SEBU9077-01 (en-us)
September 2016
Operation and
Maintenance
Manual
4006-23 and 4008-30 Industrial Engines
SD8 (Engine)
SD6 (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.
SEBU9077-01 |
3 |
Table of Contents
Table of Contents |
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Foreword ........................................................... |
4 |
Safety Section |
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Safety Messages............................................... |
5 |
General Hazard Information.............................. |
9 |
Burn Prevention............................................... |
12 |
Fire Prevention and Explosion Prevention...... |
13 |
Crushing Prevention and Cutting Prevention.. 15 |
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Mounting and Dismounting ............................. |
15 |
Before Starting Engine .................................... |
15 |
Engine Starting................................................ |
16 |
Engine Stopping.............................................. |
16 |
Electrical System............................................. |
16 |
Engine Electronics........................................... |
17 |
Product Information Section |
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Model Views .................................................... |
18 |
Product Identification Information ................... |
25 |
Operation Section |
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Lifting and Storage .......................................... |
26 |
Features and Controls..................................... |
29 |
Engine Starting................................................ |
32 |
Engine Operation ............................................ |
33 |
Engine Stopping.............................................. |
34 |
Maintenance Section |
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Warranty Section |
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Warranty Information....................................... |
83 |
Index Section |
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Index................................................................ |
84 |
Refill Capacities............................................... |
35 |
Maintenance Interval Schedule....................... |
50 |
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
SEBU9077-01
Safety Section
i06712726
Safety Messages
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. Become familiar with all warning signs.
Ensure that all 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 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 distributor can provide new warning signs.
Illustration 1
5
Safety Section
Safety Messages
g06086932
(1) |
Universal warning label locations |
(3) |
Hot surface label location |
(5) Ether warning label location |
(2) |
Do not step |
(4) |
Hot fluid under pressure label locations |
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6 |
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Safety Section
Safety Messages
Illustration 2
( |
Universal1 warning) label location |
( |
Hot3surface label) location |
g06093786
( Rotating6 shaft) hand crush hazard label location
1 Universal Warning
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Do not operate or work on this equipment unless |
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you have read and understand the instructions |
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and warnings in the Operation and Maintenance |
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Manuals. Failure to follow the instructions or |
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heed the warnings could result in serious injury |
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or death. |
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The universal warning labels ( are installed1 in two) |
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locations. One universal warning label is installed on |
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the coolant rail. The other universal warning label is |
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installed on the control box. |
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2 Do Not Step |
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This safety message is located in the center of the |
Illustration 3 |
g06019365 |
intake manifold. |
Universal Warning label
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Illustration 4 |
g01393287 |
Do not use this surface as a step or platform. This surface may not support additional weight or may be slippery. Serious injury or death could occur from a fall.
3 Hot Surface
Illustration 5 |
g01372256 |
Hot parts or hot components can cause burns or personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
7
Safety Section
Safety Messages
The hot surface warning labels ( are located2 in two)
locations. The oil cooler and heat shield of the coolant rail.
4 Hot Fluid Under Pressure
Illustration 6 |
g01371640 |
Pressurized system! Hot coolant can cause serious burns, injury or death. 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. Read and understand the Operation and Maintenance Manual before performing any cooling system maintenance.
8
Safety Section
Safety Messages
The hot fluids under pressure labels ( have3two positions. One label is on the end cover of the oil
cooler. Perkins recommends that the other hot fluid under pressure label is installed on the radiator, next
to the coolant filler cap.
5 Ether Warning
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) Ether warning label ( is on4the support)bracket for the air cleaners.
6 Rotating Shaft Hand Crush
Hazard
Illustration 7 |
g01372254 |
Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.
Illustration 8 |
g02781437 |
Rotating shaft pinch hazard. The shaft under this cover is rotating anytime the engine is running. Contact with a rotating shaft could cause injury or death. Keep hands away.
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The rotating shaft hand crush hazard label (5) is on the cover of the crankshaft vibration damper.
i06106934
General Hazard Information
Illustration 9 |
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. Attach the warning tags to the engine and to each operator control station. When appropriate, disconnect the starting controls.
Do not allow unauthorized personnel on the engine, or around the engine when the engine is being serviced.
•Tampering with the engine installation or tampering with the OEM supplied wiring can be dangerous. Personal injury, death and/or engine damage could result.
•Vent the engine exhaust to the outside when the engine is operated in an enclosed area.
•If the engine is not running, do not release the secondary brake or the parking brake systems unless the vehicle is blocked or unless the vehicle is restrained.
•Wear a hard hat, protective glasses, and other 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.
