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 Foreword
The Perkins Seryice Data Booklet contains the data which is most commonly useo oy
experiencedmechanics and technicians.
The booklet contains inlormationfor all perkins peterboroughengines and is avaalablein tlvo
parts:

Part 1: Malure 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

Parl 2: Current products up to 8,7 litres (530 cu in)

4.41
100 Series
Prima,/500 Series
700 Series
900 Series
Phaser/1000Series
Peregrine/1300 Series
The booklet should be used together with the relevant Use/s Handbook, Workshop Manual
and Service Bulletins.
Any recommendations ,or future issues of the booklet should be sent to Technical
PublicationsDepartment.

PerkinsServiceData BookletPad 1, 1997

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 Downloaded from www.Manualslib.com manuals search engine
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 Downloaded from www.Manualslib.com manuals search engine
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 Perkins companies unlted Klngdom
Perkins InternalionalLld,
Austrataa
Easttield,PelerboroughPE1 5NA,
PeftinsEnginesAustraliaPly. Ltd, England.
Suite2, 364 MainSlreet, Telephone:0173367474
Morninglon3931,Victoria,Auslralia. Telex:32501PerkenG
Telephonei597 51877 Fax101733582240
Telex:Perkoil4430816
uniled states of america
Fax: 0597 1305
- Nodh Amenca
PerkinsInternational
France
12025Tech CenterDrive
Motelfs PerkrnsS.4., L vonia
9-11AvenueMichelet, [4ichigan48150
93583Sa nl Ouen,Cedex,France. USA
Telephone: (1)40 10 42 70 Telephone:313266 5427
Ielex:642924F Fax: 313 266 2700
Fax:(1) 40-10-42'45
PerkinsEnqinesLalinAmericaInc'
Germany
sule 620,
PerkinsÄ,4otoren
GmbH, 999, Ponce de Leon Boulevard,
Saalaeckerslrasse4, Coral Gables,
63801Kleinostheim, Florida33134,U.S.A.
Germany. Telephone:305 442 7413
Telephonei6027 5010 Telex:32501PerkenG
Fax:6O27501124 Fax:305 4427419
Hong Kong
PerkrnsInlernalionalLtd, In additlon to the above companies, there a.e
VarityAsia./Pacilic, Perklns dlstrlbutors In mosl counlries. Perkins
Suile 3301 Inlernatlonal Ltd, Pelerborough or one ol the
ConventionPlaza, above companles can provide detalls.
1 Harbourroad,

HongKong.
Telephone:852 2588 1883
Fax:852 2427 2311
Italy
MoloriPerkinsS.p.A.,
VraSocrate8,
22070Casnatecon Bernale(Como),llaly.
Telephone:031 564633 or 564625
Te ex: 380658 Perkll I
Fax:031249092or 564145
Japan
Varity(Japan)K.K.,
Re nanzakaEuilding,sth Floor,
14 2 Akasaka,1-chome,Mrnalo-ku,
Tokyo107,Japan.
Te ephone: 03 586 7377
Ieex:Petkat J2424823
F a x : 0 35 8 2 1 5 9 6

Perkins SeruEe Data Booklei Pad 1. 1997

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 Downloaded from www.Manualslib.com manuals search engine
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 POWEBPABTrecommended
consumableproducts
Perkinshave made availabielhe products
fecommendedbelow if order lo assist n lhe
cotrecl operalion,serviceand malnlenanceoi your
€ngrneand yourmachrne.The instuctionslor the
use ol each productare given on lhe outside ol
eachconlainer. Theseproductsare availablelrom
yourPerkinsdrstrlbutor.
POWERPARTAntifreeze
Proleclsthe cooling syslem againsttrosl and
cotrosron.Pa( nufrber1 lilre21825166or 5 lilres
21825167.
POWERPABTEasy Flush
Cleansthe coo ing system.Pad number2182501
POWEBPARTJolntlng compound
Universal compoundwhichsealsjoinls.
tornting
CurenllyHylomar Pad number1861155 or
1861117.
POWERPARTSlllconerubber sealanl
Silrconerubbersealantwh ch prevenlsleakage
throughgaps.CutrenllyHylosi Pan number
1861108.
POWERPARTLay-Up1
A dreselluel addnivelor prolecton aga nsl
corosion.Pan number1772204.
POWERPART Lay-Up 2
Prolectsthe ns de ol the eng ne and ol other
closedsyslems.Pan number1762811
POWERPARTLay-Up3
Proteclsoutsde melalpans.Pad number1734115. To sealthe oulerdiamelerol seals.Currently
POWERPARTChiseI
A lows easy removalol o d gasketsand jornls.
Cu(entlyLoclle chisel Pad number21825163.
POWEBPARTRepel
Daesdampequrpmenland givesproteclron againsi Pan number21826039.
corosron.Passesthroughdin and corosionto
!bncale and to assistremovalot components.
CutrenllyLoclilerepel.Pan n!mber 21825164.
POWEBPARTThreadlock
To retainsmalltaslenerswhereeasy removalis
necessaryCutrenly Loctite222e.Pan number
21820222
POWERPARTStudlock
To permanently retan largelastenersand studs.
Cutrenly Loctile270. Pan number
21820270 1824222
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POWERPART NuTIocK
To retain and seal threaded tastenersand cup
plugs where easy removalls necessary,
CurentlyLoctile242e.Pan number21820242
POWERPARTLlquld gasket
To seal tlal laces oJcomponentswhere no joint is
used.Especially suilablelor aluminium
components. CutrentlyLoclite518. Pan number
21820518
POWERPARTThreadlock (hydraull./pnuemafi c)
To retainand sealpipe conneclions wrlhfine
threads.Especiallysuilablelor hydraulicand
pneumaticsyslems. Cu(ently Loctile 542. Pail
number21820542
POWERPARTThreadlock (plpe)
To retarnand seal pipe connectionswith coarse
threads-Pressuresyslems can be used
immedialely.CurentlyLoclite575. Pan number
21A20575.
POWERPART Retainer (oll tolerant)
To retarncomponentswhich have a fansition lil.
CutrentlyLoctile603. Pan number21820603.
POWERPARTRelainer (high stength)
To relain componentswhich have an inlerlerence
lit. CurentlyLoctile638. Pad number21820638.
POWEBPART Alomiser th.ead sealant
To seallhe threadsol the atomiserintolhe cylinder
head.CurientlyHylomarAdvanceFormulation.
POWERPARTCompound
LoctileFormaGasketNo 2. Pad number1861147.
POWERPARTPlatelock
Ärediumslrengthanaerobiclhreadlocklor tight
finedmetals!rlaces.SuitableIof metalplaled
surtacesand stainlesssteel, Cutrenlly Loctile 243
POWERPARTGaskel ellmlnator
lmprovestlange sealing when a gaskel is not used.
11providesa seal wrth lemperatureresistancethat
is llexibe in posilionswherevibrationand pressure
occur,CutrentlyLocllte515. Pan number
21826040
POWERPARTSiliconeadheslve
An RTV s liconeadhesivelor applicationwhere low
pressurelests occur belore the adhesivesets.
Used'or sealng llangewhereor res slalce iö
neededand movementol the joinl occurs,.Cutrenlly
Loctile5900 Pad number21826038.
Perkins SetoKe Dala Booklel Pan 1. 1997
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 Engine number guide

For enginesmadeatler 1974

Erampe ol an enginen!mber is TU20300U510256F
TU .... . Engine Famityand type code, see Tabte 1
20300 . . . . . parls lisl number or SOS order relerencenumber

Countryof manulacturecode, see Table 2

510256 ... Engineserialnumber
F ............ y e a r o fm a n u J a c l u
cor ed e s, e e T a b t e 3

Table 1 - Englne Family and Type Code

A Phaser/1004 E 4.108 LE G4.236 TV 6.3724

Nalurally EA 4.99 LF 4.24A TW 6.3544
EB 4.101 LG 4.24A2 TX C6.3544
AB Tubocharged EC 14.107 LH C4.236 ry H6.3544
Compensated ED 4.108 LJ T4.236 rz HT6.3544
AD Charge cooled EE T4.108 LK D4.236 U 700 Serles
AE Fed Charge G 4.15/V200 LL 4.38 uA 704-26
cooteo GA 4.154 Ll\,1 4.41 uB 704-30
AG Narrow Jronl end GB 4.135 N 4.318 W P€regrlne/l300
nalurally aspiraled GC 4.182 NA 4.270 wA 6.466
AH Narrow fronl end GD 4.25 NB 4.300 wB T6.466
lurbocharged GE 4.30 NC 4 . 3 1 8 wc cc6.466
New Phaser/l004 H 4.165 ND 4.31A2 WD T6.67
Naturally HA 4.165 P 6.305 wE cc6.67
asprraleo 4.203 PA P6 WF T6,76
AK Tuöocharged io P4 PB 6.288 wG cc6.76
turbocharged JB 4.192 PC 6.305 wH T6.87
Inlercooteo JC P4.192 PD PF6.3O5 wJ cc6.87
Naturally JD 4.203 R 6-247 x v8.540
asptrareo JE 04.203 RA 6.247 xA v8.510
AQ Tuöocharged G4.203 SD Sabre CC6.68 XB TV8,51O
B Prima/500 JG 4.2032 T 6.3s4 xc v8.540
BA Nalurally K Perama/l00 TA 6.306 xD v8.605
asprraleo 2 cyl.0,4 lilres TB 6.33s XE TV8.54O
BB Tuöocharged KB 3 cy].0,6 lilres TC 6.354 Y Phaser/l006
AC Gasolene KC 3 cyi-0,9 lilres TD H6.3s4 Nalurally
c 3.152 KD 3 cyl. 1,0 lites TE T6.3s4 aspiraled
CA P3 KE 3 cyl. 1,5 lites TF H6.354 YB Turbocharged
CB 3.144 KF 4 cyl. 1,9 litres TG 6.3541 YC Compensated
CC P3.144 KG 3 cyl. 1,2 lires TH T6.3s41 YD Charge cooled
CD 3.152 KH 3 cyl. 1,3 lifes TJ 6.3542 Y E Fed. Charge
CE 03.152 KJ 3 cyl. 1,5 litresD TK C6.3542 cooteo
CF G3.152 KK 4 cyl. 1,9 litresD TL 6.3s43 N€w Phaser/1006
CG P3.152 KL 3 cyl. 0,7 litres TM C6.3543 YG Naturally
CJ 3.1522 KN 2 cyl. 0,5 lites TN H6.3543 asprrated
ct\,4 3.1524 KR 4 cyl. 2,2 lites TP T6.3543 YH Tuöocharged
CN T3.1524 4.236 TQ HT6.3543 YK Tuöocharged
C 900 Series ; 4.212 TB 6.372 Inlercooled
cP 3.27 LB G4.212 TS 6.3723 z v8.640
cR 13.27 LC 4.224 TT TC6.3541 zA v8.640
cs 3.25 LD 4.236 IU T6.3544 zB TV8.640

Perk ns Seruice Data Booklet Pad 1. 1997

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 Downloaded from www.Manualslib.com manuals search engine
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 Basic tault-tindingguide
Thechartbelowis grvento assislinthecorectdiagnosrs
ol basicenginelaults
andpossible
Problems causes
Problem Possible causes
ftse slade'nolor turls ltse e^gire loo sLowL, 1.2.3.4
The eng ne does nol siai 5 , 6 , 7 , 8 , 9 , 1 0 , 1 2 ,1 3 ,1 4 ,1 5 ,1 7 ,3 4 , 3 5 ,3 6 , 3 7 , 3 8 ,
40, 42.43, 44
lhe engrne s dfiicull lo slad 5 , 7 , 8 , 9 , 10 , 1 1 . 1 2 ,1 3 . 1 4 ,15 , 1 6 , 17 , 19 , 3 4 ,3 6 , 3 7 ,
34. 40.42. 43.44
Not enough power 8 , 9 , 1 0 ,1 1 , 1 2 1
, 3 ,1 6 ,1 7 ,1 8 ,1 9 , 2 0 , 2 1 , 3 4 , 3 6 , 3 7 ,
38, 39, 42, 43, 44, 61, 63, 64
Mislre 8, 9, 10, 12, 13, 15, 20, 22, 34, 36. 37, 38, 39, 40, 4

High fue consumplon 11, 13, 15, 17, 18, 19, 21, 22, 34, 36, 37, 38, 39, 40,
42. 43. 44. 63
Black exhaust smoke 1l , 13 , 15 , 17 , 1 9 , 2 1 , 2 2 , 3 4 . 3 6s,7 , 3 8 ,3 9 ,4 0 , 4 2 ,
43, 44, 61, 63
Elueor wh(e exhaustsmoke 4 , 1 5 , 2 1 , 2 3 . 3 6 , 3 7 . 3 4 , 3 54 ,2 , 4 4 ,4 s , 5 2 ,5 A . 6 2
The pressure ol the lubricatinq o I s loo low 4, 24, 25, 26, 46. 47. 44, 50, 51, 59
The engrneknocks 9, 13, 15 17. 20, 22. 23. 36, 37, 40, 42, 44, 46, s2, 53,
60
The engine runs eralrca ly 7 , 8 , 9 ,1 0 ,1 1 ,1 2 ,1 3 ,1 5 ,1 6 ,1 4 , 2 0 , 2 2 , 2 3 , 3 4 , s 8 ,
40,41,44,52,64
Vrbral on / . 2 A , 3 4 , 3 a , 3 94 ,0 ,4 1 ,4 4 ,5 2 , 5 4
1 3 .1 8 , 2 0 , 2
-l
e p e>s-'e ol he lLbriLal -q o I s loo h q' , 2 5 ,4 9
The engrne temperalure is too high 1 1 ,1 3 ,1 5 ,1 9 , 2 7 , 2 9 , 3 03, 2 ,3 4 ,3 6 , 3 7 ,3 9 ,5 2 , 5 5 ,
56.57.64
pressure
Crankcase 31,33,39,42,44,45,52
Bad compression 1 1. 22. 37. 39. 40. 42. 43. 44 45. 53. 60
The engrne slans and stops 1 0 ,1 1 ,1 2

PerkinsServiceData BookletPan 1. 1997

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 Downloaded from www.Manualslib.com manuals search engine
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 Turbochargertault guide
The chan below is given lo asslsl in the corecl diagnosis ol luöocharger fallts.
li the inside ol the induclion manilold s wet, check that there is nol a fuel leak trom the tuelled stadinq
a d. I there is one fined.

