Perkins 403D-15G GK65597U

GK65597U
GK65597U
403D-15
2007/12/07
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. 140
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
Cylinder Block
ACPG0009
11
Timing Case
ADPG0034
37
Cylinder Block
ACPG0009
13
Timing Case
ADPG0034
39
Crankshaft, Pistons & Connecting Rods

ACPG0009
15
Timing Case
ADPG0034
41

ACPG0009
17
Camshaft & Gears

ADPG0034
43
Rear End Oil Seal

ACPG0009
19
Fuel Injection Pump

AFPG0034
45
Cylinder Head
ACPG0009
21
High Pressure Fuel Pipes

AFPG0034
47
Cylinder Head
ACPG0009
23
Atomisers
AFPG0034
49
Rocker Shaft Assembly

ACPG0009
25
Fuel Leak-Off Pipe

AFPG0034
51
Oil Pump
ACPG0009
27
Flywheel Housing
CDPG0012
53
Pipes
ACPG0009
29
Flywheel & Starter Ring

DDPG0009
55
Relief Valve
ACPG0009
31
Starter Motor
EDPG0004
57
Timing Case
ADPG0034
33
Pulleys
FBPG0009
59
Timing Case
ADPG0034
35
Lubricating Oil Sump

GBPG0016
61
Page 5
Engine Breakdown
Section
Page
Section
Page
Dipstick & Tube

GBPG0016
63
Blanking Plates
QCPG0009
89
Dipstick & Tube

GBPG0016
65
Cylinder Head Cover

TBPG0004
91
Sump
GCPG0000
67
Feed Pipes
TBPG0004
93
Filler
HBPG0007
69
Air Filter Assembly

TDPG0007
95
Oil Filter
JBPG0000
71
Pipework & Connections

TDPG0007
97
Oil Filter
JCPG0000
73
Exhaust Manifold
UBPG0004
99
Front End Drive Input

KBPG0005
75
Exhaust Connection
UDPG0001
101
Water Pump
LBPG0006
77
Lift Pump
VBPG0015
103
Thermostat & Housing

LBPG0006
79
Fuel Filter
VBPG0015
105

LDPG0005
81

VBPG0015
107
Fan Drive
MEPG0001
83
Cold Start System

WDPG0002
109
Alternator Bracket & Fixings

NDPG0016
85
Engine Lifting Eyes

XBPG0009
111
Drive Belt & Tensioner

NEPG0010
87
Throttle & Stop Controls

ZAPG0011
113
Page 6
Engine Breakdown
Section
Page
Heater/Starter Switch
ZEPG0001
115
Instrumentation
ZJPG0008
117
Instrumentation
ZLPG0006
119
Radiator & Cowling

ZMPG0008
121
Radiator & Cowling

ZMPG0008
123
Radiator & Cowling

ZMPG0008
125
Fan
ZMPG0008
127
Guards
ZMPG0008
129
Guards
ZMPG0008
131
Engine Mounts
ZMPG0008
133
Electrical Wiring & Fittings

ZPPG0002
135
Fuel Pre-Lift Pump

ZVPG0002
137
Application Miscellaneous & Auxiliaries

ZZPG0004
139
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
Cylinder Block
Plate A
ACPG0009
15
14
2
22
21
20
4
6
7
17
16
10
13
19
18
11
8
9
12
Page 10
Cylinder Block
Plate A
ACPG0009
Item
Part No.
1
2 064210025
3 064210040
4 064210040
5 064210040
6 198466010
7 198466020
8 198466020
9 198466020
10 198466940
11 165296220
12 198517222
13 042309013
14 040106203
15 064100045
16 012110635
17 012110660
18 030500616
19 030501025
20 010109441
21 030500612
22 030309005
Service Options
12
12
198517226
198517229
References
J (-)0.25MM
J (-)0.50MM
Qty.
Description
1
1
1
2
1
2
2
2
1
4
1
1
1
1
1
2
1
2
2
2
2
2
CYLINDER BLOCK ASSEMBLY

PLUG
PLUG
PLUG
PLUG
PLUG
PLUG
PLUG
PLUG
PLUG
SHAFT
BUSH
NEEDLE BEARING
BALL BEARING
PLUG
STUD
STUD
DOWEL
DOWEL
STUD
DOWEL
PIN
1
1
BUSH
BUSH
Notes
(A)
Footnotes
(A)
SERVICE BY COMPLETE ENGINE
Page 11
Cylinder Block
Plate B
ACPG0009
3
2
Page 12
Cylinder Block
Plate B
ACPG0009
Item
Part No.
1
2
3
U65166580
165996590
011310612
References
R a.
Qty.
Description
1
1
2
PLATE
GASKET - TIMING CASE
SCREW
PLATE
Notes
History
a.
1
165166580
Page 13
Plate A
ACPG0009
27
4
6
7
20
24
21
14
18
23
15
22
12
17
25
16
19
11
10
13
Page 14
26
Plate A
ACPG0009
Item
Part No.
1 115256950
2
3
115276270
4
030509020
5
030300816
6 199266200
7 199266200
8 110156171
9
10
11
030500612
12
010109406
13 011511070
14 110156181
15
16
17
030500612
18
010109406
19 011511070
20 110156191
21
22
23
030500612
24
010109406
25 010700865
26 198586050
27 198586080
Service Options
26
26
27
27
198586054
198586057
198586084
198586087
References
F 115256950
F 110156171
F 110156171
F 110156181
F 110156181
F 110156191
F 110156191
J
J
J
J
(-)0.25MM
(-)0.50MM
(-)0.25MM
(-)0.50MM
Qty.
Description
Notes
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
2
2
1
1
1
1
2
2
2
1
1
CRANKSHAFT ASSEMBLY
CRANKSHAFT
CRANKSHAFT GEAR
KEY
PIN
THRUST WASHER
THRUST WASHER
HOLDER
CAP
CAP
DOWEL
SCREW
SCREW
HOLDER
CAP
CAP
DOWEL
SCREW
SCREW
HOLDER
CAP
CAP
DOWEL
SCREW
SCREW
MAIN BEARING KIT
BIG END BEARING KIT
(A) STD.
(A) STD.
1
1
1
1
MAIN BEARING KIT - U/S

