Perkins 4.2482 - Workshop Manual

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Contents3
Engine Number Location4
Safety Precautions6
Asbestos Joints6
View of Fuel Pump Side of T4.236 Engine8
View of Camshaft Side of T4.236 Engine9
View of Fuel Pump Side of 4.248, 4.236 and 4.212 Engines10
Technical Data13
Recommended Torque Tensions14
Service Wear Limits14
Manufacturing Data & Dimensions15
Connecting Rod Alignmemnt20
Engine Checking and Fuel Pump Marking Angles, Static Timing28
Atomisers29
Fault Diagnosis33
Fault Finding Chart33
Key to Fault Finding Chart33
Cylinder Head Maintenance35
To Remove the Cylinder Head35
To Remove the Valves36
Cleaning36
Valve Guides37
Valves and Valve Seats37
Hand Grinding37
Valve Seat Inserts38
Skimming of Cylinder Head39
Valve Spring39
Rocker Shaft Assembly39
Valve Stem Oil Seals39
To Re-Assemble the Cylinder Head40
Cylinder Head Gasket - Standard40
Cylinder Head Gasket40
To Refit the Cylinder Head41
To Check or Adjust Valve Tip Clearances42
Closed Circuit Breather Vent Valve42
Pistons and Connecting Rods43
To Assemble the Pistons to the Connecting Rods44
To Fit the Pistons and Connecting Rods to the Cylinder Bore47
Fitting New Pistons47
Cylinder Block49
To Renew Bush in No.1 Camshaft Bore49
Cylinder Liners49
To Fit Unbored Flanged Cast Iron Cylinder Liners50
To Renew Cylinder Liners50
Preparation for Fitting New Liners50
To Fit New Liners50
Oversize Cylinder Liners51
Crankshaft and Main Bearings53
To Renew the Thrust Washers53
To Remove the Crankshaft54
Regrinding the Crankshaft54
Crankshaft Regrind Data55
To Refit the Crankshaft56
Rope Type Rear End Oil Seal57
Lip Type Rear End Oil Seal57
To Fit Lip Seal in Its Housing57
To Fit Lip Seal Housing58
Balancer Unit59
Use of Loctite59
Balancer Unit, Centre Mounted62
To Fit New Bushes and Bearings63
Frame Bushes63
Frame End Cover Bushes63
Needle Bearings64
To Fit Balance Weights64
To Fit Idler Gear65
To Refit and Time Balancer to Engine65
Centre Mounted Balancer Unit Assembly67
Timing Case and Drive69
To Remove the Timing Case Cover69
To Renew the Crankshaft Front Oil Seal69
To Refit the Timing Case Cover69
Checking the Timing Gear Backlash70
To Remove the Idler Gear and Hub70
To Refit the Idler Gear and Hub71
To Remove the Camshaft Gear71
To Refit the Camshaft Gear71
To Remove the Fuel Pump Gear71
To Refit the Fuel Pump Gear72
To Replace Fuel Pump Gear72
If Original Fuel Pump Gear Is Being Refitted72
To Replace Fuel Pump Gear Using Fuel Pump Timing Tool MS.67B73
To Remove the Timing Case74
To Refit the Timing Case74
New Timing Case74
New Fuel Pump Adaptor Plate75
To Remove the Camshaft and Tappets76
To Refit the Tappers and Camshaft76
Valve Timing76
Checking Valve Timing77
Lubricating System79
The Oil Pump79
To Remove the Oil Pump80
To Dismantle the Oil Pump80
To Assemble the Oil Pump82
To Refit the Oil Pump82
Oil Pressure Relief Valve82
To Remove and Dismantle the Relief Valve Assembly82
To Assemble and Refit the Relief Valve Assembly83
Lubricating Oil Filters83
To Change the Filter Element84
To Renew Screw Type Oil Filter Canister84
To Remove and Replace Oil Filter Assembly84
To Remove and Replace Oil Cooler84
Cooling System87
To Adjust the Driving Belt87
To Remove and Refit Water Pump - High Position Type87
To Remove and Refit Water Pump - Low Position Type88
To Dismantle the Water Pump - Earlier Low/High Types88
To Dismantle the Water Pump - Latest Type88
To Re-Assemble the Water Pump - Earlier Low/High Types89
To Assemble the Water Pump - Latest Type89
Current Water Pumps90
To Fit the New Seal90
To Fit New Impeller90
Water Pump Seals90
Piston Cooling Jets91
