&8 Perkins Service Data Part 1: Mature Products up to 8,85 litres (540 cu In) WARITY PerkinsPerkins 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 8.540 Series 4 Publication TPD 1357, Issue + (©) Proprietary information of Perkins Group Limited, all 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 Parkins Service Data Booklet Part 1, 1997 00,01Foreword ‘The Perkins Service Data Bookiet contains the data which is most commonly used by experienced mechanics and technicians. The booklet contains information for all Perkins Peterborough angines and is available in two parts: Part 1: Mature products up to 8,85 litres (540 cu in) 4.108 3.162 Series 4.203 Series 4.236 Series 6.3544 Series 8.540 Series Part 2: Current products up to 8, 4a 100 Series Prima/S00 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. litres (520 cu in) 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 Generaldata ............. Specification of engine fluids Standard torque settings Conversion tables Atomiser information Turbocharger waste-gate settings Thermostat ratings Compression test data Notes Perkins Service Data Booklat Part 1, 1997 00.03,General information Perkins companies 1.02 List of Perkins service publications coven 1.03 POWERPART recommended consumable products ...........6.eeeeeeeeee 1.04 Engine number location guide ..... 0.0... 2 00cceceeeeeeeeseeeeeeeeee ee + 1.05 Engine number guide bo bbeeteueeeeteseeeeeeteeeeeenenee - 1.08 Basic faultfinding guide ........ 6.0 .eee ee 1.08 Turbocharger fault ude... 6... eevee sees ce eeeette neers 140 General safety precautions ...... 600.6... csceceseeceseeeeeereeee neers . 142 Perkins Service Data Bookiet Part 1, 1997 1.01Perkins companies ‘Australia Perkins Engines Australia Ply Ltd, Suite 2, 364 Main Street, Mornington 2931, Victoria, Australia. Telephone: 597 51877 Telex: Perkoil AASOB16 Fax: 0597 1305 France Motours Perkins S.A., 9-11 Avenue Michelet, 93583 Saint Quen, Cedex, France. Telephone: (1) 40 10 42 70 Telex: 642924F Fax: (1) 40-10-4245, Germany Porking Motoren GmbH, Saalaeckorstrasse 4, 63801 Kisinostheim, Germany. Telephone: 6027 5010 Fax: 6027 501124 Hong Kong Perkins International Ltd, Vatity Asia/Pacific, Suite 3301 Convention Plaza, 1 Harbour road, Wanchai Hong Kong, Telephone: 852 2588 1883, Fax: 852 2827 2311 ttaly Motori Perkins SpA, Via Socrate 8, 22070 Casnate con Bemate (Como), Italy. Telephone: 031 564633 or 564625 Telex: 380658 Perkit| Fax: 031 249092 or 554145 Japan Varity (Japan) K.K., Reinanzaka Building, Sth Floor, 44-2 Akasaka, 1-chome, Minato-ku, Tokyo 107, Japan. Telephone: 03 586 7377 Telex: Perkoil J2424823 Fax: 03 582 1596 United Kingdom Perkins Intemational Ld, Easttiold, Peterborough PE1 SNA, England. Telephone: 01733 67474 Telex: 32501 Parken G Fax: 01793 582240 United States of America Perkins Intemational - North America 12025 Tech Center 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 23134, 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 3.152 Series TPD 0596 1285 EFG (1) ‘TPD 0696 1285 EIS (2) TPD 1081 1208 4.203, 04.203, 201 TPD 1090 1216 601 SER 0681 1010 4.2082 201 TPD 1090 1216 601 TPD 0580 1158 4.236, 4.248 TPD 1095 1291 EFG. ‘TPD 0596 1291 EIS 601 TPD 0393 1229 6.3544 Series ‘TPD 0504 1289 EFG. ‘TPD 0590 1289 EIS ‘TPD 1089 1146, VB.540 Series 201 TPD 1090 1207 601 TPD 0690 1215 (1) Printed in English, French and German, (2) Printed in English, italian and Spanish, Parkins Service Data Booklet Part 1, 1997 1.03)WERPART recommended nsumable products ‘ers have made availabe the products ‘ammended below in order to assist in the rect operation, service and maintenance of your tine and your machine, The instructions forthe ‘of each product are given on the outside of container, These produc's are available from + Perkins distributor WERPART Antitreeze tects the cooling system against frost and ‘osion. Pat number 1 Itre 21625165 or 5 litres 25167 WERPART Easy Flush fans the cooling system, Part number 2182501 WERPART Jolnting compound versal jointing compound which seals joints rently Hylomar. Part numbor 1881156 oF n7, \WERPART Sillcone rubber sealant +re rubber sealant which prevents leakage "ugh gaps. Currently Hylosl Part number “106; WERPART Lay-Up 1 iesal fuel additive for protection against ‘osion. Part number 1772204, WERPART Lay-Up2 tects the inside ofthe engine and of other ved systems, Part number 1762811 WERPART Lay-Up 3 tects outside metal pars. Part number 1734115. WERPART Chisel ws easy removal of old gaskets and joints rently Loctite chisel. Part number 21825163. WERPART Repel 1 damp equpmont and gWes protection against “osion. Passes through dir and corrosion to ‘eate and o assst removal of components. rently Loctite repel. Part number 21825164. \WERPART Threadtock ‘etain smal fasteners where easy removal essary. Currenty Loctite 222e, Part number 20222 WERPART Studiock 2ermanenty retain large fasteners and studs Tenty Loctte 270. Part number 202701820222 POWERPART Nutlock To retain and seal threaded fasteners and cup plugs where easy removal is necessary. Currently Loctite 2428, 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 21620518 POWERPART Threadlock (hydraullc/pnuematic) To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems. Currently Loctite £42, Part number 21820542 POWERPART Threadlock (pipe) To rotain and seal pipe connections with coarse ‘threads. Pressure systems can be used immediately. Currently Loctite 575. Part number 21820875. 