MAIN BEARING KIT - U/S
BIG END BRG KIT - U/S
BIG END BRG KIT - U/S
(A)
(A)
(A)
(A)
Footnotes
(A)
BEARINGS ARE PRE-FINISHED
Page 15
Plate B
ACPG0009
6
10
11
4
5
7
12
Page 16
Plate B
ACPG0009
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
115017541
References
F 115017541
115107970
115326220
036500028
036500028
115026251
F 115026251
F 115026251
198517265
115176140
020109120
Qty.
3
1
1
3
3
3
3
1
1
1
2
2
Description
Notes
PISTON AND RING KIT

PISTON
PISTON RING KIT
GUDGEON PIN
CIRCLIP
CIRCLIP
CON ROD ASSEMBLY
ROD
CAP
SMALL END BUSH
CON ROD BOLT
CON ROD NUT
Page 17
Rear End Oil Seal
Plate A
ACPG0009
Page 18
Rear End Oil Seal
Plate A
ACPG0009
Item
Part No.
198636170
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 19
Cylinder Head
Plate A
ACPG0009
22
21
1
20
14
19
13
4
18
12
17
8
11
2
6
3
5
15
9
16
10
Page 20
Cylinder Head
Plate A
ACPG0009
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
111011050
References
F 111011050
064210010
064210018
064210025
064210025
064210030
064210030
TPN646
120166380
120406070
198217470
120186080
120226070
TPN645
120176380
120406050
198217470
120186080
120226070
120216040
120216040
Qty.
1
1
2
5
2
1
1
1
3
3
3
3
3
6
3
3
3
3
3
6
3
3
Description
CYLINDER HEAD ASSEMBLY
CYLINDER HEAD
PLUG
CAP
PLUG
PLUG
CAP
CAP
VALVE SEAT INSERT
INTAKE VALVE
SEAL - VALVE STEM
VALVE SPRING
CAP
VALVE COLLET
VALVE SEAT INSERT
EXHAUST VALVE
SEAL - VALVE STEM
VALVE SPRING
CAP
VALVE COLLET
VALVE SPRING CAP
VALVE SPRING CAP
Notes
(A)
(B)
Footnotes
(A)
INLET
(B)
EXHAUST
Page 21
Cylinder Head
Plate B
ACPG0009
3
2
Page 22
Cylinder Head
Plate B
ACPG0009
Item
Part No.
1
2 111136480
3 111136490
4 012110655
5 012110860
Service Options
1
1
111147491
111147501
References
Qty.
Description
1
11
3
2
2
GASKET - CYLINDER HEAD

SCREW
SCREW
STUD
STUD
J 1.3MM
J 1.4MM
1
1

Notes
Page 23
Plate A
ACPG0009
1
4
15
9
6
14
10
8
13
11
3
16
17
12
Page 24
Plate A
ACPG0009
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
120037000
120316281
120356141
198217170
199280300
120356131
052109076
199486220
020109076
199486320
120996140
011310635
012109044
023100010
120456250
120116160
References
R a.
F 120037000
Qty.
Description
1
1
1
3
2
4
3
1
6
6
1
1
2
3
3
6
6
ROCKER BOX ASSEMBLY

