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Perkins 4.154 Workshop Manual
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Perkins 4.154 Workshop Manual

Perkins 4.154 Workshop Manual

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4.154
http://www.barringtondieselclub.co.za/
P R IN T ED IN U.S.A.

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Summary of Contents for Perkins 4.154

  • Page 1 Perkins Engines workshop manual 4.154 http://www.barringtondieselclub.co.za/ P R IN T ED IN U.S.A.
  • Page 2 Published by the Service Publications D epartm ent o f Perkins Engines Ltd., and printed in England by Abbey Printers, High Street, Spalding, Lincs.

  • Page 3: Perkins Companies

    Telephone : 562-043/562-322/562-992. Telex : 11341 YU IMR. C a b le s: 'Indmotor' Belgrade. In addition to the above, there are Perkins Distributors in the majority ot countries throughout the world. For further details, apply to Perkins Engines Ltd., Peterborough,...
  • Page 4 CONTENTS General Inform ation SECTION A Cylinder Head SECTION B Pistons and Connecting Rods SECTION C Cylinder Block and Liners SECTION D Crankshaft and Main Bearings SECTION E Timing Case an d Drive SECTION F Flywheel and Flywheel Housing SECTION G Timing SECTION H Lubricating System...
  • Page 5 Unified Threads and Engine Number Location All THREADS used on the 4.154 engine excepting proprietary equipm ent Unilied Series and American Pipe Series. The ENC1INP NUMBER is located on the cylinder block immediately behind the fuel pump. This number should be quoted in full when seeking infor­...
  • Page 6 ENGINE VIEWS View o f Fron t Left Hand Side of 4.154 Engine Perkins engines are built to individual requirem ents to suit the applications for which they are intended and the engine views do not necessarily typify any particular specification.
  • Page 7 V iew o f R e a r R ig h t f la n d S id e o f 4 .! 5 4 E n g in e...
  • Page 8 Exploded View of Cylinder Head Assembly...
  • Page 10 FxpU iW Views of Crankshaft, Connecting Rod and Piston Assemblies...
  • Page 11 Exploded View of Timing Case, Drive and Camshaft Assembly...
  • Page 12 Exploded View o f Water Pump Assembly...

  • Page 13: General Information

    Mechanical G overnor 55 bhp at 3,000 rev/m in Minimum Governed Speed 1800 rev/m in N ote: The above ratings can vary according to application. For details of individual ratings, apply to Service D epartm ent, Perkins Engines, L td., Peterborough.

  • Page 14: De Rating For Altitude

    Any necessary adjustments in this respect to the fuel pump, should be carried out by the C.A.V. dealer for the territory concerned. For any further information apply to Service Department, Perkins Engines Ltd., Peterborough, or to Overseas Companies listed on Page 2.

  • Page 15: Recommended Torque Tensions

    General Information A3 SERVICE WEAR LIMITS The following wear limits indicate the condition when it is recom m ended th a t the respective items should be serviced or replaced. Cylinder Head Bow Transverse 0.003 in (0,08 mm) concave 0.005 in (0,13 mm) convex Longitudinal 0.006 in (0,15 mm) Maximum Bore Wear...
  • Page 16 General Information A4 OPERATING INSTRUCTIONS Starting the engine. If the w eather or engine is warm, turn switch to posi­ tion “ R” and ensure the engine stop control is in the run position. Adjust the accelerator to the fully open position and engage the starter m otor by turning the starter m otor switch in a clockwise direction to the “...

  • Page 17: Post Delivery Checkover

    They are periods in Kilometres which should be used in place o f mOes in relevant countries. Check level of coolant. O perators of 4.154 engines are reminded that the Check level of lubricating oil in sump (make sure the above Preventative Maintenance schedule is general in vehicle or machine is standing level).

