English - SEBU8430
SEBU8430-00
August 2008
Operation and
Maintenance
Manual
4016-61TRS1 and 4016-61TRS2 Gas
Engines
G16 (Engine)
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.
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Table of Contents
3
Table of Contents
Index Section
Index ..................................................................... 69
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 ........................ 18
Operation Section
Lifting and Storage ................................................ 20
Gauges and Indicators .......................................... 21
Features and Controls .......................................... 22
Engine Starting ..................................................... 25
Engine Operation .................................................. 28
Engine Stopping ................................................... 29
Maintenance Section
Refill Capacities .................................................... 30
Maintenance Interval Schedule ............................ 36
Reference Information Section
Reference Materials .............................................. 65
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
i02885759
Safety Messages
g01530454
Illustration 1
Typical example
(1) Engine Oil Level
(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.
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.
(3) Engine Derate
The safety messages that may be attached on the
engine are illustrated .
6
Safety Section
Safety Messages
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(1) Engine Oil Level
g01241033
Illustration 2
Typical example
The warning label for checking the engine oil Level
(1) is located on the inlet manifold on the left side of
the engine. Refer to illustration 1.
(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
inlet manifold on the right side of the engine. Refer
to illustration 1.
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7
Safety Section
General Hazard Information
(3) Engine Derate
g01241021
Illustration 4
Typical example
The warning label for derating engine information
(3) is located on the control box. Refer to OEM
information for the location of the control box.
i03139708
General Hazard Information
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.
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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Pressurized Air and Water
Pressurized air and pressurized water can cause
debris and/or hot water to be blown out. This could
result in personal injury.
When pressurized air and/or pressurized 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.
Illustration 7
g00687600
• The engine is stopped. Ensure that the engine
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.
• Disconnect the batteries when maintenance
Containing Fluid Spillage
• Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
cannot be started.
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.
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.
• If work is carried out on the fuel system obey the
• Tools that are suitable for collecting fluids and
California Proposition 65 Warning
• Tools that are suitable for containing fluids and
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.
local regulations for isolation of the gas supply.
equipment that is suitable for collecting fluids
equipment that is suitable for containing fluids
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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
i03116980
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 is an 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
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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.
i03101447
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) 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 “−” cable should be connected last from the
external power source to the negative “−” terminal
of the starting motor. If the starting motor is not
equipped with a negative “−” 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
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Product Information
Section
Model Views and
Specifications
i02885828
Model View Illustrations
The illustrations show various typical features of
4016 Series TRS Engine. The illustrations do not
show all of the options that are available.
g01525185
Illustration 12
Typical example
(1) Ignition coils
(2) Air filter
(3) Charge air cooler
(4) Engine oil filters
(5) The inspection cover for the Crankcase
(6) Oil level gauge (dipstick)
(7) Oil filler cap
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15
Product Information Section
Model Views and Specifications
Illustration 13
g01525189
Typical example
(8) Tumbulator
(9) Turbocharger
(10) Gas control valve
(11) Rail for the engine wiring
(12) Throttle
(13) Oil drain plug
i02885810
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 gas control valve. The gas
must be at a constant pressure and the gas pressure
must be stable. The pressure must be within a range
of 5 to 25 kPa (0.72 to 3.6 psi). Higher pressure will
need to be reduced with an additional gas regulator.
(14) Open breather system
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 tumbulator, and the
charge coolers, and into the inlet manifolds. The
speed and the load is governed by electronically
controlled throttle valves.
A digitally controlled gas valve maintains the air/fuel
ratio. This system is adjustable. Refer to Systems
Operation, Testing and Adjusting for details. This is
the only means of adjusting the exhaust emissions.
Ignition System
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:
16
Product Information Section
Model Views and Specifications
• Voltage
• Duration of the spark
• Ignition timing
• Level of energy of the ignition
All 4016TRS gas engines are equipped with a device
to detect detonation which is connected directly into
the ignition system. This device automatically retards
the ignition timing.
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 415 to 450 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.
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The system is used when recovery of heat is not an
important factor.
Cogeneration engine
Cogeneration uses energy from heat which would
otherwise be wasted.
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.
i02885756
Cooling System
Specifications
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 water inlet temperature for the charge
cooler
• Battery charging alternator
Illustration 14
Sixteen cylinder
(X) Inlet valves
(Y) Exhaust valves
g01210841
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17
Product Information Section
Model Views and Specifications
Table 1
4016 Engine Specifications
Rated rpm
Number of Cylinders
Configuration
1500
16
Vee-form
Bore
160 mm (6.299 inch)
Stroke
190 mm (7.480 inch)
Displacement
Compression ratio
Aspiration
Rotation (flywheel end)
61.123 L (3729.954 in3)
13:1
Turbocharged
Counterclockwise
Inlet valve lash (cold)
0.40 mm (0.016 inch)
Exhaust valve lash (cold)
0.40 mm (0.016 inch)
Firing order
1A-1B-3A-3B-7A-7B5A-5B-8A-8B-6A-6B2A-2B-4A-4B
18
Product Information Section
Product Identification Information
SEBU8430
Product Identification
Information
Table 4
Number of Cylinders
i02978102
Plate Locations and Film
Locations
F
6
H
8
M
12
R
16
Engine Identification
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.
Perkins engines are identified by an engine serial
number.
Serial Number Plate
A typical example of an engine serial number is
DIH R**** U10001S.
D _________________________________________Made in Stafford
I ______________________________________Application (Table 2)
H _______________________________ Type of engine (Table 3)
R _________________________Number of cylinders (Table 4)
***** __________________________________Fixed build number
U ____________________________Built in the United Kingdom
00001 ____________________________________Engine Number
S _____________________________________Year of Manufacture
Table 2
Application
Illustration 15
g01266904
G
Genset
Serial number plate
I
Gas
The engine serial number plate contains the following
information:
Table 3
Type of engine (Gas)
• Place of manufacture
F
TESI Gas unit
• Telephone number of manufacturer
E
TESI Combined Heat and Power unit
• Fax number of manufacturer
G
4016-E61-TRS
H
TRS Combined Heat and Power Unit
J
TRS Gas Unit
• Type of engine
• Engine serial number
• Rated speed
• Power output
• Engine timing
• Rating
SEBU8430
Illustration 16
19
Product Information Section
Product Identification Information
g01229580
The location of the serial number plate for vee-form engines
The serial number plate (1) on a vee-form engine is
located on the rear face of the cylinder block (bank
A). See Illustration 16.
20
Operation Section
Lifting and Storage
SEBU8430
Operation Section
To remove the engine ONLY, use the lifting eyes
that are on the engine. If necessary, remove engine
components in order to avoid damage from the lifting
device.
Lifting and Storage
i02885807
Product Lifting
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.
Lifting eyes are designed and installed for specific
engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that correct lifting devices are provided. Consult
your Perkins dealer or your Perkins distributor for
information regarding fixtures for correct engine
lifting.
i03139740
Product Storage
Refer to Perkins Engine Company limited, Stafford
for information on engine storage.
There are three different levels of engine storage.
Level “A, B and C”.
Level “A ”
Level “A” will give protection for 12 month for diesel
engines and 12 month protection for gas engines.
This is for engines that are transported by a container
or a truck. Level “A” is for the transportation of items
that are within the United kingdom and within Europe.
Level “B ”
This level is additional to level “A”. Level “B ” will
give protection under normal storage condition
from −15° to +55°C (5° to 99°F) and “90%”
relative humidity for two years. Level “B” is for the
transportation of items overseas.
Level “C ”
In order to protect the product to Level “C”, contact
Perkins Engines Company Limited Stafford.
Illustration 17
g01230422
Typical example
Use a hoist to remove heavy components. Use a
lifting beam (A) 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.
SEBU8430
21
Operation Section
Gauges and Indicators
Gauges and Indicators
i02917145
Gauges and Indicators
Gauges are supplied by the OEM. 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.
2. A low oil pressure switch is installed in the oil
gallery of the engine.
3. A high pressure Backfire switch is installed to the
inlet manifold of the engine.
22
Operation Section
Features and Controls
SEBU8430
Features and Controls
i02894958
i02885816
Performance Parameters
Air/Fuel Ratio
The correct air/fuel ratio is very important for the
following considerations:
• Margin of detonation
• Control of emissions
• Engine performance
• Achieving optimum service life for the engine
Sensors and Electrical
Components
Electronic Ignition System (EIS)
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
• Compliance with legal requirements
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 turbochargers, the
valves, and other components may be reduced.