Problems and Dosslble causes

Problem Possible causes

Not enough power 1 , 4 , 5 , 6 , 7 , 8 , 9 , 1 0 ,1 1 , 1 A , 2 0 , 2 1 , 2 2 , 2 5 , 2 6 , 2 7 ,

28,34,3s,36
Blacksmoke 1. 4, 5, 6, 7, 8, 9, 10, 11, 1A,20, 21, 22, 25. 26,27,
28, 34, 35, 36
B ue smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32, 34
H gh ubrcalng oil consumption 2, 4, 15, 17, 19,20, 2A, 29, 31. 32, 34
Too much iubncatng orl al turbtne end 2 , 7 , A , 1 7 ,1 9 , 2 0 , 2 2 . 2 83. 0 .3 1 . 3 2
Too much lubncating oil ai compressor end 1, 2, 4, 5, 6, 8, 19, 20, 21, 2A, 31, 32
Not enough lubrication 8, 12, 14, 15, 16, 23, 24, 29. 32. 33. 37. 38
Lubncal ng oil in the exhausl manitold 2 , 7 , 1 7 , 1 8 .1 9 . 2 0 . 2 2 . 2 A . 3 1 . 3 2
nsrde ol lhe Induction manfold wel 1 , 2 , 3 , 4 , s , 6 , 8 , 10 , 1 1 ,1 7 , 1 A ,1 9 , 2 0 , 2 1 , 2 A , 3 2 ,
34, 39, 40
Damagedcompressor
impeller 3, 4, 6, 8, 12, 15,16,20.21,23,24,29, 32, 33, 37, 38
Damaged turbine rolor 7, A, 12, 13. 14, 15, 16, 1a, 20, 22, 23, 24, 25, 27, 29,
32, 33. 37, 38
Bolalng assemblydoes not tum lreely 3 , 6 , 7 , 4 , 1 2 ,13 , 14 , 15 , 1 6 ,18 , 2 0 ,2 1 , 2 2 , 2 3 , 2 4 , 2 9 ,
32, 33, 37, 38
Wornbearingsbearingbores,journals 6 , 7 , 8 , 12 , 1 3 ,1 4 ,1 5 , 1 6 , 2 3 , 2 4 , 2 9 , 3 3 . 3 7 , 3 A
No se iiom lurbocharger 1 , 3 , 4 , 5 , 6 , 7 , 8 , 91, 0 ,11 , 1 2 , 1 3 1
, 4 ,1 5 , 1 6 1
, 8,20,
21, 22. 23, 24, 29, 32, 33. 34, 37, 38
Sludge or carbo- deposrt r^ beanrg houstnE 2 . 1 1 , 1 3 ,1 4 ,1 5 ,17 . 1 8 .2 4 .2 9 . 3 3 .3 7 .3 8

Perkrns Seryice Data Booklet Pad 1. 1997

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 Downloaded from www.Manualslib.com manuals search engine
166 t I Ued lalNooS PtPo af,rruas surlrad
'rosserouoc
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'pre 6uruels peilenl uort eoeteel tonj 6c
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Zt
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le ol tro6ulecuqn lo ^eteo zr
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9
!eÜEqcoqrnl ol ralill re uo4 odrd ur uorlc!tser ro uor!olsrp teura)ut t
ra6rpqooqrniol uolcouuoa asool ^llceJoc 6urleas lou ro 'peuu ]ou rallUle aq] lo luaualf e
raqlearq asec)juercpalcDlsau z
Ä!rp iaürlr e öql Joluouetf !
sasneo olqlssoo lo ls|I
 General safety precautions
. Diesel Juel and ubilcalng oil (especially used
These satety precautions are lmporlant. You
lubricating oil) can damage the skin of cerlain
must reler also 10 the local regulations in the
persons. Prolect your hands wilh gloves or a
country ol use. Some items only reler to specitic
special solulion lo prolecl lhe skin.
appr carons.
. Do not wear clothing which is contam nated by
. Only use these engines in lhe type ol
lubricating oil. Do not pul malerial which is
app icalion 10r which lhey have been designed.
conlaminated with oil ioto lhe pockets of clothing.
t Do no'rndnqe I e spac{rcälron o'lhe engine
. Discard used lubricating oi1 in accordance with
' Do not smoke when you pul iuel in the tank.
local reg!lat ons lo prevenl conlamination.
. Cledr dwayluelwFrch has bee_ sorll. Material . Ensure lhat lhe control lever ol the transmission
whrch has been conlaminated by luel musl be "oufof-drive position before lhe
drive is in the
moved to a saie place.
englne rs staned.
. 0o not pul lue in the lank wh le the eng ne runs . The combustible maierial ol some componenis
(uness t s absolutey necessary).
ol the engine (lorexample cedain seals) can
' Do not clean, add lubricat ng oil, or adjust the become e(remely dangerous il il rs burned.
engine while il runs (unless you have had the Never a low lhis burnl maleral lo come inlo
correcl talnrng; even then exlreme cafe musi oe contact wilh the skin orwth the eyes.
used lo prevenl nlury). . Read and use the nstruclions relevanl lo lill
. Do nol make adjuslmenls thal yo! do not equ pmenl.
undersland. ' Wear a face mask il lhe glass fibre cover of lhe
. Ensure lhal the engine does nol run n a local on turbocharger is lo be removed or lifted.
where { can cause a concentation ol loxrc . Always use a salely cage io prolect lhe operalor
when e component Ls lo be pressure tesled in a
. Olher persons musl be kept al a sale d slance conta ner ol waler. Fil salety wires to secure ihe
whr e Ihe engine or aux liary equipmenl ls rn plugs which seal the hose conneclions of a
componeni which is to be pfessure tesled.
. Do nol permil oose clolh ng or long halr near . Do nol al ow compressed arr to contact your
movrng pads sk n. ll compressed air enlers your skin, obtain
. Keep away trom movtng pans during engtne medicai help immediately.
opetaltan Waning! Some movtng pads cannot . Turbochargers operale al high speed and at high
be seen cleaily while the engine runs temperatures. Keep lingers, lools and debris
. Do not operale the engine il a salely guard has away lrom the inlet and outlet poils of lhe
turbocharger and prevent conlacl wilh hot
' Do nol remove lhe liller cap or any componenl ol sudaces.
the cooing syslem while the engine is hol and . Fil only genuine Perkins pads.
wh le lhe coolanl s under pressure, because
dangerous hot coo ant can be discharged.
. Do not use sa t waler or any other coolanl whrch
can cause cotrosion In lhe closed crrcuil oi lhe
cool ng system
. Do nol allow sparks or Jire near the banenes
(especially when lhe baflefes are 0n charge)
because the gases lrom lhe eleclro yte are h gh y
I ammable The batlery liuid is dangerous 10 the
sk n and especia ly lo the eyes.
. D sconnecl lhe batlery lerm na s belore a repa r
s made to lhe e ectncal syslem.
' On y one person musl contol the englne
. Ens!re thal the engrne rs operaled only lrom lne
conlro pane or trom lhe operators posilron
. l io- \h n LoTps Inlo , onldcl w Ih h th
pressure tuel. oblarn medtcal assrslance
mmedrately

PerkrnsSeruce DataBookletPad 1. 1997

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 Downloaded from www.Manualslib.com manuals search engine
166t I UPd lallooS Pteo acrruas surliad
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zEz s € ü a s0 t 9 8 ^
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 2 q:oa
Basic technical data

HOrSe powet . 35,0 kW (47 bhp)

Number ol cylinders . . . . . . . . . . . 4
Cycle .. ... ,..,, rourslroxe
Induclon syslem Naturallyaspirated
Combuslion sysiem .. Indirectinieclion
Nominal bore 79,37mm (3.125in)
Stoke ... .. . 88,90mm (3.500in)
Compresston ralio .. .......... 22:1
C!bic capacity 1,760lilfes(107.4in3)
Finngorder ... 1-3-4-2
Valve lip clearances
- Inlel 0.30mm (0.012in)
icold) .
' Exhaust (cold) . 0,30mm (0.012in)
Lubricating oi1 pressure
- al maxrmum engine speed and
normal engrne temperature . .. ... . . . . 207/414 kN/n' l30t61 tbl/in l 2,1/4,2 kl|cm,
Coolant temperalure ... . .... . 60'c(140"F)
Thermoslat slans lo open
' berows ... 67n5'C (152/167.F)
rype
'waxlype .... .. . 77l85'C (170/185"F)
Thermoslat tully open
- bel ows lype . 85/88"C (185n 90.F)
- wax type .. . 92l98'C (197/208.F)
Dreclion of rotation . Clockwis€lrom troni
ldlrng speed . - .... .. 5 5 0r e v / m i n
Localion ol maximum noload speed ..... Fuel injectionpump data plate
L o c a t i o no l n u m b e r 1 c y | n d e r . . . . . . . Crankshaflpulley end
Location ol engine liming marks . .. Scribelineson luel injeclionpump and pumpllange
Alom ser codes ... . C A V = B G ,G Y ,O M A P= Y B
Fuel pump codes EH34E, EH39, PH3O
L o c a l o n o t l u e lp u m p c o d e . . . . . . . ......... D a l ap l a t e o n t u p
eul mp
Localon ol luel pump timing marks . . ... . . Fuelpump mounlingllange
Be[lensron .. 45 N (10 lbr)4,5 ksf
Belt delleclion al longesl run . . . . .. . . .. 1 0 m m ( 3 / 8i n )

2.O2 Pelkins Seruice Dala Booklel Pad 1. 1997

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 Downloaded from www.Manualslib.com manuals search engine
166 t t Ued lol)too€ eteo acrdos sur)ired
palaale iou sr ral ! | o burlec rqnt 3ql lo rats u9c aqt aoueq3 oi eNalll aql L u o q e cl l 3 a d s l ä n l
plE Z0 t a6ed uo a qet aql aas) anl aql lo lualuo3 rnqdlns aql qlM aouEqr I M Erualu aouEqo I o aql ('l
6uru Prt taaroc aqt peq sEq olM uosrad P ^8 (eJ
'sqluou
9 tu3^a paMaual
aq p noqs I srPa^ z tu3^a azaarl luE 3ql Maua8
a z a a r l ] u e l o p e a l s u p a s n s Ll o l q l q u r l u e o o c e l l \z)
pal! auo s araql ll {t)
(C) palcaqc 6re 3)a rotou taLels roleuronP aql leql €lnsul
(0) palsn pP
fuessarau I pue pa)joaqa are a! 6ue aql lo sa3uPrea f, d I a^ e^ aql leql arnsuf
rarlea p€learplr laaq lou seq I li luauaia ral i r e aql Maual ro uealc
s!oq puoa eürou
suorlrpuoc ^lsnp I auartxa
ran I r e aqt lo Moq tsnp aql ^ldua ro raueal3 rLeaql uEa 3
pal I I ral rl rossarduos rrP uee 3
(t) ran I ro 6u rec rqn aql lc rais upc aql Maua8
(t) ro 6u lecrqnl au 6ua aql Maua8
(!)e6ne6aqlte arnssard o 6!leciqnt aqllcaqC
duns aqi u lro 6u leJuqn lo t!nowe aql foaqC
rall llenl eql l0 sluaua a aql Ma!au i
fuessacau se lrprp pue rallu-ard anl eql u ratEA t0, )aaq3 I
(pau I areqa) qsnq r€ar oueu^p alec rqn-l
roteur0le eqi lo I aq a^rp aql )aaqc
(z) lue o03 lo tunoue aql !lcaqc
uorlersdo
tsr I lncro qo qa (sqluou )o s)noq) lpruetu aql le pa dde aq lsnu Mol ol qa qa sslnpaqis aq-I
(s3tru 00021) ut 00080t ro srnoq 0012 rua^f 3
(salru 000t2) ul 00090 ro srnoq 006 tua^: O
(saru 0002t) u) OO08!rosqtuou Zt )o srnoq Ogtfue^l 3
(salru 000t) u) 0009r0 sqtuou 0 ro srnoq 091 fua^: g
srnoq 8 fue^a ro ^Ep fua^: v
salnpaqss a3ueualulPy!
atr ruas qcpe tp sraualsel asooLpup aOelea rol fcaqc ol acueualu eu a^qua^ard poob s ll
'eur6ue eql
lo uolerado t3aroa arnsua ot paldepp aq ot paau
Ä e u s a r n p a c o r d p u e s p o r a d a s a q t s u o r t e l n O a rl e c o a q ] o l u r o l u o c ] s n u a u t b u a a q l l o ! o l € i a d o a q l u a q M
'lsa!oqs
ar€ qc qa spo rad aqt asn pailEtsu sr eur6ua aql qcrqM u iuaud nba aql lo rarnlselrruPU aql ^q
ua^ 6 spo rad aqt lsaqO uo lerado lo suoq puoc a6ere^e ot ^ldde spoDad acueualu eu a^q!a^ard asaql
agu49p aq) ueqt lueyodat
aaa ae uauetada p tnoq eql sdals pue sle)s uenba! qla ualaado aouelstD poqs ua :uolneJ
sporiad scueualuleu a^llua^ald
z goti,
 2 qtoa
Fuel pump codes

CAV tuel Inieclion pump

TyPe . . . . . . . . . . . . L u c aD
s PA
O reclionol rotaton . . . . . . . Clockwiselrom drive end
OullelIor number1 cylinder . . Lener 'W"
Fuel injection puhp timing
T h e e n g i n e c h e c k a n g l e m u s l b e u s e d w i t h s p e c a l t o o l 1 , 1 S . 6 7 8a n d w i t h t h e e n g i n e s e t w i t h n u m b e r 1
prston al lop dead cenlre (TDC) on the compression slroke. The pump is checked with the pump sel at the
slan ol injecl on lor number 1 cyLinder.
The code leners are included in ihe sening code siamped on the data plate ol the {uel injection pump. Some
luel pumps may have the setting code stamped on a modilication plate which is laslened to the ltange ol the
pump lf a modil cation plale is fitled, use the code etlers stamped on lhis Olale.