9
Safety Section
General Hazard Information
•Never put maintenance fluids into glass containers. Glass containers can break.
•Use all cleaning solutions with care.
•Report all necessary repairs.
Unless other instructions are provided, perform the maintenance under the following conditions:
•The engine is stopped. Ensure that the engine cannot be started.
•The protective locks or the controls are in the applied position.
•Engage the secondary brakes or parking brakes.
•Block the vehicle or restrain the vehicle before maintenance or repairs are performed.
•Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks. If equipped, allow the diesel exhaust fluid to be purged before disconnecting the battery.
•If equipped, disconnect the connectors for the unit injectors that are located on the valve cover base. This action will help prevent personal injury from the high voltage to the unit injectors. Do not come in contact with the unit injector terminals while the engine is operating.
•Do not attempt any repairs or any adjustments to the engine while the engine is operating.
•Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.
•For initial start-up of a new engine or for starting an engine that has been serviced, make provisions to stop the engine if an overspeed occurs. The stopping of the engine may be accomplished by shutting off the fuel supply and/ or the air supply to the engine. Ensure that only the fuel supply line is shut off. Ensure that the fuel return line is open.
•Start the engine from the operators station (cab). Never short across the starting motor terminals or the batteries. This action could bypass the engine neutral start system and/or the electrical system could be damaged.
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.
10
Safety Section
General Hazard Information
Cautiously remove the following parts. To help prevent spraying or splashing of pressurized fluids, hold a rag over the part that is being removed.
•Filler caps
•Grease fittings
•Pressure taps
•Breathers
•Drain plugs
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.
Illustration 10 |
g00702020 |
•Wear a hard hat, protective glasses, and other protective equipment, as required.
•When work is performed around an engine that is operating, wear protective devices for ears in order to help prevent damage to hearing.
•Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.
•Ensure that all protective guards and all covers are secured in place on the engine.
•Never put maintenance fluids into glass containers. Glass containers can break.
•Use all cleaning solutions with care.
•Report all necessary repairs.
Unless other instructions are provided, perform the maintenance under the following conditions:
•The engine is stopped. Ensure that the engine cannot be started.
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•Disconnect the batteries when maintenance is performed or when the electrical system is serviced. Disconnect the battery ground leads. Tape the leads in order to help prevent sparks.
•Do not attempt any repairs that are not understood. Use the proper tools. Replace any equipment that is damaged or repair the equipment.
Pressurized Air and Water
Pressurized air and/or water can cause debris and/or hot water to be blown out. This action 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.
The maximum air pressure for cleaning purposes |
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must be below 205 kPa ( |
psi 30The maximum |
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water pressure for cleaning purposes must be below |
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275 kPa ( psi 40 |
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Fluid Penetration
Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly.
Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure.
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11 |
Safety Section
General Hazard Information
Illustration 11 |
g00687600 |
Always use a board or cardboard when you check for a leak. Leaking fluid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting, and 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.
Static Electricity Hazard when Fueling with Ultra-low Sulfur Diesel Fuel
The removal of sulfur and other compounds in ultralow sulfur diesel fuel (ULSD fuel) decreases the conductivity of ULSD and increases the ability of ULSD to store static charge. Refineries may have treated the fuel with a static dissipating additive. Many factors can reduce the effectiveness of the additive over time. Static charges can build up in ULSD fuel while the fuel is flowing through fuel delivery systems. Static electricity discharge when combustible vapors are present could result in a fire or explosion. Ensure that the entire system used to refuel your machine (fuel supply tank, transfer pump, transfer hose, nozzle, and others) is properly grounded and bonded. Consult with your fuel or fuel system supplier to ensure that the delivery system complies with fueling standards for proper grounding and bonding.
Avoid static electricity risk when fueling. Ultralow sulfur diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur contents. Avoid death or serious injury from fire or explosion. Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices.
Inhalation
Illustration 12 |
g00702022 |
Exhaust
Use caution. Exhaust fumes can be hazardous to health. If you operate the equipment in an enclosed
area, adequate ventilation is necessary.
Asbestos Information
Perkins equipment and replacement parts that are shipped from Perkins engine company limited are asbestos free. Perkins recommends the use of only genuine Perkins replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated.
If dust that may contain asbestos is present, there are several guidelines that should be followed:
• Never use compressed air for cleaning.
12
Safety Section
Burn Prevention
•Avoid brushing materials that contain asbestos.
•Avoid grinding materials that contain asbestos.
•Use a wet method in order to clean up asbestos materials.
•A vacuum cleaner that is equipped with a high efficiency particulate air filter (HEPA) can also be used.
•Use exhaust ventilation on permanent machining jobs.
