English - SEBU8190
SEBU8190-00
April 2006
Operation and
Maintenance
Manual
4006 TRS Gas and 4008 TRS Gas
Industrial Engines
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
SEBU8190
Table of Contents
3
Table of Contents
Index Section
Index ..................................................................... 68
Foreword ................................................................. 4
Safety Section
Safety Messages .................................................... 5
General Hazard Information ................................... 7
Burn Prevention ...................................................... 9
Fire Prevention and Explosion Prevention .............. 9
Crushing Prevention and Cutting Prevention ......... 11
Mounting and Dismounting .................................... 11
Ignition Systems .................................................... 11
Before Starting Engine ........................................... 11
Engine Starting ..................................................... 12
Engine Stopping ................................................... 12
Electrical System .................................................. 12
Product Information Section
Model Views and Specifications ........................... 14
Product Identification Information ........................ 20
Operation Section
Lifting and Storage ................................................ 22
Gauges and Indicators .......................................... 23
Features and Controls .......................................... 24
Engine Starting ..................................................... 27
Engine Operation .................................................. 30
Engine Stopping ................................................... 31
Maintenance Section
Refill Capacities .................................................... 33
Maintenance Interval Schedule ............................ 36
Reference Information Section
Reference Materials .............................................. 64
4
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.
English is the primary language for all Perkins
publications. The English used facilitates translation
and consistency.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Perkins dealer or your Perkins
distributor for the latest available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
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Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
more frequent lubrication and maintenance than is
specified in the Maintenance Interval Schedule may
be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of
the original requirement. We recommend that the
maintenance schedules be reproduced and displayed
near the engine as a convenient reminder. We also
recommend that a maintenance record be maintained
as part of the engine’s permanent record.
Your authorized Perkins dealer or your Perkins
distributor can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
Overhaul
Major engine overhaul details are not covered in
the Operation and Maintenance Manual except
for the interval and the maintenance items in that
interval. Major repairs should only be carried out by
Perkins authorized personnel. Your Perkins dealer
or your Perkins distributor offers a variety of options
regarding overhaul programs. If you experience
a major engine failure, there are also numerous
after failure overhaul options available. Consult with
your Perkins dealer or your Perkins distributor for
information regarding these options.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm. Battery
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.
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5
Safety Section
Safety Messages
Safety Section
i02409464
Safety Messages
g01269446
Illustration 1
Typical example
(1) Engine Derate
(2) Universal warning
There may be several specific warning signs on your
engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become familiar with all warning signs.
Ensure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if
the words cannot be read or if the illustrations are
not visible. Use a cloth, water, and soap to clean
the warning signs. Do not use solvents, gasoline, or
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning signs. The warning signs that are loosened
could drop off of the engine.
(3) Engine Oil Level
Replace any warning sign that is damaged or
missing. If a warning sign is attached to a part of the
engine that is replaced, install a new warning sign on
the replacement part. Your Perkins dealer or your
distributor can provide new warning signs.
The safety messages that may be attached on the
engine are illustrated .
6
Safety Section
Safety Messages
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(1) Engine Derate
g01241021
Illustration 2
Typical example
The warning label for derating engine information (1)
is located on the governor control unit. The governor
control unit is located on the right hand side of the
engine.
(2) Universal Warning
Do not operate or work on this equipment unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.
Illustration 3
Typical example
g01234595
The Universal Warning label (2) is located on the
fuse box for the ignition system. The fuse box for
the ignition system is located on the right hand side
of the engine.
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7
Safety Section
General Hazard Information
(3) Engine Oil Level
g01241033
Illustration 4
Typical example
The warning label for checking the engine oil Level
(3) is located on the inlet manifold. The inlet manifold
is located on the right hand side of the engine.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
i02414560
General Hazard Information
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps
• Grease fittings
• Pressure taps
• Breathers
• Drain plugs
Illustration 5
g00104545
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine
is repaired.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
8
Safety Section
General Hazard Information
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Pressure Air and Water
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.
When pressure air and/or pressure water is used for
cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a protective face shield.
Illustration 6
g00702020
• Wear a hard hat, protective glasses, and other
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration
protective equipment, as required.
• When work is performed around an engine that is
operating, wear protective devices for ears in order
to help prevent damage to hearing.
• Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the engine.
• Ensure that all protective guards and all covers are
secured in place on the engine.
• Never put maintenance fluids into glass containers.
Glass containers can break.
• Use all cleaning solutions with care.
• Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot be started.
• Disconnect the batteries when maintenance
is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• Do not attempt any repairs that are not understood.
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
• If work is carried out on the fuel system obey the
local regulations for isolation of the gas supply.
California Proposition 65 Warning
Illustration 7
g00687600
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
Some constituents of engine exhaust are known to
the State of California to cause cancer, birth defects,
and other reproductive harm.
Obey all local regulations for the disposal of liquids.
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9
Safety Section
Burn Prevention
Dispose of Waste Properly
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot components
to contact the skin.
If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Illustration 8
g00706404
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
i02415237
i02414602
Burn Prevention
Fire Prevention and Explosion
Prevention
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure in
the appropriate system before any lines, fittings or
related items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator, the heat exchanger, the
heater and lines contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the
cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool. Ensure
that the filler cap is cool before removing the filler
cap. The filler cap must be cool enough to touch with
a bare hand. Remove the filler cap slowly in order
to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Illustration 9
g00704000
All fuels, most lubricants, and some coolant mixtures
are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
an emergency shutdown.
10
Safety Section
Fire Prevention and Explosion Prevention
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Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
If the application involves the presence of combustible
gases, consult your Perkins dealer for additional
information about suitable protection devices. All
local regulations must be observed.
Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
Illustration 10
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
a hose, or a seal failure. Exhaust shields must be
installed correctly.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines that contain flammable
fluid. Clean any such lines thoroughly with a
nonflammable solvent prior to welding or flame
cutting.
Wiring must be kept in good condition. All electrical
wires must be properly routed and securely attached.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or unnecessary.
Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
deterioration. The hoses must be properly routed.
The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
Oil filters and fuel filters must be properly installed.
The filter housings must be tightened to the proper
torque.
g00704135
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This may cause an
explosion.
The batteries must be kept clean. The covers
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
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11
Safety Section
Crushing Prevention and Cutting Prevention
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Perkins dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
i02453744
Mounting and Dismounting
The steps or handholds may not be installed on the
engine. Refer to the OEM for information before any
maintenance or repair is performed.
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
• Outer coverings are chafed or cut.
• Wires are exposed.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
controls as handholds.
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
i02143194
Crushing Prevention and
Cutting Prevention
Support the component correctly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
i02415253
Ignition Systems
Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and
wiring.
i02453806
Before Starting Engine
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
Ensure that the engine is equipped with a lighting
system that is suitable for the conditions. Ensure that
all lights work properly.
12
Safety Section
Engine Starting
SEBU8190
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Engine Stopping
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to the instructions in this Operation and
Maintenance Manual, “Engine Stopping” topic
(Operation Section).
The initial start-up of a new engine or a engine that
has been serviced make provision to shut the engine
off, in order to stop an overspeed. This may be
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corrected.
i02426322
Engine Starting
i00659907
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop
the engine if an overspeed occurs. This may be
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
i02436641
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
Electrical System
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
If there is a possibility that unburned gas remains in
the exhaust system, refer to the purge procedure in
this Operation and Maintenance Manual, “Engine
Starting” topic in the Operation Section.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature and the oil
temperature during heater operation.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “í” cable should be connected last from the
external power source to the negative “í” terminal
of the starting motor. If the starting motor is not
equipped with a negative “í” terminal, connect the
cable to the engine block.
Check the electrical wires daily for wires that
are loose or frayed. Tighten all loose electrical
connections before the engine is started. Repair all
frayed electrical wires before the engine is started.
See the Operation and Maintenance Manual for
specific starting instructions.
Grounding Practices
Note: All ground lines must return to the battery
ground.
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Illustration 11
13
Safety Section
Electrical System
g01217202
Typical example
(1) Starting motor to ground
(2) Battery negative to engine
Correct grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to the crankshaft bearing journal surfaces
and to aluminum components.
The connections for the grounds should be tight and
free of corrosion. The engine alternator must be
grounded to the negative “-” battery terminal with
a wire that is adequate to handle the full charging
current of the alternator.
The power supply connections and the ground
connections for the engine electronics should always
be from the isolator to the battery.
14
Product Information Section
Model Views and Specifications
SEBU8190
Product Information
Section
Model Views and
Specifications
i02415298
Model View Illustrations
The illustrations show various typical features of
4000 Series TRS Engine. The illustrations do not
show all of the options that are available.
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15
Product Information Section
Model Views and Specifications
Illustration 12
g01207301
Typical example
(1)
(2)
(3)
(4)
Air filter
Governor control unit
Fuses for the ignition system
Ignition
(5)
(6)
(7)
(8)
Water temperature regulator
Oil filler cap
Alternator
Oil level gauge (dipstick)
(9) Engine oil filters
(10) Relay
(11) Starting motor
(12) Charge air cooler
16
Product Information Section
Model Views and Specifications
SEBU8190
g01215253
Illustration 13
Typical example
(13) Ignition coil
(14) Zero pressure regulator
(15) Turbocharger
(16) Closed breather system
(17) The inspection cover for the Crankcase
(18) Drain plug
i02430841
Product Description
The Perkins Engines were developed in order to
provide gas engines for generator set applications.
The engines have the ability to burn a wide variety of
gaseous fuels.
Fuel System
The fuel is delivered to the zero pressure regulator.
The gas must be at a constant pressure and the gas
must be stable. The pressure must be within a range
of 1.5 to 5 kPa (0.21 to 0.72 psi). Higher pressure will
need to be reduced with an additional gas regulator.
(19) Secondary water pump
The venturi must be selected for the engine. This
selection is based on the composition of the gas that
will be used.
Any change in the composition of the gas may require
a change to the venturi.
The venturi is located in the gas mixer body
immediately before the turbocharger. As air is
accelerated through the venturi gas is mixed with the
air. This mixture is compressed by the turbocharger.
the mixture passes through the charge cooler and
into the inlet manifold. The speed and the load is
governed by an electronically controlled throttle valve.
The air/fuel ratio is adjustable by the main adjustment
screw. This screw is located on the gas mixer body
before the venturi. This is the only means of adjusting
the exhaust emissions at full load.
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17
Product Information Section
Model Views and Specifications
Ignition System
• Battery charging alternator
The engine is equipped with an Electronic Ignition
System (EIS). The EIS provides dependable firing
and low maintenance. The EIS provides precise
control of the following factors:
The system is used when recovery of heat is not an
important factor.
• Voltage
Cogeneration uses energy from heat which would
otherwise be wasted.
• Duration of the spark
• Ignition timing
The TRS2 engine is equipped with protection from
detonation. The TRS1 engine may be equipped with
protection for detonation as an option.
The ignition timing is retarded when excessive
detonation is sensed. If detonation continues after full
retardation, then the engine must be shut down.
Lubrication System
The engine lubrication oil is supplied by a pump
that is driven by a gear. The oil is cooled and the
oil is filtered. A bypass valve provides unrestricted
flow of lubrication oil to the engine parts if the
oil filter elements become plugged. The bypass
valve will open if the oil filter differential pressure
reaches 34.4 to 48.2 kPa (5 to 7 psi). The engine oil
pressure operates in a range of 413.6 to 448.1 kPa
(60 to 65 psi).
Note: The engine lubrication oil is not filtered when
the bypass valve is open. Do not allow the engine
to operate when the bypass valve is open. This can
damage the engine components.
Cogeneration engine
The following items are not supplied:
• Water pumps
• Water temperature regulator ( thermostat)
• All water tube assemblies
This system is the responsibility of the OEM.
Engine Service Life
Engine efficiency and maximum utilization of engine
performance depend on adherence to proper
operation and maintenance recommendations. This
includes the use of recommended lubricants, fuels,
and coolants.
