
30
26
27
24
20
29
21
18
28
14
23
15
12
31
22
8
17
9
25
16
11
19
10
32
13
Page 20
Plate A
ACPG0004
Item
Part No.
1 115256990
2
3
115276270
4
030509020
5 199266210
6 199266200
7 199266200
8 110156360
9
10
11
030500612
12
010109406
13 011511070
14 110156370
15
16
17
030500612
18
010109406
19 011511070
20 110156380
21
22
23
030500612
24
010109406
25 011511070
26 110156390
27
28
29
030500612
30
010109406
31 010700860
32 U5MB0025
33 U5ME0030
Service Options
32
U5MB0025A
References
F 115256990
Q 1
F 110156360
F 110156360
Q 2
F 110156370
F 110156370
Q 3
F 110156380
F 110156380
Q 4
F 110156390
F 110156390
J (-) 0.25MM
Qty.
Description
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
2
1
1
1
1
2
2
1
1
1
1
2
2
2
1
1
CRANKSHAFT ASSEMBLY
CRANKSHAFT ASSEMBLY
CRANKSHAFT GEAR
KEY
THRUST WASHER
THRUST WASHER
THRUST WASHER
HOLDER
CAP
CAP
DOWEL
SCREW
SCREW
HOLDER
CAP
CAP
DOWEL
SCREW
SCREW
HOLDER
CAP
CAP
DOWEL
SCREW
SCREW
HOLDER
CAP
CAP
DOWEL
SCREW
BOLT
MAIN BEARING KIT
BIG END BEARING KIT
MAIN BEARING KIT
Notes
Page 21
Plate B
ACPG0004
12
7
8
10
11
5
4
Page 22
Plate B
ACPG0004
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
115017491
References
F 115017491
115107970
115026330
F 115026330
F 115026330
198517265
115176140
020109120
115326220
036500028
036500028
Qty.
4
1
1
4
1
1
1
2
2
4
4
4
Description
Notes
PISTON AND RING KIT

PISTON
PISTON RING KIT
CON ROD ASSEMBLY
ROD
CAP
SMALL END BUSH
CON ROD BOLT
CON ROD NUT
GUDGEON PIN
CIRCLIP
CIRCLIP
Page 23
Rear End Oil Seal
Plate A
ACPG0004
Page 24
Rear End Oil Seal
Plate A
ACPG0004
Item
Part No.
050209083
References
Qty.
1
Description
SEAL - REAR END OIL
Notes
(A,B)
Footnotes
(A)
SEE SERVICE BULLETIN NO.195
(B)
ALSO ORDER WEAR SLEEVE - 29990037
Page 25
Cylinder Head
Plate A
ACPG0004
21
22
1
20
14
19
13
18
7
12
17
11
5
16
10
15
9
Page 26
Cylinder Head
Plate A
ACPG0004
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
111011030
References
F 111011030
064210010
064210018
064210025
064210025
064210030
064210030
120166380
TPN646
120406070
198216700
120186080
120226070
120176380
TPN645
120406050
198216700
120186080
120226070
120216041
120216041
Qty.
1
1
3
7
3
3
1
1
4
4
4
4
4
4
4
4
4
4
4
4
4
4
Description
CYLINDER HEAD ASSEMBLY
CYLINDER HEAD
PLUG
CAP
PLUG
PLUG
CAP
CAP
INTAKE VALVE
VALVE SEAT INSERT
SEAL - VALVE STEM
VALVE SPRING
CAP
VALVE COLLET
EXHAUST VALVE
VALVE SEAT INSERT
SEAL - VALVE STEM
VALVE SPRING
CAP
VALVE COLLET
VALVE SPRING CAP
VALVE SPRING CAP
Notes
(A)
(B)
Footnotes
(A)
INLET
(B)
EXHAUST
Page 27
Cylinder Head
Plate B
ACPG0004
Page 28
Cylinder Head
Plate B
ACPG0004
Item
Part No.
1
2 111136480
3 111136490
4 012110655
5 012110860
Service Options
1
1
111147711
111147721
References
Qty.
Description
1
14
4
2
2
GASKET - CYLINDER HEAD

