Perkins Engine 4006, 4008 Service Manual

TSL4184E
May 1998

User’s
Handbook

Perkins 4006 and 4008 Diesel

4006
4008

WARNING

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND
WARNIN GS M E NTIONED IN THI S M A NUAL.

IMPROPER OPERATION OR MAINTENANCE PROCEDURES
COULD R ESULT IN A SERIOUS ACCIDE NT OR D AMAGE TO THE
EQUIPME NT CAUSING IN J URY 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.

4006/8 Diesel, May 1998

INTRODUCTION

The purpose of this Manual 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 informationcontained withinthe manual 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 manual 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 Engines (Peterborough) Ltd.

Frank Perkins W ay, Eastfield,
Peterborough, PE1 5NA, England.
Tel.: [phone]
Telex: 32501 PERKEN G
Fax: [phone]

Perkins Engines (Shrewsbury) Ltd.

Lancaster Road, Shrewsbury,
SY1 3NX, England.
Tel.: [phone]
Telex: 35171/2 PESL G
Fax: [phone]

Perkins Engines (Stafford) Ltd.

Tixall Road, Stafford, ST16 3UB, England.
Tel.: [phone]
Telex: 36156 PERKEN G
Fax: [phone]

Perkins Powerpart Distribution Centre

Frank Perkins Way,
Northbank Industrial Park, Irlam,
Manchester, M44 5PP, England.
Tel.: [phone]
Specifications Help Desk
Tel.: [phone]

Fax: [phone]
Specifications Help Desk
Tel.: [phone]

Telex: 32501 PERKEN G

Perkins International - North America

12025 Tech Center Drive,
Livonia, Michigan 48150,
U.S.A.
Tel.: [phone]
Fax: [phone]

Perkins Engines Latin America Inc

999 Ponce de Leon Boulevard,
Suite 710, Coral Gables,
Florida 33134, U.S.A.
Tel.: [phone]
Telex: 3 2501 PERKEN G
Fax: [phone]

Perkins Engines Australia Pty Ltd

Suite 2, 364 Main Street, Mornington
3931, Victoria, Australie.
Tel.: [phone]
Telex: 3 0816
Fax: [phone]

Motori Perkins SpA

Via Socrate. 8,22070 Casnate
Con Bernate (Como), Italie.
Tel.: [phone]
Telex: 380658 PERKIT I
Fax: [phone]

Perkins Motoren GmbH

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

Moteurs Perkins SA

Parc de Reflets - Paris Nord II,
165 Avenue du Bois de la Pie, BP 40064,
95913 Roissy CDG Cedex, France
Tel.: [phone]
Fax: [phone]

Perkins Engines (Far East) Pte Ltd.

39 Tuas Avenue 13,
Singapour 638999.
Tel.: [phone]

Fax: [phone]

In additiontothe above companies, thereare Perkins Distributorsin most countries. PerkinsE ngies (Peterborough) Limitedor
one of the above companies can provide distributor handbooks Publication No. 1407/4/97

Publication TSL4184
Publishedby the TechnicalPublicationsDepartment, Stafford.
© 1998 Perkins Engines (Stafford) L imited.

4006/8 Diesel, May 1998 1

INTRODUCTION

PERKINS ENGINES (STAFFORD)

ENGINE DESIGNATIONS

4000 SERIES AND SE SERIES

EQUIVALENT TERMS

4000 SERIES SE SERIES

4006TG 6SET

4006TWG 6SETCR

4006TWG3 6SETCR3

4006TAG1 6SETCA1
4006TAG2 6SETCA2
4006TAG3 6SETCA3

4006TEG 6SETCW

4008TWG2 8SETCR2

4008TAG 8SETCA
4008TAG1 8SETCA1
4008TAG2 8SETCA2

2 4006/8 Diesel, May 1998

CONTENTS

PAGE

INTRODUCTION & LIST OF PERKINS COMPANIES WORLDWIDE 1
ENGINE DESIGNATIONS 2
PHOTOGRAPHS INSERTS
BRIEF DESCRIPTION OF THE 4006/8 DIESEL ENGINES 4
GENERAL INFORMATION 5-6
DIESEL ENGINE DATA 7-11
TORQUE SETTINGS 12-14
LUBRICATING OIL RECOMMENDATIONS 15-16
COOLANT, CORROSION INHIBITORS, ANTI-FREEZE 17
FUEL SPECIFICATION 18
OPERATING INSTRUCTIONS

PREPARATION FOR INITIAL START 19
BATTERIES 19
PRIMING THE LUBRICATION SYSTEM 20
FILLING COOLING SYSTEM 20
PRIMING THE FUEL SYSTEM 21
INSTRUMENT PANEL (ENGINE MOUNTED) 22-24
EXHAUST TEMPERATURE GAUGE (ENGINE MOUNTED) 24
NORMAL STARTING PROCEDURE 25

ENGINE SHUTDOWN 25
LIGHT LOAD OPERATION AND STANDBY GENERATING SETS 26
MAINTENANCE PROCEDURES 27-44
PREVENTITIVE MAINTENANCE 45-46
FAULT TRACING CHART 47
WIRING DIAGRAM CAV STARTER, WITH REPEATER RELAY 48
WIRING DIAGRAM CAV STARTER, WITHOUT REPEATER RELAY 49
WIRING DIAGRAM CAV STARTER WITH REPEATER RELAY
FOR REMOTE OR AUTOMATIC START 50
WIRING DIAGRAM ENGINE WITHOUT REPEATER (MANUAL START) 51
WIRING DIAGRAM PRESTOLITE STARTER WITH REPEATER RELAY 52
WIRING DIAGRAM PRESTOLITE STARTER WITHOUT REPEATER RELAY 53
WIRING DIAGRAM WITH HEINZMANN GOVERNOR AND PRESTOLITE
STARTER FOR MANUAL OR AUTOMATIC START 54

4006/8 SERIES ENGINE LUBRICATING OIL DIAGRAM TP376 INSERT
4006/8TG AND 4006/8TAG SERIES ENGINE FRESH
WATER CIRCULATION DIAGRAM TP377 INSERT
4006/8TWG SERIES ENGINE FRESH WATER CIRCULATION
DIAGRAM (RADIATOR COOLED) TP378 INSERT
4006/8TWG SERIES ENGINE FRESH WATER CIRCULATION
DIAGRAM (HEAT EXCHANGER) TP379 INSERT
4006/8TEG (FRESH & RAW WATER) TP380 INSERT
4006/8 SERIES ENGINE FUEL DIAGRAM TP294 INSERT

4006/8 Diesel, May 1998 3

4006TWG3

4006TG

4006TAG3

4008TAG2

BRIEF DESCRIPTION OF THE 4006/8 DIESEL ENGINES

4006TG 6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with

jacket water cooled oil cooler in engine cooling circuit.

4006TWG 6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with

jacket water cooled oil cooler and charge air cooler in engine cooling
circuit.

4006TWG3 Up-rated version of the 4006TWG.

6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with
jacket water cooled oil cooler and charge air cooler in engine cooling
circuit.

4006TAG1 6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with

jacket water cooled oil cooler in engine cooling circuit and air cooled
charge air cooler in radiator.

4006TAG2 Up-rated version of the 4006TAG1.

6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with
jacket water cooled oil cooler in engine cooling circuit and air cooled
charge air cooler in radiator.

4006TAG3 Up-rated version of the 4006TAG2.

6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with
jacket water cooled oil cooler in engine cooling circuit, and air cooled
charge air cooler in radiator.

4006TEG 6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with

jacket water cooled oil cooler in engine cooling circuit, and water cooled
charge air cooler with raw water pump in separate cooling circuit.

4008TWG2 8 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with

jacket water cooled oil cooler and charge air cooler in engine cooling
circuit.

