Perkins 4.236 Series User Handbook Manual Download Page 1 | Manualshive

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Perkins 4.236 Series User Handbook Manual Download Page 1

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Perkins 4.236 Series

Models 4.236, T4.236, 4.248, 4.2482

USER’S HANDBOOK

4 cylinder diesel engines for automotive, agricultural and

industrial use

Publication TPD 1291E, Issue 2.
© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in 1998 by Technical Publications,
Perkins Engines Company Limited, Peterborough PE1 5NA England

This document has been printed from SPI². Not for Resale

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Summary of Contents for 4.236 Series

Page 1: ...ndustrial use Publication TPD 1291E Issue 2 Proprietary information of Perkins Engines Company Limited all rights reserved The information is correct at the time of print Published in 1998 by Technica...

Page 2: ...blication is divided into six chapters 1 General information 2 Engine views 3 Operation instructions 4 Preventive maintenance 5 Engine fluids 6 Fault diagnosis The following pages contain a detailed t...

Page 3: ...ice 5 POWERPART consumable products 6 Engine identification 8 Engine data 9 2 Engine views Introduction 11 Location of engine parts 11 3 Operation instructions How to start the engine 13 How to start...

Page 4: ...22 How to drain the cooling system 23 How to check the drive belt s 24 How to clean the gauze strainer of the fuel lift pump 25 Fuel pre filter 26 How to renew the element of the fuel filter 26 Atomis...

Page 5: ...Series 5 Engine fluids Fuel specification 41 Lubricating oil specification 42 Coolant specification 43 6 Fault diagnosis Problems and possible causes 45 Code list of possible causes 46 This document...

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Page 7: ...76 0 to 37 5 kW 102 0 to 50 5 bhp More than sixty years of diesel production experience together with the latest technology have been applied to the manufacture of your engine to give you reliable and...

Page 8: ...teries especially when the batteries are on charge because the gases from the electrolyte are highly flammable The battery fluid is dangerous to the skin and especially to the eyes z Disconnect the ba...

Page 9: ...tain maintenance intervals will have to be reduced Renew the filter elements and lubricating oil regularly in order to ensure that the inside of your engine remains clean Ensure that all adjustments a...

Page 10: ...on on page 43 Note If protection against frost is not necessary and a corrosion inhibitor is to be used it is recommended that you consult the Service Department Perkins International Limited Peterbor...

Page 11: ...occur Perkins are not responsible for damage which may occur when an engine is in storage after a period in service Parts and service Introduction If problems occur with your engine or with the compon...

Page 12: ...el fuel additive for protection against corrosion Part number 1772204 see Engine preservation on page 4 POWERPART Lay Up 2 Protects the inside of the engine and of other closed systems Part number 176...

Page 13: ...o retain and seal pipe connections with coarse threads Pressure systems can be used immediately Currently Loctite 575 Part number 21820575 POWERPART Retainer oil tolerant To retain components which ha...

Page 14: ...e engine number is stamped on a label which is fastened to the left side of the cylinder block A1 On some applications the label is fastened to the right side of the cylinder block B1 An example of an...

Page 15: ...mpression ratio 4 236 16 1 T4 236 15 5 1 4 248 16 1 4 2482 18 1 Cubic capacity 4 236 T4 236 3 86 litres 236 in3 4 248 4 2482 4 06 litres 248 in3 Firing order 1 3 4 2 Tappet clearances Hot or cold Inle...

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Page 17: ...ation Location of engine parts Front and left side of 4 236 engine 1 Filler cap for lubricating oil 2 Atomiser 3 Fuel filter 4 Drain plug for cylinder block 5 Fuel injection pump 6 Breather pipe 7 Dip...

Page 18: ...tarting aid 16 Exhaust manifold 17 Alternator 18 Turbocharger 19 Dipstick for engine lubricating oil 20 Lubricating oil cooler 21 Lubricating oil sump 22 Drain plug for lubricating oil 23 Flywheel hou...

Page 19: ...ecific amount of diesel fuel in the induction manifold in order to heat the induction air Start Pilot A hand pump is used to inject a cold start fluid into the induction manifold through an atomiser T...

Page 20: ...top control ensure that it is in the run position 2 Adjust the engine speed control to the quarter open position 3 Turn the start key to the HS or S position A to engage the starter motor 4 Allow the...

Page 21: ...the starter motor Allow the key to return to the R position when the engine starts Then adjust the engine speed control to get an even idle speed 4 If the engine does not start in 30 seconds turn the...

Page 22: ...ion in order to engage the starter motor Allow the start key to return to the R position when the engine starts Then adjust the engine speed control to give an even idle speed 5 If the engine does not...

Page 23: ...the engine speed control to get an even idle speed 5 If the engine does not start in 30 seconds allow the start key to return to the R position and hold it there for another 30 seconds Then engage th...

Page 24: ...the starter motor When the engine turns press the starting aid button for a maximum period of 2 seconds If the engine does not start after the first 2 second application keep the starter motor engage...

Page 25: ...the engine operator because this can damage the engine or transmission The warranty of the engine can be affected if the seals on the fuel injection pump are broken during the warranty period by a per...