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 interterence fit. Currently Loctite 638. Pat number 21820638. POWERPART Atomiser thread sealant To seal the threads of the atomiser into the cylinder head, Currontly Hylomar Advanea Formulation. POWERPART Compound To soal the outer dlameter of seals. Currently Loctite Forma Gasket No 2. Part number 1861147, POWERPART Platelock Medium strength anaerobic threadiock 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. Pan number 21826040. POWERPART Silicone adhesive ‘An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets, Used for sealing flange where oil resistance is needed and movement othe joint occurs..Curently Loctite 5900, Part number 21826038. Perkins Service Data Booklet Part 1, 1997\gine number location guide Engine type Position 4.108 At ‘gisSees up to engine CE91244U906114W 83 from engine CE31244U906114W At 4.208 Series Bi orbs 4.236 ‘A201 B2 4248 Ae rove 6.3544 Series 43 8.540 Series a Notes: llustration A shows the left side when looked at rom the flywheel ond of the engine. llustration B shows the right side when looked at rom the flywheel end of the engine, and the rear Jew of the engine llustration C shows the top of the engine. Perkins Service Data Booklet Part 1, 1997 1.08Engine number guide For engines made after 1974 Example of an engine number is TU20300U510256F Woe 20300 Table 1 - Engine Family 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 serial number Year of manufacture code, see Table 3 ‘A Phaser/1008 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 As Naturally aspirated AK Turbocharged AM turbocharged intercooled ap Naturally aspirated |AQ Turbocharged B Prima/s00 BA Naturally aspirated BB Turbocharged BC Gasolene © 3152 cA P3 cB 344 cc Pats co 3.182 cE 03.152 GF 3.12 ca 3.152 os 3.1522 cM 31524 cN 73.1524 © 900Series eo sar cr 1327 cs 325 E 4108 EA 4.99 EB 4.107 EC T4107 ED 4.108 EE ya.108 « 4.1847200 GA 4.184 GB 4.135 ec 4.162 GD 425 GE 430 H 4.165 HA 4.165, J 4.203 vA Pa B 4.192 de 4.192 4D 4203, JE 04.203 oF 64.203 JG 4.2032 K_ Peramaiioo KA 2 oy1.0,4Itros KB 3 V1.0 litres KC 3 oy. 0,9itres KO 371. 1,0 litres KE Sol. 1 5 fitres KF 4 oy. 1.9 litres KG Boy. 1,2 ltres KH Boy. 1,3 tres KJ Syl 1,5iltres D KK 4cyl 1,91ttres D KL 3 cyl 0,7 lites KN oy. 05 litres KR 4o¥h. 22 lites L 4.236 w 4212 LB. Ga212 uc 4.224 > 4236 le 64.236 LF 4.248, Ls 4.2482 LH 04.236 u 14.296 UK 04.238 ue 4.38 iM aay N ast8 NA 4270 NB 4300 NO 4318 NO 4.3182 P 6.305 PA PS PB 6.288 PC 6.305 PO PF6.305 R 6.247 RA 6.247 SD Sabre 006.68 T 6.354 TA 6.906 8 6.395 Tc 6.354 0 6.354 TE 6.354 TF 6.354 16 6.3541 TH 76.9641 ws 6.3542 1 6.3542 Th 6.3543, ™ 06.3543 N 6.3543 Tr 76.3543, To HT6.3543 1A 6.372 1s 6.3723 7 708.9541 wu 6.3544 wv 6.3724 ™ 6.3544 ™ ceases Vv 6.3544 Z HT6.9544, U_ 700 Series UA 704-26 us 704-30 W. Peregrine/1300 WA 6.466 WB 78.466 we 008.466 wo T6.67 WE co6.67 Wr T6.76 wa cc6.76 WH Te.87 Ww cc8.87 x va.s4o XA va.s10 xB Tva.5t0 xc 8.540 xD v8.605 xe Tv8.540 Y Phaser/1006 YA ‘Naturally aspirated YB Turbocharged YC Compensated YO Charge cooled YE Fed. Charge cooled New Phaser/1006 Ye Naturally aspirated YH Turbocharged YK Turbocharged intercooled Z ves40 aA ve.640 zB Tva.640 Perkins Service Data Booklet Part 1, 1997© Compensated [F MadeinFrance |[H Horizontal P Timing chain CC Charge cooled | Fed. Federal NN Narrowfrontend }T Turbocharged D__Directinjection |G __Gasolene orgas | (Belt driven water pump) |V__Vee form ‘Table 2 - Country of manutacture code ‘This code indicates the country of manufacture of the basic engine. A ‘Argentina [H Group [M Mexico [U United Kingdom 8 Brazil | HM Indonesia | Mx Mexico |v Pakistan c Australia | HK traq |N usa |W Iran D Germany | HU Hungary | P Poland |X Pew E Spain | J Japan |S India | ¥ Yugoslavia F France |K Korea |SA South Africa 6 Greece | L ttaly | Turkey ‘Table 3 - Year of manufacture code “This code indicates the year of manufacture. The letters |, O, Q, Rand Z will not be used. A 1974 [H 1981 |S 1988 [A 1985, B 1975 |J 1982 | 1989 |B 1996 c 1976 |K 1989 JU 1990 |c 1997 o 1977 JL 1984 |v 1991 |D 1998 E 1978 |M 1985 |W 1992 | 1999 F 1979 |N 1986 |x 1993 | F 2000 G 1980 |P 1987 |Y 1994 |G 2001 Perkins Service Data Booklet Part 1, 1997 107Basic 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, 9, 10, 12, 13, 14,15, 17, 34, 35, 96, 37,38, 40, 42, 43, 44 The engine is difficult to start 5,7, 8,9, 10, 14, 12, 18, 14, 15, 16, 17, 19, 94, 06,37, 38, 40, 42, 43, 44 ‘Not enough power &, 9, 10, 11, 12, 13, 16, 17, 18, 19, 20, 21, 34, 96, 37, 38, 39, 42, 43, 44, 61, 63, 64 Mists &, 9, 10, 12, 13, 15, 20, 22, 34, 36, 57, 36, 39, 40, 41, a High fuel consumption 17, 13, 15, 17, 16, 19, 21, 42, 49, 44, 63 5, 84, 96, 37, 38, 99, 40, Black exhaust smoke 11, 19, 16, 17, 19, 21, 22, 34, 36, 37, 38, 39, 40, 42, 43, 44, 61, 6 [Blue or white exhaust smoke 4, 15, 21, 23, 36, 37, 38, 39, 42, 44, 45, 62, 58, 62 The pressure of the lubricating oils 100 1ow 4,24, 25, 26, 46, 47, 48, 50, 51, 59 The engine knocks 8, 18, 15, 17, 20, 22, 23, 86, 37, 40, 42, 44, 46, 52,53, 60 The engine runs erratically 7,8,8, 10, 11, 12, 18, 15, 16, 18, 20, 22, 23, 34, 38, 40, 41, 44, 52, 60 Vibration 13, 18, 20, 27, 28, 34, $8, 39, 40, 41, 44, 52, 54 ‘The pressure of tho lubricating oils too high 425,49 The engine temperature is too high 11, 13, 15, 19, 27, 28, 30, 32, 34, 36, 37, 39, 52, 55, 56, 57, 64 Crankcase pressure 31, 85, 39, 42, 44, 45, 52 Bad compression 11, 22, 37, 89, 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: Battery capacty ow. Bad electrical connections. Faut in starter motor. Wrong grade of lubricating ol Startor motor tums engine too stow. Fuel tank empty Fault in stop control. Restriction in a fuel pipe. Fauit in fuel it pump. Dirty tv! fitor element. Restriction in fter/leaner or air induction system, 12 Airin fuel systom. 13. Fauit in atomisors or atomisers of an incorrect ‘type. 14 Cold start system used incorrectly. 15 Fault in cold start system. 16 Restriction in fuel tank vent. 17 Wrong type or grade of fuel usad. 18 Restricted movement of engine speed contra 419 Restriction in exhaust pipe. Engine temperature is too high. Engine temperature is too low. \VaNve tip clearances are incorrect. BREB wet type oil cleaner. Not enough lubricating olin sump. Detective gauge. Dirty lubricating ol iter element. Fan damagod. Fault in engine mounting or flywheel housing, ‘Too much lubricating oil in sump. Restriction in breather pipe. Insutticiont coolant in system. ‘Vacuum pipe leaks or fault in exhauster. Fault in fuel injection pump. Broken drive on fuel injection pump. ‘Timing of fuel injection pump is incorrect. 