Perkins Engine 4000 Service Manual

User’s

4016 TAG1 4016 TAG2

TSL4186E, Issue 1

February 1998

4000 Series

andbook

Diesel

4012/16 Diesel, February 1997

WARNING

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND WARNINGS MENTIONED IN THIS MANUAL. IMPROPER OPERATION OR MAINTENANCE PROCEDURES COULD RESULT IN A SERIOUS ACCIDENT OR DAMAGE TO THE EQUIPMENT CAUSING INJURY OR DEATH. NON-COMPLIANCE WITH THESE INSTRUCTIONS AND THOSE INCLUDED IN THE INSTALLATION MANUAL TSL4068 MAY INVALIDATE THE WARRANTY OFFERED WITH THE ENGINE. MAKE QUITE CERTAIN THAT THE ENGINE CANNOT BE STARTED IN ANY WAY BEFORE UNDERTAKING ANY MAINTENANCE, PARTICULARLY IN THE CASE OF AUTOMATICALLY STARTING GENERATING SETS.

INTRODUCTION

4012/16 Diesel, February 1997 1

The purpose of this Operators Handbook is to enable the operator to carry out routine servicing of the engine. Before undertaking any work on the engine the appropriate section in the

Workshop Manual should be read

fully and completely understood prior to starting work. The information contained within this Operators Handbook is based on such information as was available at the time of going to print. In line with Perkins Engines (Stafford) Limited policy of continual development and improvement that information may change at any time without notice. The engine user should therefore ensure that he has the latest information before starting work. The instructions contained in this Operators Handbook will, provided that they are correctly carried out, ensure the safe operation of the equipment. Users are respectfully advised that it is their responsibility to employ competent persons to operate, maintain and service the equipment in the interest of safety. Certain overhaul operations are impracticable without the use of special tools, and those operators who are not equipped to undertake major repairs are urged to consult their Perkins distributor. When not working on the engine, ensure that all covers, blank flanges, doors, etc., are refitted to openings to prevent the ingress of dirt, etc. Please quote the engine type and serial number with all your enquiries. This will help us to help you. The type and serial number are on a plate fitted to the crankcase. If any doubt exists regarding the installation, use or application of the engine, the Installation Manual should be consulted for further advice contact Applications Department at Perkins Engines (Stafford) Ltd. Oil change intervals may be changed according to operating experience by agreement with Perkins Engines (Stafford) Limited and subject to oil analysis being carried out at regular intervals. Please note that this 4000 Series manual also covers SE engines dispatched from the factory from 1 March

1996. A table of equivalent engine designations is given on page 2.

PERKINS COMPANIES

erkins Group of Companies

Perkins Engines (Peterborough) Ltd.

Frank Perkins Way, Eastfield, Peterborough, PE1 5NA, England. Tel: (01733) 67474 Telex: 32501 PERKEN G Fax: (01733) 582240

Perkins Engines (Shrewsbury) Ltd.

Lancaster Road, Shrewsbury, SY1 3NX, England. Tel: (01743) 212000 Telex: 35171/2 PESL G Fax: (01743) 212700

Perkins Engines (Stafford) Ltd.

Tixall Road, Stafford, ST16 3UB, England. Tel: (01785) 223141 Telex: 36156 PERKEN G Fax: (01785) 215110

Perkins Powerpart Distribution Centre

Frank Perkins Way, Northbank Industrial Park, Irlam, Manchester, M44 5PP, England. Tel: (0161) 776 5000 Specifications Help Desk Tel: (0161) 776 5151 Fax: (0161) 776 5200 Specifications Help Desk Tel: (0161) 776 5100 Telex: 32501 PERKEN G

Perkins International - North America

12025 Tech Center Drive, Livonia, Michigan 48150, U.S.A. Tel: 313 266 5427 Fax: 313 266 2700

Perkins Engines Latin America Inc

999 Ponce de Leon Boulevard, Suite 710, Coral Gables, Florida 33134, U.S.A. Tel: (305) 442 7413 Telex: 32501 PERKEN G Fax: (305) 442 7419

Perkins Engines Australia Pty Ltd

Suite 2, 364 Main Street, Mornington 3391, Victoria, Australia. Tel: (059) 75 1877 Telex: 30816 Fax: (059) 75 1305

Motori Perkins SpA

Via Socrate. 8,22070 Casnate Con Bernate (Como), Italy. Tel: 031 56 46 25 / 031 56 46 33 Telex: 380658 PERKIT I Fax: 031 24 90 92 / 031 56 41 45

Perkins Motoren GmbH

D-63801 Kleinostheim, Saalackerstrasse 4, Germany. Tel: (49) (6027) 5010 Fax: (49) (6027) 501130

Moteurs Perkins SA

9 Avenue Michelet, 93583 Saint Quen, Cedex, France. Tel: (1) 40 10 71 / (1) 40 10 42 49 Telex: 234 924 Fax: (1) 40 10 42 45

A/S Perkins Engines (Denmark) Ltd

Industrihaven 1, DK-3300 Frederiksvaerk, Denmark. Tel: (45) 47 771055 Fax: (45) 47 771981

Perkins International Ltd.

