Perkins 4.135 Manuals

Manuals and User Guides for Perkins 4.135. We have 1 Perkins 4.135 manual available for free PDF download: Workshop Manual

Perkins 4.135 Workshop Manual (94 pages)

200 Series

Brand: Perkins | Category: Engine | Size: 34 MB

Contents
2
General Information Contents
3
Introduction
4
Safety Precautions
5
Engine Identification
6
Running-In Procedure
6
Engine Number Position
6
Powerpart Consumable Products
7
Engine Views
9
Front/Left Side of 4.135 Engine
10
Rear/Right Side of 4.135 Engine
10
Front/Left Side of 4.154 Engine
11
Rear/Right Side of 4.154 Engine
11
Front/Left Side of 4.182 Engine
12
Rear/Right Side of 4.182 Engine
12
Technical Data
13
Emngine Data
14
Approximate Installed Dry Engine Weights
14
Rating Details
15
Component Data and Dimensions
16
Cylinder Block
16
Cylinder Liners
16
Pistons - 4.135
16
Pistons - 4.154
17
Pistons - 4.182
17
Piston Rings
17
Gudgeon Pin
17
Connecting Rods
18
Connecting Rod Alignment
18
Connect Rod Bearings
18
Crankshaft
18
Camshaft
19
Cylinder Head
19
Valve Guides
19
Inlet Valves
19
Exhaust Valaves
20
Outer Valve Springs
20
Inner Valve Springs
20
Tappets
20
Idler Gear and Hub
21
Timing Gears
21
Lubricating Oil Recommendations
21
Lubricating Oil Pump Clearances
21
Thermostat
22
Fuel Recommendations
22
Fuel Injection Pump
22
Atomisers
22
Maintenance
23
Preventive Maintenance
24
Post Delivery Service
25
Engine Coolant
25
Protection of an Engine Not in Service
26
Fault Diagnosis
27
Fault Diagnosis Chart
28
Code List of Possible Causes
28
To Remove Cylinder Head
30
Rocker Assembly Removal
30
To Remove Valves
31
Valve and Valve Seat Overhaul
31
Standard Valve Stem Height
31
Maximum Permissible Valve Stem Height
31
Valve Springs
32
Rocker Assembly
32
Valve Guide Protrusion Check
32
Valve Spring Distortion Check
32
To Renew Rocker Lever Bush
33
Cylinder Head Inspection
33
Combustion Chamber Inserts
33
Rocker Lever Assembly
33
To Fit Valves
34
To Fit Cylinder Head
34
Expansion Plug Location
34
Cylinder Head Location Thimbles
34
To Adjust Valve Tip Clearances
35
Exhaust Manifold Installation
35
Inlet Manifold Installation
35
Valve Tip Clearance Adjustment
35
Pistons and Connecting Rods
36
To Remove Pistons and Connecting Rods
37
To Remove Pistons from Connecting Rods
37
Inspection
37
Piston and Connecting Rod Assembly
37
To Renew Small End Bush
38
To Check Piston Ring Gaps
38
To Assemble Piston and Connecting Rod
38
Piston Ring Gap Check
38
To Fit Piston Rings
39
To Fit Piston and Connecting Rod
39
Oil Control Ring Spring Installation
39
Piston Ring Compression Tool
39
Connecting Rod Bearing Location
40
Connecting Rod and Cap Assembly Numbers
40
Cylinder Blocks and Liners
41
Cylinder Block Inspection
42
Cylinder Liner Check
42
Cylinder Liner Check Positions
42
Liner Flange Height Check
42
Crankshaft and Main Bearing
43
Crankshaft End Clearance
44
To Renew Thrust Washers
44
Crankshaft End Clearance Check
44
Centre Main Bearing Cap Removal
44
To Remove Crankshaft
45
Crankshaft Pulley Removal
45
Crankshaft Oil Thrower, Wavy Washer and Friction Gear Removal
45
Crankshaft Removal
45
Crankshaft Overhaul
46
Finished Dimensions for Undersize Crankshafts
46
To Fit Crankshaft
47
Crankshaft Main Bearings - 4.182 (Centre Lower Half Bearing)
47
Main Bearing Cap Position Marks - 4.135 and 4.154
47
Main Bearing Cap Position Marks - 4.182
47
Crankshaft Rear End Oil Seal
48
Crankshaft Rear End Oil Sea Service Positions
48
Crankshaft Rear End Oil Seal Housing (Location Dowels)
48
Timing Case and Drive
49
To Remove Timing Case Cover
50
To Renew Crankshaft Front Oil Seal
50
To Fit Timing Case Cover
50
Timing Case Cover Removal
50
To Remove and Fit Idler Gear(S)
51
Idler Gear Removal
51
Idler Gear Hub Removal (Lubricating Oil Holes)
51
To Remove Camshaft Gear
52
To Fit Camshaft Gear
52
Idler Gear End Clearance Check
52
Camshaft Gear Removal
