Perkins T4.38 Manuals

Manuals and User Guides for Perkins T4.38. We have 2 Perkins T4.38 manuals available for free PDF download: Workshop Manual

Perkins T4.38 Workshop Manual (169 pages)

Diesel Engine

Brand: Perkins | Category: Engine | Size: 8.42 MB

Contents
3
Engine Number Location
4
Safety Precautions
6
Asbestos Joints
6
View of Fuel Pump Side of T4.236 Engine
8
View of Camshaft Side of T4.236 Engine
9
View of Fuel Pump Side of 4.248, 4.236 and 4.212 Engines
10
Technical Data
13
Recommended Torque Tensions
14
Service Wear Limits
14
Manufacturing Data & Dimensions
15
Connecting Rod Alignmemnt
20
Engine Checking and Fuel Pump Marking Angles, Static Timing
28
Atomisers
29
Fault Diagnosis
33
Fault Finding Chart
33
Key to Fault Finding Chart
33
Cylinder Head Maintenance
35
To Remove the Cylinder Head
35
To Remove the Valves
36
Cleaning
36
Valve Guides
37
Valves and Valve Seats
37
Hand Grinding
37
Valve Seat Inserts
38
Skimming of Cylinder Head
39
Valve Spring
39
Rocker Shaft Assembly
39
Valve Stem Oil Seals
39
To Re-Assemble the Cylinder Head
40
Cylinder Head Gasket - Standard
40
Cylinder Head Gasket
40
To Refit the Cylinder Head
41
To Check or Adjust Valve Tip Clearances
42
Closed Circuit Breather Vent Valve
42
Pistons and Connecting Rods
43
To Assemble the Pistons to the Connecting Rods
44
To Fit the Pistons and Connecting Rods to the Cylinder Bore
47
Fitting New Pistons
47
Cylinder Block
49
To Renew Bush in No.1 Camshaft Bore
49
Cylinder Liners
49
To Fit Unbored Flanged Cast Iron Cylinder Liners
50
To Renew Cylinder Liners
50
Preparation for Fitting New Liners
50
To Fit New Liners
50
Oversize Cylinder Liners
51
Crankshaft and Main Bearings
53
To Renew the Thrust Washers
53
To Remove the Crankshaft
54
Regrinding the Crankshaft
54
Crankshaft Regrind Data
55
To Refit the Crankshaft
56
Rope Type Rear End Oil Seal
57
Lip Type Rear End Oil Seal
57
To Fit Lip Seal in Its Housing
57
To Fit Lip Seal Housing
58
Balancer Unit
59
Use of Loctite
59
Balancer Unit, Centre Mounted
62
To Fit New Bushes and Bearings
63
Frame Bushes
63
Frame End Cover Bushes
63
Needle Bearings
64
To Fit Balance Weights
64
To Fit Idler Gear
65
To Refit and Time Balancer to Engine
65
Centre Mounted Balancer Unit Assembly
67
Timing Case and Drive
69
To Remove the Timing Case Cover
69
To Renew the Crankshaft Front Oil Seal
69
To Refit the Timing Case Cover
69
Checking the Timing Gear Backlash
70
To Remove the Idler Gear and Hub
70
To Refit the Idler Gear and Hub
71
To Remove the Camshaft Gear
71
To Refit the Camshaft Gear
71
To Remove the Fuel Pump Gear
71
To Refit the Fuel Pump Gear
72
To Replace Fuel Pump Gear
72
If Original Fuel Pump Gear Is Being Refitted
72
To Replace Fuel Pump Gear Using Fuel Pump Timing Tool MS.67B
73
To Remove the Timing Case
74
To Refit the Timing Case
74
New Timing Case
74
New Fuel Pump Adaptor Plate
75
To Remove the Camshaft and Tappets
76
To Refit the Tappers and Camshaft
76
Valve Timing
76
Checking Valve Timing
77
Lubricating System
79
The Oil Pump
79
To Remove the Oil Pump
80
To Dismantle the Oil Pump
80
To Assemble the Oil Pump
82
To Refit the Oil Pump
82
Oil Pressure Relief Valve
82
To Remove and Dismantle the Relief Valve Assembly
82
To Assemble and Refit the Relief Valve Assembly
83
Lubricating Oil Filters
83
To Change the Filter Element
84
To Renew Screw Type Oil Filter Canister
84
To Remove and Replace Oil Filter Assembly
84
To Remove and Replace Oil Cooler
84
Cooling System
87
To Adjust the Driving Belt
87
To Remove and Refit Water Pump - High Position Type
87
To Remove and Refit Water Pump - Low Position Type
88
To Dismantle the Water Pump - Earlier Low/High Types
88
To Dismantle the Water Pump - Latest Type
88
To Re-Assemble the Water Pump - Earlier Low/High Types
89
To Assemble the Water Pump - Latest Type
89
Current Water Pumps
90
To Fit the New Seal
90
To Fit New Impeller
90
Water Pump Seals
90
Piston Cooling Jets
91
To Remove Piston Cooling Jets
91
To Refit Piston Cooling Jet
91
Nozzle Position
91
Air Filters
93