Varity Asia/Pacific Suite 3301, Convention Plaza, 1 Harbour Road, Wanchai, Hong Kong. Tel: 852 2588 1883 Fax: 852 2827 2311

Varity (Japan) K.K.

5th Floor, Reinanzaka Building, 14-2 Akasaka 1 - Chome, Minato-Ku Tokyo 107, Japan. Tel: (03) 3586 7377 Telex: PERKOIL 12424823 Fax: (03) 3582 1596

Perkins Engines (Far East) Pte Ltd.

39 Tuas Avenue 13, Singapore 638999. Tel: (65) 861 1318

Fax: (65) 861 6252

In addition to the above companies, there are Perkins distrib

utors in most countries. Perkins Engines

(Peterborough) Limited or one of the above companies can provide details.

ENGINE DESIGNATIONS

2 4

012/16 Diesel, February 1997

PERKINS ENGINES (STAFFORD)

ENGINE DESIGNATIONS

4000 SERIES AND SE SERIES

EQUIVALENT TERMS

4000 SERIES SE SERIES

4012TWG 12SETCR

4012TAG 12SETCR2

4012TAG1 12SETCA

4012TA2 12SETCA1

4012TEG 12SETCA2

4012TEG2 12SETCW

4016TWG 12SETCW2

4016TWG2 16SETCR

4016TAG 16SETCR2

4016TAG1 16SETCA

4016TAG2 16SETCA2

4016TEG 16SETCW

4016TEG2 16SETCW2

CONTENTS

4012/16 Diesel, February 1997 3

PAGE

INTRODUCTION 1-2 CONTENTS 3 SAFETY PRECAUTIONS INSERT PHOTOGRAPHS 6-7 BRIEF DESCRIPTION OF THE 4012 & 4016 ENGINES 8 GENERAL INFORMATION 9-10 ENGINE DATA 11-15 TORQUE SETTINGS 16-18 LUBRICATING OIL 19-20 COOLANT CORROSION INHIBITORS AND ANTI-FREEZE 21 FUEL SPECIFICATION 22 OPERATING INSTRUCTIONS 23-32

PREPARATION FOR INITIAL START 23 PRIMING THE TURBOCHARGERS 23-24 BATTERIES 25 PRIMING THE FUEL SYSTEM 26-27 FILLING THE COOLING SYSTEM 27 INITIAL STARTING OF THE ENGINE 28 NORMAL STARTING PROCEDURE 30

ENGINE SHUTDOWN 31 LIGHT LOAD OPERATION AND STANDBY GENERATOR SETS 32 INSTRUMENT PANEL 33-35 EXHAUST TEMPERATURE GAUGE 36-38 MAINTENANCE SCHEDULE AND CHECKLIST 39-60 PREVENTIVE MAINTENANCE 61-62

STANDBY DUTY CHECKLIST 61

CONTINUOUS DUTY CHECKLIST 62 FAULT TRACING 63 4012 STARTING CIRCUIT, SINGLE STARTER (EARLY ENGINES) 64 4012/16 STARTING CIRCUIT, STARTERS AND START RELAYS (EARLY ENGINES) 65 4012/16 WIRING DIAGRAM, STARTER, GOVERNOR (EARLY ENGINES) 66 4012/16 WIRING DIAGRAM, STARTERS & RELAYS, GOVERNOR (EARLY ENGINES) 67 4012/16 WIRING DIAGRAM, SINGLE STARTER, GOVERNOR (EARLY ENGINES) 68 4012/16 WIRING DIAGRAM, TWIN STARTERS, SINGLE START RELAY, ORIGINAL AIR SHUT OFF VALVES 69 4012/16 WIRING DIAGRAM, TWIN STARTERS, SINGLE START RELAY, ELECTRONIC GOVERNOR (LATER ENGINES) 70 4012/16 WIRING DIAGRAM, TWIN STARTERS, ELECTRONIC GOVENOR, (INTERMEDIATE ENGINES) 71 4016 WIRING DIAGRAM, TWIN STARTERS, ELECTRONIC GOVENOR (INTERMEDIATE ENGINES) 72 4012 WIRING DIAGRAM, TWIN STARTERS, ELECTRONIC GOVENOR (CURRENT ENGINES) 73 4016 WIRING DIAGRAM, TWIN STARTERS, ELECTRONIC GOVENOR (CURRENT ENGINES) 74 4012/16 SERIES LUBRICATION OIL DIAGRAM TP315 4012/16TAG WATER CIRCULATION DIAGRAM TP372 4012/16TWG WATER CIRCULATION DIAGRAM TP373 4012/16TEG WATER CIRCULATION DIAGRAM TP374 4012 SERIES FUEL SYSTEM DIAGRAM TP321 4016 SERIES FUEL SYSTEM DIAGRAM TP375

PHOTOGRAPHS

6 4

012/16 Diesel, February 1997

4012 TAG

PHOTOGRAPHS

4012/16 Diesel, February 1997 7

4016 TAG

BRIEF DESCRIPTION OF THE 4012/16 SERIES DIESEL ENGINES

8 4

012/16 Diesel, February 1997

4012TWG 12 cylinder "V" form diesel engine, water cooled, turbocharged (twin

turbochargers), jacket water cooled charge air coolers and oil coolers in engine cooling circuit. Earlier engines with vertical air cleaners, later engines with horizontal air cleaners.

