All 194 pages of this Perkins 2000 Workshop Manual PDF (OEM TPD 3245) focus on the six cylinder diesel engines in the 2006 family: TG1A, TG2A, TWG2, TAG2, and TTAG. You get factory wiring diagrams covering the alternator, starter motor, and engine stop solenoid, plus a dedicated torque section and page after page of overhaul procedures for the cylinder head, crankshaft, turbochargers, and fuel injection pump. Fits and clearances tables follow every assembly, so you rebuild to spec instead of by feel. Pulling the head? Run the bolts down in stages: 136 Nm, then 204 Nm, then a final 40 degrees; injectors crack open at 240 bar. Forum threads won't rebuild your engine. Bookmarked with a real text layer: search any spec, jump to any section, and get back to the shop.
What's Inside This Perkins 2000, Perkins 2000 Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 11-18 | Introduction, New 2000 Series Engines, Cylinder Bore Identification, Engine Identification, Safety, Engine Lift Equipment, Asbestos Joints, Dangers From Used Engine Oils |
| Specifications | 19-24 | Basic Engine Data, Recommended Specific Applied Torques, Recommended Nominal Applied Torques |
| Cylinder Head Assembly | 25-44 | Rocker Cover, Rocker Assembly, Tappet Clearances, Cylinder Head, Valves, Valve Springs and Valve Rotators, Fuel Injector Sleeves, Push Rods |
| Piston and Connecting Rod Assembly | 45-56 | Piston and Rings, Fits and Clearances |
| Crankshaft Assembly | 57-66 | Damper and Pulley - Early Engines, Damper and Pulley - New Engines, Crankshaft Hub and Front Oil Seal, Rear Oil Seal, Crankshaft, Fits and Clearances |
| Wheelcase and Drive Assembly | 67-78 | Wheelcase, Backplate, Camshaft Gear - Bolt-On Type, Camshaft Gear - Integral Type, Idler Gear, Fits and Clearances |
| Cylinder Block Assembly | 79-98 | Crankcase, Cylinder Liners, Cam Followers, Camshaft, Fits and Clearances |
| Engine Timing | 99-102 | Valve Timing, Fuel Injection Pump Timing |
| Aspiration System | 103-116 | Aspiration System Maintenance, Turbocharger, Turbochargers: OE49342, OE50642, OE51140, And OE51430, Turbocharger: OE50674, Turbochargers: OE52534 and OE52535 |
| Lubrication System | 117-127 | Lubricating Oil Filter, By-Pass Filter/Separator, Sump, Sump Drain Plugs, Lubricating Oil Pump, Oil Pressure Relief Valve |
| Fuel System | 128-142 | Overhaul Instructions, Fuel Injectors, Fuel Lift Pumps, Fuel Injection Pump, Air Stop Cylinder |
| Cooling System | 143-158 | Radiator, Fan, Fan Drive Belts, Coolant Pump, Thermostat, Oil Cooler |
| Flywheel and Flywheel Housing | 159-162 | Flywheel, Flywheel Housing, Starter Motor, Starter Ring Gear, Crankshaft Rear Oil Seal, Crankcase |
| Electrical Equipment | 163-174 | Alternator Drive Belts, Alternator, Starter Motor, Engine Stop Solenoid |
| Auxiliary Equipment | 175-178 | Compressor |
| Running-In and Test | 179-182 | Running-In Schedule, Engine Load, Lubricating Oil Consumption, Engine Testing |
| List of Special Tools | 183-194 | Valve Spring, Cylinder Liners, Piston, Coolant Pump, Fuel Injector, Crankshaft, Cylinder Head |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Initial tightening of all bolts and nuts | 136 Nm (100 lbf ft) | p. 22 |
| Intermediate tightening of all bolts and nuts | 204 Nm (150 lbf ft) | p. 22 |
| Big end bearing bolts and nuts | 217 Nm (160 lbf ft) | p. 22 |
| Fuel injectors opening pressure | 240 bar | p. 20 |
| Cap screws, injector clamp | 10.8 Nm (8 lbf ft) | p. 23 |
| Air inlet depression limit (clean filter) | 254 mm (10 in) W.g. | p. 21 |
| Air inlet depression limit (dirty filter) | 559 mm (22 in) W.g. | p. 21 |