ROCKER BOX
SHAFT
ROCKER ARM ASSEMBLY
ROCKER SHAFT SPRING
WASHER
ROCKER ARM ASSEMBLY
SEAL - O RING
ADJUSTING SCREW
NUT
SCREW
SEAL - ROCKER BOX
SCREW
STUD
NUT
PUSHROD
TAPPET
ROCKER BOX ASSEMBLY
Notes
EXHAUST
INLET
History
a.
1
120037000
Page 25
Oil Pump
Plate A
ACPG0009
14
2
1
5
3
6
4
8
9
10
11
12
Page 26
Oil Pump
Plate A
ACPG0009
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 27
Pipes
Plate A
ACPG0009
3
2
Page 28
Pipes
Plate A
ACPG0009
Item
Part No.
1
2
3
4
140606941
198486780
140996260
140996260
References
Qty.
1
1
1
1
Description
Notes
OIL PIPE
BOLT
WASHER
WASHER
Page 29
Relief Valve
Plate A
ACPG0009
Page 30
Relief Valve
Plate A
ACPG0009
Item
Part No.
1
2
140036220
052109078
References
Qty.
1
1
Description
Notes
RELIEF VALVE
SEAL - O RING
Page 31
Timing Case
Plate A
ADPG0034
Page 32
Timing Case
Plate A
ADPG0034
Item
Part No.
1
2
3
4
5
165996630
011310640
011310660
023100006
References
Qty.
1
1
8
4
1
Description
TIMING GEAR
GASKET - TIMING CASE
SCREW
SCREW
NUT
Notes
(A)
Footnotes
(A)
SEE FOLLOWING PARTS LIST FOR SERVICE COMPONENTS
Page 33
Timing Case
Plate B
ADPG0034
Page 34
Timing Case
Plate B
ADPG0034
Item
Part No.
1
2
3
4
5
165106870
030300414
110416290
052300850
198636160
References
R a.
Qty.
Description
1
1
1
1
1
TIMING CASE
PIN
BEARING HOLDER ASSEMBLY
SEAL - O RING
SEAL - FRONT END OIL
TIMING CASE
Notes
History
a.
1
165116571
Page 35
Timing Case
Plate C
ADPG0034
10
8
7
6
9
5
1
2
12
11
3
13
Page 36
Timing Case
Plate C
ADPG0034
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 37
Timing Case
Plate D
ADPG0034
4
3
1
8
7
6
Page 38
Timing Case
Plate D
ADPG0034
Item
Part No.
1
2
3
4
5
6
7
8
9
125046613
125116221
025100008
125306141
125116211
025100006
024500006
198217880
031100004
References
R a.
R b.
Qty.
Description
1
1
1
1
1
1
1
1
1
CONTROL LEVER
SHAFT
WASHER
CONTROL LEVER
SHAFT
WASHER
NUT
SPRING
PIN
Notes
History
a.
1
125046612
CONTROL LEVER
125306140
CONTROL LEVER
b.
Page 39
Timing Case
Plate E
ADPG0034
1
3
4
5
8
10
9
12
11
Page 40
Timing Case
Plate E
ADPG0034
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
131046650
References
F 131046650
020109177
025100010
198217910
198346160
131276440
131466290
020109231
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 41
Camshaft & Gears
Plate A
ADPG0034
8
9
1
2
Page 42
Camshaft & Gears
Plate A
ADPG0034
Item
Part No.
1
2
3
4
5
6
7
8
9
120027000
120016240
034100508
040156304
199216320
125256240
199566651
011310612
References
Qty.
1
1
1
1
1
1
1
1
2
Description
Notes
CAMSHAFT
CAMSHAFT
CAMSHAFT GEAR
WOODRUFF KEY
BALL BEARING
SPACER
SLIDER
PLATE
SCREW
Page 43
Fuel Injection Pump
Plate A
AFPG0034
3
1
9
4
8
Page 44
Fuel Injection Pump
Plate A
AFPG0034
Item
Part No.
1 131017592
2
3
131246170
4
131246010
5
131296255
6
131296255
7
8 010800820
9 023100008
Service Options
7
7
7
7
7
7
7
131437541
131437740
131437551
131437750
131437561
131437580
131437571
References
F 131017592
J
J
J
J
J
J
J
0.20MM
0.25MM
0.3MM
0.35MM
0.4MM
0.50MM
0.50MM
Qty.
Description
1
1
1
1
1
1
1
2
2
FUEL INJECTION PUMP

FUEL INJECTION PUMP
BOLT
CONNECTION
WASHER
WASHER
SHIM
SCREW
NUT
1
1
1
1
1
1
1
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
SHIM
Notes
Page 45
Plate A
AFPG0034
1
6
Page 46
Plate A
AFPG0034
Item
Part No.
1
2
3
4
5
6
7
131507450
131507460
131507470
199106021
199106021
010110625
023100006
References
Q 1
Q 2
Q 3
Qty.
1
1
1
2
2
2
2
Description
Notes
FUEL INJECTION PIPE