Fuel Supply Pressure and Temperature
The gas supply to the control valve for the air/fuel
ratio must be between 5 to 25 kPa (0.72 to 3.6 psi).
If a higher pressure is required a separate gas
regulator must be installed into the fuel line.
The temperature of the gas into the air/fuel ratio
control system must be between 5 to 40 °C
(41 to 104°F).
Note: No zero pressure regulator is required with
the air/fuel ratio control system for the 4016-61TRS
engine.
Air, Charge Cooler Water
Temperature and Altitude
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.
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
• Ignition energy
• Protection from detonation
Switches
The engine is installed with the following switches.
• High cooling water temperature switch
• Low oil pressure switch
• High pressure switch for the manifold
SEBU8430
23
Operation Section
Features and Controls
Governor
The engine is installed with a digital governor that
includes the following components:
• Digital governor
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.
• Actuators and throttle valves
• 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 valves in
order to control the amount of combustion gas/air.
A DC Desk service tool with the appropriate software
key and cable are required in order to perform any
adjustments to the system.
Detonation System
The equipment for the detonation system senses
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:
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.
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 ignition timing is retarded. If detonation ceases,
the ignition timing that is retarded will be gradually
brought back to a normal value. If the engine
continues detonation the detonation system will
operate in order to stop the engine.
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.
24
Operation Section
Features and Controls
SEBU8430
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.
i02918497
Control Panel
All 4016TRS engines are supplied with a remote
mounted control panel. This unit contains the
following components and integrated wiring.
• Ignition system
• Detonation system
• The system for governing engine speed
The control panel is connected to the engine via 4
harness assemblies.
Illustration 18
g01544873
SEBU8430
25
Operation Section
Engine Starting
Engine Starting
• Observe the air cleaner service indicator. Service
i02894959
Before Starting Engine
the air cleaner when the diaphragm enters the red
zone, or when the red piston locks in the visible
position.
• Remove any electrical loads.
i02982579
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.
• 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).
• 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.
• 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
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.
The 4016-61TRS engine is equipped with Multitorch
spark plugs. Under certain circumstances, it is
possible for condensation to develop within the
nozzle for the spark plug. This may cause difficulty in
engine starting. If this occurs, conduct the following
procedure:
1. Remove the spark plugs from four of the engines
cylinders, refer to Disassembly and Assembly,
“Spark Plugs - Remove and Install”
2. Use a suitable tool in order to heat the tip of the
spark plug.
3. Replace the spark plugs, refer to Disassembly and
Assembly, “Spark Plugs - Remove and Install”
4. Start the engine.
Extra battery capacity may be necessary in order to
start the engine.
i02894960
Starting the Engine
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 “Min” mark and the “Max”
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.
26
Operation Section
Engine Starting
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.
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.
SEBU8430
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.
Purging Unburned Gas
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
The OEM will supply this system. Refer to the OEM
for more information.
Note: The OEM must ensure that 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.
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.
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 system.
Note: The fuel system must comply with all local
regulations.
5. Turn the manual gas shutoff valve to the OPEN
position.
The OEM will supply this system. Refer to the OEM
for more information.
6. Start the engine. Refer to the engine starting
procedure and refer to OEM in order to start the
engine.
1. The starting and the stopping of the engine must
be on no load.
Engine Starting Procedure
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.
Note: If the engine fails to start after the maximum
cranking time, the engine will be shut down. Before
attempting to restart the engine, investigate the
cause. Follow the procedure for purging unburned
gas once the cause has been detected.
3. Operate the engine at rated speed for ten minutes.
4. Inspect the engine for leaks in the oil system and
the coolant systems.
Note: The starting procedure may differ because of
the OEM system that is installed.
1. The signal is received.
SEBU8430
27
Operation Section
Engine Starting
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 starting motor.
5. Operate the starting motor for three seconds in
order to purge the system.
6. Activate the gas valve and activate the ignition.
Continue to operate the starting motor.
7. After the engine is started disengage the starting
motor.
Note: If the engine fails to start after the maximum
cranking time, the engine will be shut down.
8. 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”.
i02978143
After Starting Engine
For new installations and engines that are recently
rebuilt, check and adjust the air/fuel ratio, refer to
Systems Operation Testing and Adjusting, “Air/Fuel
Ratio Control - Adjust”. Monitor the engine in order to
detect any unusual engine performance through the
load range of the engine.
Check for leaks in the air and in the fluid systems.
28
Operation Section
Engine Operation
SEBU8430
Engine Operation
i02894963
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 and Systems Operation,
Testing and Adjusting in order to minimize operating
costs and maximize the service life of the engine.
Observe the gauges and the instrument panel
frequently during engine operation and record
the data 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 readings.
Monitor the engine operation and take action when
discrepancies are found.
Partial load and Low Load
Operation
Extended operation below 50% of the base power
load will cause the following results:
• Carbon formation in the cylinder
• Detonation
• Power loss
• Poor performance
• Accelerated wear of components
• Increased oil consumption
• Glazing of the cylinder bore
SEBU8430
29
Operation Section
Engine Stopping
Engine Stopping
i02453745
Manual Stop Procedure
i02978181
Emergency Stopping
In order to manually stop the engine, refer to the
OEM for information. The procedure will depend on
the system that has been installed.
The OEM will supply the system.
In the event of an emergency or in the event of an
engine overspeed, switch off the ignition, the gas
valve and the governor.
NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.
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.
i02978201
Pressing the Emergency Stop Button may cause
unburned gas to remain in the air inlet and in the
exhaust manifold.
After Stopping Engine
• Check the engine oil level. Maintain the oil level
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.
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.
2. With the engine stopped, switch off the ignition
and switch off the governor.
If another engine fault occurs switch off the gas valve.
between the “MIN” and “MAX” marks on 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.
30
Maintenance Section
Refill Capacities
SEBU8430
Maintenance Section
i02984445
Fluid Recommendations
(Coolant Specifications)
Refill Capacities
i02887773
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. For a list of recommended lubricating oils,
refer to the latest issue of Perkins service bulletin 48.
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.
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.
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:
• 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.
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.
SEBU8430
31
Maintenance Section
Refill Capacities
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.
If distilled water or deionized water is not available,
use water with the properties that are listed in Table 5.
• Plugging of radiators, coolers, and small passages
Glycol
Glycol in the coolant helps to provide protection
against the following conditions:
• Boiling
• Freezing
Table 5
Acceptable Water
Property
Maximum Limit
Chloride (Cl)
40 mg/L
Sulfate (SO4)
100 mg/L
Total Hardness
170 mg/L
Total Solids
340 mg/L
Acidity
pH of 5.5 to 9.0
For a water analysis, consult one of the following
sources:
• Local water utility company
• Agricultural agent
• Cavitation of the water pump
For optimum performance, Perkins recommends a
1:1 mixture of a water/glycol solution.
Note: Use a mixture that will provide protection
against the lowest ambient temperature.
Note: 100 percent pure glycol will freeze at a
temperature of −23 °C (−9 °F).
Most conventional antifreezes use ethylene glycol.
Propylene glycol may also be used. In a 1:1 mixture
with water, ethylene and propylene glycol provide
similar protection against freezing and boiling. See
Tables 6 and 7.
Table 6
Ethylene Glycol
• Independent laboratory
Additives
Additives help to protect the metal surfaces of
the cooling system. A lack of coolant additives or
insufficient amounts of additives enable the following
conditions to occur:
• Corrosion
• Formation of mineral deposits
Concentration
Freeze Protection
50 Percent
−36 °C (−33 °F)
60 Percent
−51 °C (−60 °F)
NOTICE
Do not use propylene glycol in concentrations that exceed 50 percent glycol because of propylene glycol’s
reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against
boiling or freezing.
• Rust
• Scale
• Foaming of the coolant
Many additives are depleted during engine operation.
These additives must be replaced periodically.
Additives must be added at the correct concentration.
Overconcentration of additives can cause the
inhibitors to drop out-of-solution. The deposits can
enable the following problems to occur:
• Formation of gel compounds
• Reduction of heat transfer
• Leakage of the water pump seal
Table 7
Propylene Glycol
Concentration
Freeze Protection
50 Percent
−29 °C (−20 °F)
To check the concentration of glycol in the coolant,
measure the specific gravity of the coolant.