37 Valve timing is incorract. Bad compression. Cylinder head gasket leaks. Valves are not free. Wrong high-pressure pipes. ‘Wor cylinder bores. Leakage between valves and seats. BSLSBBNBee eee Berses ‘To much oil or oil of wrong specification used in Restriction in ar or water passages of radiator. SSeLeS ee e498 & Sees Piston rings are not free or they are wom or broken. Valve stoms andlor guides are wor. Crankshaft bearings are worn or damaged, Lubricating ol pump is wor. Ree! valve does not close Rete! valve does not open. Rel! vale spring is broken Fault in suction pipe of lubricating ol purnp. Piston is damaged. Piston height is incorrect. Flywheel housing oF flywheel isnot 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 impelie is damaged or ary. Lubricating ol seal of turbocharger leaks. Induction system leaks (turbocharged engines), “Turbocharger waste-gate does not work conecty (if there is one fed), Porkins Service Data Booket Part 1, 1997 1.09Turbocharger fault guide ‘The chart below is given to assist in the correct diagnosis of turbocharger fauts. {tthe inside of the induction manifold is wet, check that there is not a fue! leak from the fuelled starting aid, if there is one fitted. Problems and possible causes Problem Possible causes Not enough power 1, 4, 5,6, 7,8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34, 35, 96. Black smoke 1, 4.5.6.7, 88, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28, 34, 35, 96 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 oil at turbine end 2, 7,8, 17, 19, 20, 22, 28, 90, 31, 32 "Too much lubricating oll 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, 82, 33, 97, 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, 99, 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, 93, 37, 38 Rotating assembly does not turn freely 3,6, 7,8, 12, 19, 14, 15, 16, 18, 20, 24, 22, 23, 24, 28, 92, 93, 37, 98 ‘Worn bearings, bearing bores, journals 6,7, 8,12, 18, 14, 15, 16, 28, 24, 29, 33, 37, 38 ‘Noise trom turbocharger 1, 3,4, 5,6, 7, 8,9, 10, 11, 12, 13, 14, 18, 16, 18, 20, 21, 22, 23, 24, 29, 32, 33, 34, 37, 38 ‘Sludge or carbon deposit in bearing housing 2,11, 13, 14, 15, 17, 18, 24, 29, 33, 97, 38 1.10 Porkins Service Data Booklet Part 1, 1997List of possible causes. 1 Element of the alrfiter dity 2. Restricted crankcase breather 3 Element of the air fiter not fited, or not sealing correctly. Loose connection to turbocharger. Intemal distortion or restriction in pipe trom air iter to turbocharger. Damaged/restricted crossover pipe, turbocharger to induction manifold. Restriction between air fiter and turbocharger. Restriction in exhaust system. Turbocharger loose or clamps/setscrews loose. Induction manifold has cracks, is loose, or has flange distortion. 10 Exhaust manifold has cracks, is loose. or has flange distortion 11 Restricted exhaust system, 12. Delay of lubricating oil to turbocharger at engine start. 19 Insufficient lubrication. 14 Diny lubricating ol, 15. Incorrect lubricating oi. 16 Restricted lubricating oll supply pipe. 17 Restricted lubricating oil drain pipe, 18 Turbine housing damaged or restricted. 19 Leakage trom turbocharger seats 20. Wom turbocharger bearings 21. Excessive dit in compressor housing. Excessive carbon behind turbine rotor. Engine speed raised too rapidly at intial start. Ineutficient engine idle period. Faulty fuel injection pump. ‘Wom or damaged atomisers, Valves bumed. Wom piston rings. ‘Lubricating oil leakage trom supply pipe. Excessive preservation fluid (on initial engine start). Excessive engine idle period. Restriction in turbocharger bearing housing. Restriction in lubricating ol iter. Wet type air cleaner: Restricted, diy element, viscosity of ol to low/high, Waste-gate actuator tauity or damaged. Waste-gate vaive not tree. 37. Engine stopped too soon from high load. Insufticient lubricating oi Fuel leakage trom fuelled starting aid. Crack in backplate of compressor. evoae BASBRLSSBBNRRREBK g see Perkins Service Data Booklet Part 1, 1987 1— General safety precautions ‘Thoee safety precautions are Important. You ‘must ter also tothe focal regulations in the country of use, Some items only refer to specific applications. ‘+ Only use these engines in the type of ‘application for which they have been designed. + Do not change the specification ofthe engine. + Do not smoke when you put tual tho tank. + Cloan away tuo! which nas been spit. Material which has been contaminated by fuel must be moved to @ sate place. + Do not put fuel inthe tank while the engine runs {unless its absolutely necessary). * Do not clean, add lubricating ol, or adjust the engine while it runs (unless you have had the ‘correct training; even then extreme care must be used to prevent injury). + Do not make aojustments tnat you do not understand. + Ensure that the engine does not run in a location ‘where itcan cause a concentration of toxic emissions. + Other persons must be kept ata safe distance ‘while the engine or auxiliary equipment is in operation + Do not permit loose clothing or long hair near ‘moving parts. + Koep away from moving parts during engine operation. Warning! Some moving parts cannot be seen clearly while the engine runs. + Do not operate the engine ita safety guard has been removed + Do not remove the filler cap or any component of the cooling system wile the engine is hot and while the coolant is under pressure, because dangerous hot coolant can be discharged, + 0 not use salt water or any other coolant which can cause corrosion in the closed circult of the cooling system. + Do not alow sparks or fre near the batteries (especially when the