FUEL INJECTION PIPE
FUEL INJECTION PIPE
CLAMP
CLAMP
SCREW
NUT
Page 47
Atomisers
Plate A
AFPG0034
Page 48
Atomisers
Plate A
AFPG0034
Item
1
2
3
Part No.
131406440
131426230
131426200
References
Qty.
3
1
3
Description
Notes
INJECTOR
SEAL - INJECTOR
SEAL - INJECTOR
Page 49
Fuel Leak-Off Pipe
Plate A
AFPG0034
2
3
1
4
Page 50
Fuel Leak-Off Pipe
Plate A
AFPG0034
Item
Part No.
1
2
3
4
131606420
198487450
025100008
025100008
References
Qty.
1
1
1
1
Description
Notes
FUEL PIPE
BOLT
WASHER
WASHER
Page 51
Flywheel Housing
Plate A
CDPG0012
6
5
4
Page 52
Flywheel Housing
Plate A
CDPG0012
Item
Part No.
1
2
3
4
5
6
110446612
398460091
011510820
010111030
026200010
027100010
References
Qty.
1
1
10
2
2
2
Description
Notes
FLYWHEEL HOUSING
PLUG
SCREW
BOLT
WASHER
WASHER
Page 53
Plate A
DDPG0009
1
3
Page 54
Plate A
DDPG0009
Item
Part No.
1
2
3
4
115357040
References
F 115357040
115376040
010109341
Qty.
1
1
1
6
Description
Notes
FLYWHEEL
FLYWHEEL
STARTER RING
BOLT
Page 55
Starter Motor
Plate A
EDPG0004
Page 56
Starter Motor
Plate A
EDPG0004
Item
Part No.
185086600
References
Qty.
1
Description
Notes
STARTER MOTOR
Page 57
Pulleys
Plate A
FBPG0009
Page 58
Pulleys
Plate A
FBPG0009
Item
Part No.
145337040
References
Qty.
1
Description
Notes
1 GROOVE WATERPUMP PULLEY
Page 59
Plate A
GBPG0016
Page 60
Plate A
GBPG0016
Item
Part No.
1
2
3
4
5
6
7
110708760
110996910
010109235
140406690
011310612
140987070
052109076
References
R a.
R a.
Qty.
Description
1
1
26
1
2
1
1
SUMP
GASKET - SUMP
SCREW
STRAINER
SCREW
PIPE - OIL SUCTION
SEAL - O RING
1
1
STRAINER
PIPE - OIL SUCTION
Notes
History
a.
4
6
140406360
140987050
Page 61
Dipstick & Tube
Plate A
GBPG0016
Page 62
Dipstick & Tube
Plate A
GBPG0016
Item
Part No.
1
2
3
4
TPN467
110756490
010109235
052100100
References
Qty.
1
1
1
2
Description
Notes
DIPSTICK
DIPSTICK TUBE
SCREW
SEAL - O RING
Page 63
Dipstick & Tube
Plate B
GBPG0016
Page 64
Dipstick & Tube
Plate B
GBPG0016
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 65
Sump
Plate A
GCPG0000
2
1
Page 66
Sump
Plate A
GCPG0000
Item
Part No.
1
2
010109238
025100016
References
Qty.
2
2
Description
Notes
SCREW
WASHER
Page 67
Filler
Plate A
HBPG0007
Page 68
Filler
Plate A
HBPG0007
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 69
Oil Filter
Plate A
JBPG0000
Page 70
Oil Filter
Plate A
JBPG0000
Item
Part No.
140517050
References
Qty.
1
Description
Notes
OIL FILTER
Page 71
Oil Filter
Plate A
JCPG0000
Page 72
Oil Filter
Plate A
JCPG0000
Item
Part No.
140546020
References
Qty.
1
Description
Notes
CONNECTION
Page 73
Plate A
KBPG0005
Page 74
Plate A
KBPG0005
Item
Part No.
1
2
3
115397350
034100508
020109086
References
Qty.
1
1
1
Description
Notes
CRANKSHAFT PULLEY
WOODRUFF KEY
NUT
Page 75
Water Pump
Plate A
LBPG0006
6
7
3
5
Page 76
Water Pump
Plate A
LBPG0006
Item
Part No.
1
2
3
4
5
6
7
145010060
145996990
011310635
023100006
145537300
2481877
2481877
References
R a.
R a.
Qty.
Description
1
1
4
1
1
1
1
WATER PUMP
GASKET - WATER PUMP
SCREW
NUT
HOSE
HOSE CLIP
HOSE CLIP
1
1
HOSE CLIP
HOSE CLIP
Notes
History
a.
6
7
067100025
067100025
Page 77
Plate A
LBPG0006
6
3
Page 78
Plate A
LBPG0006
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 79
Plate A
LDPG0005
Page 80
Plate A
LDPG0005
Item
Part No.
1
2
3
145226320
145996051
011510825
References
Qty.
1
1
2
Description
Notes
CONNECTION
GASKET - THERMOSTAT HSG
SCREW
Page 81
Fan Drive
Plate A
MEPG0001
Page 82
Fan Drive
Plate A
MEPG0001
Item
Part No.
1
2
145386910
011310625
References
Qty.
1
4
Description
Notes
EXTENSION
SCREW
Page 83
Plate A
NDPG0016
1
10
8
7
Page 84
Plate A
NDPG0016
Item
Part No.
1
2
3
4
5
6
7
8
9
10
185046500
TPN744
2314H022
023100008
011510820
185727130
011510825
026100008
011510825
026109017
References
Qty.
1
1
1
1
3
1
1
1
1
1
Description
Notes
ALTERNATOR
ALTERNATOR BRACKET
SCREW
NUT
SCREW
LEVER
SCREW
WASHER
SCREW
WASHER
Page 85
Plate A
NEPG0010
Page 86
Plate A
NEPG0010
Item
Part No.
080109134
References
Qty.
1
Description
Notes
BELT
Page 87
Blanking Plates
Plate A
QCPG0009
4
5
6
Page 88
Blanking Plates
Plate A
QCPG0009
Item
Part No.
1
2
3
4
5
6
7
165206790
052300850
010311095
020910010
027100010
165206790
052300850
References
Qty.
1
1
2
2
2
1
1
Description
Notes
COVER
SEAL - O RING
BOLT
NUT
WASHER
COVER
SEAL - O RING
Page 89
Cylinder Head Cover
Plate A
TBPG0004
3
2
10
11
4
5
6
Page 90
Cylinder Head Cover
Plate A
TBPG0004
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
111217451
110566080
011100408
110666210
110666060
015600406
111996410
011310640
011310660
024600010
140996270
References
Qty.
1
1
4
1
1
6
1
2
2
3
3
Description
Notes
CYLINDER HEAD COVER