8 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with

4008TAG

jacket water cooled oil cooler in engine cooling circuit and air cooled
charge air cooler in radiator.

4008TAG1 Up-rated version of the 4008TAG.

8 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with
jacket water cooled oil cooler in engine cooling circuit and air cooled
charge air cooler in radiator.

4008TAG2 Up-rated version of the 4008TAG1.

8 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with
jacket water cooled oil cooler in engine cooling circuit and air cooled
charge air cooler in radiator.

4 4006/8 Diesel, May 1998

SAFETY
Engine lift equipment

Use onlythe 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.

GENERAL INFORMATION

Fig. 1

Asbestos joints

Some joints and gaskets contain
compressed asbestos fibres see Warning
labelFig.1in 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.

●

Useahandscrapertoremovethejoints

- do NOT use a rotary wire brush.

●

Ensure that the joint to be removed is
wet withoil or water tocontain any loose
particles.

●

Sprayall asbestos debriswithwater and
placeitinaclosedcontainerwhichcan
be sealed for safe disposal.

Dangers from used engine oils

Prolongedandrepeated contact withmineral
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 facilitiesshould be readilyavailable.

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

1. Avoid prolonged and repeated contact
with used engine oils.

2. Wear protective clothing, including
impervious gloves where applicable.

3. Do not put oily rags into pockets.

4. Avoid contaminating clothes,
particularly underwear, with oil.

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

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

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

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

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

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

11. Degrease components before handling
if practicable.

12. Where there is the possibility of a risk to
the eyes, goggles or a face shield
should be worn. An eye wash facility
should be readily available.

4006/8 Diesel, May 1998 5

GENERAL INFORMATION

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.

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.

Practical Information
To clean components

It is important that the workarea is keptclean
and that the components are protected from
dirt and other debris. Ensure that dirt does
not contaminate the fuel system.

Before a component is removed from the
engine, clean around the component and
ensure that all openings, disconnected
hoses and pipes are sealed.

Remove, clean and inspecteach component
carefully. If it is usable, put it in a clean dry
place until needed. Ball and roller bearings
mustbe cleanedthoroughlyand inspected.If
the bearings are usable, they must be
flushed in low viscosity oiland protected with
clean paper until needed.

Before the components are assembled,
ensurethat thearea is freefrom dustand dirt
as possible. Inspect each component
immediately before it is fitted, wash all pipes
and ports and pass dry compressed air
through them before connections are made.

Use suitable gloves for protection when
components are degreased or cleaned with
trichloroethylene, white spirit, etc.
Degreasing solutions which are basically
trichloroethane are not recommended

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.

6 4006/8 Diesel, May 1998

DIESEL ENGINE DATA

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

RANGE 4006 4008

Cycle 4 stroke
No.ofcylinders 6 8
Configuration In-Line
Bore 160 mm
Stroke 190 mm
Total swept volume 22.92 litres 30.561 litres
Compression ratio 13.6:1
Rotation Anti-clockwise looking on flywheel end
Firing order 1-5-3-6-2-4 1-4-7-6-8-5-2-3
Cylinder numbering Cylinder 1 furthest from flywheel
Valve clearances

Inlet and exhaust (cold) 0,40 mm (0.016”)
Valve dia (mm)

Inlet and exhaust
Valve setting See Page 43
Valve timing See Workshop M anual Section U
Injection timing See Engine Number plate
Piston speeds Engine r/min

1000
1200
1500
1800

48 (early engine)

52 (later and uprate engines)

m/s (ft/min)

6.33 (1247)

7.60 (1496)

9.50 (1870)

11.40 (2244)

TYPICAL COOLING SYSTEM

Approved coolants See Page 17
Water capacity (block only) 36 litres (8 gal) 48 litres (10.5 gal)

Total water capacity Litres Gals Spec Litres Gals Spec.
Engine with tropical radiator 106 23.3 TG 135 29.7 TAG

110 24.2 TAG1 145 31.9 TAG1
110 24.2 TAG2 145 31.9 TAG2
125 27.5 TAG3 48 10.6 TWG2*
106 23.3 TWG
130 28.6 TWG3

46 10.1 TEG**

*Engineonly
** Engine with heat exchanger

Engine shut down temperature 96°C
Max water temperature into engine
Thermostat opening temperature 71°C

System pressure 0.5 to 0.7 bar

To be determined from heat dissipated & water flow

through each particular engine model

4006/8 Diesel, May 1998 7

DIESEL ENGINE DATA

FUEL SYSTEM

4006 4008

Approved fuels See page 18
Relief valve setting 276 kPa (40 lb/in²)
Injector nozzle pressure 225-235 atm
Injection equipment Lucas-Bryce unit injector
Filtre/water separator Spin-on expendable canister(s)
Fuel lift pump Maximum suction lift 2 metres
Fuel flow 13.4 litres/min. (3 gpm) @ 1800 r/min

GOVERNORS

Type Electronic Electronic
Type Hydraulic Hydraulic

LUBRICATION SYSTEM

Recommended oil See page 15
Type of system Wet sump, external engine mounted oil pump
Total oil capacity (oil cooler and filter) 122.7 litres (27 gal) 165.5 litres (36.5 gal)
Sump capacity (dipstick) Min. 90.7 litres (20 gal) 127 litres (27.9 gal)
Sump capacity (dipstick) Max. 113.4 litres (25 gal) 154 litres (33.9 gal)
Min. oil pressure (rated speed) to bearings 200 kPa (28 lb/in²)
Crankcase pressure 25 mm water gauge
Max. oil temperature to bearings 105°C
Lubricating oil filter disposable canister type

INDUCTION SYSTEM

Air cleaner Single air cleaner Twin air cleaners

Twin air cleaners (Uprate)
Type (paper element) S551A
Max. Air intake depression 381 mm H
Air restriction Indicator setting 380 mm H
Turbocharger

Garrett (x1)

(x2 uprate only)

O(28mmHg)

2

O

2

(x2)

8 4006/8 Diesel, May 1998

DIESEL ENGINE DATA

EXHAUST SYSTEM

4006 4008

Manifold type Dry Dry
Exhaust outlet flange (non uprate) Vertical (single) Vertical (single) Option
(uprate) Vertical (single) Option

Vertical (twin)
Mating flange (non uprate) 1 x 8" Table "D" BS4 1 x 10" Table "D"
(uprate)

Max. exhaust back pressure See Product Information Manual
Max. exhaust temperature See Product Information Manual

1 x 10" Table "D"

2 x 6" Table "D" Option

Vertical (twin)

2 x 6" Table "D"

FLYWHEEL

SAE size 14" 18"

FLYWHEEL HOUSING

SAE size 0 0

CRANKSHAFT

Max. overhung weight on rear bearing 1000 kg
Tuning plate 1 x 14.6" -

T.V. damper (non uprate) 1 x 14" 2 x 20"
(uprate) 1 x 18"

NOTE: Subject to a torsional vibration investigation different T.V. dampers may be fitted

4006/8 Diesel, May 1998 9

DIESEL ENGINE DATA

TYPICAL DRY WEIGHT

4006 4008

Dry weight (engine) 2295 kg 4006TG 3120 kg 4008TAG

2320 kg 4006TAG1/2 3250 kg 4008TAG1/2

2340 kg 4006TWG 3325 kg 4008TWG2

2420 kg 4006TEG

2400 kg 4006TAG3

2340 kg 4006TWG3

Dry weight (engine and tropical radiator) 2636 kg 4006TG 3730 kg 4008TAG

2761 kg 4006TAG1/2 4360 kg 4008TAG1/2

2477 kg 4006TWG1/2

3010 kg 4006TAG3

2790 kg 4006TWG3

Dry weight (engine and heat exchanger) 2560 kg 4006TEG 3462 kg 4008TWG2

HOLDING DOWN BOLT HOLES

Bolt size (engine feet) 20 mm
No. off 6

ELECTRICAL SYSTEM

Voltage 24
Alternator type PRESTOLITE (BUTEC) A3024 with internal regulator
Alternator output (amps) 30 at a stabilised output of 28 volts

