Need factory rebuild specs for your Perkins V8.510, V8.540, or TV8.540 diesel? This 136-page workshop manual (OEM #601 TPD 06901215) carries complete factory procedures for all three variants. Step-by-step procedures cover cylinder head removal, crankshaft regrinding, fuel injection pump timing, and full turbocharger overhaul. Wiring diagrams for the AC5/AC7B alternator systems sit alongside a lubricating oil flow diagram, exploded views, and a fault-finding chart that runs from black exhaust to excessive crankcase pressure. Torque the V8.540 cylinder head setscrews to 155 lbf ft (210 Nm); big end setscrews go to 105 lbf ft (142 Nm). Stop chasing numbers across old forum threads. Everything is bookmarked and keyword-searchable, so you can pull up the right figure on any device before you turn the first wrench.
What's Inside This Perkins V8.510, V8.540, TV8.540 Manual
| System | Pages | Key Topics |
|---|---|---|
| Engine Views | 7-10 | View of Top Front of Naturally Aspirated Engine, View of Rear Left Hand Side of Naturally Aspirated Engine, View of Rear Right Hand Side of Turbocharged Engine |
| Technical Data | 11-28 | Engine Data, Rating Details, De-Rating for Altitude, Engine Number, Recommended Torque Tensions, Cylinder Numbering, Engine Weights, Data and Dimensions |
| Operating and Maintenance | 29-34 | Starting the Engine, Starting a Warm Engine, Starting a Cold Engine, To Check the Cav in Line Pump Excess Fuel Device, Notes on Heat Start, Extreme Cold Weather Starting Aid |
| Cylinder Head | 37-46 | To Remove a Cylinder Head, To Fit a Cylinder Head, To Check or Adjust Valve Tip Clearances, To Fit High Pressure Fuel Pipes, Valve Assemblies, To Remove Valves, To Fit Valves |
| Pistons and Connecting Rods | 47-52 | General, To Remove Piston and Rings From Connecting Rod, To Remove Piston and Rod Assembly, Inspection, To Renew Small End Bush, To Check Piston Ring Gaps |
| Cylinder Block and Liners | 53-55 | Cylinder Block, Cylinder Liners, To Remove and Fit Cylinder Liner, Oversize Cylinder Liners |
| Crankshaft and Main Bearings | 56-64 | General, Crankshaft End Float, To Change Thrust Washers, To Remove Crankshaft, To Fit Crankshaft, TV8.540 and Later V8.540 Crankshaft Pulley Clamping Arrangement |
| Timing Case and Drive | 65-72 | To Remove Timing Case, To Refit Timing Case, To Remove and Refit Upper Half Timing Case, To Renew Front Oil Seal, To Remove Camshaft Gear, To Fit Camshaft Gear, To Remove Camshaft |
| Timing | 73-79 | Gear Timing Marks, Crankshaft Timing Arrangement, To Position No. 1 Piston to T.D.C. Compression Stroke, Checking Valve Timing |
| Lubricating System | 80-91 | General, Oil Strainer, Oil Filter, To Renew Earlier Lubricating Oil Filter Elements, To Renew Disposable Canister Oil Filter Elements, To Remove Oil Cooler, Oil Cooler |
| Cooling System | 92-97 | General, Fan Belts, Tensioner Pulley, Thermostats, Water Pump, Piston Cooling Jets |
| Fuel System | 98-108 | Fuel Filter, To Renew Single Fuel Filter Element, To Renew Twin Fuel Filter Elements, To Renew Screw-On Canister Fuel Fitter Elements., Fuel Lift Pump |
| Flywheel and Flywheel Housing | 109-110 | Flywheel, Flywheel Ring Gear, Flywheel Housing |
| Compressor/Auxiliary Drive | 111-117 | Sc 12 Compressor, To Remove Compressor, To Fit Compressor, To Fit Compressor Types Pcga 625/5 Onwards, To Dismantle Compressor and Auxiliary Drive, Overhaul |
| Electrical System | 118-121 | Alternators, Testing Procedures with AC5 or AC7B Alternator System Fitted to Application, Checking Operation of a Newly Wired System, Test Equipment Required, Test Procedure |
| Turbocharger | 122-127 | To Clean Impeller, To Remove Turbocharger, To Fit Turbocharger, To Check Bearings, To Dismantle Turbocharger, Inspection |
| Fuel and Lubricating Oil Specifications | 128 | Fuel Specification, Lubricating Oil Specification, Recommended Sae Viscosity Grades |
| Service Facilities | 129 | Service Publications, Use Only Genuine Perkins Parts, Service Instruction |
| Approved Service Tools | 130-133 | Tools on Page 130 (Valve Guide Remover and Replacer, Adaptor for PD.1D, Short Valve Guide Replacer/Adaptor, Piston Ring Squeezer, Piston Height and Valve Height Gauge, Universal Timing Gauge) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| V8.540/TV8.540 | ||
| Big End Setscrews | 105 lbf ft (142 Nm) 14,5 kgf m | p. 13 |
| Big End Setscrews torque | 105 lbf ft (142 Nm) 14,5 kgf m | p. 13 |
| V8.540 | ||
| Cylinder Head (Straight Shank) Setscrews/Nuts with washers and gasket 3681H401 | 155 lbf ft (210 Nm) 21,4 kgf m | p. 13 |
| Cylinder Head Setscrews/Nuts torque | 155 lbf ft (210 Nm) 21,4 kgf m | p. 13 |
| All Models | ||
| Maximum permissible longitudinal bow of cylinder head | 0.008 in (0,20 mm) | p. 42 |