batteries are on charge) because the gases from the oloctroiyte are highty flammable, The battery tid is dangerous to the skin and especially tothe eyes. + Disconnect the battery terminals before a repair is made to the electrical system. + Only one person must control the engine + Ensure thatthe engine is operated only from the control pane! or from the operetors position. + your skin comes into contact with high- preeure fuel, obtain medical assistance immediately. ‘Diesel fuel and lubricating oll (especially used lubricating oft) can damage the skin of certain persons. Protect your hands with gloves or a special solution to protect the skin. = Do not wear clothing which is contaminated by lubricating oil, Do not put material which is Contaminated with ol nto the pockets of clothing. + Discard used lubricating oil in accordance with. local regulations to prevent contamination. ‘+ Encure that the contro! levar of the transmission crive isin the “out-ol-drive" position betore the engine is started, * The combustible material of some components, of the engine (for example certain seals) can become extremely dangerous i itis Burned. ‘Never allow this burnt material to come into ‘contact with the skin or with the eyes, + Read and use the instructions relevant to lit ‘equipment. ‘+ Wear a face mask i the glass fibre cover of the turbochargor is to be removed or fitted = Always use a safety cage to protect the operator when a component is to be pressure tested in a container of water. Fit safety wires to secure the plugs which seal the hose connections of a ‘component which isto be prossure tested. + Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help immediately. ‘+ Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from tha inlet and outlet ports of the turbocharger and prevent contact with hot surfaces. ‘+ Fitonly genuine Porkins pans. Perkins Service Data Booklet Part 1, 1997Engine data 4.108 2.02 3.152 Series 2.06 4.203 Series ..... 2.12 4.236 Series ©... 6... e eee eee 2.49 6.3544 Series © 20. eeeeeeeeeeeeteee eee 2.26 V6.540 Series .. 2.32 Parkins Service Dala Booklet Par 1, 1997 201Basic technical data Horse power ee eceseee sees sess 95,0 KW (47 bhp) Number of ofinders. .... cect : 4 Cycle... Four stroke ee ne cose. Naturally aspirated ‘Combustion system ceteeeeeeecseeesseceeses Inditeetinjaction ‘Nominal bore wo coceceeseese 79,87 mm (8.125 in) SWORE ee ceeceeceseeseeeeeeteesess ceceeceeceeseess+ 88,90 mm (3.500 in) Compression ratio... ee esseseeseesseeteeeesnees ciseieees : 22s Cube capacity... ce pe0 tes 1074) Firing order. . “ 1-342 Valve tip clearances Inlet (C014) eee sees cece : 0,30 mm (0.012 in) = Exhaust (cold) en 22. 030 mm (0.012 in) Lubreating ol pressure + at maximum engine speed and normal engine temperature ......ceseeseseeeveeveeses 2O7H414 KNUM? (90/80 IOUT?) 2,1/4,2 kgllem? Coolant temperature... eee eveeeeceecsecesesseseeeeetensees ceveeses 60°C (140°F) ‘Thormostat stants to open en coceeeees OTPTS*C (152167°F) = wax ype . vecceceeeeeseceessessessees THBS*C (170185°F) “Thormostat uly open = bellows type fecuevttettetieeenseee 185/88°C (185/190°F) = wax ype co : ceccueceeseeseessssecesees 92/08 (197/208°F) Direction of rotation... cette ‘Clockwise from front ling speed ....... : . 550 revimin Locaton of maximum nooad speed ceceesesseessese Fuel injection pump data plato Location of number 1 cylinder cece Grankshatt pulley end Loceton of engine ing mane «s--s-----+--+++ Sefbe nes on fuel injecton pump ard pup Hangs ‘Atomiser codes : bictessvssevsssee CAV = BG, GY, OMAP = YB Fuel pump codes... . : ceceeseees EHSAE, EH99; PH3O Location of fuel pump code «+++ Data plate on fuel pump Location of fuel pump timing marks ......esesseeseees . Fuel pump mounting flange Bot tension ......- cosets cececeeeeees 45N (10 IDO) 45 kt Belt deflection at longest run 10 mm (38 in) 202 Perkins Service Data Bookiet Part 1, 1997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 manufacturer ofthe equipment in which the engine is installed, Use the penods which are chortes. 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's 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 montns 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. AaB] clo/e ‘Operation +] TT ] [check the amount of coolant (2) . Check the drive belt of he altemator | | Lupnicate dynamo rear bush (where tited) . (Check for watar in the fuel pre-iter and drain as necessary +/+) | Renew te elements of the fuelfiter Check the amount of lubricating oil in the sump io Check the lubricating oil pressure at the gauge (1) Renew the engine lubricating ol (4) || | Renew the canister of the lubncating oil fiter (4) Clean air compressor titer, it tited Clean the air cleaner or empty the dust bow! of the a filer . extremely dusty conditions . normal conditions . Clean or renew the air fiter element, iit has not been indicated earlier || |= |lensure that tne valve tip clearances ofthe engine are checked and, necessary. i | agusted (3) L_{. |e [Ensure mat tne atornator, starter motor te, are checked (9) | (1) t there is one fited (2) Renew the anttreaze every 2 years. Ita coolant mhibtor is used instead of antifraeze, it should be renewed every 6 montns. (8) By a person who nas nad the correct taining {@) The of change interval wil change withthe Sulphur content ofthe fuel (see the table on page 3.02 and fuel specification). The interval to change the canister of the lubricating ol fiter isnot affected. Perkins Service Data Booklet Part 1, 1997 203Fuel pump codes CAV fue! injection pump Type 2 cevteeeeeee Lucas DPA Diroction of rotation... . feo eesetceteetesstsessseseees Clockwise from dive end Outlet for number 1 cylinder cece Letter “W* Fuel! injection pump timing The engine check angle must be used with special tool MS.67B and with the engine set with numbor 1 piston at top dead centre (TDC) on the compression stroke. The pump is chacked