Starter motor type
No. of teeth (gear ring) 190

No. of teeth (starter motor) 12
Battery capacity cold cranking amps

to IEC Standard at 0°C (32°F)
Battery (lead acid) 24 V (2 x 12V) Total 143 Ah (2 x 12V) Total 178 Ah

PRESTOLITE/BUTEC

MS1/105

540 (each battery) 600 (each battery)

MS7/3A

10 4006/8 Diesel, May 1998

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.
Standard settings for protection equipment are as follows:

4006 4008

Shutdown switches

High Oil temperature 105°C 110°C
Low oil pressure 2.06 bar (30 lb/in²) 1.93 bar (28 lb/in²)
Hight water temperature
71°C Thermostat 91°C 96°C

Alarm Shutdown

Caution: Theabove standardsettingsdo not supersede anysettings specifiedin theengine

sales contract.

Overspeed

15% (on 1500 rev/min)

7% (on 1800 rev/min)

AIR STARTING

Air starter pressure 30 bar
Compressed air supply 17 bar
Type Ingersoll-Rand Type SS350
Type GALI A25

INSTRUMENT PANEL (ENGINE MOUNTED)

Normal Operation

Oil pressure Between 300-560 kPa (42.6-80 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
Boost pressure See Test Certificate

COOLANT JACKET HEATING

Heater 1 x 2 kW 1 x 4 kW

4006/8 Diesel, May 1998 11

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 and threads must be lubricated with clean engine oil.

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

on thethreads with P.B.C. (Poly-Butyl-Cuprysil) grease. Important:See SectionR10 in the

Workshop Manual before fitting. All other bolt threads only to be lubricated with clean

engine oil. Care must be taken not to oil the heads and faces.

TORQUE SETTINGS
CYLINDER HEAD GROUP lbf.ft Nm

Cylinder head bolt ** (early type) M24 550 750
Cylinder head bolt ** (later (waisted) type) M24 530 723
Rocker shaft bolt/nut M16 90 120
Rocker adjuster nut inlet/exhaust M12 35 50
Rocker adjuster nut pump/injector M14 50 70
Rocker box bolt M10 35 50
Air manifold bolt M10 35 50
Exhaust manifold bolt M10 50 70
Turbocharger V-band clamp nuts M8 8 11

CRANKCASE AND CRANKSHAFT GROUPS

* Main bearing bolt M24 580 783
Side bolts (main bearing caps) M16 124 168
Bolts sump to crankcase M10 40 57
* Connecting rod bolt M16 210 285
Viscous damper botls (4006/8 series) M12 120 160
Flywheel bolts M16 250 340
Front drive adaptor bolts M16 250 340
Balance weight bolt M16 250 340
Front crankshaft pulley bolt M16 250 340
Piston cooling jet bolt M10 7 10
Flywheel housing bolt M10 35 50
Crankcase side bolts M16 200 270

12 4006/8 Diesel, May 1998

TORQUE SETTINGS

LUBRICATING OIL PUMP lbf.ft Nm

Bolts, pump housing to gearcase plate M10 35 50
Thin nut, gear to drive shaft M24 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 header to gearcase bolts M10 35 50
Raw water pump gear securing nut, dry thread M35 18 244

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 M10 35 50

GOVERNOR

Control shaft mounting plate bolt M10 35 50

FAN DRIVE

1

Fan driven pulley taper lock bush screws
Fan driven pulley taper lock bush screws

/

" BSW 35 50

2

5

/

" BSW 65 90

8

ALTERNATOR

3

Drive pulley taper lock bush nuts

/

" BSW 15 20

8

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 l inkage screw 2BA 6 8
Unit injector control lever capscrews M5 6 8

FLEXIBLE COUPLING (HOLSET)

1

Flexible coupling cover screw M12 or
Coupling driving flange screws (coupling size 2.15) M12 or

/

" UNC 90 129

2

1

/

" UNC 90 129

2

4006/8 Diesel, May 1998 13

TORQUE SETTINGS

GENERAL TORQUE LOADINGS

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

Thread size (mm) lbf.ft Nm

81825
10 35 50

General Note:

M10-12.9 steel 50 70
These are based to BS 3692.

14 4006/8 Diesel, May 1998

LUBRICATING OIL RECOMMENDATIONS

QUANTITY OF OIL

Sump capacity dipstick 4006 4008
Minimum 90.7 litre (20 gal) 127.4 litre (28 gal)
Maximum 113.4 litre (25 gal) 154 litre (34 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

Use oil of:
SAE10W/30 in starting temperatures below -15°C (without sump heater)
SAE15W/40 in starting temperatures from -15°C to 0°C
SAE30 in starting temperatures from 0°C to 32°C or Mobil Delvac
SAE40 in starting temperaturesabove 32°C 1300 SAE 15W/40

}

OIL CHANGE PERIODS

For normal operation of the engine the oil should be changed every 250 hours or annually
whichever is the sooner.
Under certain circumstances where a centrifugal oil filter is fitted to the engine and an oil
analysis programme has been carried out with the oil supplier over a period of 1000 hours
of engine operation, it may be possible to extend the oil change period up to maximum of
350 hours.
To achieve this extended oil change period, a centrifugal oil filter must be fitted and cleaned
every 250 hours between routine oil changes, and at every oil change point i.e. 350 hours
maximum.
As the oil deteriorates it is essential that the following parameters must not be exceeded at
the oil change point:

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

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

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

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

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

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

4006/8 Diesel, May 1998 15

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.
Anup-to-date listis maintainedby Perkins Engines(Stafford) Limited ofmajor oilcompanies
products and information, which can be obtained from Perkins Engines (Stafford) Service
Department.

WARNING

FAILURE TO COMPLY WITH THESE INSTRUCTIONS WILL
INVALIDATETHEWARRANTY OFFEREDWITHTHEENGINE, 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
MOBIL Delvac Super 1300 (15W/40)
SHELL Rimula X
ESSO Essolube XD 3+
TEXACO Ursa Super LA

16 4006/8 Diesel, May 1998

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
PROTECTION.

ENGINE COOLING SYSTEM

To protectthe enginecooling system against
corrosion it is essential that the engine
coolant contains suitable additives which will
give the necessary protection.

Caution: untreated water is not suitable.
WATER QUALITY

Thewatertobemixedwiththeadditivemust
have the following characteristics:
Chloride less than 80 PPMV (PPMV = parts
per million by volume)
Sulphateslessthan80PPMV
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.
This mixture will give frost protection down to

-35°C. In areas where Shell anti-freeze is
unobtainable contact Perkins Engines
(Stafford) Ltd for advice.
Under no circumstances should an additive
containing nitrites, borates, phosphates,
chromates, nitrates or silicates be used, as
these materials are not compatible with the
materials used in the cooling system.

When mixing the antifreeze with the water
always follow the manufacturer's
recommendationwhichistoaddtheanti­freeze to water and mix thoroughly before
adding the mixture to the engine cooling
system.
Mixing water to the anti-freeze can lead to
the formation of gel in the mixture, due to
over concentration, and this can lead to
blockage of water passages and subsequent
loss of water flow causing overheating.

MAINTENANCE OF COOLANT

The water/anti-freeze mixture should be
replacedin operatingenginesat leastonce a
year.
It is essential to maintain the coolant at the
correct alkalinity level i.e. the pH should not
increase above 7.5. A hydrometer only
shows the proportion of ethylene glycol. This

is not a measure of protection against
corrosion.