SCREW
SCREW
STUD
STUD
J 1.2MM
J 1.3MM
1
1

Notes
Page 29
Plate A
ACPG0004
1
7
8
10
3
16
15
14
12
11
13
Page 30
Plate A
ACPG0004
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
120036821
References
F 120036821
120316201
052109076
120356131
120356141
198217170
199486220
020109076
199280300
120996130
120456310
120116160
012109044
023100010
011310635
Qty.
1
1
1
1
4
4
3
8
8
6
1
8
8
4
4
2
Description
ROCKER BOX
ROCKER BOX
ROCKER SHAFT
SEAL - O RING
ROCKER ARM ASSEMBLY
ROCKER ARM ASSEMBLY
ROCKER SHAFT SPRING
ADJUSTING SCREW
NUT
WASHER
SEAL - ROCKER BOX
PUSHROD
TAPPET
STUD
NUT
SCREW
Notes
INLET
EXHAUST
Page 31
Oil Pump
Plate A
ACPG0004
14
2
1
5
3
6
4
8
9
10
11
12
Page 32
Oil Pump
Plate A
ACPG0004
Item
Part No.
1 165026270
2
3
4
5
198517290
6
030509018
7
198217760
8 140116220
9
10 198216720
11 199236540
12 036800010
14 199266270
Service Options
9
9
9
9
199286150
199286160
199286170
199286180
References
F 165026270
F 165026270
F 165026270
J
J
J
J
(+)0.10MM
(+)0.15MM
(+)0.20MM
(+)0.50MM
Qty.
Description
1
1
1
1
3
3
1
1
1
1
1
1
1
IDLER GEAR
IDLER GEAR
ROTOR
ROTOR
BUSH
DOWEL
SPRING
COVER
SHIM
SPRING
COLLAR
CIRCLIP
THRUST WASHER
1
1
1
1
SHIM
SHIM
SHIM
SHIM
Notes
Page 33
Pipes
Plate A
ACPG0004
4
1
3
2
Page 34
Pipes
Plate A
ACPG0004
Item
Part No.
1
2
3
4
140607020
198486780
140996260
140996260
References
Qty.
1
1
1
1
Description
Notes
OIL PIPE
BOLT
WASHER
WASHER
Page 35
Relief Valve
Plate A
ACPG0004
Page 36
Relief Valve
Plate A
ACPG0004
Item
Part No.
1
2
140036220
052109078
References
Qty.
1
1
Description
Notes
RELIEF VALVE
SEAL - O RING
Page 37
Timing Case
Plate A
ADPG0016
Page 38
Timing Case
Plate A
ADPG0016
Item
Part No.
1
2
3
4
5
165996630
011310640
011310660
023100006
References
Qty.
1
1
7
4
1
Description
TIMING CASE
GASKET - TIMING CASE
SCREW
SCREW
NUT
Notes
(A)
Footnotes
(A)
SEE FOLLOWING PARTS LIST FOR SERVICE COMPONENTS
Page 39
Timing Case
Plate B
ADPG0016
Page 40
Timing Case
Plate B
ADPG0016
Item
Part No.
1
2
3
165106870
030300414
198636160
References
Qty.
Description
1
1
1
TIMING CASE
PIN
SEAL - FRONT END OIL
1
1
SEAL - O RING
BEARING HOLDER ASSEMBLY
Notes
History
a.
052300850
110416290
Page 41
Timing Case
Plate C
ADPG0016
10
8
7
6
9
5
1
2
12
11
3
13
Page 42
Timing Case
Plate C
ADPG0016
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
125616120
165996640
125156262
198217870
052100070
198217750
023100008
2315C039
2648A120
26420462
2315C039
2318A207
011310614
References
R a.
Qty.
Description
1
1
1
1
1
1
1
1
1
1
1
1
4
BRACKET
GASKET
ARM
SPRING
SEAL - O RING
SPRING
NUT
SCREW
NUT
ANTI-TAMPER CAP
SCREW
NUT
SCREW
ARM
Notes
History
a.
3
125156261
Page 43
Timing Case
Plate D
ADPG0016
11
2
6
3
1
10
4
8
9
7
5
Page 44
Timing Case
Plate D
ADPG0016
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
125046613
125116221
025100008
131046560
020800010
125306151
125116211
024500006
025100006
198217880
031100004
References
R a.
R b.
Qty.
Description
1
1
1
1
1
1
1
1
1
1
1
CONTROL LEVER
SHAFT
WASHER
SPEED SENSOR
NUT
CONTROL LEVER
SHAFT
NUT
WASHER
SPRING
PIN
Notes
History
a.
1
125046612
CONTROL LEVER
125306150
CONTROL LEVER
b.
Page 45
Timing Case
Plate E
ADPG0016
1
3
4
5
8
10
9
12
11
Page 46
Timing Case
Plate E
ADPG0016
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
131046650
References
F 131046650
020109177
025100010
198217910
198346160
131276440
131466251
020109239
025100006
064210012
131466270
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
Description
Notes
SCREW
BOLT
NUT
WASHER
SPRING
RING
ANTI-TAMPER CAP
BOLT
NUT
WASHER
CAP
ANTI-TAMPER CAP
Page 47
Camshaft & Gears
Plate A
ADPG0016
9
1
2
5
6
Page 48
Camshaft & Gears
Plate A
ADPG0016
Item
Part No.
1
2
3
4
5
6
7
8
9
120026950
References
F 120026950
034100508
120016240
040109057
199216320
125256240
199566750
011310612
Qty.
1
1
1
1
1
1
1
1
1
Description
Notes
CAMSHAFT
CAMSHAFT
WOODRUFF KEY
CAMSHAFT GEAR
BALL BEARING
SPACER
SLIDER
PLATE
SCREW
Page 49
Fuel Injection Pump
Plate A
AFPG0016
5
1
Page 50
Fuel Injection Pump
Plate A
AFPG0016
Item
Part No.
1 131010080
2
3 010800820
4 010700820
5 027100008
6 023100008
Service Options
2
2
2
2
2
2
2
131437490
131437730
131437500
131437760
131437510
131437520
131437530
References
J
J
J
J
J
J
J
(+) 0.2MM
(+) 0.25MM
(+) 0.3MM
(+) 0.35MM
(+) 0.4MM
(+) 0.5MM
(+) 0.5MM
Qty.
Description
1
1
2
1
1
3
FUEL INJECTION PUMP