Engine check Pumpmark

Fuel pump code lefters angle
(oegrees) (degrees)
.H. EH34E EH39 241 290
H30 2a 292
PH, PH23E, PH27 PH28. PH3O 241 290
tsnz5E5UU/5/245U
PH25E500/9/1990
PH25E500/9/2090
PH30/500/5/2450
279.5 290
PH30/500/6n570
PH30/500/9n990
PH30/500/9/2090
FH. RH30E 279.5 290
SH33E 279.5 290
T B ,I H 2 3 E 241 291

Recommendedtorque tensions
The torq!e lensions below apply lo components tubricated lightly wilh clean engine oil beJore they are Jined

Thread
Torque
Descriplon
Nm tbf tl Kgl m
Nuts, cylinder head 1t2 81 60 4,3
Sumpp ug 3t4 50 37 5.1
12 1,7
Inteclor prpe unron nul M 1 2x 1 . 5 20 5 2.1
Marn beailng 115 85 11.8
Brg end bearnq 3/8 51 42 5,8
Fronl pu ley 5/8 203 150 20,7
7 /t 6 81 60 8.3

PerkinsServiceData BookleiPan 1. 1997

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 Downloaded from www.Manualslib.com manuals search engine
1661 I led lelloo€ etec acrDas suqlad
'ilnoq
09/92 ßalta
'acuanbas
0001/00q atl 0091 /009 )ole lcarrao
atll ut enbtal peloc eql ol ue6e paualqou ae
slnu peaq )aputtt eql leql lueuoout st il :uoltne)
'enbrol
lceroc €qt ol tr uatq6[ uaql pue urn] e
'paLicear
,o ("09 ol.0g) 9/L o) Ztlt lnu eqt uosoot sr
anbrol lceroc eql eroloq e^ou lou saop ]nu e ]l .
'anbro]
lcaxoo
eql ol il uatqoq pa)ioaq3 uaqM sa^ou n! e lt .
'acuanbas
lcer@ aql ur stnu aql lo ssaulqol aql )icaqc ]
'!o
aur6ua aqi qcirMs (C.21) 3.01 t st ainteradual
U e l o o a o q l t l u n I u n r p u p € u r b u a a L . l lU e l S e
u jot €'8(utqro9)
uN !8 ol a6elsleullaqturslnuaqlualqbrlseoels
oorqlurstnuaqluolq6ri ^lua^epup^[pnpeigZ
ppaq rapurt^c aq] ]o spearql eql elE.uqnt ^Dq6rt I
'lenuew
doqslaM
'lqnop
atlt ot )apr ut lt oututeL pauoc aql qtß
uoged e Iq ouap aq $na uauaado sillf :uo\neC
acuanbasanbJol ppaq iaputlÄC
zsotn
 2 3 . 1 5 2S e r i e s

Basic technical data

-3.152......... .... . . . . 3 3 , 6k w ( 4 5b h p )
- D 3 . 1 5 2. . . . . .... . . . . 3 6 , 5k w ( 4 9b h p )
-3.1522.... .... . . . 3 3 , 2k W ( 4 4 . 5b h p )
-3.1524.......... ... . . . . 3 8 , 8k W ( 5 2b h p )
- T 3 . 1 5 2.4. . . . . . .. . ... 4 4 , 7k W ( 6 0b h p )
Numberof cylinders 3
C y c l e. . . . . . Four stroke
Inductionsyst6m
- 3.152,03.152.3.1522,3.1324 . . . . ...... Nalurallyaspiraled
- 1 3 . 1 5 2 4. . . ....... .. Tuöocharged
Combustionsyslem
-3.152...... Indfect Injeclion
- o3.152,3.1522,3.1524,r3.1 524 . . Direct injeclion
bore
Nomrnal . ... .... 9 1 . 4 4m m ( 3 . 6 0i n )
Sfoke .. ... .. 1 2 7m m ( 5 I n )
Compressionralro
-3.152..... ...... 17-4:1
- D 3 . 1 5 2. . . ..... 18.5:1
- 3 . 1 5 2 .2. . ..... 19.0:1
.31524... .... 16.5:1
- T 3 . 1 5 2 4. . . . .. 15.5:1
Cubic capacity . . 2.5 litres(152.7in3)
F ring order ..... 1-2-3
Valve tip clearances
-lnlel (cold)
3.152, D3.152 . .. . . .. . 0 . 3 0m m ( 0 . 0 1 2i n )
3 . 1 5 2 23,. 1 5 2 41 ,3 . 1 5 2 4. . . . . . . . . . .. . ... . 0 , 2 0m m ( 0 , 0 0 8i n )
- Exhausl(cold)

3.152D , 3.152 . . . . . . . 0 , 3 0m m ( 0 . 0 1 2r n )
3 . 1 5 2 23,. 1 5 2 4 , 1 3 . 1 5. 2. .4. . . . . . ... ... 0.32mm(0,0125in)
Lubricatingoil pressure
- al maximumenginespeed and
n o r m a l e n g i n e t e m p e r a l.u. ,r.e. . 2071414kN/m' (30/60 lbllin') 2,1 14,2kgilcm'
Coolantlemperature ... 60'c(140'F)
Thermostatslads lo open
- bellowslype ...... 7 4 8 2 " C\ 1 7 0 / 1 7 9 ' F l
- wax lype . . .. . . 81/84'C(177l183'F)
Thermoslallully open
- bellowstype . . . 93'C (199'F)
- wax rype . .. . 98.C (208.F)

Continued

Pe*ins SeruiceDala BooklelPad 1, 1997

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 Downloaded from www.Manualslib.com manuals search engine
166t I led lollooS ElEo ooruos sur|rad
(ur8/€) uu 0t ' ' ' ' ,' lnr lsaEuoltP Uopallopla8
t6tsroqtor)Ngt uorsualllaS
abuEll6u[unou dund lönl ' $ireu 6uru[ dund lanJlo uo[Eco-]
'- - apoc ouno lanJJo uolPco ]
dll ro eprspuPqua l
'
MC'M'^A tzgt €1 -
'/r\M 'M3 ''''' '''zgt€-
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' ''''''
^x zzglE-
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M/ü '
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sopoc dond lanl
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ose. ourul lo ecel reo] 'aoue[ dund uolpolur lenl Jo
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pua Iailnd Ueqsluero JOUOIeCO-]
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uru/^ai 0E1 - poads6u(pl
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luoil uoil esra)i@lc lo
panutuoo 'elep lec!uqaal clspg
z9[e
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 2 3 . 1 5 2S e r i e s

Preventivemaintenanceperiods
Caution: On shon dslance apetailan wlh kequent slans and stops the hauß af operailan arc more
nponant lhan lhe dtslence

These prevenl ve ma nlenance per ods app y lo average cond lrons of operalron. Check the per ods grven
by lhe manulacturer ol lhe eqlrpmenl n wh ch lhe eng ne s nslal ed. Use the peflods whrch are shodesi
When lhe cperal on ol lhe eng ne mlsl conlorm to the loca regulalions these perods and procedures may
need lc be adapted to ensuae coftecl operalron ol lhe enqrne

t s qocd prevent ve ma nlenance lo check lor eakage and oose iasteners al each servrce

Maintenance schedules

A Frslserurceat25/50hours(a engrnes) F Every500hoursorl2months(D3152)

B Every day or every 8 hours (al eng nes) G Every 800 hours or l2 months (3.1524 T3 1524)
C Elery200hoursor4 months (3 1524 T3 1524) H Every2400 hours(3 1524,f3.1524)
DEyen/250hoursor4months(D3152) I Every2500hours{D3152)
E Elery 400 holrs or 12 Tonlhs 13 1524 T3 1524)

Th€ scfedu es wh ch foi ow mlst be appl ed al lhe Interval (hours or monlhs) wh ch occur firsl.

Operation
Check lhe amounl ol coolant
Check the dnve be 1(s)

Check for water n lhe fuel preji ter (1)

Fenew lhe fueLi iter e ement(s)
Ensure lhal lhe atomrsers are checked (2)
F .'odlF pppd.'. radd ddl-.ed

Check lhe amounl oi lbrcat ng o n the slmp

Check lhe !bfrcal ng c I pressure al the gauge (1)

Refew the :ubr calrno o | (31

Fenew the can sl€(s) ol lhe ubrcal ng o lLter

C ean the a'cjeaner or emply lhe dlst bow ol the a r fi tel

' exlremeLydusly cond I ons

C e a n o r r € . e w l h e a r i 1t e r e e m e n l , f { h a s n o t b e e n n d r c a l e d e a i l r e f
f -,..'p t Lo.lö -pÄlF d.d'-.bo.hd'qar.olpo.\o' d! a

C ean lhe cc'npressor arr fi ter (1)

E.sure lhat rhe exfa!ster or compressor ('l) s checked (2)
F, ., d . poo . .d d a- d p. rp.-oo d_d ddj--lFd l lorF! .d1
\2)
Ens!.e ihat lfe a ternalor staner molor etc are checked (2)

'l"ere sonelileo
B! a !ersof rrro has rac lie correcl lra nrnq
rh-. .,, .han!t-o nle.ra w .hanqe w lr thc amounl cl su phur n lhe fue (see the table on page 3.02
rr'l the lle spec j cal o:r ihe fl€fr'a lo change lhe can ster of lhe ubrcal ng o I fLter s nol

PerkinsSeruiceDataBookletPan 1, 1997

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 Downloaded from www.Manualslib.com manuals search engine
166t I Ued let)ioog eleo e3rru3s surllad
zze 9Z
gaua apoc
el6ue )ileu dund al6uElcöqc aurOu3 dOnd lanl
3802t t60t cdI idquru uolPcnqnd'tPnuPU
'el6uE
doqsryoa eas lrpu dund aql las ol rapu[Ic €uo röqunu eql rol uot.olur Jo uels aql le las dund
aql qlrM pelieqc sr dund oqf alorls uorssarduoc aql uo (COf) €rluac peop do] te rapurl^c I raqunu €ql
lo uolsrd aq] qlrM tas au16ua aql qlrM pue E19 S!"\| tool terc€ds q}ra pesn eq lsnu a 6ue lcauc aur6ua €qf
6u!uI ctpls
'''uals^slanl
lue^-llas
JSLNIJOlS pue a^!p uolJ uotelor ,o uolcarc
'''''
dund eql lo rear oql uorl uees sp uolrsod )icolco I I rapurtlc t requnulollallno
' ' ' ' ' ' ' ' ' ' ' ' a o ^ f
aL^peuelS
dund uorlcalu! lont ou^peuels
8€ 0€
19Mt/{ legM!'!
'6tmn
LE 9Z MZ L€ 9Z 31tMt/{
9€ 6Z 309MX o, 6Z 6EM t SqM l
9t 1Z
'0L92/9tMM
'0022/9/MM
'0LrzlE/Mt
a€ 6Z zqMt tsMl
L€ 9Z osl 1 0t zt
LE LZ l8'M_t 9e 992
'19MS 'ZgMS
LE 9Z 89MS
LE tz 8r^ s
TE 9ZZZ 068y8/MS
'008y8/Ms
Moteqldecxa Ms lz
LE 92 rgmB Z9t B 09MU 9e LZ
8€ 6Z z
(saar6ap) (sear0ap) (searOep) (saar6ap)
sraual sraual
a 6uP at6ue al6ue
apo90un0 anl
)ireu dund tcaqc aur6uf Nleu dund lcaqc €urOu3
'öteld srql uo p€duels eanal apoc aql asn 'pauu sr €letd !olecurpou € dund
1l
aql lo aOueuaql ol paualselsr qcrqMolplduoleaupoo e uo paduels apoc6urnasaql a^eq ^eu sdund lanl
auos dund uolcefu1 lan] oql lo atetd plep oql uo padue]s epoc 6uLuas aq] ur pepnlcurare srallal apoc aq-t
'rapurl^c raqunu iol uoqaelur
L ,o U€]s
aqi le tas dund aul qla pal.eqc sr dund eql elolls uorsserduoceql uo (3Ol) arlua. peap dot le uolsrd
! raqunu qtra]as au 6ua aql qlrMpue 919 sy\l lool lercadsql M pasn aq tsnu al6ue)jcaqcaur6uaaqf
6u!u!l dund uo!l3olu! tenl
' ' ' '
,2, ro M' rana l repur ^c I raqunu rol ta 1nO
asrMtcotc pua a^up uorj uole]or lo uo lcar c
' ' ' ' ' ' -
002 do ro vdo a o ^ I
dund uolpelu! lan, sern_l
sapoc dund lanJ
z seueszgt €
'-il
 2 3 . 1 5 2S e r i e s

Becommendedtorque tensions
Therorquetensions
berowappiyrocomponents
rubricaled
lighrywilhcreanengineoirbetorerhevarefifled

Thread Torque
Descriplion
size Nm tbf tl Kgr m
cylrnder head (cold) 7/16UNF
95 70
- nuts
81 60 8.3
Sumpplug 1/2PIF 34
Alonrser clamp Y8 UNF 2 1,7
Injeclor prpe union n!t t 12X1,5 20 1.0
Marn bearing 9/16 UNF 150 110 15,0
Big end bearing 7/16 UNF
- cadmium plated
45
.
Phosphated 81 60 8,3
.non-plated
95 70
Frontpulley 7/8 UNF
'with 4,8 mm i0.19 in) spacel
142 105 14,5
-with 8,9 mm (0.35in) space.
325 240 33,2
I/2 UNF 106 7a 10,8

