Perkins Engine 4006 TRS Gas, 4008 TRS Gas Service Manual
Operation and
Maintenance
Manual
SEBU8190-00
April 2006
4006 TRS Gas and 4008 TRS Gas
Industrial Engines
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
SEBU8190 3
Table of Contents
Table of Contents
Foreword ............................................. .................... 4
Safety Section
Safety Messages .................................................... 5
General Hazard Information ................................... 7
Burn Prevention ...................................................... 9
Fire Prevention and Explosion Prevention .............. 9
Crushing Prevention and Cutting Prevention ......... 11
Mounting and Dismounting .................................... 11
Ignition Systems .................................................... 11
Before Starting Engine ........................................... 11
Engine Starting ..................................................... 12
Engine Stopping ................................................... 12
Index Section
Index ..................................................................... 68
Electrical System .................................................. 12
Product Information Section
Model Views and Specifications ........................... 14
Product Identification Information ........................ 20
Operation Section
Lifting and Storage ................................................ 22
Gauges and Indicators .......................................... 23
Features and Controls .......................................... 24
Engine Starting ..................................................... 27
Engine Operation .................................................. 30
Engine Stopping ................................................... 31
Maintenance Section
Refill Capacities .................................................... 33
Maintenance Interval Schedule ............................ 36
Reference Information Section
Reference Materials .............................................. 64
4 SEBU8190
Foreword
Foreword
Literature Information
This manual con
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literatur
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 consiste
Some photographs or illustrations in this manual
show details
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvemen
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises reg
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 si
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on
this product.
tains safety, operation instructions,
e holder or literature storage area. Read,
ncy.
or attachments that may be different
t and advancement of product design
arding your engine, or this manual, please
tuations. Read and understand the basic
Recommended se
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine a
Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
more frequen
specified in the Maintenance Interval Schedule may
be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the prevent
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should mini
avoidances resulting from reductions in unscheduled
downtime and failures.
ive maintenance program is followed, a
mize operating costs through cost
rvice should be performed at the
lso governs the Maintenance Interval
t lubrication and maintenance than is
Maintenance Intervals
Perform maintenance on items at multiples of
the original requirement. We recommend that the
maintenan
near the engine as a convenient reminder. We also
recommend that a maintenance record be maintained
as part of
Your authorized Perkins dealer or your Perkins
distribu
maintenance schedule to meet the needs of your
operating environment.
ce schedules be reproduced and displayed
the engine’s permanent record.
tor can assist you in adjusting your
Overhaul
Operatio
Operating techniques outlined in this manual are
basic. Th
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop
engine and its capabilities.
The oper
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and sto
discussion of electronic diagnostic information.
n
ey assist with developing the skills and
as the operator gains knowledge of the
ation section is a reference for operators.
pping the engine. This section also includes a
Maintenance
The mai
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
interv
referenced to detailed instructions that follow.
ntenance section is a guide to engine care.
als. Items in the maintenance schedule are
Major engine overhaul details are not covered in
the Operation and Maintenance Manual except
for the i
interval. Major repairs should only be carried out by
Perkins authorized personnel. Your Perkins dealer
or your P
regarding overhaul programs. If you experience
a major engine failure, there are also numerous
after f
your Perkins dealer or your Perkins distributor for
information regarding these options.
nterval and the maintenance items in that
erkins distributor offers a variety of options
ailure overhaul options available. Consult with
California Proposition 65 Warning
Diesel engine exhaust and some of its c onstituents
are known to the State of California to cause cancer,
defects, and other reproductive harm. Battery
birth
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.
SEBU8190 5
Safety Section
Safety Messages
Safety Section
i02409464
Safety Messages
Illustration 1
Typical example
(1) E ngine Derate (2) Universal warning (3) Engine Oil Level
There may be several specific warning signs on your
engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become familiar with all warning signs.
Ensure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if
the words cannot be read or if the illustrations are
not visible. Use a cloth, water, and soap to clean
the warning signs. Do not use solvents, gasoline, or
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning signs. The warning signs that are loosened
could drop off of the engine.