SHIM
SCREW
SCREW
WASHER
NUT
1
1
1
1
1
1
1
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
Notes
(A)
Footnotes
(A)
FLAT
Page 51
Plate A
AFPG0016
Page 52
Plate A
AFPG0016
Item
Part No.
1
2
3
4
5
6
7
8
131507520
131507530
131507540
131507550
199106021
199106021
010110625
023100006
References
Q
Q
Q
Q
1
2
3
4
Qty.
1
1
1
1
3
3
3
3
Description
Notes
FUEL INJECTION PIPE

FUEL INJECTION PIPE
FUEL INJECTION PIPE
FUEL INJECTION PIPE
CLAMP
CLAMP
SCREW
NUT
Page 53
Atomisers
Plate A
AFPG0016
Page 54
Atomisers
Plate A
AFPG0016
Item
1
2
3
Part No.
131406440
131426230
131426200
References
Qty.
4
1
4
Description
Notes
INJECTOR
SEAL - INJECTOR
SEAL - INJECTOR
Page 55
Fuel Leak-Off Pipe
Plate A
AFPG0016
4
2
3
Page 56
Flywheel Housing
Plate A
CDPG0001
Page 58
Flywheel Housing
Plate A
CDPG0001
Item
Part No.
1
2
3
4
5
6
7
110367570
011510816
011511220
010111030
020900010
026200010
027100010
References
Qty.
1
10
2
2
2
2
2
Description
Notes
BACKPLATE
SCREW
SCREW
BOLT
NUT
WASHER
WASHER
Page 59
Plate A
DDPG0000
Page 60
Plate A
DDPG0000
Item
Part No.
010109341
References
Qty.
6
Description
Notes
BOLT
Page 61
Starter Motor
Plate A
EDPG0001
Page 62
Starter Motor
Plate A
EDPG0001
Item
Part No.
185086600
References
Qty.
1
Description
Notes
STARTER MOTOR
Page 63
Pulleys
Plate A
FBPG0001
Page 64
Pulleys
Plate A
FBPG0001
Item
Part No.
145336620
References
Qty.
1
Description
Notes
WATER PUMP PULLEY
Page 65
Sump
Plate A
GBPG0001
Page 66
Sump
Plate A
GBPG0001
Item
Part No.
1
2
3
4
5
6
7
110708390
110996920
010109235
140406680
140987020
052109076
011310612
References
A U713161N
A U713161N
Qty.
1
1
30
1
1
1
2
Description
Notes
SUMP
GASKET - SUMP
SCREW
STRAINER
PIPE - OIL SUCTION
SEAL - O RING
SCREW
Page 67
Plate A
GBPG0001
Page 68
Plate A
GBPG0001
Item
Part No.
1
2
3
4
198416690
110756490
010109235
052100100
References
Qty.
1
1
1
2
Description
Notes
DIPSTICK
DIPSTICK TUBE
SCREW
SEAL - O RING
Page 69
Plate B
GBPG0001
Page 70
Plate B
GBPG0001
Item
Part No.
1
2
3
4
198436290
052100100
052100100
011310612
References
Qty.
1
1
1
1
Description
Notes
PLUG
SEAL - O RING
SEAL - O RING
SCREW
Page 71
Sump
Plate A
GCPG0001
4
3
2
1
Page 72
Sump
Plate A
GCPG0001
Item
Part No.
1
2
3
4
198736310
025100016
010109238
025100016
References
Qty.
1
1
1
1
Description
Notes
VALVE
WASHER
SCREW
WASHER
Page 73
Filler
Plate A
HBPG0000
Page 74
Filler
Plate A
HBPG0000
Item
Part No.
1
2
3
4
198436350
052100400
398430080
052100280
References
Qty.
1
1
1
1
Description
Notes
OIL FILLER CAP