  • Page 18: Preservation Of Laid-Up Engine

    PRESERVATION OF LAID-UP ENGINE Remove the battery or batteries from the Where an application which is powered by a Perkins engine and top up the cells with distilled engine is to be laid-up for several m onths, it is advis­...
  • Page 19 General Information A7 The proprietary brands of oils listed are recom­ PREPARING THE ENGINE FOR RETURN TO mended for the purpose by the respective oil com­ SERVICE panies. They may n o t be available in all parts o f the When the engine is to be returned to service, th e fol­...

  • Page 20: Frost Precautions

    Air vent and prime the pum p (see page L.7). products are suitable for use in Perkins Engines, also to ensure th at their products will have no harmful effect on the cooling system generally. It is our ex­...
  • Page 21 General Information A9 fault findin g chart Fault Possible Cause Low cranking speed 1. 2, 3, 4. Will not start 5. 6, 7, 8, 9, 10, 12. 13, 14, 15, 16, 17. 18, 19. 20. 22, 31. 32. 33. Difficult starting 5, 7, 8, 9.

  • Page 22: Cylinder Head

    Cylinder Head B1 Section B CYLINDER HEAD operate in cast iron guides pressed in to the head. The The cylinder head is a one piece high d uty iron cast­ u p p e r p a rt com bustion chamber ing of “...
  • Page 23 Cylinder Head B2 Valves. Inlet Valve stem diam eter 0.312/0.313 in (7,92/7,95 mm) Clearance fit of Valve stem in Guide 0.0015/0.0035 in (0,04/0,09 mm) Valve head diam eter 1 -591/1.598 in (40,41/40,59 mm) Valve face angle Valve depth below Cylinder Head face (Production) 0.029/0.041 in (0,74/1,04 mm) (Service) 0.060 in (1,52 mm)
  • Page 24 Fig.B.3. VALVE SEAT INSERTS cannot be fitted to the 4.154 engine. Valve Guides When renewing valve guides, remove th e w orn guides by using a suitable dolly and press. F o r the replace­...
  • Page 25 Cylinder Head B4 Valve Springs Check th e valve springs for pressures developed at specific lengths against the figures quoted on Page B.2, and for any signs o f deterioration caused by fatigue. It is advisable to fit new springs when an overhaul is undertaken.
  • Page 26 Cylinder Head B5 Refitment of Cylinder Head With the valves rocking on No. 2 cylinder, set the clearance on No. 3 cylinder. Before refitting the cylinder head, ensure th at the oilway in the block to p face and cylinder head is With the valves rocking on No.

  • Page 27: Pistons And Connecting Rods

    Pistons and Connecting Rods Cl Section C' PISTONS AND CONNECTING RODS The pistons are m anufactured from high silicon aluminium -alloy, flat topped w ith three compression connecting rods m anufactured from rings, and one scraper ring above the gudgeon pin and one below it.
  • Page 28 Pistons and Connecting Rods C2 Connecting Rod End Float 0.0095/0.0131 in (0,24/0,33 mm) Big End Bolt Size 7/16 in (11,11 mm) Thread of Bolt U.N.F. Type of Big End N ut Self Locking Note: When Big End nuts are removed, they must be replaced by new ones. Connecting Rod alignment Large and small end Connecting Rod bores must be square and parallel with each oth er within the lim its o f ±...
  • Page 29 Pistons and Connecting Rods C3 Removal o f Piston and Rods Sump On some applications it will be found necessary to remove the engine from the chassis because the engine support brackets are fastened to the sump. The pistons and connecting rods are removed from the cylinder block through the to p of the cylinder bores, see Fig.
  • Page 30 Pistons and Connecting Rods C4 Connecting Rods To renew small end bushes, remove the worn bushes by means of a suitable press and dolly. Press in the new bushes, making sure that the oil holes in the bush and rod small end align when fitted. Ream out the new bush to dimension quoted on Page C.2, ensuring squareness with big end bore.
  • Page 31 Pistons and Connecting Rods CS assembly num ber (A to F) is the connecting rod weight code. i When refitting the connecting rod bearings, ensure j that the locating tabs o f the bearings are correctly I located in the machined recesses of the rod and cap, i see Fig.

