Perkins Service Data Book Part 1 PDF

€3 Perkins Service Data Part 1: Mature Products up to 8,85 litres (540 cu in) WARITY PerkinsPerkins Service Data Booklet Part 1: Mature products up to 8,85 litres (540 cu in) 4.108 3.152 Series 4.203 Series 4.236 Series 6.3544 Series V8.540 Series 4 Publication TPD 13576, Issue 1 (¢) Proprietary Information of Perkins Group Limited, al rights reserved. The information is correct at the time of going to press. Published in January 1997 by Technical Publications, Perkins International Limited, Peterborough PE1 SNA, England Perkins Service Data Booklet Part 1, 1997 00.01Foreword ‘The Perkins Service Data Booklet contains the data which is most commonly used by ‘experienced mechanics and technicians. The booklet contains information for all Perkins Peterborough engines and is available in two pai Part 1: Mature products up to 8,85 litres (540 cu in) 4.108 3.152 Series 4.203 Series 4,236 Series 6.3544 Series 8.540 Series Part 2: Current products up to 8,7 litres (530 cu in) 4a 100 Series. Prima/500 Series 700 Series 900 Series Phaser/1000 Series Peregrine/1300 Series The booklet should be used together with the relevant User's Handbook, Workshop Manual and Service Bulletins. ‘Any recommendations for future issues of the booklet should be sent to Technical Publications Department. 00.02 Perkins Service Data Booklet Part 1, 1997 Contents General information .. Perkins companies List of Perkins service publications Powerpart recommended consumable products Engine number location guide Basic fault finding guide Turbocharger fault guide General safety precautions Engine data .......... Maintenance Schedules Basic technical data Fuel pump codes Recommended torque tensions Cylinder head torque sequence General data ......... Specification of engine fluids Standard torque settings Conversion tables ‘Atomiser information Turbocharger waste-gate settings Thermostat ratings Compression test data Notes Perkins Service Data Booklet Part 1, 1997General information Perkins companies .............. fleece eee twee ees ee 102 List of Perkins service publications ..........6...ceeeeeeeeee eee seve 1.03 POWERPART recommended consumable products 1.04 Engine number location guide ....... 6.2.00. 00seeeeee eee eee vee 1.05 Engine number guide 2.0.2.0... 000ee0 es Sope pe gneeeceogad 1.08 Basic fault-finding guide ................ poe pepe seaneaceubuce c 1.08 ‘Turbocharger fault guide 1.10 General safety precautions bee ee ooue eoouceogueoood agua vee eeee es 1.12 Parkins Service Data Booklet Part 1, 1997 1.01Perkins companies Australia Perkins Engines Australia Pty. Ltd, Suite 2, 364 Main Street, Momington 3931, Victoria, Australia ‘Telephone: 597 51877 Telex: Perkoil AASO816 Fax: 0597 1305 France Moteurs Perkins S.A., 9-11 Avenue Michelet, 193583 Saint Quen, Cedex, France. Telephone: (1) 40 10 42 70 Telex: 642924F Fax: (1) 40-10-42-45, Germany Perkins Motoren GmbH, Saalaeckerstrasse 4, 63801 Kieinostheim, Germany. ‘Telephone: 6027 5010 Fax: 6027 501124 Hong Kong Perkins Intemational Ltd, Varity Asia/Pacific, Suite 3301 Convention Plaza, 1 Harbour road, Wanchai Hong Kong. Telephone: 852 2588 1883 Fax: 852 2827 2311 Italy Motori Perkins S.p.A., Via Socrate 8, 22070 Casnate con Bemate (Como), Italy. Telephone: 031 564633 or 564625 Telex: 380658 Perkit I Fax: 031 249092 or 564145 Japan Varity (Japan) KK, Reinanzaka Building, Sth Floor, 14-2 Akasaka, 1-chome, Minato-ku, Tokyo 107, Japan. Telephone: 03 586 7377 Telex: Perkoil J2424823 Fax: 03 582 1596 United Kingdom Perkins international Ltd, Eastfield, Peterborough PE1 SNA, England. Telephone: 01733 67474 Telex: 32501 Perken G Fax: 01783 582240 United States of America 4, Perkins International - North America 12025 Tech Genter Drive Livonia Michigan 48150 USA ‘Telephone: 313 266 5427 Fax: 313 266 2700 Perkins Engines Latin America Inc, Suite 620, ‘999, Ponce de Leon Boulevard, Coral Gables, Florida 33134, U.S.A. ‘Telephone: 305 442 7413 Telex: 32501 Perken G Fax: 305 442 7419 In addition to the above companies, there are Perkins distributors in most countries. Perkins International Ltd, Peterborough or one of the above companies can provide details. 1.02 Perkins Service Data Booklet Part 1, 1997 List of Perkins service publications Engine type User's Handbook Workshop Manual 4.108 201 TPD 1090 1218 601 SER 0692 1088 3.182 Series ‘TPD 0596 1285 EFG (1) ‘TPD 0696 1285 EIS (2) TPO 1091 1208 4.203, 04.203, 201 TPD 1090 1216 601 SER 0681 1010 4.2032 201 TPD 1090 1216 601 TPD 0580 1158 4.236, 4.248 TPD 1095 1291 EFG ‘TPD 0596 1291 EIS. 601 TPD 0393 1229, 6.3844 Series ‘TPD 0594 1289 EFG ‘TPD 0590 1289 EIS TPD 1089 1146 8.540 Series 201 TPD 1090 1207 601 TPD 0690 1215, (1) Printed in English, French and German. (2) Printed in English, talian and Spanish. Perkins Service Data Booklet Part 1, 1997 1.03WERPART recommended nsumable products kins have made available the products ommended below in order to assist in the fect operation, service and maintenance of your ne and your machine. The instructions for the ‘of each product are given on the outside of h container. These products are available from r Perkins distributor. WERPART Antifreeze lacts the cooling system against frost and sion. Part number 1 litre 21825166 or 5 litres 25167. WERPART Easy Flush ans the cooling system. Part number 2182501 WERPART Jointing compound versal jointing compound which seals joints. rentiy Hylomar. Part number 1861155 or 1117. WERPART Silicone rubber sealant ‘one rubber sealant which prevents leakage ugh gaps.Currently Hylosil Part number 1108. WERPART Lay-Up 1 esel fuel additive for protection against osion. Part number 1772204. WERPART Lay-Up 2 ects the inside of the engine and of other ed systems. Part number 1762811 WERPART Lay-Up 3 ects outside metal parts. Part number 1734115. WERPART Chisel ws easy removal of old gaskets and joints. rently Loctite chisel. Part number 21825163. WERPART Repel 3s damp equipment and gives protection against osion. Passes through dirt and corrosion to cate and to assist removal of components. rently Loctite repel. Part number 21825164, WERPART Threadlock etain small fasteners where easy removal is essary. Currently Loctite 222e. Part number 20222. WERPART Studlock permanently retain large fasteners and studs. rently Loctite 270. Part number 20270.1820222. POWERPART Nutlock To retain and seal threaded fasteners and cup plugs where easy removal is necessary. Currently Loctite 242e. Part number 21820242 POWERPART Liquid gasket To seal flat faces of components where no joint is used. Especially suitable for aluminium ‘components. Currently Loctite 518. Part number 21820518 POWERPART Threadlock (hydraulle/pnuematic) To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems, Currently Loctite 542. Part number 21820542 POWERPART Threadlock (pipe) To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately. Currently Loctite 575. Part number 21820575. POWERPART Retainer (oll tolerant) To retain components which have a transition fit. Currently Loctite 603, Part number 21820603. POWERPART Retainer (high strength) To retain components which have an interference fit. Currently Loctite 638, Part number 21820638. POWERPART Atomiser thread sealant ‘To seal the threads of the atomiser into the cylinder head. Currently Hylomar Advance Formulation, POWERPART Compound To seal the outer diameter of seals. Currently Loctite Forma Gasket No 2. Part number 1861147. POWERPART Platelock Medium strength anaerobic threadlock for tight fitted metal surfaces. Suitable for metal plated surfaces and stainless steel, Currently Loctite 243. Part number 21826039. POWERPART Gasket eliminator Improves flange sealing when a gasket is not used. It provides a seal with temperature resistance that is flexible in positions where vibration and pressure ‘occur, Currently Loctite 515. Part number 21826040. POWERPART Sillcone adhesive ‘An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets. Used for sealing flange where oll resistance is needed and movement of the joint occurs, Currently Loctite 5900, Part number 21826038, Perkins Service Data Bookiet Part 1, 1997 Engine number location guide Engine type Position 4.108 AL 3.182 Series ~ up to engine CE31244U906114W B3 - from engine CE31244U906114W_ AS 4.208 Series Bt or B4 4.296 ‘A2 or B2 4.248 Az 6.3544 Series a3 8.540 Series a Notes: Illustration A shows the left side when looked at trom the flywheel end of the engine. Illustration B shows the right side when looked at from the flywheel end of the engine, and the rear view of the engine Ilustration C shows the top of the engine, Perkins Service Data Booklet Part 1, 1997 1.05Engine number guide For engines made after 1974 Example of an engine number is TU20300U5 10256F UW oo 20300 uv 510256 ... F Table 1 - Engine Famity and Type Code Engine Family and type code, see Table 1 Parts list number or SOS order reference number Country of manufacture code, see Table 2 Engine seria! number Year of manufacture code, see Table 3 ‘A Phaser/1004 AA Naturally aspirated AB Turbocharged AC Compensated AD Charge cooled AE Fed. Charge cooled AG Narrow front end naturally aspirated AH Narrow front end turbocharged New Phaser/1004 Ad Naturally aspirated AK Turbocharged AM. turbocharged intercooled AP Naturally aspirated AQ Turbocharged B Prima/500 BA Naturally aspirated BB Turbocharged BC Gasolene © 3.152 cA Pa cB 3.144 co P3144 cD 3.152 cE 03.152 cr 3.152 ce P3.152 a 3.1522 cM 3.1524 cN 73.1524 C900 Series cP 3.27 cr 13.27 cs 3.25 E 4.108 EA 4.99 eB 4.107 EC 14.107 £D 4.108 EE 4.108 6 4.154200 GA 4.154 GB 4.135 ec 4.182 6D 425 GE 4.30 H 4.165 HA 4.165 J 4.203 JA Pa iB 4.192 Jc P4.192 uD 4.203 JE 04.203 oF 4.203, JG 4.2032 K Perama/oo KA 2oyi.0.4 litres KB Seyi. 0.6 litres, KC Soy. 0.9 ites KD Soy. 1.0 tres KE 3oyi.1'Sitres KF doy. 1:9 litres KG Seyi. 1.2 itres KH Soyi. 13 litres KI Soy. 1.5 itres D KK yl. 1.9 litres D KL 3cyl.0,7 litres KN 2cyl. 0.5 litres KR 4cyl. 22 itres, L 4236 wa 4212 1B @a212 tc 4.224 Lo 4.236 ir 64.236 [TV 6.3724 LF 4.248 [TW 6.3544 LG 4.2482 | TX 6.3544 tH 4.236 |TY H6.3544 u 14.236 |Z HT6.9544 uk 04.236 |U_ 700 Series ue 4.38 |UA 704-26 iM 4.41 UB 704-30 N 4318 W_Peregrine/1300 NA 4.270 | WA 6.466 NB 4.300 | we 76.466 NC 4.318 [WC 06.466 ND 4.3182 |WD 6.67 P 6.305 WE cc6.67 PA Pe | WF 16.76 PB 6.288 | WG cc6.76 PC 6.305 | WH 16.87 PO PF6.305 | WJ cce.87 R 6.267 x ve.s40 RA 6.247 | XA ve.510 SD Sabre CC6.68 xB Tva.si0 T 6.354 xc vB.540 TA 6.306 | xD v8.605 TB 6.335 | XE 18.540 Tc 6.354 |Y Phaser/1006 1D H6.354 | YA Naturally Te 76.354 aspirated TF H6.354 |YB Turbocharged 1G 6.3541 |¥C_ Compensated TH 76.3541 |YD Charge cooled ws 6.3542 | YE Fed. Charge TK 6.3542 cooled Te 6.3543 | _ New Phaser/1006 ™ 6.9543 | YG Naturally ™ H6.3543 aspirated TP 76.3543 [YH Turbocharged To HT6.3543 |YK Turbocharged ™R 6372 intercooled Ts 63723 |Z va.640 7 706.3541 | ZA ve.s40 wu 76.3544 |ZB Tv8.640 Perkins Service Data Booklet Part 1, 1997 ‘© Compensated [F MadeinFrance |H Horizontal P Timing chain CC Charge cooled || Fed. Federal N__ Narrow frontend |T Turbocharged D_ Direct injection |G __Gasolene or gas _| (Belt driven water pump) |V__Vee form Table 2- Country of manufacture code This code indicates the country of manufacture of the basic engine. « ‘Argentina [H Group [M U United Kingdom B Brazil | HM Indonesia | MX Mexico |V Pakistan c Australia | HK Iraq |N usA |W tran D Germany | HU Hungary |P Poland | x Peru E Spain |J Japan |S India | ¥ Yugoslavia F France | k Korea | SA ‘South Africa G Greece |L Italy |T Turkey ble 3 - Year of manufacture code ‘This code indicates the year of manufacture, The letters |, O, Q, R and Z will not be used. A 1974 ]H 1981 |S. 1988 A 1995) B 1975 | J 1982 |T 1989 |B 1996 c 1976 |K 1983 |U 1990 |c 1997 D 1977 |L 1984 |v 1991 |D 1998 E 1978 |M 1985 |W 1992 |E 1999 F 1979 |N 1986 |x 1993 | F 2000 G 1980 |P 1987 |Y 1994 |G 2001 Perkins Service Data Booklet Part 1, 1997 1.07Basic fault-finding guide The chart below is given to assist in the correct diagnosis of basic engine faults, Problems and possible causes Problem Possible causes [The starter motor tums the engine too slowly _|1, 2, 3,4 The engine does not start 5,6, 7, 8, 8, 10, 12, 13, 14, 15, 17, 94, 95, 36, 97,38, 40, 42, 43, 44 The engine is difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 19, 34, 36, 37, 38, 40, 42, 43, 44 Not enough power 8, 9, 10, 11, 12, 19, 16, 17, 18, 19, 20, 21, 34, 96, 37, 38, 39, 42, 43, 44, 61, 63, 64 Misfire 8, 9, 10, 12, 13, 15, 20, 22, 34, 36, 37, 38, 39, 40, 41, 43. High fuel consumption 11, 13, 15, 17, 18, 19, 21, 22, 34, 36, 37, 38, 39, 40, 42, 43, 44, 63 Black exhaust smoke 11, 13, 15, 17, 19, 21, 22, 34, 36, 37, 38, 99, 40, 42, 43, 44, 61, 63 Blue or white exhaust smoke 4, 15, 21, 23, 36, 37, 38, 39, 42, 44, 45, 52, 58, 62 [The pressure of the lubricating oil is too low 4, 24, 25, 26, 46, 47, 48, 50, 51, 59 The engine knocks 9, 13, 15, 17, 20, 22, 23, 36, 37, 40, 42, 44, 46, 52, 53, 60 The engine runs erratically 7,8, 9, 10, 11, 12, 18, 15, 16, 18, 20, 22, 23, 34, 38, 40, 41, 44, 52, 60 Vibration 18, 18, 20, 27, 28, 34, 38, 39, 40, 41, 44, 52, 54 The pressure of the lubricating oil is too high 4,25, 49 The engine temperature is too high 11, 13, 16, 19, 27, 29, 30, 92, 34, 36, 37, 39, 62, 55, 56, 57, 64 Crankcase pressure 31, 83, 39, 42, 44, 45, 52 ‘Bad compression. 11, 22, 37, 99, 40, 42, 43, 44, 45, 53, 60 The engine starts and stops: 10, 11,12 1.08 Perkins Service Data Booklet Part 1, 1997 List of possible causes. 1 2 3 4 5 6 7 a 9 0 1 1 1 12 13 4 15 16 7 18 19 20 a1 22 23 SBSRBRE Bees 5 seers 1 2 ae Per Battery capacity low. Bad electrical connections. Fault in starter motor. Wrong grade of lubricating oil Starter motor tums engine too slowly. Fuel tank empty. Fault in stop control Restriction in a fuel pipe. Fault in fuel it pump. Diny fuel fter element. Restriction in fiter/cleaner or air induction system. Air in fuel system. Fault in atomisers or atomisers of an incorrect ‘ype. Cold start system used incorrectly. Fault in cold start system. Restriction in fuel tank vent. Wrong type or grade of fuel used. Restricted movement of engine speed control. Restriction in exhaust pipe. Engine temperature is too high. Engine temperature is t00 low. Valve tip clearances are incorrect. To much oil or cl of wrong specification used in wet type oil cleaner. Not enough lubricating oil in sump. Detective gauge. Dirty lubricating oil fiter element. Fan damaged. Fault in engine mounting or flywheel housing. ‘Too much lubricating oil in sump. Restriction in air or water passages of radiator. Restriction in breather pipe. Insufficient coolant in system. Vacuum pipe leaks or fault in exhauster. Fault in fuel injection pump. Broken drive on fuel injection pump. Timing of fue! injection pump is incorrect. ‘Valve timing is incorrect. Bad compression. Cylinder head gasket leaks. Valves are not free. ‘Wrong high-pressure pipes. ‘Worn cylinder bores: Leakage between valves and seats. ins Service Data Booklet Part 1, 1997 88 898 F feeerssessa 288 Piston rings are not free or they are worn or broken. Valve stems and/or guides are worn. CCrankshatt bearings are wom or damaged. Lubricating oil pump is worn. Relief valve does not close. Roliet valve does not open. Roliet valve spring is broken. Fault in suction pipe of lubricating oil pump. Piston is damaged. Piston height is incorrect. Flywheel housing or flywheel is not aligned correctly Fault in thermostat or thermostat is of an incorrect type. Restriction in coolant passages. Fault in water pump. Valve stem seal is damaged (if there is one fitted). Restriction in sump strainer. Valve spring is broken. Turbocharger impeller is damaged or diy. Lubricating oil seat of turbocharger leaks. Induction system leaks (turbocharged engines). Turbocharger waste-gate does not work correctly (f there is one fitted) 1.09Turbocharger fault guide ‘The chart below is given to assist in the correct diagnosis of turbocharger faults. Ifthe inside of the induction manifold is wet, check that there is not a fuel leak from the fuelled starting aid, if there is one fitted. Problems and possible causes Problem Possible causes Not enough power 4, 4, 5,6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34, 35, Black smoke 1, 4,5, 6,7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34, 35, 38 Blue smoke 1,2,4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32, 34 High lubricating oll consumption 2, 8, 15, 17, 19, 20, 28, 29, 31, 32, 34 Too much lubricating oll at turbine end 2, 7,8, 17, 19, 20, 22, 28, 30, 31, 32 ‘Too much lubricating oil at compressor end 1,2, 4,5, 6, 8, 19, 20, 21, 28, 31, 32 ‘Not enough lubrication 8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 37, 38 Lubricating olin the exhaust manifold 2,7, 17, 18, 19, 20, 22, 28, 31, 32 Inside of the induction manifold wet 1, 2,3, 4, 5, 6,8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 34, 39, 40 Damaged compressor impeller 3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 37, 38 Damaged turbine rotor 7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 32, 33, 37, 38 Rotating assembly does not turn freely 3,6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32, 93, 37, 38 Worn bearings, bearing bores, joumals 6,7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 39, 37, 38 Noise from turbocharger 1,3, 4,5, 6, 7,8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 92, 33, 34, 37, 38 Sludge or carbon deposit in bearing housing 2,11, 13, 14, 15, 17, 18, 24, 29, 33, 37, 38 1.10 10 Data Booklet Part 1, 1997 List of possible causes Element of the air filter dirty Restricted crankcase breather Intemal distortion or restriction in pipe from air iter to turbocharger. Damaged/restricted crossover pipe, turbocharger to induction manifold Restriction between air fier and turbocharger. Restriction in exhaust system. ‘Turbocharger loose or clamps/setscrews loose. Induction manifold has cracks, is loose, or has flange distortion Exhaust manifold has cracks, is loose, or has flange distortion, Restricted exhaust system Delay of lubricating oil to turbocharger at engine start. Insufficient lubrication. Dirty lubricating ot Incorrect lubricating ol Restricted lubricating oil supply pipe. Restricted lubricating ol drain pipe. Turbine housing damaged or restricted. Leakage from turbocharger seals. Worn turbocharger bearings. Excessive dirt in compressor housing. Excessive carbon behind turbine rotor. Engine speed raised too rapidly at intial start. Insutticient engine idle period. Faulty fuel injection pump. Wom or damaged atomisers. Valves burned. Wom piston rings. Lubricating ol leakage from supply pipe. Excessive preservation fluid (on intial engine start). Excessive engine idle period, Restriction in turbocharger bearing housing, Restriction in lubricating oil fiter. Wet type air cleaner: Restricted, dirty element, viscosity of oil to low/high. Waste-gate actuator faulty or damaged. Waste-gate vaive not free. Engine stopped too soon from high load. Insufficient lubricating oi Fuel leakage from fuelled starting aid. Crack in backplate of compressor. weransene Bsstaarsnste SSBENBREBRE BREB8 g b88 Element of the air fier not fitted, or not sealing correctly. Loose connection to turbocharger. Perkins Service Data Booklet Part 1, 1997 1ee General safety precautions Diese! fuel and lubricating oil (especially used Theee safety precautions ary important. You lubricating a) can damage the skin of certain persons. Protect your hands with gloves ora one of use, Some Hams only refer to specie Seal eckuona te poker adil . ln '* Do not wear clothing which is contaminated by Oniy use these engines inthe Wpe cl” iubrcating ol Do not put material which is BE recan e iay iain contaminated wih ol into the pockets of lating. 7 * Discard used lubricating oil in accordance with Deret smoke when youutfstin meta” al ragutons fo prover cotaminaton Sessa: oh a Demet dies ‘+ Ensure that the control lever of the transmission which nas been contaminated by fuel mustbe—* givin tha “out ave" positon bear the Pt engine is started. + Do not put fuel in the tank while the engine runs ‘+ The combustible material of some components eS eee ee of the engine (tor example certain seals) can + Do not clean, add lubricating ol, or adjust the become extremely dangerous iit is bummed. engine while it runs (unless you have had the ‘Never allow this burt material to come into correct training; even then extreme care must be contact withthe skin or wth the eyes. used to prevent injury). + Read and use the instructions relevant to it + Do not make adjustments that you do not equipment. understand, + Wear a face mask if the glass fibre cover of the + Ensure that the engine does not run ina location "turbocharger is to be removed or fitted. Ne ee + Always use a safety cage to protect the operator 7 when a component is to be pressure tested in a + Other persons must be kept at a sate distance container of water. Fit safety wires to secure the while the engine or auxiliary equipment isin plugs which seal the hose connections of a operation. component whichis to be pressure tested. + Do not permit loose clothing or long hairnear «Do not allow compressed air to contact your moving parts. skin, compressed air enters your skin, obtain + Keep away from moving parts during engine medical help immediately ‘operation. Warning! Some moving parts cannot» Turbochargers operate at high speed and at high be seen clearly while the engine runs. temperatures. Keep fingers, tools and debris + Do not operate the engine fa safety guard has, away from the inlet and outlet ports of the been removed. turbocharger and prevent contact with hot + Do not remove the filer cap or any component of surfaces. the cooling system while the engine is hot and Fit only genuine Perkins parts. while the coolant is under pressure, because dangerous hot coolant can be discharged. + Do not use salt water or any other coolant which ‘can cause corrosion in the closed circuit of the cooling system. + Do not allow sparks or fre near the batteries (especially when the batteries are on charge) because the gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especialy to the eyes. + Disconnect the battery terminals before a repair is made to the electrical system. + Only one person must control the engine. + Ensure that the engine is operated only from the control panel or from the operators position + ifyour skin comes into contact with high- pressure fuel, obtain medical assistance immediately. 