SEAL - O RING
OIL FILLER CAP
SEAL - O RING
Page 75
Oil Filter
Plate A
JBPG0000
Page 76
Oil Filter
Plate A
JBPG0000
Item
Part No.
140517050
References
Qty.
1
Description
Notes
OIL FILTER
Page 77
Oil Filter
Plate A
JCPG0000
Page 78
Oil Filter
Plate A
JCPG0000
Item
Part No.
140546020
References
Qty.
1
Description
Notes
CONNECTION
Page 79
Plate A
KBPG0001N
Page 80
Plate A
KBPG0001N
Item
Part No.
1
2
3
U15397401
020109086
034100508
References
R a.
Qty.
Description
1
1
1
CRANKSHAFT PULLEY
NUT
WOODRUFF KEY
CRANKSHAFT PULLEY
Notes
History
a.
1
115397400
Page 81
Water Pump
Plate A
LBPG0003
2
7
4
5
Page 82
Water Pump
Plate A
LBPG0003
Item
Part No.
1
2
3
4
5
6
7
145010060
145996921
145537300
2481877
2481877
011310635
023100006
References
Qty.
1
1
1
1
1
4
1
Description
Notes
WATER PUMP
GASKET
HOSE
HOSE CLIP
HOSE CLIP
SCREW
NUT
Page 83
Plate A
LBPG0003
6
3
Page 84
Plate A
LBPG0003
Item
Part No.
1
2
3
4
5
6
7
145046110
145206230
145996930
011310655
023100006
064500030
064500060
References
Qty.
1
1
1
2
2
1
1
Description
Notes
THERMOSTAT HOUSING
THERMOSTAT
GASKET - THERMOSTAT HSG
BOLT
NUT
PLUG
PLUG
Page 85
Plate A
LDPG0001
Page 86
Plate A
LDPG0001
Item
Part No.
1
2
3
145226320
145996051
011510825
References
Qty.
1
1
2
Description
Notes
CONNECTION
GASKET - THERMOSTAT HSG
SCREW
Page 87
Fan
Plate A
MDPG0003
Page 88
Fan
Plate A
MDPG0003
Item
Part No.
145306730
References
Qty.
1
Description
Notes
FAN
Page 89
Fan Drive
Plate A
MEPG0017
Page 90
Fan Drive
Plate A
MEPG0017
Item
Part No.
1
2
145386390
011310620
References
Qty.
1
4
Description
Notes
PLATE
SCREW
Page 91
Alternator
Plate A
NDPG0002
9
8
11
10
2
3
1
6
12
4
Page 92
Alternator
Plate A
NDPG0002
Item
1
2
3
4
5
6
7
8
9
10
11
12
Part No.
References
TPN766
F TPN766
3113E031
TPN744
2314H022
011510820
185727130
011510825
026100008
011510825
026109017
023100008
Qty.
1
1
1
1
1
3
1
1
1
1
1
1
Description
Notes
ALTERNATOR
ALTERNATOR
ALTERNATOR PULLEY
ALTERNATOR BRACKET
SCREW
SCREW
LEVER
SCREW
WASHER
SCREW
WASHER
NUT
Page 93
Plate A
NEPG0001
Page 94
Plate A
NEPG0001
Item
Part No.
080109107
References
Qty.
1
Description
Notes
BELT
Page 95
Plate A
QCPG0001
4
9
1
8
Page 96
Plate A
QCPG0001
Item
Part No.
1
2
3
4
5
6
7
8
9
U65166580
110416290
U65206791
052300850
052300850
U65206791
052300850
2314J017
2318A604
References
Qty.
1
1
1
1
1
1
1
2
2
Description
Notes
PLATE
BEARING HOLDER ASSEMBLY
COVER
SEAL - O RING
SEAL - O RING
COVER
SEAL - O RING
SCREW
NUT
Page 97
Cylinder Head Cover
Plate A
TBPG0002
3
9
10
11
8
1
Page 98
Cylinder Head Cover
Plate A
TBPG0002
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
111217411
111996401
110566080
011100408
110666210
110666060
015600406
011310640
011310660
024600010
140996270
References
Qty.
1
1
1
4
1
1
6
2
3
4
4
Description
Notes
CYLINDER HEAD COVER