  • Page 32: Cylinder Block And Liners

    Cylinder Block and Liners D1 Section D CYLINDER BLOCK AND LINERS cylinder block is cast integrally with the Ventilation of the crankcase is by a breather pipe crankcase in high duty cast iron. Flanged cast iron situated on the cylinder head top cover, which is “...
  • Page 33 Cylinder Block and Liners D2 Cylinder Block The top face of the cylinder block may be skimmed up to a maximum of 0.020 in (0,5 1 mm). Where this is necessary, the cylinder liner recess depth and piston height should be lowered by the same am ount, and the cylinder block face (outside the gasket area) marked accordingly.

  • Page 34: Crankshaft And Main Bearings

    Crankshaft and Main Bearings El Section E CRANKSHAFT AND MAIN BEARINGS The crankshaft is forged from chrome-molybdenum Five main bearings are fitted, which are replaceable steel w ith integral balance weights on the front, rear thin wall, aluminium tin lined, steel backed and re­ and two centre webs.
  • Page 35 Crankshaft and Main Bearings E2 Crankshaft End Float If the thrust washers are to be renewed, remove the centre main bearing cap which provides the location for each o f the two bottom halves of the thrust washers. With the cap removed, the tw o to p halves of the washers are.accessible, see Figs.
  • Page 36 Crankshaft and Main Bearings E3 Lightly coat the cylinder block and bearing cap side of the jo in t with jointing com pound, and place the joint in position, ensuring that the securing holes are aligned. Lightly coat the b u tt faces of the half housings with jointing com pound.
  • Page 37 Crankshaft and Main Bearings E4 Oil Throw er Flange When refitting the crankshaft, do not omit to fit the oil throw er flange, see Fig. E.6, o nto the front end of the crankshaft before fitting the timing case cover and crankshaft pulley.
  • Page 38 Crankshaft and Main Bearings ES Crankshaft Regrind Data 0.010 in (0,25 mm ) 0.020 in (0,51 mm ) 0.030 in (0,76 mm) Undersize Undersize Undersize 2.7385/2.739 in 2.7285/2.729 in 2.71 85/2.719 in (69,56/69,57 m m ) (69,30/69,32 mm) (68,80/68,81 mm) 2.2385/2.239 in 2.2285/2.229 in 2.2185/2.219 in...

  • Page 39: Timing Case And Drive

    Timing Case and Drive FI Section F TIMING CASE AND DRIVE A helical gear drive is used, the timing gear train consisting of hardened steel crankshaft and idler gears driving cast iron cam shaft and fuel pum p gears, provi­ sion being made for fuel pum p timing adjustm ent.
  • Page 40 Timing Case and Drive F2 Fuel Pump Gear, Hub and A daptor for Hydraulically Governed Engines inside Diameter of Gear for Fuel Pump 1.7507/1.7516 in (44,47/44,49 mm) Drive Hub Spigot 1.7496/1.7503 in (44,44/44,46 mm) Drive Hub Gear Spigot 0.0004/0.002 in (0,01/0,05 mm) Clearance fit of Gear on Hub Spigot 1.4063/1.4076 in (35,72/35,75 mm) A daptor Parent Bore Diameter for Bushes...
  • Page 41 Timing Case and Drive F3 To Remove the Timing Case The timing case is also attached to the sum p by two setscrews, and to prevent damage to the sump joints take great care when separating the case from the sump joints or, lower the sump and com pletely renew the sum p joints on reassembling.
  • Page 42 Timing Case and Drive F4 Refit the timing gears ensuring that the timing marks align. Refit timing case cover using the crankshaft pulley for correct location of oil seal and cover. To Renew the F ront Oil Seal (F ro n t cover removed) Press o u t the old seal from the timing case cover using a suitable dolly and press, supporting the cover in the area o f the seal bore.
  • Page 43 Timing Case and Drive F5 Fit the retaining plate, Fig. F.6, No. 1 and tighten tw o new self locking nuts to a torque of 19— 21 Ibf ft (2 ,6 -2 ,9 kgf m) Fig. F.6. No. 2. Check the end float of the gear on the hub to a dim ension o f 0.006/0.012 in (0,15/0,30 mm).
  • Page 44 Refit idler gear and tim e engine. Check backlash which should be 0.004/0,008 in (0,10/0,20 mm). To Fit New Fuel Pump Gear In the event of a new fuel pump gear being required, this will be supplied w ithout timing marks and to ensure correct fitm ent of the gear and timing of the fuel injection pum p, the following procedure should be adopted.
  • Page 45 Timing Case and Drive F7 With the gear removed, withdraw the hub. See Fig. F.10. To Refit the Fuel Pump Drive Hub Following the reverse procedure, refit the hub. Remove the idler gear to facilitate timing. Refit the fuel pump gear as described in the previous sub-section.
  • Page 46 Timing Case and Drive F8 Refit the idler gear, ensuring th a t the tim ing marks on the teeth of idler gear/fuel pump gear align. ADJUST THE BACKLASH manipulate the adaptor housing until a figure of 0.004/0.008 in (0,10/0,20 mm) is obtained, and tighten the housing to block setscrews.
  • Page 47 Timing Case and Drive F9 Invert the engine, remove the sump and lubricating oil pump assembly, See Page J.3. Remove the front timing case cover, idler gear and camshaft gear. See Page F.3. Remove the cam shaft th ru st pad secured to the cylinder block by tw o setscrews, See Fig.