For the engine maintenance that is required,
refer to the Operation and Maintenance Manual,
“Maintenance Interval Schedule” in the Maintenance
Section.
i02415458
Specifications
Cooling System
The water enters the engine from the oil cooler and
the water is passed through the cylinder block. The
water exits the cylinder head into the rail. The water
exits the engine from the water outlet.
General Engine Specifications
Electrounit
This type of engine is supplied with the following
components:
• Jacket water coolant pump
• Water temperature regulator (thermostat)
• Coolant pipe for the charge cooler
• A water pump for the charge cooler
• A water temperature regulator (thermostat) that
controls the system for the charge cooler
Illustration 14
Six cylinder
(A) Inlet valves
(B) Exhaust valves
g01216853
18
Product Information Section
Model Views and Specifications
SEBU8190
Table 1
4006 Engine Specifications
Rated rpm
1500
Cylinders and arrangement
In-line six cylinders
Bore
160 mm (6.2992 inch)
Stroke
190 mm (7.4803 inch)
Displacement
22.9 L (1397.4436 in3)
Compression ratio
Aspiration
12:1
Turbocharged
Rotation (flywheel end)
Counterclockwise
Inlet valve lash (cold)
0.40 mm (0.0157 inch)
Exhaust valve lash (cold)
0.40 mm (0.0157 inch)
Firing order
1,5,3,6,2,4
g01207434
Illustration 15
Eight cylinder
(A) Inlet valves
(B) Exhaust valves
Table 2
4008 Engine Specifications
Rated rpm
Cylinders and arrangement
1500
In-line eight cylinder
Bore
160 mm (6.2992 inch)
Stroke
190 mm (7.4803 inch)
Displacement
30.56 L (1864.8855 in3)
Compression ratio
Aspiration
Rotation (flywheel end)
12:1
Turbocharged
Counterclockwise
Inlet valve lash (cold)
0.40 mm (0.0157 inch)
Exhaust valve lash (cold)
0.40 mm (0.0157 inch)
Firing order
1,4,7,6,8,5,2,3
SEBU8190
19
Product Information Section
Model Views and Specifications
Piston Positions for Valve Lash
Setting
Table 3
The six cylinder engine
Top Center Position
Engine cylinder with valves
on the rock
Set the bridge adjustment and
set valve lash.
1-6
6
1
2-5
2
5
3-4
4
3
1-6
1
6
2-5
5
2
3-4
3
4
Table 4
The eight cylinder engine
Top Center Position
Engine cylinder with valves
on the rock
Set the bridge adjustment and
set valve lash.
1-8
8
1
4-5
5
4
2-7
2
7
3-6
3
6
1-8
1
8
4-5
4
5
2-7
7
2
3-6
6
3
20
Product Information Section
Product Identification Information
SEBU8190
Product Identification
Information
Perkins dealers and Perkins distributors require all of
these numbers in order to determine the components
that were included in the engine. This permits
accurate identification of replacement part numbers.
i02531889
Plate Locations and Film
Locations
Serial Number Plate
Engine Identification
Perkins engines are identified by an engine serial
number.
A typical example of an engine serial number is
DGE F**** U00001M.
D _________________________________________ Made in Stafford
G ____________________________________Application (Table 5)
E ________________________________Type of engine (Table 6)
F _________________________Number of cylinders (Table 7)
***** __________________________________Fixed build number
U ____________________________Built in the United Kingdom
00001 ____________________________________Engine Number
M ____________________________________Year of Manufacture
Illustration 16
Serial number plate
The engine serial number plate contains the following
information:
• Place of manufacture
• Telephone number of manufacturer
Table 5
Application
G
Genset
I
Gas
• Fax number of manufacturer
• Type of engine
• Engine serial number
Table 6
Type of engine (Gas)
• Rated speed
F
TESI Gas Unit
• Power output
E
TESI Combined Heat and Power Unit
G
4016-E61 TRS
H
TRS Combined Heat and Power Unit
J
TRS Gas Unit
Table 7
Number of Cylinders
F
6
H
8
g01266904
• Engine timing
• Rating
SEBU8190
Illustration 17
21
Product Information Section
Product Identification Information
g01212991
Location of the serial number plate for in-line engines
The serial number plate (1) on an in-line engine is
located on the right side of the cylinder block. See
Illustration 17.
22
Operation Section
Lifting and Storage
SEBU8190
Operation Section
Some removals require lifting fixtures in order to
obtain proper balance and safety.
Lifting and Storage
To remove the engine ONLY, use the lifting eyes that
are on the engine.
i02427136
Product Lifting
Lifting eyes are designed and installed for the specific
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Perkins dealer for information regarding fixtures for
proper engine lifting.
i02427139
Product Storage
Refer to Perkins Engine Company limited, Stafford
for information on engine storage.
There is three different levels of engine storage.
Level “A, B and C”.
Level “A ”
Level “A” will give protection for six month for diesel
engines and protection for one year for gas engines.
This is for engines that are transported by a container
or a truck.
Level “B ”
Illustration 18
g01203936
Typical example
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle
between the supporting members and the object becomes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
This level is additional to level “A”. Level “B ” will
give protection under normal storage condition from
í15° to +55°C (5.0000° to 99.0000°F) and “90%”
relative humidity for one year.
Level “C ”
This level is additional to level “B”. Level “C” will give
protection for five year in tropical temperatures or
arctic climates. Level “C” also meets MOD NES 724
level “J” for europe, when engines are stored in a
unheated building or in the open under waterproof
covers.
SEBU8190
23
Operation Section
Gauges and Indicators
Gauges and Indicators
i02427382
Gauges and Indicators
Your engine may not have the same gauges or all of
the gauges that are described. For more information
about the gauge package, see the OEM information.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a period of time.
Noticeable changes in gauge readings indicate
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if the readings are within specifications.
Determine and correct the cause of any significant
change in the readings. Consult your Perkins dealer
or your Perkins distributor for assistance.
NOTICE
If no oil pressure is indicated, STOP the engine. If
maximum coolant temperature is exceeded, STOP
the engine. Engine damage can result.
Engine Oil Pressure – The range for
the engine oil pressure is 415 to 450 kPa
(60 to 65 psi).
Jacket Water Coolant Temperature –
Typical water temperature into the engine
is 71°C (160°F). Higher temperatures
may occur under certain conditions. The water
temperature reading may vary according to load. The
reading should never exceed 96°C (204°F).
1. A high water temperature switch is installed in the
cooling system.
Tachometer – This gauge indicates engine
speed (rpm).
Ammeter – This gauge indicates the
amount of charge or discharge in the
battery charging circuit. Operation of the
indicator should be to the right side of “0” (zero).
Service Hour Meter – The gauge indicates
operating hours of the engine.
24
Operation Section
Features and Controls
SEBU8190
Features and Controls
i02427718
i02427696
Sensors and Electrical
Components
Performance Parameters
Electronic Ignition System (EIS)
Air/Fuel Ratio
The correct air/fuel ratio is very important for the
following considerations:
• Margin of detonation
• Control of emissions
• Achieving optimum service life for the engine
If the air/fuel ratio is not appropriate for the fuel and
the operating conditions, a failure of the engine may
occur. The service life of the turbocharger, the valves,
and other components may be reduced.
Fuel Supply Pressure and Temperature
The fuel supply for the zero pressure regulator
must be at a constant pressure of 1.5 to 5 kPa
(0.21 to 0.72 psi). If a higher pressure is required a
separate gas regulator must be installed into the fuel
line.
The minimum temperature for the gas into ZPR is
5 °C (41.0 °F). The maximum temperature into the
ZPR is 40 °C (104.0 °F).
Zero Gas Pressure Regulator
The zero gas pressure regulator is a control valve that
operates on demand. The pitot tube in the regulator
outlet controls the flow. As the air is drawn through
the venturi a depression is created. Gas at higher
pressure is drawn in. This is mixed into the air flow.
This mixture then passes through the turbocharger.
As the engine load increases the pressure at the
outlet of the ZPR is reduced and the valve opens
supplying more gas.
Air, Charge Cooler Water
Temperature and Altitude
The Electronic Ignition System includes the following
components:
• The control module for the ignition
• Timing sensor
• Ignition coil on each cylinder
• Spark plugs
• Ignition harness
The ignition system generates high voltage. Do
not come in contact with the ignition system with
the engine in operation. This voltage can cause
personal injury or death.
The EIS control module is a sealed unit with no
serviceable parts. The timing sensor uses the
magnets that are mounted on the camshaft in order
to generate the timing pulses. One pulse for each
cylinder plus an index magnet in order to indicate the
start of each cycle. The EIS control module has a
output to each ignition coil. To initiate combustion in
each cylinder, the EIS sends a pulse to the primary
winding of the ignition coil. The coil increases the
voltage on the secondary winding which creates a
spark across the spark plug electrode.
The electronic ignition system provides control for the
following activities:
• Ignition timing
• Protection from detonation (if equipped)
Switches
The engine is installed with the following switches.
Refer to technical date sheet for the charts for
the derate in order to determine the maximum
temperatures into the engine and the altitude derate.
• High cooling water temperature switch
• Low oil pressure switch
• Overspeed switch and magnetic pickup
• High pressure switch for the manifold
SEBU8190
25
Operation Section
Features and Controls
Governor
The engine is installed with a digital governor that
includes the following components:
Engines may be equipped with optional engine
protective devices that are not included in this section.
This section contains some general information about
the function of typical engine protective devices.
Alarms and shutoffs are electronically controlled.
The operation of all alarms and shutoffs utilize
components which are actuated by a sensing unit.
The alarms and shutoffs are set at critical operating
temperatures, pressures, or speeds in order to
protect the engine from damage.
• Digital governor
• Actuator and throttle valve
• Magnetic pickup
• Wiring harness
The governor uses the magnetic pickup to sense
engine speed from the flywheel gear teeth. This
signal is fed into the governor, which drives an
actuator. This is connected to the throttle valve in
order to control the amount of combustion gas/air.
A Pandaros Packager service tool and cable are
required in order to make any adjustments to the
system.
The alarms function in order to warn the operator
when an abnormal operating condition occurs. The
shutoffs function in order to shut down the engine
when a more critical abnormal operating condition
occurs. The shutoffs help to prevent damage to the
engine.
Shutoffs may cause unburned gas to remain in the
air inlet and in the exhaust manifold.
Detonation System ( If Equipped)
The equipment for the detonation system is available
to sense detonation or knock which may be caused
by poor gas or may be caused by high combustion
temperatures.
The detonation system includes the following
components:
Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal
injury and/or property damage may result.
Before starting an engine that may contain unburned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.
• Detonation sensor on each cylinder
If an engine protective device shuts off the engine,
always determine the cause of the shutoff. Make
the necessary repairs before attempting to start the
engine.
• Control module for detonation
• Wiring harness
The detonation system operates by measuring
vibrations on the crankcase. The signal is processed
in order to eliminate normal engine vibrations. If
detonation above a predetermined level is detected
the engine timing is retarded. If the engine continues
detonation the detonation system will operate in order
to stop the engine. If detonation ceases, the ignition
timing that is retarded will be gradually brought back
to a normal value.
Become familiar with the following information:
• Types of the alarm and shutoff controls
• Locations of the alarm and shutoff controls
• Conditions which cause each control to function
• Resetting procedure that is required before starting
the engine
i02427728
Alarms and Shutoffs
Testing Alarms and Shutoffs
The OEM will supply this system. Refer to the OEM
for more information.
Alarms must function properly in order to provide
timely warning to the operator. Shutoffs help to
prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.
26
Operation Section
Features and Controls
SEBU8190
NOTICE
During testing, abnormal operating conditions must be
simulated.
The tests must be performed correctly in order to prevent possible damage to the engine.
Periodic testing of engine protective devices for
proper operation is recommended maintenance. To
prevent damage to the engine, only authorized
service personnel should perform the tests.
i02452757
Control Panel
Refer to the OEM for information on the control panel
that is installed.
SEBU8190
27
Operation Section
Engine Starting
Engine Starting
• If the engine is not equipped with a header tank
i02452805
Before Starting Engine
maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant
level in the sight glass.