112 Perkins Service Data Booklet Part 1, 1997 Engine data 4.108 .. 2.02 3.152 Series 2.06 4.203 Series 2.412 4.236 Series 2.19 6.3544 Series .. oe heeeee 2.26 8.540 Series .. eee tenes 2.32 Perkins Service Data Bookiet Part 1, 1997 201Basic technical data Horse pow 35,0 KW (47 bhp) fener lO 4 Cycle Four stroke Induction system ..... eevocobeeebo0 ss... Naturally aspirated Combustion system ee ceeeeess Indirect injection Nominal bore 79,87 mm (3.125 in) Stroke ..-.. ss 88,90 mm (3.500 in) Compression ratio peooneoHn 9686900 peppnnecooaobonc0 221 Cubic capacity . 1,760 litres (107.4 in®) Firing order ......- eeponcoccan ceeeectneeeeeeees 1-3-4-2 Valve tip clearances + Inlet (cold) 0,90 mm (0.012 in) - Exhaust (cold) 0,30 mm (0.012 in) Lubricating oil pressure - at maximum engine speed and normal engine temperature... -.s esse 207/414 Kim (30/60 ifn’) 2,1/4,2 kgtlem? Coolant temperature 60°C (140°F) ‘Thermostat starts to open. bellows type... pbeeaoennos Ore G7/75°C (152/167°F) = wax type 77185°C (170/185°F) Thermostat fully open - bellows type 85/88°C (185/190°F) =wax type . 92/98°C (197/208°F) Direction of rotation . ‘Clockwise from front Idling speed ..... Goeee pepoeucd fet eeeteeeeeeeeeeeees 850 rovimin Location of maximum no-load speed Fuel injection pump data plate Location of number 4 cylinder... Boe coccseeees Crankshaft pulley end Location of engine timing marks seccse Setibe fines on fuel injection pump and pump flange ‘Atomiser codes eeeboounbuoa epee eo CAV = BG, GY, OMAP = YB Fuel pump codes . EHS4E, EH99, PH30 Location of fuel pump code coe sevseeees Data plate on fuel pump Location of fuel pump timing marks cones : Fuel pump mounting flange Bett tension .. eccoo ooo pep oc8s 45N (10 Ibf) 4,5 kot Bolt deflection at iongest run arn beecone = 10mm (3/8 in) 202 Perkins Service Data Booklet Part 1, 1997 Preventive maintenance periods Caution: On shor distance operation with frequent starts and stops the hours of operation are more important than the distance. ‘These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed. Use the periods which are shortest. When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine. It is good preventive maintenance to check for leakage and loose fasteners at each service. Maintenance schedules A Every day or every 8 hours B Every 150 hours or 3 months or 6000 km (4000 miles) © Every 450 hours or 12 months or 18000 km (12000 miles) D Every 900 hours or 38000 km (24000 miles) E Every 2700 hours or 108000 km (72000 miles) ‘The schedules which follow must be applied at the interval (hours or months) which occur first. B/C) je Operation ‘Check the amount of coolant (2) . Check the drive belt of the alternator Lubricate dynamo rear bush (where fitted) | . Check for water in the fuel pre-fter and drain as necessary + |+| [Renew the elements of the fuel-fiter | Check the amount of lubricating oil in the sump Check the lubricating oil pressure at the gauge (1) +| | | | Renew the engine lubricating oil (4) Renew the canister of the lubricating oil fier (4) Clean air compressor fier, it fitted Clean the aicleaner or empy the dust bow ofthe air fier “extremely dusty conditions = ermal conditions + | | | cteamor renew te ar iter element, iit has not been indicated eater Ensure that the valve tip clearances of the engine are checked and, adjusted (3) + | Ensure that the alternator, starter motor etc, are checked (3) necessary. (1) there is one fitted (2) Renew the antifreeze every 2 years. It a coolant inhibitor is used instead of antifreeze, it should be renewed every 6 months. (3) By a person who has had the correct training (4) The oil change interval will change with the sulphur content of the fuel (see the table on page 3.02 and fuel specification). The interval to change the canister of the lubricating ol fier is not affected Perkins Service Data Booklet Part 1, 1997 2.03Fuel pump codes CAV fuel injection pump UU) 200¢ooo 9900096 a g999eo5 Hr ScoE ao eoed ao suo ob ouuuacocaeas9oed Lucas DPA Direction of rotation peesuueegeosocaocg nog Clockwise from drive end Outlet for number 1 cylinder ceeeerseeee Letter "We Fuel injection pump timing ‘The engine check angle must be used with special tool MS.67B and with the engine set with number 1 piston at top dead centre (TDC) on the compression stroke. The pump is checked with the pump set at the Start of injection for number 1 cylinder. ‘The code letters are included in the setting code stamped on the data plate of the fuel injection pump. Some fuel pumps may have the setting code stamped on a modification plate which is fastened to the flange of the pump. ita modification plate is fitted, use the code letters stamped on this plate. Engine check | Pump mark Fuel pump code letters angie angle (degrees) (degrees) EH, EH34E, EH39 281 250 TH30 281 202 PH, PH23E, PH27, PH28, PH30 281 290 PH25E500/5/2450 PH25E500/9/1990 PH25E500/9/2090 PH30/500/5/2450 2795 290 PH30/500/6/1570 PH30/500/9/1990 PH30/500/9/2090 RH, RHSOE, 2705 230 ‘SHIGE 2785 230 TH, THOSE 281 ot Recommended torque tensions ‘The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted. Torque naa Neo hm [win [eat ‘Nuts, cylinder head v2 ai] eo] 83 ‘Sump plug Ea so] a7[ at ‘Atomiser clamp sie_| 16[ 12 17 injector pipe union nut wiexts | 20] t6| 29 Main bearing te | 15 | 95 | 118 Big end bearing 38 37 | #2] 58 Front pulley sa__| 203 | 150 | 20,7 Flywheel 7me_| s1| 60] 83 2.04 Perkins Service Data Booklet Part 1, 1997 Cylinder head torque sequence Caution: This operation must be done by a person with the correct training. tin doubt, refer to the workshop manual. 1 Lightly lubricate the threads of the cylinder head studs and nuts. 2 Gradually and evenly tighten the nuts in three ‘tages. Tighten the nuts in the final stage to 81 Nm (60 bff) 8,3 kgf m. 3 Start the engine and run it until the coolant temperature is 170°F (77°C). Switch the engine oft 4 Check the tightness of the nuts in the correct sequence. * Ita nut moves when checked, tighten ito the correct torque. * It a nut does not move before the correct torque is reached, loosen the nut 1/12 to 1/6 (30° to 60°) of a turn and then tighten it to the correct torque. Caution: itis important that the cylinder head nuts, are tightened again to the correct torque, in the ‘correct sequence, after 800/ 1600 km (50/1000 miles) 25/50 hours. Perkins Service Data Booklet Part 1, 1997 2.05Basic technical data Basic technical data, Continued aaa! epreopruesesaeearoues ae a eee 03.152 36,5 KW (49 th) 3.1524 bees foe to = ‘38,6 KW (52 bhp) Location of number 1 cylinder. 00 Crankshaft pulley end BULA Ls ocooeGeo eorapmabeee e095 oe eee coe) Location of engine timing marks . . Fuel injection pump flange, rear face of timing case ese ; eaten - 150, 0.182, 3.1822, 91504 Natura aspirated “Size prceeeeeeeannee ee tin SS ‘Compression ratio Location of fuel pump code Lett hand side of FIP. ae ee a ceed a 3.1522, 19.0:1 Belt tension ........ 2. ve vbeteeteeeeenee 45.N (10 Ibf) 4,5 kgf “Beat test ce rn een an oe ceeeeeee is 827) aes me seal 3.1522, 3.1524, T3.1524 0,82 mm (0,0125 in) Lubricating oil pressure at maximum engine speed and normal engine temperature .......--eseseeee ++ 207/414 kN/m? (30/60 Ibtfin?) 2,1/4,2 kgtlcm? Coolant temperature 60°C (140°F) Thermostat starts to open = bellows type 99900 99900050005 - 72182°C (170/179°F) = wax type 81/84°C (17/183°F) ‘Thermostat fully open bellows type 93°C (19°F) = wax type 98°C (208°F) Continued 2.06 Perkins Service Data Booklet Part 1, 1997 Perkins Service Data Booklet Part 1, 1997 2.072 3.152 Series Preventive maintenance periods Caution: On short distance operation with frequent starts and stops the hours of operation are more important than the distance. ‘These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manutacturer of the equipment in which the engine is installed, Use the periods which are shoviest When the operation of the engine must conform to the local -equlations these periods and procedures may need to be adapted to ensure correct operation of the engine. itis good preventive maintenance to check for leakage and loose fasteners at each service. Maintenance schedules A First service at 25/50 hours (all engines) F Every 500 hours or 12 months (03.152) B Every day or every 8 hours (all engines) G Every 800 hours or 12 months (3.1524, T3.1524) © Every 200 hours oF 4 months (3.1524, T3.1524) _H Every 2400 hours (3.1524, T3.1524) D Every 250 hours or 4 months (D3.152) 1 Every 2500 hours (03.182) E Every 400 hours or 12 months (3.1524, T3.1524) ‘The schedules which follow must be applied at the interval (hours or months) which ocour first (SEE TFICAL! Operation ra [| [check the amount of coolant | ‘Check the drive belt(s) oe) ele Check for water in the fuel pre-fiter (1) ole | | Renew the fuel-tter element(s) | «| |» | Ensure that ine atomisers are checked (2) . Ensure idle speed is checked and adjusted, it necessary (2) . || check the amount of lubricating oil in the sump | Check the lubricating oil pressure at the gauge (1) \. ele Renew the lubricating oil (3) | || | ctean near cleaner or empy the dst how of he after | | Sxremely dusty conations | | | normal eanditons Clean or renew the air fiter element, iit has not been indicated earlier + |» | Ensure that the turbocharger impeller and turbocharger compressor casing are cleaned clean me comoressr ait) see nena” cmpreesor (1) checked (2) | Sree ree esr arnare re cached ad agusod necessary (2) 1 | LL | fale Ete inatne tomato sar mor wea hota (2) (1) ifthere is one titted (2) By a person who has had the correct training. {3} the ol cnange interval will change wit the amount of sulphur in the ful (see the table on page 3.02 ‘and the fuel specification). The interval to change the canister of the lubricating oil iter is not affected. Fuel pump codes Lucas fuel injection pump Ve vececuteeeecsetseerttteteessestesesess DPAOr DP 200 Direction of rotation rom drive end. ....essecsccceereeeeesererresseeeetseteesesssss Clockwise Outlet for number 1 cylinder Letter *W" or ‘Z" Fue! Injection pump timing “The engine check angle must be used with special tool MS.67B and with the engine set with number 1 piston at top dead contre (TDC) on the compression stroke, The pump is checked withthe purnp set at the start of injection for number 1 cylinder. “The code letters are included in the setting code stamped on the data plate ofthe fuel injection pump. Some quel pumps may have the setting code stamped on a modification plate whichis fastened tothe flange ofthe pump. Ifa modification plate is fited, use the code letters stamped on this plate uel pump code [Enaie check} Pump mark | Fel pump code Engine check | Pump mark oe angle angle eee angle angle (degrees) | (degrees) (degrees) | (degrees) AW. a a__[Pws0 29 Eg ‘BW, YW 27 35___| R50, RWS2, RWS4 25 a7 ‘ow 27 35 | SW except below 25 ‘a7 ‘SWis/1800, ‘SW/8/1890 22.25 37 Sw48 24 a ‘SW52, SWS7, SW58 25 37 ow 265 35 ___ | TWa8e 27 37 Lwas, LWaS 32 40__[ TW50 26 37 Lwst, LW52 29 38 | WW except below 25 35 wwraie470, |wwer2200, wwisi2470, Wwa7e, WW48 27 35 Tws8, LW59 20 40 [Xw50E 29 36 MWATE, M9, 2 a [aw 25 37 MWS3E, MWS7 Was, P44, 30 6 Stanadyne fuel injection pump Type woe eeesseeeseerteeees cecseeees Stanadyne Outlet for number 4 cylinder . seen from the rear of the pump Clockwise Selt-vent Direction of rotation from drive end Fuel system Static timing “The engine check angle must be used with special too! MS.67B and with the engine set wit the piston of the puraber 1 cylinder at top dead centre (TTC) on the compression stroke. The pump is checked with the pump set atthe start of injection for the number one cylinder. To set the pump mark angle, see workshop ‘manual, publication number TPD 1091 1208E. Fuel pump Engine check angle Pump mark angle code letters (degrees) (degrees) EW 26 322 Perkins Service Data Bookiet Part 1, 1997 2.09Basic technical data Horse power = 4.203 vehicle agriculture - 4.2082 Number of cylinders Cycle Induction system ‘Combustion system = 4.203 . + 4.2032, D4.203 Nominal bore Stroke Compression ratio 4,203 - 4.2032 Cubie capacity Firing order Valve tip clearances AIL 4.192 and 4.203 and D4.203 up to engine number JE....U564083G + Inlet (cold) - Exhaust (cold) 4.203 from engine number JE....U564083G + Inlet (cold) - Exhaust (cold) Lubricating oil pressure at maximum engine speed and normal engine temperature Coolant temperature Thermostat starts to open Thermostat fully open bellows type = wax type Direction of rotation Idling speed Location of maximum no-load speed Location of number 1 cylinder Location of engine timing marks 47,0 kW (63 bhp) 4215 KW (57 bhp) 44,7 KW (60 bhp) 4 Four stroke Naturally aspirated Indirect injection Direct injection 91,44 mm (3.6 in) chon 127 mm (5 in) 17.431 19:1 3,83 litres (203 in’) 1-9-4-2 0,30 mm (0.012 in) 0,30 mm (0.012 in) 0,20 mm (0.008 in) 10,30 mm (0.012 in) 207/414 kN/mé (30/60 tbt/in’) 2,1/4,2 kgtlem® 60°C (140°F) 82°C (179°F) 95°C (203°F) 98°C (208°F) Clockwise trom front 550 - 750 depending on application Fuel injection pump data plate Crankshatt pulley end Timing pin on timing case and crankshaft pulley Continued 242 Perkins Service Data Booklet Part 1, 1997 Basic technical data, Continued ‘Atomiser codes Fuel pump codes... Location of fuel pump code 4.203 - 4.2032 Location of fuel pump timing marks Belt tension Belt detlection at longest run AV, BM, DN, EC, EG, EV, FJ, FM, FR, FS, GB, GC, GM, GR, GS, GW, H, HM, HW, HX, J, TC, YA, Z, UA, VA AF, BF, LF, MP, PP, RP, SP, TP, Fuel pump mounting flange and fuel pump carrier plate Fuel pump mounting flange and timing case Fuel pump mounting flange 45'N (10 Ib) 4,5 kgt 10 mm (3/8 in) Perkins Service Data Booklet Part 1, 1997 213Preventive maintenance periods Caution: On short distance operation with frequent starts and stops the hours of operation are more important than the distance, These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed. Use the periods which are shortest. When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine. !tis good preventive maintenance to check for leakage and loose fasteners at each service. Maintenance schedule 4.203 A Every day or every 8 hours © Every 500 hours or 12 months B Every 250 hours or 4 months D Every 2500 hours The schedules which follow must be applied at the interval (hours or months) which occur first, alale|o Operation o | Check the amount of coolant | Check the concentration of the coolant (2) . | Check the drive bet + | Lubricate dynamo rear bush (where fitted) + | | ciean the sediment chamber and the strainer ofthe fuel it pump + | |_| check torwater inthe presiter (1) + |+ | Fenew the element of the ‘vel-‘fiter Ensure that the atomisers are checked (3) ‘Check the amount of lubricating oil in the sump | Check the lubricating oil pressure at the gauge (1) + | | | Renew the engine lubricating oll) + | | | Renew the canister of the lubricating ot fiter | | | clean the air cleaner or empty the dust bow ofthe air fiter I | extremely dusty conditons | |. normal conditions | | [+] | ctean or renew the airfiter element, it ithas not been indicated earlier + | Ensure thatthe valve tip clearances ofthe engine are checked and, it necessary, adjusted o + | Ensure that the altemator, starter mator ete are checked (3) {) itthere is one tited (2) Renew the anttreeze every 2 years. Ifa coolant inhibitor is used instead of antifreeze, it should be renewed every 6 months. (3) By a person who has had the correct training, (4) The cil change interval will change with the sulphur content of the fuel (see the table on page 3.02 and fuel specification). The interval to change the canister of the lubricating oil fiter is not affected. 2.44 Perkins Service Data Booklet Part 1, 1997 Preventive maintenance periods Caution: On short aistance operation with frequent starts and stops the hours of operation are more important than the distance. ‘These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed, Use the periods which are shortest ‘When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine. It is good preventive maintenance to check for leakage and loose fasteners at each service, Maintenance schedule 4.2032 A Every day or every 8 hours, D Every 800 hours B Every 200 hours or 4 months E Every 2400 hours © Every 400 hours or 12 months The schedules which follow must be applied at the interval (hours or months) which occur first. inoGoG Operation “| ] | Check the amount of coolant |_| | | |[Ghecktne concentration ofthe coolant 2) \* | Check the drive belt | J+] | |ctean the sediment chamber and the strainer ofthe fuel it pump | . Check for water in the pre-fter (1) . Renew the element of the fuel-filter | + | | Ensure that the atomisers are checked (3) Ensure idle speed is checked and adjusted, it necessary (3) *| ‘Check the amount of lubricating oil in the sump . | Check the lubricating oil pressure at the gauge (1) io Renew the engine lubricating oil (4) . Renew the canister of the lubricating oil fiter Clean the air cleaner or empty the dust bow! of the air iter | extremely dusty conditions ye] normal conditions leila Clean or renew the air filter element, it it has not been indicated earlier | bile Ensure that the valve tip clearances of the engine are checked and, if necessary, | adjusted (3) (1) if there is one tittea (2) Renew the antifreeze every 2 years. Ifa coolant inhibitor is used instead of antifreeze, it should be renewed every 6 months (8) By a person who has had the correct training, (4) The oil change interval will change with the sulphur content of the fuel (see the table on page 3.02 and fuel specification). The interval to change the canister of the lubricating oi fier is not affected Perkins Service Data Booklet Part 1, 1997 2.45Fuel pump codes 4,203 and 4.2032 CAY fuel Injection pump Type eee OPA Direction of rotation from drive end Counter-clockwise Outlet for number 1 cylinder Letter "Ww" Fuel injection pump timing ‘The engine check angle must be used with special tool MS.67B and with the engine set with number 1 piston at top dead centre (TDC) on the compression stroke. The pump is checked with the pump set at the start of injection for number 1 cylinder. ‘The code letters are included in the setting code stamped on the data plate of the fuel injection pump. Some fuel pumps may have the setting code stamped on a modification plate which is fastened to the flange of the pump. if a modification plate is fited, use the code letters stamped on this plate. 4.203 Series 4.203 Series Fuel pump code | Engine check | Pump mark }evei pump code | Engine check | Pump mark elie ‘angle angle eae angle angle (degrees) (degrees) (degrees) (degrees) [AFS7 287, a7 LF59 289) 279 [AFaaE 287 277 LP5S, 287 275 (AF46/60070/280 285 277 MP5O 290 277, [AF46/60070/292 286 277 MP54 293 280) [AF49E 287 277 MPSS. 293 280) JAFSO 267 277 MPS7 293 280) aioe) eae Gu RABE 289.5 281 [AF56 289) 279) PPSSE, 289.5, 281 BFaTE 290 281 PAGE, 289.5) 281 BFSt 290) 281 PSOE 2895 281 LFa8 289) 278) PSOE 280.0 281 [LF51 289 279) ‘SP 2895 281 LFS6 289 279) TP 290.0 281 2.16 Perkins Service Data Booklet Part 1, 1997 nee Recommended torque tensions The torque tensions below apply to components lubricated lightly with clean engine oil before they are fitted. 4.203, Torque Thread Description ze, | Nm | tbttt | kt m Fasteners, cylinder head nuts only 76 at| 60] 33 nuts and setscrews 95| 70] 97 ~ engine numbers JG..U609019S to JG...U609185S 95| 70| 97 ‘Sump plug) aa 30] a7] 51 with washer! a4] 25] 35 = with ‘O' ring aa] 25] 35 ‘Atomiser clamp a8 | 12] 16 Injector pipe union nut Mizxis | 20] 15| 24 Main bearing one | 56 | 115 | 159 Big end bearing = phosphate 76 at| 60] 33 = cadmium 6i| 45] 62 Front pulley 78 149 | 110 [152 Fiywheel 2 108 [80 | 114 4.2032 Torque ‘Thread Description Mee, | Nm | itt | kgfm Fasteners, cylinder head 76 os | 70] 97 ‘Sump plug ara 50] a7] 51 = with ‘washer ara 34| 25] 35 with ‘O' ring Ea 34| 25] 35 ‘Atomiser clamp SHE | 12[ 16 Injector pipe union nut Mizxts | 20] 16| 24 Main bearing one | 156 | 115 | 159 Big end bearing TAG sol 45 [ 62 Front pulley 778 149 | 110 | 152 Flywheel 12 110 [80 | 14,4 Perkins Service Data Bookiet Part 1, 1997 247Cylinder head torque sequence 4.203 and 4.2032 Caution: This operation must be done by a person with the correct training. fin doubt refer to the Workshop Manual. Flame protected engines stil have all nuts. All other engine were changed to nuts and setscrews, from. the engine numbers below. 