Coolant Recommendations
• ELC____________________________Extended Life Coolant
• SCA___________________ Supplement Coolant Additive
32
Maintenance Section
Refill Capacities
SEBU8430
• ASTM D4985 ____________________________________ASTM
specification for coolant specification
The following two coolants are used in Perkins diesel
engines:
Preferred – Perkins ELC
Acceptable – A commercial heavy-duty antifreeze
that meets “ASTM D4985” specifications
NOTICE
Do not use a commercial coolant/antifreeze that only meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light automotive applications.
Perkins recommends a 1:1 mixture of water and
glycol. This mixture of water and glycol will provide
optimum heavy-duty performance as a antifreeze.
This ratio may be increased to 1:2 water to glycol if
extra freezing protection is required.
Note: A commercial heavy-duty antifreeze that
meets “ASTM D4985” specifications MAY require a
treatment with an SCA at the initial fill. Read the label
or the instructions that are provided by the OEM of
the product.
In stationary engine applications and marine engine
applications that do not require anti-boil protection
or freeze protection, a mixture of SCA and water
is acceptable. Perkins recommends a six percent
to eight percent concentration of SCA in those
cooling systems. Distilled water or deionized water
is preferred. Water which has the recommended
properties may be used.
• Heavy-duty diesel engines
• Automotive applications
The anti-corrosion package for ELC is different from
the anti-corrosion package for other coolants. ELC
is an ethylene glycol base coolant. However, ELC
contains organic corrosion inhibitors and antifoam
agents with low amounts of nitrite. Perkins ELC
has been formulated with the correct amount of
these additives in order to provide superior corrosion
protection for all metals in engine cooling systems.
ELC is available in a premixed cooling solution with
distilled water. ELC is a 1:1 mixture. The Premixed
ELC provides freeze protection to −36 °C (−33 °F).
The Premixed ELC is recommended for the initial
fill of the cooling system. The Premixed ELC is also
recommended for topping off the cooling system.
Containers of several sizes are available. Consult
your Perkins distributor for the part numbers.
ELC Cooling System Maintenance
Correct additions to the Extended Life
Coolant
NOTICE
Use only Perkins products for pre-mixed or concentrated coolants.
Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. Failure to
follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed.
Table 8
Coolant Service Life
Coolant Type
Service Life
Perkins ELC
6,000 Service Hours or
Three Years
Commercial Heavy-Duty
Antifreeze that meets
“ASTM D4985”
3000 Service Hours or
Two Years
Perkins POWERPART
SCA
3000 Service Hours or
Two Years
Commercial SCA and
Water
3000 Service Hours or
Two Years
ELC
Perkins provides ELC for use in the following
applications:
• Heavy-duty spark ignited gas engines
In order to maintain the correct balance between
the antifreeze and the additives, you must maintain
the recommended concentration of ELC. Lowering
the proportion of antifreeze lowers the proportion of
additive. This will lower the ability of the coolant to
protect the system from pitting, from cavitation, from
erosion, and from deposits.
NOTICE
Do not use a conventional coolant to top-off a cooling
system that is filled with Extended Life Coolant (ELC).
When using Perkins (ELC), do not use standard SCA’s
or SCA filters.
SEBU8430
33
Maintenance Section
Refill Capacities
ELC Cooling System Cleaning
Note: If the cooling system is already using ELC,
cleaning agents are not required to be used at
the specified coolant change interval. Cleaning
agents are only required if the system has been
contaminated by the addition of some other type of
coolant or by cooling system damage.
Clean water is the only cleaning agent that is required
when ELC is drained from the cooling system.
After the cooling system is drained and the cooling
system is refilled, operate the engine until the coolant
level reaches the normal operating temperature and
until the coolant level stabilizes. As needed, add
the coolant mixture in order to fill the system to the
specified level.
Changing to Perkins ELC
To change from heavy-duty antifreeze to the Perkins
ELC, perform the following steps:
NOTICE
Care must be taken to ensure that all fluids are
contained during performance of inspection, maintenance, testing, adjusting and the repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or disassembling any component containing fluids.
Dispose of all fluids according to local regulations and
mandates.
1. Drain the coolant into a suitable container.
2. Dispose of the coolant according to local
regulations.
3. Flush the system with clean water in order to
remove any debris.
4. Use Perkins cleaner to clean the system. Follow
the instruction on the label.
5. Drain the cleaner into a suitable container. Flush
the cooling system with clean water.
6. Fill the cooling system with clean water and
operate the engine until the engine is warmed to
49° to 66°C (120° to 150°F).
NOTICE
Incorrect or incomplete flushing of the cooling system
can result in damage to copper and other metal components.
To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water.
Continue to flush the system until all the signs of the
cleaning agent are gone.
7. Drain the cooling system into a suitable container
and flush the cooling system with clean water.
Note: The cooling system cleaner must be thoroughly
flushed from the cooling system. Cooling system
cleaner that is left in the system will contaminate the
coolant. The cleaner may also corrode the cooling
system.
8. Repeat Steps 6 and 7 until the system is
completely clean.
9. Fill the cooling system with the Perkins Premixed
ELC.
ELC Cooling System Contamination
NOTICE
Mixing ELC with other products reduces the effectiveness of the ELC and shortens the ELC service life.
Use only Perkins Products for premixed or concentrate coolants. Failure to follow these recommendations can result in shortened cooling system component life.
ELC cooling systems can withstand contamination to
a maximum of ten percent of conventional heavy-duty
antifreeze or SCA. If the contamination exceeds ten
percent of the total system capacity, perform ONE of
the following procedures:
• Drain the cooling system into a suitable container.
Dispose of the coolant according to local
regulations. Flush the system with clean water. Fill
the system with the Perkins ELC.
• Drain a portion of the cooling system into a suitable
container according to local regulations. Then, fill
the cooling system with premixed ELC. This should
lower the contamination to less than 10 percent.
• Maintain the system as a conventional Heavy-Duty
Coolant. Treat the system with an SCA. Change
the coolant at the interval that is recommended for
the conventional Heavy-Duty Coolant.
34
Maintenance Section
Refill Capacities
SEBU8430
Commercial Heavy-Duty Antifreeze and
SCA
NOTICE
Commercial Heavy-Duty Coolant which contains
Amine as part of the corrision protection system must
not be used.
NOTICE
Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
correct operating temperature. Cooling system problems can develop without water temperature regulators.
Check the antifreeze (glycol concentration) in
order to ensure adequate protection against boiling
or freezing. Perkins recommends the use of a
refractometer for checking the glycol concentration.
Perkins engine cooling systems should be tested at
500 hour intervals for the concentration of SCA.
Additions of SCA are based on the results of the test.
An SCA that is liquid may be needed at 500 hour
intervals.
Refer to Table 9 for part numbers and for quantities
of SCA.
Table 11 is an example for using the equation that
is in Table 10.
Table 11
Example Of The Equation For Adding The SCA To
The Heavy-Duty Coolant At The Initial Fill
Total Volume
of the Cooling
System (V)
Multiplication
Factor
Amount of
SCA that is
Required (X)
15 L (4 US gal)
× 0.045
0.7 L (24 oz)
Adding The SCA to The Heavy-Duty
Coolant For Maintenance
Heavy-duty antifreeze of all types REQUIRE periodic
additions of an SCA.
Test the antifreeze periodically for the concentration
of SCA. For the interval, refer to the Operation
and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section). Test the
concentration of SCA.
Additions of SCA are based on the results of the
test. The size of the cooling system determines the
amount of SCA that is needed.
Use the equation that is in Table 12 to determine the
amount of Perkins SCA that is required, if necessary:
Table 12
Table 9
Equation For Adding The SCA To The Heavy-Duty
Coolant For Maintenance
Perkins Liquid SCA
Part Number
Quantity
21825735
10
Adding the SCA to Heavy-Duty Coolant
at the Initial Fill
Commercial heavy-duty antifreeze that meets “ASTM
D4985” specifications MAY require an addition of
SCA at the initial fill. Read the label or the instructions
that are provided by the OEM of the product.
Use the equation that is in Table 10 to determine the
amount of Perkins SCA that is required when the
cooling system is initially filled.
Table 10
Equation For Adding The SCA To The Heavy-Duty
Coolant At The Initial Fill
V × 0.045 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.
V × 0.014 = X
V is the total volume of the cooling system.
X is the amount of SCA that is required.
