Parts kit instruction 21820291

Installation of Coolant Expansion Tank

This Parts Kit Instruction applies to certain 1200 series six cylinder engines model BL where a coolant expansion tank is to be installed.
Cautions:
 Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
 Care must be taken to ensure all fluids are contained during the disassembly of the system, assembly of the new system and
subsequent testing and operation. Be prepared to collect any fluid in a suitable container before opening any part which contains
fluid. Dispose of fluids according to local regulations.
Drain the engine coolant. Refer to Operation and Maintenance Manual, ‘Cooling System Coolant - Change’ for the correct procedure.
The parts that are required are listed in Table 1.

Table 1
Part Number Description Qty Part Number Description Qty
T412958 Coolant Tank 1 T413061 Bracket 1
2314H001 Setscrew 1 2314H003 Screw 1
T412983 Coolant Hose 1 T412987 Hose Clip 1
1 Hose Assembly 1 2481883 Clip 1
T412916
2481876 Hose Clip 1 T412898 Connector 1
T411990 Coolant Hose 1 21825197 Clip 2
2481D160 Clip 2 T412334 Setscrew 1
T413013 Bracket 1 2314H102 Setscrew 1
2314H002 Setscrew 1 T409664 Cable Tie 1
T412783 Cap 1 T407744 Clamp 1
Note: Hose assembly (Perkins part number T412916) consists of one hose (Perkins part number T412916), one coolant hose
(Perkins part number T411989) and four hose clips (Perkins part number 2481B020).

A B

1 If necessary, remove setscrew (A1) and locknut (not shown).

2 If necessary, remove plug (B2) and O-ring (not shown) from the cylinder head. Discard O-ring.
3 Install a new O-ring to connector (B1). Install connector (B1) to the cylinder head. Tighten the connector to a torque of 20 Nm
(177 lbf/in) 2 kgf m.
 1
1

2
3
3
C D

4 Position bracket (C2) to the radiator. Install screws (C3) and screw (C1) to bracket (C2). Tighten screws (C3) to a torque of 22 Nm
(195 lbf/in) 2.2 kgf m. Tighten screw (C1) to a torque of 44 Nm (32 lbf/ft) 4.4 kgf m.
5 Position coolant tank (D1) to bracket (D3). Ensure that the outlet pipe is correctly orientated. Install screws (D2) to bracket (D3).
Tighten screws finger tight.
6 Tighten the screws (D2) to a torque of 22 Nm (195 lbf/in) 2.2 kgf m.

1 2 3

3
4

2
5
E F

7 Install hose clip (E4) to coolant hose (E5). Install coolant hose (E5) to hose (E3). Use suitable tooling to secure hose clip (E4) to
coolant hose (E5).
8 Install clip (E2) to T connection on hose (E3). Install hose (E3) to coolant tank (E1).
9 Install hose clip (F3) to hose (F2). Install hose (F2) to radiator connection (F1).

2 3
1 1

G H

10 Ensure that hose clip (G5) is installed to hose (G1). Install hose (G1) to connector (G4). Use suitable tooling to secure hose clip
(G5) to hose (G1). Tighten clip (E1), clip (F3) to a torque of 5 Nm (44 lbf/in) 0.5 kgf m. Install a new cable tie (G3) to secure hose
(G1) to air pipe (G2).
11 Install clip (H2) to hose (H3). Install hose (H3) to coolant tank (H1).
 3
2
2
1
1

4
3
5
J K

12 Install clip (J1) to hose (J2). Install hose (J2) to connection (J3).
13 Position bracket (K2) to the radiator. Install setscrew (K1) to bracket (K2). Position clip (K4) to hose (K5) and bracket (K2). Install
setscrew (K3) to clip (K4).
14 Tighten clip (H2) and clip (J1) to a torque of 5 Nm (44 lbf/in) 0.5 kgf m. Tighten setscrew (K1) and setscrew (K3) to a torque of
14 Nm (124 lbf/in) 1.4 kgf m. Ensure that bracket (K2) and clip (K4) are parallel to the floor.

1 1 2
2

4
L M

15 Position clip (L1) to hose (L2). Install spacer (L4) and screw (L3) to clip (L1). Tighten the screw to a torque of 14 Nm (124 lbf/in)
1.4 kgf m.
16 Install a new cable tie (M2) to secure hose (M1) to the support bracket.

1
1 2

3 2

N P 4

17 Remove existing coolant hose (N3) from the outlet connection (N1) below the radiator cap. Retain existing coolant hose.
18 Install cap (N2) onto outlet connection (N1). Install clamp (N4) to cap (N2). Ensure that cap is secure.
19 Install existing coolant hose (P1) to coolant tank (P2).
20 Loosen the three setscrews down the left hand side of the radiator. Position three hose clips (P3) close to each of the three
setscrews. Slide part of the three hose clips under the guard (P4). Tighten the three setscrews to a torque of 14 Nm (124 lbf/in)
1.4 kgf m.
21 Position existing coolant hose (P1) to the hose clips (P3). Ensure that the coolant hose is secure.
Fill the engine coolant. Refer to Operation and Maintenance Manual, ‘Cooling System Coolant - Change’ for the correct procedure.
Operate the engine. Check for leaks.
End
Issued by Perkins Engines Company Limited 2016, Peterborough England. © Proprietary information of Perkins Engines Company Limited 2016, all rights reserved. The
information is correct at the time of going to press. This Instruction is for technical information only and cannot be used as a basis for a warranty claim.