BREATHER VALVE
METRIC BOLT
RETAINING PLATE
GAUZE
SCREW
GASKET - CYL. HEAD COVER
SCREW
SCREW
NUT
WASHER
Page 91
Feed Pipes
Plate A
TBPG0004
5
4
6
Page 92
Feed Pipes
Plate A
TBPG0004
Item
Part No.
1
2
3
4
5
6
135566570
135996950
011310620
165206810
3688A035
010109600
References
Qty.
1
1
2
1
1
2
Description
Notes
PIPE - AIR
GASKET
SCREW
COVER
GASKET
SCREW
Page 93
Air Filter Assembly
Plate A
TDPG0007
Page 94
Air Filter Assembly
Plate A
TDPG0007
Item
Part No.
1
2
3
4
5
6
135016340
References
F 135016340
135326205
26510402
26510194
26510417
Qty.
1
1
1
1
1
1
Description
Notes
AIR FILTER ASSEMBLY

BODY
MAIN AIR FILTER
INDICATOR
VALVE
BRACKET
Page 95
Plate A
TDPG0007
2
5
Page 96
Plate A
TDPG0007
Item
Part No.
1
2
3
4
5
6
7
8
U30976790
2314H003
199216340
2314H005
023100008
TPN505
21825194
21825194
References
R a.
Qty.
Description
1
2
1
2
2
1
1
1
BRACKET
SCREW
SPACER
SCREW
NUT
HOSE
CLIP
CLIP
BRACKET
Notes
History
a.
1
TPN643
Page 97
Exhaust Manifold
Plate A
UBPG0004
Page 98
Exhaust Manifold
Plate A
UBPG0004
Item
Part No.
1
2
3
4
135617690
135997120
011510860
023100008
References
Qty.
1
1
4
2
Description
Notes
EXHAUST MANIFOLD
GASKET - EXHAUST MANIFOLD
SCREW
NUT
Page 99
Exhaust Connection
Plate A
UDPG0001
1
3
Page 100
Exhaust Connection
Plate A
UDPG0001
Item
Part No.
1
2
3
4
5
6
314120070
314990013
011510825
314120070
314990013
011510825
References
Qty.
1
1
4
1
1
4
Description
Notes
FLANGE
GASKET - EXHAUST
SCREW
FLANGE
GASKET - EXHAUST
SCREW
Page 101
Lift Pump
Plate A
VBPG0015
Page 102
Lift Pump
Plate A
VBPG0015
Item
Part No.
1
2
3
130506351
2415A070
2314F003
References
Qty.
1
1
2
Description
Notes
LIFT PUMP
SEAL - O RING
SCREW
Page 103
Fuel Filter
Plate A
VBPG0015
3
9
4
13
12
6
5
10
7
8
11
Page 104
Fuel Filter
Plate A
VBPG0015
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
2656613
130976780
010111030
026200010
020900010
027100010
011510825
026100008
26561117
References
R a.
F 26561117
0490786
0490786
26560014
Qty.
Description
1
1
2
2
2
2
2
2
1
1
1
1
1
FUEL FILTER ASSEMBLY

BRACKET
BOLT
WASHER
NUT
WASHER
SCREW
WASHER
FUEL FILTER KIT
ELEMENT
SEAL
SEAL
SEAL - O RING
SCREW
Notes
History
a.
7
011510820
Page 105
Plate A
VBPG0015
11
12
13
14
2
7
6
10
Page 106
Plate A
VBPG0015
Item
Part No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
131246270
33811114
068209126
067100015
067100015
131246290
33811114
068209104
067100015
067100015
32184226
0920146
0650204
0920154
References
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
2
2
Description
Notes
FUEL PIPE
OLIVE
HOSE
CLIP
CLIP
PIPE - LOW PRESSURE FUEL
OLIVE
HOSE
CLIP
CLIP
PLUG
WASHER
PLUG
WASHER
Page 107
Cold Start System
Plate A
WDPG0002
Page 108
Cold Start System
Plate A
WDPG0002
Item
Part No.
1
2
3
4
5
6
7
185366190
References
F 185366190
F 185366190
185376140
020100004
027100004
185606170
Qty.
3
1
1
1
1
1
1
Description
Notes
GLOWPLUG
GLOWPLUG
NUT
CONNECTOR
NUT
WASHER
CABLE
Page 109
Engine Lifting Eyes
Plate A
XBPG0009
1
2
Page 110
Engine Lifting Eyes
Plate A
XBPG0009
Item
Part No.
1
2
3
195816100
011511020
195816100
References
Qty.
1
1
1
Description
Notes
LIFTING EYE
SCREW
LIFTING EYE
Page 111
Plate A
ZAPG0011
Page 112
Plate A
ZAPG0011
Item
Part No.
1
2
3
125416440
185206450
025100016
References
Qty.
1
1
1
Description
Notes
CONTROL LEVER
SOLENOID
WASHER
Page 113
Plate A
ZEPG0001
ON
Page 114
Plate A
ZEPG0001
Item
Part No.
1
2
3
4
5
385201161
References
F 385201161
385210061
385800010
390190030
Qty.
1
1
1
1
1
Description
Notes
SWITCH
IGNITION SWITCH
KEY
CAP
PLATE
Page 115
Instrumentation
Plate A
ZJPG0008
2
3
Page 116
Instrumentation
Plate A
ZJPG0008
Item
Part No.
1
2
3
4
5
185246290
198486871
140996260
140996260
064400010
References
Qty.
1
1
1
1
1
Description
Notes
OIL PRESSURE SWITCH

