Service Bulletin

Phaser 4 and 6 cylinder 3

Timing of Clayton Dewandre compressors July 1988

New Clayton Dewandre 159 and 229 compressors have been introduced.
Also a new compressor drive assembly has been introduced which will enable the timing of the new
compressor to the engine. This will reduce the noise from the compressor and gears.
These changes were introduced from engine number YB-----503415S for six cylinder engines and
AB-----506964S for four cylinder engines.
The gears, the drive shaft, the nuts of the drive shaft and the housing of the drive assembly have been
changed. The tab washers have been removed. The spacer between the rear idler gear and the bearing (only
used in the drive assembly for the Clayton Dewandre 159 compressor) has also been removed.
Caution: The new and the old components are not interchangeable.
The dowel on the timing case side of the drive assembly has been removed. Correct location of the drive
assembly is now controlled by a close tolerance hole for the fastener at the bottom centre position in the drive
housing.
The components of the new drive assembly will now be the same when used with either the Clayton Dewandre
159 or 229 compressor.
There have also been changes to the Clayton Dewandre 159 and 229 compressors.
The thread on the front of the compressor crankshaft has been changed from 3/4 UNF to M20 by 1,5 mm. A
label which has timing marks has been fastened with adhesive to the rear face of the compressor.
The part numbers of the old and the new components are listed in the table on page 2.
Continued

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Service Bulletin - Phaser 4 and 6 cylinder 3 July 1988

Part numbers

Component Old New

159 compressor 2488A254 2488A256
229 compressor 2488735 2488A257
Compressor gear
26 teeth 3117C101
42 teeth 3117F071
Nut for compressor gear
3
/4 UNF 33222109(1)
3
/4 UNF 33222111(2)
M20 3331E003
Front idler gear
27 teeth 31171762
26 teeth 3117C121
Rear idler gear
27 teeth 31171762(1)
3117C091(2)
39 teeth 3117C131
Drive shaft
3/ UNF threads 3276P006(1)
4
M20 threads 3276P008(2)
M20 threads 3276P011
Nuts for drive shaft
3
/4 UNF thread 33222109(1)
M20 thread 3331E002(2)
M20 thread 3331E003
Drive housing 3751C061 3751C062

(1) Used only with the drive for the Clayton Dewandre 159 compressor.
(2) Used only with the drive for the Clayton Dewandre 229 compressor.

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Service Bulletin - Phaser 4 and 6 cylinder 3 July 1988

To dismantle and assemble the drive assembly

The procedure to be used to assemble and dismantle the drive assembly is the same as given in the Workshop
Manual except for the instructions given below.
To remove the bearing
1 Provide a suitable support for the timing case side of the housing. Heat the housing to a temperature of
130 °C/140 °C (266 °F/284 °F).
Caution: Ensure that no local overheating of the housing occurs.
2 Protect the compressor end of the shaft and press the shaft and bearing assembly out through the timing
case side of the housing.
To fit the bearing
1 Clean the outer face of the bearing and apply a narrow ring of POWERPART Retaining Compound to the
bearing at location 'A' (A).
2 Heat the housing until the bearing and shaft assembly can be fully fitted by hand, 130°C/140°C (266°F/284°F).
Caution: Ensure that no local overheating of the housing occurs.
Note: The assembly must be fitted in one movement in less than three seconds or the retaining compound
will harden at this temperature. Clean excess retaining compound off the bearing.
3 When the gears are to be fitted apply a narrow ring of POWERPART Retaining Compound to the bore of
the gears at locations indicated by 'B' (A). Ensure that the boss of the rear idler gear is toward the bearing
when the gear is fitted. Clean off excess retaining compound.
4 When the nuts at each end of the drive shaft are to be fitted, ensure that the threads at each end of the shaft
are clean and apply POWERPART Studlock to the threads. Fit the nuts and tighten them to 130 Nm
(96 lbf ft) 13,3 kgf m. Ensure that there is no Studlock on the end of the shaft which fits into the bush.
5 If the new compressor is to be fitted and the earlier drive assembly is to be used, ensure that the drive gear
from the old compressor is fitted.
Continued

B B

A CG L0320

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Service Bulletin - Phaser 4 and 6 cylinder 3 July 1988

6 Ensure that the new M20 nut (part number 3331E003) is used. When this nut is to be used discard the tab
washer and apply a narrow ring of POWERPART Retaining Compound to the bore of the drive gear at
locations indicated by 'B' (A on page 3).
7 Apply POWERPART Studlock to the thread of the crankshaft. Fit the nut and tighten to 130 Nm (96 lbf ft)
13,3 kgf m. Clean off excess Studlock. Timing of the new compressor to the engine is not possible if the earlier
drive assembly is used.