Replace any warning sign that is damaged or
missing. If a warning sign is attached to a part of the
engine that is replaced, install a new warning sign on
the replacement part. Your Perkins dealer or your
distributor can provide new warning signs.
The safety messages that may be attached on the
engine are illustrated .
g01269446
6 SEBU8190
Safety Section
Safety Messages
(1) Engine Derate
Illustration 2
Typical example
The warning label for derating engine information (1)
is located on the governor control unit. The governor
control unit is located on the right hand side of the
engine.
(2) Universal Warning
Do not operate or work on this equipment unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.
g01241021
The Universal Warning label (2) is located on the
fuse box for the ignition system. The fuse box for
the ignition system is located on the right hand side
of the engine.
Illustration 3
Typical example
g01234595
SEBU8190 7
Safety Section
General Hazard Information
(3) Engine Oil Level
Illustration 4
Typical example
The warning label for checking the engine oil Level
(3) is located on the inlet manifold. The inlet manifold
islocatedontherighthandsideoftheengine.
i02414560
General Hazard Information
Illustration 5
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.
g00104545
g01241033
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
Filler caps
•
Grease fittings
•
Pressure taps
•
Breathers
•
Drain plugs
•
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.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
8 SEBU8190
Safety Section
General Hazard Information
Pressure Air and Water
Illustration 6
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
•
securedinplaceontheengine.
g00702020
Pressurized ai
and/or hot water to be blown out. This could result in
personal injury.
When pressure air and/or pressure water is used for
cleaning, wear protective clothing, protective shoes,
and eye prote
oraprotectivefaceshield.
The maximum a
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 ps
Fluid Penetr
r and/or water can cause debris
ction. Eye protection includes goggles
ir pressure for cleaning purposes
i).
ation
Never put maintenance fluids into glass containers.
•
Glass containers can break.
Use all cleaning solutions with care.
•
Report all necessary repairs.
•
Unless other instructions are provided, perform
the maintenance under the following conditions:
The engine is stopped. Ensure that the engine
•
cannot be started.
Disconnect the batteries when maintenance
•
is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
Do not attempt any repairs that are not understood.
•
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
If work is carried out on the fuel system obey the
•
local regulations for isolation of the gas supply.
California Proposition 6 5 Warning
Some constituents of engine exhaust are known to
the State of California to cause cancer, birth defects,
and other reproductive harm.
Illustration 7
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.
g00687600
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.
Tools that are suitable for collecting fluids and
•
equipment that is suitable for collecting fluids
Tools that are suitable for containing fluids and
•
equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.
SEBU8190 9
Safety Section
Burn Prevention
Dispose of Waste Properly
Illustration 8
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed o
Always use leakproof containers when you drain
fluids. Do
drain, or into any source of water.
f according to local regulations.
not pour waste onto the ground, down a
g00706404
i02414602
Burn Prevention
Oils
Hot oil and hot lubricating components can cause
personal injury . Do not allow hot oil or hot components
to contact the skin.
If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolytetocontacttheskinortheeyes.
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
i02415237
Fire Prevention and Explosion
Preventio
n
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure in
the appropriate system before any lines, fittings or
related items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator, the heat exchanger, the
heater and lines contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the
cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool. Ensure
that the filler cap is cool before removing the filler
cap. The filler cap must be cool enough to touch with
a bare hand. Remove the filler cap slowly in order
to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Illustration 9
All fuels, most lubricants, and some c oolant mixtures
are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
an emergency shutdown.
g00704000
10 SEBU8190
Safety Section
Fire Prevention and Explosion Prevention
Determine whet
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engi
property damage, or engine damage could result.
If the applic
gases, consult your Perkins dealer for additional
information about suitable protection devices. All
local regula
Remove all flammable materials such as fuel, oil, and
debris from t
materials to accumulate on the engine.
Store fuels a
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers
storing flammable materials.