GASKET - CYL. HEAD COVER
BREATHER VALVE
METRIC BOLT
RETAINING PLATE
GAUZE
SCREW
SCREW
SCREW
NUT
WASHER
Page 99
Cylinder Head Cover
Plate B
TBPG0002
Page 100
Cylinder Head Cover
Plate B
TBPG0002
Item
Part No.
1
2
3
135566570
135996950
011310620
References
Qty.
1
1
2
Description
Notes
PIPE - AIR
GASKET
SCREW
Page 101
Feed Pipes
Plate A
TBPG0002
Page 102
Feed Pipes
Plate A
TBPG0002
Item
Part No.
1
2
3
165206810
3688A035
010109600
References
Qty.
1
1
2
Description
Notes
COVER
GASKET
SCREW
Page 103
Exhaust Manifold
Plate A
UBPG0002
1
6
5
4
3
Page 104
Exhaust Manifold
Plate A
UBPG0002
Item
Part No.
1
2
3
4
5
6
135617150
135996780
011510860
010310880
023100008
027100008
References
Qty.
1
1
4
2
2
2
Description
Notes
EXHAUST MANIFOLD
GASKET - EXHAUST MANIFOLD
SCREW
SCREW
NUT
WASHER
Page 105
Exhaust Manifold
Plate A
UDPG5503
Page 106
Exhaust Manifold
Plate A
UDPG5503
Item
Part No.
1
2
314990013
011510825
References
Qty.
1
1
Description
Notes
GASKET - EXHAUST
SCREW
Page 107
Lift Pump
Plate A
VBPG0006
Page 108
Lift Pump
Plate A
VBPG0006
Item
Part No.
1
2
3
130506351
2415A070
2314F003
References
Qty.
1
1
2
Description
Notes
LIFT PUMP
SEAL - O RING
SCREW
Page 109
Fuel Filter
Plate A
VBPG0006
1
6
10
Page 110
11
Fuel Filter
Plate A
VBPG0006
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
130316190
130366120
130976260
130976250
010111035
026200010
020900010
027100010
010310820
023100008
011510816
References
Qty.
1
1
1
1
2
2
2
2
2
2
2
Description
Notes
FUEL FILTER HEAD

