Perkins 4.236 Series 4-Cylinder Diesel Engines OEM Service & Repair Manual
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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
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This publication is written in
Perkins Approved Clear English
This publication 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 table of contents
User’s Handbook, TPD 1291E, Issue 2 iii
4.236 Series
Contents
1 General information
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1
Safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2
How to care for your engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Engine preservation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4
Parts and service ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 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 a warm engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 14
How to start a cold engine without starting aids .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 15
How to start a cold engine with the fuelled starting aid ... ... ... ... ... ... ... ... ... ... ... ... ... . 16
iv User’s Handbook, TPD 1291E, Issue 2
4.236 Series
How to start a cold engine with manually operated ptart pilot . ... ... ... ... ... ... ... ... ... ... 17
How to start a cold engine with KBi or electrically operated start pilot ... ... ... ... ... ... ... 18
How to stop the engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
Adjustment of engine speed range .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
Running-in ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
Turbocharged engines . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20
Altitude . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20
4 Preventive maintenance
Preventive maintenance periods . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21
Schedules ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 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
Atomiser fault ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
How to renew an atomiser ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
How to eliminate air from the fuel system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29
How to renew the lubricating oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
How to renew the canister of the lubricating oil filter .. ... ... ... ... ... ... ... ... ... ... ... ... ... 34
Air cleaner ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35
Air filter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36
Restriction indicator . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
How to clean the engine breather valve .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
How to check the valve tip clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39
User’s Handbook, TPD 1291E, Issue 2 v
4.236 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
vi
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User’s Handbook, TPD 1291E, Issue 2 1
1
4.236 Series
General information 1
Introduction
The 4.236 Series is a family of automotive, industrial and agricultural engines with power outputs from 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 economic power.
To ensure that you use the relevant information for your specific engine type, refer to "Engine identification"
on page 8.
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2 User’s Handbook, TPD 1291E, Issue 2
4.236 Series
Safety precautions
These safety precautions are important. You must refer also to the local regulations in the country of use.
Some items only apply to specific applications.
Only use these engines in the type of application for which they have been designed.
Do not change the specification of the engine.
Do not smoke when you put fuel in the tank.
Clean away fuel which has been spilt. Material which has been contaminated by fuel must be moved to a
safe place.
Do not put fuel in the tank while the engine runs (unless it is absolutely necessary).
Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training;
even then extreme caution must be used to prevent injury).
Do not make adjustments that you do not understand.
Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.
Other persons must be kept at a safe distance while the engine or equipment is in operation.
Do not permit loose clothing or long hair near moving parts.
Warning! Keep away from moving parts during engine operation.
The fan cannot be seen clearly while the engine runs.
Do not operate the engine if a safety guard has been removed.
Do not remove the filler cap or any component of the cooling system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.
Do not use salt water or any other coolant which can cause corrosion in the closed cooling circuit.
Do not allow sparks or fire near the batteries (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.
Disconnect the battery terminals before a repair is made to the electrical system.
Only one person must control the engine.
Ensure that the engine is operated only from the control panel or from the operator's position.
If your skin comes into contact with high-pressure fuel, obtain medical assistance immediately.
Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.
Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets.
Discard used lubricating oil in accordance with local regulations to prevent contamination.
Do not move mobile equipment if the brakes are not in good condition.
Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is
started.
Use extreme care if emergency repairs must be made at sea or in adverse conditions.
The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes.
Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from
the inlet and outlet ports on the turbocharger and prevent contact with hot surfaces.
Fit only genuine Perkins parts.
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User’s Handbook, TPD 1291E, Issue 2 3
4.236 Series
How to care for your engine
This handbook has been written to assist you to maintain and operate your engine correctly.
To obtain the best performance and the longest life from your engine, you must ensure that the maintenance
operations are done at the intervals indicated in Chapter 4, Preventive maintenance. If the engine works in a
very dusty environment or other adverse conditions, certain 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 and repairs are done by personnel who have had the correct training. Perkins
distributors have this type of personnel available. You can also obtain parts and service from your Perkins
distributor.
The left and right sides of the engine are as seen from the rear.
Read the "Safety precautions" on page 2 and remember them. They are given for your protection and must be
applied at all times.
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4 User’s Handbook, TPD 1291E, Issue 2
4.236 Series
Engine preservation
Introduction
The recommendations indicated below are designed to prevent damage to the engine when it is withdrawn
from service for a prolonged period. Use these procedures after the engine is withdrawn from service. The
instructions for the use of POWERPART products are given on the outside of each container.