Do not expo
Exhaust shields (if equipped) protect hot exhaust
component
a hose, or a seal failure. Exhaust shields must be
installed correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines that contain flammable
fluid. Cle
nonflammable solvent prior to welding or flame
cutting.
Wiring must be kept in good condition. All electrical
wires must be properly routed and securely attached.
Check all
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all elec
Eliminate all wiring that is unattached or unnecessary.
Do not us
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintai
or sparking.
Inspec
deterioration. The hoses must be properly routed.
The lines and hoses must have adequate support
and sec
recommended torque. Leaks can cause fires.
Oil fil
The filter housings must be tightened to the proper
torque.
trical connections.
ned battery cables will help to prevent arcing
t all lines and hoses for wear or for
ure clamps. Tighten all connections to the
ters and fuel filters must be properly installed.
her the engine will be operated in an
ne to overspeed. Personal injury,
ation involves the presence of combustible
tions must be observed.
he engine. Do not allow any flammable
nd lubricants in properly marked
. Do not smoke in areas that are used for
setheenginetoanyflame.
s from oil or fuel spray in case of a line,
an any such lines thoroughly with a
electrical wires daily. Repair any wires
e any wires or cables that are s maller than
Illustration 10
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
ahydrometer.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This may cause an
explosion.
The batteries must be kept clean. The covers
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
g00704135
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Lines, Tubes and Hoses
Donotbendhighpressurelines.Donotstrikehigh
pressure lines. Do not install any lines that are bent
or damaged.
SEBU8190 11
Safety Section
Crushing Prevention and Cutting Prevention
Repair any line
can cause fires. Consult your Perkins dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to
to the recommended torque.
Replace the p
are present:
End fittings
•
Outer coverings are chafed or cut.
•
Wires are exposed.
•
Outer coveri
•
Flexible part of the hoses are kinked.
•
Outer covers have embedded armoring.
•
End fittings
•
Make sure that all clamps, guards, and heat shields
are installe
will help to prevent vibration, rubbing against other
parts, and excessive heat.
s that are loose or damaged. Leaks
check for leaks. Tighten all connections
arts if any of the following conditions
are damaged or leaking.
ngs are ballooning.
are displaced.
d correctly. During engine operation, this
i02143194
i02453744
Mounting and Dismounting
The steps or han
engine. Refer to the OEM for information before any
maintenance or repair is performed.
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these
Mount the engine and dismount the engine only at
locations th
climb on the engine, and do not jump off the engine.
Face the engi
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use o
controls as handholds.
Do not stand
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment w
Do not carry tools or supplies when you mount the
engine or w
line to raise and lower tools or supplies.
dholds may not be installed on the
items in good repair.
at have steps and/or handholds. Do not
ne in order to mount the engine or
ne foot and two hands. Do not use any
on components which cannot support
ill not move.
hen you dismount the engine. Use a hand
Crushing Prevention and
Cutting Prevention
Support th
the component is performed.
Unless oth
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 perfor
reinstall the guards.
Keep obje
blades will throw objects or cut objects.
When obje
order to avoid injury to the eyes.
Chips or o
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
e component correctly when work beneath
er maintenance instructions are provided,
med. After the maintenance is performed,
cts away from moving fan blades. The fan
cts are struck, wear protective glasses in
ther debris may fly off objects when objects
i02415253
Ignition
Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and
wiring.
Systems
i02453806
Before Starting Engine
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
Ensure that the engine is equipped with a lighting
system that is suitable for the conditions. Ensure that
all lights work properly.
12 SEBU8190
Safety Section
Engine Starting
All protective
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that
around the parts carefully.
Do not bypass
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are
engine damage.
The initial s
has been serviced make provision to shut the engine
off, in order to stop an overspeed. This may be
accomplish
engine, or shutting off the ignition system.