FUEL FILTER
BRACKET
STAY
BOLT
WASHER
NUT
WASHER
BOLT
NUT
SCREW
Page 111
Plate A
VBPG0006
7
9
6
8
2
1
12
13
10
Page 112
11
Plate A
VBPG0006
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
TPN673
2411156
068209227
067100015
067100015
131246240
TPN731
2411156
2411156
068209126
067100015
067100015
References
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
Description
Notes
FUEL PIPE
WASHER
FUEL PIPE
CLIP
CLIP
CONNECTION
BANJO BOLT
WASHER
WASHER
HOSE
CLIP
CLIP
FUEL FILTER HEAD
Page 113
Cold Start System
Plate A
WDPG0000
Page 114
Cold Start System
Plate A
WDPG0000
Item
Part No.
1
2
3
4
5
6
185366190
References
F 185366190
F 185366190
185376150
020100004
027100004
Qty.
4
1
1
1
1
1
Description
Notes
GLOWPLUG
GLOWPLUG
NUT
BAR
NUT
WASHER
Page 115
Engine Lifting Eyes
Plate A
XBPG0000
2
3
Page 116
Engine Lifting Eyes
Plate A
XBPG0000
Item
Part No.
1
2
3
4
195816100
011510820
026100008
195816100
References
Qty.
1
1
1
1
Description
Notes
LIFTING EYE
SCREW
WASHER
LIFTING EYE
Page 117
Plate A
ZAPG0002
Page 118
Plate A
ZAPG0002
Item
Part No.
1
2
3
U25416480
185206450
025100016
References
Qty.
1
1
1
Description
Notes
CONTROL LEVER
SOLENOID
WASHER
Page 119
Instrumentation
Plate A
ZJPG0000
Page 120
Instrumentation
Plate A
ZJPG0000
Item
Part No.
1
2
3
4
5
198486871
140996260
140996260
064400010
References
Qty.
1
1
1
1
1
Description
Notes
BANJO BOLT
WASHER
WASHER
PLUG
ROCKER BOX ASSEMBLY
Page 121
Instrumentation
Plate A
ZLPG0002
Page 122
Instrumentation
Plate A
ZLPG0002
Item
Part No.
385720500
References
Qty.
1
Description
Notes
WATER TEMPERATURE SENSOR
Page 123
Plate A
ZPPG0001
Page 124
Plate A
ZPPG0001
Item
1
2
Part No.
References
20195
F 20195
Qty.
1
3
Description
Notes
CONNECTION KIT
CONNECTION
Page 125
Fuel Pre-Lift Pump
Plate A
ZVPG0001
Page 126
Fuel Pre-Lift Pump
Plate A
ZVPG0001
Item
Part No.
1
2
3
5
4
6
130306380
References
F 130306380
26560182
26560183
130306360
26560184
Qty.
1
1
1
3
1
1
Description
Notes
PRE-FUEL FILTER ASSY

FUEL FILTER HEAD
FUEL FILTER BOWL
DRAIN PLUG
FUEL FILTER
SEAL - O RING
Page 127
Parts Index
Page 128
Parts Index
Description
Part No.
Page
ADJUSTING SCREW
199486220
ALTERNATOR
Part No.
Page
31
198486780
35
TPN766
93
198487450
57
ALTERNATOR
BRACKET
TPN744
93
125616120
43
130976260
111
ALTERNATOR
PULLEY
3113E031
93
BREATHER VALVE
110566080
99
ANTI-TAMPER CAP
131276440
47
BUSH
198517222
17
131466270
47
198517226
17
26420462
43
198517229
17
125156261
43
198517290
33
125156262
43
CAMSHAFT
120026950
49
BACKPLATE
110367570
59
CAMSHAFT GEAR
120016240
49
BALL BEARING
040106203
17
CAP
064210012
47
040109057
49
064210018
27
198486871
121
064210030
27, 27
TPN731
113
120186080
27, 27
BAR
185376150
115
036500028
23, 23
BEARING HOLDER
ASSEMBLY
110416290
41, 97
036800010
33
CLAMP
199106021
53, 53
BELT
080109107
95
CLIP
067100015
BIG END BEARING