  • Page 48: Flywheel And Flywheel Housing

    Flywheel and Flywheel Housing G1 Section G’ FLYWHEEL AND FLYWHEEL HOUSING To Remove th e Flywheel Six setscrews and plain washers secure the flywheel to the crankshaft flange. The setscrews are tightened to a torque o f 80 Ibf ft {11,1 kgf m) To facilitate safe flywheel removal, it is recommended that tw o diametrically opposed securing setscrews are removed and in their place, fit two suitably sized...
  • Page 49 Flywheel and Flywheel Housing G2 To Remove the Flywheel Housing Remove the flywheel and starter m otor. Unscrew the securing setscrews and tap the housing carefully to dislodge if from the locating dowels. To Refit the Flywheel Housing Ensure th a t the rear face of the cylinder block and the mating face of the flywheel housing are clean and free from burrs.
  • Page 50 Section H Timing HI TIMING Because tim ing gears are fitted on the 4.154 engine, it is unlikely th a t tim ing will alter unless the gears are refitted in the wrong position during an overhaul. The removal of the cylinder head does n o t affect the timing of th e engine.
  • Page 51 Timing H2 Remove the rocker shaft. Turn the crankshaft until No. 1 piston is at T.D.C., on compression stroke. At this point the keyway in the crankshaft spigot will be upperm ost. Fit the camshaft gear to its spigot, locating on the key and secure with setscrew and tab-washer.
  • Page 52 Timing H3 With hydraulically governed pum ps, the scribed tine on the pump m ounting flange should align with the scribed line on the m ounting flange of the fuel pum p adaptor, see Fig. H,3. To obtain access to the fuel pum p rotor markings, it is necessary to remove the fuel return adaptor plate for hydraulically governed pum ps, or the inspection cover on the side of the body of mechanically...
  • Page 53 Timing H4 Checking Fuel Pump Timing (Hydraulically governed) j Ensure pum p timing circlip is correctly positioned as i previously described. Ensure that the scribed lines on the fuel pump mounting flange and adaptor end plate align. Position No. 1 piston at T.D.C. on the compression stroke.