• Observe the air cleaner service indicator. Service
Before the engine is started, perform the required
daily maintenance and any other periodic
maintenance that is due. Refer to the Operation
and Maintenance Manual, “Maintenance Interval
Schedule” for more information.
the air cleaner when the diaphragm enters the red
zone, or when the red piston locks in the visible
position.
• Remove any electrical loads.
i02427758
• For the maximum service life of the engine, make a
thorough inspection within the engine compartment
before the engine is started. Look for the following
items: oil leaks, coolant leaks, loose bolts, and
excessive dirt and/or grease. Remove any excess
dirt and/or grease buildup. Repair any faults that
were identified during the inspection.
• Inspect the cooling system hoses for cracks and
for loose clamps.
• Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage.
• Inspect the wiring for loose connections and for
worn wires or frayed wires.
• Open the fuel supply valve (if equipped).
Cold Weather Starting
A jacket water heater is required for starting when the
temperature is below 10 °C (50 °F). The temperature
of the jacket water should be maintained at 40 °C
(104 °F).
Note: A oil pan immersion heater must not be
installed.
Extra battery capacity may be necessary in order to
start the engine.
Consult your Perkins dealer for more information on
the starting aids that are available for cold weather
starting.
• Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
to the controls.
i02427781
Starting the Engine
• Ensure that the areas around the rotating parts are
clear.
• All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair
any damaged guards. Replace damaged guards
and/or missing guards.
• Check electrical cables and check the battery for
poor connections and for corrosion.
• Reset all of the shutoffs or alarm components (if
equipped).
• Check the engine lubrication oil level. Maintain the
oil level between the “ADD” mark and the “FULL”
mark on the engine oil level gauge.
• Check the coolant level. Observe the coolant level
in the header tank (if equipped). Maintain the
coolant level to the “FULL” mark on the header
tank.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
fuel supply and/or the ignition to the engine.
28
Operation Section
Engine Starting
SEBU8190
Purging Unburned Gas
Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal
injury and/or property damage may result.
Before starting an engine that may contain unburned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.
The OEM will supply this system. Refer to the OEM
for more information.
Note: Using the “EMERGENCY STOP” button will
shut off both the fuel and the ignition.
Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or to
the controls.
The following events cause unburned gas to remain
in the air inlet and in the exhaust manifold:
• Emergency stop
• Engine overspeed
• Unsuccessful successive attempts to start the
engine
Unburned gas may remain in the air inlet and exhaust
system after several unsuccessful attempts to start
the engine. The unburned gas may increase to a
concentration that may ignite during a successive
attempt to start the engine.
Perform the following procedure in order to purge
the unburned gas:
1. Turn the manual gas shutoff valve to the CLOSED
position.
Ensure that no one will be endangered before the
engine is started and when the engine is started.
2. Disable the ignition system. Remove the fuses
from the ignition.
Perform the procedures that are described in this
Operation and Maintenance Manual, “Before Starting
Engine” (Operation Section).
3. Turn the engine control switch to the START
position. Crank the engine for a minimum of six
seconds.
Final Checks and First Engine Start
4. Enable the ignition by connecting the fuses that
was disconnected in Step 2.
Note: The fuel system must comply with all local
regulations.
The OEM will supply this system. Refer to the OEM
for more information.
1. The starting and the stopping of the engine must
be on no load.
2. The procedure for starting and stopping a radiator
cooled and CHP gas engine will be determined
by the OEM relative to each individual engine
installation.
5. Turn the manual gas shutoff valve to the OPEN
position.
6. Start the engine. Refer to the engine starting
procedure and refer to OEM in order to start the
engine.
Engine Starting Procedure
Note: The starting procedure may differ because of
the OEM system that is installed.
1. The signal is received.
3. Operate the engine at rated speed for ten minutes.
4. Inspect the engine for leaks in the oil system and
the coolant systems.
5. Stop the engine and check the engine oil and the
engine coolant level.
6. Operate the engine under normal working
conditions. Check the gauges in order to see the
condition of the engine.
7. If the engine fails to start after two attempts turn
off the gas supply and investigate the cause.
2. Check that the gas pressure is in limits. If the gas
pressure is incorrect a warning is activated and
the electrical system will shut down. If the gas
pressure is in limits, go to the next step.
3. Activate the governor.
4. Activate the starter.
5. Operate the engine for three seconds in order to
purge the system.
SEBU8190
29
Operation Section
Engine Starting
6. Activate the gas valve and activate the ignition.
Continue to operate the starter.
1. After the engine is started disengage the starter.
Note: If the engine fails to start after the maximum
cranking time, the engine will be shut down.
2. The engine is now operating.
Operation of the Generator Set
Control Panel
For information on operation for a specific generator
set control panel, refer to the Operation and
Maintenance Manual for the generator and the
control panel.
Automatic Starting
When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid personal
injury, always remain clear of the the engine when
the engine is in the AUTOMATIC mode.
Manual starting
Refer to the OEM manual for information on the
controls in order to manually start the engine.
i02428473
Starting with Jump Start
Cables
Do not use jump start cables in order to start the
engine. Charge the batteries or replace the batteries.
Refer to Operation and Maintenance Manual,
“Battery - Replace”.
i02428529
After Starting Engine
For new installations and engines that are recently
rebuilt, carefully monitor the engine in order to detect
any unusual engine performance.
Check for leaks in the air and in the fluid systems.
30
Operation Section
Engine Operation
SEBU8190
Engine Operation
i02428569
Engine Operation
Proper operation and maintenance are key factors in
attaining the maximum service life and economy for
the engine. Follow the instructions in this Operation
and Maintenance Manual in order to minimize
operating costs and maximize the service life of the
engine.
Observe the gauges frequently while the engine is
operating. Record the data from the gauges in a log
regularly. Compare the data to the specifications
for normal engine operation. Comparing the data
over time will help to detect changes in engine
performance.
Investigate any significant change in the gauge
readings. Monitor the engine operation and take
action when discrepancies are found.
Partial load and Low Load
Operation
Extended operation at low load or reduced load will
cause the following results:
• Carbon formation in the cylinder
• Detonation
• Power loss
• Poor performance
• Accelerated wear of components
• Increased oil consumption
• The cylinder bore to glaze
SEBU8190
31
Operation Section
Engine Stopping
Engine Stopping
2. With the engine stopped, switch off the ignition
and switch off the governor.
i02428635
Emergency Stopping
3. If an overspeed occurs, switch off the ignition, the
gas valve and the governor..
4. If another engine fault occurs switch off the gas
valve.
The OEM will supply the system.
i02453745
NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.
Pressing the Emergency Stop Button may cause
unburned gas to remain in the air inlet and in the
exhaust manifold.
Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal
injury and/or property damage may result.
Before starting an engine that may contain unburned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.
The emergency stop button is in the OUT position
for normal engine operation. Push the button for
emergency stopping. This shuts off both the fuel
and the ignition. The engine will not start when the
button is locked. To reset the button, turn the button
clockwise. The spring-loaded button will return to the
OUT position.
NOTICE
Do not use this method to stop the engine unless
an emergency has occurred. Continuous emergency
shutdowns can cause damage to some engine components. This will leave unburned fuels in the combustion chambers and in the exhaust system. If an emergency shutdown occurs, purge the system by cranking
the engine for 5 to 10 seconds with the ignition shutoff.
Typical Procedure in Order to Stop
the Engine
Note: The stopping procedure will differ because
of the different types of OEM controls that can be
installed.
1. In order to stop the engine, switch off the gas
valve.
Manual Stop Procedure
In order to manually stop the engine, refer to the
OEM for information. The procedure will depend on
the system that has been installed.
NOTICE
Stopping the engine immediately after the engine has
been operating under a load can result in overheating
and accelerated wear of the engine components.
Allow the engine to gradually cool before stopping the
engine.
32
Operation Section
Engine Stopping
SEBU8190
i02508920
After Stopping Engine
• Check the engine crankcase oil level. Maintain
the oil level between the “ADD” and “FULL” marks
on the “ENGINE STOPPED” side of the oil level
gauge.
• If necessary, perform minor adjustments. Repair
any leaks and tighten loose bolts.
• Note the service hour reading. Perform the
maintenance that is scheduled in this Operation
and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section).
NOTICE
Only use antifreeze/coolant mixtures recommended in
the Refill Capacities and Recommendations section of
this manual. Failure to do so can cause engine damage.
• Allow the engine to cool. Check the coolant level.
• If freezing temperatures are expected, check the
coolant for protection against freezing. The cooling
system must be protected against freezing to the
lowest expected outside temperature. Add the
proper coolant/water mixture, if necessary.
• Perform all required periodic maintenance on all
driven equipment. Refer to the instructions that are
provided by the OEM of the driven equipment.
SEBU8190
33
Maintenance Section
Refill Capacities
Cooling System
Maintenance Section
Refill Capacities
i02478642
Refill Capacities
To maintain the cooling system, the Total Cooling
System capacity must be known. The approximate
capacity is for the engine cooling system. External
System capacities will vary among applications.
Refer to the OEM specifications for the External
System capacity. This capacity information will be
needed in order to determine the amount of coolant
that is required for the Total Cooling System.
TRS 4006
Lubrication System
Table 10
The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will
require additional oil. Refer to the OEM specifications
for the capacity of the auxiliary oil filter. Refer to this
Manual, “Maintenance Section” for more information
on fluid recommendations.
TRS 4006
Refill Capacities
Compartment or System
Engine block only
Compartment or System
(2)
Crankcase Oil Sump(1)
Liters
Quarts
122.7
129.6
(2)
These values are the approximate capacities for the crankcase
oil sump which includes the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil
filter.
The Total Lubrication System includes the capacity for the
Crankcase Oil Sump plus the capacity of factory installed oil
filters and other filters added to the lubrication system. Enter
the value for the capacity of the Total Lubrication System in
this row.
TRS 4008
Refill Capacities
Compartment or System
Engine block only
External System Per
Table 9
(2)
TRS 4008
Refill Capacities
Total Lubrication
(1)
(2)
Liters
Quarts
166.6
176
System(2)
These values are the approximate capacities for the crankcase
oil sump which includes the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil
filter.
The Total Lubrication System includes the capacity for the
Crankcase Oil Sump plus the capacity of factory installed oil
filters and other filters added to the lubrication system. Enter
the value for the capacity of the Total Lubrication System in
this row.
Liters
Quarts
48
64.4
OEM(1)
Total Cooling System(2)
TRS 4008
Crankcase Oil Sump(1)
The External System includes a radiator or an expansion
tank with the following components: heat exchanger and
piping. Refer to the OEM specifications. Enter the value for the
capacity of the External System in this row.
The Total Cooling System capacity includes the capacity of
the Engine plus the External System. Enter the value for the
capacity of the Total Cooling System in this row.
TRS 4008
(1)
Compartment or System
42.3
Table 11
Total Lubrication System(2)
(1)
36
Total Cooling System(2)
Table 8
TRS 4006
Refill Capacities
Quarts
External System Per OEM(1)
(1)
TRS 4006
Liters
The External System includes a radiator or an expansion
tank with the following components: heat exchanger and
piping. Refer to the OEM specifications. Enter the value for the
capacity of the External System in this row.
The Total Cooling System capacity includes the capacity of
the Engine plus the External System. Enter the value for the
capacity of the Total Cooling System in this row.
34
Maintenance Section
Refill Capacities
SEBU8190
i02481783
Fluid Recommendations
General Lubricant Information
Engine Oil
The engine oil recommendation for an application
can change due to advances in the specification
of the oil. Refer to Perkins Engines Stafford for the
latest information.
Multigrade oils must not be used.
Recommendation
Engines that operate on natural gas should be
lubricated by oils that have a nominal ash content
of 0.5% by weight. The total base number must be
between 5 and 7. The following SAE40 monograde
engine oils comply:
• Mobil Pegasus 705
• Texaco/Caltex Geotex LA
• Q8 Mahler MA
• Castrol Duratec L
• The oil change interval for Mobil Pegasus HPC40
is up to 2000 hours. Use scheduled oil analysis in
order to determine the oil change interval.