Dry Type Two Stage "Cyclopac"
93
Dry Type Two Stage "Cyclone"
93
Extreme Heavy Duty Two Stage, with Multiple Elements "Rotopamic"
94
Oil Bath Air Filters
94
Tractor Type Air Filter
94
Fuel Filters
95
To Renew Earlier Type Filter Element
95
To Renew Later Type Filter Element
96
Fuel Lift Pump - Testing the Pump in Position
96
Pressure Checking of Fuel Lift Pump in Position
96
To Clean the Pump Chamber
96
To Remove the Pump
97
To Dismantle the Pump
97
Inspection of Parts
97
To Re-Assemble the Pump
97
Fuel Injection Pump
98
To Refit the Pump
98
To Remove the Fuel Pump
98
To Refit the Fuel Pump
98
To Re-Set the Fuel Pump Timing - D.P.A.
99
Hydraulically Governed Pump
99
To Check Marking Angle of Fuel Injection Pump Using Tool MS.67B
100
Mechanically Governed Pumps
100
To Check Marking Angle of Fuel Injection Pump
101
N17B Stanadyne Mechanical Fuel Injection Pump
101
Maximum Speed Setting
102
Idling Speed Setting
102
Priming the Fuel System
102
Priming Procedure after Changing Earlier Filter Element
103
Atomisers General
103
Atomiser Identification
104
Fuel Lift Pump - Later
104
Fuel Pipes
105
D.P.S. Mechanical Fuel Injection Pump
105
Flywheel and Flywheel Housing
107
To Remove the Flywheel
107
To Renew the Flywheel Ring Gear
107
To Refit the Flywheel
107
Oil Seal for Fluid Drive
108
Exhauster
109
End Cover Bearings and Seals - to Renew
111
Plain Bearing
111
Roller Bearing and Shaft Collar - to Renew
112
Compressor
113
To Remove Compressor
113
To Replace Compressor
113
Removing and Dismantling Cylinder Head and Cylinder
114
Removing and Dismantling Piston and Connecting Rod Assemblies
114
Removing Crankshaft
114
Cylinder Inspection of Parts
114
Wear in Bore
115
Cylinder Head
115
Remedy
115
Wabco Compressor
116
Fault Finding
116
Compressor Fails to Maintain Adequate Pressure in the System
116
Compressor Passes Excessive Oil
116
Air Leakage Test
117
Check after Installation
117
Dismantling the Compressor
118
To Assemble the Compressor
118
Data and Dimensions for Wabco Compressor
118
New Wabco Compressor and Drive Housing
121
To Fit the Compressor Only
121
To Fit the Compressor and Drive Assembly
121
To Dismantle the Drive Assembly
121
To Assemble the Drive Assembly
122
Alternator, Dynamo & Starter Motor
123
Fault Finding on AC5
123
Fault Finding on 11AC
124
Fault Diagnosis Procedure for 11 AC
125
Alternator Fails to Charge
125
Low-Unsteady Charging Rate
125
Flat Battery or Low State of Charge
125
Alternator Output Test with Regulator Inoperative
126
Regulator Test
126
Dynamo Maintenance
127
Dynamo Lubrication
127
Inspection of Brushgear
127
Belt Adjustment
127
Testing in Position to Locate Fault in Charging Circuit
128
Starter Motor
128
Routine Maintenance
128
Starter Motor General Description
129
Testing on the Vehicle
129
Operating the Starter
129
Brush Gear and Commutator
130
Turbocharger
131
To Remove Turbocharger
131
Airesearch T-31
132
Internal Parts Inspection
132
To Fit Turbocharger
134
Wastegate Operation/Calibration Test
134
Index
139
Engine Views
146
Operating and Maintenance
153
Preventive Maintenance
153
To Drain the Cooling System
153
Lubrication System
157
Standard Engines
158
Drive Belts
158
Fresh Water Pump
159
To Dismantle the Water Pump
160
To Re-Assemble the Water Pump
160
Sea Water Pump
161
Dismantling the Pump
161
Heat Exchanger and Oil Cooler
162
To Remove the Heat Exchanger
164
To Dismantle the Heat Exchanger
164
To Assemble the Heat Exchanger
164
To Fit the Heat Exchanger
164
Gearbox Oil Cooler
165
To Remove the Oil Cooler
165
To Assemble the Oil Cooler
165
To Fit the Oil Cooler
165
Thermostat
166
Testing the Thermostat
166
Gearbox
167
To Remove the Gearbox
167
To Refit the Gearbox
167

Perkins T4.38 Workshop Manual (168 pages)

Brand: Perkins | Category: Engine | Size: 19.54 MB

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Perkins T4.38 Workshop Manual (169 pages)

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Perkins T4.38 Workshop Manual (168 pages)

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