KIT
U5ME0030
21
113, 113,
113, 113
COLLAR
199236540
33
BOLT
010109341
61
115026330
23
010111030
59
CON ROD
ASSEMBLY
010111035
111
CON ROD BOLT
115176140
23
010310820
111
CON ROD NUT
020109120
23
010700860
21
CONNECTION
131246240
113
011310655
85
140546020
79
131466251
47
145226320
87
ARM
BANJO BOLT
Description
BRACKET
CIRCLIP
Page 129
Parts Index
Description
Part No.
Page
Description
Part No.
Page
CONNECTION KIT
20195
125
FAN
145306730
89
CONTROL LEVER
125046612
45
FUEL FILTER
130306360
127
125046613
45
130366120
111
125306150
45
FUEL FILTER BOWL
26560182
127
125306151
45
FUEL FILTER HEAD
130316190
111
U25416480
119
131507520
53
140116220
33
FUEL INJECTION
PIPE
165206810
103
131507530
53
U65206791
97, 97
131507540
53
CRANKSHAFT
ASSEMBLY
115256990
21
131507550
53
131010080
51
CRANKSHAFT
GEAR
115276270
FUEL INJECTION
PUMP
FUEL PIPE
068209227
113
CRANKSHAFT
PULLEY
115397400
TPN673
113
135996950
101
145996921
83
165996640
43
3688A035
103
GASKET - CYL.
HEAD COVER
111996401
99
GASKET CYLINDER HEAD
111147711
29
111147721
29
GASKET EXHAUST
314990013
107
GASKET EXHAUST
MANIFOLD
135996780
105
GASKET - SUMP
110996920
67
GASKET THERMOSTAT HSG
145996051
87
COVER
21
81
GASKET
U15397401
81
CYLINDER HEAD
ASSEMBLY
111011030
27
CYLINDER HEAD
COVER
111217411
99
DIPSTICK
198416690
69
DIPSTICK TUBE
110756490
69
DOWEL
030500612
17, 21,
21, 21, 21
030500616
17
030501025
17
030509018
33
DRAIN PLUG
26560183
127
EXHAUST
MANIFOLD
135617150
105
EXHAUST VALVE
120176380
Page 130
27
Parts Index
Description
GASKET - TIMING
CASE
Part No.
Page
145996930
165996590
Description
Part No.
Page
85
020109086
81
19
020109177
47
020109239
47
020800010
45
020900010
59, 111
023100006
39, 53,
83, 85
023100008
43, 51,
93, 105,
111
165996630
39
GAUZE
110666060
99
GLOWPLUG
185366190
115
GUDGEON PIN
115326220
23
HOLDER
110156360
21
110156370
21
110156380
21
023100010
31
110156390
21
024500006
45
068209126
113
024600010
99
145537300
83
2318A207
43
HOSE CLIP
2481877
83, 83
2318A604
97
IDLER GEAR
165026270
33
2648A120
43
INJECTOR
131406440
55
198436350
75
INTAKE VALVE
120166380
27
398430080
75
KEY
030509020
21
OIL FILTER
140517050
77
LEVER
185727130
93
OIL PIPE
140607020
35
LIFT PUMP
130506351
109
PIN
030300414
41
LIFTING EYE
195816100
117, 117
030309005
17
MAIN BEARING KIT
U5MB0025
21
031100004
45
U5MB0025A
21
PIPE - AIR
135566570
101
METRIC BOLT
011100408
99
U31607080
57
NEEDLE BEARING
042309017
17
PIPE - FUEL INJ

LEAK OFF
042309018
17
PIPE - OIL SUCTION
140987020
67
020100004
115
PISTON AND RING

KIT
115017491
23
020109076
31
PISTON RING KIT
115107970
23
HOSE
NUT
OIL FILLER CAP
Page 131
Parts Index
Description
Part No.
Page
PLATE
145386390
Part No.
Page
91
010109238
73
199566750
49
010109406
U65166580
19, 97
21, 21,
21, 21
064100045
17
010109600
103
064210010
27
010110625
53
064210025
17, 27, 27
010310880
105
064210040
17, 17, 17
010700820
51
064400010
121
010800820
51
064500030
85
011310612
19, 49,
67, 71
064500060
85
011310614
43
198436290
71
011310620
91, 101
198466010
17
011310635
31, 83
198466020
17
011310640
39, 99
198466920
17
011310660
39, 99
198466940
17
011510816
59, 111
PRE-FUEL FILTER
ASSY
130306380
127
011510820
93, 117
PUSHROD
120456310
31
011510825
87, 93,
93, 107
RELIEF VALVE
140036220
37
011510860
105
RETAINING PLATE
110666210
99
011511070
21, 21, 21
RING
198346160
47
011511220
59
ROCKER ARM
ASSEMBLY
120356131
31
015600406
99
120356141
31
111136480
29
ROCKER BOX
120036821
31
111136490
29
ROCKER SHAFT
120316201
31
131046650
47
ROCKER SHAFT
SPRING
198217170
31
2314F003
109
2314H022
93
SCREW
010109235
2314J017
97
PLUG
Page 132
67, 69
Description
Parts Index
Description
Part No.
Page
2315C039
SEAL - FRONT END
OIL
198636160
SEAL - INJECTOR
131426200
55
131426230
55
Part No.
Page
43, 43
131437730
51
41
131437760
51
199286150
33
199286160
33
052100070
43
199286170
33
052100100
69, 71, 71
199286180
33
SLIDER
125256240
49
052100280
75
052100400
75
SMALL END BUSH
198517265
23
052109076
31, 67
SOLENOID
185206450
119
052109078
37
SPACER
199216320
49
SPEED SENSOR
131046560
45
052300850
41, 97,
97, 97
SPRING
198216720
33
2415A070
109
198217750
43
26560184
127
198217760
33
SEAL - REAR END