Engine Star
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the contro
thewarningtagbeforetheengineisstarted.
guards and all protective covers must
is caused by parts in rotation, work
the automatic shutoff circuits. Do not
also provided in order to help prevent
tart-up of a new engine or a engine that
ed by shutting off the fuel supply to the
i02426322
ting
ls. Consult with the person that attached
i00659907
Engine Stopping
To avoid overhe
wear of the engine components, stop the engine
according to the instructions in this Operation and
Maintenance M
(Operation Section).
Use the Emerge
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency st
problem that caused the emergency stop has been
corrected.
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop
the engine i
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
ating of the engine and accelerated
anual, “Engine Stopping” topic
ncy Stop Button (if equipped) ONLY
op, DO NOT start the engine until the
f an overspeed occurs. This may be
i02436641
Electrical System
All protec
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident
around the parts carefully.
If there i
the exhaust system, refer to the purge procedure in
this Operation and Maintenance Manual, “Engine
Starting
Always start the engine according to the procedure
that is de
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
proper
temperature during heater operation.
Engine
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. I
vent the engine exhaust to the outside.
tive guards and all protective covers must
that is caused by parts in rotation, work
s a possibility that unburned gas remains in
” topic in the Operation Section.
scribed in the Operation and Maintenance
major damage to the engine components.
ly , check the water temperature and the oil
exhaust contains products of combustion
f the engine is started in an enclosed area,
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 “í” cable should be connected last from the
external power source to the negative “í” terminal
of the starting motor. If the starting motor is not
equipped with a negative “í” terminal, connect the
cabletotheengineblock.
Check the electrical wires daily for wires that
are loose or frayed. Tighten all loose electrical
connections before the engine is started. Repair all
frayed electrical wires before the engine is started.
See the Operation and Maintenance Manual for
specific starting instructions.
Grounding Practices
Note: All ground lines must return to the battery
ground.
SEBU8190 13
Safety Section
Electrical System
Illustration 11
Typical example
(1) Starting motor to ground
(2) Battery negative to engine
g01217202
Correct grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to the crankshaft bearing journal surfaces
and to aluminum components.
The connections for the grounds should be tight and
free of corrosion. The engine alternator must be
grounded to the negative “-” battery terminal with
a wire that is adequate to handle the full charging
current of the alternator.
The power supply connections and the ground
connections for the engine electronics should always
be from the isolator to the battery.
14 SEBU8190
Product Information Section
Model Views and Specifications
Product Information
Section
Model Views and
Specifications
i02415298
Model View Illustrations
The illustrations show various typical features of
4000 Series TRS Engine. The illustrations do not
show all of the options that are available.
SEBU8190 15
Product Information Section
Model Views and Specifications
Illustration 1 2
Typical example
(1) Air filter
(2) Governor control unit
(3) Fuses for the ignition system
(4) Ignition
(5) Water temperature regulator
(6) O il filler cap
(7) Alternator
(8) Oil level gauge (dipstick)
g01207301
(9) Engine oil filters
(10) Relay
(11) Starting motor
(12) Charge air cooler
16 SEBU8190
Product Information Section
Model Views and Specifications
Illustration 1 3
Typical example
(13) Ignition coil
(14) Zero pressure regulator
(15) Turbocharger
(16) Closed breather system
(17) The inspection cover for the Crankcase
(18) Drain plug
i02430841
Product Description
The Perkins Engines were developed in order to
provide gas engines for generator set applications.
The engines have the ability to burn a wide variety of
gaseous fuels.
Fuel System
The fuel is delivered to the zero pressure regulator.
The gas must be at a constant pressure and the gas
must be stable. The pressure must be within a range
of1.5to5kPa(0.21to0.72psi).Higherpressurewill
need to be reduced with an additional gas regulator.
g01215253
(19) Secondary water pump
The venturi must be selected for the engine. This
selection is based on the composition of the gas that
will be used.
Any change in the composition of the gas may require
a change to the venturi.
Theventuriislocatedinthegasmixerbody
immediately before the turbocharger. As air is
accelerated through the venturi gas is mixed with the
air. This mixture is compressed by the turbocharger.
the mixture passes through the charge cooler and
into the inlet manifold. The speed and the load is
governed by an electronically controlled throttle valve.