•Wear an approved respirator if there is no other way to control the dust.
•Comply with applicable rules and regulations for the work place. In the United States, use Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in “29 CFR 1910.1001”.
•Obey environmental regulations for the disposal of asbestos.
•Stay away from areas that might have asbestos particles in the air.
Dispose of Waste Properly
Illustration 13 |
g00706404 |
Improperly disposing of waste can threaten the environment. Potentially harmful fluids should be disposed of according to local regulations.
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Always use leakproof containers when you drain fluids. Do not pour waste onto the ground, down a drain, or into any source of water.
i06545886
Burn Prevention
Coolant
When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine 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 that 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 to relieve pressure. Refer to this Operation and Maintenance Manual, Cooling System Coolant Level - Check for more information.
Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.
Oils
Skin may be irritated following repeated or prolonged exposure to mineral and synthetic base oils. Refer to your suppliers Material Safety Data Sheets for detailed information. Hot oil and lubricating components can cause personal injury. Do not allow hot oil to contact the skin. Appropriate personal protective equipment should be used.
Diesel Fuel
Diesel may be irritating to the eyes, respiratory system, and skin. Prolonged exposure to diesel may cause various skin conditions. Appropriate personal protective equipment should be used. Refer to supplier Material safety Data sheets for detailed information.
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.
Do not smoke whilst checking the battery electrolyte levels. Batteries give off flammable fumes which can explode.
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Always wear protective glasses when you work with batteries. Wash hands after touching batteries. The use of gloves is recommended.
i06545894
Fire Prevention and Explosion
Prevention
Illustration 14 |
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.
After the emergency stop button is operated, ensure that you allow 15 minutes, before the engine covers are removed.
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 and/ or your Perkins distributor for additional information about suitable protection devices.
Remove all flammable combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any flammable
combustible materials or conductive materials to accumulate on the engine.
Store fuels and lubricants in correctly 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.
13
Safety Section
Fire Prevention and Explosion Prevention
Exhaust shields (if equipped) protect hot exhaust components from oil or fuel spray if there was a line,
a tube, or a seal failure. Exhaust shields must be installed correctly.
Do not carry out any work on the fuel lines or tanks that could ignite residual fuel. Grinding, welding, cutting, chiseling, and sawing have the potential to create a source of ignition must be avoided.
Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to welding or flame cutting.
Wiring must be kept in good condition. Ensure that all electrical wires are correctly installed 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 correctly maintained battery cables will help to prevent arcing or sparking.
Ensure that the engine is stopped. Inspect all lines and hoses for wear damage, leakage or for deterioration. Ensure that the hoses are correctly routed. The lines and hoses must have adequate support and secure clamps.
Oil filters and fuel filters must be installed correctly. The filter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for more information.
14 |
SEBU9077-01 |
Safety Section
Fire Prevention and Explosion Prevention
Illustration 15 |
g00704059 |
Use caution when you are refueling an engine. Do not smoke whilst you are refueling an engine. Do not refuel an engine near open flames or sparks. Always stop the engine before refueling.
Avoid static electricity risk when fueling. Ultra-low Sulfur Diesel fuel (ULSD fuel) poses a greater static ignition hazard than earlier diesel formulations with a higher sulfur content. Avoid death or serious injury from fire or explosion. Consult your fuel or fuel system supplier to ensure that the delivery system is in compliance with fueling standards for proper grounding and bonding practices.
Illustration 16 |
g00704135 |
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.
Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer.
Incorrect 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. A frozen battery 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.
Ether
Ether is flammable and poisonous.
Do not smoke whilst you are replacing an ether cylinder or whilst you are using an ether spray.
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Do not store ether cylinders in living areas or in the engine compartment. Do not store ether cylinders in direct sunlight or in temperatures above 49° C (120° F). Keep ether cylinders away from open flames or sparks.
Lines, Tubes, and Hoses
Do not bend high-pressure lines. Do not strike highpressure lines. Do not install any lines that are damaged.
Leaks can cause fires. Consult your Perkins distributor for replacement parts.
Replace the parts if any of the following conditions are present:
•End fittings are damaged or leaking.
•Outer coverings are chafed or cut.
•Wires are exposed.
•Outer coverings are ballooning.
•Flexible parts 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, correct installation will help to prevent vibration, rubbing against other parts, and excessive heat.
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.
15
Safety Section
Crushing Prevention and Cutting Prevention
i05875651
Mounting and Dismounting
Do not climb on the engine. The engine has not been designed with mounting or dismounting locations.
Refer to the OEM for the location of foot and hand holds for your specific application.
i04257031
Before Starting Engine
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 air and/or fuel supply to the engine.