Page 26: ...pirated engine is to run at an altitude above 600 m 2 000 ft the fuel delivery can be changed to reduce fuel consumption and smoke Perkins can give the percentage of fuel reduction necessary if detail...

Page 27: ...y use the shorter periods When the operation of the engine must conform to the local regulations these periods and procedures may need to be adapted to ensure correct operation of the engine It is goo...

Page 28: ...ter element s z Ensure that the atomisers are checked 2 z Ensure that the idle speed is checked and adjusted if it is necessary 2 z Check the amount of lubricating oil in the sump z z Check the lubric...

Page 29: ...r to drain the radiator If the radiator does not have a tap or drain plug disconnect the hose at the bottom of the radiator Where a lubricating oil cooler filter assembly is fitted this must also be d...

Page 30: ...belt is 10 mm 3 8 in If twin belts are fitted check adjust the tension on the tighter belt How to adjust the belt tension 1 Loosen the pivot fasteners of the alternator B1 and the adjustment link fast...

Page 31: ...ent from the lift pump body 3 Clean the gauze strainer joint and cover 4 Assemble the lift pump Use a good joint and ensure that the lift pump body and the cover are fitted together correctly because...

Page 32: ...re of the element B1 3 Lower the bottom cover of the filter B2 4 Remove the element and discard it 5 Clean the inside surfaces of the filter head and of the cover 6 Renew the seals and lightly lubrica...

Page 33: ...be seen clearly while the engine runs An atomiser fault can cause an engine misfire In order to find which atomiser is defective operate the engine at a fast idle speed Loosen and tighten the union nu...

Page 34: ...pressure connection on the top ensure that the fuel leak off connection A6 is not toward the engine Position the clamp if fitted and engage the atomiser setscrews Ensure that the atomiser is not tilt...

Page 35: ...standard method on page 30 Self vent method This method is used on the Stanadyne DB2 fuel injection pump Vent screws are not fitted to this pump Refer to How to eliminate air from the fuel system self...

Page 36: ...stop control is in the run position If an electrical stop control is used turn the start key to the R position 5 Loosen the vent screw in the lock screw of the hydraulic head C1 and the vent screw on...

Page 37: ...om air comes from the pipe connections Tighten the high pressure pipe connections 9 The engine is now ready to start Note If the engine runs correctly for a short time and then stops or runs roughly c...

Page 38: ...operate the priming lever In this situation the crankshaft must be turned one revolution Caution Do not tighten the nuts of the high pressure pipes more than the recommended torque tension If there is...

Page 39: ...s washer and drain the lubricating oil from the sump Ensure that the washer is not damaged Fit the drain plug and its washer and tighten the plug to 34 Nm 25 Ibf ft 3 5 kgf m 3 Fill the sump to the ma...

Page 40: ...ere is lubricating oil in the sump On turbocharged engines ensure that the engine will not start and operate the starter motor until oil pressure is obtained To ensure that the engine will not start e...

Page 41: ...must be drained at a suitable interval The container and element A1 must be cleaned with kerosene or with another suitable fluid Do not use gasolene Check that the seal A2 is not damaged and renew it...

Page 42: ...n air filters have automatic dust valves B1 through which dust is expelled from the filter The rubber dust valve must be kept clean Ensure that the sides of the valves close completely together and th...

Page 43: ...ilter outlet or between the air filter and the induction manifold When the red warning indicator A1 is seen through the clear panel A2 after the engine has stopped the air filter element must be remov...

Page 44: ...the small hole A1 in the top cover of the breather valve with a water proof tape 4 Wash the breather valve in kerosene and dry it with low pressure air Remove the seal from the top of the breather val...

Page 45: ...umber 4 cylinder has just opened and the exhaust valve of the same cylinder has not closed completely Check the clearances of the valves of number 1 cylinder and adjust them if it is necessary 2 Set t...

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Page 47: ...ocarbons in the fuel A high ratio of light weight hydrocarbons can affect the combustion characteristics Low temperature fuels Special winter fuels may be available for engine operation at temperature...

Page 48: ...icating oil is used for the ambient temperature range in which the engine will run as shown in the chart A below 1 Not recommended during the first 25 50 hours of operation with naturally aspirated en...

Page 49: ...ibiting engine coolant concentrate antifreeze Perkins POWERPART antifreeze exceeds the requirements of the above standards The quality of the antifreeze coolant must be checked at least once a year fo...

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Page 51: ...36 37 38 39 40 42 43 44 63 Black exhaust smoke 11 13 15 17 19 21 22 34 36 37 38 39 40 42 43 44 61 63 Blue or white exhaust smoke 4 15 21 23 36 37 38 39 42 44 45 52 58 62 The pressure of the lubricatin...

Page 52: ...ow 22 Incorrect valve tip clearances 23 Too much oil or oil of a wrong specification is used in wet type air cleaner 24 Not enough lubricating oil in sump 25 Defective gauge 26 Dirty lubricating oil f...

Page 53: ...d correctly 55 Fault in thermostat or thermostat is of an incorrect type 56 Restriction in coolant passages 57 Fault in water pump 58 Valve stem seal is damaged if there is one fitted 59 Restriction i...

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