4012TWG2 Up rated version of the 4012TWG 12 cylinder "V" form diesel engine, water

cooled, turbocharged (twin turbochargers) jacket water cooled charge air coolers in engine cooling circuit. Horizontal air cleaners.

4012TAG 12 cylinder "V" form diesel engine, water cooled, turbocharged (twin

turbochargers), air cooled charge air intercooler in radiator. Oil coolers in engine cooling circuit. Earlier engines with vertical air cleaners, later engines with horizontal air cleaners.

4012TAG1 Up rated version of the 4012TAG 12 cylinder "V" form diesel engine, water

cooled, turbocharged (twin turbochargers) air cooled charge air intercooler in radiator. Oil coolers in engine cooling circuit. Horizontal air cleaners.

4012TAG2 Up rated version of the 4012TAG1 12 cylinder "V" form diesel engine, water

cooled, turbocharged (twin turbochargers), air cooled charge air intercooler in radiator. Oil coolers in engine cooling circuit. Horizontal air cleaners.

4012TEG 12 cylinder "V" form diesel engine, water cooled, turbocharged (twin

turbochargers), raw water cooled charge air coolers with raw water pump and separate cooling circuit. Oil coolers in engine cooling circuit. Earlier engines with vertical air cleaners, later engines with horizontal air cleaners.

4012TEG2 12 cylinder "V" form diesel engine, water cooled, turbocharged (twin

turbochargers), raw water cooled charge air coolers with raw water pump and separate cooling circuit. Oil coolers in engine cooling circuit. Horizontal air cleaners.

4016TWG 16 cylinder "V" form diesel engine, water cooled, turbocharged (twin

turbochargers), jacket water cooled air coolers and oil coolers in engine cooling circuit. Horizontal air cleaners.

4016TWG2 Up rated version of the 4016TWG 16 cylinder "V" form diesel engine, water

cooled, turbocharged (four turbochargers), jacket water cooled charge air coolers and oil coolers in engine cooling circuit. Horizontal air cleaners.

4016TAG 16 cylinder "V" form diesel engine, water cooled, turbocharged (twin

turbochargers), air cooled charge air intercooler in radiator. Oil coolers in engine cooling circuit. Earlier engines with vertical air cleaners, later engines with horizontal air cleaners.

4016TAG1 Up rated version of the 4016TAG 16 cylinder "V" form diesel engine, water

cooled, turbocharged (four turbochargers) air cooled charge air intercooler in radiator. Oil coolers in engine cooling circuit. Horizontal air cleaners.

4016TAG2 Up rated version of the 4016TAG1 16 cylinder "V" form diesel engine, water

cooled, turbocharged (four turbochargers) air cooled charge air intercooler in radiator. Oil coolers in engine cooling circuit. Horizontal air cleaners.

4016TEG 16 cylinder "V" form diesel engine, water cooled turbocharged (twin

turbochargers) raw water cooled charge air coolers with raw water pump and separate cooling circuit. Oil coolers in engine cooling circuit. Earlier engines with vertical air cleaners, later engines with horizontal air cleaners.

4016TEG1 AND 4016TEG2

Uprated versions of the 4016TEG 16 cylinder "V" form diesel engine, water cooled, turbocharged (four turbochargers), raw water cooled charge air coolers with raw water pump and separate cooling circuit. Oil coolers in engine cooling circuit. Horizontal air cleaners.

GENERAL INFORMATION

4012/16 Diesel, February 1997 9

SAFETY Engine lift equipment

Use only the lift equipment which is designed for the engine.

Use lift equipment or obtain assistance to lift heavy engine components such as the cylinder block, cylinder head, flywheel housing, crankshaft and flywheel.

Check the engine lift brackets for security before the engine is lifted.

Asbestos joints

Some joints and gaskets contain compressed asbestos fibres see Warning label Fig. A in a rubber compound or in a metal outer cover. The 'white' asbestos (Chrysotile) which is used is a safer type of asbestos and the danger of damage to health is extremely small.

Contact with asbestos particles normally occurs at joint edges or where a joint is damaged during removal, or where a joint is removed by an abrasive method.

To ensure that the risk is kept to a minimum, the procedures given below must be followed when an engine which has asbestos joints is dismantled or assembled.

● Work in an area with good ventilation.

● Do NOT smoke.

● Use a hand scraper to remove the joints

do NOT use a rotary wire brush.

● Ensure that the joint to be removed is

et with oil or water to contain any loose

particles.