BANJO BOLT
WASHER
WASHER
PLUG
Page 117
Instrumentation
Plate A
ZLPG0006
Page 118
Instrumentation
Plate A
ZLPG0006
Item
Part No.
385720510
References
Qty.
1
Description
Notes
WATER TEMPERATURE SWITCH
Page 119
Radiator & Cowling
Plate A
ZMPG0008
1
3
Page 120
Radiator & Cowling
Plate A
ZMPG0008
Item
1
2
3
4
Part No.
References
TPN440
F TPN440
24850072
24850083
Qty.
1
1
1
1
Description
Notes
RADIATOR
RADIATOR
RADIATOR CAP
SHROUD
Page 121
Radiator & Cowling
Plate B
ZMPG0008
Page 122
Radiator & Cowling
Plate B
ZMPG0008
Item
1
2
3
4
5
6
Part No.
TPN431
TPN465
TPN465
TPN432
TPN465
TPN465
References
Qty.
1
1
1
1
1
1
Description
Notes
HOSE
HOSE CLIP
HOSE CLIP
HOSE
HOSE CLIP
HOSE CLIP
Page 123
Radiator & Cowling
Plate C
ZMPG0008
3
1
4
2
Page 124
Radiator & Cowling
Plate C
ZMPG0008
Item
Part No.
1
2
3
4
5
6
7
8
9
U45976820
011310625
U45976830
2314H003
011511025
010211425
U45976840
2314H003
010211425
References
Qty.
1
2
1
4
2
4
1
4
4
Description
Notes
BRACKET
SCREW
BRACKET
SCREW
SCREW
BOLT
BRACKET
SCREW
BOLT
Page 125
Fan
Plate A
ZMPG0008
2
1
Page 126
Fan
Plate A
ZMPG0008
Item
Part No.
1
2
3
145306880
145386910
011310625
References
Qty.
1
1
4
Description
Notes
FAN
EXTENSION
SCREW
Page 127
Guards
Plate A
ZMPG0008
Page 128
Guards
Plate A
ZMPG0008
Item
Part No.
1
2
3
145546850
U45977010
U85736550
References
Qty.
1
1
1
Description
Notes
FAN GUARD
FAN GUARD
GUARD
Page 129
Guards
Plate B
ZMPG0008
3
5
Page 130
Guards
Plate B
ZMPG0008
Item
Part No.
1
2
3
4
5
6
7
8
2638D017
U45977030
023100008
011510816
011510812
011510812
011510820
011510812
References
Qty.
1
1
1
1
6
1
4
2
Description
Notes
MOUNTING
BRACKET
NUT
SCREW
SCREW
SCREW
SCREW
SCREW
Page 131
Engine Mounts
Plate A
ZMPG0008
2
3
Page 132
Engine Mounts
Plate A
ZMPG0008
Item
Part No.
1
2
3
4
110267030
010211425
110267030
010211425
References
Qty.
1
4
1
4
Description
Notes
MOUNTING BRACKET
BOLT
MOUNTING BRACKET
BOLT
Page 133
Plate A
ZPPG0002
Page 134
Plate A
ZPPG0002
Item
1
2
3
Part No.
References
20195
F 20195
385620200
Qty.
1
3
2
Description
CONNECTION KIT
CONNECTION
CONNECTION
Notes
(A)
Footnotes
(A)
STARTER MOTOR
Page 135
Fuel Pre-Lift Pump
Plate A
ZVPG0002
Page 136
Fuel Pre-Lift Pump
Plate A
ZVPG0002
Item
Part No.
130506300
References
Qty.
1
Description
Notes
PRIMER
Page 137
Plate A
ZZPG0004
Page 138
Plate A
ZZPG0004
Item
Part No.
185306091
References
Qty.
1
Description
Notes
LAMP
Page 139
Parts Index
Page 140
Parts Index
Description
Part No.
Page
1 GROOVE
WATERPUMP
PULLEY
145337040
59
ADJUSTING SCREW
199486220
AIR FILTER
ASSEMBLY
135016340
ALTERNATOR
185046500
85
ALTERNATOR
BRACKET
TPN744
85
ANTI-TAMPER CAP
131276440
41
131466270
41
26420462
37
125156261
37
125156262
37
040106203
11
040156304
43
BANJO BOLT
198486871
117
BEARING HOLDER
ASSEMBLY
110416290
35
BELT
080109134
87
BIG END BEARING