• Mobil Pegasus 805
Oil analysis
The oil analysis will complement the preventive
maintenance program.
The oil analysis is a diagnostic tool that is used to
determine oil performance and component wear
rates. Contamination can be identified and measured
through the use of the oil analysis. The oil analysis
includes the following tests:
• The Wear Rate Analysis monitors the wear of the
engine’s metals. The amount of wear metal and
type of wear metal that is in the oil is analyzed. The
increase in the rate of engine wear metal in the
oil is as important as the quantity of engine wear
metal in the oil.
• Tests are conducted in order to detect
contamination of the oil by water, glycol or fuel.
• The Oil Condition Analysis determines the loss of
the oil’s lubricating properties. An infrared analysis
is used to compare the properties of new oil to the
properties of the used oil sample. This analysis
allows technicians to determine the amount of
deterioration of the oil during use. This analysis
also allows technicians to verify the performance
of the oil according to the specification during the
entire oil change interval.
Fuel Specification
A new engine is set to operate with clean natural gas
that conforms to the British natural gas specifications.
Refer to Perkins Engines Stafford in order to use a
different specification of gas.
Cooling System Specifications
• BP Energas NGL
• Shell Mysella LA
• Total Nateria MH40
• Chevron HPLX low ash
• Chevron/Caltex HDAX 0% and 0.5% sulfated ash.
The oil has a lower total base number than the
recommended minimum value. The additive will
give the equivalent performance.
• The oil change interval for any of the oils must be
General Coolant Information
NOTICE
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first.
NOTICE
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temperature or drained completely to prevent damage.
approved by Perkins Engines Stafford.
• Engines which operate on landfill gas must use
the oil that is currently recommended by Perkins
Engines Stafford. These oils have a higher ash
content.
NOTICE
Frequently check the specific gravity of the coolant for
proper freeze protection or for anti-boil protection.
Clean the cooling system for the following reasons:
SEBU8190
• Contamination of the cooling system
• Overheating of the engine
• Foaming of the coolant
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system problems can develop without water temperature regulators.
Many engine failures are related to the cooling
system. The following problems are related to cooling
system failures: Overheating, leakage of the water
pump, and plugged radiators or heat exchangers.
These failures can be avoided with correct cooling
system maintenance. Cooling system maintenance is
as important as maintenance of the fuel system and
the lubrication system. Quality of the coolant is as
important as the quality of the fuel and the lubricating
oil.
Coolant is normally composed of three elements:
Water, additives, and glycol.
Water
Water is used in the cooling system in order to
transfer heat.
Distilled water or deionized water is
recommended for use in engine cooling systems.
DO NOT use the following types of water in cooling
systems: Hard water, softened water that has been
conditioned with salt, and sea water.
For a water analysis, consult one of the following
sources:
• Local water utility company
• Agricultural agent
• Independent laboratory
Coolant Recommendations
Use 50 percent ethylene glycol and 50 percent clean
soft water in the cooling system. You can use 50
percent propylene glycol and 50 percent clean soft
water in the cooling system. Also use an inhibitor in
the cooling system.
35
Maintenance Section
Refill Capacities
Use 21825735 powerpart inhibitor for cooling
systems that operate in temperatures above 10 °C
(50 °F). This cooling system must use clean soft
water.
21825735 powerpart innibitor can be used in
systems that use combined heat and power.
Refer to Perkins Engines Stafford for the correct
coolant for your cooling system. The incorrect coolant
will damage the cooling system.
36
Maintenance Section
Maintenance Interval Schedule
SEBU8190
i02451168
Maintenance Interval Schedule
Initial 1000 Service Hours or 1 Year
Crankshaft Vibration Damper - Inspect ................. 43
Every 1000 Service Hours
Engine - Clean ...................................................... 44
When Required
Battery - Replace ..................................................
Cooling System Coolant - Change .......................
Engine Air Precleaner - Clean ..............................
Engine Oil - Change .............................................
Engine Oil Filter (Auxiliary) - Change ...................
Engine Oil Filter - Change ....................................
Fuel Filtration System - Service ............................
Ignition System Timing - Check/Adjust .................
Overhaul (In-Frame) .............................................
Overhaul (Major) ...................................................
Overhaul (Top End) ...............................................
Overhaul Considerations ......................................
Radiator - Clean ....................................................
Water Temperature Regulator - Replace ..............
39
40
46
48
48
49
54
57
58
59
60
60
61
62
Crankshaft Vibration Damper - Inspect ................. 43
Every 2000 Service Hours
Alternator - Inspect ...............................................
Engine Crankcase Breather - Clean/Replace .......
Engine Oil - Change .............................................
Engine Oil Filter (Auxiliary) - Change ...................
Engine Oil Filter - Change ....................................
Engine Valve Lash and Bridge - Adjust ................
Ignition System Spark Plugs - Check/Adjust/
Replace ...............................................................
37
46
48
48
49
52
55
Every Year
Daily
Alternator and Fan Belts - Inspect ........................
Control Panel - Inspect .........................................
Cooling System Coolant Level - Check ................
Driven Equipment - Inspect/Replace/Lubricate ...
Engine Air Cleaner Service Indicator - Inspect .....
Engine Oil Level - Check ......................................
Engine Protective Devices - Check ......................
Exhaust Piping - Inspect .......................................
Fuel System Fuel Filter Differential Pressure Check ..................................................................
Hoses and Clamps - Inspect/Replace ..................
Walk-Around Inspection ........................................
Every 1000 Service Hours or 1 Year
37
40
42
44
45
49
51
53
54
54
61
Carburetor Air/Fuel Ratio - Check/Adjust ............. 40
Engine Speed/Timing Sensor - Clean/Inspect ...... 51
Every 4000 Service Hours
Cylinders - Inspect ................................................
Driven Equipment - Check ....................................
Gas Pressure Regulator - Check ..........................
Ignition System Timing - Check/Adjust .................
Inlet Air System - Inspect ......................................
44
44
54
57
58
Every 5000 Service Hours
Battery Electrolyte Level - Check .......................... 40
Initial 100 Service Hours
Alternator Pulley - Check ...................................... 38
Fan Drive Pulley - Check ...................................... 54
Every 7500 Service Hours
Water Pump - Inspect ........................................... 62
Every 250 Service Hours
Every 8000 Service Hours
Engine Oil Sample - Obtain .................................. 50
Cooling System Coolant - Test/Add ...................... 42
Initial 500 Service Hours
Every 8000 Service Hours or 1 Year
Engine Oil - Change .............................................
Engine Oil Filter (Auxiliary) - Change ...................
Engine Oil Filter - Change ....................................
Engine Valve Lash and Bridge - Adjust ................
Ignition System Spark Plugs - Check/Adjust/
Replace ...............................................................
48
48
49
52
Engine Mounts - Check ........................................ 47
Every 16 000 Service Hours or 6 Years
Turbocharger - Inspect .......................................... 61
55
Every 500 Service Hours
Alternator and Fan Belts - Replace ....................... 37
Battery Electrolyte Level - Check .......................... 40
Engine Air Cleaner Element - Replace ................. 45
SEBU8190
37
Maintenance Section
Alternator - Inspect
i02322311
Alternator - Inspect
i02449716
Alternator and Fan Belts Replace
Perkins recommends a scheduled inspection of
the alternator. Inspect the alternator for loose
connections and correct battery charging. Check the
ammeter (if equipped) during engine operation in
order to ensure correct battery performance and/or
correct performance of the electrical system. Make
repairs, as required.
Alternator
Check the alternator and the battery charger for
correct operation. If the batteries are correctly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. When the
engine is not run for long periods of time or if the
engine is run for short periods, the batteries may not
fully charge. A battery with a low charge will freeze
more easily than a battery with a full charge.
i02449713
Alternator and Fan Belts Inspect
Illustration 19
g01222905
Typical example
To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.
1. Remove the fasteners (5) and the plate (6).
Remove the fastener (3) and remove the fasteners
(1 and 4).
Refer to this manual, “Alternator and Fan Belts Replace”.
2. Remove the guard (2).
3. Loosen the fastener (8) and remove the fastener
(9) in order to remove the belt.
4. Install the new belt and install the fastener (9).
38
Maintenance Section
Alternator Pulley - Check
SEBU8190
Fan Drive Belts
Illustration 20
g01222934
Typical example
5. Tension the belt. Apply pressure of 15.6 N (3.5 lb)
between the two pulleys (7). The correct deflection
of the belt is 1.5 mm (0.0591 inch). Tighten the
fasteners (8 and 9) securely.
6. Install the guard and tighten all the fasteners
securely.
Illustration 21
g01222953
Typical example
1. Remove the guards.
2. Loosen the fastener (1) and loosen the belt
tensioner (2). Remove the belts.
3. Install new belts. Adjust the belt tensioner in order
to give the correct tension to the belts.
Note: Change the belts as a set.
4. Tighten the fastener (1) securely. Ensure that the
deflection on the belts is correct.
5. Apply hand pressure to the belts between the
pulleys (3). The correct deflection for the belts is
12.5 mm (0.4921 inch) .
6. Install the guards and tighten all fasteners
securely.
i02530854
Alternator Pulley - Check
1. Isolate the electrical supply to the engine.
SEBU8190
39
Maintenance Section
Battery - Replace
i02429553
Battery - Replace
Batteries give off combustible gases which can
explode. A spark can cause the combustible gases to ignite. This can result in severe personal injury or death.
Illustration 22
g01237956
Typical example
2. Remove the guard (3) in order to gain access to
the drive pulley (1) for the alternator (2).
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in order to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
1. Refer to the OEM for instruction for switching the
engine to the OFF position.
2. Turn off any battery chargers. Disconnect any
battery chargers.
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the NEGATIVE “-” terminal
on the starting motor. Ensure that the NEGATIVE
“-” battery terminal is disconnected first.
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the POSITIVE “+” terminal
on the starting motor. Disconnect the cable from
the POSITIVE “+” battery terminal.
Illustration 23
g01233693
Typical example
3. Tighten the grub screws (4) to a torque of 20 N·m
(15 lb ft).
4. Install the guard (3).
5. Restore the electrical supply to the engine.
Note: Always recycle a battery. Never discard a
battery. Dispose of used batteries to an appropriate
recycling facility.
5. Remove the used battery.
6. Ensure that all the battery connections are clean
and free from corrosion.
7. Install the new battery.
Note: Before the cables are connected, ensure that
the engine start switch is OFF.
8. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
9. Connect the NEGATIVE “-” cable to the
NEGATIVE “-” battery terminal.
40
Maintenance Section
Battery Electrolyte Level - Check
SEBU8190
i02322318
Battery Electrolyte Level Check
Ensure that the adjustment screw is adjusted properly
so that the air/fuel ratio is correct.
i02450196
Control Panel - Inspect
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries
are correctly charged, the ammeter reading should
be very near zero, when the engine is in operation.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the filler caps. Maintain the electrolyte
level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
2. Check the condition of the electrolyte with a
suitable battery tester.
Inspect the condition of the panel. If a component is
damaged, ensure that the component is repaired or
that the component is replaced. If equipped, ensure
that the electronic displays are operating properly.
Inspect the wiring for good condition. Ensure that the
wiring connections are secure.
Refer to the OEM for more information.
i02462593
Cooling System Coolant Change
Refer to the OEM for information on cogeneration
engines.
Drain
3. Install the caps.
4. Keep the batteries clean.
Clean the battery case with one of the following
cleaning solutions:
• A mixture of 0.1 kg (0.2 lb) of washing soda or
baking soda and 1 L (1 qt) of clean water
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
Thoroughly rinse the battery case with clean water.
i02450166
Carburetor Air/Fuel Ratio Check/Adjust
Illustration 24
g01228758
Typical example
An engine failure may occur if the air/fuel ratio is
not appropriate for the fuel and for the operating
conditions. The service life of the turbocharger, of the
valves, and of the other components may be reduced.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
SEBU8190
41
Maintenance Section
Cooling System Coolant - Change
2. Open the drain cock or remove the drain plug on
the radiator.