Table 13 is an example for using the equation that
is in Table 12.
Table 13
Example Of The Equation For Adding The SCA To
The Heavy-Duty Coolant For Maintenance
Total Volume
of the Cooling
System (V)
Multiplication
Factor
Amount of
SCA that is
Required (X)
15 L (4 US gal)
× 0.014
0.2 L (7 oz)
SEBU8430
35
Maintenance Section
Refill Capacities
Cleaning the System of Heavy-Duty
Antifreeze
Perkins cooling system cleaners are designed
to clean the cooling system of harmful scale
and corrosion. Perkins cooling system cleaners
dissolve mineral scale, corrosion products, light oil
contamination and sludge.
• Clean the cooling system after used coolant is
drained or before the cooling system is filled with
new coolant.
• Clean the cooling system whenever the coolant is
contaminated or whenever the coolant is foaming.
i02885763
Refill Capacities
Lubrication System
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.
4016-61TRS
Table 14
4016-61 TRS
Refill Capacities
Liters
Quarts
Crankcase Oil Sump
257
271
Total Lubrication System
286
302
Compartment or System
Cooling System
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.
4016-61TRS
Table 15
4016-61 TRS
Refill Capacities
Compartment or System
Engine block only
Liters
Quarts
95
100
36
Maintenance Section
Maintenance Interval Schedule
SEBU8430
i02896508
Maintenance Interval Schedule
Every 500 Service Hours or 1 Year
Battery Electrolyte Level - Check .......................... 39
Belts - Inspect/Adjust/Replace .............................. 39
Belts - Inspect/Adjust/Replace .............................. 39
Note: These intervals apply for engines that are
powered by natural gas only. For other gases, consult
Perkins Applications Engineering (Stafford ) for more
information.
Every 1000 Service Hours
When Required
Every 1000 Service Hours or 1 Year
Battery - Replace ..................................................
Cooling System Coolant - Change .......................
Engine Crankcase Breather - Clean/Replace .......
Engine Oil Filter (Auxiliary) - Change ...................
Engine Oil Filter - Change ....................................
Fuel Filtration System - Service ............................
Overhaul (In-Frame) .............................................
Overhaul (Major) ...................................................
Overhaul (Top End) ...............................................
Overhaul Considerations ......................................
Radiator - Clean ....................................................
Water Temperature Regulator - Replace ..............
38
40
46
48
49
56
59
59
60
61
62
63
Daily
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 ........................................
40
42
44
45
50
51
55
56
56
62
Engine - Clean ...................................................... 44
Engine Valve Lash and Bridge - Adjust ................ 52
Crankshaft Vibration Damper - Inspect ................. 43
Every 2000 Service Hours
Alternator - Inspect ...............................................
Engine Air Cleaner Element - Replace .................
Engine Crankcase Breather - Clean/Replace .......
Engine Oil - Change .............................................
Engine Oil Filter (Auxiliary) - Change ...................
Engine Oil Filter - Change ....................................
Ignition System Spark Plugs - Inspect/Replace
37
45
47
48
48
49
Every Year
Carburetor Air/Fuel Ratio - Check/Adjust ............. 40
Engine Speed/Timing Sensor - Clean/Inspect ...... 51
Every 4000 Service Hours
Cylinders - Inspect ................................................
Driven Equipment - Check ....................................
Ignition System Timing - Check/Adjust .................
Inlet Air System - Inspect ......................................
44
44
58
58
Every 7500 Service Hours
Water Pump - Inspect ........................................... 63
Every Week
Every 8000 Service Hours
Jacket Water Heater - Check ................................ 58
Aftercooler Core - Inspect/Clean .......................... 37
Cooling System Coolant - Test/Add ...................... 42
Initial 100 Service Hours
Alternator Pulley - Check ...................................... 37
Fan Drive Pulley - Check ...................................... 55
Every 8000 Service Hours or 1 Year
Engine Mounts - Check ........................................ 47
Every 250 Service Hours
Every 16 000 Service Hours or 6 Years
Engine Oil Sample - Obtain .................................. 50
Turbocharger - Inspect .......................................... 62
Initial 500 Service Hours
Engine Oil - Change .............................................
Engine Oil Filter (Auxiliary) - Change ...................
Engine Oil Filter - Change ....................................
Engine Valve Lash and Bridge - Adjust ................
Ignition System Spark Plugs - Inspect/Replace
48
48
49
52
SEBU8430
37
Maintenance Section
Alternator - Inspect
Alternator - Inspect
6. Flush the core thoroughly in order to remove
residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the
core is clear and free of debris.
This section refers to the alternator for charging
the battery. For information about the generator
alternator, refer to the OEM for the appropriate
information.
Personal injury can result from air pressure.
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.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
i03178662
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.
i03109422
Aftercooler Core Inspect/Clean
(Air Charge Cooler)
Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.
7. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
8. Prior to installation, inspect any O-rings or seals
for damage. If necessary, replace the O-rings or
seals.
9. Inspect the core for trapped debris and
cleanliness. If it is necessary, remove the debris
and repeat the cleaning procedure.
10. Inspect the core for damage and perform a
pressure test in order to detect leaks.
11. Install the core. Refer to Disassembly and
Assembly Manual, “Aftercooler Core - Install” for
the procedure.
For more information on cleaning the core, consult
your Perkins dealer.
i02888334
1. Remove the core. Refer to the Disassembly and
Assembly Manual, “Aftercooler Core - Remove”
for the procedure.
Alternator Pulley - Check
2. Turn the aftercooler core on one side in order
to remove debris. Remove the debris that is
accessible.
1. Isolate the electrical supply to the engine.
3. Remove the drain plug.
4. Steam clean the core in order to remove any
residue. Flush the fins of the aftercooler core.
Remove any other trapped debris from the inside
and from the outside of the core.
Note: Do not use high pressure when the fins are
cleaned. High pressure can damage the fins.
5. Wash the core with hot, soapy water.
38
Maintenance Section
Battery - Replace
SEBU8430
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 19
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.
Illustration 20
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.
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.
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.
SEBU8430
39
Maintenance Section
Battery Electrolyte Level - Check
i02747977
i03104621
Battery Electrolyte Level Check
Belts - Inspect/Adjust/Replace
(Alternator Belt)
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.
Inspection
1. Isolate the electrical supply to the engine.
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.
3. Install the caps.
Illustration 21
g01233715
Typical example
2. Remove the bolts (2) and remove the guard (3).
3. Inspect the belt (1) for cracks. Inspect the belt
for contamination. If necessary, replace the belt.
Refer to “Replacement” for more information.
4. Keep the batteries clean.
Clean the battery case with one of the following
cleaning solutions:
• Use a solution of 0.1 kg (0.2 lb) baking soda
and 1 L (1 qt) of clean water.
• Use a solution of ammonium hydroxide.
Thoroughly rinse the battery case with clean water.
i03104600
Belts - Inspect/Adjust/Replace
(Fan Drive Belts)
Illustration 22
g01239310
4. Apply 15.6 N (3.5 lb) of pressure at point (X).
The total deflection should not exceed 1.5 mm
(0.06 inch).
The OEM supplies this system. Refer to the OEM for
the appropriate information.
Replace the belt if the total deflection exceeds
1.5 mm (0.06 inch). Refer to “Replacement” for
more information.
5. Install the guard (3) and bolts (2).
40
Maintenance Section
Carburetor Air/Fuel Ratio - Check/Adjust
SEBU8430
6. Restore the electrical supply to the engine.
Adjustment
The alternator belt is a toothed belt. The belt tension
is not adjustable. The belt does not require a preload.
Light tension will ensure that the belt is a snug fit on
the pulleys.
Replacement
4. Check the tension of the belt. Refer to “Inspection”
for the correct procedure.
5. If necessary, restore the electrical supply to the
engine and install the guards.
i02894971
Carburetor Air/Fuel Ratio Check/Adjust
Removal of the Alternator Belt
1. If necessary, Isolate the electrical supply to the
engine and remove the guards.
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.
Refer to the Systems Operation, Testing and
Adjusting for the correct procedure.
i02450196
Control Panel - Inspect
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.
Illustration 23
g01239580
Typical example
2. Remove nut (5) and bolt (4).
i02888193
Cooling System Coolant Change
3. Loosen nut (7) and push the alternator (6) toward
the engine.
4. Remove the belt (1).
Installation of the Alternator Belt
1. Install the belt (1) over the pulleys.
Note: Ensure that the teeth on the belt are engaged
with the teeth on the pulleys.