KIT
198586080
15
BIG END BRG KIT U/S
198586084
15
ARM
BALL BEARING
BOLT
Description
Part No.
Page
131246170
45
131466290
41
25
198486780
29
95
198487450
51
125616120
37
130976780
105
26510417
95
TPN643
97
U30976790
97
U45976820
125
U45976830
125
U45976840
125
U45977030
131
BREATHER VALVE
110566080
91
BUSH
198517222
11
198517226
11
198517229
11
198517290
27
CABLE
185606170
109
CAMSHAFT
120027000
43
CAMSHAFT GEAR
120016240
43
CAP
064210012
41
BRACKET
198586087
15
010109341
55
064210018
21
010111030
53, 105
064210030
21, 21
010211425
125, 125,
133, 133
120186080
21, 21
010311095
89
385800010
115
011310655
79
036500028
17, 17
CIRCLIP
Page 141
Parts Index
Description
Part No.
Page
Description
Part No.
Page
036800010
27
111011050
21
CLAMP
199106021
47, 47
CYLINDER HEAD
ASSEMBLY
CLIP
067100015
107, 107,
107, 107
CYLINDER HEAD
COVER
111217451
91
21825194
97, 97
DIPSTICK
TPN467
63
COLLAR
199236540
27
DIPSTICK TUBE
110756490
63
CON ROD
ASSEMBLY
115026251
17
DOWEL
030500612
11, 15,
15, 15
CON ROD BOLT
115176140
17
030500616
11
CON ROD NUT
020109120
17
030501025
11
CONNECTION
131246010
45
030509018
27
140546020
73
EXHAUST
MANIFOLD
135617690
99
145226320
81
EXHAUST VALVE
120176380
21
385620200
135
EXTENSION
145386910
83, 127
CONNECTION KIT
20195
135
FAN
145306880
127
CONNECTOR
185376140
109
FAN GUARD
145546850
129
CONTROL LEVER
125046612
39
U45977010
129
125046613
39
FLANGE
314120070
101, 101
125306140
39
FLYWHEEL
115357040
55
125306141
39
110446612
53
125416440
113
FLYWHEEL
HOUSING
140116220
27
FUEL FILTER
ASSEMBLY
2656613
105
165206790
89, 89
FUEL FILTER KIT
26561117
105
165206810
93
131507450
47
CRANKSHAFT
ASSEMBLY
115256950
15
FUEL INJECTION
PIPE
131507460
47
CRANKSHAFT
GEAR
115276270
15
131507470
47
CRANKSHAFT
PULLEY
115397350
75
131017592
45
COVER
Page 142
FUEL INJECTION
PUMP
Parts Index
Description
Part No.
Page
Description
Part No.
Page
FUEL PIPE
131246270
107
HOSE
068209104
107
131606420
51
068209126
107
135996950
93
145537300
77
165996640
37
TPN431
123
3688A035
93
TPN432
123
GASKET - CYL.
HEAD COVER
111996410
91
TPN505
97
067100025
77, 77
GASKET CYLINDER HEAD
111147491
23
2481877
77, 77
111147501
23
TPN465
123, 123,
123, 123
GASKET EXHAUST
314990013
101, 101
IDLER GEAR
165026270
27
GASKET EXHAUST
MANIFOLD
135997120
99
INDICATOR
26510402
95
INJECTOR
131406440
49
GASKET - SUMP
110996910
61
INTAKE VALVE
120166380
21
GASKET THERMOSTAT HSG
145996051
81
KEY
030509020
15
385210061
115
GASKET
HOSE CLIP
145996930
79
LAMP
185306091
139
165996590
13
LEVER
185727130
85
165996630
33
LIFT PUMP
130506351
103
GASKET - WATER
PUMP
145996990
77
LIFTING EYE
195816100
111, 111
MAIN AIR FILTER
135326205
95
GAUZE
110666060
91
MAIN BEARING KIT
198586050
15
GLOWPLUG
185366190
109
198586054
15
GUARD
U85736550
129
MAIN BEARING KIT

- U/S
GUDGEON PIN
115326220
17
198586057
15
HOLDER
110156171
15
METRIC BOLT
011100408
91
110156181
15
MOUNTING
2638D017
131
110156191
15
MOUNTING
BRACKET
110267030
133, 133
GASKET - TIMING
CASE
Page 143
Parts Index
Description
Part No.
Page
Description
Part No.
Page
NEEDLE BEARING
042309013
11
PIPE - AIR
135566570
93
NUT
020100004
109
131246290
107
020109076
25
PIPE - LOW
PRESSURE FUEL
020109086
75
PIPE - OIL SUCTION
140987050
61
020109177
41
140987070
61
020109231
41
PISTON AND RING