203u93838CL, 203U69630L. 2031304340. (On 4.203 engines, all but two of the studs were changed to setscrews as well as the eight special studs which also retain the atomisers. Z at Fastener ustration ‘ype and position Stud ‘A 10,11 Setscrew ‘A 1to9and 121019 ‘On D4.203 and 4.2032 engines, all but two of the studs were changed to setscrews, Fastener Illustration type and position ‘Stud B 16.17 ‘Setscrew B_ 110 15 and 18 to 23 Hi these two studs are removed they must be put back in their correct positions, because they guide the cylinder head gasket into position. 1 Lightly lubricate the threads of the fasteners. 2 Gradually and evenly tighten the fasteners to the correct torque in the sequence shown in (A or B). Repeat to ensure that all the fasteners are tightened, to the correct torque shown in the table below. Fastener type Torque Nats only fitted {81 Nm (60 Ibf ft) 8,3 kgt m Nuts and setscrews | 95 Nm (70 ibt ft) 9,7 kgf m Caution: Engines fitted with cylinder head gasket, part number 36812138, must have the fasteners for the cylinder head tightened again after the first 25/50 hour of use. PAHO OF DLL OS 16S ® one ® © % 0% oA S23 2% @2 1 O54 3A) (ORO. PREESE) om Y res Gees eet b& vo Note: Release the cylinder head setscrews evenly and gradually in the reverse sequence to that shown in). 2.18 Perkins Service Data Bookiet Part 1, 1997 Basic technical data Horse power = 4.236 vehicle .. Sec industriaVagricuture - 4.248 Number of cylinders cycle Induction system ‘Combustion system Nominal bore = 4.236 -4248 Stroke .. Compression ratio Cubic capacity Firing order Valve tip clearances + Inlet (cold) - Exhaust (cold) Lubricating oil pressure - at maximum engine speed and normal engine temperature Coolant temperature ‘Thermostat starts to open ‘Thermostat fully open Direction of rotation Idling speed Location of maximum no-load speed Location of number 1 cylinder Location of engine timing marks ‘Atomiser codes ~ 61,1 KW (82 bhp) 60,0 KW (81 bhp) 62,6 KW (84 bhp) 4 Four stroke Naturally aspirated Direct injection 98,43 mm (3.857 in) 100,96 mm (3.975 in) 127 mm (5 in) 16:1 7 3,86 litres (236 in*) 19-42 0,30 mm (0.012 in) 0,30 mm (0.012 in) 207/414 kN/m# (90/60 lbt/n#) 2,1/4,2 kgllcm? ceeeee sees 60°C (140°F) T7IB3°C (170/180°F) 94°C (202°F) ‘Clockwise from front ‘560 - 70 - 1000 revimin Fuel injection pump data piate Crankshatt pulley end ‘Scribe lines on fuel injection pump and pump flange 4296... sess @F,UA, AC, DM, CU, AB, EA, FY, XD, FC, FL, HY, NB, NC, ND, XE, YC = 4.248 Fuel pump codes DL, BU, CU, RG, FW AAS, AT, BS, 8, OT, FT, GT, MT JT, KT, LS, LT, MS, MT, PS, PT, RS, AT, SS, ST, TT, TS, VS, VT, WS, XS, XT, YT, 2S, ZT Location of fuel pump code Location of fuel pump timing marks. . Data plate on fuel pump Fuel pump mounting flange and timing case Belt tension 45N (10 Ibf) 4,5 kgt Belt deflection at longest run... -....0seeesseeteeeeeesteeeeeeeteeeeeeeeeeeee 10 mm (3/8 in) Perkins Service Data Bookiet Part 1, 1997 219Preventive mi tenance periods Caution: On short aistance operation with frequent starts and stops the hours of operation are more mportant than the distance. ‘These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed. Use the periods which are shortest ‘When the operation of the engine must conform to the local regulations these periods and procedures may eed to be adapted to ensure correct operation of the engine, Its good preventive maintenance to check for leakage and loose fasteners at each service, Maintenance schedules A First 25/50 hours D Every 500 hours or 12 months B Every 8 hours or every day E Every 2500 hours © Every 250 hours or 4 months. The schedules which follow must be applied at the interval (hours or months) which occur firs. BOGOGE ‘Operation . ‘Check the amount of coolant | +} |e Check the drive belt of the alternator Clean the sediment chamber and the strainer of the fuel lit pump oo Check for water in the fuel pre-fiter (1) + |_| Renew the elements of the tuel-titer + | Ensure that the atomisers are checked (2) . Ensure idle speed is checked and adjusted, if necessary (2) Check the amount of lubricating oil in the sump Check the lubricating oil pressure at the gauge (1) |" | | Renew the engine lubricating oil (3) (5) +] | [Renew the canister of the lubricating ol iter (3) CCiean the air cleaner or empty the dust bow! ofthe air fiter oo ~ extremely dusty conditions . normal condtions ‘+ |__| Clean or renew the air fiter element, it it has not been indicated earlier (4) + | Clean the vent vaive of the engine breather system (1) Ensure that the turbocharger impeller and turbocharger compressor casing are cleaned . Clean the compressor air fiter (1) * | Ensure that the exhauster or compressor (1) is checked (2) . * | Ensure that the valve tip clearances are checked and adjusted, it necessary(2) I + | Ensure that the alternator, starter motor etc. are checked (3) (1) If there is one fitted (2) By a person who has had the correct training (8) 4.2482 engines, every 500 hours or 12 months. (4) 4.2482 engines, every 1000 hours, (8) The oil change interval will change with the sulphur content of the fuel (see the table on page 3.02 and fuel specification). The interval to change the canister of the lubricating oll fer is not affected. 2.20 Perkins Service Data Booklet Part 1, 1997 ee Fuel pump codes CAV fuel injection pump Type oo cesses DPAand DPS Direction of rotation from drive end : Clockwise Outlet for number 1 cylinder DPA letter °W", DPS letter "x" Fuel injection pump timing ‘The engine check angle must be used with special tool MS.67B and with the engine set with number 1 piston at top dead centre (TDC) on the compression stroke. The pump is checked with the pump set at the start of injection for number 1 cylinder. The code letters are included in the setting code stamped on the data plate of the fuel injection pump. Some fuel pumps may have the setting code stamped on a modification plate which is fastened to the flange of the pump. it modification plate is fitted, use the code letters stamped on this plate. na mark Engine check] Pump mark Funlpurp aie [Emectex] PimoT= T unpumpense [Eranecbest| Pore ee (degrees) | (degrees) ot (degrees) | (degrees) AS, ATGOE,ATeTE | __ 278 200 [P5266 28H 292 BS 2a 296 [PT (26430270) 2795 281 BS..40, 54, 62,68 Zar 290 [PT (264921) 2805 291 BIG 2805 293 AS..45, 52,56, 58 206 297, OT74E 260 239 |r 281 202. FTTOE 220) 290 | $S..64, 66,68 205 297 FTTGE ST B75 234 before U940900L 206 293 -from 9409001 284 233 FT 734 293 | TT baa at 280 288 1350272) GTTeE Era Zt 15.59, 2 22 TEE TSE7 exceptbeiow | 281 292 “petore vozsa7om | 281 293 from U028270M 280 293, TISTE 2785 Zar] TSB7IeS07272580 25 we TS67/850/2/2480 1867/850/62700 rs 3a 72 |vssivsst 24 26, tsa 28 296 [vT 280 293 15.45, 49,5055 | 2645 236 | W562, 66 200, 292, 1S.57.61.63,67 | 2645 296 [xs 200) 293 i362 283.5 206 | XSSGE, XSEOE 281 233 1366 281 208 | xt 281 202. or 325 17 | YSeRE 281 288 S67 279 292 ]vT 280 234 MTBOL 276 75 [255 270.25 231 PS..45,48, 51,58, | 281 292 55,57 PS6i excecpibeiow | 287 22 PSerre50/8/aT20 PS61/850/7/13100 2005 292 861/850/9/2400 Perkins Service Data Booklet Pan 1, 1997 221Cylinder head torque sequence Caution: This operation must be done by a person with the correct training. It in doubt refer to the workshop manual. {tis important that the studs and the three different lengths of setscrews are fitted in their correct positions. 4.236, 4.240 and 4.2482 engines Fastener IMlustration type ‘and position ‘Stud = ‘A 19,22 Setscrew] Small [A 5,6, 11, 12, 16, 7 Setscrew| Medium [A 1,2,3,4,7,8,9, 10, 13, 14, 15, 20 Setscrew| Large [A 18.21 Setscrew| Large |B 14,19 Choose the correct methd and torque from the table below. Engine Torque | __ Tove ‘we method nim [ibe ft [kgf m jaza6 lengines with nuts only | 1 | a1] 60] 93 lup to usso18sW 1 | 196] 100] 136 rom Us501a5W 2_| 120] 86] 118 fr.4296 lup toengine UO27774M} 1 | 196] 100] 13,8 ltrom engine Uo27774M| 2 | 120| 88] 11,8 [4.248 and 4.2482 lup toengine us73000 | 1 | 136] 100] 13,8 ltrom engine us73000_| 2 | 120] #8] 11,8 ‘14.236 engines a Fastener | Fastener twasration © 695 01 Type | length mm (in) | and postion ee oe ‘Stud : B 16,21 Setscrew| Smal |B -3,5,7.10,76, & 19.22 ‘Setscrew Medium: B 1,2, 4,6, 8,9, 11, 12, 13, 14, menoa 17.20 1 Light lubricate the threads ofthe cyinder head fasteners. 2 Gradually and evenly tighten the fasteners to the Correct torque and method shown in the table opposite. Tighten the fasteners in the correct sequence (A or B) 3 Start and run the engine unti it reaches normal ‘temperature of operation. Stop the engine. 4. Remove the rocker shaft and remove the atomisers, then tighten the fasteners again to the correct torque in the correct sequence. Ita fastener moves when checked, tighten it to the correct torque. Ita fastener does not move when checked, loosen it 1/12 to 1/6 (90° fo 60*) of a tum then tighten it to the correct torque. 5 Check the first 10 positions again, during this check do not loosen the fasteners. 6 The fasteners ofall engines except the 4.2482 ‘must be tightened again after the first 25/50 hours use. 2.24 Perkins Service Data Booklet Part 1, 1997 Method 2 Follow steps 1 and 2 in method 1, then: Use the special angle gauge MS 1531 to tighten the setscrews, in the correct sequence, a further halt of a turn (180°) If the special angle gauge MS 1531 is not available, make a suitable mark on the cylinder head in line with a corner of each setscrew (A). Make another mark, at 180° (counter-clockwise), on the edge of the flange of each setscrew. Tighten each setscrew inthe correct sequence until the marks on the flange are next to, and in line with, the marks on the 180. cylinder head. pen Note: Release the cylinder head setscrews evenly and gradually in the reverse sequence to that shown in (A). Perkins Service Data Booklet Part 1, 1997 2.25Basic technical data Horse power 6.3544 cee oper Geubou duo cuooabbonocopbonccueecee 95.5 KW (128 bhp) 76.3544 : feteiereeseeceees 115 KW (155 bhp) Number of eylinders 6 Cytle eee erecee veceeeeees Four stroke Induction system ec corti ettetieettitettteessecssessees Naturally aspirated - 76.3544 ‘Turbocharged ‘Combustion system Direct injection Nominal bore cette tteeeceeesees 98,4 :mm (3.875 in) ‘Stroke 427 mm (6 in) ‘Compression ratio 76.9544 ceupopaooone coo eepoeeueeceoeresespoeeg 3) + 76.3544 a : cee 15.54 ‘Cubic capacity 5.80 litres (354 in’) Firing order. beeen oboe necob oer ieee nace ce 1586-24 Valve tip clearances = Inlet (cold). . coe eteteeteeeteeceeceteseseseeeees 0:20 nm (0,008 in) - Exhaust (cold) : = = Bppeneesooecose + 0,45 mm (0.018 in) Lubricating oil pressure - at max engine speed and normal engine temperature 2071414 KN/m? (90/60 lbfn®) 2.1/4.2 kgtlcm? Coolant temperature... er eee +++ 60°C (140°F) Thermostat starts to open =DONOWS IPE ee eee cee teeteeeees cote ecteeeeeeeecses 67AISO (152167°F) eye epeeuceo ceceteeeeceees THIBSG (I70/85°F) ‘Thermostat fully open bellows type. : ee eoeerc (ioe) =waxtype . 