2. Pull the alternator (6) away from the engine. Install
bolt (4) and nut (5).
3. Tighten nuts (5) and (7).
Refer to the OEM for information on cogeneration
engines.
Jacket Water System Drain
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.
2. Open the drain cock or remove the drain plug on
the radiator or the heat exchanger.
SEBU8430
41
Maintenance Section
Cooling System Coolant - Change
Charge Water System Drain
1. Stop the engine and allow the engine to cool. Open
the charge water drain cock (OEM installation).
2. Remove the drain plugs (2 & 3) on each of the
charge coolers and remove the cooling system
filler cap.
Illustration 24
g01515804
Typical example
3. Open the drain cock (1) on the engine oil cooler.
4. Allow the system to drain.
Jacket Water System Fill
Refer to the OEM for information on cogeneration
engines.
Note: The cooling system must be filled slowly. Refer
to Perkins Engines Stafford for more information.
1. Close the drain cock or install the drain plug on
the radiator or the heat exchanger. Close the drain
cock on the engine oil cooler (1).
2. Slowly refill the cooling system. Check that the
coolant level is within 25 mm (1.0 inch) of the
bottom of the filler pipe.
3. Install the cooling system filler cap.
4. Start the engine. Operate the engine until the
engine is at the correct operating temperature.
Inspect the cooling system for leaks.
5. 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”.
6. In order to check the specific gravity of the coolant,
refer to this manual , “Coolant System Coolant Test/Add”.
Illustration 25
g01515913
Typical example
3. Allow the system to drain.
Charge Water System Fill
Note: The cooling system must be filled slowly. Refer
to Perkins engines Stafford for more information.
1. Close the drain cock on the charge water circuit
(OEM installation). Install the drain plugs (2 & 3)
into each charge cooler.
2. Loosen the vent plug (2) in order to release any
air from the system. When the coolant runs free of
air, tighten the vent plug.
3. Install the charge water system filler cap.
4. Follow steps 4 to 6 on jacket water system in order
to complete charge water refill.
42
Maintenance Section
Cooling System Coolant - Test/Add
SEBU8430
i02894972
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 26.
Note: If necessary, fill the system or replenish
the coolant in the system with premixed
coolant of the correct strength. Refer to the
Operation and Maintenance Manual, “Fluid
recommendations”.Perkins POWERPART antifreeze
with a concentration of 50% will give protection
against frost to a temperature of −35 °C (−31 °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.
i02888192
Illustration 26
g00997964
The chart for the Specific gravity
Cooling System Coolant Level
- Check
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.
SEBU8430
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.
i02895011
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 27
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 gets hot could be 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.
Illustration 28
g01229602
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.
Typical example
Inspect the damper and replace the damper for any
of the following reasons.
2. Maintain the coolant level within 25 mm (1.0 inch)
of the bottom of the filler cap.
• 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
SEBU8430
• The damper has been dropped.
i02453750
i02978267
Cylinders - Inspect
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:
• Valve wear
Driven Equipment Inspect/Replace/Lubricate
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.
• Inspection
• Lubricating grease and lubricating oil requirements
• Specifications for adjustment
• Marks on the piston crown
• Replacement of components
• Deposits on the valve seat
• Requirements for ventilation
• Deposits on the valve face
i02895015
• Polishing of the cylinder walls
Engine - Clean
• Scratching of the cylinder walls
• Deposits on the cylinder walls that are above the
upper limit of the piston stroke
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.
Personal injury or death can result from high voltage.
Moisture could create paths of electrical conductivity.
i02453747
Driven Equipment - Check
Make sure the unit is off line (disconnected from
utility and/or other generators), locked out and
tagged "Do Not Operate".
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.
NOTICE
Water or condensation can cause damage to generator components. Protect all electrical components
from exposure to water.
Check the alignment according to the instructions
that are provided by the following manufacturers:
• OEM of the coupling
• OEM of the driven equipment
NOTICE
Do not point high pressure water cleaners directly on
to electrical components.
SEBU8430
45
Maintenance Section
Engine Air Cleaner Element - Replace
A clean engine provides the following benefits:
• Easy detection of fluid leaks
• Maximum heat transfer characteristics
• Ease of maintenance
i02947520
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 (if equipped) before
maintenance is performed on the air filter. Refer to
, “Engine Air Precleaner - Check/Clean” for more
information.
severe operating conditions may require more
frequent service of the air filter.
Illustration 29
g01461009
Typical example
1. Remove the retaining clips (3). Remove the cover
(4).
2. Remove the old element (2). Dispose of the old
element.
Note: Ensure that dirt can not enter the air filter
assembly.
3. Install a new element into the air filter housing (1).
Install the cover (4). Fit the retaining clips (3).
i02888185
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.
46
Maintenance Section
Engine Crankcase Breather - Clean/Replace
SEBU8430
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 31
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 30
g01223729
Typical service indicator
5. Clean the cover and clean the body of the
breather.
In order to reset the indicator, you must press the
button (1).
6. Install the filter elements (3) to the breather body
(4).
If the service indicator does not reset easily, the
service indicator should be replaced.
7. Ensure that the seal in the cover (2) is free from
damage. If necessary, replace the seal.
The service indicator may need to be replaced
frequently in environments that are severely dusty.
8. Align the cover (2) with the dowel (5). Install the
cover to the breather body (4).
i02888182
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).
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.
SEBU8430
47
Maintenance Section
Engine Crankcase Breather - Clean/Replace
i02978569
Engine Crankcase Breather Clean/Replace
Closed Breather System
Ensure that the power supply is disconnected from
the engine.
Illustration 33
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.
i03032640
Illustration 32
g01224943
Engine Mounts - Check
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.
Note: The filter element is removed by pulling down
on the filter element.
2. Ensure that the seal (3) is installed onto the new
filter element (4).
Misalignment of the engine and the driven equipment
will cause extensive damage. Excessive vibration of
the engine and the driven equipment can be caused
by the following conditions:
• Improper mounting
• 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
SEBU8430
i02888179
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.
Illustration 35
g01441988
Typical example
1. Remove the drain plug and the sealing washer
(4). Allow the engine oil to drain.
4. Remove the filler cap (1). Fill the engine with the
required amount of engine oil. Refer to Operation
and Maintenance Manual, “Refill Capacities”.
2. Replace the sealing washer, if necessary. Install
the drain plug. Tighten the plug to 68 N·m (50 lb ft).
5. Check the oil gauge (dipstick) (2). Ensure that the
engine oil is on the correct mark.
6. Operate the engine and check for engine oil leaks.
Stop the engine. Check the engine oil level. Add
engine oil, if necessary. Refer to Operation and
Maintenance Manual, “Engine Oil Level - Check”.
i02888172
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 34
g01441987
Typical example
3. Replace the engine oil filters (3). Refer to
Operation and Maintenance Manual, “Engine Oil
Filter - Change or Engine Oil 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.
SEBU8430
49
Maintenance Section
Engine Oil Filter - Change
i02888171
Engine Oil Filter - Change
Note: Refer to Operation and Maintenance Manual,
“Engine Oil sample - Obtain” before performing
maintenance.
Replace the Oil Filter
Table 16
Required Tools
Illustration 36
g01233078
Typical example
The changeover valve (1) has three positions.
• (A) The oil flow is to both oil filters.
Tool
Part
Number
Part Name
Qty
A
-
Strap Wrench
1
NOTICE
Perkins oil filters are manufactured to Perkins Engine
Company LTD specifications. Use of an oil filter that is
not recommended by Perkins Engine Company LTD
could result in severe damage to the engine. Large
particles from unfiltered engine oil will cause damage
to the engine. Do not use oil filters that are not recommended by Perkins Engine Company LTD.
• (B) The oil flow is to the left hand oil filter.
• (C) The oil flow is to the right hand oil filter.
Note: All six oil filters must be changed as a set.
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.
5. Clean any spillage of engine oil.
Illustration 37
g01442022
Typical example
1. Use Tooling (A) in order to remove the oil filters (1).
2. Ensure that the sealing face of the filter base (3)
is clean.
50
Maintenance Section
Engine Oil Level - Check
SEBU8430
3. Lubricate the sealing rings (2) with clean engine
oil.
4. Install the new oil filters (1).
Note: Apply hand pressure only in order to tighten
the oil filters.