To fit the new compressor and drive assembly to the engine

1 Set the piston of number 1 cylinder to TDC.
2 Fit a new O-ring in its recess in the drive housing and lubricate it with clean engine lubricating oil.
3 Turn the crankshaft of the compressor until the mark (B1) on the rear face of the crankshaft aligns with the
6A line (six cylinder engines) or the 4A line (four cylinder engines) on the label on the rear face of the
compressor.
4 Put the compressor and drive assembly in position on the studs of the timing case. Slide the assembly
forward until the front idler gear of the compressor drive is against the engine idler gear. Slowly turn the
crankshaft of the compressor clockwise (from the rear) until the front idler gear will mesh with the engine idler
gear.
5 Carefully push the compressor assembly forward until the spigot on the drive assembly is fully fitted in the
timing case. In this position, the mark on the rear of the crankshaft should align with the dark area marked 6
(six cylinder engines) or 4 (four cylinder engines) on the timing label (B).
Note: If it does not, pull the assembly out of engagement and move the crankshaft of the compressor in the
relevant direction to mesh with the next gear tooth.
Continued

TO P

A
B

A B
4

B C G L0321

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Service Bulletin - Phaser 4 and 6 cylinder 3 July 1988

6 Carefully push the compressor assembly into position again and check that the mark on the rear of the
crankshaft is in the correct position. Fit the nuts to the studs and tighten the nuts, ensure that the nut on the
front of the timing case cover is fitted and tightened.
For six cylinder engines: Fit the support bracket to the compressor and tighten the setscrews. Put the
mounting bracket in position between the cylinder block and the support bracket and loosely fit the fasteners.
Adjust the mounting bracket to ensure that there will be no tension on the compressor. Tighten the setscrews
and then the nuts and bolts.
For four cylinder engines: Fit the support bracket to the bottom of the compressor and tighten the setscrews.
Check that the nuts for the oil filter head are correctly tightened and put the two washers into position on the
studs. Put the mounting bracket in position between the oil filter head and the support bracket and loosely fit
the fasteners. Adjust the mounting bracket to ensure that there will be no tension on the compressor. Tighten
the nuts and then tighten the setscrews.
7 Check that the O-ring in the cover for the rear of the compressor is not damaged. Fit the cover and tighten
the setscrews.
8 Ensure that there is no restriction in the oil pipe between the engine and the compressor. Before the oil pipe
is connected to the compressor, ensure that the engine stop solenoid is disconnected or that the engine stop
control is in the 'stop' position. Operate the starter motor until a free flow of oil comes from the oil pipe. Connect
the engine stop solenoid.
9 Connect the oil pipe, the compressor coolant pipes and the air pipes to the compressor.

To fit the new compressor only

1 Set the piston of number 1 cylinder to TDC.
2 Ensure that the dowels are fitted correctly in the flange of the drive housing and fit a new joint to the flange.
3 Turn the crankshaft of the compressor until the mark (B1 on page 4) on the rear face of the crankshaft aligns
with the 6B line (six cylinder engines) or the 4B line (four cylinder engines) on the label on the rear face of the
compressor.
4 Lubricate lightly the bush in the compressor casing with clean engine lubricating oil. Put the compressor in
position on the studs of the timing case. Slide the compressor forward until the compressor gear is against the
rear idler gear of the drive assembly. Slowly turn the crankshaft of the compressor clockwise (from the rear)
until the compressor gear will mesh with the rear idler gear.
5 Carefully push the compressor forward until the gears are fully in mesh. In this position the mark on the rear
of the crankshaft should align with the dark area marked 6 (six cylinder engines) or 4 (four cylinder engines)
on the timing label (B on page 4).
Note: If it does not, pull the compressor out of engagement and move the crankshaft of the compressor in the
relevant direction to mesh with the next gear tooth.
6 Carefully push the compressor into position again and check that the mark on the rear of the crankshaft is
in the correct position. Fit the nuts and the setscrews which fasten the compressor to the drive assembly and
tighten them.
For six cylinder engines: Fit the support bracket to the compressor and tighten the setscrews. Put the
mounting bracket in position between the cylinder block and the support bracket and loosely fit the fasteners.
Adjust the mounting bracket to ensure that there will be no tension on the compressor. Tighten the setscrews
and then the nuts and bolts.
For four cylinder engines: Fit the support bracket to the bottom of the compressor and tighten the setscrews.
Check that the nuts for the oil filter head are correctly tightened and put the two washers into position on the
studs. Put the mounting bracket in position between the oil filter head and the support bracket and loosely fit
the fasteners. Adjust the mounting bracket to ensure that there will be no tension on the compressor. Tighten
the nuts and then tighten the setscrews.
7 Check that the O-ring in the cover for the rear of the compressor is not damaged. Fit the cover and tighten
the setscrews.
Continued

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Service Bulletin - Phaser 4 and 6 cylinder 3 July 1988

8 Ensure that there is no restriction in the oil pipe between the engine and the compressor. Before the oil pipe
is connected to the compressor, ensure that the engine stop solenoid is disconnected or that the engine stop
control is in the 'stop' position. Operate the starter motor until a free flow of oil comes from the oil pipe. Connect
the engine stop solenoid.
9 Connect the oil pipe, the compressor coolant pipes and the air pipes to the compressor.

End

Issued by Perkins Engines Company Ltd, Peterborough PE1 5NA, England.  Proprietary information of Perkins Engines Company Ltd
1988, all rights reserved. The information is correct at the time of print. This bulletin is for technical information only andcannot be used
as a basis for any claim including but not limited to warranty.