To Remove Piston Cooling Jets91
To Refit Piston Cooling Jet91
Nozzle Position91
Air Filters93
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 Filters94
Tractor Type Air Filter94
Fuel Filters95
To Renew Earlier Type Filter Element95
To Renew Later Type Filter Element96
Fuel Lift Pump - Testing the Pump in Position96
Pressure Checking of Fuel Lift Pump in Position96
To Clean the Pump Chamber96
To Remove the Pump97
To Dismantle the Pump97
Inspection of Parts97
To Re-Assemble the Pump97
Fuel Injection Pump98
To Refit the Pump98
To Remove the Fuel Pump98
To Refit the Fuel Pump98
To Re-Set the Fuel Pump Timing - D.P.A.99
Hydraulically Governed Pump99
To Check Marking Angle of Fuel Injection Pump Using Tool MS.67B100
Mechanically Governed Pumps100
To Check Marking Angle of Fuel Injection Pump101
N17B Stanadyne Mechanical Fuel Injection Pump101
Maximum Speed Setting102
Idling Speed Setting102
Priming the Fuel System102
Priming Procedure after Changing Earlier Filter Element103
Atomisers General103
Atomiser Identification104
Fuel Lift Pump - Later104
Fuel Pipes105
D.P.S. Mechanical Fuel Injection Pump105
Flywheel and Flywheel Housing107
To Remove the Flywheel107
To Renew the Flywheel Ring Gear107
To Refit the Flywheel107
Oil Seal for Fluid Drive108
Exhauster109
End Cover Bearings and Seals - to Renew111
Plain Bearing111
Roller Bearing and Shaft Collar - to Renew112
Compressor113
To Remove Compressor113
To Replace Compressor113
Removing and Dismantling Cylinder Head and Cylinder114
Removing and Dismantling Piston and Connecting Rod Assemblies114
Removing Crankshaft114
Cylinder Inspection of Parts114
Wear in Bore115
Cylinder Head115
Remedy115
Wabco Compressor116
Fault Finding116
Compressor Fails to Maintain Adequate Pressure in the System116
Compressor Passes Excessive Oil116
Air Leakage Test117
Check after Installation117
Dismantling the Compressor118
To Assemble the Compressor118
Data and Dimensions for Wabco Compressor118
New Wabco Compressor and Drive Housing121
To Fit the Compressor Only121
To Fit the Compressor and Drive Assembly121
To Dismantle the Drive Assembly121
To Assemble the Drive Assembly122
Alternator, Dynamo & Starter Motor123
Fault Finding on AC5123
Fault Finding on 11AC124
Fault Diagnosis Procedure for 11 AC125
Alternator Fails to Charge125
Low-Unsteady Charging Rate125
Flat Battery or Low State of Charge125
Alternator Output Test with Regulator Inoperative126
Regulator Test126
Dynamo Maintenance127
Dynamo Lubrication127
Inspection of Brushgear127
Belt Adjustment127
Testing in Position to Locate Fault in Charging Circuit128
Starter Motor128
Routine Maintenance128
Starter Motor General Description129
Testing on the Vehicle129
Operating the Starter129
Brush Gear and Commutator130
Turbocharger131
To Remove Turbocharger131
Airesearch T-31132
Internal Parts Inspection132
To Fit Turbocharger134
Wastegate Operation/Calibration Test134
Index139
Engine Views146
Operating and Maintenance153
Preventive Maintenance153
To Drain the Cooling System153
Lubrication System157
Standard Engines158
Drive Belts158
Fresh Water Pump159
To Dismantle the Water Pump160
To Re-Assemble the Water Pump160
Sea Water Pump161
Dismantling the Pump161
Heat Exchanger and Oil Cooler162
To Remove the Heat Exchanger164
To Dismantle the Heat Exchanger164
To Assemble the Heat Exchanger164
To Fit the Heat Exchanger164
Gearbox Oil Cooler165
To Remove the Oil Cooler165
To Assemble the Oil Cooler165
To Fit the Oil Cooler165
Thermostat166
Testing the Thermostat166
Gearbox167
To Remove the Gearbox167
To Refit the Gearbox167

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