Fill the Oil Pan
Refer to Operation and Maintenance Manual, “Fluid
Recommendations” for information on suitable oils.
1. Remove the oil filler cap.
2. Fill the oil pan with the correct amount of new
engine lubricating oil. Refer to Operation and
Maintenance Manual, “Refill Capacities” for more
information.
Illustration 38
g01165836
(Y) “Min” mark. (X) “Max” mark.
NOTICE
Perform this maintenance with the engine stopped.
NOTICE
If equipped with an auxilliary oil filter system or a remote filter system, follow the OEM or the filter manufacture’s remonmendations. Under filling or over filling
the crankcase with oil can cause engine damage.
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.
Note: Before starting the engine, crank the engine on
the starter in order to obtain oil pressure.
1. Maintain the oil level between the “MIN” mark (Y)
and the “MAX” mark (X) on the engine oil dipstick.
Do not fill the crankcase above the “MAX” mark
(X).
3. Start the engine and run the engine for two
minutes. Perform this procedure in order to ensure
that the lubrication system has oil and that the oil
filters are filled.
4. Inspect the oil filters for oil leaks.
5. Stop the engine. Check the engine oil level. Add
engine oil, if necessary. Refer to Operation and
Maintenance Manual, “Engine Oil Level - Check”
i02888170
Engine Oil Level - Check
NOTICE
If you operate the engine with the oil level above the
“MAX” 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.
i02888169
Engine Oil Sample - Obtain
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
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.
SEBU8430
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.
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
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
51
Maintenance Section
Engine Protective Devices - Check
i02430590
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.
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.
Visual Inspection
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.
• Nitration 30 abs/cm max
• Oxidation 30 abs/cm max
• Water 0.2% vol max
i02948519
Engine Speed/Timing Sensor Clean/Inspect
• Iron - Fe less than 20 ppm
• Copper - Cu less than 40 ppm
Note: Perkins Engines Stafford must agree to the
maintenance schedule.
Ensure that all power is disconnected to the engine
before performing these procedures.
Table 17
Required Tools
Tool
Part
Number
A
SE252
Part Name
Engine cranking device
Qty
1
52
Maintenance Section
Engine Valve Lash and Bridge - Adjust
SEBU8430
Speed Sensor
Illustration 40
Illustration 39
g01234089
Typical example
1. Remove the connection (3). Loosen the locknut
(1).
2. Remove the sensor (2). Clean any debris from the
sensor.
3. Install tooling (A).
g01554776
Typical example
2. Remove the sensor (2). Clean any debris from the
sensor.
3. Install tooling (A).
4. Screw in the timing sensor by hand until light
contact is made with the timing disc. unscrew the
sensor. Unscrew one complete turn in order to
give a clearance of 1 mm (0.04 inch).
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 for the timing
sensor.
5. Tighten the locknut. Do not allow the sensor to
rotate. Connect the connection (3).
Connect the power to the engine.
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 for the timing sensor (not
shown). Loosen the locknut (1).
6. Remove tooling (A).
i02888165
Engine Valve Lash and Bridge
- Adjust
Ensure that all power is disconnected to the engine.
SEBU8430
53
Maintenance Section
Engine Valve Lash and Bridge - Adjust
Monitoring the Valve Recession
Table 18
Required Tools
The recorded values can be used to identify any
excessive valve seat wear on individual valves. The
recorded values can be used to schedule a top end
overhaul.
Tool
Part
Number
Part Name
Qty
An example of recorded valve lash
A
-
Valve
recession
measurement
tool
1
Table 19
Depth
micrometer
1
B
-
Hours
Every 1000 service hours record the valve lash. The
monitoring of the valve seat wear should be carried
out before any adjustment of the valve lash.
In order to measure the protrusion of the valve stems,
use the following procedure:
1. Remove the valve mechanism covers from all
cylinders.
2. Remove the bridge assembly for all the inlet
valves.
3. Remove the bridge assembly for all the exhaust
valves.
4. Remove the rocker assemblies.
5. Install Tooling (A) to the stud for the bridge
assembly.
Note: Tooling (A) must be located correctly onto the
cylinder head.
6. Tooling (B) is used in order to measure the
distance from the top of Tooling (A) to the top of
the valve stem.
7. Record this measurement for all valves.
Also, record the average engine load factor for
the previous 1000 hours.
When you fit a new cylinder head assembly,
conduct the measurement procedure in order to
establish a baseline for the protrusion of the valve
stem. Keep a log of the protrusions of the valve
stems over the life of the engine. Plan for a top
end overhaul as the valve recession approaches
the following maximum limits:
• Inlet valves 2 mm (0.08 inch)
• Exhaust valves 1 mm (0.04 inch)
Recorded clearances
on A1 cylinder
Total valve wear
Inlet
Exhaust
Inlet
Exhaust
500
0.4mm
0.4mm
0
0
1000
0.4
0.4
0
0
1500
0.35
0.35
0.05
0.05
2000
0.35
0.35
0.1
0.1
2500
0.3
0.3
0.2
0.2
3000
0.25
0.3
0.35
0.3
3500
0.25
0.35
0.5
0.35
4000
0.25
0.3
0.65
0.45
After 4000 hours running, the total valve recession
on the inlet is 0.65 mm (0.026 inch) and the exhaust
is 0.45 mm (0.018 inch).
In this example, the valves are still serviceable after
4000 hours running.
When the valves approach the maximum wear limit,
the rockers can be removed and a measurement
from the cylinder head face to the top of the valve
stems can be taken. When a new valve is installed
the protrusion of the valve stem would be 29.75 mm
(1.171 inch). therefore, a maximum wear limit would
be 30.75 mm (1.211 inch).
Adjusting the Valve Lash and
Bridge
Table 20
Required Tools
Tool
Part
Number
Part Name
Qty
C
SE252
Engine
cranking
device
1
54
Maintenance Section
Engine Valve Lash and Bridge - Adjust
SEBU8430
3. Ensure that there is clearance between the rocker
arm and bridge pad.
Illustration 41
g01235020
Typical example
Illustration 43
1. Remove the spark plug. Refer to this
manual, “Ignition System Spark Plugs Check/Adjust/Replace”.
Typical example
2. Remove the setscrews (1) and remove the cover
(2). Discard the old joint.
3. Remove the spark plug tube (3).
4. Install tooling (C) in order to rotate the crankshaft.
Adjust the bridge
Illustration 42
g01235021
4. 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 43.
5. 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
g01235025
Typical example
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.
2. Rotate the crankshaft to the required position.
Illustration 44
Typical example
g01235023
SEBU8430
55
Maintenance Section
Exhaust Piping - Inspect
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.
i02887782
Fan Drive Pulley - Check
1. Isolate the electrical supply to the engine.
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.
3. Install the lead for the spark plug.
4. Remove tooling (C). Connect the power supply
to the engine.
i02430592
Exhaust Piping - Inspect
Illustration 45
g01238304
Typical example
2. Remove the guards (not shown) in order to gain
access to the fan drive pulley (1).
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
g01238305
3. Tighten the grub screws (2) to a torque of 90 N·m
(66 lb ft).
4. Install the guards (not shown).
5. Restore the electrical supply to the engine.
56
Maintenance Section
Fuel Filtration System - Service
SEBU8430
i02478666
Fuel Filtration System - Service
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.
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:
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.
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
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.
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:
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.
• For the service of the fuel filter on the low pressure
Each installation application can be different. The
differences depend on the following factors:
• For the service of the fuel filter on the high pressure
• Type of hose
gas fuel system, refer to the OEM for information.
gas fuel system, refer to the OEM for information.
• Type of fitting material
i02430593
Hoses and Clamps Inspect/Replace
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the
fittings
Replace the Hoses and the Clamps
Inspect all hoses for leaks that are caused by the
following conditions:
• Cracking
• Softness
• Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
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.
SEBU8430
57
Maintenance Section
Ignition System Spark Plugs - Inspect/Replace
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.
3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
4. Remove the hose clamps.
5. Disconnect the old hose.
6. Replace the old hose with a new hose.
7. Install the hose clamps with a torque wrench.
8. Refill the cooling system.
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.
i02887646
Ignition System Spark Plugs Inspect/Replace
g01507793
Illustration 47
1. Remove the lead (1) for the spark plug from the
ignition coil.
2. Install tooling (A). Remove the spark plug (2).
Replace the Spark Plug
The spark plug is not a serviceable part. A
replacement spark plug must be used.