Procedure
1 Completely clean the outside of the engine.
2 When a preservative fuel is to be used, drain the fuel system and fill it with the preservative fuel.
POWERPART Lay-Up 1 can be added to the normal fuel to change it to a preservative fuel. If preservative fuel
is not used, the system can be kept full with normal fuel but the fuel must be drained and discarded at the end
of the storage period together with the fuel filter element(s).
3 Operate the engine until it is warm. Then correct leakages of fuel, lubricating oil or air. Stop the engine and
drain the lubricating oil from the sump.
4 Renew the canisters) of the lubricating oil filter.
5 Fill the sump to the full mark on the dipstick with new and clean lubricating oil and add POWERPART Lay-
Up 2 to the oil to protect the engine against corrosion. If POWERPART Lay-Up 2 is not available, use a correct
preservative fluid instead of the lubricating oil. If a preservative fluid is used, this must be drained and the
lubricating oil sump must be filled to the correct level with normal lubricating oil at the end of the storage period.
6 Drain the cooling system, see "How to drain the cooling system" on page 23. In order to protect the cooling
system against corrosion, fill it with an approved antifreeze mixture because this gives a protection against
corrosion, see "Coolant specification" 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, Peterborough.
7 Operate the engine for a short period in order to circulate the lubricating oil and the coolant in the engine.
8 Disconnect the battery. Then put the battery into safe storage in a fully charged condition. Before the battery
is put into storage, protect its terminals against corrosion. POWERPART Lay-Up 3 can be used on the
terminals.
9 Clean the engine breather pipe (if one is fitted) and seal the end of the pipe.
10 Remove the atomisers and spray POWERPART Lay-Up 2 for one to two seconds into each cylinder bore
with the piston at BDC.
11 Slowly turn the crankshaft one revolution and then fit the atomisers with new seat washers and new dust
seals.
12 Remove the air filter. Then, if necessary, remove the pipes installed between the air filter/cleaner and
induction manifold or turbocharger. Spray POWERPART Lay-Up 2 into the induction manifold or turbocharger.
It is recommended that the spray time for the turbocharger is 50% longer than the spray time for the manifold,
which is indicated on the container label. Seal the manifold or the turbocharger with waterproof tape.
13 Remove the exhaust pipe. Spray POWERPART Lay-Up 2 into the exhaust manifold or the turbocharger.
It is recommended that the spray time for the turbocharger is 50% longer than the spray time for the manifold,
which is indicated on the container label. Seal the manifold or the turbocharger with waterproof tape.
14 If the lubricating oil filler is fitted onto the rocker cover, remove the filler cap. If the lubricating oil filler is not
fitted onto the rocker cover, remove the rocker cover. Spray POWERPART Lay-Up 2 around the rocker shaft
assembly. Fit the filler cap or rocker cover.
Continued
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Perkins 4.236 Series 4-Cylinder Diesel Engines OEM Service & Repair Manual
Models Covered:
- Perkins 4.236
- Perkins T4.236
- Perkins 4.248
- Perkins 4.2482
- Perkins 4.212
- Perkins T4.38
Manuals Included:
- Perkins 4.236 Series 4-Cylinder Diesel Engines OEM Service & Repair Manual
- Perkins 4.236 Series 4-Cylinder Diesel Engines User's Handbook
This Perkins 4.236 Series 4-Cylinder Diesel Engines OEM Service & Repair Manual bundle offers comprehensive factory-grade coverage for one of the most widely used engine platforms in agricultural, industrial, marine, and construction applications. Whether you're maintaining a tractor, excavator, or generator set, this manual includes the official procedures and specifications needed for effective service.
In addition to the detailed repair manual, the included user’s handbook provides essential operation guidelines, service intervals, and general maintenance practices. Both documents together ensure you're equipped with the proper factory-correct methods for diagnosing and repairing everything from fuel systems to timing gear setups.
Content Overview:
- Covers Perkins 4.236 Series 4-cylinder diesel engines
- Engine specifications, torque values, and general data
- Disassembly and reassembly: cylinder head, crankshaft, pistons
- Fuel system maintenance and injection pump procedures
- Cooling, lubrication, and air intake servicing
- Timing gear setup and adjustment instructions
- Turbocharger and compressor component service
- Starter motor, alternator, and full electrical breakdown
- Flywheel, exhauster, and balancer unit procedures
- Approved tools list and marine-specific service sections
Whether you're a professional technician or fleet operator, this manual set provides an authoritative and complete solution for properly maintaining Perkins 4-cylinder diesel engines across a wide range of equipment.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device
Requirements: Adobe Reader (free)