The air/fuel ratio is adjustable by the main adjustment
screw. This screw is located on the gas mixer body
before the venturi. This is the only means of adjusting
the exhaust emissions at full load.
SEBU8190 17
Product Information Section
Model Views and Specifications
Ignition System
The engine is equipped with an Electronic Ignition
System (EIS). The EIS provides dependable firing
and low maintenance. The EIS provides precise
control of the following factors:
Voltage
•
Duration of the spark
•
Ignition timing
•
The TRS2 engine is equipped with protection from
detonation. The TRS1 engine may be equipped with
protection for detonation as an option.
The ignition timing is retarded when excessive
detonation is sensed. If detonation continues after full
retardation, then the engine must be shut down.
Lubrication System
The engine lubrication oil is supplied by a pump
that is driven by a gear. The oil is cooled and the
oil is filtered. A bypass valve provides unrestricted
flow of lubrication oil to the engine parts if the
oil filter elements become plugged. The bypass
valve will open if the oil filter differential pressure
reaches 34.4 to 48.2 kPa (5 to 7 psi). The engine oil
pressure operates in a range of 413.6 to 448.1 kPa
(60to65psi).
Battery chargi
•
The system is used when recovery of heat is not an
important fac
Cogeneration
Cogeneration uses energy from heat which would
otherwisebew
The following items are not supplied:
Water pumps
•
Water tempera
•
All water tube assemblies
•
This system is the responsibility of the OEM.
ng alternator
tor.
engine
asted.
ture regulator ( thermostat)
Engine Service Life
Engine effic
performance depend on adherence to proper
operation and maintenance recommendations. This
includes the
and coolants.
For the engin
refer to the Operation and Maintenance Manual,
“Maintenance Interval Schedule” in the Maintenance
Section.
iency and maximum utilization of engine
use of recommended lubricants, fuels,
e maintenance that is required,
Note: The engine lubrication oil is not filtered when
the bypass valve is open. Do not allow the engine
to operate when the bypass valve is open. This can
damage the engine components.
Cooling System
The water enters the engine from the oil cooler and
the water is passed through the cylinder block. The
water exits the cylinder head into the rail. The water
exits the engine from the water outlet.
Electrounit
This type of engine is supplied with the following
components:
Jacket water coolant pump
•
Water temperature regulator (thermostat)
•
Coolant pipe for the charge cooler
•
A water pump for the charge cooler
•
A water temperature regulator (thermostat) that
•
controls the system for the charge cooler
Specificat
ions
General Engine Specifications
Illustration 14
Six c ylinder
(A) Inlet v a lves
(B) E xhaus t valves
i02415458
g01216853
18 SEBU8190
Product Information Section
Model Views and Specifications
Table 1
4006 Engine Specifications
Rated rpm 1500
Cylinders and arrangement In-line six cylinders
Bore 160 mm (6.2992 inch)
Stroke 190 mm (7.4803 inch)
Displacement
Compression ratio
Aspiration Turbocharged
Rotation (flywheel end) Counterclockwise
Inlet valve lash (cold) 0.40 mm (0.0157 inch)
Exhaust valve lash (cold) 0.40 mm (0.0157 inch)
Firing order 1,5,3,6,2,4
22.9 L (1397.4436 in3)
12:1
Illustration 15
Eight cylinder
(A) Inlet valves
(B) Exhaust valves
Table 2
g01207434
4008 Engine Specifications
Rated rpm 1500
Cylinders and arrangement
Bore
In-line eight cylinder
160 mm (6.2992 inch)
Stroke 190 mm (7.4803 inch)
Displacement
30.56 L
(1864.8855 in
Compression ratio 12:1
Aspiration Turbocharged
ion (flywheel end)
Rotat
Count
erclockwise
Inlet valve lash (cold) 0.40 mm (0.0157 inch)
Exhaust valve lash (cold) 0.40 mm (0.0157 inch)
ng order
Firi
7,6,8,5,2,3
1,4,
3
)
SEBU8190 19
Product Information Section
Model Views and Specifications
Piston Positions for Valve Lash
Setting
Table 3
The six cylinder engine
Table 4
Top Center Position
1-6 6 1
2-5 2 5
3-4 4 3
1-6 1 6
2-5 5 2
3-4 3 4
Top Center Position
1-8 8 1
4-5 5 4
2-7 2 7
3-6 3 6
1-8 1 8
4-5 4 5
2-7 7 2
3-6 6 3
Engine cylinder with valves
on the rock
The eight cylinder engine
Engine cylinder with valves
on the rock
Set the bridge adjustment and
set valve lash.