3. Open the drain cock or remove the drain plug (1)
on the engine.
Illustration 26
g01228755
Typical example
Note: The cooling system must be filled slowly. Refer
to Perkins engines Stafford for more information.
Illustration 25
g01230401
Typical example
4. Open the drain cock (2) on the engine oil cooler.
5. If equipped, open the drain cock or remove the
drain plug (4) on the cooler.
Allow the system to drain.
Fill
Refer to the OEM for information on cogeneration
engines.
1. Close the drain cock or install the drain plug in the
engine. Close the drain cock or install the drain
plug on the radiator. Close the drain cock on the
engine oil cooler. If equipped, close the drain cock
or install the drain plug (4) on the cooler.
2. If equipped, loosen the vent screw (3). Fill the
cooling system until coolant free of air flows from
the vent screw.
3. Stop filling the cooling system. Tighten the vent
screw securely. Check that the coolant level is
within 25 mm (1.0 inch) of the bottom of the filler
pipe.
4. Install the cooling system filler cap.
5. Start the engine. Operate the engine until the
engine is at the correct operating temperature.
Inspect the cooling system for leaks.
6. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Check that the level of coolant
is correct. If necessary, add more coolant. Refer
to this manual, “ Cooling System Coolant Level
Check”.
7. In order to check the specific gravity of the coolant,
refer to this manual , “Coolant System Coolant Test/Add”.
42
Maintenance Section
Cooling System Coolant - Test/Add
SEBU8190
i02460258
Cooling System Coolant Test/Add
4. Remove the filler cap of the cooling system.
5. Drain some of the coolant from the cooling system
into a suitable container.
Check the specific gravity of the
coolant
6. Use a special hydrometer that will check the
temperature and the specific gravity of the coolant,
and follow the manufacturer’s instructions.
Note: If a special thermo-hydrometer for coolant is
not available, put an hydrometer and a separate
thermometer into the antifreeze mixture and check
the readings on both instruments. Compare the
readings with the data in illustration 27.
Note: If necessary, fill the system or replenish the
coolant in the system with premixed coolant of the
correct strength. Perkins POWERPART antifreeze
with a concentration of 50% will give protection
against frost to a temperature of í35 °C (í31 °F).
The solution will also protect against corrosion. This
is especially important when there are aluminum
components in the cooling circuit.
7. Adjust the strength of the mixture if it is necessary.
i02460267
Cooling System Coolant Level
- Check
Illustration 27
g00997964
The chart for the Specific gravity
A = Percentage of antifreeze by volume
B = The temperature of the mixture in °F
C = Specific gravity
D = The temperature of the solution in °C
The following procedure must be used to measure
coolant that contains antifreeze:
1. Operate the engine until the coolant temperature
opens the thermostat. Continue to run the engine
until the coolant has circulated around the cooling
system.
2. Stop the engine.
3. Allow the engine to cool until the temperature is
below 60 °C (140 °F).
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
Refer to the OEM for information on cogeneration
engines.
Check the coolant level when the engine is stopped
and cool.
SEBU8190
43
Maintenance Section
Crankshaft Vibration Damper - Inspect
3. Clean the cooling system filler cap and inspect the
gasket. If the gasket is damaged, discard the old
filler cap and install a new filler cap. If the gasket
is not damaged, use a suitable pressurizing pump
in order to pressure test the filler cap. The correct
pressure is stamped on the face of the filler cap. If
the filler cap does not retain the correct pressure,
install a new filler cap.
i02450294
Crankshaft Vibration Damper
- Inspect
The crankshaft vibration damper limits the torsional
vibration of the crankshaft. The visconic damper has
a weight that is located inside a fluid filled case.
Illustration 28
g01228685
Typical example
1. Remove the cooling system filler cap (1) or (2)
slowly in order to relieve pressure.
Damage to the crankshaft vibration damper or failure
of the damper can increase torsional vibrations. This
can result in damage to the crankshaft and to other
engine components. A deteriorating damper can
cause excessive gear train noise at variable points
in the speed range.
A damper that is hot is due to excessive torsional
vibration. Monitor the temperature of the damper
during operation.
Note: If you use an infrared thermometer to monitor
the temperature of the damper, use the thermometer
during operation with similar loads and speeds. Keep
a record of the data. If the temperature begins to rise,
reduce the interval for inspecting the damper.
If the temperature of the damper reaches 100 °C
(212 °F), consult your Perkins dealer.
Inspect the damper for evidence of dents, cracks,
and leaks of the fluid.
If a fluid leak is found, replace the damper. The fluid
in the damper is silicone. Silicone has the following
characteristics: transparent, viscous, smooth, and
sticky.
Illustration 29
g01229602
Typical example
2. Maintain the coolant level within 25 mm (1.0 inch)
of the bottom of the filler pipe.
Inspect the damper and replace the damper for any
of the following reasons.
• The damper is dented, cracked, or leaking.
• The paint on the damper is discolored from heat.
• The engine has had a failure because of a broken
crankshaft.
• There is a large amount of gear train wear that is
not caused by a lack of oil.
44
Maintenance Section
Cylinders - Inspect
SEBU8190
i02450387
Cylinders - Inspect
i02453750
Driven Equipment Inspect/Replace/Lubricate
Use a borescope to inspect the cylinders. The
inspection will provide information about the internal
condition of the engine.
A borescope with a lens that can be angled up and
down is recommended. This type of borescope
provides a clear view of the combustion chamber and
of the bottom deck of the cylinder head. Photographic
documentation or video documentation is also
recommended. Consult your Perkins dealer for
information on available borescopes.
To perform this procedure, insert the borescope
through the openings for the spark plugs. Use the
borescope to look for the following conditions:
Observe the driven equipment during operation. Look
for the following items:
• Unusual noise and vibration
• Loose connections
• Damaged parts
Perform any maintenance that is recommended
by the OEM of the driven equipment. Refer to the
literature of the OEM of the driven equipment for the
following service instructions.
• Valve wear
• Inspection
• Deposits on the valve seat
• Lubricating grease and lubricating oil requirements
• Deposits on the valve face
• Specifications for adjustment
• Polishing of the cylinder walls
• Replacement of components
• Scratching of the cylinder walls
• Requirements for ventilation
• Deposits on the cylinder walls that are above the
upper limit of the piston stroke
i02453751
Engine - Clean
Note: If you use a borescope be aware of the effect
of magnification. Minor scratches and marks can
be misunderstood. This can result in unnecessary
maintenance.
i02453747
Driven Equipment - Check
Personal injury or death can result from high voltage.
Moisture could create paths of electrical conductivity.
To minimize bearing problems and vibration of the
engine crankshaft and the driven equipment, the
alignment between the engine and driven equipment
must be maintained properly.
Make sure the unit is off line (disconnected from
utility and/or other generators), locked out and
tagged "Do Not Operate".
Check the alignment according to the instructions
that are provided by the following manufacturers:
• OEM of the coupling
NOTICE
Water or condensation can cause damage to generator components. Protect all electrical components
from exposure to water.
• OEM of the driven equipment
A clean engine provides the following benefits:
• Easy detection of fluid leaks
• Maximum heat transfer characteristics
SEBU8190
45
Maintenance Section
Engine Air Cleaner Element - Replace
• Ease of maintenance
2. Remove the old element (1). Dispose of the old
element in a safe place.
i02450440
Engine Air Cleaner Element Replace
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent airborne debris from entering the air inlet.
NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.
Renew the air filter element if the service indicator is
triggered. Refer to this manual, “Engine Air cleaner
Service Indicator - Inspect” for more information.
Clean the air intake precleaner before maintenance
is performed on the air filter. Refer to , “Engine Air
Precleaner - Check/Clean” for more information.
Operating condition may require more frequent
service of the air filter.
Note: Ensure that dirt can not enter the air filter
assembly.
3. Install a new element into the air filter assembly.
Install the cover (2) and install the washer and
wing nut (3). Tighten the wing nut securely.
i02451134
Engine Air Cleaner Service
Indicator - Inspect
Some engines may be equipped with a different
service indicator.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner element or in a remote location.
Observe the service indicator.
Replace the air filter element if the indicator is
triggered by the following event:
• The red piston locks in the visible position.
Test the Service Indicator
Service indicators are important instruments.
Illustration 30
g01223389
Typical example
1. Remove the wing nut and the washer (3). Remove
the cover (2).
46
Maintenance Section
Engine Air Precleaner - Clean
SEBU8190
Note: Ensure that dirt can not enter the air filter
assembly.
2. Ensure that the precleaner is clean and dry. Install
the precleaner.
i02478561
Engine Crankcase Breather Clean/Replace
Open Breather
1. Ensure that the power supply is disconnected
from the engine.
2. Remove the wing nut (1) and the cover (2).
Illustration 31
g01223729
Typical service indicator
In order to reset the indicator, you must press the
button (1).
If the service indicator does not reset easily, the
service indicator should be replaced.
The service indicator may need to be replaced
frequently in environments that are severely dusty.
i02451208
Engine Air Precleaner - Clean
Illustration 33
g01224945
Typical example
3. Remove the filter elements (3) from the breather
body (4).
4. By using a suitable cleaning fluid, clean the filter
elements (3) and dry the filter elements. Inspect
the filter elements for damage or deterioration. If
necessary, replace the filter elements.
Illustration 32
g01224873
5. Clean the cover and clean the body of the
breather.
Typical example
The precleaner (1) must be cleaned when a new
element is installed in the air filter assembly.
1. Remove the precleaner from the air filter assembly
and wash the precleaner.
6. Install the filter elements (3) to the breather body
(4).
7. Ensure that the seal in the cover (2) is free from
damage. If necessary, replace the seal.
SEBU8190
47
Maintenance Section
Engine Mounts - Check
8. Align the cover (2) with the dowel (5). Install the
cover to the breather body (4).
9. Install the wing nut (1). Tighten the wing nut
securely.
10. Connect the power supply to the engine. Operate
the engine and check for leaks.
Closed Breather System
Ensure that the power supply is disconnected from
the engine.
Illustration 35
g01235923
Typical example
3. Install the new filter element. Align the clips (1).
Install the bowl (2).
Connect the power supply to the engine. Operate the
engine and check for leaks.
i02463642
Engine Mounts - Check
Illustration 34
g01224943
Typical example
1. Release the four clips (1). Remove the bowl (2)
and remove the old filter element. Discard the old
filter element in accordance with local regulations.
Misalignment of the engine and the driven equipment
will cause extensive damage. Excessive vibration
can lead to misalignment. Excessive vibration of the
engine and the driven equipment can be caused by
the following conditions:
Note: The filter element is removed by pulling down
on the filter element.
• Improper mounting
2. Ensure that the seal (3) is installed onto the new
filter element (4).
• Loose bolts
• Deterioration of the isolators
Ensure that the mounting bolts are tightened to the
proper torque.
Ensure that the isolators are free of oil and
contamination. Inspect the isolators for deterioration.
Ensure that the bolts for the isolators are tightened to
the correct torque.
Replace any isolator that shows deterioration. For
more information, see the literature that is provided
by the OEM of the isolators.
48
Maintenance Section
Engine Oil - Change
SEBU8190
i02468905
Engine Oil - Change
Note: Refer to the Operation and Maintenance
Manual, “Engine Oil Sample - Obtain” before
performing maintenance.
Do not drain the engine lubricating oil when the
engine is cold. As the engine lubricating oil cools,
suspended waste particles settle on the bottom of
the oil pan. The waste particles are not removed with
draining cold oil. Drain the oil pan with the engine
stopped. Drain the oil pan with the oil warm. This
draining method allows the waste particles that are
suspended in the oil to be drained properly.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
Ensure that the vessel that will be used is large
enough to collect the waste oil.
1. Remove the drain plug and the sealing washer
(1). Allow the engine oil to drain.
2. Replace the sealing washer, if necessary. Install
the drain plug. Tighten the plug to 68 N·m (50 lb ft).