WARNING

FAILURE TO FOLLOW

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

4006/8 Diesel, May 1998 17

FUEL SPECIFICATION

Fuel should be wholly hydrocarbon oil derived from petroleum, with which small quantities
of additivesmay be incorporatedfor the improvementof 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
Water 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.

Northern

}

Hemisphere

ENGINE FUELS

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

fuels.Class A1is ofhigher qualityandis intendedprimarilyas an automotive dieselfuel,
whilst Class A2 is intended as a general purpose diesel fuel. Classes A1 and A2 are
distillate grades and are so specified as to prevent the inclusion of residuum.

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

chosen to cover seasonal requirements in the United Kingdom.

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

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

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

18 4006/8 Diesel, May 1998

PREPARATION FOR INITIAL START
BATTERIES (PERKINS BATTERIES ARE
SUPPLIED DRY CHARGED. SEE

INSTALLATION MANUAL TL4068)

OPERATING INSTRUCTIONS

WARNING

HAND PROTECTION

MUST BE WORN
WHEN CHECKING ELECTROLYTE
LEVEL IN THE BATTERY.
INFLAMMABLE GAS IS GIVEN OFF BY
THE BATTERY. DO NOT CHECK WITH A
NAKED FLAME.

Check the level of electrolyte in each of the
batterycells; it shouldbe 8-16mm above the
plates. Using a hydrometer, check that the
batteries are fully charged. A fully charged
battery will have a specific gravity of 1.27 to

1.285, assuming the air temperature is
below 32°C. For higher temperatures the
specific gravity will be 1.24 to 1.255. When
topping up the batteries always use pure
distilled water and always replace the plugs
after filling.

WARNING

NEVERCONNECTA

BATTERYINTOTHE
SYSTEM WITHOUT FIRST CHECKING
THE POLARITY AND VOLTAGE.
NEVER DISCONNECT THE BATTERY
WHILST THE ENGINE IS RUNNING.
NEVER FLASH CONNECTIONS TO
CHECK FOR CURRENT FLOW.

Fig. 2

Fig. 3

FILLING THE ENGINE WITH OIL

Remove the drain plug to ensure sump is
clean and empty, refit and tighten the plug.
Remove the oil filler plug situated on the left
hand side of the gearcase by rotating T-bar
anti-clockwise and pulling see Fig. 2. Fill the
sump to maximum mark on the dipstick see
Fig. 3 with the appropriate grade and quality
of oil specified, see Pages15-16and
replace the plug,rotating the T-bar to tighten
and seal it.

4006/8 Diesel, May 1998 19

OPERATING INSTRUCTIONS

PRIMING THE LUBRICATION SYSTEM

Before starting the engine for the first time,
or if it has stood idle for more than three
months the crankshaft and turbocharger
bearings should be primed.
To prime the lubrication system the engine
needs to be motored over on the starter. In
order that the engine does not run up to
speedwhenoperatingthekeyswitch(i.e.
energising the stop solenoids) it will be
necessary to hold the governor lever in the
stop position (see Fig. 4).
Prime the lubricating system through the oil
filters until approximately 0.3 bar (5lb/in²) is
indicated on the oil pressure gauge.
Continue pumping for a further 10 seconds
to ensure that oil has reached the
turbocharger.

Fig. 4

FILLING THE COOLING SYSTEM

WARNING

THE COOLING

SYSTEM IS
PRESSURISED - DO NOT REMOVE THE
FILLER CAP FROM THE RADIATOR
WHILST THE ENGINE IS HOT. HAND
PROTECTION MUST BE WORN.

The use of plain drinking water is not
recommended owing to chemical reactions
which can result in corrosion and furring-up
of the cooling system. A solution of either
water and universal anti-freeze or water and
corrosion preventative must be used. Refer

to page 17.

After installation and before the first start
remove the radiator cap Fig. 5 by rotating i t
anti-clockwise. Fill the cooling system with
the required coolant. Should the engine be
fitted with water cooled exhaust manifolds
then these may need bleeding (see

Workshop Manual Section F8).Runthe

engine off-load for one minute to ensure that
the system is completely filled, then stop the
engine and top up the system to 25 mm (1")
below the top of the filter neck then replace
the cap.

Fig. 5

11.2

20 4006/8 Diesel, May 1998

PREPARATION FOR INITIAL START
PRIMING THE FUEL SYSTEM

Turn on the fuel feed from the day tank,
loosen the union on the tee-piece (1) Fig. 6
then operate the priming pump by repeatedly
pressing the rubber button (2) until air free
fuel flows from the union, re-tighten the
union.

Fuel flow circuit Fig. 6

A. Combined fuel filter/water separator

Normal fuel flow
Priming circuit

Loosen the union on the fuel feed pipe (3)
Fig. 7 at the flywheel end of the fuel rail.
Operate the priming pump until air free fuel
flows and re-tighten the union, continue this
operation at the fuel feed union (4) and the
fuel returnunion (5) at thispoint one cylinder
will be primed and a considerable amount of
fuel will have reached other cylinders the
engine will run in this condition if a little
unevenly until air is fully vented from the
system.

OPERATING INSTRUCTIONS

Fig. 6

OPTIONAL CHANGE OVER FILTER

On engines fitted with a change over filter
system prime the system as described
above but prime the filter on the engine feed
side union (6) Fig. 8 before priming the fuel
rail.

Fig. 7

Fig. 8

4006/8 Diesel, May 1998 21

INSTRUMENT PANEL (ENGINE MOUNTED)

DESCRIPTION

The instrument panel is flexibly mounted on the engine on the left hand side of the engine,
between the air manifold mating flanges (see Fig. 9). The basic engine mounted panel
includes the instruments associated with the engine only, which show the readings for the
following conditions:

(1) Cooling water temperature (4) Battery charging rate (7) Fuse holder
(2) Lubricating oil temperature (5) Speed and hours run (8) Exhaust temperature
(3) Lubricating oil pressure (6) Keyswitch gauge (when fitted)

Fig. 9

22 4006/8 Diesel, May 1998

Engine water temperature gauge

(Fahrenheit/Centigrade) Fig. 10
The coolant temperature during normal
operation should be between 65°C - 85°C
(149°F - 185°F). If the temperature should
rise above 93°C (200°F) for a prolonged
period of time, stop the engine and
investigatethe cause. Theengine should,on
the other hand, not be run at too low a
temperature for long periods either.

Engine oil temperature gauge
(Engine mounted)

(Fahrenheit/Centigrade) Fig. 11
The lubricating oil temperature should be
between 80°C - 90°C (176°F - 194°F) when
the engine is hot. If the temperature should
rise above 115°C (240°F), stop the engine
immediately and investigate the cause.

INSTRUMENT PANEL

Fig. 10

Engine oil pressure gauge Fig. 12

(pounds per square inch/kiloPascal x 100)
The lubricating oil pressure should be
between 300 - 350 kPa (45 - 50 lb/in²) when
the engine is hot. If the pressureshould drop
below 200 kPa (30 lb/in²) at higher engine
speeds than idling, stop the engine
immediately and investigate the cause.

Ammeter (Ampere) Fig. 13

The ammeter indicates at what charging
current the battery is being charged by the
alternator, or to what extent current is taken
from the battery without the battery being
recharged.

Fig. 11

Fig. 12

Fig. 13

4006/8 Diesel, May 1998 23

INSTRUMENT PANEL

Engine tachometer and hour counter

(revolutions per minute x 1000 and hours)
Fig. 14.
The electrically operated tachometer/hour
countershowsthespeedoftheengineinr/
min. and the actual operating hours the en­gine has run. The tachometer/hour counter
starts operating from an alternator voltage of
12 V onwards, which has already been
reached at engine idling speed.