● Spray all asbestos debris with water and

place it in a closed container which can be sealed for safe disposal.

Dangers from used engine oils

Prolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading to dryness, irritation and dermatitis. The oil also contains potentially harmful contaminants which may result in skin cancer.

Adequate means of skin protection and washing facilities should be readily available.

The following is a list of 'Health Protection Precautions', suggested to minimise the risk of contamination.

1 Avoid prolonged and repeated contact

with used engine oils.

2 Wear protective clothing, including

impervious gloves where applicable.

3 Do not put oily rags into pockets. 4 Avoid contaminating clothes,

particularly underwear, with oil.

5 Overalls must be cleaned regularly.

Discard unwashable clothing and oil impregnated footwear.

6 First aid treatment should be obtained

immediately for open cuts and wounds.

7 Apply barrier creams before each period

of work to aid the removal of mineral oil from the skin.

8 Wash with soap and hot water, or

alternatively use a skin cleanser and a nail brush, to ensure that all oil is removed from the skin. Preparations containing lanolin will help replace the natural skin oils which have been removed.

9 Do NOT use petrol, kerosene, diesel

fuel, gas oil, thinners or solvents for washing the skin.

10 If skin disorder appears, medical advice

must be taken.

11 Degrease components before handling

if practicable.

12 Where there is the possibility of a risk to

the eyes, goggles or a face shield should be worn. An eye wash facility should be readily available.

Fig. A

GENERAL INFORMATION

4012/16 Diesel, February 1997 1

Environmental protection

There is legislation to protect the environment from the incorrect disposal of used lubricating oil. To ensure that the environment is protected, consult your Local Authority who can give advice.

Viton seals

Some seals used in engines and in components fitted to engines are made from Viton.

Viton is used by many manufacturers and is a safe material under normal conditions of operation.

If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this burnt material to come into contact with the skin or with the eyes.

If it is necessary to come into contact with components which have been burnt, ensure that the precautions which follow are used:

● Ensure that the components have

ooled.

● Use Neoprene gloves and discard the

gloves safely after use.

● Wash the area with a calcium hydroxide

solution and then with clean water.

● Disposal of gloves and components

which are contaminated, must be in accordance with local regulations.

If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or with a calcium hydroxide solution for 15-60 minutes. Obtain immediate medical attention.

DIESEL ENGINE DATA

4012/16 Diesel, February 1997 1

For full technical data please refer to the Product Information Manual.

Type: Water-cooled, turbocharged, charge cooled, industrial diesel engine.

RANGE 4

012 4016

Cycle 4 stroke 4 stroke

No. of cylinders 12 16

Configuration V-form V-form

Bore 160 mm 160 mm

Stroke 190 mm 190 mm

Total swept volume 45,84 litres 61,123 litres

Compression ratio 13,6:1 13,6:1

Rotation Anti-clockwise looking on flywheel end

Firing order

1A-6B-5A-2B-3A-4B-

6A-1B-2A-5B-4A-3B

1A-1B-3A-3B-7A-7B-5A-5B-

8A-8B-6A-6B-2A-2B-4A-4B

Valve Timing

inlet valve opens 60° BTDC

inlet valve closes 46° ABDC

exh valve opens 46° BBDC exh valve closes 60° ATDC

Cylinder numbering Cylinder 1 furthest from flywheel

Cylinders designated A are on the right hand side of the engine, when viewed from the fly-wheel end and cylinders designated B are on the left hand side of the engine.

Valve Clearances exhaust 0,40 mm (0,016”)

(Engine cold) inlet 0,40 mm (0,016”)

Valve dia. (mm) inlet and exhaust 48 48

(52 on 4012TAG1/2 AND 4016TAG1/2)

Valve Timing See Workshop Manual Sections U4 and U5

Injection Timing S

ee engine nameplate

Piston Speeds Engine r/min m/s (ft/min)

1000 6,33 (1247)

1200 7,60 (1496)

1500 9,50 (1870)

1800 11,40 (2244)

Fig. B

‘A’ BANK

‘B’ BANK

DIESEL ENGINE DATA

12 4

012/16 Diesel, February 1997

TYPICAL COOLING SYSTEM

* Engine only *

* Engine with heat exchanger

FUEL SYSTEM

OVERNORS

4006 4008

Approved Coolants) See page 21

Total water capacity L

trs Gals Spec Ltrs Gals Spec

200 44 TAG 255 56.1 TAG

232 51 TAG1 316 70 TAG1

232 51 TAG2 316 70 TAG2

185 40 TWG 95 21 TWG*

205 45 TWG2 95 21 TWG2*

82 18 TEG** 108 23.7 TEG**

Max radiator top tank temperature 93°C

Max water temperature into engine 80°C

Thermostat opening temperature 71°C

System pressure 0.5 to 0.7 bar

4012 4016

Approved fuels See

page 20

Minimum size fuel tank 14000 litres (3000 gal.) 18000 litres (

4000 gal.)