Set the bridge adjustment and
set valve lash.
20 SEBU8190
Product Information Section
Product Identification Information
Product Identification
Information
i02531889
Plate Locations and Film
Locations
Engine Identification
Perkins engines are identified by an engine serial
number.
A typical example of an engine serial number is
DGE F**** U00001M.
_________________________________________ MadeinStafford
D
G
____________________________________ Application (Table 5)
E
________________________________Type of engine (Table 6)
Perkins dealer
these numbers in order to determine the components
that were included in the engine. This permits
accurate iden
Serial Number
s and Perkins distributors require all of
tification of replacement part numbers.
Plate
_________________________ Number of cylinders (Table 7)
F
*****
_________________________________ _ Fixed build number
U
____________________________Built in the United Kingdom
00001
M
Table 5
Table 6
____________________________________Engine Number
____________________________________ Year of Manufacture
Application
G Genset
I
F TESI Gas Unit
E TESI Combined Heat and Power Unit
G 4016-E61 TRS
H
J
Gas
Type of engine (Gas)
TRS Combined Heat and Power Unit
TRS Gas Unit
Illustration 16
Serial number plate
The engine serial number plate contains the following
information:
Place of manufacture
•
Telephone number of manufacturer
•
Fax number of manufacturer
•
Type of engine
•
Engine serial number
•
Rated speed
•
Power output
•
Engine timing
•
Rating
•
g01266904
Table 7
Number of Cylinders
F 6
H 8
SEBU8190 21
Product Information Section
Product Identification Information
Illustration 17
Location of the serial number plate for in-line engines
g01212991
The serial number plate (1) on an in-line engine is
located on the right side of the cylinder block. See
Illustration 17.
22 SEBU8190
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
Product Lifting
i02427136
Some removals r
obtain proper balance and safety.
To remove the e
are on the engine.
Lifting eyes a
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obs
that proper lifting devices are provided. Consult your
Perkins dealer for information regarding fixtures for
proper engin
equire lifting fixtures in order to
ngine ONLY, use the lifting eyes that
re designed and installed for the specific
olete. If alterations are made, ensure
elifting.
i02427139
Product Storage
Refer to Perkins Engine Company limited, Stafford
for information on engine storage.
There is three different levels of engine storage.
Level “A, B and C”.
Illustration 18
Typical example
NOTICE
Never ben
the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle
between
comes less than 90 degrees.
When it i
angle, only use a link bracket that is properly rated for
the weight.
d the eyebolts and the brackets. Only load
the supporting members and the object be-
s necessary to remove a component at an
g01203936
Level “A ”
Level “A” will give protection for six month for diesel
engines and protection for one year for gas engines.
This is for engines that are transported by a container
or a truck.
Level “B ”
This level is additional to level “A”. Level “B ” will
give protection under normal storage condition from
í15° to +55°C (5.0000° to 99.0000°F) and “90%”
relative humidity for one year.
Level “C ”
This level is additional to level “B”. Level “C” will give
protection for five year in tropical temperatures or
arctic climates. Level “C” also meets MOD NES 724
level “J” for europe, when engines are stored in a
unheated building or in the open under waterproof
covers.
Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
suppor
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted
ting members (chains and cables) should be
.
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