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 Downloaded from www.Manualslib.com manuals search engine
/66t I UPd lAtIoO€ PIPO af,rruas sur)irad
'as4 Jnoq
1o 09/92
lsl aq Jaue uebe pauelqjt peeq )opu6. aqt
)ol soualsel oqt e^eq tsnu 9LOZL89' raqunu ued
'lalse6 peeq Japun{. qtß paul sau6u3 :uoltneC
rl 9l zl
'sraueFel aql uasool
lou op lcoqc '!!'0t'6'9'9 aarcslas
t s \a/Lü v'a6
srqtOuunp'ure6psuolrsod Ol ]srlaqllceqC S
'enbrol 8 1 e Z g \ilt t) 948 MArasles
lsroc
8t'9t tt 0t ' s (8/S e) 0 26 pnls
oq) ol 1ruo1q6quaql unl e to (.09 ol .0e) 9/t ol ZUt
I UaSOOI pa)icaqcuoqM o^ou lou saop rau€FPl e ll
uo[rsod puP (ur)uu qt6ual ed^l
'anblol
Pel03 uolelsnlll reuaFel ioueFeJ
aql ot I uatq6rl'pa)i3aqcuaqMsa^ou rauelse] s il
'ocuanoos 'spnls ol
Pgoueqc
laaroc aql ur onuol lc€loc
aqt ol ute6e sreueFel sql ualq6[ uor.ll'slosruote aröa sMorcslesserqt raqloue lt6tl6sn- 33
aql o^ouar pue lalcor aql 6^ouou ' raqunu €urOueuorl seu!6uezsl'eo uo
ueqs
'eur6ueeqt dots uolerodo a]nlereduel
lo '9t
1t zt
teulou saqoparlr llun aurouooqt unr pup uels c
!r'0t'6'9'9't s (8/1 0) t 86 MAJCSIeS
u lbt 1.6 (u lqt 01) uN 96 saatslas puP sFN Mar3slas
8t 9t t g (8/S 0) 0 26
u töt €'B (U tqt 09) uN tg pault^tuosnN
8 r'E Z A $/r e) 9 28 Marcslas
anbrol ad^l raualsej r! €l s (8/9 e) 0 26 pnts
'(€ ro uoIrsodpue (ur)uu rtFual od^l
V) ur uMorlsacuanbas
sql u 'aolaq olqel aql ur uMoqssnbJollcaxoc uolerlsnlll rauelsel rauals€l
€ql ot eauolsel aql ualqot ^lua^a pue ^llenpprC z 'saaroslas ol po6ueqc areM
'sreuatselaql spearql aqt €lecuqnl^Dq6r_t
lo ! spnls leur6uo aql Jo oAl lnq ltE'soul6ue Zs!'eO uO
' 9 1t t
zt 9r
z t ' r t ' 0 t ' 9 ' tv \BtL€)I A6 MSJCSl€S
6 8 I V (8/S8) 0 Z6 Marcslas
€t zt 1 9 € z v (8/9 0l 0 26 pnls
uoilsod pue (ur)u0 qlbuel
uoIeltsntl raualsel raueFel
'MOlaqpalst €sorll rol ldesxa sMalcslas
ol pa6ueqcaraMspnlsaql'soul6ue z9! E uO
suoüsoo
peroc raqt ur pe[!J aq sMarcstas]o sqFuel
tuaraUp aarqt aqt pue spnls aqt leql lueuodul sl ll
to908l€fvnzst 009286n29t
]tsorrrSzvnzgl f9tttznzg.
:pouuaraMsM€rsles pue snu spnls peeq
r€purt^J'aotlolqcrqMeaqunu ouroueeql uo4 sV
'slnu pue spnls ^q )icolq
i sC eos O g sC o
. ")- t:E_-z ^9-e!. rapurl,b aql ol peualspJaraM speaq ropuub lEUL6uo
'saur6ue
o - ' . z9L €o pue zsl e
!o pesn uaaq a^eq srouelsel peeq rapu[^c lua]aJIO
- : ; - :
o o lenueu daqs\roa
,oto o t ! fr aql ol )oJd tqnop ut tt 6uute4 lcouoa eqt ql!il
\i-,.oido lolqgax uosad e Iq auop aq lsna uoltsado sltll :uollneC
acuanbas enbrol peaq :aput1Ä3
zgte
z saues
 2 +.203Series

Basic technical data

Horse power
.4.243
venlcte .
. 47,0 kW (63 bhp)
dgflcutrure . . . 42,5 kw (s7 bhp)
. 4 . 2 0 3 2 . .. . . . .
44,7 kW (60 bhp)
\utrbero'cylirders ... . . . . . . . . . . . . .4.
Cycle
,...,,. Fourstoke
,^d,(l on <yster
. Naturallyasptrated
Combuslon system
.4.20J
- 4 2032. Da.20J
... Indirectinjection
. . .. . Directinjeclion
Nom nal bore
. 91,44mm (3.6in)
Slroke . .
. ... . 1 2 7m m ( 5 i n )
Compress on ratio
.4203
. 4 )0i2
........... 17.4:j
.. .. 19:1
C-b. cdoac ty
.. 3,33 l[res (203 in3)
Frr ng o.der
......... 1-3-4-2
Valve lp clearances

All 4 192 and 4.203

and D4 203 up 10 enqine number JE....U564OB3c
'r/el
r' oo, .
. ErFa-5.rcotd)
0,30 mm {0.012in)
0,30 mm (o.012in)
D4 203 lrom engrne number JE....u564083G
. rl Ft {cotd)
. Frndu\r r.oldJ
0,20 mm (0.008in)
. . 0,30mm (0.0i2 in)
Lubrcal ng oi pressure
- a1maxrmum eng ne speed and
^orrd eng ne
lempa'a'ure . . . 207/414 kN/m' 130/60tbl/n ) 2,1/4.2 kgltcn,
Cooldn lenperalure .. . . . ... . 6o.c (14o.F)
-fp
no.tar ilads to open
....82.C(179.F)
Thermoslat lully open
- oFr ows ype
'wa< l)pe
...... 95"C(203"F)
. . .. . 98"C (208"F)
D roL'ron o' rolat on . . . ......... Clockwisefromfronl
ro I g \peeo ........ 550-T50dependingonapptication
LorJl on ol nax n-n -o-lodd spFeo
. Fuel inlectionpump data plate
Lo L d l r o n o l n - n b e r '
cyl nde' ......... C r a n k s h apfui l l e y e n d
Lo' a'ro' oi Prqne ltTtig ndrks Trmng pin on trmingcase and crankshaftpuiley

Conrnued

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 Downloaded from www.Manualslib.com manuals search engine
166t I Ued leüoo€ Pleo asrNäs surlrad
''''''
(JrI C) ru Ol unrlsa6uolleuoqcallaplla8
,6\9rCqror)Nst uorsua] lla€
'
a6uPrl6urlu"oü dund lanl s)ileu 6uru[ dund lan] ]o uolPcol
rgpr 6uruil pup r6up[ 6ulunou dünd trnJ ' '' -
zeozb
aleldraurm dünd lanlpue a6upU6ulunou dund lanl ''''''' 002t-
epoc ouno lanJJo uolecol
'dt- ''''sapocounolanj
ds du'dd d!\'lt l8'lv
't'xH'MH'nH'H'M0's9'99'
v^'vn'z'v^'3f
' , " / e' 3 c ' s e ' s l ' u l ' I E ,' sepocras uolv
fl'^f cf cS No't"t8'^v
PanuttuoC'elep lecluqcal clseg
z seuaseozt
 2 4 . 2 0 3S e r i e s

Prevenlive mainlenance periods

Caution: On shan distance ope2tian wlh lrequenl sbns and stops the haurs of oDezrbn are more
rmDanant lhan lhe dtstance.

ihese prevent ve ma nl€nance per ods app y to average cond tions ol operation. Check the penods glVen
bythemänliactuferoltheequpmenl nwhchlheengne s nstaled.Usetheperodswhichareshodesl.
!Vhen lhe cperal on ol the eng ne must conlorm lo the ocal reguiations lhese perods and procedures may
nee0 lo !e adapled lo ensure corTecl operalon ol the eng ne.

t s gooc prevenl ve marnlenance lo check tor leakage and loose iasleners at each serutce

Maintenance schedule 4.203

A Everyday or every8 hours C Every500 hoursor 12 months
D Every2500hours

Tae schedules whrch fo ow must be app red al the nlerval (hours or months) wh ch occur rrsr

Operation
Chechlh€ amcunl ol coolanl
. L o - t r e . o i - r , . d r , o no ' h c . o o t a n t
{2)
Check lhe a ve re I

. Lubr cale dynamo rear bush frhere lined)

.l o .öd - a-t I onber d-o t-e s.rd.ner o. r^p ,ua, ,n

ouTo
C h e c l l o r w a r e r n t h e p r e - ll l e r ( 1 )
. . Fenewlheeemenlo{rhe'ue frXer
I Ersire lhat lhe alomrsers are checked (3)

I Check the amc!nl c{ lubncalrng o I n lhe sump

Che.( the ubrcat ng or pressure at lhe gauge (1)
Fenew Ihe engrne ubrcating oi (4)
Be.ew lhe can sier ol lhe ubr cating o | | ter

Clean lhe ar cleaner or emply the dust bowLof lhe arr filter
' exlremely dusiy con0( ons
' norma cono l ars
e p : . . r r F n F w .r h
t ap . r I ) 1 i l e .l ean1ec^. t- I| n h 2 s n . r n o o n ' n ^ .
d'Iha, I r d s o l O c p , r - O C a . e OF A , . p r

. fus-re lhal lhe ?a ve t p c earances oi the engine are checked and, i necessary, adjusled

. EnSrre lhat the a ternalor. slader molor etc are checked (3)

(1) I lhere s cne 't1ed

(2) Renew lhe an! lreeze every 2 years lJa cootant Inhrbilor rs used nstead ol anl iieeze, il should be
r e n e w e 0 e v e n r '6 m o n l h s
(3) By a personwho has hadlhecorectlranrng.
(4) The . change Inrerua w change w th lhe sulphu. content ot the tue (see lhe labte on page 3.02 and
1!e sp-o.fcalon) The nleryallochangelhecansleroilhelubrcaltngollfiterisnotatlected.

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 Downloaded from www.Manualslib.com manuals search engine
'l ped
1661 lal)ioo8 eteo ac!ruos surlled
palcale lou s ran i o 6u lec!qn aql lo rals uec aql a6ueqr ol leNatu aql luo tpr lrads lanl
pre Z0 e a6ed uo atqel aqt aes) tanj aqt |o luatuoc )nqdlns aql qtlM aolpqc ra Eruatu abuEq. ro eql (')
buru erl traroo aqt peq seq oqM uosrao e ^8 ( e )
sqluou g fua^a paMauar
aq plnoqs I azaarl luE lo p€alsur pasn sr rolq qu lue oo3 p I s r € a i Z f u a ^ a a z a a r l t u e a q t M e l a u \z)
pet I auo s araql l ( ! )
(c)parreq.erp .raroroura!ers!oreurar
E aq,irlii:iiil:
'pue palc€qo
fuessa3au I erP e! 6!a aqt lo saauerea13dq €^ p^ aql tp!l arnsul
ra rea petea pu uaaq lo! seq I ! tuauale ral l ri€ aqt Mauar ro uEa 3
sloq puoS €urou -
r€*i E€q'o^* ,""0"u,no''1""'ll3l::i:'i:J
ili*:i,
lal I I o 6uuecrqnl aql lo ials uea aqt ^\auaE I
(t) ro 6utec!qnl aur6ua aqt ^\auaE
(!)a6nebaqltearnsserd o6uteorqn eqtlceqC
duns aq) u tro 6u te?uqn to tunoup aqt )3eqO
(t) tuessa9au |'patsnip€ pue palcaqf, s) paa0s alp arnsuf
(e) pa)jcaLlcare sras uole aql leql arnsul
ralt | 3nl aql lo tuauata aq) aauaS
{1, ra} taro eqt ur reteMrot lc€q3
dund U ont aqt lo reu Brls aqt pue iaquEqc tuaurpas aqt uee 3
I aq e^ rp aql )raqc
(2, tue ooc aql lo uo tertuacuos aqt )oaqJ
luetooc lo tunoüe aql )caqc
uollErodo
lsr I rn9ro qcrqM (sqluo[ ro s]noq) erualu aql te parldde aq tsnu Mo tol qa qM sa npaqcs aql
sqtuou z I ro sinoq 00t tua^f c
srnoq00tZ tua^f a sqtuou tro srnoqOOZfua^f I
srno! 008 tua^3 o srnoqI fua^aro ^ep fua^: V
zeoz t alnpaqcs a3ueualurehl
elrdas qapa lp srauatspl asool pup abeleat rol l3aqf, ot af,ueualu eu a^ lua^ard poo6 s tl
eur6ua aql lo uo tprado tcaroc arnsua ot patdepE aq ol paa!
^eu sarnpacoid pue spo rad esaqt suoqe n6ar lecol eqt ot uro/uo3 tsnu aurOua aql lo !ortelado eqt uaqM
tsaloqs are qcrqM sporad aqt asn pal Etslr s aur6le eqt qjrqM u tuaud nba aqt lo )arntcelnueu aql ^q
ua^16spo!ed aqt loaq3 uo tprado lo suorl puog a6era^e ot ^ldde sporad aoueualu pu a^ tua^ard asalll
dJrP,s.a ö\) JPtl luPPaddl
aou ae uaqetado lo stnoq aql sdals pue sueß uenba4 qla uorc)ado acuetstp uoqs uO :uolveC
spouao a3ueualu!eu a^rlua^3Jd
z sauos80zt
 2 4.203series

Fuef pump codes 4-203 and 4.2032

CAV tuel Injectlon pump

Type
......... DPA
D r e c t o ^ o lo l a l r o n l r o n c i l v e e a.o. . . . Countetrclockwise
Outle'fo'numbe' I cyltroer . ..... Letter"W"
Fuel iniection pump timlng

The engine check angle must be used wilh special lool MS.678 and with the engine set with number 1
prslon al top dead cenlre (TDC) on the compression stoke. The pump is checked with the pump
set at lhe
slan ol In eclion tor number I cvlinder.
The code letlers are included in the seting code stamped on lhe data ptale ot the fuel inieclion pump.
Some
ruei pumps may have rhe serting code stamped on a modificatron plaie which is fasrened to rhe llanoe
of th€
pump. lf a modificalion p/ale is tjfted, use the code leners stamoed on this oiate.