Relief valve setting 310 kPA (45 psi)

Inferior nozzle pressure 225-235 atm

Injection equipment Lucas-Bryce unit injector

Filter/water separator Spin-on expandable canister(s)

Fuel lift pump Maximum suction lift 1 metre

Fuel flow 20.457 litre/min. (4.5 gpm) @ 1800 r/min

4012 4016

Type Electronic Electronic

Type Hydraulic Hydraulic

DIESEL ENGINE DATA

4012/16 Diesel, February 1997 1

LUBRICATION SYSTEM

INDUCTION SYSTEM

EXHAUST SYSTEM

FLYWHEEL

FLYWHEEL HOUSING

4012 4016

Recommended oil See

pages 19 and 20

Type of system Wet sump, external engine mounted oil pump

Total oil capacity (including cooler and filter) 178 litre (39.2 gal) 238 litre (53 gal)

Sump capacity (dipstick)

Min. 136 litre (30 gal) 147 litre (33 gal)

Max. 159 litre (35 gal) 214 litre (47 gal)

Crankcase pressure (max) 25 mm (1”) water gauge

Lubricating oil temperature max. to bearings 105°C

Lubricating oil pressure at 80°C temp. to bearings 0.34 mPa

Max. oil temperature in sump 115°C

Min. oil pressure (1500 rpm)(at filter head) 200 kPa (30 lb/in²)

Oil filter Disposable canister type

Oil pump location ‘A’ Bank

4012 4016

Air cleaners (earlier)

(current)

Twin vertical air cleaners

Twin horizontal air cleaners

Type Paper element

Air restriction indicator setting 380 mm H

urbochargers x2 off x4 off

4012 4016

Manifold Type Dry or water cooled

Exhaust outlet flange Vertical (Twin)

Mating flange See Installation Manual

Max. exhaust back pressure See Product Information Manual

Max. exhaust temperature

012 4016

Drive size SAE 18”

SAE 21” Optional

4012 4016

SAE size 00

DIESEL ENGINE DATA

14 4

012/16 Diesel, February 1997

TYPICAL DRY WEIGHT

HOLDING DOWN BOLT HOLES

ELECTRICAL SYSTEM

4012 4016

Dry weight (engine) 4360 kg 4012TAG 5500 kg 4016TAG

4360 kg 4012TAG1 5750 kg 4016TAG1

4400 kg 4012TAG2 5750 kg 4016TAG2

4975 kg 4012TWG 5940 kg 4016TWG/2

5315 kg 4012TWG2 5820 kg 4016TEG

4680 kg 4012TEG2

Dry weight engine & tropical radiator 5280 kg 4012TAG 6900 kg 4016TAG

5760 kg 4012TAG1 8010 kg 4016TAG1

5800 kg 4012TAG2 8010 kg 4016TAG2

4995 kg 4012TWG

5315 kg 4012TWG/2

Dry weight engine & heat exchanger 4860 kg 4012TEG 6000 kg 4016TEG

4012 4016

Hole dia. (Engine feet) 22 mm

No. off 8

Hole dia. (Radiator feet) 18 mm x 6 4012TAG 22 mm x 6 4016TAG/2

Turbochargers 22 mm x 6 4012TAG2

22 mm x 6 4012TWG/1

4012 4016

Voltage 24V

Alternator Belt Driven

Alternator output 30A

Starter motor

Single CAV

(Earlier Engines)

Twin Prestolite

(Current Engines)

Twin Prestolite

No. of teeth (gear ring)

144 (Early Engines)

156 (Current Engines)

156

No. of teeth (starter pinion) 12

Battery (lead acid) 24V DC (2 x 12V)

Capacity down to 0°C (32°F) 286 Ah

DIESEL ENGINE DATA

4012/16 Diesel, February 1997 1

PROTECTION EQUIPMENT

Before resetting protection equipment, it must be established whether special settings (for that individual engine) have been specified in the engine sales contract. This is particularly important with ALL

high water temperature settings, and ALL Cogen applications.

Standard settings for protection equipment are as follows:-

Caution: The above standard settings do not supersede any settings specified in the engine sales contract.

AIR STARTING

INSTRUMENT PANEL (ENGINE MOUNTED)

COOLANT JACKET HEATING

Alarm Shutdown

High Oil temperature (in sump) 110°C 115°C

Low oil pressure 2.06 bar (30 lb/in²) 1.93 bar (28 lb/in²)

High water temperature

71°C Thermostat 91°C 96°C

85°C Thermostat 96°C 101°C

96°C Thermostat 100°C 105°C

Overspeed

15% above max. running speed

(Except 1800 r/min which is 7%)

4012 4016

Air starter See I

nstallation Manual

Air starter pressure 150 lb/in2(10.34 bar)

Compressed air supply 170 lb/in2(11.72 bar)

Normal Operation

Oil pressure Between 276-413 kPa (40-60 lb/in²)

Oil temperature Between 80-90°C (176-194°F)

Water temperature Between 65-85°C (149-185°F)

Exhaust temperature See Product Information Manual

4012 4016

eater 2 x 4 kW

Voltage 210-250V ac

TORQUE SETTINGS

16 4

012/4016 Diesel, February 1997

NOTE: * Bolt heads and threads must be lubricated with clean engine oil.