with the pump set at tho Start of injection for number 1 cylinder. ‘The code letters are included in the setting code stamped on the data plate ofthe fuel injection purnp. Some ‘uel pumps may have the setting code stamped on a modification plate which is fastenad to the tlange of the ‘pump. fa modification plate is fitted, use the code letters stamped on this plate Engine check | Pump mark Fuel pump code letters ‘angle angie (degrees) (degrees) EH, EHS4E, EHSS Bi 280 LH30 281 22 PH, PHOSE, PH27, PH2B, PH30 281 200 PH25ES005/2450 PH25E500/9/1990 PH25€500/9/2090, PH30/500/5/2450 2795 280 PH30/500/6/1570 PH30/500/0/1990 PH30/500/0/2090 RH, RH3OE 2795 290 SHIGE 2795 200 TH, THESE 287 281 Recommended torque tensions ‘The torque tensions below apply to components lubricated ight with clean engine oil betore they are fitted. rea Torque Deserintion “ae Nm | lbtft | kgtm Nis, evinder head vw | arf sof a3 Sump poe meat Atomiser clamp wis | t0| 12} 17 Injector pipe union nut wiexts | 20| 15] 24 Main bearing vw | us} a5 | ine Big end bearing ae_| s7| 2] 50 Front puley 36 | 203| 150 | 207 Flywheel i me 81] eo] 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. fn doubt, refer to the ‘workshop manual. 1 Lightly lubricate the threads of the oylindar had ‘studs and nuts. 2 Gradually and evenly tighten the nuts in three ‘stages. Tighten the nuts in the final stage to 1 Nr (60 lot tt) 8.3 kat m. Start the engine and run it until the coolant temperature is 170°F (77°C). Switch the engine off 4 Check the tightness of the nuts in the correct sequence. ‘= It anut moves when checked, tighten it to the cortect torque. ‘© It a nut does not move betore the correct torque is reached, loosen the nut 1/12 to 1/6 (30° to 60°) of, ‘a tum and then tighten it tothe correct torque. Caution: Its important that the cylinder head nuts are tightened again to the correct torque, in the ‘correct sequence, after 800/ 1600 km (500/000 miles) 25/50 hours. 17 II 14 es e,0¢ 7 <2) ise : He Oe BC So as aie) bh wl 18 Perkins Service Data Booklet Part 1, 1997 2.05Basic technical data Horse power 3.182... seeeeee 33,6 kW (45 bhp) = 03.152 : teeseeee 36,5 KW (49 bhp) 3.1522 33,2 kW (44.5 bhp) 8.1524 ‘ 38,8 KW (62 bhp) - 73.1824. 144.7 kW (60 bhp) Number of cylinders. seve cycle Induction system - 9.182, 03.152, 9.1522, 3.1524 . ~T3.1524 Combustion system 3.182... . : . = 03.152, 3.1522, 3.1524, 73.1524 ceeceteetteneee Direct injection Nominal bore... ceeeeeeseeeeeeetees 91,44 mm (3.60 in) Stroke 127 mm (5 in) Compression ratio 8182 ese - 03.152 : 3.1822 3.1524 = 73.1524 (Cubic capacity ....... Firing order... ecscesseseeceeeteeeeeenee Valve tip clearances, Inet (cots) 3.182, 03.152 ...... 3.1822, 3.1524, 73.152. ~ Exhaust (cold) 9.182, 08.152 2... eee 8.1822, 9.1524, T3.1824 0.2... Lubricating oll pressure at maximum engine speed and rormal engine temperature : 123 0:30 mm (0.012 in) 0,20 mm (0,008 in) 0,30 mm (0.012 in) 0,32 mm (0,0125 in) 207/414 KN (30/60 lotfn?) 2,1/4,2 kgtfem* Coolant temperature .. 60°C (140°F) ‘Thermostat staits to open = bellows type ceceees 722°C (1701179°F) 222175 KW (235 bhp) Number of indore ees eevesssseseereesceeee - a8 we sestccees Fourstroke tote Naturaty asprated Turbocharged Combustion systern - Diet inoction Nominal bora vee seseceses 106.0 mm (4.28 in) stoke 20,7 mm (4.75 i) ‘Compression ro ves40 « ten vost Wasao 1st cube capa0ty 6... fs tres Fring order : 19754962 \Valv tp clearances = nto) Vast0 sevvreeeeeneiee esses 25mm (0.10 n) Waseo. : UI SII 02s mm (020) + Exhaust (208) ves 025mm 10%) Waseo 0,50 mm (0.20'9) Luang i prossixe ternal eng opera. 200 eV (40 Be) 28 tem? Coclrt temperature . : ec (14077) ‘Teno tat opon cesses OTMB'C(NSQNOTAY Thermostat ly open 858°C (185/190°F) Dhecton of cation. Cock rom ont ting speed « Fuel injection pump data plate Location of masirum nolo speed Fal injection pump doa plate Location of number t eytinder ses Front eftbankaterankshat puley end Location of angine ting maNkS e+. ‘Serbo tines on fue injction pump and pump Fange Moms Codes eee ee eeessees VALVE, NU, VN, ING, FG, GU, YW, IW, WY, WZ, XA, XB, XY Fuol pump codes. : TBA ual injacton pum data plate Location o uo! pump COd9 «es .sseeees Location of fuel pump tiring marks Fuel pump mounting flange and pump adaptor plato Botttersion .... <. 45 (10169 45 egt Bott detection at longost run 10mm (98 in) 232 Pethins Service Data Booklet Part 1, 19978.540 Series 2 —_— Preventive maintenance periods Caution: On shor cistance operation with frequent starts and stons the hours of aperation are mere Important than ie csience. “These preventive maintenance periods apply fo average concitons of operation. Check the periods aiven by the manctactuer ofthe equipment in whch the engine is iretalled. Use the poriods which are shortest Wren the eporation of he engine must conte to he ‘eal regulations these periods and procedures may reed t be adapted to ensure correct operation othe engine. It's good preventive maintenance to check fr leakage and loose fasteners al ach service Maintenance schedules A Every &nours or every day Every 2000 hours B Every 500 hours or 6 months Every 2500 hours © Every 1000 hous F Every 400 hours “The schedules which ‘olew must be appbed atthe interval (heute or months) which occur fst BOGOGG Operation . ‘Gheok te amount of ecolart . (Cheok to dive Dats of he aerator a crack for watar inthe previner (1) . Renew the elements of the fuel iter +} | [ensure mac te aersers are checked (3) cheek he amount of usreating olin he sump (Gnack the lubricating of prescuro atthe gauge (1) ‘Ranow the engine lubricating ol (4) Ronew tha eanitor af to lreating ol ter (8) * ‘Clean the engine brastnarsystom ‘Clean the ar cleaner or ey the duet bom ofthe ai iter riromely dusty conations . = ormalcenditers . ‘Cleaner renew the alr iter samen, i! thas rot been incicated cartor + | | Giean the turoocharaer impeller and casing (3) if [Crack te