4.203Series 4.203Series

Fue pump cod€

Engjne check Pumpmark Engine check Pump mark
Fuel pump code
angre angle angle angle
leners
(degrees) (degrees) (oegrees) (degrees)
287 27f F59 289 279
247 277 _P55 247 27s
\f461600/0/280 245 277 {P50 290 271
\F46/600/0/292 286 üP54 293 280
rF49E 287 277 t\rP55 293 280
'F50 287 277 MH5/ 293 2AO
241 2// PP48E 289.5 241
249 275 PP53E 289.5 241
290 241 PP46T 289.s
lF51 290 241 PP5OE 289.5
289 279 RP50E 290.0 2A
289 279 289.5
-F56 289 279 290.0

2.16 pe*ins SeryiceDataBooktetpan 1.1997

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166t I U e d l A l N O O Se l e c e C r r u e s S u r l r o d
I tI 08 0
z9l 0tt 6tl 8/l ^oiln0 l!orj
z9 99 09 9l/r
69r 991 9t/6 6uueaqurel^
I Z 9t oz zt!,{ lnu uorune0rorolceul
z 9t/9 duelg rasruolv
9e 9Z m ,tt 6uu O, qth -
9e 9Z tt v/t
t9 LE 09 ,/e 6ntddunS
16 o1 96 9 t /L peaq rapurl^c sraualsel
uFt UN
azts
u Jql pearq-l !olducsao
anbrol
zEoz'v
I tI 08 80r zll
z9t otI 6rl 8il ^allno tuorl
z9 It unrupe3 -
08 09 t8 9l/L aleqosorlo-
6ureaq pue 6r€
6'9r 991 9t/6 6uueaquren
lz oz zt|/! lnu uotun aoto tolcatul
8/e duelS rasruolv
9e 9Z te 6uD O, qlrM -
9t 9Z nt,
ts TE 09 nt€ 6nld dunS
L6 OL 96 s98t609n ef ot s6t0609n"ef srequnu auroua-
L6 OL s6 sMarcslaspuP slnu
e8 09 t8 9ltL ^]uosnu -
peeqropul^c'gaualsel
u 16l u Jql UN uoIdrcsaC
peor!j
anoro.I
poul erp ^aql e]o]oq I o aut6ua ueetc qlrM ^ßq6tl palectqnl stuauodüoc ol ^ dde Mo aq suotsual enblol aql
suolsuel änDrol papuauuosa8
z seuoseozt
 2 c.203Series

Cylinder head torque sequence

4.203 and 4.2032
Cautlon:fhis operclionmustbe doneby a person - o i r -
-{7-?:ilrc::: r s z - r o p
with the efte! lraining. ll in doubt rcfer to the 3
Workshop Manual. Lt 7^ o . S r 1 o t o t6
t ^ o t
Flameprot@tedenginesstill have all nuls. All other ^ o^ t o
engrnewere chäng€dto nuts and selscrews,trom u^i.'^' q^ä'?-'',
f il'ol.'-iol-
the enginenumbersbelow.
203U93838CL
8eF,bi
203U6963D1
203U41304340L
On 4.203ongln€s, all bul two of the studs were
changedto setscrewsas well as lhe eighl special
studs whichalso relainthe alomisers.

Faslener lllustralion
-^ -o
rype and oosition
,, -' .-.ro a
t - ea r ] r ? J.6?r
Slud a 10,1
ö o n a ^ ? i 2 ^
Setscrew A 1to9and121o19 .--.-^"? "" "Y
- 3 : 8 _) 1 0 - 1 4
1 5 - 1 36 . ?
On D4.203and 4.2032 englnes, all bul two of the
sludswere changedio setscrews.

Fastener lllustation
type and posilion

St!d B 17 Not6: Release lhe cylinder head selscrews eventy

Selscrew B 1to15and18to23 and gradually in the reveße sequence to lhal shown
in (A).
ll llese tuo studs are removed they must be pul
back n lheir correct posilions, because they guide
lhe cylinder head gaskel inlo posilion.
'|
Lighlly lubricate lhe threads ol the fasten€6.
2 Gradually and evenly tighten lhe lasteners to the
correct lorque In lhe sequence shown in (A or B).
Repeat to ensure thal all th€ lasteneß are tightened
10 the coiiecl toreue shown in the lable below.

Faslener lype Torque

Nutsonlvtned 81 Nm (60 lbf tt) 8,3 kal m

Nuls and selscrews 95 Nm (70 lbl tl) 9.7 kol m

Ceutlon: Engines litted with cylinder head gasket,

pan number 3681213A, must have the lasleneE for
lhe cylindet head lighlened again aner the fist
25/54 hau of use

PerkinsServiceData Booklel Part 1, 1997

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 Downloaded from www.Manualslib.com manuals search engine
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 2 + . 2 3 6S e r i e s

Preventivemaintenanceperiods
Caution: A. stcn atslarce aaerailan wth lrcquenl slans and stops lhe haurs af aperalnn are more
,npodan! lisn the drstsnae

Tlrese !revenl ve marnlenafce pef cds apply lo average cond{ ons or operalron
check the per ods grven
Ly rhe manllacr!fe'!i rfe eq! pment n wn ch lhe engrne is rnsla ed. use rhe penods wn cn are snonest
i r r ' h - e nl f e a l e f a t c n c l l h e e n q n e m l s l c o f l o r m t o t h e o c a r e g ! a t o n s l h e s e p e f i o d s
afo proceoufes may
need lc:e adapteo lo ensure.orrect operalron ol the engine

I slcoCofeverlrvemanlenancelo.iecklor eakag€andtooselastenersateachseruce.

l M a i n t e n a n c es c h e d u l e s
A F rsl 25 50 folrs O Every500 hoursor I 2 monlhs
B EveryShoLrsoreveryaay E Every2500 ho!rs
C Elery 250 nolrs or4 monlhs

T ß e s c n - o a ue s w h c h l c o w m u s l b e a t p t e d a l t h e n t e r u a ( h o u r s o r m o n l h s ) w h r c h o c c ! r n r s l

Operation

C:eck'he amcunl 9l coo a.t

Check lfe dr !e be I ol lhe a ternalor

C ean ltse seC menl cnam!er and the stra ner oi tfe tuel fi pump
Check :o. waler n the iue pre i tef (1)
Fef€w the elemenls oi the fLe i tef
. E rsrrE ihat t.e atorn sers are checked (2)
trs!re .r e speeC s checkeC and adlusted f necessary (2)

C h e . ( l h E a m o ! n t o 1 ! b r c a 1n ! . I n t h e s ! m p
C-eck :h-. l!br cat ng o press!re at lhe ga!ge (1)
P-.new lhe erE ne ubr cal ng o I i3) (5)
F-.new lhe can ster of lhe !cncal ng o I i ller (3)

e -eaann l fl ! ar .f . : .edannperr D
C o rr e r tp l y t h e d u s l b o w o j t e a r li ter
. exlrene y d!Sly conC I ..S

. Ens!re lfal ife l!rbocfarger moe er and lurbocharger compressor cas ng are c eaned

:.rsure :h;l the ,/a ve I p . earances are checkec and adlusted. i necessary(2)

E-sL,reifal ihe aiernalrr slanermcloretc arechecked (3)

(1) llrere srrelticc

( 2 ) 8 , , ,a p e r s r n w h o h a s h a d . n e c o r r e c I r a n n ! l
(3) I 2+82 ef! fes e,/.r/ 500 hours.r 12 monlhs
(4) tr 2482 €.! fes eve.r 10!0 fours
(5) It,.: u h a . ! e n t e . , ' aw c f a n q e w t h t h e s ! p h u r c c n l e n t c l r h e t u e L ( s e e l h e l a b e o n p a g e 3 . 0 2 a n d
I -e sp.r. I .al nn) Tie -lerrar 10 chj:ae ih. can ster af lhe tubncal fq orl f ler s not affected

SeruiceData Booktetpan 1. 1997

PerkLns

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 Downloaded from www.Manualslib.com manuals search engine
166t I Ued laHooS Pleo acLNas surlrad
00tz16/0s8/r9sd
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0zt€/ü/0q8/t9sd
z6z lsd Motaq ldcarra Lqsd
19 S9
't9 't9 '9t
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t6z 9Z ELZ I t9SZ 9gz 8LZ toSl n
t6z 082 z6z 6LZ 19St{
qz6 ''l
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0012/9/0s8/19s1
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t6z oaz f.{012820nuorf
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l6z 9 6/Z \olzat 9a) la 962 ttsa
z6z l8z 99 Z9 Sd z6z f/9tv'lo9lv s!
(saerOap) (saerOep) (saarOap)
sraual sranal
et6ue ei6uE al6ue atOue
apocdund tenl
IPU OUnd lcaqc aur6uj )ileu dund lcaqc au 6ul
'öt€ld 'paULl
srql !o poduels srolel apoc eql esn s La l e d u o q E c l r p o u e J l d u n d
eq] lo a6uplJ aql ol peuolse] sr qcrqM oleld uolPollpou p uo padupls apoc 6uruas aql e^eq ^eu sdund lanl
auos dund uoDelur tonl eql ro oleld elpp aqt uo paduEls opoc ouruas aql ur papnlcur are siötla apoc aql
fapurllc t raqunu rol uo lcalut lo !els
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6uluI dund uollcalu!lanl
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sepoc dund lanl
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 2 4.236series

Fuel pump codes, conl,inued

Stanadyneluel iniection pump
Type ... Slanadyne DB2
O u l l e l l o r n u m b e rcly l i n d e r. . . . 7 oclock posilion as seen kom lhe rear ol the pump
Direclionol rolationfrom drive end Clockwise
Fuelsyslem Self-venl

Fuel Inlectlon pump tlmlng

The engrne check angle must be used with special tool MS.678 and wilh the engine set with the piston of
lhe number 1 cylinder at lop dead cenlfe (TDC) on lhe compression stroke. The pump is checked with lhe
pump set at the slad oJ injection Jor the number one cylinder. To set lhe pump mark angle, see workshop
manual, publication number 601 TPD 0393 1229.

Enginecheck Pumpmark
Fuel pump code lefters angle angle
(degrees) (degrees)

-beloreeng.U524012W 280
- tromeno.U524012W 285 72
244.5 64
244.5 64

Recommendedtoroue tensions
The lofque tensions below apply to components lubricaled lightly wilh clean engine oil belore lhey are fitled.

Torque
Thread
Descriplion NM tbf ft x$m
size
Fasleners, cylinder head, reter lo head torque sequence 1/2
Sumpplug 3t4 50 37
3/4 34 25
'with O'ring 3/4 34 25
Alomrserclamp
- secuangnuts 18 14
- ctampnu6 5/16 I
Inleclor prpe unron nul M 1 2x 1 - 5 20 5
Marnbearing
- belore 5/8 203 150 20,7
- liom 5/8 244 180
engrnenumbers212U582,212uA119095,236U82408, 236U450507,
236UC1 236US12 129. 248U6330.248U458746
9949.236UE4404.
Brg end beanng
- Cadm um srlver tinnish 1t2 95 70
- Phosphated black linnish 1t2 122 90
7ta 406 300 42,O
- Cadmrum 7ta 325 240 33,0
- Phosphated 7/8 390 285 39,0
- 32186139 (3 Setsc@ws) 7t16 95 70 9.7

- Selscrews 1/2 108 80 11.0

- Placebolls 1t2 122 90

PerkinsSeruiceDala Booklel Pan 1, 1997

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266l I Ued tet)ioo8elPo ecrru3s surlröd
10t 9'LL 901 lNn z/l o] laaqMlr'saor9slas
ueq$1uerc
L 6 OL 96 lNn 9l/l Aollnd [Pq$1uero'sMarcslas
L'Zl z6 9Zl lNn z/l spor 6ulcauuoc'slnN
vBl o9z lNn 8/9 DuuPaqurEU'sM€rcslas
9t oz atw sadrdlanl ornssardqbrq'snN
z'l 6 8t 'l duelc rasruolP'snN
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9e t€ reqspMpup 6ntd He00OZ8CO uoit seur6ua-
89 09 89 lNn r/€ ^tuo6ntd'HC0OCZBCO aroraqsaur6ua-
duns tro6ulEcuqnt'6ntd
'peoq repurl^c sleualsel
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uFf ozls
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pearql
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 2 4.236Series

Cylinder head torque sequence

Cautlon: Thts operatian must be done by a peßon

with the cailect taning. ll in doubt reler to ne
wotkshop manual.

ll rs rmpodanl lhal the sluds and the three ditterent

englhs of selscrews are lilted in thetr corecl
pos tons

Fastener llluslralron
lype lenglh mm I n) an0 posüon

Stud A 19.22
Selscrew Smal a 5 , 6 , 1 1 ,1 2 ,1 6 ,
17
Selscrew Medium a 1,2,3.4,7,A,9.
1 0 ,1 3 ,1 4 ,1 5 , 2 0 l q 8 2 1 3
19 - 9 ö ?
Setscrew Larqe a 18.21 r s Q ra
? . . o i
2 0 1 0 7 4 r c
ll uslralon 421 22c11 12. 6 'S.17 .16.
type lefqth mm ( n) anC posilon a a a a a a a a

Slud B 16,2
Selscrew Smal B 3 , 5 , 7 ,1 0 ,1 5

Setscrew Medium B 1,2,4,6,8,9,

Method 1
1 1 ,1 2 , 1 3 , 1 4 ,
1f.20 1 Lightly lubricale the threads of the cylinder head
Selscrew Larqe B 14,19 lasleneß,
2 Gradually and eventy tighten lhe fasteners to ihe
Choose the cotrecl methbd and lorque from lhe correcl lorque and method shown in lhe lable
lable below opposite. Tighten the lasteners in lhe co(ect
sequence (A or B).
3 Slad and run the engine untit it reaches normal
Torque
Engine Torque lemperalure ol operation. Stop the engine.
type 4 Remove lhe rocker shaft and remove lhe
NM bt fl Kgl m
alomrsers, lh€n lighlen the lasteners again lo lhe
1.236 cotrect lorque in the correcl sequence.
)nglnesw[h nutson y 1 8 1 60 8 , 3 It a lastener moves when checked, tighien il to the
rp lo u550185W 1 r36 100 13,8 correcl totque.
rom U550185W 2 120 88 1 1 , 8 It a fastener does nol move when checked, loosen il
r.4236 1/ 1 2 t o 1 / 6 ( 3 0 ' l o 6 0 " ) o l a t u r n t h e n t i g h t e n i t t o t h e
correcr torque.
rp lo engineU027774V l 136 100 13,8
5 Check the first 10 positions again, dunng this
rom enorneU027774M 2 120 8 8 1i , 8
check do nol loosen lhe fasleners_
1.24Aand 4.2492
6 The fasteners of all engines except the 4.2482
rp lo engineU573000 1 136 100 13,8 must be tightened again atter lhe tirst 25150 hours
rom enqine 1J573000 2 120 114 use.