Illustration 37
g01231267
Typical example
5. Remove the filler cap (3). Fill the engine with the
required amount of engine oil.
6. Check the oil gauge (dipstick) (2). Ensure that the
engine oil is on the correct mark.
7. Operate the engine and check for engine oil leaks.
Stop the engine. Check that engine oil level. Add
engine oil, if necessary. Refer to this manual,
“Engine Oil Level - Check”.
i02472513
Engine Oil Filter (Auxiliary) Change
Note: Refer to the Operation and Maintenance
Manual, “Engine Oil Sample - Obtain” before
performing maintenance.
Change the Filter with the Engine
in Operation
Illustration 36
g01231597
Typical example
3. Replace the engine oil filters.
4. Refer to this manual, “Engine Oil Filter - Change
or Engine Oill Filter (Auxiliary) - Change” in order
to change the engine oil filter.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
SEBU8190
49
Maintenance Section
Engine Oil Filter - Change
i02472515
Engine Oil Filter - Change
Note: Refer to the Operation and Maintenance
Manual, “Engine Oil Sample - Obtain” before
performing maintenance.
Illustration 38
g01233078
Typical example
The changeover valve (1) has three positions.
• (A) The oil flow is to both oil filters.
• (B) The oil flow is to the left hand oil filter.
• (C) The oil flow is to the right hand oil filter.
Illustration 39
g01233082
Typical example
1. Rotate the changeover valve to position B. By
using a suitable tool (2), remove the right hand
oil filter.
Note: Oil flow direction (D and E ).
2. Ensure that the sealing face on the housing is
clean. Fill the new oil filter with clean engine oil.
Install the new oil filter. Rotate the changeover
valve to position A. Check for oil leaks.
3. Rotate the changeover valve to position C. By
using a suitable tool, remove the left hand oil filter.
4. Ensure that the sealing face on the housing is
clean. Fill the new oil filter with clean engine oil.
Install the new oil filter. Apply hand pressure
only in order to install the oil filter. Rotate the
changeover valve to position A. Check for oil
leaks.
All three oil filters must be changed as a set.
1. Use a suitable tool in order to remove the oil filter
(2). Ensure that the sealing housing is clean.
2. Lubricate the sealing ring (1). Install the new oil
filter. Apply hand pressure only in order to install
the oil filter.
3. When all three oil filters have been installed fill
the engine with engine oil. Refer to this manual,
“Engine Oil - Change”.
i02463768
Engine Oil Level - Check
5. Clean any spillage of engine oil.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
50
Maintenance Section
Engine Oil Sample - Obtain
SEBU8190
In order to determine the optimum program for the
oil and filter service, use the oil analysis program
that follows.
Initiating an Oil analysis Program
The oil sample must be taken from the mean level in
the engine oil pan. Do not take an oil sample from
the drain plug.
Illustration 40
g01165836
(Y) “Min” mark. (X) “Max” mark.
Oil analysis in the first 500 hours will show higher
levels of iron and copper than the acceptable
parameters. This is shown in the list that follows. As
the engine continues to operate the levels will drop
within the specified parameters.
Every 250 Hours
NOTICE
Perform this maintenance with the engine stopped.
Note: After the engine has been switched OFF, wait
for ten minutes in order to allow the engine oil to drain
to the oil pan before checking the oil level.
1. Maintain the oil level between the “ADD” mark (Y)
and the “FULL” mark (X) on the engine oil dipstick.
Do not fill the crankcase above the “FULL” mark
(X).
NOTICE
If you operate the engine with the oil level above the
“FULL” mark, this may cause your crankshaft and balance weights to be dipped in oil. If you drive the crankshaft and balance weights through oil, excessive drag
will occur and this will increase the load on the engine. Air bubbles will be created when the crankshaft
and balance weights are driven through oil. This will
reduce the lubricating characteristics of the oil and result in a loss of power.
2. Remove the oil filler cap and add oil, if necessary.
Clean the oil filler cap. Install the oil filler cap.
i02472647
Engine Oil Sample - Obtain
Run the engine for the first 500 hours. Replace the
engine oil and the engine oil filter. Every 250 hours
obtain an oil sample.
A trend can be established by analyzing the results
of the oil sampling. Each individual operator can
develop a service program for the engine.
Note: The engine oil and the engine oil filter must be
replaced at 2000 hours.
Critical Parameters for the Lubricating
Oil
• viscosity at 100 °C cSt max 20% above original
value
• Insolubles 1.5% wt.max
• Total base number 60% less than new oil value
• Nitration 30 abs/cm max
• Oxidation 30 abs/cm max
• Water 0.2% vol max
• Iron - Fe less than 20 ppm
• Copper - Cu less than 40 ppm
Note: Perkins Engines Stafford must agree to the
maintenance schedule.
Replacement Program for the
Engine Oil and Filter
The life of the lubricating oil and filter is governed by
the engine load and quality of the gas that is supplied.
SEBU8190
51
Maintenance Section
Engine Protective Devices - Check
i02430590
Speed Sensor
Engine Protective Devices Check
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.
A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective
devices are functioning properly.
NOTICE
During testing, abnormal operating conditions must be
simulated.
Illustration 41
g01234089
Typical example
The tests must be performed correctly in order to prevent possible damage to the engine.
To prevent damage to the engine, only authorized
service personnel or your Perkins dealer should
perform the tests.
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
immediately.
i02473236
Engine Speed/Timing Sensor Clean/Inspect
Ensure that all power is disconnected to the engine
before performing these procedures.
Table 12
Required Tools
Part
Number
A
SE252
2. Remove the sensor (2). Clean any debris from
the sensor.
3. Install tooling (A).
Visual Inspection
Tool
1. Remove the connection (3). Loosen the locknut
(1).
Part Name
Engine cranking device
Qty
1
4. Rotate the engine in order to align one teeth to the
tapped hole. By hand, install the sensor. When
light contact is made with the teeth you must stop.
Unscrew the sensor half of one turn. This will give
a clearance of 0.5 to 0.8 mm (0.02 to 0.03 inch).
5. Tighten the locknut. Do not allow the sensor to
rotate. Connect the connection (3).
6. Remove tooling (A).
Timing Sensor
The timing sensor is a hall effect sensor that is
located in the gear case.
1. Remove the connection (3). Loosen the locknut
(1).
52
Maintenance Section
Engine Valve Lash and Bridge - Adjust
SEBU8190
Remove the Cover
g01236930
Illustration 42
Illustration 43
Typical example
g01235020
Typical example
2. Remove the sensor (2). Clean any debris from
the sensor.
3. Install tooling (A).
4. Rotate the engine in order to align a magnet to the
tapped hole. By hand, install the sensor. When
light contact is made with the magnet you must
stop. Unscrew the sensor. Unscrew one complete
turn. This will give a clearance of 1 mm (0.04 inch).
1. Remove the lead for the spark plug. Refer to
this manual, “Ignition SystemSpark Plugs Check/Adjust/Replace”.
2. Remove the setscrews (1) and remove the cover
(2). Discard the old joint.
3. Remove the spark plug tube (3).
4. Install tooling (A) in order to rotate the crankshaft.
5. Tighten the locknut. Do not allow the sensor to
rotate. Connect the connection (3).
Adjust the bridge
6. Remove tooling (A).
Connect the power to the engine.
i02474878
Engine Valve Lash and Bridge
- Adjust
Ensure that all power is disconnected to the engine.
Table 13
Illustration 44
Required Tools
Tool
Part
Number
A
SE252
Part Name
Engine cranking device
g01235025
Typical example
Qty
1
1. Use the timing pointer (1) in order to set the
engine to top dead center. Refer to this manual,
“Specifications” for the sequence of piston position
for valve lash.
SEBU8190
53
Maintenance Section
Exhaust Piping - Inspect
2. Rotate the crankshaft to the required position.
1. Rotate the crankshaft to the required position.
Refer to this manual, “Specifications” for the
sequence of piston position for valve lash.
Note: The bridge adjustment must be checked before
adjustment is performed on the valve lash.
2. Use a suitable feeler gauge in order to check the
valve lash. If adjustment is required loosen the
locknut (1). Adjust the screw (2) so that the correct
clearance is obtained.
3. Tighten the lock screw to a torque of 35 N·m
(25 lb ft).
Install the Cover
1. Install the spark plug tube.
2. Install a new joint. Align the cover to the cylinder
head. Install the setscrew and tighten securely.
Illustration 45
g01235021
Typical example
3. Loosen the locknut (3). Adjust the screw (2) so
that the fixed side of the bridge contacts the
valve. Apply hand pressure to the bridge. Refer to
illustration 45.
4. Adjust the screw so that light contact is made with
the valve. Tighten the locknut (3) to a torque of
35 N·m (25 lb ft). Ensure that the screw has not
rotated.
Valve lash
3. Install the lead for the spark plug.
4. Remove tooling (A). Connect the power supply
to the engine.
i02430592
Exhaust Piping - Inspect
Hot engine components can cause injury from
burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
Inspect the components of the exhaust system.
Repair the components or replace the components if
any of the following conditions occur:
• Damage
• Cracks
• Leaks
• Loose connections
Consult your Perkins dealer for assistance.
Illustration 46
Typical example
g01235023
54
Maintenance Section
Fan Drive Pulley - Check
SEBU8190
i02463729
i02478666
Fan Drive Pulley - Check
Fuel Filtration System - Service
1. Isolate the electrical supply to the engine.
Engines that use bio-gas may require special
equipment for processing the fuel. Service the fuel
filtration system according to the instructions that are
provided by the OEM of the equipment.
i02478685
Fuel System Fuel Filter
Differential Pressure - Check
A fuel filter differential pressure gauge may be
installed in order to determine when the fuel filter
requires service.
A fuel filter differential pressure gauge indicates the
difference in fuel pressure between the inlet side
and the outlet side of the fuel filter. The differential
pressure increases as the fuel filter becomes
plugged.
Illustration 47
g01238304
Typical example
2. Remove the guards (not shown) in order to gain
access to the fan drive pulley (1).
Operate the engine at the rated speed and at the
normal operating temperature. Check the fuel filter
differential pressure. Service of the fuel filter depends
on the pressure of the fuel system:
• For the service of the fuel filter on the low pressure
gas fuel system, refer to the OEM for information.
• For the service of the fuel filter on the high pressure
gas fuel system, refer to the OEM for information.
i02475489
Gas Pressure Regulator Check
Illustration 48
g01238305
3. Tighten the grub screws (2) to a torque of 90 N·m
(66 lb ft).
Before the regulator is set the supply pressure must
be checked. The supply pressure must be1.5 to 5 kPa
(0.2 to 0.7 psi).
i02430593
4. Install the guards (not shown).
5. Restore the electrical supply to the engine.
Hoses and Clamps Inspect/Replace
Inspect all hoses for leaks that are caused by the
following conditions:
SEBU8190
55
Maintenance Section
Ignition System Spark Plugs - Check/Adjust/Replace
• Cracking
Replace the Hoses and the Clamps
• Softness
• Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
NOTICE
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the recommended torque.
Check for the following conditions:
• End fittings that are damaged or leaking
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
1. Stop the engine. Allow the engine to cool.
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
• Outer covering that is chafed or cut
3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
• Exposed wire that is used for reinforcement
4. Remove the hose clamps.
• Outer covering that is ballooning locally
5. Disconnect the old hose.
• Flexible part of the hose that is kinked or crushed
6. Replace the old hose with a new hose.
• Armoring that is embedded in the outer covering
7. Install the hose clamps with a torque wrench.
A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
clamp.
8. Refill the cooling system.
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
9. Clean the cooling system filler cap. Inspect the
cooling system filler cap’s gaskets. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
10. Start the engine. Inspect the cooling system for
leaks.
