Perkins Engine 4000 Service Manual

TSL4186E, Issue 1

February 1998

User’s

Handbook

4000 SERIES DIESEL

4016 TAG1

4016 TAG2

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.

4012/16 Diesel, February 1997

INTRODUCTION

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
Perkins Group of Companies	Perkins International - North America		Moteurs Perkins SA
Perkins Engines (Peterborough) Ltd.	12025 Tech Center Drive,		9 Avenue Michelet, 93583 Saint Quen,
Frank Perkins Way, Eastfield,	Livonia, Michigan 48150,		Cedex, France.
Peterborough, PE1 5NA, England.	U.S.A.		Tel: [phone]
Tel: [phone]	Tel: [phone]		Telex: 234 924
Telex: 32501 PERKEN G	Fax: [phone]		Fax: [phone]
Fax: [phone]
	Perkins Engines Latin America Inc		A/S Perkins Engines (Denmark) Ltd
Perkins Engines (Shrewsbury) Ltd.	999 Ponce de Leon Boulevard,		Industrihaven 1, DK-3300
Lancaster Road, Shrewsbury,	Suite 710, Coral Gables,		Frederiksvaerk, Denmark.
SY1 3NX, England.	Florida 33134, U.S.A.		Tel: [phone]
Tel: [phone]	Tel: [phone]		Fax: [phone]
Telex: 35171/2 PESL G	Telex: 32501 PERKEN G
Fax: [phone]	Fax:	[phone]	Perkins International Ltd.
			Varity Asia/Pacific
Perkins Engines (Stafford) Ltd.	Perkins Engines Australia Pty Ltd		Suite 3301, Convention Plaza,
Tixall Road, Stafford, ST16 3UB, England.	Suite 2, 364 Main Street, Mornington		1 Harbour Road, Wanchai,
Tel: [phone]	3391, Victoria, Australia.		Hong Kong.
Telex: 36156 PERKEN G	Tel: [phone]		Tel: [phone]
Fax: [phone]	Telex: 30816		Fax: [phone]
	Fax:	(059) 75 1305
Perkins Powerpart Distribution Centre			Varity (Japan) K.K.
Frank Perkins Way,	Motori Perkins SpA		5th Floor, Reinanzaka Building,
Northbank Industrial Park, Irlam,	Via Socrate. 8,22070 Casnate		14-2 Akasaka 1 - Chome,
Manchester, M44 5PP, England.	Con Bernate (Como), Italy.		Minato-Ku Tokyo 107, Japan.
Tel: [phone]	Tel: [phone]		Tel: [phone]
Specifications Help Desk	Telex: 380658 PERKIT I		Telex: PERKOIL 12424823
Tel: [phone]	Fax: [phone]		Fax: [phone]
Fax: [phone]
Specifications Help Desk	Perkins Motoren GmbH		Perkins Engines (Far East) Pte Ltd.
Tel: [phone]	D-63801 Kleinostheim,		39 Tuas Avenue 13,
Telex: 32501 PERKEN G	Saalackerstrasse 4, Germany.		Singapore 638999.
	Tel:	(49) (6027) 5010	Tel: [phone]
	Fax:	(49) (6027) 501130	Fax: [phone]

In addition to the above companies, there are Perkins distributors in most countries. Perkins Engines (Peterborough) Limited or one of the above companies can provide details.

Publication TSL4186

Published by the Technical Publications Department, Stafford. © 1997 Perkins Engines (Stafford) Limited.

4012/16 Diesel, February 1997

1

ENGINE DESIGNATIONS

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

2	4012/16 Diesel, February 1997

CONTENTS
	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

4012/16 Diesel, February 1997

3

PHOTOGRAPHS

4012 TAG

4012 TAG

6	4012/16 Diesel, February 1997

PHOTOGRAPHS

4016 TAG

4016 TAG

4012/16 Diesel, February 1997

7

BRIEF DESCRIPTION OF THE 4012/16 SERIES DIESEL ENGINES

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 Uprated versions of the 4016TEG 16 cylinder "V" form diesel engine, water AND cooled, turbocharged (four turbochargers), raw water cooled charge air 4016TEG2 coolers with raw water pump and separate cooling circuit. Oil coolers in

engine cooling circuit. Horizontal air cleaners.

8	4012/16 Diesel, February 1997

GENERAL INFORMATION

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 wet 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.

Fig. A

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

1Avoid prolonged and repeated contact with used engine oils.

2Wear protective clothing, including impervious gloves where applicable.

3Do not put oily rags into pockets.

4 Avoid	contaminating	clothes,
particularly underwear, with oil.

5Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear.

6First aid treatment should be obtained immediately for open cuts and wounds.

7Apply barrier creams before each period of work to aid the removal of mineral oil from the skin.

8Wash 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.

9Do NOT use petrol, kerosene, diesel fuel, gas oil, thinners or solvents for washing the skin.