OIL
050209083
25
198217870
43
198217880
45
SEAL - ROCKER
BOX
120996130
31
198217910
47
SEAL - VALVE
STEM
120406050
27
STARTER MOTOR
185086600
63
STAY
130976250
111
SEAL - O RING
SHAFT
SHIM
Description
120406070
27
STRAINER
140406680
67
125116211
45
STUD
010109441
17
125116221
45
012109044
31
165296220
17
012110635
17
131437490
51
012110655
29
131437500
51
012110660
17
131437510
51
012110860
29
131437520
51
110708390
67
131437530
51
SUMP
Page 133
Parts Index
Description
Part No.
Page
TAPPET
120116160
31
THERMOSTAT
145206230
85
THERMOSTAT
HOUSING
145046110
85
THRUST WASHER
199266200
21, 21
199266210
21
199266270
33
TIMING CASE
165106870
41
VALVE
198736310
73
VALVE COLLET
120226070
27, 27
VALVE SEAT
INSERT
TPN645
27
TPN646
27
VALVE SPRING
198216700
27, 27
VALVE SPRING CAP
120216041
27, 27
WASHER
025100006
45, 47
025100008
45, 57, 57
025100010
47
025100016
73, 73,
119
026100008
93, 117
026109017
93
026200010
59, 111
027100004
115
027100008
51, 105
027100010
59, 111
Page 134
Description
Part No.
Page
140996260
35, 35,
121, 121
140996270
99
199280300
31
2411156
113, 113,
113
WATER PUMP
145010060
83
WATER PUMP
PULLEY
145336620
65
WATER
TEMPERATURE
SENSOR
385720500
123
WOODRUFF KEY
034100508
49, 81

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GN65770N

How To Use Your Parts Book

Parts Lists & Illustrations

How to use your Parts Book

Crankshaft, Pistons & Connecting Rods

Crankshaft, Pistons & Connecting Rods

Camshaft & Gears

Rear End Oil Seal

Fuel Injection Pump

High Pressure Fuel Pipes

Rocker Shaft Assembly

Fuel Leak-Off Pipe

Flywheel & Starter Ring

Dipstick & Filler Tube

Drive Belt & Tensioner

Dipstick & Filler Tube

Front End Drive Output

Cylinder Head Cover

Cylinder Head Cover

Front End Drive Input

Thermostat & Housing

Water Outlet & Inlet

Pipework & Connections

Cold Start System

Engine Lifting Eyes

Throttle & Stop Controls

Electrical Wiring & Fittings

Fuel Pre-Lift Pump

Symbols and Notes

From Engine Number

Upto Engine Number

Repairs and Replaces

See Appropriate Section - Reference Number

New for Old Part

Reference for Detailed Breakdown

Other Service Options Available

See History Section

Recommended stocking and service lists

Recommended stocking and service lists

Recommended stocking and service lists

SERVICE BY COMPLETE ENGINE

GASKET - TIMING CASE

Crankshaft, Pistons & Connecting Rods

Crankshaft, Pistons & Connecting Rods

MAIN BEARING KIT

Crankshaft, Pistons & Connecting Rods

Crankshaft, Pistons & Connecting Rods

PISTON AND RING KIT

Rear End Oil Seal

Rear End Oil Seal

SEE SERVICE BULLETIN NO.195

ALSO ORDER WEAR SLEEVE - 29990037

GASKET - CYLINDER HEAD

GASKET - CYLINDER HEAD

Rocker Shaft Assembly

Rocker Shaft Assembly

SEE FOLLOWING PARTS LIST FOR SERVICE COMPONENTS

Camshaft & Gears