Each installation application can be different. The
differences depend on the following factors:
• Type of hose
• Type of fitting material
i02475603
Ignition System Spark Plugs Check/Adjust/Replace
• Anticipated expansion and contraction of the hose
Table 14
• Anticipated expansion and contraction of the
Required Tools
fittings
Tool
Part
Number
A
T6253/265
Part Name
Spark plug removal tool
Qty
1
56
Maintenance Section
Ignition System Spark Plugs - Check/Adjust/Replace
SEBU8190
Check the Spark Plug
Illustration 51
Illustration 49
g01235566
1. Remove the lead (1) for the spark plug from the
cylinder head.
g01264908
Typical example
Faint marks may extend from shell (2) onto the
insulator (1). The marks may be a result of corona
that forms at the top of the shell. The conductor will
develop a corona when a very high voltage potential
ionizes the air. This is a normal condition. This is not
an indication of leakage between the shell and the
insulator.
Inspect shell (2) for damage. Cracks can be caused
by overtightening the spark plug. Overtightening can
also loosen the shell. Discard any spark plug that has
a shell that is cracked or loose.
Install a new sealing washer (3) before installing the
old spark plug.
1. Clean the spark plug by using a nylon brush.
Illustration 50
g01235569
2. Install tooling (A). Remove the spark plug (2).
Check the Plug and Adjust the Plug
Inspect the spark plug closely for damage. The
condition of the spark plug can indicate the operating
condition of the engine.
Note: The electrodes (5) must not be damaged. If the
electrodes are damaged replace the spark plug. Do
not file the electrodes or use abrasive paper in order
to clean the electrodes.
2. If necessary, adjust the gap on the spark plug. Set
the gap to 0.25 mm (0.0098 inch).
SEBU8190
57
Maintenance Section
Ignition System Timing - Check/Adjust
Note: Refer to this manual, “Plate Locations and Film
Locations” in order to find the ignition timing.
1. Install a timing light to the lead on number six
cylinder 4006TRS or number eight cylinder
4008TRS.
Note: The leads for the timing light must not come in
contact with the exhaust manifold.
g01235576
Illustration 52
Typical example
Replace the Plug
Table 15
Required Tools
Tool
Part
Number
B
27610178
Part Name
Qty
Cylinder head spark plug
thread cleaning tool
1
Ensure that the threads in the cylinder head are not
damaged. Clean the threads in the cylinder head by
using tooling (B).
Ensure that the gap of the spark plug is set correctly.
Ensure that the spark plug is in a working condition.
Install the spark plug by using tooling (A). Tighten the
spark plug by hand and then tighten the spark plug to
a torque of 50 N·m (36 lb ft).
i02477244
Ignition System Timing Check/Adjust
After maintenance has been performed on the
ignition system, check the timing of the ignition
system. Adjust the timing, if necessary.
The optimum ignition timing for a gas engine varies
according to several factors:
• Compression ratio of the engine
• Inlet air temperature
• Methane number of the gas
Illustration 53
g01237060
Typical example
2. Operate the engine and check the timing marks
on the flywheel.
3. If necessary, adjust the ignition timing. Remove
the cap (1). By using a suitable tool, rotate the
screw (2) in order to adjust the ignition timing.
4. Ensure that the cap (3) is not removed. This is set
for the application in the factory.
5. Install the cap (1) when the ignition timing is
correct. Remove the timing light.
• Rotating the screw (2) clockwise advances the
ignition timing.
• Rotating the screw (2) counterclockwise retards
the ignition timing.
58
Maintenance Section
Inlet Air System - Inspect
SEBU8190
Note: For engines that are installed with a detonation
sensor, the timing is controlled by the detonation
system. refer to a separate manual.
i02477819
Inlet Air System - Inspect
Inspect the components of the air inlet system for
the following conditions:
• Cracks
The engine does not require an overhaul if the
engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder
compression.
Periodically measure each of the three conditions.
The first measurement should occur during the
engine commissioning. This establishes a baseline
for future measurements. Additional measurements
are scheduled at regular intervals in order to
determine a schedule for the next in-frame overhaul.
The following changes in the three conditions
normally require a scheduled overhaul:
• Leaks
• An increase in oil consumption
• Loose connections
• An increase in crankcase blowby
Inspect the following components:
• A loss of cylinder compression
• Piping between the air cleaner and the turbocharger
Note: Oil consumption will be initially high. This will
be reduced when the rings are seated to the bore.
• Turbocharger
Note: These indications do not require an engine
to be shut down for service. These indications
only mean that an engine should be scheduled for
service in the near future. If the engine operation
is satisfactory, an immediate overhaul is not a
requirement.
• Piping between the turbocharger and the
aftercooler
• Aftercooler
• Connection of the aftercooler to the air inlet
manifold
• Connection of the air inlet manifold to the cylinder
head
Ensure that all of the connections are secure. Ensure
that the components are in good condition.
i02484880
Overhaul (In-Frame)
Scheduling an In-Frame Overhaul
Scheduling an in-frame overhaul normally depends
on the following conditions:
• An increase of oil consumption
• An increase of crankcase blowby
• A decrease or a variation of cylinder compression
Each individual condition may not indicate a need
for an overhaul. However, evaluating the three
conditions together is the most accurate method of
determining when an overhaul is necessary.
Monitor the engine as the engine accumulates
service hours.
Usually, an in-frame overhaul does not require
removal of the engine. Instead, the service is
performed with the engine in place.
In-Frame Overhaul Information
An in-frame overhaul includes all of the work that is
done for a top end overhaul. Additionally, some other
components that wear are replaced. The condition
of components is inspected. Those components are
replaced, if necessary.
Your Perkins dealer can provide these services and
components. Your Perkins dealer can ensure that
the components are operating within the appropriate
specifications.
SEBU8190
59
Maintenance Section
Overhaul (Major)
i02484872
Overhaul (Major)
Scheduling a Major Overhaul
Generally, a major overhaul is performed at 32000
hours. The need for a major overhaul is determined
by several factors. Some of those factors are the
same factors that determine the in-frame overhaul:
• An increase of oil consumption
• An increase of crankcase blowby
• A decrease and variation of cylinder compression
Other factors must also be considered for determining
a major overhaul:
Major Overhaul Information
A major overhaul includes all of the work that is done
for top end overhauls and in-frame overhauls. In
some cases, the engine is relocated for disassembly.
Components that wear are disassembled and
inspected. If necessary, the parts are replaced. The
crankshaft is measured for wear. The crankshaft
may require regrinding. Alternatively, the crankshaft
may be replaced with a Perkins replacement part.
Your Perkins dealer can provide these services and
components. Your Perkins dealer can ensure that
the components are operating within the appropriate
specifications.
If you elect to perform an overhaul without the
services of a Perkins dealer, be aware of the following
recommendations.
Replacing of Components
• The service hours of the engine
Replace the following components during the major
overhaul.
• The wear metal analysis of the lube oil
• Connecting rod bearings
• An increase in the levels of noise and vibration
• Cylinder liners
An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
need to be serviced. An increase in the levels of
noise and vibration indicates that rotating parts
require service.
• Piston rings
Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder
liners may be worn so that polishing of the bore
occurs. Also, the increased use of lube oil will dilute
the wear metals.
• Gaskets and seals
Monitor the engine as the engine accumulates
service hours. Consult your Perkins dealer about
scheduling a major overhaul.
Rebuilding or Replacing of Components
Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
• Cylinder heads
• Joints and bolts
• Main bearings
• Water temperature regulators
Rebuild the following components during the major
overhaul.
• Carburetor
• Gas regulator
• Turbochargers
• Engine Water pumps
Inspecting Components
Inspect the following components:
• Chargecooler
• Camshafts
60
Maintenance Section
Overhaul (Top End)
SEBU8190
• Camshaft bearings
i02484859
Overhaul Considerations
• Camshaft followers
• Connecting rods
• Crankshaft
Overhaul Information
• Gear train and bearings
An overhaul is replacing the major worn components
of the engine. An overhaul is a maintenance interval
that is planned. The engine is rebuilt with certain
rebuilt parts or new parts that replace the worn parts.
• Governor
• Inlet air piping
An overhaul also includes the following maintenance:
• Oil cooler
• Inspection of all the parts that are visible during
• Oil pump
the disassembly
• Pistons
• Replacement of the seals and gaskets that are
removed
• Transformers
• Cleaning of the internal passages of the engine
• Valve train that includes the rocker gear
and the engine block
i02484906
Overhaul (Top End)
It is not practical to wait until the engine exhibits
symptoms of excessive wear or failure. It is not less
costly to wait. A planned overhaul before failure may
be the best value for the following reasons:
• Costly unplanned downtime can be avoided.
Scheduling a Top End Overhaul
Top end overhauls are scheduled according to the
valve recession. This is achieved by recording the
valve clearance at each service and calculating
the valve recession. This measurement provides
an accurate indication of the rate of valve wear.
This measurement can be used to predict when a
cylinder head must be replaced. Plan for the top end
overhaul as the valve stem projection approaches
the maximum limit 1 mm (0.04 inch). Do not allow the
recession of the valves to exceed this limit.
• Many original parts can be reused according to the
guidelines for reusable parts.
• The service life of the engine can be extended
without the risk of a major catastrophe due to
engine failure.
• Achieve the best cost/value relationship per hour
of extended service life.
Overhaul Intervals
Note: Generally, cylinder heads wear out at different
rates. In some cases, servicing the cylinder heads at
different times may be the most economic decision.
This depends on the valve recession of the individual
cylinders. However, this decision must include the
costs of additional downtime that is caused by this
procedure. Perform an economic analysis in order to
determine if cylinder heads should be serviced as a
group or divided into smaller groups.
Top end overhauls are determined by the recession
of the valves. In-frame overhauls are determined by
cylinder compression, crankcase blowby, and oil
consumption. Major overhauls are determined by the
in-frame tests, and by results of oil analysis.
Note: The generator or the driven equipment may
also require service when the engine overhaul is
performed.
• Performance of preventive maintenance
Some other factors that are important for determining
the overhaul intervals include the following
considerations:
• Use of recommended lubricants
• Use of recommended coolants
• Use of recommended fuels
SEBU8190
61
Maintenance Section
Radiator - Clean
• Operating conditions
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). In order to clean
a radiator with dual cores, one core will need to be
removed from the radiator. This will allow access to
both sides of the core.
• Operation within acceptable limits
• Engine load
• Engine speed
Overhaul Inspection
If the parts are not within the inspection specifications,
the parts should be replaced. The use of parts that
are not in wear limits could result in unscheduled
downtime and/or costly repairs. This can also
contribute to increased fuel consumption and
reduction of engine efficiency.
Your Perkins dealer can provide the parts that are
needed to rebuild the engine at the least possible
cost.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
Inspect the fins for damage. Bent fins may be
repaired. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
i02479722
Turbocharger - Inspect
Overhaul recommendation
Perkins recommends a scheduled overhaul in order
to minimize downtime. A scheduled overhaul will
provide the lowest cost and the greatest value.
Schedule an overhaul with your Perkins dealer.
i02481257
Do not inspect the turbocharger. The turbocharger
must be replaced.
i02484850
Walk-Around Inspection
Radiator - Clean
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.
Inspect the Engine for Leaks and
for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
For maximum engine service life, thoroughly inspect
the engine room before starting the engine. Look for
items such as leaks, loose bolts, loose connections
and trash buildup. Make repairs, as needed.
Personal injury can result from air pressure.
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
of the fan’s air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move the
air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
NOTICE
For any type of leak, clean up the fluid. If leaking is observed, find the source and correct the leak. If leaking
is suspected, check the fluid levels more often than
recommended until the leak is found or fixed, or until
the suspicion of a leak is proved to be unwarranted.
62
Maintenance Section
Water Pump - Inspect
SEBU8190
i02482020
NOTICE
Accumulated grease and oil on an engine is a fire hazard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.
• Ensure that cooling lines are properly clamped.
Check for leaks. Check the condition of all pipes.
• Inspect the water pumps for coolant leaks. Refer to
this manual, “Water Pump - Inspect”.
Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur when the engine cools and the
parts contract.
• Inspect the lubrication system for leaks at the front
Water Pump - Inspect
A failed water pump might cause severe engine
overheating problems that could result in cracks in
the cylinder heads, a piston seizure or other potential
damage to the engine.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace the
water pump.
i02484837
Water Temperature Regulator Replace
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve covers.