92/98°C (197/208°F) Direction of rotation feeb teteteeeees cecteeeeeeeeeerees Clockwise from front Idling speed... Oe _ Flinioction guar ata plots Location of maximum no-load speed Location of number 1 cylinder Location of engine timing marks Fuel injection pump data plate Crankshatt pulley end Crankshaft, main idler gear and camshaft gear Atomiser codes FL, FN, GD, GG, GH, GK, GL, GX, HC, HE, HK, HP, HS, HT, HU, RA, RB, VU, XX, Y Fuel pump codes. AY, BY, CY, DY, EX, EY, FX, FY, GY, HY, JY, KY, LX, LY, MR, MX, MY, PX, PY, SX, TX, TY, VR, VX, WR, WX, XX, ZX Location of fuel pump code - cescecseseseessssesessssssese Fu! injection pump data plate Location of fuel pump timing marks Fuel pump mounting flange and adaptor plate Belt tension cette ceteeteectneees o cece 45. (10160 4,5 kgf Belt deflection at longest run : sete tetteeeeetteeeeereeseees 10mm (3/8 in) 2.26 Perkins Service Data Booklet Part 1, 1997 Preventive maintenance periods Caution: On short distance operation with frequent starts and stops the hours of operation ave more important than the distance. ‘These preventive maintenance periods apply to average conditions of operation. Check the periods given by the manufacturer of the equipment in which the engine is installed. Use the periods which are shortest. When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine. Itis good preventive maintenance to check for leakage and loose fasteners at each service, Maintenance schedules 6.3544 and 76.3544 A First service at 25/50 hours D Every 500 hours or 12 months B Every day or every 8 hours E Every 1000 hours © Every 250 hours or 4 months F Every 2500 hours The schedules which follow must be applied at the interval (hours or months) which occur first. [aje|c[ole|F Operation [-]> Check the amount of coolant el] fe Check the drive belt(s) . Clean the sediment chamber and the strainer of the fuel ft pump oo Check for water in the fuel pre-fiter (1) . Renew the fuel iter element (fuel fter with single element) «| | Renew the fuel fter element (fuel filter with twin element) ‘= | Ensure that the atomisers are checked (2) Ensure that the idler speed is checked and adjusted it necessary (2) \. | Check the amount of lubricating oil in the sump +. | Check the lubricating oil pressure at the gauge (1) «| fe Renew the lubncating oi (3) | [> | Renew the canister of the lubricating oi filter | ‘= | Clean the vent vaive of the engine breather system (1) | Clean the air cleaner or empty the dust bow! of the airfiter o> || extremely dusty conditions S = normal conditions . Clean or renew the air filter element, ift has not been indicated earier «| | Ensure that the turbocharger impeller, turbocharger compressor casing and | | turbocharger drain pipe forthe lubricating ol are cleaned (2) . | Clean the compressor air filter (1) * | Ensure that the exhauster or compressor (1) is checked (2)° . + | Ensure that the valve tip clearances are checked and adjusted, it necessary (2) I [+ [Ensure thatthe altemator, starter motor etc. are checked (3) | (1) it there is one fited, (2) By a person who has had the correct training, (3) The oil change interval will change with the amount of sulphur in the fuel (see the table on page 3.02 and fuel specttication). The interval to change the canister of the lubricating oil fiter is not attected, Perkins Service Data Booklet Part 1, 1997 227Fuel pump codes 6.3544 CAV fuel injection pump Type ee oo se. DPA Direction of rotation from drive end Counter-clockwise Outlet for number 1 cylinder... bd Fue! injection pump timing ‘The engine check angle must be used with special too! MS.67B and with the engine set with number 1 piston at top dead centre (TDC) on the compression stroke. The pump is checked with the pump set at the start of injection for number 1 cylinder. ‘The code letters are included in the setting code stamped on the data plate of the fuel injection pump. Some fue! pumps may have the setting code stamped on a modification plate which is fastened to the flange of the pump. it a modification plate is fitted, use the code letters stamped on this plate. Fuel pump code | Endine check| Pump mark | E61 pump code | Endine check | ‘Pump mark Leia ‘angie angle pump angle ‘angle (degrees) | (degrees) (degrees) | (degrees) AY 760 746 MTATBEAO Tet 746, BY 160 746 MX/5/2420 from 159 146 longine no. 728207. x 760 746] Mxs5/2590 Tet 146 FX 160 146 PX (except below) 159 146 GY 162 754 | PX ist TW31012 only | __160 146 HY. 162 tea__[x (6.3724) 159 146 MA (except below) 158 744__[1¥ 153 1415 MR from engine no. 158 147 [WR 160 146 U780609° MX (except below) 160 146 WX 157 144 2.28 Perkins Service Data Booklet Part 1, 1997 — Fuel pump codes 76.3544 CAV fuel injection pump Type oe ceeeee papper poounnogggdsd0 bese aocoubD - DPA Direction of rotation from drive end .......eeeeeeceseeeee es cesses Counter-clockwise Outlet for number 1 cylinder Gpoorcaa eoooaooeoE6s ee sie Fuel injection pump timing ‘The engine check angle must be used with special too! MS.67B and with the engine set with number 1 piston at top dead centre (TDC) on the compression stroke. The pump is checked with the pump set at the start of injection for number 1 cylinder. ‘The code letters are included in the setting code stamped on the data plate of the fuel injection pump. Some fuel pumps may have the setting code stamped on a modification plate which is fastened to the flange of the pump. If a modification plate is fitted, use the code letters stamped con this plate. Fuel pump code | Esine check] Pump mark | eves pump coue | Enaine check} Pump mark rae ‘angle angle nae angie angle iene (degrees) | (degrees) (degrees) | (degrees) ra 753 745__ [PY 160 144 DY 760 144 [1x 159 144 ni 159 144 [va 159 144 x 159 14 x 159 148 Ly 153 145 [yx 160 144 MY, 159 14a [x 159 144 Bosch fuel injection pump Type . ope gouoedg ce hola Direction of rotation from drive end ceeterees oan0 . Counter-clockwise Outlet for number 1 cylinder .-.-...... bpppepoponbovoocceecooucccn c D Fuel injection pumptiming The engine check angle must be used with special tool MS.67B and with the engine set with the piston of the number 1 oylinder at top dead centre (TDC) on the compression stroke. The pump is checked with the pump set at the start of injection for the number one cylinder. Engine check | Pump mark Fuel pump code letters ‘angle angle (degrees) (degrees) Ey (21-2) 135 1255, FY (L21-3) 135 1275, Ky (L107) 123 118 VX (121 oF 73) 135 127 ‘The settings given for Bosch fuel pumps are with the pump set at 1 mm plunger lift. It is important that these pumps are not fitted at the static timing positions for the CAV pumps. The code given is stamped on the side of the pump. Perkins Service Data Booklet Part 1, 1997 2.292 6.3544 Series Recommended torque tensions The torque tensions below apply to components lubricated ligntly with clean engine oil betore they are fitted. 6.3544 and 76.3544 Description Torque Thread ‘size | Nm | ttt | kgf m ‘Setsorews, oyiinder head, refer fo head lightening sequence Sump plug 2 UNE a aaunr | 34| 25| 36 ‘Atomiser clamp ane vz [_ ef 42 Injector pipe union vat Miz w|i at Main bearing al cadmium SIBUNF | 270 | 200 | 27,7 =phosphated 102| 75 | 10.4 Big end bearing = cadmium, veunr | 129| 95 | 13,1 = phosphated 8} 65 | 90 Front pulley THe UNF | 126 | 02 | 127 Flywheel weunr [ioe [eo [ 111 2.30 Perkins Service Data Booklet Part 1, 1997 6.3544 Series 2 — Cylinder head torque sequence Cautlon: This operation must be done by a person with the correct training. ifn doubt refer to the workshop manual. ‘Any oylinder head studs removed trom the cylinder biock should be fited with “Loctite” ‘The oylinder head gasket fitted to the 76.544 and 6.3544 engine is not interchangeable with other 6.354 Series engines. itis marked "TOP FRONI”. A different cylinder head gasket is used on 6.3724 engines because of the larger bore size. The cylinder head gasket must be fited dry. ‘There are two methods to tighten the cylinder head fasteners for service, methods 1 and 2 shown below. Currentiy, the factory uses method 2. Metnod 1 - hot torque 1 Lightly oil threads of cylinder head studs and setscrews. See the table below. 2 Gradually and evenly tighten the fasteners to the ‘correct torque shown inthe table below, in the ‘sequence shown in (A). ‘3. Start and run the engine unti i reaches normal temperature of eparation. Siop the engine. Tighten the fasteners again to the correct torque in the correct sequence. Torque Fastener type | Position Nim | tot ft | kgtm Piain fastoners jwhich are fited with |a 10.92 | 130) 95)13.1 |separate washers Method 2 - torque and angle Follow steps 1 and 2 ln method 1, ther: Use the special angle gauge MS 1531 to tighten the selscrews, in the correct sequence (A), a further part ofa turn according to the length of the setscrews, ‘see the table below. Further part of a turn 180° or 2 1/2 fats A 1,2,3,4,7, 8,9, 10, 13, 44, 15, 18, 18, 20, 20,24 | 190" ora tars [A_24, 25, 20, 30 210° or 8 172 fats ‘A 3310.38 None, check torque lithe special angle gauge MS 1531 is not available, make a suitable mark on the oylinder head in line with a comer of each setscrew (B). Make another mark, at the correct angle (counter-clockwise), on the edge of the flange of each fastener. Tighten ‘each setscrow in the correct sequence until the marks on the flange are next o, and in line with, the ‘marks on the cylinder head. 150- 180: 210- Flanged fasteners fimeawinnead [a 11032 | 156] 115/159) gasket, par number 136812611 pas | [Small setscrews A33to38| 38] 28] 3,9 4 6 18 i784 81% BM 19%3 yee ee 21 12 2 14 22 30 ° 5 29 24 1815 7 5 3 10 162026 32 2.31 Perkins Service Data Booklet Part 1, 19972 V8.540 Series a Basic technical data Horse power -Va540 ., : . 134 KW (180 bhp) TVB AO seceeceses 175 QW (236 bhp) Number of oylinders: settee 8 OYole ese ceeseseees steers Four stroke Induction system Ve.540 . Tva.540 bee teses Turbocharged ‘Combustion system Direct injaction 108,0 mm (4.25 in) 120,7 mm (4.75 in) Nominal bore... Stroke ‘Compression ratio VB.540 ve Tvasd0 0. toe ene ‘Cuble capacity 8,85 litres Firing order. 