turboenarger (3) Enaure that ne vave to clearances are checked are adjusted, i necessary (3) . ve540 Tva.s40 Ensure thatthe alternate; etter motor et, are check (3) (1) Hrthere is one fted. (2) Renew ine aniieeze every 2 years. If coolant inbitr is used instead oan renewed avery 6 monins. (9) Bya person who has hac ihe coroct tain. {4} Tha at crange ivenal wil change withthe sulphur coment ofthe fut (200 hw tabla on page 3.02 anc at spectcaticr). Tre interval to change tha eanstar af tre iubicaing of fitaris not afected should be Pethins Service Data Bocklt Pat 1, 1997 2332 V8.540 Series —— Fuel pump codes Fuel Injection pump Type... fitceteteteees ssesesss CAV Minimec, DP15 or Bosch MW Direction of rotation from drive end .... --. Clockwise ‘Spill timing of CAV Minimec or Bosch MW Spiltiming | Piston Fuel pump coda letters. position position BTDC ‘BTOC (degrees) | mm (in) 18987 17800/A02/1800 _ RIB71/800/47A/2360 2642A210MB/CO2/1575 MB71/900/A02/1880 © RB71/800/41/2380 2642A211MB/AC2/1890 MB7V/e00/Co2/1560 RBT1/800/41A/2480 2642A215RB/41A/2500 MBTV/eo0/Co2/1575 © RB71/800/41A/2500 2642A215AB/41A/2530 26 7,62 (0.300) Ressi800/e1A/2350 © RB71/800/41A/2590 _2642A228RB/41A/2930 FRB69/800/41A/2530 —AB71/800/41A/2560 FiB69/800/44A/2830 —RB72/B00/47A/2380 Re71/800/41A/2330__ RB72/B00/41 4/2590 LB71/600/12/2500 —-RBTO/BOW/44N/2910 _2642A21SMB/D01/2960 LB71/e00'22/2500 —RB71/B00/41A/2560 2642A213MB/D01/2420 B71/800/D01/2340 RB71/800/41N/2860 2642A213MB/DO1/2520 MB71/B00/D01/2960 AB71/800/414/2730 2642A214R5/444V2770 ‘MB71/800/D01/2080 AB71/800/44A/2830 2642A215AB/41A/2550 28 8,80 (0.350) MB71/e00/D01/2400 —RB71/600/44A/2770 _2642A215RB/414/2600 MB71/800/D01/2420 RB71/e00/s4A/2830 _2642A22RB/E01/2720 MB71/800/D01/2520 RB71/800/44A/2850" MB71/800/E01/2720 Laeee/s00/44A/2060 YBSEE/BO0/44N/2960 —2642A209RD/44A/2960 AIB7 ye00/s4a2850" (2642A214R5/444/2850 FIB7 1e00/444/2010 2642A230..G/44A/2960 23 8,53 (0.375) FiB71/800/44A/2960 PB7SL/000/01/2400 PBSIE/100/D01/2610 PBSIE/ 1000172740 PeBiE/1 100/D01/2520 PBBTE/1100/001/2620 2¢42A243°B/D01/2600 at 10,85 (0.427) PRSIE/1100/D01/2600 PBBIE/100/001/2650 s4oa049°6/D01/2520 * Non-vehicle applications ** Vehicle applications: Static timing of CAV DP15 The engine check angle must be used with special too! MS.678 and with the engino sot with number 1 piston at top dead certre (TDC) on tha compression stroke. The pump is checked with the pump set at the stam of injection for number 1 cylinder. Static timing postion BTDC. Timing check angle ......... 16° sie 226 Perkins Service Data Bookiet Part8.540 Series 2 —_— Recommended torque tensions “The torque tensions below apply to components lubricated lightly with clean engine oil before they are fited. Desoription Tweed Zelscrens, cylinder head, see torque sequence OG UNF Sump plug 3/6 UNF ‘tomiser clamp 5/1 UNF Injector pipe union nut mi2x1s Main bearing 5/8 UNF Big end bearing 916 UNF Front pulley 78 UNF Flywheel 42 UNF Perkins Service Data Booklet Part 1, 1987 2.352 V8.540 Series Cylinder head torque sequence Caution: This operation must be done by a pereon with the correct training. tn doubt refer to the workshop manual tis important that the studs and the three different lengths of setscrews are fitted in their correct positions. : 7 20 ei 96 OOH let99/5 7 23 (05 92-130! 190157 e3(e5 ebe13 «)17| Fastener | _ Fastener ‘station 11) QeiQc 21 ‘Stud = A181 016e!2 08 402 05 ei4eli, Setscrow ‘Small A_2, 4, 6, 8, 12,14, — Setscrew | Medium A 3.5, 7.9, 13, 18,] Note: Release the cylindar head sotsoraws evenly 417.19 ‘and gradually in the reverse sequence to that shown Setsorow, Large A_4, 10, 11, 20,24 in). 11 Lightly lubricate the threacs of the studs and the cylinder head sotscrows and the thrust facos of the setserew. 2 Gradually and eveniy tighten the setscrews and ‘nuts of each bank to the oorract torque, in the ‘sequence (A), Tighten again all the setscrews and ‘nuts to the correct torque, in the sequence (A). Engine and Tome fastener type wm Jorn fear lva.s40 Inanged tasteners 169 | 128 | 17,3 |flanged testeners, scant shank [seiscrews wth gasket 36811401] 185 | 135 | 18,2 |pisin fasteners with separate washers with gasket 36811401 |210 | 155 | 1,47 jrvs.s40 {tanged fastenors ato [ss | ava 3 un the engine until it reaches normal temperature ol operation. Stop the engine. Tighten again all the setscrews and nuts of each bank to the correct torque, in the sequence (A), 238 Perkins Service Data Booklet Part 1, 1997GENERAL DATA 3 General data ‘Specification of engine fluids 3.02 Standard torque settings... 6... 66 ee cece eee ceeeeeceeeseeeeeeseeeseeres 3,08 Conversion tables 3.04 Atomiser information 3.06 Turbocharger waste-gate settings 3.10 Thermostat ratingS ©... eevee eee eee cette n nares eter een ence renee 3.10 Compression test data... cece ee eee ree ee eee e eee eres baees 3.11 Notes beeen scenes Ree eee eee ne eee renee ere Eee ee 3.12 C—O Parkins Service Data Booklet Part 1, 1997 3.013 GENERAL DATA ‘Specification of engine fluids [Lubricating oll specification 4.108, 3.152, 4.203, 4.2092, 4.236, 4.248 6.3944, 76.2644, Ve.540 Minimum ubneating ol! specification + naturally aspirated engines: |= turbocharged engines APLCCISE API CDISE or CCMC D4 (1) Lubricating oii capacity Dependent on sump fitted, see application user's handbook Fuel specification Viscosity 4.236, 4.248, VB540...... 2.5/4.5 centistokes at 40°C 4.108, 3.152, 4.203, 4.2082, 6.9544, T6544. + 2.0/4.5 centistokes at 40°C Density 0.83500 855 kgfitre Distitation 85% at 350°C [Aviation kerosene fuels ‘JPS and JP8 only, refer to user's handbook Cetane number A 4236, 4.248 Vehicte only 6.3544, 78.3544, V8.540 50 minimum industria/ag 6.3544, 76.3546, V8.540 ‘All 4.108, 3.152, 4,203, 4.2092 ......... 48 minimum [Suphur (2) 4108, 4.208, 4.2082, 6.3544 79.9544, V8.540 ..... 0.5% of mass, maximum 9,182, 4.296,4.240 0...» 