** Cylinder head bolts to be lubricated under the heads, under the washers and on

the threads with PBC (Poly-Butyl-Cuprysil) grease. Important: See Workshop Manual

ection R11

before fitting. However, d

ry threads are required for connecting rod bolts and

the raw water pump shaft nut, but all other threads only to be lubricated with clean engine oil and care must be taken NOT to oil the heads or faces.

TORQUE SETTINGS

CYLINDER HEAD GROUP lbf.ft Nm

Cylinder head bolt ** (early type) M24 550 750

Cylinder head bolt ** (later waisted type) M24 530 720 Rocker shaft capscrew/nut M16 90 120 Rocker adjuster nuts inlet/exhaust M12 35 50 Rocker adjuster nuts pump injectors M14 50 70 Injector clamp capscrews M12 70 95 Bridge piece adjuster nuts M10 25 35 Injector clamp to cylinder head capscrews M12 70 95 Rocker box bolts M10 35 50 Air manifold bolt M10 35 50 Exhaust manifold bolts M10 50 70 Exhaust bellows to exhaust manifold (16 cyl only) prevailing torque bolts / nuts M10 45 60 Exhaust Y piece (16 cyl only) prevailing torque bolts M10 38 50 Schwitzer turbocharger 'V'-band clamp nuts M8 8 11 Sandwich plate retaining capscrews M10 35 50

CRANKCASE AND CRANKSHAFT GROUPS

Main bearing bolts * See Section W4 M24 580 786 L

ateral capscrews, main bearing caps for sequence M16 124 168 Bolts sump to crankcase M10 40 54 New connecting rod bolts (must be fitted with dry threads) M16 210 285 Inspection covers M10 35 50 Viscous damper bolts M16 250 340 Flywheel bolts See

Section X3 for sequence M16 250 340

ront drive adaptor bolts (12 cylinder engines only) M16 250 340 Front drive adaptor bolts (16 cylinder engines only) M20 380 520 Balance weight bolts M16 250 340 Crankshaft pulley bolts M16 250 340 Piston cooling jet screws M10 20 27 Flywheel housing bolts M10 35 50 Lifting bracket Durlock screws M10 50 70

WARNING

IT IS ESSENTIAL THAT THE CORRECT LENGTH OF SCREW OR

BOLT IS USED. INSUFFICIENT LENGTH MAY RESULT IN THE THREAD BEING STRIPPED, WHEREAS TOO LONG A THREAD MAY RESULT IN BOTTOMING IN A BLIND HOLE, OR CATCHING ON ADJACENT COMPONENTS.

TORQUE SETTINGS

4012/4016 Diesel, February 1997 1

LUBRICATING OIL PUMP lbf.ft Nm

Bolts, pump housing to gearcase plate M10 35 50 Thin nut, gear to drive shaft M30 175 237

CAMSHAFT GROUP

Camshaft gear bolt M12 110 150 Camshaft thrust plate bolt M10 35 50 Camshaft follower housing bolt M10 35 50 Idler gear hub bolts M10 35 50

WATER PUMP

Water pump gear nut M24 170 230 Water header to oil cooler bolts M10 35 50 Water pump to gearcase bolts M10 35 50 Raw water pump gear securing nut, dry thread M35 180 244

ENGINE FEET

Engine feet to base frame bolts M20 350 475 Engine feet to cushion feet bolts M16 160 215 Engine feet to gearcase and suspension plate bolt M12 70 95

GOVERNOR

Control shaft mounting plate bolt M10 35 50

FAN

Fan driven pulley taper lock bush screws 1/2" BSW 35 50 Fan driven pulley taper lock bush screws 5/8" BSW 65 90

ALTERNATOR

Drive pulley taper lock bush screw 3/8" BSW 15 20

FUEL PUMP/INJECTORS

Injector capscrew clamp to cylinder head, early engines M10 50 70 Injector capscrew clamp to cylinder head, later engines M12 70 95 Injector nozzle nut to holder M27 150 203 Fuel pump control linkage screw 2BA 6 8 Unit injector control lever capscrews M5 6 8

FLEXIBLE COUPLING

Flexible coupling cover screw M12 or 1/2" UNC 47 64 Coupling driving flange screws (coupling size 2.15) M12 or 1/2" UNC 47 64 Coupling driving flange screws (coupling size 3.86) M16 or 5/8" UNC 114 155

TORQUE SETTINGS

18 4

012/4016 Diesel, February 1997

GENERAL TORQUE LOADINGS

The following torque loadings are general for metric coarse threads and for grade 8.8 steel, but do not supersede the figures quoted above.

THREAD lbf ft Nm

M5 5 7 M6 9 12 M8 21 28 M10 41 56 M12 72 98 M16 180 244 M20 351 476 M24 606 822

GENERAL NOTE:

M10 - 12.9 Steel 50 70

TIGHTENING TORQUES

These are based on 85% of the proof loads designated in BS3692.