Exhaust temperature gauge

Temperature range -20 +800°C
The gauge shows readings of turbine outlet
temperature Fig. 15.

Key switch (3 position) (Off/run/start) The hand operated keyswitch with switch lock is moved by a separate key to the posi­tions shown, (see Fig. 16)viewedfromfront of switch.

Fig. 14

Fuse holder

To protectthe instrumentpanel a 2 amp fuse
is fitted to remove the fuse (1) unscrew its
holder (2) (see Fig. 17).

Fig. 15

Fig. 16

2

1

2

3

1

Fig. 17

24 4006/8 Diesel, May 1998

NORMAL STARTING PROCEDURE

Ensureany engine controlswitchis setto the
run position, with the load disengaged.
Manually set the air shut-off valve (if fitted) to
the run position (see Fig. 18). Turn the
keyswitch to the start position, which will
energise the solenoid allowing the engine to
crank over for a few seconds then start.

Check the instrument panel is showing
normal running oil pressure, and the
ammeter for charge to the engine batteries

(see pages 22-25).

Allow the engine to run for five minutes
checking the instruments are reading
correctly. Stop the engine and check the oil
and coolant levels, replenish if necessary

(see pages 19-20).

Key
(Fig. 18)

1. Position - closed

2. Position - open

OPERATING INSTRUCTIONS

Fig. 18

It is essential to allow the engine to run at no
load for 3-5 minutes before stopping to allow
the circulating lubricating oil to take the heat
away from the bearings and shafts, etc. This
is especially important with turbocharged
engines where extremely high temperatures
are experienced within the turbocharger.
Heat rise by suddenly stopping the engine
on load can cause seizure of bearings and
damage to oil seals.

WARNING

THE COOLING

SYSTEM IS
PRESSURISED - DO NOT REMOVE THE
FILLER CAP FROM THE RADIATOR
WHILST THE ENGINE IS HOT. HAND
PROTECTION MUST BE WORN.

ENGINE SHUTDOWN

The engine is normally stopped by operating
an electric stop control via a key switch. In
this case it is only necessary to turn the key
in an anti-clockwise direction which de­energises the stop solenoid to stop the
engine. The solenoide remains de-energised
until the engine is started up again.

With the manual system the stop control
must be held in the stop position until the
engine stops. Manual stopping can be used
to override the electrical system if
necessary.
Shouldtheenginestopduetotheairshut-off
valves being operated, it is imperative that
the cause of the fault be investigated
immediately.

WARNING

DO NOT RUN THE

ENGINE
EXCESSIVELY AT LOW S PEEDS OR
LOADS.IFTHEENGINEISNOTBEING
USED SHUT IT DOWN.

NOTE: Excessive idling of the engine will
result in only partial burning of the fuel,
causing high carbon build-up on injector
nozzles, valves, piston rings, etc. Also
unburnt fuel will tend to wash the
lubricating oil from cylinder bores and
dilute the oil in the sump. This can
eventually cause inefficient lubrication of
bearings and result in seizure.

4006/8 Diesel, February 1998 25

LIGHT LOAD OPERATION & STANDBY GENERATING SETS

If an engine is operated on a load less than
25-30% of its rated outout, certain symptoms
will be observed which may give cause for
concern.
The usual results of this operation are
heavier than normal lubricating oil
consumption, and oil leaks from the air and
exhaust manifolds. This condition is
particularlyevident on standby generatorset
applications, where a weekly exercise on no
load is common practice.
These phenomena are due to the fact that:

1. Turbocharger oil seals are not fully
effective on light load, which results in oil
being delivered together with the air into
the engine air manifolds.

2. The cylinder temperatures are too low to
ensure complete burning of all the fuel
delivered.
This results in an unsightly drip from the
exhaust manifold junction glands.

A further result is that of abnormal carbon
build-up on the valves, piston crowns and
exhaust ports. Thus the normal service
interval of see Maintenance Schedules
between top overhauls may be reduced.
Fuel dilution of the lubricating oil will also
occur.
It is therefore recommended that the
following precaution are observed:

1) Running on light load should be avoided
or reduced to the minimum period. If
weekly exercising on no load is carried
out, the running period should be kept
down to say, 10 minutes, or until the
battery charging rate returns to normal

2) Every year the engine or generator set
should be run on full load for four hours,
to burnoff accumulations ofcarbonin the
engine and exhaust system. This may
require the use of a ‘dummy load’. The
load should be built up gradually from
zero over the four hour run.
On standby sets, air cleaner elements
should be changed annually. Oil and fuel
filter elements should be changed every
six months. The fuel injectors should be
checked every 2 years.

There is absolutely no danger of failure or
breakdownresultingfrom lightload operation,
providing the above recommendations are
followed, in addition to the normal procedures
laid down in this manual.

26 4006/8 Diesel, May 1998

Towards the rear of this section there is a
check list sheet for continuous duty
generatorsets which is to be usedas a guide
for operators and maintenance personnel.
The following schedule details some of the
maintenancetobecarriedoutasinthe
maintenance check lists, however not all are
detailed. In these cases please refer to the

Workshop Manual.

The schedule within this section will be
perfectly suitable for an engine working
under average conditions. If your engine is
working under particularly dirty or dusty
conditions, more frequent servicing will be
necessary particularly in respect of the
lubricating oil and air cleaners. Correct and
regularmaintenancewillhelp prolongengine
life.

WARNING

MAKE QUITE

CERTAIN THE
ENGINE CANNOT BE STARTED
BEFORE UNDERTAKING ANY
MAINTENANCE, PARTICULARLYIN THE
CASE OF AUTOMATICALLY STARTING
GENERATING SETS OR REMOTE
STARTING ENGINES.

MAINTENANCE PROCEDURES

A

B

Fig. 19

COOLANT LEVEL

WARNING

THE COOLING

SYSTEM IS
PRESSURISED - DO NOT REMOVE THE
FILLERCAPWHENTHEENGINEISHOT.
HAND PROTECTION MUST BE WORN.

With the engine stopped removethe radiator
cap; the coolant should be 25 mm (1") below
the topof the filler neck. If the levelis low top
up with a solution of water and inhibitor or
water and anti-freeze similar to that already
in the engine. Refer to Engine Data section

pages 7 to 10.

DAILY INSPECTION
LUBRICATING OIL LEVEL

With the engine stopped for at least 5
minutes:­i) Withdraw the dipstick and wipe clean.
ii) Re-insert thedipstick fully into the sump.
iii) Wait for at least 5 seconds, withdraw

andchecktheoillevelinrelationtothe
two marks on the dipstick.

iv) Repeat operation (i) (ii) (iii) at least

twice, until identical readings are

observed.
If the oil level is below the top mark add
sufficient of the same grade as that already
intheenginetobringtheoilleveluptothe
top mark.
Always replace the filler plug immediately
replenishment is completed.

LEAKS

Visuallycheck theengine forgas, oil,coolant
and exhaust leaks, repairing where
necessary.

WEEKLY INSPECTION

Deal with items under DAILY INSPECTION.

AIR CLEANER RESTRICTION INDICATOR

The middle section of the restrictionindicator
'A' will remain clear while the air cleaner is in
a serviceable condition. When the filter
reaches its contamination limit the restriction
indicator will sense the change in manifold
pressure and middle section 'A' will change
to red. At this point the air filter must be
changed (see page 40). When the air filters
have been changed reset the indicator by
pressing button 'B'. (See Fig. 19).