PerkinsSeruiceDataBookletpad 1 1997

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 Downloaded from www.Manualslib.com manuals search engine
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 2 6.3544Series

Easic technical data

6.3544 .. ... gs.s kW (128 bhp)

16.3544.. .. . .. . 1 1 5k w ( 1 s 5b h p )
Nuaber of cytr-ders ' ' , . ' ' - - . .6
Cycle ...,... FOUrStroke
Inducton system
-6354
... Naturallyaspirated
-T6.3544
..... Tuö@harged
Corbusl,on syslem . Direct injection
Nomina bore 98,4 mm (3.875in)
Sroke ..... ..... t27mm(Sin)
Compression ralio
-6.3544
..... 16:l
'T63544...
.......... 15.5:1
CJbrc.apacity..... .. 5.8o tires (354 in3)
Frnng order . . . .... 1-5_3_6_2_4
Valve tp clearances
. /rlel {Lold)
. . 0,20 mm (0.008in)
- Exhausl {coldt .. . .
. _ 0,45 mm (0.018in)
Lubricaling oil pressure
- at max engine speed and normal engine temperalure
... 2O7/ 414 kNI m' 130/60 lbl/in l 2.1/ 4,2 kgilcm,
Coolan temperature . . . . . . 6 0 . c( 1 4 0 . F )
Thermostat stads to open
. bel ows lype
67ns.C lJ52J167"F)
-waxlype ..... 77/85"C 117O/1A5"F)
Thermoslat lully open
-betlowslype ....
. . 85/88.C(185/190"F)
- war
rype .. 92/98.C(197/208.F)
Drrecilon of rolaton Clockwisefrom kont
ldling speed .... Fuel injectionpump data ptate
I ocal,o- or maxtmdm 10-'oad speed .. Fuel injectionpump data ptate
Localon of -unber 1 cylinder Crankshatlpuiley end
Locafion ol engrne Ln,ng ma'ks . . , .. Crankshatl,main idler gear and camshall gear
Alomrsercodes.. . FL, FN, cD, GG, GH, cK, cL, GX, HC, HE, HK, Hp, HS, HT, HU, RA, RB, VU, XX. y
Fuel pump codes AY, AY, CY. DY, EX, EY, FX, FY, GY, HY, JY, KY, LX, LY, MR,
. -. . MX, MY, PX, PY, SX, TX, ry, VR, VX, WR, WX, XX, ZX

":
:'":":':::ll-11T
Location ol fuel pump code . .. .. ... Fuel in,ectionpump data plate
Location ot luel pump timing marks

1lj1läil;
Bell tension

Belt dellectron al longest run . . . .

Pe*rns Seruce Data Booklet Parl 1, 1997

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 Downloaded from www.Manualslib.com manuals search engine
166! I led lAHooE eleo eclru3s sulllad
palralJp tou sr rat I iro 6u ler!qn aqt lo lats uea aqt aOueqc ot teruatu aqI {ucrlec I trads tanl pue
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6u lrprl trarroc aql pe! s€! o!M uosrad e ^8 (z)
Pan I auo s araql ll ( t)
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'palsnlpe pue pa]caqc
(Z) fupssacau J arE s€cuereat3 dt a^ p^ aql tEql arnsuf
pa:rBq. s (L) rossarduoe ro ralsneqxa aql tEqt arnsul
.(z)
( L) rail J rE rossar0uoc aqt uea c
(Z) p€ueair are ro 6utecrqnl aql rol adrd u Erp rabreLltroqrnt
puE 6urseo rossarduoa ra6reqsoqrnl !a 3du ra6reqcoqrnt aqt leql arnsu:
ra !ea palEcrpuruaaq loJ seq ) | tuauot€ rall! r e aql Mauar ro uPai3
suoq puoc lPUro!
suo lP!oo ^isnP ^lauarlxa _
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(f) uatsÄs raqtearq au 6ua aqt lo a^ E^ tua^ aqt uea 3 .

l
rat | | o DU{€3Lqn aql lo ralsruea aql MauaS
(e) ro 6utPrrqnt aql MouaE
(!) abne6 aql te arnssard o outeorqn eqt l3aq3
duns aqt u lro 6u tecuqnl lo tlnoue aql lceq3
(Z) fupssaca! I pelsnlpe pup palcaqc sr paads ralpr aql teql arnsul
(z) p€)caq3 ere sresruole aqt tEql arnsul .
ouaua a lrMl qla rallt Ian, luoua a ral I lanl eqt Maua8
ouaüa a a 6u s qlM rallt lan, tloua a ra] | anl aqt MauaU
{!) ralt lald lanl aqt ur ratea rol }caq3
dund Ur lanl aqt lo raurels aqt p!e raqueqc luaürpas aql uea 3
(s)l eq a^!p eql ,tcaqO
lue oo3 lo lunouE 3q] )caq3
uorlerado
lsi I rncco!3rqM(sqluour0 srnoq)lerual! aql lE pe dde aq lsnu Mollolqo qM sa npaqcsaql
srnoq00qz fua^f I sqtlou t ro srnoqOqZtua^f C
srnoq0001tua^3 3 srnoqI tua^ar0 ^ep tua^f I
srltuouz I ro srnoq009fua^f o srnoqos/92te ar ruastsrLl v
ttge'91 pue ttge 9 salnpaqcs acueualurenl
'arNas qrEate srauatspl
esoolpuEabelee rol loaqc ot aoueuatureu a^q!a^ardp006 s ll
'aurOua a!l Jouo'leiadotcarof,arnsuaot paldepeaq ot paau
^pu s€rnpaoord pue sporadasaqls!oqpn6ar eaotaqt ot urotuootsnu aurOua aql io !o leradoaq] uaqM
'lsaloqs are qf,qMspoLrad
aql asn pa €isu sr au 6ua aqt qf,rqM
! aql ^q
luaud nba aql lo rarntoElnuEU
ua^r6sporadaqtlcaqO !oqpradola s!oqrpuoca6Era^€ot Ildde spolad aoueualureu a^tua^ardaseqf
dJuPl<tPd tl uP41lueUadL
aoa ae uat)qadaja stnoq aq)sCalspue syets luanbal qta uauetadaacuelstppaqs uA :uollneC
sporJoo a3ueualureu a^rlua^ard
z sauast?90 9
.:FT
 2 6.3s+aseries

Fuel pump codes 6.3544

CAV fuel iniection pump

T y p e. . . ...........-. DPA
Direction ol rotationlrom drve end . .. . . .., ,.. Counterclockwise
O u t l e l f o r n u m bceyrl li n d e. r. . . ...... _....... x
Fuel injectlonpump timing
The enginecheckangtemustbe !sed with specialtool MS.678and withthe engineset with number1
prs10nal rop dead cente (TDc) on the compressionstroke.The pump is checkedwilh
the pump set ai the
slad ol njeclon for number 1 cylinder.
The code leners are ncrudedin the seftingcode stampedon rhe data prateor lhe foer injectionpump.
some
ruerpumps may have lhe seiling code srampedon a modiJicalionpratewhich is fastenedto the flange
ot the
pump I a modificationplate ts lined, use the code leters slamDedon this olate.

Fuel pump code

Eng ne check Pumpmark Engine check Pumpmark
Fuel pump code
angre angle angle
leners tetters
(oegrees) (oegrees) (oegrees) (degrees)
160 146 MXl4/2640 161 146
160 146 MN5/242O tom 159 146
enqineno.728207L
:x t60 146 MV5/2530 6
160 46 PX (except below) 159 46
162 PX lisl M31012 onlv r60 146
162 54 sx (6.3724) 46
t58 144 ry 153
MH lrom engtne no, r58 r60 146
u780699P
MX (excepl below) 160 146 151 144

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 Downloaded from www.Manualslib.com manuals search engine
1661 t led lal)ioo8 Pleo aclruas surlrad
'ouno
aql lo aprs
oql uo peduels sr ue^r6 apoc aql sdund ^VC aql rol suoqrsod 6uruI clels aql le pauq iou are sdund
aseq] leql luelodu sr I Ut raounld uu t te las dund aql qlrM are sdund anl qcsog rot ua^r6 s6uulas oq1
LZI (c/t io tzt) xA
8tl tzt (1or"t) ^v
9 LZI 9tt € - r z t )^ l
qtt (z-tzt)^l
(soerOap) isoorOap)
el6ue al6ue sroüelopoc ouno lanl
|]eu 0und lcaqc aurOul
ropu[^c auo requnu 0ql ]oJuorlcorur
lo uels aql le ]as ouno
aqt qlrMpqcaqc sr dund aql atorts uorssarduoooql uo (3O1) aluec peep dol te rapurt^cI laqunu aql
lo uolsd oqt ql!fl l€s aurbuaaql qlrMpu€ EZg St/,1
tool lercodsqlrMpasn eq lsno al6uelcaqc ouroua€qI
6u!ulldund uollcalu! lonl
-
o rapu l^c I r€qunu roj lalno
asa)colc-repnoc pua a^rp uorl uo[P]oJ Jo uolcaio
' ' ' ' " ' a o ^ l
tuetoU
dund uoll.alu! lenl qrsog
69t 9?t 691 ^t
091 X stl t9t 1l
6qt X]
691 ttl 69t ^t
69r XI frl 091 ^o
09L qtL eql ^:
(saa6ep) (saer6ap) (saer6ep) (saar6ap)
srällal 9anal
el6uE al6ue al6ue
apoc dund lanl apo. dund lanl
)irPU dund loaqc eur6ul )llPU dund lcaqc aur6uf
'aleld srql uo paduels sralal apoc aql asn 'paUllsr alpld uolpcllrpou e dund
ll
oql lo oOuelJoql ol pauatsels qcrqa eletd uollpcqlpou p uo peduels epoc 6uruaseql e^Eq ^eu sdund anJ
aoos dund uoFolur tonl aql oleld elpp aql uo poduels apoc 6urlles eql ur popnlc!r ere sanal apoo aql
lo
!opurllo I raqunu rol uolcaluilo lels
oql )e las dund eql qlrMpa)icaqcsr dund aql-oiots uorssorduogaql uo (CC1) aruec p?op dol le uols d
t requnu qlrn tes ourOua aql quil puEg19 Sl l toottercödsqlrMposn oq lsnu etOueloeqc eur6ueaql
6uluI dund uollcelu! lenl
' ' '
,,x, rau3-l rapu l^c I raqunu iol ]olno
asrNi90lcraluno3 pua a^up u04 uo lelor lo uo[9airo
, ' , , - a o ^ l
v d o . '
dund uolloelu! lent ^VC
ttge'91 sapoo dund lanJ
z seuesttgS g
-"t
 2 6.3544Series

Recommendedtoroue tensions
The lorque lensions below apply to components lubrjcated lightly wilh clean engine oil belore they are litted

Torque
Thread
Descrjption NM tbt tt kgl m

Setscrews, cylinder head, refer to head tightening sequence 1/2UNF

Sumpplug 3/4 UNF 34 25 3.5
Alomiserclamp 5/16 I
nleclorprpe unron nul Mt2 20
Marn bearing
- cadmtum 5/8 UNF 270 200 27,7
- phosphated
102 75 10,4
Big end bearing
- cadmrum 1/2 UNF 129 95 13,1
- phosphated
88 65 9,0
Frontoull€v 7/16UNF 125 92 12.7
1/2 UNF t08 80 11.1

2.30 perkins SeruiceData Booktetpan 1, 1997

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 Downloaded from www.Manualslib.com manuals search engine
1661 | !ed lalloo8 elPc acrruas sur{ad
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sröuolset po6uel:
sleqsea alereda!
t e I 96 0et z€ol t v qlrM peuil are qcrq^
9aualsel urel<
uF) u lql U N
uoIrsod eo^l raualseJ
anbrol
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00@ '€cuanb€s
lcoroc
€ql ur onbrol lcoxm aqt ol ure6e sraueFel aqt
'peaq rapurne aqt uo $feu uolq6rf aor6uaaql dols uoleredo ]o ernteradua]
oql'qrm ourtur pue'ot uou are a6ueuoql uo s)irpu leurou saqcear lr llun aurbueoql un] puE pels e
'(V) ur uMoqsacuönbes
oq] llun oguonboslcor03 aql ur Me]cslesqcpa
uetqbrl louols€l qaeo lo oouell eql lo a6pa eql aql ur 'Molaqelqel eql ur uMor.lsanbroi paroa
uo '(asr$icolcralunoc) el6up peroc eql lp')ireu aqt ol sreuolsel aql uolqol ^lua^a pue ^llpnper3 z
raqtoueoien (€) Morrslas qaea lo rauoo e qtM 'Moleqolqel oql eas saalcslas
sUrlur pPaqrepurl^3eql uo )ire0 alqPlrnsP a)igu pue spnlsppaqiopu[I. lo spperq]Io ^llq6r"l !
'alqelre^e sr
tou !e9! SII a6ne6 al6ue lercads6qt jl
anDrolloq- lpoqlsll
anbJol )iceqc'ouoN 8€otee v 'Z poqlou sosn fuol3el eqt
{UarnC
sle[ z/t 0 ro ,0Lz 0 e 6 z 9 z v zv Molaquaoqs z puP I spoqlou ecrNes rol srauals€l
peeq rapur6c aql uatqorlol spoqteu oMl ere eraql
sleue lo o08t 'Ez'oz'61'al '9r ', I
' e tz
! '6 'fup poull aq
lsnu ]alse6 p€€q iopurl^c eql
0 t 8 ' 1t ' g ' z ' ! v 'ezrs aroq ra6rpl aql esneceq sour6ua
s l P [z / t z r o . 0 g t lo
zE le Lz 9z zz tzle 9 uo pesn sr talseo peaq rapurl^cluorarjrp
l z ' L l ' 9 t ' z t ' [ ' 9 ' 9v
V ,,INOUI dol' pa)peu si 1l saurouasauas tge g
uJnl e lo Ued roq!nl reueFPl roqlo qlrMelqeaoueqoalurtou sr aurouattge 9
pue ttge 91 6ql oi polll la)jse6 peeq rapurllc aql
''alpo-],, qlrMpeutJoq plnoqs )icolq
'aoloq olqel eql ees
'sMarcslasaql l.ll6ualaql ol 6urproccEunl E ropurllo eql uo4 pa^ouar spnls peoq reput^c ^uV
lo Jo 'lenueu dousriloil
ped raqpnl e '(V) acuonbaslaaroc eql ur 'sMeraEes
aql uatq6qot lesl Sl/ a6ne6al6up lercadsaqt asn aql ol lap) lqnop u! tt 6utute4 patoc aqt Llttil
uosad e ^q auop aq lsnu uoteledo silll:uollneJ
:uoqt 't poqlau ut z pue t sdols Mollol
et6uB puE enbrol - z poql.fl ecuenbas snbJol peaq raputlÄ3
z sauastt98'9
 2 v8.540Series