Table 22
Required Tools
Table 21
Required Tools
Tool
Part
Number
A
484/49
Part Name
Spark plug removal tool
Qty
Tool
Part
Number
B
27610178
Part Name
Cylinder head spark plug
thread cleaning tool
Qty
1
1
Inspect the Spark Plug
Ensure that the threads in the cylinder head are not
damaged. Clean the threads in the cylinder head by
using tooling (B).
Inspect the spark plug closely for damage. The
condition of the spark plug can indicate the operating
condition of the engine.
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).
On the initial start-up of a new engine or an engine
that has been serviced, it is possible for condensation
to have built up in the spark plugs. If this occurs, refer
to this manual, “Cold Weather Starting”.
58
Maintenance Section
Ignition System Timing - Check/Adjust
SEBU8430
i02887641
Ignition System Timing Check/Adjust
4. Install the cap when the ignition timing is correct.
Remove the timing light.
• Rotating the screw (1) clockwise retards the
ignition timing.
• Rotating the screw (1) counterclockwise advances
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
the ignition timing.
i02895042
Inlet Air System - Inspect
• Inlet air temperature
Inspect the components of the air inlet system for
the following conditions:
• Methane number of the gas
• Cracks
Note: Refer to this manual, “Plate Locations and Film
Locations” in order to find the correct ignition timing
for the engine.
• Leaks
1. Install a timing light to the lead on number One A
cylinder for the 4016TRS Gas.
Inspect the following components:
Note: The leads for the timing light must not come in
contact with the exhaust manifold.
• Loose connections
• Piping between the air cleaner and the
turbochargers
• Turbochargers
• Piping between the turbochargers and the
aftercoolers
• Aftercoolers
• Piping between the air/fuel ratio and the gas mixer
units
• Piping between the closed circuit breather and the
turbochargers
• Connection of the aftercooler to the air inlet
manifolds
• Connection of the air inlet manifolds to the cylinder
heads
Ensure that all of the connections are secure. Ensure
that the components are in good condition.
Illustration 48
g01521796
Typical example
2. Operate the engine and check the timing marks
on the flywheel.
3. If necessary, adjust the ignition timing. Remove
the cap (not shown) that covers the screw for
timing adjustment (1). By using a suitable tool,
rotate the screw (1) in order to adjust the ignition
timing.
i03140143
Jacket Water Heater - Check
Jacket water heaters help to improve startability in
ambient temperatures that are below 10 °C (50 °F).
All installations that require automatic starting should
have jacket water heaters.
SEBU8430
59
Maintenance Section
Overhaul (In-Frame)
Check the operation of the jacket water heater. For
an ambient temperature of 0 °C (32 °F), the heater
should maintain the jacket water coolant temperature
at approximately 40 °C (104 °F).
i02895045
Overhaul (In-Frame)
Scheduling an In-Frame Overhaul
Scheduling an in-frame overhaul normally depends
on the following conditions:
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.
i02895678
Overhaul (Major)
• An increase of oil consumption
• An increase of crankcase blowby
• A decrease or a variation of cylinder compression
• A reduction in the detonation margin
• An increase in throttle position
Each individual condition may not indicate a need for
an overhaul. However, evaluating these conditions
together is the most accurate method of determining
when an overhaul is necessary.
The engine does not require an overhaul if the
engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder
compression.
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
• A reduction in the detonation margin
• An increase in throttle position
Periodically measure each of these 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.
Other factors must also be considered for determining
a major overhaul:
Note: Oil consumption will be initially high. This will
be reduced when the rings are seated to the bore.
• An increase in the levels of noise and vibration
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.
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.
• The service hours of the engine
• The wear metal analysis of the lube oil
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.
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.
Monitor the engine as the engine accumulates
service hours. Consult your Perkins dealer about
scheduling a major overhaul.
60
Maintenance Section
Overhaul (Top End)
SEBU8430
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.
• Chargecooler
Major Overhaul Information
• Camshaft bearings
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.
• Camshafts
• Camshaft followers
• Connecting rods
• Crankshaft
• Gear train and bearings
• Governor
• Inlet air piping
• Oil cooler
If you elect to perform an overhaul without the
services of a Perkins dealer, be aware of the following
recommendations.
• Pistons
Replacing of Components
• Valve train that includes the rocker gear
• Ignition coils
Replace the following components during the major
overhaul.
• Connecting rod bearings
i02960029
Overhaul (Top End)
• Cylinder liners
• Piston rings
Scheduling a Top End Overhaul
• Turbochargers
Table 23
• Cylinder heads
Required Tools
Tool
Part
Number
Part Name
Qty
A
-
Valve
recession
measurement
tool
1
B
-
Depth
micrometer
1
• Oil pump
• Joints and bolts
• Gaskets and seals
• Main bearings
• Water temperature regulators
Rebuilding or Replacing of Components
Rebuild the following components during the major
overhaul.
• Carburetor
• Engine Water pumps
Inspecting Components
Inspect the following components:
Top end overhauls are scheduled according to the
valve recession. Valve recessions are calculated
by measuring the protrusions of the valve stems.
Measure the valve recession at every 1000 running
hours. This measurement gives an accurate
indication of valve wear. This information can be used
to predict when a cylinder head must be replaced.
Anticipated replacement intervals for the cylinder
head are 12,000 hours for the 4016-61TRS2 engine,
and 16,000 hours for the 4016-61TRS1 engine.
In order to measure the protrusion of the valve stems,
use the following procedure:
SEBU8430
61
Maintenance Section
Overhaul Considerations
1. Remove the valve mechanism covers from all
cylinders.
• Cleaning of the internal passages of the engine
2. Remove the bridge assembly for all the inlet
valves.
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:
3. Remove the bridge assembly for all the exhaust
valves.
4. Remove the rocker assemblies.
5. Install Tooling (A) to the stud for the bridge
assembly.
Note: Tooling (A) must be located correctly onto the
cylinder head.
6. Tooling (B) is used in order to measure the
distance from the top of Tooling (A) to the top of
the valve stem.
and the engine block
• Costly unplanned downtime can be avoided.
• 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
7. Record this measurement for all valves.
Also, record the average engine load factor for
the previous 1000 hours.
Top end overhauls are determined by the recession
of the valves. In-frame overhauls are determined by
the following conditions:
When you fit a new cylinder head assembly,
conduct the measurement procedure in order to
establish a baseline for the protrusion of the valve
stem. Keep a log of the protrusions of the valve
stems over the life of the engine. Plan for a top
end overhaul as the valve recession approaches
the following maximum limits:
• An increase of oil consumption
• Inlet valves 2 mm (0.08 inch)
• An increase in the throttle position
• Exhaust valves 1 mm (0.04 inch)
Major overhauls are determined by the in-frame
tests, and by results of oil analysis.
Do not allow the recession of the valves to exceed
these limits.
i02896454
Overhaul Considerations
• An increase of crankcase blowby
• A decrease or a variation of cylinder compression
• A reduction in the detonation margin
Some other factors that are important for determining
the overhaul intervals include the following
considerations:
• Performance of preventive maintenance
• Use of recommended lubricants
Overhaul Information
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.
• Use of recommended coolants
• Use of recommended fuels
• Operating conditions
• Operation within acceptable limits
An overhaul also includes the following maintenance:
• Engine load
• Inspection of all the parts that are visible during
• Engine speed
the disassembly
• Replacement of the seals and gaskets that are
removed
62
Maintenance Section
Radiator - Clean
SEBU8430
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.
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.
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.
i02885745
Turbocharger - Inspect
Do not inspect the turbocharger. The turbocharger
must be replaced.
i02885738
i02481257
Radiator - Clean
Walk-Around Inspection
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the Engine for Leaks and
for Loose Connections
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.
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.
Personal injury can result from air pressure.
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 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.
• 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.
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.
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.
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.
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.
SEBU8430
63
Maintenance Section
Water Pump - Inspect
• 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
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve covers.
i02885734
Water Temperature Regulator Replace
If Equipped, 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).
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.
• 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 49
g01240519
Typical example
i02885735
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.
Refer to the latest issue of Perkins service bulletin
157 for more information on inspecting the water
pump.
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.
64
Maintenance Section
Water Temperature Regulator - Replace
SEBU8430
Note: If the valve (1) is open at ambient temperature
the elements must be renewed.