LUBRICATING OIL RECOMMENDATIONS

4012/16 Diesel, February 1997 1

QUANTITY OF OIL

TYPE OF OIL

The industrial diesel engine should be lubricated with a good quality oil conforming to API CD or CCMC D4 specifications. All the major oil companies formulate oils to the above specifications.

VISCOSITY OF OIL

Use oil of:

SAE10W/30 in starting temperatures below -15°C (without sump heater)

SAE10W/40 in starting temperatures from -15°C to 0°C

SAE30 in starting temperatures from 0°C to 32°C or Mobil Devlac Super

SAE40 in starting temperatures above 32°C 1300 SAE 15W/40

OIL CHANGE PERIODS

For normal operation of the engine the oil should be changed every 250 hours or annually whichever is the sooner.

Under certain circumstances where a centrifugal oil filter is fitted to the engine and an oil analysis programme has been carried out with the oil supplier over a period of 1000 hours of engine operation, it may be possible to extend the oil change period up to maximum of 350 hours.

To achieve this extended oil change period, a centrifugal oil filter must be fitted and cleaned every 250 hours between routine oil changes, and at every oil change point i.e. 350 hours maximum.

As the oil deteriorates it is essential that the following parameters must not be exceeded at the oil change point:

1 The viscosity of the oil must not increase by more than 10cSt at 100°C.

2 The total base number of the oil should not reduce to less than 50% of the value of new

oil.

3 The flash point of the oil should exceed 180°C.

4 The water content of the oil must not exceed 1%.

5 The fuel content of the oil must not exceed 1%.

6 Oil samples should be taken from the mean sump oil level of the engine.

Sump Capacity Dipstick 4012 4016 Minimum 136 litre(30 gal) 147 litre (33 gal) Maximum 159 litre (35 gal) 214 litre (47 gal)

LUBRICATING OIL RECOMMENDATIONS

20 4

012/16 Diesel, February 1997

ENGINE OPERATION

Excessive periods of idling or repeated cold starts should be avoided, as they will cause excessive dilution of the oil by fuel, requiring more frequent oil changes and dangerously lowering the flash point of the oil.

Should there be a lubricating oil supply problem, or if the fuel being used contains more than

0.5% sulphur, Perkins Engines (Stafford) Limited must be consulted to give advice in selecting a suitable grade.

The following list gives details of some of the oils that meet the required specifications. Note that the brand names may change as oils are upgraded or reformulated.

An up-to-date list is maintained by Perkins Engines (Stafford) Limited of major oil companies products and information, which can be obtained from Perkins Engines (Stafford) Service Department.

APPROVED INDUSTRIAL OIL A1 SPECIFICATIONS BSEN 590

(Suitable for fuel to Class A2 specifications BS2869 Part 2).

Oil Company Type

CASTROL CRH/RX Super ELF Multiperfo XC KUWAIT OIL Co Q8 T400 MOBIL Delvac 13

Delvac Super 1300 (15W/40) SHELL Rimula X ESSO Essolube XD 3+ TEXACO Ursa Super LA

WARNING

FAILURE TO COMPLY WITH THESE INSTRUCTIONS WILL INVALIDATE THE WARRANTY OFFERED WITH THE ENGINE, AS

IT MAY RESULT IN ENGINE DAMAGE.

COOLANT

4012/16 Diesel, February 1997 2

ENGINE COOLING SYSTEM

The cooling system of an engine contains many different materials e.g. cast iron, aluminium, copper, solder, rubber (various types). To prevent deterioration of these materials, it is essential to use a very good quality coolant. Untreated water is not suitable. It is essential that the water is treated with an additive that gives the necessary protection.

WATER QUALITY

The water to be mixed with the additive must have the following characteristics:

Chlorides less than 80 PPMV

(PPMV = parts per million by volume) Sulphates less than 80 PPMV

Total hardness less than 200 PPMV

pH of water between 7 to 7.5

(neutral to slightly alkaline)

ADDITIVES TO WATER

Due to the complexity of the cooling system it is necessary to use an additive that contains a balanced package of corrosion inhibitors.

To achieve the required solution a 50/50 mix of Shell Safe Premium antifreeze with water should be used at all times, even in areas where frost is unlikely.**

The 50/50 mixture will give frost protection down to -35°C. In areas where Shell Safe Premium is not available contact Perkins Engines (Stafford) Limited for advice on a recommended alternative.

Under no circumstances should an additive containing nitrites, borates, phosphates, chromates, nitrates, or silicates be used, as they are not compatible with the materials used in the cooling system.

When mixing the antifreeze with the water always follow the manufacturer's recommendation to add the antifreeze in the correct proportion before introducing it into the engine cooling system. Adding water to antifreeze can lead to the formation of a gel in the mixture, which can cause blockage of the water passages and subsequent local overheating.