10If skin disorder appears, medical advice must be taken.

11Degrease components before handling if practicable.

12Where 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.

4012/16 Diesel, February 1997

9

GENERAL INFORMATION

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 cooled.

●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.

4012/16 Diesel, February 1997

10

DIESEL ENGINE DATA

‘A’ BANK	‘B’ BANK

Fig. B

For full technical data please refer to the Product Information Manual. Type: Water-cooled, turbocharged, charge cooled, industrial diesel engine.

	RANGE	4012	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-	1A-1B-3A-3B-7A-7B-5A-5B-
		6A-1B-2A-5B-4A-3B	8A-8B-6A-6B-2A-2B-4A-4B
	Valve Timing	inlet valve opens 60° BTDC	exh valve opens 46° BBDC
		inlet valve closes 46° ABDC	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		See 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)

4012/16 Diesel, February 1997

11

DIESEL ENGINE DATA

TYPICAL COOLING SYSTEM

		4006			4008
Approved Coolants)			See page 21
Total water capacity	Ltrs	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**

*Engine only

**Engine with heat exchanger

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
	FUEL SYSTEM
		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
	GOVERNORS
		4012		4016
Type		Electronic		Electronic
Type		Hydraulic		Hydraulic

12	4012/16 Diesel, February 1997

		DIESEL ENGINE DATA
LUBRICATION SYSTEM
	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
INDUCTION SYSTEM
	4012		4016
Air cleaners (earlier)	Twin vertical air cleaners
(current)	Twin horizontal air cleaners
Type	Paper element
Air restriction indicator setting	380 mm H20
Turbochargers	x2 off		x4 off
EXHAUST SYSTEM
	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
FLYWHEEL
	4012		4016
Drive size		SAE 18”
	SAE 21” Optional
FLYWHEEL HOUSING
	4012		4016
SAE size		00

4012/16 Diesel, February 1997

13

DIESEL ENGINE DATA

TYPICAL DRY WEIGHT

		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
HOLDING DOWN BOLT HOLES
		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
	ELECTRICAL SYSTEM
		4012		4016
Voltage			24V
Alternator		Belt Driven
Alternator output			30A
		Single CAV		Twin Prestolite
Starter motor		(Earlier Engines)
		Twin Prestolite
		(Current Engines)
No. of teeth (gear ring)		144 (Early Engines)		156
		156 (Current Engines)
No. of teeth (starter pinion)			12
Battery (lead acid)		24V DC (2 x 12V)
Capacity down to 0°C (32°F)			286 Ah

14	4012/16 Diesel, February 1997

DIESEL ENGINE DATA

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:-

	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

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

Overspeed

15% above max. running speed (Except 1800 r/min which is 7%)

AIR STARTING

		4012		4016
Air starter		See Installation Manual
Air starter pressure		150 lb/in2 (10.34 bar)
Compressed air supply		170 lb/in2 (11.72 bar)
INSTRUMENT PANEL (ENGINE MOUNTED)
		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
	COOLANT JACKET HEATING
		4012		4016
Heater		2 x 4 kW
Voltage		210-250V ac

4012/16 Diesel, February 1997

15

TORQUE SETTINGS

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.

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 Section R11 before fitting. However, dry 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
Lateral 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
Front 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

16	4012/4016 Diesel, February 1997

TORQUE SETTINGS

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

4012/4016 Diesel, February 1997

17

TORQUE SETTINGS

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.

18	4012/4016 Diesel, February 1997

LUBRICATING OIL RECOMMENDATIONS

QUANTITY OF OIL

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

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:

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

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

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

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

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

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

4012/16 Diesel, February 1997

19

LUBRICATING OIL RECOMMENDATIONS

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.

WARNING	FAILURE TO COMPLY WITH THESE INSTRUCTIONS WILL
	INVALIDATE THE WARRANTY OFFERED WITH THE ENGINE, AS
IT MAY RESULT IN ENGINE DAMAGE.

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

20	4012/16 Diesel, February 1997

COOLANT

	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.

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.

	WARNING	FAILURE TO FOLLOW
		THE ABOVE

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

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.

4012/16 Diesel, February 1997

21

FUEL SPECIFICATION

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").

ENGINE FUELS

1The 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.

2The specifications for Classes A1 and A2 include limits for cold filter plugging point chosen to cover seasonal requirements in the United Kingdom.

3Ignition 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.

22	4012/16 Diesel, February 1997

OPERATING INSTRUCTIONS

PREPARING FOR INITIAL START FILLING THE ENGINE WITH OIL

	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.

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).

NOTE: 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 the air shut-off valves have been manually set to the run position (see Fig. 12).

Key

(Fig. 2 & Fig. 3)

1. Electronic plug

Fig. 1

1

Fig. 2

1

Fig. 3

4012/16 Diesel, February 1997

23