  • Page 54: Lubricating System

    Lubricating System J1 Section J LUBRICATING SYSTEM The lubrication o f the engine is by full pressure feed shaft main bearings. An oil control feed is incor­ from a rotor type oil pum p driven by spiral gears porated in No. 1 camshaft journal from which an from the camshaft.
  • Page 55 Lubricating System J2 LUBRICATING OIL SYSTEM DATA AND PUMP DIMENSIONS Lubricating Oil Pressure 30/60 lbf/in2 (2,1/4,2 kgf/cm : ) at maximum speed and normal operating tem perature Sump Capacity Varies according to application Dipstick Position Either side of engine Lubricating Oil Pump Type R otor Number of Lobes - Inner R otor...
  • Page 56 Lubricating System J3 Removal of Oil Sump On some applications it will be found that the sump cannot be removed unless the engine is either supported, or removed from the chassis, because the engine bearers are secured to the sides of the sump. To Refit the Oil Sump Prior to refitting the sump, new crankcase to sump joints and new front and rear cork join ts must be...
  • Page 57 Lubricating System J4 Remove the outer ro to r, noting th a t there is a chamfer at one end. The gear can now be removed using a suitable puller. Withdraw the shaft complete w ith inner ro to r from the pump body .
  • Page 58 Lubricating System J5 CHI Filters [ There are tw o types o f oil filter used. Earlier engines ( had a removable bowl and separate element whilst I current engines have a spin-on filter which consists o f I a canister w hich is a com bined casing and element. Oil Filter - To Remove and Replace the Filter Elem ent...
  • Page 59 Cooling System K1 Section K' COOLING SYSTEM A centrifugal type w ater pum p, m ounted on the front o f the engine and belt driven from the crankshaft, delivers coolant directly into a gallery cast in the cylinder block. C oolant is delivered to the cylinder head through jets to the valve bridge and fishtail area in th e com bustion chamber inserts.
  • Page 60 Fan Belt - to Adjust Adjust by first slackening the generator adjusting lever setscrew, the lever to the generator support bracket and to support bracket bolts. Move the generator so that the tension is such that w ithout undue pressure, the thum b applied mid-way on the longest unsupported length of belt, can depress it approxim ately % in.( 10 mm), see Fig.
  • Page 61 Cooling System K3 Remove seal and counter face from shaft. On some applications, the w ater pum p body is in two parts. The splitting apart of these two halves will enable the shaft com plete w ith impeller to be pressed o u t o f the pump body.
  • Page 62 Cooling System K4 To Test the Thermostat Immerse the therm ostat in w ater and heat, checking the tem perature of the water. If the therm ostat does not open within the required tem perature range, see Page K .l, fit a replacement, because no adjustm ent is possible.

  • Page 63: Fuel System Data

    Fuel System LI Section'L' FUEL SYSTEM of the cylinder block and is driven by an eccentric on A distributor type fuel injection pum p is mounted the camshaft. The atomisers are positioned vertically horizontally at the rear of the timing case on the left on the fuel pum p side o f the cylinder head, and hand side of the cylinder block, and is driven by the contain pintle type nozzles.
  • Page 64 Im portant N ote The type of fuel pump and atomisers fitted to the 4.154 engine may vary according to application and rating. Reference should therefore be made to the appropriate Parts Literature to ensure correct replacem ents are fitted...
  • Page 65 Fuel System L3 Testing th e Lift Pump F itted to the Engine Disconnect the outlet fuel pipe. Rotate the engine, or operate the hand priming lever. A spurt of fuel should emit from the outlet port once every tw o engine revolutions, or every tim e the hand priming lever is depressed.
  • Page 66 Fuel System L4 When re-assembling the tw o pum p halves, push the rocker arm towards the pump until the diaphragm is level w ith the body flanges. The cover assembly can now be placed in position, w ith th e file marks aligned.
  • Page 67 Fuel System L5 The fuel pump gear will remain in mesh w ith the idler Maximum Speed Setting gear, and will only drop against the inside of the timing case approxim ately 1/8 in <3,17 mm). The maximum speed screw is set and sealed by the m anufacturers and must n o t be altered in any way Precaution must be taken th a t the engine is not unless factory authority is first obtained.
  • Page 68 Maintenance Atomisers should be taken o u t for exam ination at regular intervals. Refer to Preventative Maintenance, Page A .5. NO ATTEMPT SHOULD BE MADE TO ADJUST T H E IN JE C T IO N PRESSURE WITHOUT P R O P E R TESTING PUMP PRESSURE...
  • Page 69 A w orn valve will cause fuel to leak into the inlet manifold causing a sm oky exhaust and excessive fuel consum ption. 4.154 engines are fitted w ith efficient starting equipm ent, and no responsibility can b e accepted for any damage caused by unauthorised starting aids.
  • Page 70 Turn the engine until fuel, free from air, issues from b oth fuel pipes. Tighten the unions on b o th fuel pipes, and the engine is ready for starting. For engines fitted with mechanical type fuel pumps and fuel filters w ith air vent valves, the following procedure is necessary.