0.2% of mass, maximum ‘Coolant epacitication Recommended coolant POWERPART antifesze Concentration of antireeze 50% [Conosion inhibitor mixture. ‘as BS8580 or MOD AL29 Must have 2 specication atleast as good eter to user's handbook ‘Coolant eapacky ‘See application user's handbook (1) Not recommenda for naturally aspirated engines during the frst 20 to 80 hours or for ight load applications. (2) The oil change interval will change with the amount of sulphur in the fuel (see the table below and the fual spectication) Amount of ephurnhe te | oy cranga in 05 Normal 05-10 ‘3/4 of normal >10 172 of normal 3.02 Parkins Service Data Booklet Part 1, 1997GENERAL DATA 3. ee — Standard torque settings General notes 1 For service’, use the nominal torque value. Tolerances 1o be win 425% of nominal 2. Itthere are changes to phosphated surfaces orto threed tolarances, the torque values must change, 3 Torque values in these tables are for ‘dry threads’. 4 These values are not eultable for Merwin C3 type fasteners. Studs Nominal torque Thread size Nm | tot | kgtm M6 x 1,00 6] 37] ost M8 x 1,25 nf] ar] ste Mioxiso | 18| 133) 184 Miaxt7s | 25 | 1e4| 255 ‘Setserews and ni Nominal torque Thread size Nm | torte | kotim wexioo | 0| 66 | og Max 1,25, 22| 162 | 2.24 mioxiso | 44) 325 | 440 Mi2xt75 | 78] 578 | 7.95 mi4x200 | 126] 916 | 1% miex200 | 190 | 1400 | 19,37 Pipe threaded fasteners Nominal torque ‘Thread size 4 Nm | itt | kof V8" PTF 96] 70| 097 Va" PTF 170 | 128] 1,73 9/8" PTF 30,0] 22.1 | 3:06 84" PTF 450 | 932 | 4.59 Perkins Service Data Booklat Pant 1, 1997 3.033 GENERAL DATA Conversion tables ah | met | mmm | oom | ncn Miles Kilometres] Kilometres Miles va | 025] 6a] 1 | aos we | os | 127} 2 | 008 a4 | 07] 01} 3 | ore 1 1 asa} 4 | ote 2|.2 sos} § | 020 a | 3 ve2| 6 | od ale rors} 7 | 028 6 | 5 sero} 8 | ast e|e 1524] 9 | 095 717 178} 10 | 039 ais 2032] 20 | 079 9 | 9 | 2286) 30} 118 10 } 10 | 2540] 40 | 157 20 | 2 | soso} so | 197 30 | 90 | 7820] 100 | a4 40 | 40 | 1016.0] 1000 | 30.37 3.08 Potkins Service Data Booklet Part 1. 1997GENERAL DATA 3 Conversion tables, continued Pounds } Kilograms | Kilogram | Pounds Galons | Litres ] Lites | Gators oA 00s | 04 0.22 1 ass] 1 oz 02 ooo | 02 | 04s 2 vo | 2 0.44 08 on a one 3 1363] 3 0.88 04 oa} o. 088 4 tes] 4 oss 05 oz} 05 | 44 nana) 5 “4 08 oz} 08 | 422 5 07 ox] o7 | ase e ara | 6 1.32 08 oss | 08 | 176 7 sez] 7 184 09 oa | 09 | 4.90 8 sosr | 8 1.78 1 os] 1 22 8 wose | 9 1.98 2 ost | 2 aay 10 4548 | 10 22 3 198 | 3 6st 4 var} 4 8.82 5 axl s th08 Pits | Lives eps jae) [a pe 1543, 8 se] 8 1764 ‘ ons 8 sos} 9 19.84 2 “ 10 454] 10 22.05 3 1.65 20 907 | 20 4409 4 22 30 wer | 30 66.14 5 275 40 ve1a | a0 88.18 50 zoo} 50 | 110.29 Perkins Service Data Bookiet Part 1, 1997 3.053 GENERAL DATA TT Atomiser information ‘Sot and reset pressure Code Holder Nozzle aim tine) Pa 7B BKBLETSSIS | BDL 60554087 175 2573 Tr OxLL6752080 | —OLL15086705 aC. 2646460 2546577 178 2578 tar av, BKELG7S5151 | _BDLLS0S6a72 170 2408 iz BC. ‘BxBIssD5260_| _ GDLITOSeTSS 72) 1784 122 5G exedosos224 | BONTZSD8208 135, 1985 137 BM BKB35605260 | BDLTT0S6267 120) 174 722, BT__| BKBLe7SD5151 | _BDLL1S088310, 175, 2573 177, Bu BKBLE7S5151 | _ BDLLT5086495 15, 2573 17 BV BKBLE7S6IS1__| BOLLT5OSE519 170 2498 172 oR BKBLETSSI51 | BOLL15086513 170 2499 12 OF BKBLE7S5290 | BDLL 15086507 185 2720 787 cs BKBLE7SS151__| SDL 15086554 179) 2498 72 ct BxBtersosis1 | epLirs0s6555 175 2573 177 cu BKBLETSS151/ | BOLL 1S0S6556/ 15 2573 ad oK.L6752930__| 1115083555 CY __|_OKLLeewita40 | OL rsoranane 230 Eo 238 Bo BKBS5S5258 BOL11085188 120 1764 122 DE BKB35S6258 BOL11088267 120 1764 122 DF BKBLE7S51St | BDLLTSOS558 170 2400 2 ox | Breterasoos | “epi isosvesis | 210 oor | aia | OM BKBLE7S5161 | _ BOLLI50S6561 175 2573 WT BN BKBLE7SS299 | BDLL1S0S6564 170 2499 7 EA BKBLO7SSe9e7 | BDLLIS0S65017 2165 aie 218 Oktis7s2800_| OL 15080049 EC FIKBLE785268 | ADLLIS0S6554 185, 2426 167 ee 2648466 2546805 100 2788 188 EG 2646466 2546826, 210 3087 21a EV BKBG5S0s260 | _BOLT/050207 7180 2646 182 Fo 2646466 2546831 210 3067 213) Fi BKBA5S05259_| _ ADL11086267 170) 2409 17.2, FL BKaLO7SS290__| BOLL 1086673 "200 72940 20.8 FM ‘BKBSSEDS260_| _ GOL1T056065 170 2498 172 FN BKBLE7SS209__ | BOLLTS08869) 195 2067 138 FR 'BKB35S05260__| _ BOL110S6267 170 2490 172 78 BKBLE7S5009 | BOLL 16088674 170) 2490 772 Fw 2646866 2546826 165 2720 737 FY 2646460 2646842 175 2578 177 cB BKB35SD5260_| _ BOLI1056700 770) 2490 72 Continued Parkins Serviee Data Booklet Part 1, 1997GENERAL DATA 3 ——— Atomiser information continued Set and reset pressure Code Hokier Nozzle ain (bifee) MPa Ge | BxBssenses0 | epLiTose7a | _170 2198 72 GD] BKBLE7S5209 | EDLLIS0SE730 | 200 2940 208 oe 26506466 2546885 210 3087 213 GH] BKBLE7S5250 | BOLLI508e790 | __210, 3087 218 oK 2640572 BMGT 275 2082 787 Gl 2646460 2646044 175 2578 177 om 2546466 7546848 185 2720 187 as 2040475 2546260 252 3704 7A ew | BkBoSSDEL6E | BOLLIGOSE7Oe | 170, 290 72 ox zetera01 | _2645F601 250) 3676 253 oY 2640522 2646724 50 2205; 132 7 exBeessrat | eput0se2e7 | 120 1784 122 HA 2646466 2546854 zig 3161 28 HE 2646465 2646855 2165 a6t 21.8 HC | eeasaace | _2045a602 245 3602 248 HO | 2645Aa01 | _2645A801 260 22 254 HE | 2essaace | 2645608 230) 3961 233 HF | URBe7014 | JBes0t022 210 3087 24.8 HG | _Lrse70rs | _J56801022, 230 3967 2a HH 26s6as02 | 2e4sK60s 250 3876 258 HK 26456466 | _ 26450605 216; 3161 Bs Ce 230 3561 258 Hi [ 26zensor | 2646K005 250 3675 Ba HN 2646467 2546860 240 3528 243. HP | 64sAs02 | 2646aso2 225 3308 228 HA] 2646as02 | 26450605 a8 3568 184 HS 2646466 2456044 200 2040 208 HiT | —uRBe7014 | _seea01019 200 2040 208 ww 2e45as02 | 2646K506 220) 3238 23 wo Bea5asoi | 2646x603 210) 3067 213 HY 2686406 2646645 175 2579 TW 7) expscsosia | BoLiross133 | 120 Tee 122 Zz 25a5Ag01 | 26450672 230 84 233) Ne zeasia0t | 2451602 185, 2067 708 NC | 28451502 | 26451609 170 2400 m2. [no [726451301 25461608 175 2578 177, NH 2ea5ia04 | 264516060 230 sat 233 PA 25457903 | 2545002 247 3631 168 a 2) 75 253 Contioved —SSSSSSSSSSSSSSSSsSses Perkins Service Data Booklet Part 1, 1997 3.073 GENERAL DATA Atomiser information, continued ‘Set and reset pressure Code Holder Nozzle aim () MPa Te__| BKBs5806259 | BDLI1086700 170 2400 72 UA ‘2645M01 2645MB01 TEA TBA TBA UB, 2648622 2646724 180) 2205 152 VA 2645301 2645M607 TBA Tea, TBA Ve HBS4S693 NUS5O 170. 