4006/8 Diesel, May 1998 27

MAINTENANCE PROCEDURES

BATTERIES

WARNING

HAND PROTECTION

MUST BE WORN
WHEN CHECKING ELECTROLYTE
LEVEL IN THE BATTERY.
INFLAMMABLE GAS IS GIVEN OFF BY
THE BATTERY. DO NOT CHECK WITH A
NAKED FLAME.

Remove the plugs or 'quick fill' covers and
check the level of electrolyte. It should be
approximately 3 mm above the top of the
plates. If it is low, top-up with pure distilled
water. Replacethe plugs and wipe the top of
the battery clean and dry (see page 25 for

fuller information).

NOTE: Check the specific gravity (see

Maintenance Schedules).

RADIATOR

If the engine is working in dirty or dusty
conditions check that the air passages in the
radiatorare not becoming choked. They can
be cleaned out by blowing compressed air in
thedirection oppositeto thatof the normalair
flow.

1

Fig. 20

FLANGES AND FASTENERS

Check the torque on all external fasteners
including the exhaust manifold and
turbocharger flanges. Tighten all hose clips
and pipe unions.

EQUALISE BRIGDEPIECES AND CHECK VALVE CLEARANCES

(see page 44).

FENNER TAPER LOCK BUSHES MAINTENANCE INSTRUCTIONS

Experience has shown that taper lock
bushesasfittedinthefanpulleysand
battery alternator driven pulley can work
loose shortly after being put into service.
Check using a hexagon wrench to tighten
screws (1) gradually and alternately until all
are tightened to the required torque (see

Torque Settings on pages 12 - 14) full

details of taper lock pulley see Section B2

and D1 of the Workshop Manual.Replace

any guards removed before running the
engine (see Fig. 20).

NEW OR REBUILT ENGINES

It is essential to carry out the following
maintenance procedure after the initial 100
hours.

28 4006/8 Diesel, May 1998

TURBOCHARGERS

If the engine has been overhauled and a
filter joint fitted to the turbocharger oil feed,
this should now be removed and replaced
with thestandard joint. See Service Bulletin

301 (Revised) and 1.

ENGINE OIL AND SPIN-ON FILTERS,
ALSO CENTRIFUGAL OIL FILTER
(WHERE FITTED)

Change engine oil and disposable filters

(see page 36) clean centrifugal filter (see

page 34)

DRAINING THE WATER TRAP/
SEDIMENTER (WHERE FITTED)

There are no moving parts or elements to
service,however daily open the drain plug to
remove collected water and sediment. The
plug is self retaining, unscrew until loose.
Leave open until clean fuel is seen. Screw
back in (see Fig. 21).

MAINTENANCE PROCEDURES

ENGINE ALTERNATOR DRIVE BELT

WARNING

DISCONNECTING
BATTERIES OR ANY

OTHER MEANS OF STARTING.

Remove the small mesh guard (1) around
the alternator. The toothed belt used to drive
the alternator relies on tooth engagement to
transmit to load. It does not require
preloading,however a slight initial tension to
ensure that the belt fits snugly round the
pulleys is desirable. Using light pressure
midway between the two pulleys a total

1

deflection of 1.5 mm (

/

") is satisfactory

16

(see Fig. 22). Refit the guard.

Fig. 21

Fig. 22

4006/8 Diesel, May 1998 29

MAINTENANCE PROCEDURES

FAN BEARINGS AND BELTS

WARNING

DISCONNECT

BATTERIES OR ANY
OTHER MEANS OF STARTING.

Remove the mesh guard around the fan
belts, grease the fan and jockey pulley
bearings Fig. 23 using high melting point
lithium based grease (e.g. Shell Alvania
R.A.)
Check the tension and condition of the fan
belts. Using a spring balance and rule, or a
belt tension indicator, check that the force
compares with the kgf (lbf) values shown
belowfor the correct beltdeflection. See Fig.

23.

Deflection

11 mm

kg Force

3-4.3

lb Force

6.67 - 9.47

To adjust slackenthe jockey pulley pivot and
adjuster bolts, and operate the jockey pulley
lever.
Moving the jockey pulley lever outwards will
tension thebelts and inwards willslacken the
belts.
The correct tension is obtained by
measuring the deflection at the mid point
between the fan pulley and the crankshaft
pulley when the above force is applied.
To apply the force place a rule across the
outside width of the belts and attach spring
balance as shown Fig. 23 pull on the spring
balance until the required force is reached
and measure the belt deflection.
Adjust the position of the jockey pulley lever
until the force on the spring balance and the
belt deflection agree with the figures given
above.

Fan belts if worn, should be replaced as a
complete, matching set. Individual belts
should NOT be replaced.

deflection 11 mm

force

Fig. 23

30 4006/8 Diesel, May 1998

When using a belt tension indicator position
the indicator on top of a belt at the mid centre
distance and apply a force at right angles to
the belt deflecting it to the point where the
lower marker is level with the top of the
adjacent belt. Read off the force value
indicated by the top edge of the upper
marker.
Having set the tension on the belts, tighten
the adjuster and pivot bolts.
Refit the fan belt guard.
NOTE: If the measured force falls within the
values given, the drive should be
satisfactory, if it is below the lower value
under tensioning is indicated.
A new drive should be tensioned to the
highervaluetoallowforthenormaldropin
tension during the running-in period.
After the drive has been running for 30
minutes, the tension should be checked and
re-adjusted to the higher value.

MAINTENANCE PROCEDURES

FAULT TRACING

a) Small cracks on V-Belt Side and Base

Generally caused by lack of belt tension
but excessive heat and/or chemical
fumes can also lead to similar failure.

b) V-Belt swelling and softening

Caused by excessive contamination by
oil, certain cutting fluids or rubber
solvents.

c) Whipping during running

Usually caused by incorrect tensioning
principally on long centre drives. If a
slightly higher (or lower) tension does
not cure the problem there may be a
critical vibration frequency in the system
which requires re-design or a banded
belt (2 belts banded together to make a
Wbelt).

Fig. 24

CRANKCASE BREATHING
(SEE MAINTENANCE SCHEDULES)

WARNING

DISCONNECT

BATTERIES OR ANY
OTHER MEANS OF STARTING. WHEN
USING COMPRESSED AIR OR
CLEANING AGENTS ALWAYS WEAR
EYE PROTECTION, AND PROTECTIVE
GLOVES.

CRANKCASE BREATHER ON EARLIER ENGINES (RADIATOR COOLED)

The crankcase breather is mounted on the
side of the radiator Fig. 24 and is connected
to an elbow mounted on the gearcase by a
flexible pipe Fig. 26.

4006/8 Diesel, May 1998 31

MAINTENANCE PROCEDURES

CRANKCASE BREATHER ON EARLIER ENGINES (HEAT EXCHANGER COOLED)

The crankcase breather is mounted on the
side of thethermostat housing Fig. 25 and is
connected to a breather body mounted on
the gearcase by a flexible extension pipe
Fig. 26.
Unscrew the breather by turning it anti­clockwise, wash thoroughly using a suitable
cleaning agent, shake as dry as possible,
finally blow dry with compressed air then
screw the breather firmly back into position.

Key
(Fig. 26)

1. Position of breather when engine is fitted
witharadiator

2. Position of breather when engine is fitted
with heat exchanger

3. Flexible pipe

4. Elbow

Fig. 25

1

2

3

4

Fig. 26

32 4006/8 Diesel, May 1998

MAINTENANCE PROCEDURES

WARNING

DISCONNECT

BATTERIES OR ANY
OTHER MEANS OF STARTING. WHEN
USING COMPRESSED AIR OR
CLEANING AGENTS ALWAYS WEAR
EYE PROTECTION, AND PROTECTIVE
GLOVES.