  • Page 71: Air Cleaner

    Section M Air Cleaner M l AIR CLEANER General O perating conditions play the most im portant part in* deciding how frequently it is necessary to service the aircleaner. Vehicle or machines operating on normal road conditions usually experienced in the United Kingdom, or industrial engines operating in relatively clean conditions in w hich th e concentration o f dust is minimal, require the air cleaner to be serviced at...
  • Page 72 Restriction Indicator If a restriction indicator is fitted it should be located in the transfer piping betw een air cleaner outlet and engine manifold away from bends or elbows. It will indicate' by means of a visual signal when to service the element.
  • Page 73 Air Cleaner N ote: When replacing an air filter assembly, care should be taken that the correct assembly is fitted. Owing to the similar appearance of the vertically and horizontally m ounted unit, it is possible to replace one w ith the other, and incorrectly connect the inlet and outlet trunking in the same m anner as the displaced unit.
  • Page 74 Air Cleaner M4 Element Renewal Unclamp the pre-cleaner panel and move to one side. Pull out the dirty single unit, multiple elem ent filter cartridge and replace with a new one. Locate the pre-cleaner panel and re-clamp in place. Wanting U nder no circumstances should petrol/gasoline be used for cleaning any part, filter element or filter body, o f the air cleaner.

  • Page 75: Electrical System

    Electrical System N1 Section N ELECTRICAL SYSTEM Alternator Lucas or C.A.V. M anufacturer 11 AC or ACS Type Clockwise viewed from drive end R otation 43 amps at 13.5 volts Maximum o utp ut 1 2 v o lt(h o t) 11 AC 55 amps at 13.S volts Maximum o utp ut 12 volt (hot) AC5 1000 rev/min...
  • Page 76 E lectrical S y ste m N 2 Maintenance ALTERNATOR Models ACS with 440 Regulator (See Fig. N .I.) The alternator charging system will normally require very little attention, b u t it should be kept free from and 11 AC w ith 4T R Control Box (See Fig. N.2.) build-up of dirt, and a check made if it fails to keep the battery charged.
  • Page 77 Electrical System N3 Close the warning light switch (m aster electric Warning lamp does n o t go out switch on dashboard) when the warning lamp w hen running and Ammeter should light up. shows reduced o u tp u t with full output only at maximum Switch on a 10—15 amperes load such as lights, speed...
  • Page 78 E lectrica l S y ste m N 4 Check Warning Light Control Test 3 If warning light does not function either by remaining Checking or Adjusting the Voltage Setting “ o n ” or “ o f f ’, but the system is charging satisfactor­ ily, connect voltm eter betw een the alternator “...
  • Page 79 Electrical System N5 Dynamo Servicing Models C40A and C40L Testing in Position to Locate Fault in Charging Circuit. General Inspect the driving belt and adjust if necessary. The C40A is a non-ventilated u n it.lt will be found Check the connections on the com m utator end fitted to applications such as agricultural machines, bracket.
  • Page 80 Electrical System N6 Arm ature braking system to ensure rapid The lamps do not dim, the voltm eter return to rest when the start b u tto n is reading remains steady at about 12 volts, released. and the m otor does not crank the engine. R outine Maintenance Connect voltm eter from solenoid term inal ‘BAT’, to starter yoke and operate starter;...
  • Page 81 Electrical System N7 Starter Motor It is essential that replacement brushes are the same grade as those originally fitted. Genuine spares should Model M50 always be used. To remove the brushes, unscrew the four fixing screws, one to each brush. In re­ assembling cate must be taken to reconnect the field Genera] Description coil and interconnectorleads, held by tw o of the...