2498 172 ws | aKetsassai2 | BDLLIS0S6573 170. 2499 172 Ww 2646562 2646862 200 2940) 205) VR | OKLLs4s2065 | OLL1S0S3365, 195, 2867 198 Wr __[ oKitsassai2 | OLL1S08777 195 2887 198 ww 26450564 (26466865 225 3308) 228 Ww. 2646562 2546869 210 3087, 218 VX__| OKiUsass912 | OLLIs0ST777 795 2067 198 W__| OKLUs4S3824 | OLLISOSTI77 795, 2867 198 vz__| OxLtsas2ez4 | OLL1s087706 795: 2867 198 WA | OKLL5aS2e24 | OLLis0ss3a5 795 2867 198 We 2646568 2646871 195, 2867 198 WO | OKLUS4S2e66 | OLL150S7604 195 2867 198 wo | OKLLS#S30r4 | OLLT60S7786 195 2867 198 Wk | OKLLS4S3014 | OLLI50S9906 195, 2867 19.8 wi __| OKLLSsSs01¢ | OLLIS0S7777 195 2867 19.8 wn 2646568 2646872 27 3190) 218 Wr | OKuLS4S3062 | OLL160S3985 210 087, 218 WU | OKLLS4MS059 | OLLIS0S8085 235) 3455, 238 wy | oxLisamaose | OLLis0s77e8 195 2a? 19.8 ww 26450902 28450602 240 628, 24.3 Wx 26480308 26450804 201 2055, 20,4 WY 26450905, 26450605 235, 3455 238 we 2546568 2846868 195 2667 19.8 XA 25450308 ‘2845K601 230 3981 233 xB 26450308 2645K608 235 3455 238 XC 26450905 28450608 175 2573) 177 XD) 28460908 26450603 170 2490) 17.2 XE, 28450305 28450610 185 2067 13.8 XG 28460305 26450615 210 3087, ae xd, 28450905, 26460621 170 2499) 172 XL 28460905 26450619 170 2490 17.2 co (26450307, 26450618 245 3602, 248 xy 2546508 2eacees 210 ‘3087 23 xz 25450308 26450614 220 aah 23 Continued 3.08 Perkins Service Data Booklet Part 1, 1997GENERAL DATA Atomiser information, cantinued ‘Set and sel pressure Code ‘Holder Nozzle atm (ibtin?) MPa Y 2645160 BeaBere a NE 77, Ya | 20asc008 | 2etsosie 240 3508 243 Yo | 2s1sca0s | 261sca16 13 {s 157 Yo] _2e4scao7 | _2eascsi7 230 251 233) Yo | 2eascaro | essai 240 3528 243 2 [exBLerspsist | BoLisesssss | 170 2489 172 ooo Perkins Service Data Booidet Part 1, 1997 3.083 GENERAL DATA A ‘Turbocharger waste-gate settings Waste-gate test pressure for rod movement of 1,00 mm (0.038 In) ‘The turbocharger art number ison the turbocharger identification plate, which is fited tothe body of the turbocrarger. ‘Veaste-gato pressure Waste-gate pressure Turbocharger ‘Turbocharger part number art number kPa id kPa ‘wing | kgveme Beranoss| t1a/i20_| 1847174 2674R098| 06 EX} 08 2674A054) 1107120, ‘2a74Atoa| S608 _| 14.9154 | 090/1,07 2674A055] 1207190 | 17.4718.9 2674A105| 96/108 | 14.376.4 | 0,901.07 2674A0G6| 120/180 _| 17.4189 | 1,207.92 | —2674A108| go/i08 | 14.4/15.4 | 0,99/1,07 ‘eraaos7| 118/126 | 77.1/183 | 1,207.28 | 2674a108| 99108 | 14.378.4 | 0.97.07 aeranose | 11626 [77.1183 | 1.20%,20 | 2674arze| —sen0s | 14.9784 | o.sen.or eranose| 116/126 | 17.1183 | 1.201,28 | _2674a126| 01/109 | 14.6718.8 | 4,0071,11 ‘aaraaone| Taiz | 164/174 | 1,19/,22 | 2674arz0| 101/100 | 14.618. | 1,02A,11 aeranoss| same | 13.342 | 0,030 | 2674ig0] 110120 | 1e4n74 | 1.16.22 aeranosa| Tonos | 16.9149 | 1.117.086 | 2674aiat] 101/108 | 14.6788 | 1,028.11 ‘2e7sA0e7| 120790] 174/189 | 1,227,42 | 2674A198] 1197120 | 16.4/17.4 | 1,15A,22 ‘2e7anoes| 11003 | 15.9/14.9 | 1,11/1,04 | _2674A190| 1207130 | 17.4189 | 1,20A.c2 2oranore| T20n390_|17.4718.9 | 1.2271,92 | _2674a140] 90/106 | 14.a75.4 | 0.99.07 aerano7s| Tene | 17.10 | 1207.28 | 2674aaa] viariao | te.a7.a | 1,15A,22 aarano77 | ttan20 | 1eanir4 | 4,151.22 | 2674arae| 1197120 | 16.4/17.4 | 1,16N,20 2eranora| 120h30_| W740. | 1,2271,92 | _2674ar4o] 199/140] 19.9°90.7 | 1.95.45 aeranoei| eee | 12.8742 | 0,907.00 | 2674160] 145/165 _| 21.08.5 | 1.471.508 ‘2e74A0e2| ee | 126/195 | 0.90085 | _2674A304| 108 152 7,04 Bar4noBs | T1a/t28 | 17.1786 | 1,2071,90 | 2674A305| 105 16.2 7.04 2e74n0es| 8/96 | 12.8714.2 | 0,907.00 | _2674A306| 06 138 0.98) ‘2674A0e8| T1e/i26 | 17.1718.9 | 1,207.28 | _267anati| 145 210 1.47 2674A087| 11/09 | 1477156 | 1,007.09 | _Pe7aAsis| 96 73 098 2674R083[ 150 21.8 152 Beraasta| 145 210 147 2676A003| 110 75.9) ait 2e74ASTS| 150 218 452 26740004] 105. 125) 1.04 2E74AS16| 96 138) 0.88 ‘2674A095| 145 210 147, 26744701] 155 225 158 26740006] 150 218 152 Thermostat ratings Nominal temperature “Start to open* seuly open® | Minimum valve lt, stamped on thermostat by-pass vave | temperature temperature fuly open aC, TRS. °C ‘omm (180°F) (n70°M185°F) (186°7208°F) (038 in) 71°C ar"775°C 85°/68°C, omen (160°) (153°167°F) (185°190°F) (0.95 in) 3.10 Perkins Service Data Booklet Part 1, 1997GENERAL DATA 3 Compression test data Tests have shown that mary tactors affect compression pressures, Battery and starter motor condition, ‘ambient conditions and the type of gauge used can give a wide variation of results for a given engine. itis not possibie to give accurate data for compression pressure, but tests have shown that the results ‘should be within 2000/3600 KPa (300/500 lotfin2) 21,0/36,0 kgl/em? for diesel engines. Comaression tests should only be used to compare betwoen the eyindars of an engine. It one or more ‘oyindors vary by more than 350 kPa (60 Ibfiné) 3,6 gic, 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 bbe used together with ather symptoms and tests. How to do a compression test Caution: Bofore the compression test, ensure that the battery is in good condition and that ts fully charged. Also ensure that the starter motor is in good condition. 1 Ensure that the valve tip clearances are set correctly. 2 Remove the atomisers. 2 Fita suitable gauge into tho atomiser hole of the cylinder to be tasted. 4 Ensure that the engine cannot start: Disconnect the stop solenoid or put the stop contra in the no-fusl positon, ‘Operate the starter motor and note the pressure indicated on the gauge. 5 Ropeat for each cylinder. Porkine Service Data Booklet Par 1, 1997 ant