| Cylinder head bolt torque | 136 Nm (100 lbf ft) then 204 Nm (150 lbf ft) then 40 degrees additional angle for black circles | p. 29 |
| connecting rod nut torque | 217 Nm (160 lbf ft) | p. 48 |
| End float of the shaft (OE49342, OE50642, OE51140, and OE51430) | 0.10 mm to 0.16 mm | p. 107 |
| Radial travel of the shaft (OE49342, OE50642, OE51140, and OE51430) | 0.30 mm to 0.46 mm | p. 107 |
| By-pass filter nut torque | 20 Nm (15 lbf ft) | p. 121 |
Perkins 2000, Perkins 2000 Common Problems This Manual Covers
Coolant temperature climbs under load, overflow pushing coolant out, fan belt squeals on startup
Check coolant level and look for external leaks; the system holds 24.4 litres when full. Tension the fan drive belts, then inspect the radiator core for blockage and rod it out if choked. If the coolant pump weeps from its drain hole or the shaft has play, overhaul it using the Cooling System procedures beginning on page 143.
Manual Section: Cooling System p. 143Loses coolant with no visible leak, white smoke at startup, oil looks milky on dipstick
Pressure-test the cooling system, then pull the injectors and look for a steam-cleaned piston crown to find the leaking cylinder. Remove the head, inspect it for distortion, and fit a new gasket. Torque the head bolts in sequence per page 29: 136 Nm (100 lbf ft), then 204 Nm (150 lbf ft), then a further 40 degrees on the marked bolts.
Manual Section: Cylinder head p. 29Frequently Asked Questions
What are the tappet clearance specifications for the Perkins 2000 Series engine?
The tappet clearances for the Perkins 2000 Series engine, measured when the engine is cold, are 0,25 mm (0.010 in) for the inlet valves and 0,50 mm (0.020 in) for the exhaust valves. p. 19
How do you fix perkins 2000 diesel cranks slowly and won't fire in cold weather after sitting overnight?
Check battery capacity and clean the main cable connections before condemning the starter. Test the solenoid pull-in coil against the 1.34 ohm spec on page 171, with the hold-in coil at 2.7 ohms. Replace carbon brushes worn below 15.9 mm and torque the starter cable terminal nuts to 34 to 41 Nm. p. 171
How do you fix runs rough and misfires at idle, white smoke until warm, worse after fuel filter change?
Bleed the fuel system first; air pulled in during a filter change mimics injector failure. Pull and pop-test each injector against the 240 bar minimum opening pressure on page 133. Clean blocked spray holes with a cleaning wire protruding no more than 1.5 mm, then refit with pipe nuts torqued to 25 Nm. p. 133
How do you fix down on power under load with black exhaust smoke, turbo whistle sounds different than before?
Measure air inlet depression at full load and replace the element if it exceeds the dirty-filter limit of 559 mm (22 in) W.g. listed on page 21. Then check turbocharger shaft play in the Aspiration System section starting on page 103; end float on OE49342 through OE51430 units must stay between 0.10 mm and 0.16 mm. p. 103
How is this Perkins 2000 Workshop Manual delivered?
You download the Workshop Manual yourself: 194 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Does this Perkins 2000 manual allow printing?
You can. The PDF is unlocked and carries no copy protection, so print the sections you want and keep the file as your backup.
Does this Perkins 2000 manual show the machine's wiring?
Yes, you get complete wiring diagrams with circuit descriptions, ground locations, and connector identification. See page 163 for an example.
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