  • Page 82 Exhauster PI Section P EXHAUSTER Description The H.175 type exhauster is a high speed, rotary, sliding vane u nit, w ith an eccentrically mounted rotor. At all speeds, the roto r blades Fig. P .l , No. are kept in contact with the bore of the body by centrifugal force, assisted by the hydraulic action of the oil beneath the blades.
  • Page 83 Exhauster P2 Servicing the Exhauster Unit Every 60,000 miles (90,000 km ) or 2400 running hours. Remove and dism antle the exhauster, and thoroughly clean and inspect for wear and damage. After removing the grease and dirt from the exterior, clean with a solvent and brush.
  • Page 84 Exhauster P3 End float of rotor in the exhauster body should be 0.0015/0.0035 in (0,04/0,09 mm). Rotate the rotor b y hand to ensure th a t it turns w ithout binding after tightening the end cover set­ screws. Screw the oil check valve and union, together w ith the copper washers and tighten.
  • Page 85 Marine Engines Q1 Section Of 4.154 marine engine General Data Four Cylinder, Four Stroke, In-Line T y p e ............... in (88,9 mm) Bore (N o m in al)..........4.0 in (101,6 mm) S t r o k e ............
  • Page 86 Marine Engines Q2 Dimensions M O D E L 71 W A R N E R " V " D R I V E...
  • Page 87 Marine Engines Q3 Engine Views P e rk in s e n g in e s are built to in divid u a l re q u ire m e n ts to suit the a p p lic a tio n s for w h ic h they are in te n d ed a n d th e se e n g in e v ie w s d o n o t n e c e ssa rily typify a n y particular spe cification .
  • Page 88 Marine Engines Q4 Preventive Maintenance If a Parkins marine diesel engine is to give long and troubiefree service, it is imperative that it be maintained in accordance with the following Periodical Attentions: — Daily Check coolant level in header tank. Check su m p oil level.
  • Page 89 Marine Engines Q5 Gearboxes Transm issions incorporating reduction gear m ust have m eans of stopping the transm ission output shaft from prolonged or continuous freewheeling. Th is is because the engine, being stopped, does not drive the oil pum p in the gearbox.
  • Page 90 Marine Engines Q6 T o Dismantle the Sea Water Pump Refit the pum p to the cylinder block front face, securing it with spring w ashers and setscrews. Rem ove the end cover fixed to the water pump body by Reconnect the by-pass and water inlet hoses.

  • Page 91: Fresh Water System

    Marine Engines Q7 Fresh water heat exchanger FRESH WATER SYSTEM To water injected exhaust or Heat exchanger overboard SEA WATER CIRCUIT Sea water inlet...
  • Page 92 Marine Engines Q8 Heat Exchanger To Test the Thermostat (Refer to Engine views, page Q3) If it is suspected that the thermostat is not operating correctly it m ay be tested in the follow ing manner. The heal exchanger unit is com bined with the exhaust manifold and header tank a s a single assembly.
  • Page 93 To Remove the Engine/Gearbox Oil Cooler (Refer to Engine views, page Q3). If a sump drain pump is fitted it will have to be removed as follows: - Unscrew the union securing the drain pump to the sump. The clamp which secures the pump body to the cooler support bracket with two nuts and bolts may now be removed to enable the pump assembly to be drawn out of the sump.
  • Page 94 Lubricating Oils Lubricating oils should meet the requirements of the U.S. Ordnance Specifications MIL-L-46152 or MIL-L-2104C. The lubricating oils for use in Perkins Diesel engines should have a minimum Vis­ cosity index of 80. Some of these oils are listed below. Any other oils which meet these specifications are also suit­...
  • Page 95 Abbreviations o f Technical Terms Applicable to Service Literature Where it is found necessary to use abbreviations in Service Literature the units and symbols adopted are those laid down in British Standards Publications 1991, A glossary of such term s with their British Standard equivalent is given below for reference purposes. G L O S S A R Y O F T E R M S TERM BRITISH STANDARD...