52
To Remove Fuel Pump Gear
53
Fuel Pump Friction Gear Removal - 4.135 and 4.182
53
Fuel Pump Gear Removal - 4.135 and 4.182
53
Fuel Pump Gear Removal - 4.154
53
To Fit Fuel Pump Gear
54
To Remove Camshaft and Tappets
54
Camshaft Removal
54
Tappet Removal
54
To Fit Camshaft and Tappets
55
To Remove Timing Case
55
Camshaft Thrust Plate
55
Timing Case Removal - 4.182 (Location Thimble)
55
To Fit Timing Case
56
Timing Case Installation - 4.135 and 4.154
56
Timing
57
Gear Timing Marks
58
Crankshaft Timing Arrangement
58
To Check Valve Timing
58
Flywheel Timing Marks
58
Fuel Pump Timing Marks
59
To Check Fuel Pump Timing
59
Crankshaft Pulley Timing Marks
59
Piston TDC Check
59
Pump Plunger Measurement Device in Position
60
Lubrication System
61
Lubrication Circuit
62
Lubrication Diagram
62
To Renew Lubricating Oil Filter Canister
63
Lubricating Oil Flow through Cooler and Filter
63
Lubricating Oil Filter Canister Removal
63
To Remove Lubricating Oil Sump - 4.135 and 4.154
64
To Remove Lubricating Oil Sump - 4.182
64
To Fit Lubricating Oil Sump - 4.135 and 4.154
64
Lubricating Oil Sump - 4.135 and 4.154
64
To Fit Lubricating Oil Sump - 4.182
65
To Remove and Fit Lubricating Oil Relief Valve - 4.135 and 4.154
65
To Remove and Fit Lubricating Oil Relief Valve - 4.182
66
To Remove and Fit Lubricating Oil Dump Valve - 4.182
66
To Remove and Fit Lubricating Oil Pump - 4.135 and 4.154
66
Lubricating Oil Relief Valve Removal - 4.182
66
To Remove and Fit Lubricating Oil Pump - 4.182
67
Lubricating Oil Pump Inspection
67
Lubricating Oil Pump Removal - 4.182
67
Lubricating Oil Pump
67
To Remove and Fit Lubricating Oil Cooler - 4.182
68
Lubricating Oil Cooler By-Pass Valve - 4.182
68
Inner Rotor to Outer Rotor Clearance Check
68
Rotor End Clearance Check
68
To Remove and Fit Piston Cooling Jets - 4.182
69
Lubricating Oil Cooler Removal - 4.182
69
Cooler By-Pass Valve Removal - 4.182
69
Piston Cooling Jet Removal - 4.182
69
Cooling System
70
To Check and Adjust Fan Belt Tension
71
To Drain Cooling System
71
Fan Belt Tension Check
71
Coolant Drain Position - 4.135
71
To Remove and Fit Water Pump - 4.135
72
To Remove and Fit Water Pump - 4.154 and 4.182
72
Thermostatic Fan Removal
72
Water Pump Removal - 4.135
72
To Dismantle Water Pump
73
Water Pump Removal - 4.154
73
Water Pump Removal - 4.182
73
To Assemble Water Pump
74
To Remove and Fit Thermostat
74
To Check Thermostat
75
Fuel System
76
Release of Fuel Pump Gear - 4.154
77
Release of Fuel Pump Gear - 4.135 and 4.182
77
Removal of Fuel Pump Gear Fasteners
77
Fuel Pump Removal
77
To Fit Fuel Injection Pump
78
To Adjust Idle Speed
78
Fuel Pump Position Marks
78
Pump Speed Adjustment Screws
78
Maximum no Load Speed Adjustment
79
To Remove and Fit Atomisers - 4.135 and 4.182
79
Fuel Leak off Pipe Removal - 4.135 and 4.182
79
Atomiser Removal - 4.135 and 4.182
79
To Remove and Fit Atomisers - 4.154
80
Atomiser Removal - 4.154
80
Atomiser Assembly - 4.135 and 4.182
80
Atomiser Assembly - 4.154
80
To Remove Air from the Fuel System
81
Removal of Air from Fuel Pump
81
Flywheel and Backplate
82
To Remove and Fit Flywheel
83
Flywheel Ring Gear
83
Flywheel Fastener Hole Positions
83
Flywheel Run-Out Check
83
To Remove and Fit Flywheel Backplate
84
Backplate Face Alignment Check
84
Backplate Flange Concentricity Check
84
Electrical Equipment
85
Alternator
86
To Test Voltage
86
Output Test
86
Alternator Voltage Check
86
Starter Motor
87
Glow Plugs
87
Checks in Service
87
To Check Glow Plug Inside Circuit
87
To Check Glow Plug Electrical Supply
88
Glow Plug Removal
88
Exhauster
89
To Remove Exhauster
90
To Fit Exhauster
90
Exhauster Body Removal
90
Exhauster Rotor Removal
90
Index
91

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Perkins 4.135 Workshop Manual (94 pages)

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