1875-43-62 Valve tip clearances - Inet (cold) ve.s40 feet eetseeees 0.25 mm (0.10 in) Tv8.540 fete (0,25 mm (0.10 in) ~ Exhaust (cold) VO5HO ee ccecsereeeeerceeess sees 0,25 mm (0.10 in) THB SID ee ceecieeeee te 0,50 mm (0.20in) Lubricating oll pressure = at maximum engine speed and normal engine temperature. seiereretireteeeeessess 280 KIM? (49 btn! 2,8 kgtiom? Coolant temperature... see cere reteeteseeseesees 608 (140°) ‘Thermostat starts to open s+ B7/75C (182/167"F)) Thermostat fully open ++ 85/88°C (185/190°F) Direction of rotation . ses ‘Clockwise from front Idling 2peed ese eer seeeesceeeeeeeanee : s+s++ Fuel injection pump data plate Location of maximum no-load speed seeeeeteteees Fuel injection pump data plate Location of number 1 cylinder .. sereeeseess Front of left bank at crankshaft pulley end Location of engine timing marks .. seecseee+ Seftbs lines on fuel injection pump and pump flange Atomiser codes... sesers VALVB, Vd, VN, WC, FG, GU, VW, WW, WY, WZ, XA, XB, XY Fuel pump codes. : TBA Location ot uel pune code fiteeees seseeee Ful injection pump data plate Location of fuel pump timing marks. Fuel pump mounting flange and pump adaptor plate Belt tansion eee eee . secceees 45.N (10 thf 4.5 kat Belt deflection at longest run ....... 101mm (8/8 in) 2.92 Perkins Service Data Booklet Part 1, 1997 8.540 Series 2 ee Preventive maintenance periods Caution: On short distance operation with frequent starts ana stops the hours of operation are more ‘Important than the distance. ‘These preventive maintenance periads apply to average concitions of operation. Check the periods given by the manutacturor of the equipment in which tha angina is installed. Use the periods which are shortest. When the operation of the engine must conform to the iocal regulations these periods and procedures may ‘need to be adapted to ensure correct operation of the engine. Itis good preventive maintenance to check for leakage and loese fasteners at each service. Maintenance schedules A Every 8 hours or every day B Every 500 hours or 6 months © Every 1000 hours D Every 2000 hours E Every 2500 hours F Evory 4000 hours ‘The schedules which follow must be applied at the interval (hours or months) which occur first. ajeje[ble|F ‘Operation . ‘Check the amount of coolant . Check the drive betts of the alternator . Check for water in the pre-fiter (1) . Renew the elements of the fuel-fiter . Ensure that the atomisers are checked (3) : (Cheek the amount of lubricating oil in the sump . Check the lubricating oll pressure at the gauge (1) Renew the engine lubricating ail (4) Renew the canister of the lubricating ol fiter (4) . Glean tha engine breather system Clean the air cleaner or empty the dust bow! of the sir filter o extremely dusty conditions . = normal conditions . Clean or renew the air fiter element, if it has not been indicated earlier CCean the turbocharger impeller and casing (3) + [Gneck the turbocharger (3) Ensure that the valve tip clearances are checked and adjusted, it necessary (3) . = V8.540 . = TVB.540 «| [ensure that ine altemator, starter motor etc. are cheoked (3) (1) I there is one fitted. (2) Renew the antitreeze avery 2 years. Ita cootant inhibitor is used instead of antifreeze, it should be renewod every 6 months. (@) By a person who has had the corcect raining. {4} The ol change interval will change with the sulphur content ofthe fuel (see the table on page 3.02 and {uel specification). The interval to change the canister ofthe lubticating oi fier is not affected. Perkins Service Data Booklet Part 1, 19972 V8.540 Series Fuel pump codes Fuel Injection pump TYPO eee eteeeeeeeeeeee ctettteescreeeee ‘CAV Minimeo, DP15 or Bosch MW Direction of rotation from drive end ....... Clockwise Spill timing of CAV Minimec or Bosch MW Spill timing | Piston Fuel pump code letters position position BTDC BTOC (degrees) | mm (in) MB71/e00/A02/1800RB71/800/41A/2350 2642A210MB/002/1875 MB71/800/A02/1880 RB71/800/41A/2390 2642421 1MB/A02/1890 MB71/800/C02/1560 RB71/800/41A/2480 —2642A215RB/41A/2500 MB71/800/C02/1575 —RIB71/800/41A/2500 2642A215RB/41A/2530 268 17,62 (0.300) FB69/800/41A/2350 — RB71/800/41A/2530 2642A228RB/41 4/2330 ABey/EOW47A/2530 —_RB71/800/41/2560 B69/800/444/2830 © RB72/800/414/2380 RB71/00/414/2330 _RB72/800/41 4/2530 LB71/600/12/2500 —RB7O/E00/48/2910 _2642A213MB/D01/2360 LB7i/soq/22/2500 —RB71/B00/61A/2550 2842A213MB/D01/2420 (MB71/e00/D01/2340 —RB71/800/414/2660 —2642A213MB/D01/2520 MB71/800/D01/2360 RB71/800/41A/2730 2642A214RB/444/2770 ‘MB71/e00/001/2280 AB71/B00/44A/2630 2642A21BRB/41A/2550 28 8,89 (0.350) Me71/eoo/buT/za00 © RB71/800/44A/2770 _2642A215FIB/41A/2660 MB71/800/D01/2420 RB71/800/444/2830 _2842A223RB/E01/2720 MB71/800/D01/2520 RB71/800/44A/2850" MB71/800/E01/2720 Lasséve0oraga/2960 YBS8E/B00/44A/2960 2642A209RB/44A/2060 ABT 1/e00/44a/2850"" 2642A214RB/44A/2850 B71/800/444/2910 26424230LG/44A/2960 29 9,83 (0.378) FRB71/800/444/2960 PB73L/900/001/2400 PBB1E/1100/D01/2610 PBB1E/1 10/01/2740 PBBIE/1100/D01/2520 PBBTE/1100/001/2620 2642A243PB/D01/2600 st 10,85 (0.427) PRRB1E/1100/001/2600 PBB1E/1100/D01/2650 2642A243PB/001/2520 * Nomvehicle applications ** Vehicle applications Statle timing of CAV DP15 ‘The unyiue check angle must be used with special too! MS.6/8 and with the engine set with number 1 piston at top dead centre (TDC) on the compression stroke, The pump Is checked with the pump sel at the start of injection for number 1 cylinder. Static timing position BTDC ‘Timing check angla siete 16" 312" 234 Perkins Service Data Booklet Part 1, 1997 8.540 Series 2 ee Recommended torque tensions ‘The torque tensions below apply to components lubricated lightly with clean engine oll before they are fined. Torque Threaa Description Mee | Nm | tote | kat m ‘Setsorews, cylinder head, see torque sequence oneunF[ -| -| ‘Sump plug aaunr | 50] 37] 5.41 ‘Atomiser clamp sneunr | 16] 12] 1,7 Injector pipe union nut Mize15 | 20] 15| 21 ‘Main beating s@euNF | 265] 210] 20 Big end bearing ane unr | 142] 105 | 145 Front pulley qreunr | 407 | 300 | 41,5 Flywhee! veunr | toa} 80 | 11,1 Perkins Service Data Booklet Part 1, 1997 2.352 V8.540 Series —eeeeeeeSSsSeSeSSSSSSSSSSseFe Cylinder head torque sequence Caution: This operation must be done by a person with the correct training. it in doubt refer to the workshop manual, Wis important that the studs and the three altferent engths of setscrews are fitted in their correct positions. Fasiener| — Fastanar ustration type | length mm (in) | and postion ‘Stud : A 16,18 Setscrow | Small [A 2.4.6, 8, 12.14, A_3,5,7, 9, 13, 15,1 Note: Release the cylinder head setscrews evenly 17.19) and gradually in the reverse sequence to that shown A_14,10, 11, 20, 21 in (A). 11 Lightly lubricate the threads of the studs and the cylinder head setscrews and the thrust faces of the setscrew. 2 Gradually and eveniy tighten the setsorews and. ‘auts of each bank to the correct torque, in the ‘sequence (A). Tighten again all the setscrews and nuts to the correct torque, in the sequence (A). Setscrew| Medium Setscrew] Large Engine and Torque ‘fastener type we ora arm \va.sa0 Hanged fasteners 169] 125 | 17,3 Ilanged fasteners, scant shank Iseiscrews with gasket S681H401 | 186 | 135 | 18,2 Jpiain fasteners with separate lwashers with gasket a681H401 | 210 | 155 | 1,47 [rve.840 Hanged fasteners 210 | 155 214 3 un the engine until it reaches normal ‘temperature of operation. Stop the engine. Tighten again all the setsorews and nuts of each bank to the ‘correct torque, in the sequence (A). 2.96 Perkins Service Data Booklet Part 1, 1997 GENERAL DATA 3 SS General data Specification of engine fluids 3.02 Standard torque settings ......... 3.03 Conversion tables 3.04 Atomiser information 3.06 Turbocharger waste-ale settings 2.0... cece eee eee ee ee ee eeee nents 3.10 Thermostat ratings... 0.06. eee eee eee eee etree eee etree eee 3.10 Compression test data... 6... cee ee eee ee ne eee eee ee eee ee eee ne ene 344 Notes cece etre eee erent sete nse nett eee eee 312 3.01 Perkins Service Data Booklet Part 1, 19973 GENERAL DATA Specification of engine fluids ~ 4.108, 3.152, 4.203, 4.2032, 4.236, 4.248 Lubricating ol! specification gee To9544, Vo.s40 Minimum lubricating ol specification + naturally aspirated engines APICCISE, - turbocharged engines: API CDSE or CCMC D4{1) Lubricating oll capacity Dependent on sump ited, $86 application user's handbook Fuel specification Viscosity 4296,4.248, V8540_...... 2.5/4.5 centistokes at 40°C 4.108, 3.182, 4.203, 4.2032, 6.3544, T6.3644 « = 2.0/4.5 centistokes at 40°C Density 0,895/0,855 kglitre| Distillation 85% at 360°C Aviation kerosene fuels JPS and JP8 only, refer to user's handbook Cetane number ‘Al 4.296, 4.248 Vehicle only 6.3644, 76.3544, VB.540 50 minimum industiavag 6.3544, 76.3544, VB.540 All 4.108, 3.192, 4.203,4.2032 ...-..... 45 minimum Sulphur (2) 4.108, 4.203, 4.2032, 6.3544 6.3544, VB.540 ...., 0.5% of mass, maximum 81182, 4.996, 4.48 0.2% of mass, maximum ‘Coolant specification Recommended coelant POWERPART antifreoze Concentration of antireeze 50% [Corrosion inhibitor mixture. ‘Must have @ specification at least as good as BS6580 or MOD AL39 Refer to user's handbook Coolant capacity Soe application user's handbook (1) Not recommenced for naturally aspirated engines during the fist 20 t0 60 hours or for ight load applications, (2) The oil change interval will change with the fuel specification) ‘amount of sulphur in the fuel (see the table below and the ‘Amount of suiphurin 8 Wt | oy Grange interval 25 Normal 05-10 ‘3/4 of normal >10 172 of normal 3.02 Perkins Service Data Booklet Part 1, 1997 GENERAL DATA 3 eee Standard torque settings Goneral notes 1 For'service’, use the nominal torque value. Tolerances to be within 225% of nominal, 2 If there are changes to phosphated surfaces or to thread tolerances, the torque values must change, 3 Torque values in these tables are for ‘dry threads’. 