  • Page 96: A P P R O V E D Service T O O Ls

    M/F. 863961 Horizontal Turbo 6430754 6.372 — — - PD.1D-7 A D A P T O R FO R PD .10 4.154 A 16.5 mm (21/32") distance place /J B e used to replace valve guides to a set height.
  • Page 97 Tool No. Description Application PD.1D-8 SH O R T V A LV E G U ID E V8.510 (Current) R E P L A C E R / A D A P T O R V8.540 20 mm (0,787") No.8 P IST O N RIN G S Q U E E Z E R All Types PD.41B...
  • Page 98 Application Tool No. Description PD .140-2 FU EL PU M P T H R U ST C O L L A R 6.354 Se riss R E M O V E R / R E P L A C E R A D A P T O R S 6.372 PD.141 TIM IN G C O V E R O IL S E A L R E P L A C E R...
  • Page 99 A D A P T O R S FO R PD.155A All types Used to remove water pump pulleys. A lso suitable to remove Camshaft Gears on 4.236, 6.354 and 4.154. PD.155-4A A D A P T O R S F O R PD.155A 3.144 Used to remove Oil Pump Gear.
  • Page 100 V A L V E S P R IN G C O M P R E S S O R 611 SB All types PD.6118-1 A D A P T O R F O R 6118B 4.99 4.107 4.108 4.154 PD .6118-3 A D A P T O R F O R 611BB 3.144 3.152 4.192 4.203 4.270 4.300...
  • Page 101 Tool No. Description Application B118B-5 A D A P T O R FOR 6118B T6.354-3...
  • Page 102 316-10 Pilot ( % " dia. Valve Guide) 3.152 4.192 4.203 S.286 6.305 4.99 4.107 4.108 4.154 4.270 316-12 Pilot ( j " dia. Valve Guide| 4.300 4.236 (With Valve G u id e s) 6.354 6.372 4.212 4.248 A4.300 A4.318...
  • Page 103 P D 317-29 4.270 Inlet Valve Seat Cutter 4.300 A4.300 A4.318 " PD 317-35M Valve Seat Cutter Exhaust D3.152 35° Seats 4.154 PD.317-37M Valve Seat Cutter Exhaust 317-30 Valve Seat Cutter D3.152) Inlet and D4.203{ Exhaust V8.510) Inlet and V8.540 j Exhaust 4.154...
  • Page 104 Tool No. Description Application 317G-25 Valve Seat Glazebreaker P3.144 Inlet 3.152 4.192 4.203 6.288 6.305 Exhaust 4.270 4.300 A4.318 317G-30 D3.152 Inlet and D4.203 Exhaust VS.510 ' VS.540 4.212 inlet 4.236 4.248 A4.300 A4.318 6.354 6.372 4.270 Exhaust...
  • Page 105 EXAMPLES OF SERVICE FACILITIES Service Publications The following Service Literature may be purchased through your local Perkins Distributor. Workshop Manuals Workshop Data Operators Handbooks Turbocharger Service Instructions Crankshaft Regrinding. Valve Seat Inserting and Cylinder Head Skimming Simms Fuel Pump Workshop Manual...
  • Page 106 INDEX C ontents Page 3 A daptor, Fuel Pump Drive Cooling System, Type ........(Hydraulic) Data ..........Crankshaft, Data ..........E .l Drive Hub, to R e m o v e ........Drive Hub, to Refit ........Description ..........E .l End F lo a t............
  • Page 107 Shaft, Rocker, D a t a ......... Overheating, Fault Finding ......Description ..........A sse m b ly ............Perpetuity, Perkins P la n ........Appendix Speed Setting, Fuel Pump ......Pipes, F u e l ............Springs, Valve, D a ta .........
  • Page 108 Marks, Timing, G e a rs ........H .l To Remove ..........Pin, Timing ............H .l Re-set T im in g ............H .l Tappets, To R e f it..........T orque, Recom mended T e n sio n s....... To Remove ..........