CRANKCASE BREATHER (IMPROVED DESIGN) FITTED TO LATER ENGINES

The crankcase breather is mounted on the
side of the thermostat housingFig. 27 and is
connectedtotheengineviaaflexiblepipe
and elbow fitted on the front of the gearcase
(see Fig. 28).
To clean the breather remove the top cover
and withdraw the two wire mesh elements
and wash thoroughly using a suitable
cleaning agent. Shake as dry as possible,
finally blow dry with an compressed air. Refit
the elements into the breather body, and fit
the top cover firmly. (See Fig. 26).
NOTE: When replacing the cover check the
sealing gasket is in good condition and the
cover has located on its dowel.

Fig. 27

974.3

Fig. 28

4006/8 Diesel, May 1998 33

MAINTENANCE PROCEDURES

WARNING

DISCONNECT

BATTERIES OR ANY
OTHERMEANS OFSTARTING.ALWAYS
WEAR PROTECTIVE GLOVES.

CLEANING THE CENTRIFUGAL
LUBRICATING OIL FILTER SEE FIG. 29
REFER TO MAINTENANCE SCHEDULE

Stop the engine, and allow time for
lubricating oil to drain back to sump.
(1) Unscrew the cover nut and lift off the

filter body cover.

(2) Examine 'O' ringfor damage, renew if

necessary.

(3) Withdraw rotor assembly from

spindle and allow oil to drain from
nozzle before removing from filter
body. Hold rotor body and remove
rotor knurled nut. Separate the rotor
cover from the rotor body. Remove
central stand tube.

(4) Remove sludge from the insideof the

rotor cover by means of a wooden
spatula or suitably shaped piece of
wood and wipe clean.

(5) Clean and wash out the central stand

tube using asuitable solvent ensuring
that the strainer holes are not
blocked.

(6) Clean out nozzles with brass wire to

ensure free passage of oil. Examine
top and bottom bearings in rotor body
to ensure that they are free from
damage or excessive wear. Examine
'O' ring for damage renew if
necessary.

(7) Re-assemble rotor complete, tighten

cover nut to 9.5 Nm - 10.8 Nm (7-8
lbft.).

(8) Examine spindle journals to ensure

that they are free from damage or
excessive wear, remove cut-off valve
plug from filters only and remove cut­off valve assembly.
Check that the spring and shuttle are
undamaged and free to move.
Examine gasket for damage. Renew
if necessary.

(9) Re-assemble cut-off valve assembly.

COVER NUT

BOND SEAL
BODY COVER

‘O’ RING
KNURLED NUT

ROTOR COVER

STRAINER
‘O’ RING

ROTOR BODY

SPINDLE
FILTER BODY

CUT-OFF VALVE ASSEMBLY

Fig. 29

(10) Re-assemble filtercomplete,checking

that the rotor assemblyis free torotate
then replace filter cover and tighten
cover nut by hand until full resistance
is felt.

(11) With the engine running check all

connections and joints for leakage.

34 4006/8 Diesel, May 1998

CHANGING ENGINE OIL AND STANDARD SPIN-ON TYPE LUBRICATING OIL FILTERS

MAINTENANCE PROCEDURES

WARNING

DISCONNECT

BATTERIES OR ANY
OTHERMEANS OFSTARTING.ALWAYS
WEAR PROTECTIVE GLOVES.

With the engine stopped, place a suitable
container of at least 148 litres (32.5 gal)
beneath the drain plug. Remove the drain
plug andallow the oilto drain. This operation
is best carried out while the engine is still
warm as the thinner oil will drain more
efficiently. While the oil is draining remove
the three oil filters turning them anti­clockwise with a strap wrench Fig. 30.
NOTE: Removal of oil filters will allow an
escape of oil from the filter header. It is
therefore recommended that a suitable
containerof atleast 5 litres (1gal) capacityis
positioned under each filter prior to removal.
Wipe clean the sealing faces and threaded
bosses of the oil header. Smear engine oil
on the captive rubber sealing ring and
carefully screw each new filter up to the oil
header using firm hand pressure only.
Use only genuinePerkins oil filters. The use
of other filtersmay cause serious damage to
the engine.
Refit the drain plug and fill the engine with
the appropriate grade of new oil (see pages

15 - 16). (If fitted) manually set the air shut

off valves to the run position, hold the stop
lever in the stop position. Turn the keyswitch
to the start position, and crank the engine
over until the oil pressure gauge registers

0.4 kg/cm² (5lb/in²).
Continue cranking for a further 10 seconds
which will ensure that oil has reached the
turbocharger bearings.
Stop cranking the engine and visually check
the engine for oil leaks, top up the oil level.

Fig. 30

4006/8 Diesel, May 1998 35

MAINTENANCE PROCEDURES

WARNING

DISCONNECT

BATTERIES OR ANY
OTHERMEANS OFSTARTING.ALWAYS
WEAR PROTECTIVE GLOVES.

CHANGING THE OPTIONAL CHANGE­OVER LUBRICATING OIL FILTERS

These special duplex filters are normally
intended for use on long running engines, or
where a servicing requirement may occur
when it is impractical to stop the engine. For
this reason they are fitted with a three way
change-over valve in the head which
enables the elements to be changed, one at
a time, whilst the engine continues to run.
They are normally mounted on the engine,
but may be remotely mounted, and
connected to the engine by means of flexible
pipes.

NOTE: If the flexible connections to the filter
are removed for any reason, it is essential
that they are reconnected correctly to avoid
unfilteredoil getting intothe engine.See Fig.

31. Failure to change filters when due can
also lead to trouble from unfiltered oil.

CHANGING THE FILTER ELEMENTS WHEN THE E NGINE IS STOPPED

All that is necessary is to unscrew the
canisterswithastrapwrenchasshownin
Fig. 31, without moving the change-over
valve, as there is no pressure in the system
when the engineis stationary. The underside
of the header is then wiped clean, and a
smear of oil applied to the sealing rings on
the new canisters, before screwing them up
by hand and tightening them by no more
than three quarters of a turn after the seals
contact the header. Check the filter for leaks
after the engine is restarted.

Fig. 31

36 4006/8 Diesel, May 1998

MAINTENANCE PROCEDURES

WARNING

REDUCE ENGINE

SPEED TO IDLING IF
CHANGING THE FILTERS WHILST THE
ENGINE IS RUNNING.

CHANGING THE FILTER ELEMENTS WITHOUT STOPPING THE ENGINE

The normal position of the change-over
valve is with marking on the valve spindle for
the spanner showing the leg of the inverted
T pointing upwardswhen bothfilterelements
are in circuit. Turning the valve with the
spanner provided so that the leg of the T
points to the left, puts the right hand filter out
of service, so that it may be exchanged for a
new one, fill the new filter with clean oil
before fitting. Turning the valve so that the
leg points to the right, puts the left hand filter
out of service, so that this one can now be
exchanged for a new filter canister. The
valve is then returned to its original position,
so that both elements of the filter are back in
service. Check for oil leaks.

NOTE: Prepare for a small spillage of oil
from the filter as each canister is removed,
by placing a container of about 5 litres or 1
gallon capacity under the filter.

Note the piston jet filters which can only
be changed with the engine stopped.

(Fig. 32)

1. Change right filter

2. Normal running position

3. Change left filter

4. Dirty oil into filter

5. Clean oil into engine

Fig. 32

4006/8 Diesel, May 1998 37

MAINTENANCE PROCEDURES

CHANGING THE COMBINED FUEL FILTER WATER SEPARATOR

Remove the filter separator canister using a
strap wrench see Fig. 33 fill the new filter/
separator with clean engine oil to the rubber
seal, then screw the canister onto the
housing using firm hand pressure. Bleed air
from the system follow the procedure on

page 21.