Basic technical data

- v8.540
. TV8.540
.
: t;ltwll:3
Bill
Number ot cylinders

C y c l e . . . . . . . . . ..... Fourstroke
Induction system

v8.540 .. ..
TV8.540 . .. -"'ii'13:frXil::
Combusl on syslem .- Direct injection
Nom nal bore 108,0mm (4.25in)
Sfoke . .. 120,7mm (4.75in)
Compression ratio

v8.540 .. . ..
TV8.540 ... '
Cub c capacity . . .. . 8,85 litres
F r r i n go r d e r . . 1-8-7-5-4-3-6,2
Valve tip ciearances
-lnlel (cold)
v8.540 .. . .
TV8.540 .. . . '
Exhaust (co1d)

v8.540 . . .. . 0 . 2 5m m ( 0 . 1 0I n )
TV8.540 .. ... 0,50 mm (0.20in)
Lubncaling oil pressure
- at maximum engine speed and
norma engrnelemperalure ...... 280 kN/mz {40 tbt/in') 2,8 kgt/cm?
Coo ant lemperalure . 60'c (1{0"F)
Thermostat stans lo open . .. . .. . . 67ns"c 052J167"F))
Thermostat lul y open 85/88'C (185/190.F)
D recton ot rotaton Clockwisefrom lront
dl ng speed . . .. Fuelinjeclionpump data plate
Localon ol max mum noload speed . .. . Fuelinjeclionpump data plate
Localionol number 1 cylinder ..... ..... Fronl of lell bank al crankshalt pulley end
Location ol engine timing marks . .. ....... Scribe |nes on tuel injectionpump and pump llange
Alomiser codes VA. VB, VJ, VN, WC, FG, GU, VW, WW, WY, WZ, XA, XB, XY
Fuel pump codes .. . TBA
Location ol luel pump code . . .. . .. .. Fuet injectionpump data plate
Localion ol luel pump liming marks ...-... Fuelpump mountingllangeand pump adaptorptale
Bell tension . 45 N (10 lbl)4,5 kgf
Bell delleclion at ongesl run .. . . . . 10 mm (3/8in)

PerkinsSeruiceData Booklet Part 1. 1997

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 Downloaded from www.Manualslib.com manuals search engine
1661 ! Ued laloo8 elec öcrNas surfrad
palralelous rat llro6ulPtrrqn alll!ralsrueaaqlabJ!JJ!r E^ral! aql 1.,!rlE3lrä0s ;nl
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6ur! Erl trar.r 3q: plq s?! ollM !osrad P ^g ( t l
sqluou, S fu3^ts Pa^1auar
aqprclst azaarfluelcoEalsu pasns rolqq! luPoore' s,t3'{afuar!a/aa,llueaqlMa!48 Q)
pall, auc s ara!l J ( t J
(C) pallaqa 6 r e a 1 6r o l o u r a ! E l s ! a t P l r a l P a q ; t E q t , r r s ! l
tfs ttL
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(e)fupssara!I pslsnlpP,uE palraL: alE sea!ErEaI a I !^ E1aql :e!l :rra.,f
( C ) r a ö r P q : o q r ' r 1 a . t 1t . a . , f ,
{e) 5u se. DU€ ra adu ra6rerrcqrnl ;ql lEa f,
ra rEa patPsrpu usaq to! sEq I l luauala ral I I E aql Mauar ro lPa 3
suo !p!aa eur.!
suol p!o3 ^lsnp ^ auarlxa
ral:l r E aqt lo lMcc tsap aqt ^ldua )o r€uE3l, I E aql !?a :
ualsls raqlearq aJ bua aq: !:'a 3
(') rat.l I n 5!rlEcrqn aql lo rals !E3 3ql /idiaB
{t) o 6uLler rqn a! 6ua :qt /iaidg
(t)abnpF aultparnssard rc 6utpr)qn a!t!r:ql
dur5 6!i u ro 6u leruqn lo tunouE alt !:aq:
(C) patcaqc are sras uotp aqt tpqt arrs!f
rat flanl aqi lc sluaua a aql M?ra8
(t) räl tard aql u rateMroj t:aqf
role!ral E aqt to sl tsq a^ rp al; !raqf,
i u e l o o sl a : ! n o u ! a q l r r a L t l
uorlerado
tsr I rnaso qo qM {sqluou ro srrcq) €/!atur aql le par dd! 3q tsnur Ali nl qa q^l sainpaqcs aq1
srnoqOOO'tuan! I siNoq000!,{ra^f C
srnoq0092rua^f f sqt!cu 9ro srnoq009 fua^3 I
srnoqOOOZtuä^: C lPp y'ra^arosrnoq€,4ra^l V
salnpaqcs asueualulenl
ac tuas loea tE srauslsel asoc puE abefpa rol ll?qr ot a3u!ualu ei! a^ lla^ald poos s I
a-r6.. a ll,o .or,F.dd , o ,o o 1 rd o. po,dÖD'do o, oouu
iEU sarfpascjd pu€ spo!ad asaqt suo le n6ar l€rc aqt ot utoluoa tsnu au 6ua aql lc !o lErado aql !aqM
)s?!oqs arp qcrqM spo rad aql asn pal Elsu s au 6ua aql q3rqM ur luaud nba aql l. ralnlaelnuPu aql trq
u3^ 0 spo rad aqi lraq:) uo tErado lc suo rDUor abera/'P oi itddE spo rad eauPUalu eur a^llu6^ar0 asaql
'aauelstp aq) ueq)
)ueuooutl
aca ae uatlaaco Jo troq aül sdols puP slPls luanb4) qla rau?ada aateistp paqs uo :uollnet
spouod aoueualureu o^!lua^9id
z söuas0t9 84
-ta
 2 V8.540Series

Fuel pump codes

Fuel inlection pump

TyPe CAV Minimec,DP15or Boschlvlw
D{eclror O' rolanor lrom dilve end . . . . . .
.-...... Clockwise
Spill tlming ot CAV Minimecor Bosch MW

Sp llliming Pislon
Fue pump code lenel posIron Posiljon
BTDC BTDC
(oegrees) mm (in)
MB71/800/40211800 AB71/800/41N2350 2642A210M8/CO2h57;
MB71/800/A0211880 Rg7l /AOO/41 N23gO 2642A211MB/AOZ1A}O
MB71/800ic02l1560 BBT t /800/41N2480 2642A215R8/41N2500
MB71t800/CA2/1575 RB71/800/41N25oO 2642A215AA141N25gO 26 7,62(0.300)
R869i800/41AJ2350 RB71/800/41ÄJ2530 2642A228R8/41N2330
R869/800/414,/2530 BB71/AOO/41N2560
RB69/800/44r'J2830 RB72t8oO/41N23AO
RB71/800/41A/2330 RA72ßOA/41N2530
LB71t800112/2500 RB70/AO0/44N2910 2642A213M9/DO1/2360
LB71/AOO/22/2sOO BB71/AAO|41 N2ss0 2642A213M8/OO1 t2420
MB71/800/D01/2340 RB71/A00/41 N2660 2642A213M8/DO1/2520
MB71/800/D01/2360 BB71/aO0/41N2730 2642A214RB/44N2770
M871/800/D01/2380 RB71/AO0|44N2630 2642A215F'P./41N2550 28 8,89 (0.350)
MB71tA00/D01/2400 RB71/A00/44N2770 2642A215R8/41 N2660
MB71t800/D01/2420 RB71/800t44N2A30 2642A223R8/EO1/2720
MA711800/OA1 1252A aB7 1/AO0/44N2850'
MB71tA00lEO1t2720
LG68E/800i44Al2960 yA68E/800/44ÄJ2960 2642A20sFtS/44N2g60
RB71/800/44A,/2850" 2642421 4RB/44N2a50
RB71/800/44AJ291 0 2642A23OLG/4N2960 29 9,53 (0.37s)
RB71taA1/44 N2960
P873U900/D01/2400 p88lE/1 100/001/2610 ?BAIE/1100/EO1/2140
PB81E/1100/001/2520 PB81E/j 1o0/DO1/2620 2642A24gp8/DO1
pBBr E/r i 00/D0r/2600 pBB1E/1100/Do1/26s0 t2600 1O,85(O.427)
"uo, o"o"rä,ür,irri
'
Non vehrcle applicalions
"
Vehrcle appltcations

Static tihing of CAV DPl5

The eng ne check ang e must be !sed with spectal tool MS.678 and with
the engine sel wlh number 1
prslon al top dead cenlre (TDC) on the compression stroke.
The pump is check;d with rne pump set at lhe
slan ol Inleclron
10rn!mber 1 cylinder
Stalrclming pos(ionBTDC . . .. .
16'
T mrngcheckangle
3 12 '

PerkinsServiceDala Bookletpan 1, 1997

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 Downloaded from www.Manualslib.com manuals search engine
1661 I Ued laHoo€ eleo earruessur)l]ad
08 80t lNn z/t taaqM^tJ
9tt 008 Lot lNn 8/1 ^ellno ]uorl
9 tt 90t zvl lNn 9v6 6uue€q pua 6rg
6Z alz 982 lNn B/9 6uueaq ule!1
l z 9t oz I t x zty'l lnu uorun odrd lol3alul
L I zl lNn 9r/9 ouelc roslu0]v
l 9 LC 09 lNn t/€ 6nld duns
lNn 9v6 acuonbas enbrol ees peaq rapul^c'sMelsslas
UN
azts
uF) u lql uo[drcsaO
pParql
onbrol
poull arE ^aql oroJeq lro eu16ua uEalc q]rM ^llq6rl patecuqnl sluouoduoc ot 4dde aolaq suorsu€l enblol aql
suo!sual anDrol pepuauuosau
z sauas0t9 84
 2 v8.sqoseries

Cylinder head torque sequence

Cautlon: This operaron must be done by a person

wlh lhe cotrect taining. lf in doubt refer to the

[ /s rmpodanlthat the studs and the three d]iterent

lengthsot selscrewsare titted n their cotrect
positions
'..aia
lllusfation
type ength mm ( n) and Posilon .10) i )iC21
Stud A 16,18 .14 . 118
Selscrew Small a 2,4,6,8,12,14,
Selscrew N,ledrum a 3 , 5 , 7 , 9 , 1 3 ,1 5 ,
Note: Release the cylinder head selscrews evenly
1 7 .1 9
and gradually tn the reverse sequence to thar snown
Setscrew Laroe a 1 , 1 0 .1 1 . 2 0 . 2 1 in iA).

1 Lrghlly lubrcate lhe lhreads ol lhe studs and lhe

cylnder head selscrews and lhe lhrusl laces of lhe

2 Gradua ly and eventy lighlen the setscrews ano

nus ol each bank lo the cotrect lorque, in lhe
sequence 1A) Trghten aga n a I the setscrews and
nuts to lhe correcl lorque in the sequence (A).

E n g r n ea n d
Torque
Taslenef lype
Nm bt 1t kgl m
/8.540
anged iasteners 1 6 9 125
angeo tasleners, scanl shank
erscrews wth gasket 3681H401 1 8 5 1 3 5 14,2
arn tasleners wlh separaie
/ashers wilh gasket 3681H40j 210 1 5 5 1 , 4 7
ry8.s40
anqed lasleners 214 1 5 5 21.4

3 Fun lhe engtne unttl t reaches normal

Iemperature ot operation. Stop the eng ne Tighten
aga n al the setscrews and nuls ol each bank lo lhe
cotrecl lorque, In the sequence 1A).