MAINTENANCE OF COOLANT

The water/antifreeze mixture should be regularly replaced in operating engines at least once a year.

In engines used for standby duty it is essential to maintain the water/antifreeze mixture at the correct alkalinity level i.e. the pH should not increase above 7.5. A hydrometer only shows the proportion of ethylene glycol, not the degree of corrosion protection.

4012TWG2 only to this rule is when two section radiators are used in conjunction with charge air coolers under tropical conditions. It may be necessary to reduce the antifreeze content of the coolant from 50% to 10% to achieve an adequate heat transfer coefficient.

WARNING

ALWAYS STOP THE

ENGINE AND ALLOW THE PRESSURISED SYSTEM TO COOL BEFORE REMOVING FILLER CAP. AVOID SKIN CONTACT WITH ANTIFREEZE BY WEARING HAND, ETC.

WARNING

FAILURE TO FOLLOW

THE ABOVE RECOMMENDATIONS MAY RESULT IN DAMAGE TO THE ENGINE, AND WILL INVALIDATE THE ENGINE WARRANTY.

FUEL SPECIFICATION

22 4

012/16 Diesel, February 1997

Fuel should be wholly hydrocarbon oil derived from petroleum, with which small quantities of additives may be incorporated for the improvement of ignition or other characteristics and should conform to British Standard Specification 2869. Class A1 or A2.

If fuels other than the above classes are considered, the operator must consult Perkins Engines (Stafford) Limited, and ensure that a suitable grade of lubricating oil is used.

BS2869 REQUIREMENTS FOR ENGINE FUEL

Property Class A1 Class A2

Viscosity, Kinematic at 40°C, cSt *

Min. 1.5 1.5

Max. 5.0 5.5

Cetane number, min. 50 45

Carbon residue, Ramsbottom on 10% residue, % (m/m), max. 0.20 0.20

Distillation, recovery at 350°C, % (V/V), min. 56°C 56°C

Sulphur content, % (V/V), max. 0.05 0.05

Sediment, % (m/m), max. 0.01 0.01

Ash, %(m/m), max. 0.01 0.01

Sulphur content, % (m/m), max. 0.30++ 0.50++

Copper corrosion test, max. 1 1

Cold filter plugging point C, max.

Summer (March/September inclusive) -4 -4

Winter (October/February inclusive) -15 -12

* cSt = 1 mm²/s.

++ This limit is set in accordance with the legislative requirements for gas oil of the 'Council Directive (75/716/EEC of the European Economic Community) on the approximation of the laws of Member States relating to the sulphur content of certain liquid fuels'.

In countries where this legislation does not apply, it is permissible to run 4000 Series engines on fuels with up to 1.0% sulphur. (See

page 20 "Engine Operation").

NGINE FUELS

1 The two classes of fuel specified in the table are marketed specifically as oil engine

fuels. Class A1 is of higher quality and is intended primarily as an automotive diesel fuel, whilst Class A2 is intended as a general purpose diesel fuel. Classes A1 and A2 are distillate grades and are so specified as to prevent the inclusion of residuum.

2 The specifications for Classes A1 and A2 include limits for cold filter plugging point

chosen to cover seasonal requirements in the United Kingdom.

3 Ignition quality is specified in terms of cetane number, but the calculated cetane index

is referred to as an alternative for routine purposes with fuels not containing ignition improver additives.

NOTE: If local supply problems dictate that fuels which fall outside the above specification are to be used, our Service Department must be consulted prior to use.

OPERATING INSTRUCTIONS

4012/16 Diesel, February 1997 2

PREPARING FOR INITIAL START FILLING THE ENGINE WITH OIL

Remove the drain plug to ensure that the sump is clean and empty. Refit and tighten the plug. Remove the oil filler situated on the left hand side of the crankcase, by rotating the T-bar anti-clockwise and pulling up (Fig.

1). Fill the sump to the maximum mark on the dipstick with the appropriate grade and quantity of oil (see page 19 & 20).

NOT

E: If the engine has been overhauled

ensure that, with the governor in the stop position, the pump injectors are set in the 'NO FUEL' position.

PRIMING THE TURBOCHARGERS ON ENGINES FITTED WITH THE ELECTRONIC GOVERNOR

Before starting the engine for the first time, or if it has stood idle for more than three months, the turbocharger bearings should be primed. To prime the turbocharger, the engine needs to be motored over on the starter. In order that the engine does not run up to speed when operating the key switch (i.e. energising the stop solenoids) it will be necessary to hold the governor lever in the stop position (see Fig. 13) but ensure that t

he air shut-off valves have been manually

set to the run position (see Fig. 12).

(Fig. 2 & Fig. 3)

1. Electronic plug

WARNING

NEVER OPERATE

THE ENGINE WHEN THE OIL LEVEL IS BELOW THE MINIMUM MARK OR ABOVE THE MAXIMUM. ALWAYS WEAR PROTECTIVE GLOVES WHEN HANDLING ENGINE OIL.

Fig. 1

Fig. 2

Fig. 3

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