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.
Inspect the engine for potential hazards.
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.
Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel.
If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work properly, if equipped.
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.
Do not start an engine when the governor linkage is disconnected.
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.
16
Safety Section
Engine Starting
i06545901
Engine Starting
Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.
If a warning tag is attached to the engine start switch, or to the controls DO NOTstart the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.
All protective guards and all protective covers must be installed if the engine must be started to perform service procedures.
Start the engine from the operators compartment or from the engine start switch.
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.
Ensure that the jacket water heater (if equipped) is working correctly, check the water temperature reading on the control panel of the original engine manufacture.
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.
Note: The engine may be equipped with a device for cold starting. If the engine will be operated in cold conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the correct type of starting aid for your region of operation.
i01462046
Engine Stopping
Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components.
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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 NOTstart the engine until the problem that caused the emergency stop has been corrected.
Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled. This may be accomplished by shutting off the fuel supply to the engine and/or shutting off the air supply to the engine.
To stop an electronically controlled engine, cut the power to the engine.
i06088340
Electrical System
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.
To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” jump-start 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 jump-start cable to the engine block.
Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical wires before the engine is started. Repair all frayed electrical wires before the engine is started. Refer to the “Engine Starting” section of this Operation and Maintenance Manual for specific starting instructions.
Grounding Practices
Proper grounding for the engine electrical system is necessary for optimum engine performance and reliability. Improper grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.
Uncontrolled electrical circuit paths can result in damage to main bearings, to crankshaft bearing journal surfaces, and to aluminum components.
Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge.
To ensure that the engine and the engine electrical systems function properly, an engine-to-frame ground strap with a direct path to the battery must be used. This path may be provided by way of a starting motor ground, a starting motor ground to the frame, or a direct engine ground to the frame.
SEBU9077-01
All 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.
i02414684
Engine Electronics
Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/ or engine damage.
The engine is controlled by a digital Pandoras governor. The control system includes the following components.
•Control unit
•Actuator
•Setpoint adjusters (if equipped)
•Sensors
•Wiring Harness
System Description
The system is controlled by an Electronic control Unit (ECU). The ECU contains a microprocessor that has an Electronic Programmable Read Only Memory (EPROM). The operating parameters for the governor are stored in the EPROM. The actuator is connected to the fuel injectors via a mechanical linkage.
A laptop computer is used to set the operating parameters of the governor. The laptop computer is connected to the governor via an interface cable. The operating parameters for the governor should only be modified by a trained Perkins representative. Refer to the Special Instruction, “Pandoras Digital Governor” for more information.
17
Safety Section
Engine Electronics
18 |
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Product Information Section
Model Views
Product Information
Section
Model Views
i06681533
Model View Illustrations
(Engine Views for the Six and Eight Cylinder 4000 Series Engines)
The following model views show typical features of the engine. Due to individual applications, your engine may appear different from the illustrations.
SEBU9077-01 |
19 |
Product Information Section
Engine Views for the Six and Eight Cylinder 4000 Series Engines
4006-23 Engine Views
Illustration 17 |
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g06072657 |
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Typical example |
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( |
Twin1 air cleaners) |
( |
Adjustment3 housing) |
( Belts5 |
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( |
Crankcase2 breather) |
( |
Fan4 hub pulley) |
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The major engine differences on six cylinder engine to an eight cylinder engine are shown in illustration 17 . These differences are, air cleaner end cap design the crankcase breather design. The adjustment plate. The belts that drive the fan and the belt pulley for the fan drive.