2.36 PerkinsServiceDaia Booktelpan 1, I 997

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 Downloaded from www.Manualslib.com manuals search engine
'L
z66t Ued tallooS elEC acrruas su)rad
zlt saloN
IIe €l€p lsal uorsserduoC
. s6urler
0tt lelsoureql
0t'0 s6urllesale6-elsemra6reLtrooqrnl
''' uorlPulolurrosruolv
90e
' salqeluorsra^uoc
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e0€
200 sprnllaul6ualo uouecurcadS
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t vr-vo]vu3Nr0
 3 cenEnelonrr

Speciticationol engine tluids

Lubilcatingoil specification 4.108, 3.152, 4.203, 4.2032, 4.236. 4.248

6.3544,T6,3544, V8.540

N4rnimum lubricatrng
oil specittcalion
- naturaly asptraledengines
APt CC/SE
- turb0charged engines API CD/SE or CCi\.,|CD4 (1)
Lubncating oil capacity Dependenl on sump lined, see apptication users handbook

Fuelspecllication

V scosily 4.236,4.248,VA540 . . ... . 2.5/4.5centistokesat4O'C

4.108, 3.152,4.203,4.2032,
6.3544,T6.3544 2.0/4.5centistokesal 40"C
Denslv 0,835/0,855kg/lite
Drsl I al on 85% al 350"C
Avralon kerosene luels JP5 and JP8 only, relerto use/s handbook

Celane number At 4.236,4.248

Vehlcleonly 6.3544,T6.3544,V8.540 . . . . . 50 minimum
Industial/ag
6.3544,T6.3544,V8.540
414.108,3.152,4.203,4.20 . .3. .2. _ . . . 45minimum
Sulphur(2) 4.108, 4.203,4.2032,6.3544
T6.3544,V8.540 0.S7oof mass, max mum
3152,4.236,4.24A . .... 0.2%olrnass,maxrmum

Coolantspecificalion

Recommended coolanl POWERPARTantitreeze

Concenlralion ol antilreeze 50%

Corosron Inhibltor mtxl!re. Feler to use/s handbook

Must have a specilication at least as good
as 8S6580 or [4OD AL39

Coo anl capacity See app[cation user's handbook

(1)Notrecommendedlornaluralyasptratedenginesduringlhelirst20to50hoursorlorllght
oad
aDDrcatons.
(2) The or change intetual will change wilh the amounl of sulphur rn the fuet (see the table
be ow and the
lue spec ircalron)

Amounlol sulphurin the luel

Oil change nterval

<0,5 Nomal
0 . 5- 1 . 0 3/4 ol normal
1,0 1/2 of normal

Perk ns Servce Dala Booklet pad 1, 1997

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 Downloaded from www.Manualslib.com manuals search engine
166t t U€d ietloo8 Pl?o acrNas sur)irad
69t ztt 09, )rd,,b/t
90e tzz 00e 1Id,8/e
EL'I 9Zt oL, Jrd ,,ntl
160 OL 96 lJ-d ,,0/r
u Jot u tql UN
0zrspearql
enoiol leuruoN
siaualsel popeoiqt
/e 6r 0'0tl 06t 00 2 x gly{
,9Zl 9t6 ,zl 002xtt|/'l
96L sLs 8L 9Llxzlw
6tt 9ZE tt 09 t x 0tr1
z9l zz 9Ztx8N
260 99 6 00txgy!
u tbr u lql UN
ezrspearql
anbro)t€uruoN
alnu pue
992 t8t 9L'l z tvl
'8r 8t 0tv'{
zll t 8 9Z ( 8y,{
ts0 L€ I 00 ( 91,{
u ,6r u lql UN
ozrs peerql
anblol leuruoN
spnls
'sraualsel ad^l eC urruall loJ alqP]rns lou ol? sanle^ asaql t
',spPerql
&p, roJ erp salqel as€ql ur sanle^ anbrol 0
'e6upqc 'secuelalol pearql ol ro s€cepns poleqdsoqd
]snu sanle^ anbrol eql ot sa6uPqc ere elaql ll Z
'Jeuruou 3ql asn lol
lo %92+ urqlLil oq ol sesuerslol anlP^ anblol leuluou ,oclNos I
salou lerouo0
sOu!$as anbrot prPpuets
e vrvo-rvurNso
 3 celennl onrn

Conversiontables

mm N4iles Kilomefe

I j.61 l 0.62
114 o.25 6.4 1 0.04
2 3.22 2 1.24
112 0.5 2 0.08
3 4.83 3 1.86
3/4 o.75 19 . 1 3 o.12
4 6.44 4 2.49
I l 25.4 4 0 . 16
5 8.05 5 3.10
2 2 s0.8 5 o.2a
6 9.66 6 s.73
3 3 76.2 6 o.24
7 1 1. 2 7 f 4.35
4 4 1 0 1. 6 7 0.28
a 12.A7 4_97
5 5 127.O 8 0.31
I 14.48 9 5.59
6 6 152.4 I 0.35
10 16.09 10 6.21
7 7 177.8 10 0.39
20 32.19 20 12.43
I 8 203.2 20 0.79
30 4A.2A 30 18.64
I I 22A.6 30 1.18
40 64.37 40 24.85
t0 10 254.O 40
50 ao.47 50 31.07
20 20 508.0 50 1.97
ro0 160.93 100 62.14
30 30 762.0 100 3.94
40 40 1 0 1 6 . 0 I 000 39.37

lüekes Metres Feel

l 0.31 1 3.28
2 0.61 2
3 0.91 3 9.84
4 1.22 4 13.12
5 1.25 5 16.4
6 1.83 6 19.69
7 213 7 22.97
8 2.44 8 26.25
I 2.74 I 29.53
t0 3.05 l0 32.81
20 6.1 20 65.62
30 9.15 30 98.43
40 1 21 9 40 9 2 . 1I
50 15.24 50 164.04

PerkinsServiceDala Booktelparl 1. I 997

Downloaded from www.Manualslib.com manuals search engine

 Downloaded from www.Manualslib.com manuals search engine
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Atomiser information

Sel and fesel pressure

Code Holdel Nozzle alm ltblhn2)
AB tsKBL67S5t
51/ BDLL15os6435/ 175 2573 17.7
oKLL6752930 oLL150S670s
AC 2646460 2646677 17s 2513 7
BKBL67S5151 BDLL50S6372 170 2499 17.2
8C BKB35SD5260 BOLl 1056133 120 1764 12,2
BKB40SD5224 BDNl 25D6236 '135
1985 13,7
Bt\4 BKS35SD5260 BDLl 1056267 124 1764 12.2
8T BKBL67SD5151 aDLLIs056310 2573 77
BU BKBL67S5151 BDLLl50S643s 175 2573 7
BV BKAL67S51 5t BDLL1s0S6513 170 2499 17,2
CR a K B L 6 7 S ss11 BDLL150S6513 170 2499 7,2
CF BKBL67S5299 BDLL 50s6507 185 2720 1A.7
cs BKBL67S51
51 BDLL150S6s54 170 2499 17.2
CT BKBL67SD5151 BDLLl50S6555 7 7
CU BKAL67Ss1
5tl aDLLI 50s6556/ 2573 l7.7
oK116752930 oLLl 50S6556
CY oKLL66t\,,t1
1s40 o1L150M9302 230 3381 23,3
DD 8KA35S5258 BDLl 1056133 120 1764 12.2
DE 8K835S5258 8D111056267 120 1764 12,2
DF BKBL67S515 BDLL150S6558 170 2499 17,2
DL aKBL67S5299 BDLL150SY6s45 210 3087 21,3
DN,4 8KBL67S51
5 BDLLl50S6561 2573 7 7
DN BKBL67S5299 BDLLl50S6554 170 2499 17.2
BKBL67S5299/ BDLL150S6591/ 215 21.8
oKLL67s2930 o11150S6649
EC RK8L67S5268 RDLLls0S65s4 t65 2426
EE 2646466 2646825 190 2793 19.3
EG 2646466 2646A26 210 3087 21,3
EV BKB35SD526O BDLl 1056267 180 2646 18.2
FC 2646466 2646831 210 3087 2 1. 3
BKB35SD5259 BDLrr 056267 170 2499 7,2
Ft BKBL67S5299 BDLL1s0S6673 200 2940 20,3
BKA35SD5260 BDL110S668s 170 2499 17.2
FN 8K8L67S5299 BDLLl50S6639 195 2467 t9,8
BKB35SD5260 BDLl 1056267 170 2495 7,2
FS BKBL67S5299 BDLL150S6674 170 2499 17.2
2646466 2646A26 185 2720
2646460 2646A42 175 2573 7,7
BKB35SD526O aDLl 1056709 170 2495 17.2

PerkrnsSetuiceDala Bookletpad 1, 1997

Downloaded from www.Manualslib.com manuals search engine

 Downloaded from www.Manualslib.com manuals search engine
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Atomiser intormation, cantinued

Sel and resel pressure

Code Holder Nozzle aIm (lbt/in2) N,4PA
TC BKB35SD52s9 8D111056709 170 2499
2645[,,t30
1 2645i,t601 TSA TAA TBA
UB 2646522 2646724 150 2205 15.2
2645M301 2645[,1601 TBA IBA TBA
VB H454S693 NL55O 170 2499
BKBL54S5312 BDLL150S6573 170 2499 17.2
VN 2646562 2646862 200 2940 2A,3
VR oKLL54S2965 o1L150S3385 195 2467 19,8
oKLL54Ss312 o1L150S7777 195 2A6l 19,8
VU 2645C564 26466866 225 3308 22,4
2646562 2646869 210 3087 21.3
VX oKLL54S5312 oLLl 50S7777 195 2867 19,8
oKLL54S2924 oLLr 50S7777 195 2467 19,8
vz oKLL54S2924 oLLl 50s7788 195 2867 19.8
oKLL54S2924 o1L150S3385 195 286 19,8
WC 2646568 2646871 195 286 19,8
WD oKLL54S2996 o1L150S7604 195 286 19.8
oKLL54S3014 o1L150S7788 195 286
oKLL54S3014 oLL1s0s338s 195 286 19,8
oKLL54S3014 o1L150S7777 195 286 19.8
2646568 2646872 217 3190 21,9
oKLL54S30s2 oLLl 50S3385 214 3087 21.3
oKLLs4[r30s9 oL1150S8388 235 3455 23.8
oKLL54M3052 oLLl 50S7788 195 2467 19,8
2645C302 2645C602 240 3528
2645C303 2645C804 201 2955 20.4
2645C303 2645C605 235 3455 23,8
wz 2646568 2646869 195 2467 19.8
XA 2645C303 2645K601 230 3381 23,3
XB 2645C303 2645K604 235 3455 23,A
XC 2645C305 2645C608 175 2573
XD 2645C306 2645C609 170 2499 7,2
XE 264sC30s 2645C610 195 2867 19,8
2645C305 2645C615 210 3087
2645C305 2645C621 170 2499 .2
2645C305 2645C619 170 2499 7.2
XX 2645C307 264sC613 245 3602 24,8
XY 2646568 26/.6864 210 3087 21.3
xz 2645C308 2645C614 220 3234 22,3

Perkns ServiceDala BookletPan 1, 1997

Downloaded from www.Manualslib.com manuals search engine

 Downloaded from www.Manualslib.com manuals search engine
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 3 oerueRrl
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Turbocharger waste-gate settings

Wastegate tesl pressure for rod hovement of 1,OOmm (0.039 In)

The lurbochargerpan number is on the lurbochargeridentificationprale,which is rified ro rne Dodvol the
tu.boLla.ge .

Wasle-gale pressure Wasle-galepressure

Iurbocharger Tulbocharger

16l/ir2 kgl/cm2 kPa lbl/in2 k91/cm2

26744053 16 4t17 15/1.22 26744098 96 13.9 0,98
26744454 16.O/17.4 1 , 1 2 / 1 , 2 2 26744104 99/ 06 14.3/1s 0,99/1,07
26744055 17.4/1A.9 1 , 2 2 t 1 , 3 2 26744105 :t/15
26744056 1.22/1.32 26f 4410€ t4 3/15.4 o,99/1,07
2674AOs7 7.1/18.3 1 . 2 0 t 1 . 2 4 26744108 99/ o6 14.3/15.4 0,99/1,07
26f44058 1 7 . 1 / 1 4 . 3 1,2Ot128 26744122 99/106 0.99/1.O7
26744051 1,2Qt1.28 26744128 to1/109 4.6/15.8 1 . 0 2 / 1 .
2674446i u/121) 16.4/ 1.15/1.22 26744129 o 1 / 1 0 9 1 4 . 6 / 1 5 . 8 1 , O Z t 1,
2674406: 92/98 1s.3/14.2 0,93/0,99 26744130 113/120 16.4/17 15t1,22
26744064 110/103 15.9/14.9 26144131 101/109 4.6/15.8 1 . 0 2 / 1 . 1 1
26744O6i 120/130 7.4/14.9 22/1.32 2674413t 113/120 16.4t17.4 15/1,22
26 /44068 11 0 / 1 0 3 1 5 . 9 1 1 4 I 26744134 120n30 17.4/1A.9 1 , 2 2 t 1 , 3 2
26744472 1 2 0 / 1 3 0 17.4/14S 26744143 99/106 0,99/1.07
26744O75 tü126 7.1/14.3 20/1.2A 26744144 113/120 16.4/17.4 1 . 1 5 / 1 . 2 2
26 /4AO7l 113/120 16.4117.4 267441 46 113/120 16.4t17 1, 1 5 1t ,22
267 44079 120/130 7.4t149 1,22/1,32 2674Ä.149 133/143 19.3t20.7 1 . 3 5 / 1 . 4 5
2674AOA1 88/98 12.4/14.2 0.90/1.00 2674415C 1 4 5 / 1 5 5 21.O/22.s 1,47/1,58
26744082 aa/92 12.8/13.5 0,90/o,93 26744304 105 15.2 o
26744044 tla/128 / . 1 /1 4 6 r,20/t,30 26744305 105 15.2 1.04
26744085 6U/94 12.4/142 2674^30e 96 13.9 0,98
2674AOa6 11A/126 i 7 1 / 1 83 1.20/1.24 145 21.O
26744087 10 1 / 10 9 //15 n 103/1,09 26744313 96 13.9 0.98
26744089 50 21.4 26744314 145 21.O
2674409: 110 5.9 2674431 5 r50 21.4 52
26744094 105 12.5 26744316 96 13.9 0,98
26744095 145 21.O 26744701 55 1.58
2674409t 150 21.8 .52

Thermostatratings

Nomtnal lemperalure "Slan 'Fully

to open open Minimum valve lilt,
slamped On lhermostal by-pass valve remperalure remperalure lully open

82"C 77./85.C 92./98"C 9mm

080"F) (170Y185"F) (198'/208.F) (0.35in)
71' C 67'n5"C 85V88'C 9mm
( 16 0 " F ) (1ssvl 67"F) {1854190"F) (0.35 in)

Perkins Serurce Data Booktet Pad 1.1997

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 Downloaded from www.Manualslib.com manuals search engine
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PerkrnsSeruiceDataBooklelPan 1, 1997

Downloaded from www.Manualslib.com manuals search engine

 SPerkins
Perkins Engines Company Limited
Peterborough PE1 sNA United Kinodom

Printed in Engtand

Downloaded from www.Manualslib.com manuals search engine