Rebuilding a Perkins 900 Series diesel? This 240-page Perkins 900 CP and CR shop manual PDF (factory publication TPD 1345) takes you from cylinder head and valve work through crankshaft, timing case, cylinder liners, and complete engine timing. You get full data and dimensions, standard and special torque tensions, compression test data, and step-by-step procedures for the Delphi fuel injection pumps, atomisers, and turbocharger. Turbocharger fault tables and alternator diagnosis are in here too, plus the special tools section: valve guide tools, timing pins, crankshaft seal drivers, piston height gauge. Set atomiser nozzle protrusion between 1.6 and 2.13 mm on KB-code injectors, and pull the fuel pump gear setscrews to 27 Nm (20 lbf ft). Guesswork wrecks liners. Bookmarked and keyword-searchable; download it, walk to the engine, and find your spec in seconds.
What's Inside This Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 1-20 | Introduction, Engine Views, Engine Identification, Safety Precautions, Engine Lift Equipment, Viton Seals, Powerpart Recommended Consumable Products |
| Specifications | 21-44 | Data and Dimensions, Thread Sealant, Standard Torque Tensions, Special Torque Tensions, Compression Test Data |
| Cylinder Head Assembly | 45-72 | Rocker Assembly, Valves and Valve Springs |
| Piston and Connecting Rod Assembly | 73-86 | Big End Bearing, Piston Rings |
| Crankshaft Assembly | 87-100 | Crankshaft Pulley, Rear Oil Seal Assembly, Thrust Washers, Main Bearings, Crankshaft |
| Timing Case and Drive Assembly | 101-120 | Timing Case Cover, Front Oil Seal, Idler Gear and Hub, Fuel Pump Gear, Camshaft Gear, Crankshaft Gear, Timing Case, Camshaft |
| Cylinder Block Assembly | 121-130 | Cylinder Block, Cylinder Liner |
| Engine Timing | 131-136 | Top Dead Centre, Valve Timing, Fuel Injection Pump Timing, Locking Angle |
| Aspiration System | 137-148 | Turbocharger, Turbocharger Faults, Closed Breather System, Open Breather System, Breather Separator |
| Lubrication System | 149-172 | Lubrication System Flow Diagram, Filter Canister, Filter Head, Canister Type Lubricating Oil Cooler, Sump, Oil Strainer and Suction Pipe Assembly, Lubricating Oil Pump |
| Fuel System | 173-204 | Fuel Filter, Atomisers, Fuel Lift Pump, Delphi Fuel Injection Pumps |
| Cooling System | 205-216 | Cooling System Flow Diagram, Thermostat, How to Fill the Cooling System, Coolant Pump, Fan |
| Flywheel and Flywheel Housing | 217-220 | Flywheel, Ring Gear, Flywheel Housing |
| Electrical Equipment | 221-234 | Alternators, Starter Motors |
| Auxiliary Equipment | 235-236 | Section Not Used |
| Special Tools | 237-240 | Valve Guide Tools, Piston Height Gauge, Crankshaft Seal Tools, Fuel Pump Gear Puller, Valve Spring Compressor, Timing Pins |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Maximum protrusion of the atomiser nozzle (Code letter KB) | 1,6/2,13 mm (0.0629/0.0838 in) | p. 22 |
| Maximum protrusion of the atomiser nozzle (Code letter KK) | 3,49/4,01 mm (0.1374/0.1579 in) | p. 22 |
| Static pressure - no delivery | 41/69 kPa (6/10 lbf/in2) 0,4/0,7 kgf/cm2 | p. 36 |
| Test pressure at 1000 rev/ min | 42/70 kPa (6/10 lbf/in2) 0,4/0,7 kgf/cm2 | p. 36 |
| Setscrews for the gear of the fuel injection pump torque | 27 Nm (20 lbf ft) 2,7 kgf m | p. 41 |
| Torx screw, for the gear of the fuel injection pump torque | 27 Nm (20 lbf ft) 2,7 kgf m | p. 41 |
| Cubic capacity | 2,7 litres | p. 21 |
| Inlet valve tip clearance | 0,20 mm | p. 21 |
| Exhaust valve tip clearance | 0,45 mm | p. 21 |
| Lubricating oil pressure | 207 kPa | p. 21 |
| Cylinder head setscrew torque (initial) | 70 Nm | p. 60 |
| Thermostat 'Starts to open' temperature | 80/84 °C | p. 36 |