Illustration 50
g01240533
Typical example
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
(160 °F). Ensure that the valve starts the process
of opening at this temperature. Ensure that the
valve opens to the full amount.
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).
Illustration 51
g01240519
Typical example
2. Install both elements (4) into the housing. Install
the setscrew and washer (6).
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).
4. Install the outlet hose (1) and tighten the hose clip.
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.
SEBU8430
65
Reference Information Section
Reference Materials
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.
66
Reference Information Section
Reference Materials
SEBU8430
i02481255
Maintenance Log
Table 24
Engine Model
Customer Identifier
Serial Number
Arrangement Number
Service
Hours
Quantity
Of Fuel
Service Item
Date
Authorization
SEBU8430
67
Reference Information Section
Reference Materials
i02885832
Valve Data Sheet
Table 25
Engine Model
Cylinder
1
Serial Number
Valve Location
Cylinder
Pressure
-
Service Hours
Current
Measure
Reset size
Wear
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
(continued)
68
Reference Information Section
Reference Materials
SEBU8430
(Table 25, contd)
9
Inlet
Inlet
Exhaust
Exhaust
10
Inlet
Inlet
Exhaust
Exhaust
11
Inlet
Inlet
Exhaust
Exhaust
12
Inlet
Inlet
Exhaust
Exhaust
13
Inlet
Inlet
Exhaust
Exhaust
14
Inlet
Inlet
Exhaust
Exhaust
15
Inlet
Exhaust
Inlet
Exhaust
16
Exhaust
Inlet
Exhaust
Exhaust
i02885737
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.
SEBU8430
69
Index Section
Index
A
After Starting Engine .............................................
After Stopping Engine............................................
Aftercooler Core - Inspect/Clean (Air Charge
Cooler) .................................................................
Alarms and Shutoffs ..............................................
Testing Alarms and Shutoffs ..............................
Alternator - Inspect ................................................
Alternator Pulley - Check.......................................
27
29
37
23
23
37
37
B
Battery - Replace................................................... 38
Battery Electrolyte Level - Check .......................... 39
Before Starting Engine ..................................... 11, 25
Belts - Inspect/Adjust/Replace (Alternator Belt) .... 39
Adjustment ......................................................... 40
Inspection........................................................... 39
Replacement...................................................... 40
Belts - Inspect/Adjust/Replace (Fan Drive Belts)... 39
Burn Prevention....................................................... 9
Batteries............................................................... 9
Coolant................................................................. 9
Oils....................................................................... 9
C
Carburetor Air/Fuel Ratio - Check/Adjust .............. 40
Cold Weather Starting ........................................... 25
Control Panel......................................................... 24
Control Panel - Inspect .......................................... 40
Cooling System Coolant - Change ........................ 40
Charge Water System Drain .............................. 41
Charge Water System Fill .................................. 41
Jacket Water System Drain ............................... 40
Jacket Water System 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 ................................................... 12
Grounding Practices .......................................... 12
Emergency Stopping ............................................. 29
Typical Procedure in Order to Stop the Engine .. 29
Engine - Clean....................................................... 44
Engine Air Cleaner Element - Replace.................. 45
Engine Air Cleaner Service Indicator - Inspect...... 45
Test the Service Indicator................................... 46
Engine Crankcase Breather - Clean/Replace.. 46–47
Closed Breather System .................................... 47
Open Breather ................................................... 46
Engine Mounts - Check ......................................... 47
Engine Oil - Change .............................................. 48
Engine Oil Filter - Change ..................................... 49
Fill the Oil Pan.................................................... 50
Replace the Oil Filter ......................................... 49
Engine Oil Filter (Auxiliary) - Change .................... 48
Change the Filter with the Engine in Operation.. 48
Engine Oil Level - Check ....................................... 50
Engine Oil Sample - Obtain ................................... 50
Replacement Program for the Engine Oil and
Filter ................................................................. 50
Engine Operation................................................... 28
Partial load and Low Load Operation................. 28
Engine Protective Devices - Check ....................... 51
Visual Inspection................................................ 51
Engine Speed/Timing Sensor - Clean/Inspect....... 51
Speed Sensor .................................................... 52
Timing Sensor.................................................... 52
Engine Starting ................................................ 12, 25
Engine Stopping .............................................. 12, 29
Engine Valve Lash and Bridge - Adjust ................. 52
Adjust the bridge ................................................ 54
Adjusting the Valve Lash and Bridge ................. 53
Install the Cover ................................................. 55
Monitoring the Valve Recession......................... 53
Valve lash........................................................... 54
Exhaust Piping - Inspect........................................ 55
F
Fan Drive Pulley - Check....................................... 55
Features and Controls ........................................... 22
Fire Prevention and Explosion Prevention .............. 9
Fire Extinguisher ................................................ 10
Lines, Tubes and Hoses .................................... 10
Fluid Recommendations........................................ 30
General Lubricant Information ........................... 30
Fluid Recommendations (Coolant Specifications).. 30
ELC Cooling System Maintenance .................... 32
General Coolant Information.............................. 30
Foreword ................................................................. 4
California Proposition 65 Warning ....................... 4
Literature Information........................................... 4
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 4
Safety................................................................... 4
70
Index Section
SEBU8430
Fuel Filtration System - Service............................. 56
Fuel System Fuel Filter Differential Pressure Check................................................................... 56
G
Gauges and Indicators .......................................... 21
General Hazard Information .................................... 7
Containing Fluid Spillage ..................................... 8
Dispose of Waste Properly .................................. 9
Fluid Penetration.................................................. 8
Pressurized Air and Water ................................... 8
H
Hoses and Clamps - Inspect/Replace ................... 56
Replace the Hoses and the Clamps .................. 56
I
Ignition System Spark Plugs - Inspect/Replace..... 57
Inspect the Spark Plug....................................... 57
Replace the Spark Plug ..................................... 57
Ignition System Timing - Check/Adjust .................. 58
Ignition Systems ..................................................... 11
Important Safety Information ................................... 2
Inlet Air System - Inspect....................................... 58
J
Jacket Water Heater - Check ................................ 58
L
Lifting and Storage ................................................ 20
M
Maintenance Interval Schedule ............................. 36
Maintenance Log ................................................... 66
Maintenance Records............................................ 65
Maintenance Section ............................................. 30
Manual Stop Procedure......................................... 29
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 .....................
20
59
59
59
Overhaul (Major)....................................................
Major Overhaul Information ...............................
Scheduling a Major Overhaul.............................
Overhaul (Top End) ...............................................
Scheduling a Top End Overhaul ........................
Overhaul Considerations .......................................
Overhaul Information .........................................
59
60
59
60
60
61
61
P
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 ” ..........................................................
22
22
22
18
18
18
15
16
16
16
16
15
15
16
18
14
20
20
20
20
20
R
Radiator - Clean .................................................... 62
Reference Information Section .............................. 65
Reference Materials .............................................. 65
Refill Capacities............................................... 30, 35
Cooling System.................................................. 35
Lubrication System ............................................ 35
S
Safety Messages ..................................................... 5
(1) Engine Oil Level ............................................. 6
(2) Universal Warning .......................................... 6
(3) Engine Derate................................................. 7
Safety Section ......................................................... 5
Sensors and Electrical Components ..................... 22
Detonation System............................................. 23
Electronic Ignition System (EIS) ........................ 22
Governor ............................................................ 23
Switches............................................................. 22
Specifications ........................................................ 16
General Engine Specifications........................... 16
SEBU8430
Starting the Engine ................................................
Automatic Starting..............................................
Engine Starting Procedure.................................
Final Checks and First Engine Start ..................
Manual starting ..................................................
Operation of the Generator Set Control Panel...
Purging Unburned Gas ......................................
Starting with Jump Start Cables ............................
71
Index Section
25
27
26
26
27
27
26
27
T
Table of Contents..................................................... 3
Turbocharger - Inspect .......................................... 62
V
Valve Data Sheet................................................... 67
W
Walk-Around Inspection ........................................
Inspect the Engine for Leaks and for Loose
Connections .....................................................
Warranty Information .............................................
Water Pump - Inspect............................................
Water Temperature Regulator - Replace ...............
Check.................................................................
If Equipped, Remove the Water Temperature
Regulator (Thermostat) ....................................
Replace..............................................................
62
62
68
63
63
63
63
64
72
Index Section
SEBU8430
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 © 2008 Perkins Engines Company Limited
All Rights Reserved
Printed in U.K.
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