NEVER use a flame to check for gas leaks. Use a
gas detector.
An open flame can ignite mixtures of air and fuel.
This will cause explosion and/or fire which could
result in severe personal injury or death.
Remove the Water Temperature
Regulator (Thermostat)
1. Drain sufficient coolant from the cooling system in
order to remove the water temperature regulator
(4). Remove the outlet hose (1).
• Check the fuel system for leaks. Look for loose fuel
line clamps.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
• Inspect the ground straps for good connections
and for good condition.
• Check the condition of the gauges. Replace any
gauge that is damaged. Replace any gauge that
can not be calibrated.
• Inspect the exhaust system for leaks. If a leak is
found, make repairs.
Illustration 54
Typical example
g01240519
SEBU8190
63
Maintenance Section
Water Temperature Regulator - Replace
2. Remove the retaining nuts (7) and lift off the top
cover (2). Discard the joint (3).
3. Remove the setscrew and washer (6). Then
remove the elements (4) from the housing (5).
Check
Visually inspect the elements for damage.
1. Fill a suitable container with coolant. Place the
element in the container.
Note: If the valve (1) is open at ambient temperature
the elements must be renewed.
Illustration 56
g01240519
Typical example
2. Install both elements (4) into the housing. Install
the setscrew and washer (6).
Illustration 55
g01240533
3. Install a new joint (3) and install the top cover.
Evenly torque all the retaining nuts (7) to a torque
of 50 N·m (37 lb ft).
Typical example
4. Install the outlet hose (1) and tighten the hose clip.
2. Heat the coolant gradually. Use a thermometer
(2) in order to check the temperature of the
coolant. The opening temperature of the valve is
71 °C (159.8 °F). Ensure that the valve starts the
process of opening at this temperature. Ensure
that the valve opens to the full amount.
5. Fill the cooling system with the correct amount of
coolant. Refer to this manual , “Cooling System
Coolant Level - Check”. Operate the engine and
check for leaks.
3. If the valve does not open or the valve does not
open to the full amount discard the old element.
Replace
1. Clean the mating face of the housing (5), and
clean the mating face of the cover (2).
64
Reference Information Section
Reference Materials
SEBU8190
Reference Information
Section
Reference Materials
i02484851
Maintenance Records
Perkins recommends the retention of accurate
maintenance records. Accurate maintenance records
can be used for the following purposes:
• Determine operating costs.
• Establish maintenance schedules for other engines
that are operated in the same environment.
• Show compliance with the required maintenance
practices and maintenance intervals.
Maintenance records can be used for a variety of
other business decisions that are related to engine
maintenance.
Maintenance records are a key element of a
maintenance program that is well managed. Accurate
maintenance records can help your Perkins dealer to
fine tune the recommended maintenance intervals in
order to meet the specific operating situation. This
should result in a lower engine operating cost.
SEBU8190
65
Reference Information Section
Reference Materials
i02481255
Maintenance Log
Table 16
Engine Model
Customer Identifier
Serial Number
Arrangement Number
Service
Hours
Quantity
Of Fuel
Service Item
Date
Authorization
66
Reference Information Section
Reference Materials
SEBU8190
i02484853
Valve Data Sheet
Table 17
Engine Model
Cylinder
1
Serial Number
Valve Location
Cylinder
Pressure
Inlet
Inlet
Exhaust
Exhaust
2
Inlet
Inlet
Exhaust
Exhaust
3
Inlet
Inlet
Exhaust
Exhaust
4
Inlet
Inlet
Exhaust
Exhaust
5
Inlet
Inlet
Exhaust
Exhaust
6
Inlet
Inlet
Exhaust
Exhaust
7
Inlet
Inlet
Exhaust
Exhaust
8
Inlet
Inlet
Exhaust
Exhaust
-
Service Hours
Current
Measure
Reset size
Wear
SEBU8190
67
Reference Information Section
Reference Materials
i02484854
Warranty Information
The engine installation and the service interval for
the engine must be approved. The engine must
be operated with the approved fuel, lubricant and
coolant. Refer to Perkins Engines Stafford for more
information.
68
Index Section
SEBU8190
Index
A
After Starting Engine .............................................
After Stopping Engine............................................
Alarms and Shutoffs ..............................................
Testing Alarms and Shutoffs ..............................
Alternator - Inspect ................................................
Alternator and Fan Belts - Inspect .........................
Alternator and Fan Belts - Replace .......................
Alternator ...........................................................
Fan Drive Belts ..................................................
Alternator Pulley - Check.......................................
29
32
25
25
37
37
37
37
38
38
B
Battery - Replace................................................... 39
Battery Electrolyte Level - Check .......................... 40
Before Starting Engine ..................................... 11, 27
Burn Prevention....................................................... 9
Batteries............................................................... 9
Coolant................................................................. 9
Oils....................................................................... 9
C
Carburetor Air/Fuel Ratio - Check/Adjust .............. 40
Cold Weather Starting ........................................... 27
Control Panel......................................................... 26
Control Panel - Inspect .......................................... 40
Cooling System Coolant - Change ........................ 40
Drain .................................................................. 40
Fill ...................................................................... 41
Cooling System Coolant - Test/Add....................... 42
Check the specific gravity of the coolant............ 42
Cooling System Coolant Level - Check ................. 42
Crankshaft Vibration Damper - Inspect ................. 43
Crushing Prevention and Cutting Prevention ......... 11
Cylinders - Inspect................................................. 44
D
Driven Equipment - Check..................................... 44
Driven Equipment - Inspect/Replace/Lubricate ..... 44
E
Electrical System ...................................................
Grounding Practices ..........................................
Emergency Stopping .............................................
Typical Procedure in Order to Stop the Engine ..
Engine - Clean.......................................................
Engine Air Cleaner Element - Replace..................
Engine Air Cleaner Service Indicator - Inspect......
Test the Service Indicator...................................
12
12
31
31
44
45
45
45
Engine Air Precleaner - Clean ............................... 46
Engine Crankcase Breather - Clean/Replace........ 46
Closed Breather System .................................... 47
Open Breather ................................................... 46
Engine Mounts - Check ......................................... 47
Engine Oil - Change .............................................. 48
Engine Oil Filter - Change ..................................... 49
Engine Oil Filter (Auxiliary) - Change .................... 48
Change the Filter with the Engine in Operation.. 48
Engine Oil Level - Check ....................................... 49
Engine Oil Sample - Obtain ................................... 50
Replacement Program for the Engine Oil and
Filter ................................................................. 50
Engine Operation................................................... 30
Partial load and Low Load Operation................. 30
Engine Protective Devices - Check ....................... 51
Visual Inspection................................................ 51
Engine Speed/Timing Sensor - Clean/Inspect....... 51
Speed Sensor .................................................... 51
Timing Sensor.................................................... 51
Engine Starting ................................................ 12, 27
Engine Stopping .............................................. 12, 31
Engine Valve Lash and Bridge - Adjust ................. 52
Adjust the bridge ................................................ 52
Install the Cover ................................................. 53
Remove the Cover ............................................. 52
Valve lash........................................................... 53
Exhaust Piping - Inspect........................................ 53
F
Fan Drive Pulley - Check....................................... 54
Features and Controls ........................................... 24
Fire Prevention and Explosion Prevention .............. 9
Fire Extinguisher ................................................ 10
Lines, Tubes and Hoses .................................... 10
Fluid Recommendations........................................ 34
Cooling System Specifications........................... 34
General Lubricant Information ........................... 34
Foreword ................................................................. 4
California Proposition 65 Warning ....................... 4
Literature Information........................................... 4
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 4
Safety................................................................... 4
Fuel Filtration System - Service............................. 54
Fuel System Fuel Filter Differential Pressure Check................................................................... 54
G
Gas Pressure Regulator - Check........................... 54
Gauges and Indicators .......................................... 23
SEBU8190
69
Index Section
General Hazard Information ....................................
Containing Fluid Spillage .....................................
Dispose of Waste Properly ..................................
Fluid Penetration..................................................
Pressure Air and Water........................................
7
8
9
8
8
P
Ignition System Spark Plugs - Check/Adjust/
Replace................................................................ 55
Check the Plug and Adjust the Plug .................. 56
Check the Spark Plug ........................................ 56
Replace the Plug................................................ 57
Ignition System Timing - Check/Adjust .................. 57
Ignition Systems ..................................................... 11
Important Safety Information ................................... 2
Inlet Air System - Inspect....................................... 58
Performance Parameters ......................................
Air, Charge Cooler Water Temperature and
Altitude .............................................................
Air/Fuel Ratio .....................................................
Plate Locations and Film Locations.......................
Engine Identification...........................................
Serial Number Plate...........................................
Product Description ...............................................
Cogeneration engine..........................................
Cooling System..................................................
Electrounit ..........................................................
Engine Service Life ............................................
Fuel System .......................................................
Ignition System ..................................................
Lubrication System ............................................
Product Identification Information ..........................
Product Information Section ..................................
Product Lifting........................................................
Product Storage.....................................................
Level “A ” ...........................................................
Level “B ” ...........................................................
Level “C ” ..........................................................
L
R
Lifting and Storage ................................................ 22
Radiator - Clean ....................................................
Reference Information Section ..............................
Reference Materials ..............................................
Refill Capacities.....................................................
Cooling System..................................................
Lubrication System ............................................
H
Hoses and Clamps - Inspect/Replace ................... 54
Replace the Hoses and the Clamps .................. 55
I
M
Maintenance Interval Schedule ............................. 36
Maintenance Log ................................................... 65
Maintenance Records............................................ 64
Maintenance Section ............................................. 33
Manual Stop Procedure......................................... 31
Model View Illustrations......................................... 14
Model Views and Specifications ............................ 14
Mounting and Dismounting..................................... 11
O
Operation Section..................................................
Overhaul (In-Frame) ..............................................
In-Frame Overhaul Information..........................
Scheduling an In-Frame Overhaul .....................
Overhaul (Major)....................................................
Major Overhaul Information ...............................
Scheduling a Major Overhaul.............................
Overhaul (Top End) ...............................................
Scheduling a Top End Overhaul ........................
Overhaul Considerations .......................................
Overhaul Information .........................................
22
58
58
58
59
59
59
60
60
60
60
24
24
24
20
20
20
16
17
17
17
17
16
17
17
20
14
22
22
22
22
22
61
64
64
33
33
33
S
Safety Messages ..................................................... 5
(1) Engine Derate................................................. 6
(2) Universal Warning .......................................... 6
(3) Engine Oil Level ............................................. 7
Safety Section ......................................................... 5
Sensors and Electrical Components ..................... 24
Detonation System ( If Equipped) ...................... 25
Electronic Ignition System (EIS) ........................ 24
Governor ............................................................ 25
Switches............................................................. 24
Specifications ........................................................ 17
General Engine Specifications........................... 17
Piston Positions for Valve Lash Setting ............. 19
Starting the Engine ................................................ 27
Automatic Starting.............................................. 29
Engine Starting Procedure................................. 28
Final Checks and First Engine Start .................. 28
Manual starting .................................................. 29
Operation of the Generator Set Control Panel... 29
Purging Unburned Gas ...................................... 28
Starting with Jump Start Cables ............................ 29
70
Index Section
SEBU8190
T
Table of Contents..................................................... 3
Turbocharger - Inspect .......................................... 61
V
Valve Data Sheet................................................... 66
W
Walk-Around Inspection ........................................
Inspect the Engine for Leaks and for Loose
Connections .....................................................
Warranty Information .............................................
Water Pump - Inspect............................................
Water Temperature Regulator - Replace ...............
Check.................................................................
Remove the Water Temperature Regulator
(Thermostat).....................................................
Replace..............................................................
61
61
67
62
62
63
62
63
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name:
Branch:
Address:
Dealer Contact
Sales:
Parts:
Service:
Phone Number
Hours
Copyright © 2006 Perkins Engines Company Limited
All Rights Reserved
Printed in UK
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