| Interference Fit of Production Liner in Cylinder Block Parent Bore | 0.001/0.003 in (0,025/0.076 mm) | p. 15 |
| Max. Permissible Worn Inside Diameter of Liner - New Rings Fitted | 4.255 in (108,08 mm) | p. 15 |
| Atomiser Securing Nuts torque | 12 lbf ft (16 Nm) 1,7 kgf m | p. 13 |
| Atomisers (Code Letters VA and VB) Working Pressure | 170 atmospheres (176 kgf/cm²) 2500 lbf/in² | p. 26 |
| Main Bearing Cap Setscrews torque | 210 lbf ft (285 Nm) 29,0 kgf m | p. 13 |
| DP15 Pump | ||
| Fuel Injection Pump Gear Capscrews (DP 15 Pump) torque | 35 lbf ft (47 Nm) 4,8 kgf m | p. 13 |
| V8.540 and AV8.540 Engines | ||
| Spill Timing Position B.T.D.C. | 28° | p. 25 |
Perkins V8.510, V8.540, TV8.540 Common Problems This Manual Covers
Perkins V8.540 engine overheats under load with one cylinder bank running much hotter than the other. p. 92
Inspect the cooling system starting on page 92. Remove the water pump and check the impeller shaft. Verify the one-piece shaft interference fit of the impeller is within 0.0005/0.0015 in (0,01/0,04 mm) as specified on page 24. Replace the pump assembly if the impeller is slipping.
Manual Section: Cooling SystemRepeated coolant loss and blown head gaskets after sustained high temperature operation. p. 42
Remove the cylinder head and check for thermal distortion. Measure the maximum permissible longitudinal bow of the cylinder head on page 42; it must not exceed 0.008 in (0,20 mm). If warping is present, observe the maximum skimming allowance of 0.015 in (0,38 mm) detailed on page 18.
Manual Section: Cylinder HeadErratic fuel delivery and rough running accompanied by surging and heavy black exhaust smoke. p. 98
Check the fuel injection pump timing. For V8.540 engines, adjust the spill timing position to exactly 28° B.T.D.C. as instructed on page 25. Bleed the entire fuel system to eliminate air pockets. Inspect the pump drive gear for backlash before locking down the adjustments.
Manual Section: Fuel SystemRapid bearing wear and knocking noises from the bottom end during heavy loaded operation. p. 80
Drain the oil sump and drop the pan to inspect the bottom end. Test the piston cooling oil control valve pressure setting, which should reach 40 lbf/in2 (276 kN/m2) as specified on page 23. Clean the main oil strainer and replace the filter canister before restarting.
Manual Section: Lubricating SystemCylinder sleeve stress fractures and premature internal damage found during top end teardown. p. 53
Examine the cylinder block parent bore for damage. When installing replacement components, verify the interference fit of the production liner is 0.001/0.003 in (0,025/0.076 mm) as outlined on page 15. If the bore is damaged, machine the block for 0.010 in (0,25 mm) oversize cylinder liners.
Manual Section: Cylinder Block and LinersFrequently Asked Questions
What are the torque specs for Perkins V8.510 head bolts?
Head bolt torque on the V8.510 depends on the setscrew and gasket. Standard Cylinder Head Setscrews/Nuts (V8.510/V8.540) take 125 lbf ft (169 Nm). Scant Shank Setscrews/Nuts used with gasket 3681H401 (V8.510/V8.540) take 135 lbf ft (183 Nm).
What are the torque specs for Perkins V8.540 main bearing caps?
Main bearing cap torque depends on the setscrew. The main cap setscrews take 210 lbf ft (285 Nm). Transverse setscrews vary: 75 lbf ft (102 Nm) on the "S" range, 100 lbf ft (136 Nm) on the "W" range, and 50 lbf ft (68 Nm) for the rest.
How do I bleed the fuel system on a Perkins V8.510?
Start by unscrewing the vent plug on top of the fuel filter and one of the two vent plugs on the right-hand side of the injection pump. Work the fuel lift pump priming lever until air-free fuel flows from each venting point, then tighten the plugs. Page N.10 has the full sequence.
What are the replacement specifications for Cylinder sleeves/liners?
Pre-finished service liners are sold as replacements. The earlier type is a 0.000/0.002 in (0,00/0,05 mm) clearance fit with a fitted internal diameter of 4.251/4.252 in (107,975/108,000 mm). The later type is a 0.001/0.001 in (0,025/0,025 mm) transition fit, fitted internal diameter 4.252/4.253 in (108,000/108,026 mm).
How will I receive this Perkins V8.510, V8.540, TV8.540 Workshop Manual?
This is a 136-page searchable PDF ready for immediate download. It works on any device: pull it up on your phone while you're under the hood. No shipping, no waiting.
Am I able to print pages from this Perkins V8.510, V8.540, TV8.540 manual?
The PDF is DRM-free, so print whatever sections you want to take out to the shop. Standard letter or A4 paper works.
Are hydraulic system diagrams in this Perkins V8.510, V8.540, TV8.540 manual?
A lubricating oil flow diagram is included, showing the internal oil circuits and component locations for the Perkins V8.510, V8.540, TV8.540.
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