KIT
115017541
17
020900010
105
PISTON RING KIT
115107970
17
020910010
89
PLATE
165166580
13
023100006
33, 47,
77, 79
199566651
43
023100008
37, 45,
85, 97,
99, 131
390190030
115
U65166580
13
064100045
11
064210010
21
064210025
11, 21, 21
064210040
11, 11, 11
064400010
117
064500030
79
064500060
79
0650204
107
198436290
65
198466010
11
198466020
11, 11, 11
PLUG
023100010
25
024500006
39
024600010
91
2318A207
37
2648A120
37
198436350
69
398430080
69
OIL FILTER
140517050
71
OIL PIPE
140606941
29
OIL PRESSURE
SWITCH
185246290
117
OLIVE
33811114
107, 107
198466940
11
PIN
030300414
35
32184226
107
030300816
15
398460091
53
030309005
11
PRIMER
130506300
137
031100004
39
PUSHROD
120456250
25
OIL FILLER CAP
Page 144
Parts Index
Description
Part No.
Page
RADIATOR
TPN440
RADIATOR CAP
Description
Part No.
Page
121
011510816
131
24850072
121
011510820
RELIEF VALVE
140036220
31
53, 85,
105, 131
RETAINING PLATE
110666210
91
011510825
RING
198346160
41
81, 85,
85, 101,
101, 105
ROCKER ARM
ASSEMBLY
120356131
25
011510860
99
011511020
111
120356141
25
011511025
125
ROCKER BOX
ASSEMBLY
120037000
25, 25
011511070
15, 15
ROCKER SHAFT
SPRING
198217170
25
015600406
91
111136480
23
SCREW
010109235
61, 63
111136490
23
010109238
67
131046650
41
010109406
15, 15, 15
199486320
25
010109600
93
2314F003
103
010110625
47
2314H003
010700865
15
97, 125,
125
010800820
45
2314H005
97
011310612
13, 43,
61, 65
2314H022
85
2315C039
37, 37
011310614
37
SEAL
0490786
105, 105
011310620
93
198636160
35
011310625
83, 125,
127
SEAL - FRONT END

OIL
SEAL - INJECTOR
131426200
49
131426230
49
052100070
37
011310635
25, 77
011310640
33, 91
011310660
33, 91
052100100
63, 65, 65
011510812
131, 131,
131
052100280
69
052100400
69
SEAL - O RING
Page 145
Parts Index
Description
Part No.
Page
Description
Part No.
Page
052109076
25, 61
SMALL END BUSH
198517265
17
052109078
31
SOLENOID
185206450
113
052300850
35, 89, 89
SPACER
199216320
43
2415A070
103
199216340
97
26560014
105
198216720
27
SEAL - REAR END

OIL
198636170
19
198217750
37
198217760
27
SEAL - ROCKER
BOX
120996140
25
198217870
37
SEAL - VALVE
STEM
120406050
21
198217880
39
198217910
41
STARTER MOTOR
185086600
57
STARTER RING
115376040
55
STRAINER
140406360
61
140406690
61
010109441
11
012109044
25
012110635
11
012110655
23
012110660
11
012110860
23
SUMP
110708760
61
SWITCH
385201161
115
TAPPET
120116160
25
THERMOSTAT
145206230
79
145046110
79
199266200
15, 15
199266270
27
SPRING
120406070
21
120316281
25
125116211
39
125116221
39
165296220
11
131437541
45
131437551
45
131437561
45
131437571
45
131437580
45
131437740
45
131437750
45
199286150
27
199286160
27
199286170
27
199286180
27
THERMOSTAT
HOUSING
SHROUD
24850083
121
THRUST WASHER
SLIDER
125256240
43
SHAFT
SHIM
Page 146
STUD
Parts Index
Description
Part No.
Page
TIMING CASE
165106870
Description
Part No.
Page
35
0920154
107
165116571
35
131296255
45, 45
VALVE
26510194
95
140996260
VALVE COLLET
120226070
21, 21
29, 29,
117, 117
VALVE SEAT
INSERT
TPN645
21
140996270
91
199280300
25
TPN646
21
WATER PUMP
145010060
77
VALVE SPRING
198217470
21, 21
385720510
119
VALVE SPRING CAP
120216040
21, 21
WATER
TEMPERATURE
SWITCH
WASHER
025100006
39, 41
WOODRUFF KEY
034100508
43, 75
025100008
39, 51, 51
025100010
41
025100016
67, 113
026100008
85, 105
026109017
85
026200010
53, 105
027100004
109
027100010
53, 89,
105
0920146
107
Page 147

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GK65597U

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

Lubricating Oil Sump

Dipstick & Tube

Dipstick & Tube

Cylinder Head Cover

Air Filter Assembly

Pipework & Connections

Front End Drive Input

Thermostat & Housing

Thermostat & Housing

Pipework & Connections

Cold Start System

Alternator Bracket & Fixings

Engine Lifting Eyes

Drive Belt & Tensioner

Throttle & Stop Controls

Radiator & Cowling

Radiator & Cowling

Radiator & Cowling

Electrical Wiring & Fittings

Fuel Pre-Lift Pump

Application Miscellaneous & Auxiliaries

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

CYLINDER BLOCK ASSEMBLY

SERVICE BY COMPLETE ENGINE

Crankshaft, Pistons & Connecting Rods

Crankshaft, Pistons & Connecting Rods

MAIN BEARING KIT - U/S

BEARINGS ARE PRE-FINISHED

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

ROCKER BOX ASSEMBLY

ROCKER BOX ASSEMBLY

SEE FOLLOWING PARTS LIST FOR SERVICE COMPONENTS

Camshaft & Gears