4 These values are not suitable for Merwin C3 type fasteners, studs Nominal torque Thread size Nim | tottt | kgf M6 x 1,00, s| a7] os MB x1.25, ni] at] 12 mioxiso | 18] 133] 1.84 Miext7s | 25| 184| 255 Setsorews and nuts Nominal torque Thread size Nim | ett | kofm M6 x 1.00 2] se] ose M8 x1.25 22| 162 | 2.24 mioxis0 | 44) 325 | 4.49 miaxt7s | 78 | 575 | 7.95 aaxzo00 | 124] 915 | 12.64 Miex200 | 190 | 1400 | 19.97 Pipe threaded fasteners Nominal torque Thread size Nm | ben | kgtm } ver PTE 95 | 70 | 0.97 vepte | 170 | 125] 1,73 ge pTr | 30,0 22.1 | 3,06 rg" PTF 450 | 332 | 459 Perkins Service Data Bookiet Part 1, 1997 3.03‘3 GENERAL DATA Conversion tables tt | tech | mn | mm | ich Miles Kilometres} Kilometres Mile 1 vor | ot 0.82 we | o25| es} 1 | a6 2 ao | 2 1208 we | os | ta7} 2 | 008 3 aaa | 3 186 as | os] tart 2 | ox2 4 oul 4 249 yyt Bap 4 | 016 5 aos | 5 340 2)? S08} 5 | 020 6 oss | 6 373 s | 38 72) 6 | 024 7 naz] 7 4.98 4 | 4 | wre] 7 | 028 8 er | 8 4a7 5 | 5 | wolf 8 | on ° vasa) 0 559 6 | 6 | 1824) 9 | 035 10 roo | 10 621 7 | 7 | 17a] 10 | 9.99 20 seta | 20 12.49 8 | 8 | m2] 20 | 070 20 4a20 | 30 s0.64 9 | @ | 226] a0 | 148 ‘0 cast | 40 aes to | 10 | 2540] 40 | 1.57 50 soar | 50 3107 2 | 20 | Sapo) so | 197 ro e093 | wo 62.14 30 | 30 | vez0} 100 | 390 40 | 40 | 1016.0} 1000 | 99.37 Feet | Metres | Metres | Feet 1 oat | 4 928 2 ost | 2 6.56 3 os | 3 9.84 4 we] 4 | 1312 5 1] os | 164 6 rc 7 ata} 7 | 2287 8 244] 8 | 2025 9 2m} 9 | 2958 10 305 | 1 | saat 20 ei | 20 | e562 0 os} a0 | ones 40 vaio | 40 | gate 50 r24 | 50 | 16408 3.04 Perkins Service Data Booklet Part 1. 1997 GENERAL DATA. sees Conversion tables, continued Pounds | Kilograms | Kilograms | Pounds os os | os 0.22 02 ooo | o2 | 44 03 oa} 03 | oss oa ora | 04 | 08s 05 ozs | os | it 06 oz | 06 | 132 07 ose | 07 | 1.56 08 oss | 08 | 176 09 on | 09 | 1.98 1 oss | 1 22 2 ost | 2 4at 3 138 | 3 661 4 rai | 4 802 - 5 2a} 5 11.02 Pints | tres s any 8 1323 0s 027 3 sey 7 1843 1 oss 8 aca} 8 1784 8 408 | 9 19.84 2 “ 10 454 | 10 22.08 3 1.65 20 sor | 20 4408 4 22 30 1361 | 90 5 278 40 ee 58.18 50 azca | 50 | t10.03 Perkins Service Data Booklet Part 1, 1997 3.053 GENERAL DATA Atomiser information Set and reset pressure Code Holder Nozzle atm (tine) MPa AB AKALe7s51517 | BDLL1S0S64957 476 2573 | ‘OKLL6752930 ‘OLL15086705 aC 72646460, 2646677 175 [ 2573 177 AV BKBLE7SSt61 | BDLLSOSSR72 770 2498 72 BC BKB35SD5260 BOLT10s6133 120 1764 12,2 BG BKB40SD5224 BONI2SD6206 135 1985 137 BM ‘BKBS5S05260 BDLi10S6267 120 1768 12.2 BT BKBLE7SDS1S1 | BDLL1S0S6310 175 2578, 177 Bu BKBLE7S5151 BDLL1S0S6495 175 2573, 177 BV BKBLE7S5151 BDLLI5086518 170 2498 17.2 oR BKBLO7S5151 BOLL1S0S6613 170 2499 72 oF BKBLE7S5299 | _SDLL1S0S6507 186 2720 187 cs (BKBLE7S151 BDLLIS0SES54 170 2499) 72 or DADLG7SDS1S1 | BDLL16058555 175 2573 7 cu BKBL6785151/ BDLL1sose556/ 175 2573 177 ‘OKLL6752990 ‘OLL 15086556 cy ‘OKLLe6M 1340 _[~ OLLTS0Mea02 230 aaa 2a DD BKBSSS5256 BDL11086133 120 1764 12.2 DE BKBS5S5258 BDL 11086267 120 1764 12.2 DF BKBLE7S5151 BDLL 15086658 170 2499 17.2 [ov BKBLE7SS209 | BDLLIS50Sve545 210 3087 21,8 OM BKBLE7S5151 ‘BDLL1S0S6561 175 2573 77 DN BkaLe7ss209 |” BDLLTS0Se554 170 2499) 17.2 EA BKBLE7S52057 | BDLLIS0S6591/ 215 316 218 ‘OKLLE752930 ‘OLL 15086649 EC RKBLE7S5268 | ADLLTS0S6554 165 2026 167 EE 2040400 2640825 790 2793) 19.5 EG 2646466 2646826 210 3087 213 av BKB36SD5260 BDLI10S6267 780 26468 18,2 FC 2046466 2616831 210 3087 21,9 Fo BKBS5S05250 BDL11056267 170 2498) 17.2 FL BKBLG7S5200 BDLL 15086678 200 2940 208 FM ‘BKBS5SD5260 BDLT10S6685 170 2488 172 FN BKBLE7S5299 | BOLL1S0S6639 195 2867 19.8 FR BKB35S05260 BDLI10S6267 170 2499) 17.2 FS BKBLE7S5299 | BDLL1S086674 170 2409) 172 Fw 2646466, 2646826 165 2720 18,7 FY 2646460, 2646842 175, 2578 177 8 BKBSSSD5260 BOLT10S6709 170 2408 17.2 Continued Perkins Service Data Booklet Part 1. 1997 GENERAL DATA 3 ——_— Atomiser information continued Set and reset pressure Code Holder Nozzie atm (tot) MPa ee] skBasspsa50 | ADLTIOSa70a 170 2498 172 eD__| BkBLE7S52e9 | BDLLIS0SE7G0 | 200 2940 20,3 6G 2646466 2646845 210 3087 a8 GH | BxBLE7ss2ee | BDLLIsOSe738 | 210 3087 213) GK 2546572 2646782, 275 4042, 18,7 cL 2546460, 2046844 175 2573 17.7 GM 20A6466 2546848 185 2720 187 as 2646475 2646850 252 3704 17 aw | Bxasssps268 | BDLLts0se709 | 170 2499) 2 x 2645F301 2645F501 250 3675, 258 [rey 2646528, 2646724 150) 2205, 152 H BKBs255141_| BDLI10S6267 120 1764 12,2 HA 2646468 2646854 215 set 218 HB 2646466 2646855 215 eT 218 HC 26454302 2645A602 245 3602, HO 2845 A301 26454801 260 3822 He ‘Beasaaee 2545A608 280 Ea HF ‘R674 | _JBea0T022 210 3087 213 HG: LABe7014 | _JBee0To22 280 Ea 238 HH 2O45AR02 2645K603 260 3675 253 HK 26456466 ‘26A5AG05 26 ae 218 AL 2645A302 2645K602 290 3381 238 ro ‘2645301 (2845K603 2a 3675, 25.3 HN 2646467 2646850 240 3628 243 HP 264GASO2 2645AG02 225 3808 228 Ha 26AEASO2 2645A605 270 3968 18.4 HS 2646466 26456844 200 2940 20.8 aT TRB67OV4 | _dBe801019 200 2040) 208 HU 2645A302 2645K604 220 3234 228 Hx 2645301 2645K603 210 3087 218 HY 2646466 2646845 176 2578 27 Z| pxes2sbstar | BDL11086133 120 1764 12.2 =z 2645A301 2645A622 280 3387 23.3 NB 26451901 2645602 195, 2867 188) Ne 2845302, 26451603 170 2498 72 NO 26451301 245.604 175 2573, vr Na 26451904 ‘25451606 230 3361 23.5 RA 2645F308 2545F 602 247 3631 168 FB 26450304 2545F506 250 3675 25.3 Gontinued Perkins Service Data Booklet Part 1, 1997 3.073 GENERAL DATA : GENERAL DATA 3. : —— Atomiser information, continued Atomiser information, continued ‘Set and reset pressure i ‘Set and reset pressure Code Holder Nozzle atm ovine) Pa | Code Holder Nozzle atm (totine) MPa Te__| BkBassbsaso | spLiiosa7s 70 2488) 72 ¥ 2EARAED 2646672 176 2573 77 uA 72645M301 2645M601 TEA TBA TBA YA 26450308 26450618 240 3628) 24,3 vB 2646522 2646724 150 2205 152 : Ye 26450304 26450616 188 2279 15.7 VA 2645M301 2645M601 TBA TBA TBA | Ye 26450307 26450617 230 3381 23,3 vB 1HB54S603 NLS60 170) 2499 17.2 1 YD. 26460310 2e45C618 240 3528 243 w | BkBLssssaiz_| BDLLIS0ses73 | 170 2499) 7.2 Z___[ekBLe7soste1 | BDLLS0S6355, 170 2468 72 | VN 2646562, e602 200 2040 208 | vr “| oxttsaseees | O1l1s0s3305 195) 2867 18,8 | Wi__[ okitsasso12 | OLL150877 195 2867 19,8 Ww. 26450564 26466866 225 3908 22.8 Ww ‘2646562 2646869) 210 3087 21,3 Vx__| oxitsessa12_[OLL16087777 195 2867 19.8 W | Oxit5482624 | OLL160877 195 2067 19.8 . Vz__ | OKLLs4s2924 | OLL15057788 195 2867 19.8 WA | OKLUsAS2e04 | OLLis0ssa65 795 2867 19.8 We 2646568 E4687 195 2067 19.8 WO | OKuLs4s2096 | OLLi80s7608 138 2667 798 WI | OKLLSaSa0i4 | OLL1S0S7768 195 2867 198 WK | OKULS4S3014 | OLL16059065 195 2867 19.8 i wi | oKtusasaota | oLL1608777 108 79.8 ‘ WN 2646508 ‘2646872 27, 21,9 | we | oxitsass0s2 | O11 15089965 210 213 WU | OKLUSaninsa | OLLTaNSAAAA Ww OKLLS4M3052 | OLL150S7768 | ww 26450902 2645C802 wx 26450908 26450804 ( WY 26450303 26450605 | WZ, 2646568 2646860 : XA 26450303 ‘2645K601 | x8 26450303 ‘2645K604 ! xc 26450308 26450608 i x0) 26450906 26450608 170 i XE 26450305 26450610 195. : xe 26460305 26450615 210 i xd 26450305 26450621 170 : xD 28450305 26450819 170 XK 26450907 26460613 245 : xv 2646568 BEAEBEE 210 xz 726486308 26450614 220 | 3.08 Perkins Service Data Booklet Part 1, 1997 Perkins Service Data Booklet Part 1, 19973 GENERAL DATA ee ‘Turbocharger waste-gate settings Waste-gate test pressure for rod movement of 1,00 mm (0.038 in) ‘The turbocharger part number is on the turbocharger identiication plate, which is fitted to the body of the turbocharger. Waste-gate pressure: Waste-gate pressure ‘Turbocharger part number Turbocharger part number kPa Torin | kglfome kPa ovine | kgveme 2e7an0ss| tiazo | 16.4774 [716022 | 26740086) 96 13.9 0,98 2674a0s4| T1020 | 16.0774 | 1.12/22 | 2674Ai04| 98/106 _| 14a/t64 | 0.90/07 ‘zeraacss| 120/130 | i7.a7ie9 | Leese | 2e/4arus| 99/106 | 14.354 | 0,99H,07 ‘2eraans6| 120730 | 174/180 [1.22.82 | “2e74ato6| 99106 _| 14.2954 | 0,99A,07 e74a057| “118/128 | 1748.3 | 1.207128 | 2674At08| 99/106 _| 14.315.4 | 0,991.07 aeraaos6| 11e/126 | 17.7/18.3 | 1,207.28 | 2674Ate2| 96/06 _| 14.0715.4 | 0.99.07 zé7anose| 116/126 [17.1183 | 1,200.28 | 2674A128| 101/100 | 14.675.8 | 1,021,11 aarsaoee| tart20 | 16.4774 [1161.22 | 267eAt29| 1017109 | 14.675. | 1,029,17 2ersaoes| 92/08 | 13.8142 [0,980.99 | 26740130] 118720 | 16.4/17.4 | 1,161.22 aerahosa| Ton | Ye.0ne | 1,1171,04 | ec74atar| 10108 | 14.6/158 | 1,02/1,11 zeraaner| 120730 | 17.aneo | 1,227,90 [ se7aaias| 11920 | 16.4A7< | 1,159,22 2674a068| 110/03 | 150/49 | 1,19,04 | _2674A199| 120130 | 17.4718.9 | 1,20A,30 eeranore| Taos | Wane. | 122182 | 267daras| Gatos | 14.a75.4 | 0,997.07 Berano7s| teres | 17.1183 | 1.201,28 | 267aaraa| Vari20 | 16.474 | 1,157,22 aeranorT| taned | 16.474 | 1,167,22 | 267aar4s| 119/120 | Teariz4 | 1,157,20 Berandra| 12030 [17.409 | 1.227,92 | 2e7aarae| 199743 | 19.9907 | 1,957,458 Baraanai| Aa/sa | 12.0742 | 0,907.00 | 2674A150| 145765 | 27.0225 | 1,477.50 : 2ersnoe2| 88/92 | 12.8135 | 0,900,935 | _2674A308| 105 152. 7,04 2e74nned | T1ei28 | 17.1186 | 1,204.30 | 2674A305| 105 16.2 1,04 ‘2e74noes | 88/98 | 12.814.2 | 0,007.00 | _2674A908| 06 139 0,98 Zeranows| Te26 | 17.17BS | 120728 | —2674AaIT| 145 20 1.47 2674A087| Totio9 | 74.7758 | 7,097,00 | 267aasta| 96 13.9 0,98 2e74A0es| 150 238 2e7aasta| 145, 210 1.47 2674R093| 110 15.9 2e74Agi5| 150 ie 1.52 2674A094[ 105 12.5 2074A316| 96 13.8) 0,98 ‘2674A095| 145 21.0 2674A701| 185 225 156 26740086) 150 218 Thermostat ratings Nominal temperature “Start to open* “Fully open" Minimum valve lit, ‘stamped on thermostat by-pass valve | temperature temperature fully open B2°C TREC 92°798°C. 9mm (180°F) (1707185°F) (198°7208°F) (0.35 in) TPC er 778°C 85°788°C, ‘mm (180°F) (153°167°F) (185°7190°F) (0.35 in) 3.10 Perkins Service Data Booklet Part 1, 1997 GENERAL DATA 3. Compression test data ‘Tests nave shown that many factors alfect wornpression pressures. Ballery and starter motor condition, ambient conditions and the type of gauge used can give a wide variation of results for a given engine. Its not possible to give accurate data for compression pressure, but tests have shown thal the results should be within 2000/3500 kPa (300/500 Ibt/in2) 21,0/35,0 ktm for diesel engines. ‘Compression tests should only be used to between the cyiindars of an engine. it one or more cylinders vary by more than 350 kPa (50 Ibtfin2) 2,5 kgl/eme, then those cylinders may be faulty. Compression tests should not be the only method used to show the condition of an engine, but they should be used together with other symptoms and tests. How to do a compression teat Caution: Before the compression test, ensure that the battery is in goad condition and that itis fully ‘charged. Also ensue that the starter motor is in good condition. 1 Ensure that the valve tip clearances are set correctly. 2 Remove the atomisers. 3 Fitta suitable gauge into the atomiser hole ofthe cylinder to be tested. 4 Ensure that the engine cannot start Disconnect the stop solenoid or put the stop control in the no-tul positin. Operate the starter motor and note the pressure indicated on the gauge. 5 Ropost for each cylinder Perkins Service Data Booklet Part 1, 1997 att

Perkins Service Data Book Part 1 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Perkins Service Data Book Part 1 PDF

Uploaded by

Copyright:

Available Formats

You might also like