20 |
SEBU9077-01 |
Product Information Section
Engine Views for the Six and Eight Cylinder 4000 Series Engines
4006-23 Radiator
Illustration 18 |
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g06072687 |
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Typical example |
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( |
Radiator1 lifting) eyes |
( |
Radiator3 |
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( |
Fuel5 cooler ) |
( |
Radiator2 pressurized) filler cap |
( |
Radiator4 drain) |
( |
Air6charge cooler) |
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SEBU9077-01 |
21 |
Product Information Section
Engine Views for the Six and Eight Cylinder 4000 Series Engines
4008-30 Engine Views
Illustration 19 |
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g06004723 |
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Typical example |
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Twin1 air cleaners) |
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Stop7 solenoid) |
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Oil13drain location |
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Electronic2 governor) control unit |
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Oil8filler cap ) |
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Oil14filters |
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Oil3cooler |
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Coolant9 pump) |
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Starter15 relay |
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Alternator4 |
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( |
Primary10 fuel filter |
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Starting16 motor |
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Front5 lifting eye) |
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1 Fuel1 priming) pump |
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Thermostat6 housing) |
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Oil12gauge (Dipstick) |
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22 |
SEBU9077-01 |
Product Information Section
Engine Views for the Six and Eight Cylinder 4000 Series Engines
Illustration 20 |
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g06004738 |
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Typical example |
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Twin17 turbochargers ) |
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Left19 side rear lifting eye) |
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Right18 side rear lifting eye) |
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Crankcase20 breather ) |
SEBU9077-01 |
23 |
Product Information Section
Engine Description
4008-30 Radiator
Illustration 21 |
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g06005784 |
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Typical example |
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(1) |
Radiator assembly lifting eye |
(4) |
Coolant filler cap |
(7) |
Fan belt pulley adjuster |
(2) |
After cooler |
(5) |
Radiator assembly lifting eye |
(8) |
Coolant drain |
(3) |
Radiator |
(6) |
Fan belts |
(9) |
Fuel cooler |
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i06681623 |
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Engine Description
The 4006-23 and the 4008-30 engines are available with turbocharged aftercooled aspiration. The 400623 and the 4008-30 industrial engines are designed as a constant speed engine.
Engine Specifications
The front end of the engine is opposite the flywheel end of the engine. The left and the right sides of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder.
Illustration 22 |
g03897666 |
Typical example of an 8 cylinder engine
(A)Inlet valves
(B)Exhaust valves
24
Product Information Section
Engine Description
Table 1
4006-23 Engine Specifications
Number of cylinders |
In-line 6 cylinder |
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Bore |
160 mm |
( |
6.29920inch |
Stroke |
190 mm |
( |
7.48030inch |
Displacement |
22.921 L () |
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Compression Ratio |
13.6:1 |
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Firing order |
1-5-3-6-2-4 |
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Aspiration |
Turbocharged after cooled |
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Valve seat angle |
20° |
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Valve lash |
0.4 mm |
( |
0.01575inch |
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Cold |
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Table 2
4008-30 Engine Specifications
Number of cylinders |
In-line 8 cylinder |
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Bore |
160 mm |
( |
6.29920inch |
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Stroke |
190 mm |
( |
7.48030inch |
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Displacement |
30.56 L |
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( |
1864.88549cubic inch |
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Compression Ratio |
13.6:1 |
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Firing order |
1-4-7-6-8-5-2-3 |
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Aspiration |
Turbo charged after cooled |
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Valve seat angle |
20° |
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Valve lash |
0.4 mm |
( |
0.01575inch |
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Cold |
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Engine Cooling and Lubrication
The cooling system consists of the following components:
•Gear-driven water pump
•Water temperature regulators
•Gear-driven oil pump (rotor type)
•Oil cooler
The engine lubricating oil is supplied by a gear-driven pump. The lubrication oil is cooled and filtered. Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high. Bypass valves can also provide unrestricted flow of lubrication oil to the engine parts if the oil filter element should become plugged.
SEBU9077-01
Engine efficiency, efficiency of emission controls, and engine performance depend on adherence to proper operation and maintenance recommendations.
Engine)performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and coolants) . Refer to this Operation and Maintenance
Manual for more information.
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SEBU9077-01 |
25 |
Product Information Section
Product Identification Information
Product Identification
Information
i06516715
Plate Locations and Film
Locations
The engine serial number plate is on the right side rear of the engine.
Illustration 24 |
g06016214 |
Typical example
(1) Engine serial number plate
Your Perkins distributor needs all the number from the plate when service information is required.
Emission Label
The emission label (2) is installed on the inlet manifold of the engine.
Illustration 23 |
g06017751 |
Typical example
(1)Engine serial number plate
(2)Emission label location
26 |
SEBU9077-01 |
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
i06700907
Engine Lifting
(4006-23 and 4008-30 Engines)
Engine Lifting Only
NOTICE
Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees.
When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight.
Use a hoist to remove heavy components. Use a lifting beam to lift the engine. All supporting members (chains and cables) should be parallel to each other. The chains and cables should be perpendicular to the top of the object that is being lifted.
To remove the engine ONLY, use the lifting eyes that are on the engine. If necessary, remove engine components to avoid damage from the lifting device.
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 distributor for information regarding fixtures for correct engine lifting.
SEBU9077-01 |
27 |
Operation Section
4006-23 and 4008-30 Engines
Illustration 25 |
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g06006861 |
Typical example |
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( Rear1 lifting eye) |
( Rear2 lifting eye) |
( Front3 lifting eye) |
Radiator Lifting Only
Illustration 26 |
g06006867 |
Typical example
( Radiator1 lifting) eye |
( Radiator2 lifting) eye |
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