CHANGING THE CHANGE OVER FUEL FILTER ELEMENTS WHEN THE ENGINE IS STOPPED

All that is necessary is to unscrew the
canisters with a strap wrench as shown in
Fig. 34, leaving the change-over lever in the
verticalposition asthere isno pressurein the
fuel system with the e ngine stationary. The
replacement canisters are screwed on by
hand, after applying a smear of clean engine
oil to the rubber seals, and tightening by firm
hand pressure only. Bleed the air from the
new filters by slackening the vent screw (2)
and operating the priming pump. Check for
leaks when the engine is restarted.

NOTE: Prepare for some spillage of fuel by
placing a bowl of about 5 litres or 1 gallon
capacity under the filter when changing the
capacities.

Fig. 33

Fig. 34

38 4006/8 Diesel, May 1998

MAINTENANCE PROCEDURES

WARNING

REDUCE ENGINE

SPEED TO IDLING IF
CHANGING THE FILTERS WHILST THE
ENGINE IS RUNNING.

CHANGING THE CHANGE OVER FUEL FILTER ELEMENTS WHEN THE ENGINE IS RUNNING

Both filters are in use with the change over
lever inthe vertical position. Moving the lever
to the left puts the right hand filter out of
service (1) see Fig. 35 and Fig. 36 and
moving it to the right for the left hand filter.
With the lever positioned remove the
appropriate filter canister using a strap
wrench see Fig. 35 fill the new filter with fuel
apply a smear of engine oil to the rubber
seal, then screw the canister onto the
housing using firm hand pressure. Air must
be vented from each new filter slacken the
vent screw (2) Fig. 33 slowly raise the lever
toward the vertical position stop when fuel
flows from vent screw, when air free fuel
flows tighten the vent screw return the lever
to the vertical position and repeat the
operation on the second filter. Wipe any
spilled fuel fromthe filter unit, check for leaks
at idling and normal running speed.

Fig. 35

Fig. 36

2

1

3

1157.2

1156.3

NOTE: Prepare for some spillage of fuel by
placing a bowl of about 5 litres or 1 gallon
capacity under the filter when changing the
capacities.

Key
(Fig. 35)

1. Both filters in use (Normal Running
Position)

2. Change right hand filter

3. Change left hand filter

4006/8 Diesel, May 1998 39

MAINTENANCE PROCEDURES

WARNING

DISCONNECT
BATTERIES OR ANY

OTHER MEANS OF STARTING ENGINE.

CHANGING AIR FILTER (SEE SECTION

A1 IN THE MAINTENANCE MANUAL)

STANDARD

Remove the end cover (3) of the air filter
housing, after unscrewing the retaining wing
nut, carefully lift out the paper air filter
element (1). For servicing the element see
General Servicing Instructions below.
When all servicing procedures are
completed, fit the new or cleaned element
into the housing. When fitting the end cover
ensure it has seated fully in the housing
before tightening the wing nut. Inspect and
tighten all air filter connection before
resuming equipmentoperation (see Fig. 37).

HEAVY DUTY

The heavy duty air filter incorporates a
cyclone unit (4) fitted to the air intake of the
filter (replacing the mesh guard (2)). To
clean the cyclone unit remove it from the air
filter and blow out any foreign matter within
the unit. Changing the paper air filter
element the procedure isthe same as for the
standard air filter above.

GENERAL SERVICING INSTRUCTIONS

Servicing procedures include cleaning or
replacingthe filterelement,cleaning thefilter
housing, and assuring that all piping and
hose connection from the filter outlet to the
turbocharger intake are sealed airtight.

FILTER ELEMENT SERVICE

Clean the exterior of the filter housing and
then carefully remove the element. Inspect
the "clean air side" of the element and the
outlet side of the filter housing for any
unusual dust accumulations.
(a) Dustaccumulations on the cleanair side

of the element usually indicates a
rupture in the filter medium. Immediate
replacement of the element is
necessary.

1

2

3

4

Fig. 37

(b) Dust accumulation on the inlet side of

the housingis usually causedby leaking
gaskets and/or damaged gasket
surfaces. If this condition exists, leaking
gaskets should be replaced and
damaged gasket surfaces should be
repaired before placing the unit back
into service.

WARNING

REPLACE ANY

ELEMENT WHICH IS
DAMAGED.
NEVER "BLOW" DIRT OUT OF THE
FILTER HOUSING. THIS MAY
INTRODUCE DUST INTO THE ENGINE.
INSTEAD, USE A CLEAN, DAMP,
CLOTH, DO NOT OIL THE ELEMENT.
WHEN USING COMPRESSED AIR
ALWAYS WEAR EYE PROTECTION.

ELEMENT CLEANING

If the filter element is in good condition with
light dust contamination on its outer surface
and the air flow restriction indicator (see

Page 27) has not been triggered, the

element can be cleaned using a vacuum
cleaner or compressed air.

40 4006/8 Diesel, May 1998

CLOSED CIRCUIT BREATHER SYSTEM

3

The closed circuit breather separator is
mountedontherighthandsideofthe
gearcase and is connected to the air inlet
system between the air cleaner and
turbocharger via the breather valve (see Fig.

38).
It consists of a filter separator (1) and two
breather valves (2) with a pipe feeding into
the air inlet system (between the air cleaner
and turbocharger).
To clean the breather valves release the
pipe clips (A) and pull away the breather
valves and the valve manifold from the
engine. Release the clamp (3) see Fig. 39
and remove the breather valves from the
valve manifold. Wash the breathers
thoroughly in a suitable solvent paying
particular attention to any deposits on the
internalareaof thebreather.Shakeas dryas
possible and blow dry with compressed air.
Before refitting ensure that the cup at the
base of the two breather valves are full of
clean engine oil and the 'O' ring at the base
ofthe breathervalve is in tact. (See Fig. 39).

MAINTENANCE PROCEDURES

Fig. 38

Fig. 39

4006/8 Diesel, May 1998 41

1005.3

MAINTENANCE PROCEDURES

CLOSED CIRCUIT BREATHER SYSTEM

Release the retaining clips and remove the
top cover (1) see Fig. 40 from the filter
separatorbody (2) removethe foam element
(3) and the gauze strainer (4) check it for oil
sludge saturation wash thoroughly in a
suitable solvent, shake off excess solvent
andblow drywith compressedair.Clean any
oil sludge deposits from the filter body re­assemble and fit to engine.

NOTE: Cleaning agents must not enter the
engine via the breather system as oil dilution
may occur causing engine damage.

Fig. 40

42 4006/8 Diesel, May 1998

EQUALISING ROCKER BRIDGES AND
SETTING VALVE CLEARANCES
NOTE: Thebridgepieces mustbe set before

attempting to set the valve clearances.

MAINTENANCE PROCEDURES

WARNING

DISCONNECT

BATTERIES AND ALL
OTHER MEANS OF STARTING THE
ENGINE.

Remove the 4 screws (1) from each rocker
cover (2), lift off the covers and peel off and
throw away the old gaskets Fig. 41.
To equalise the bridge pieces the
appropriate valves must be rocking, use the
table on page 44.
In orderthat the enginemay be rotated while
the batteries are disconnected a special
cranking device (SE253) can be fitted to a
starter motor hole in the flywheel housing
see Fig. 42. The flywheel housing has an
inspection hole directly below the
turbocharger through which the flywheel
markings may be seen to line up with the
pointer set in the flywheel housing Fig. 43.
Using a socket and ratchet wrench press
against the spring loaded bolt head until the
pinion engages with the flywheel gear then
crank the engine to the desired position.

Fig. 41

Fig. 42

Fig. 43

4006/8 Diesel, May 1998 43

MAINTENANCE PROCEDURES

EQUALISING THE BRIDGE PIECES

WARNING

DISCONNECT

BATTERIES OR ANY
OTHER MEANS OF STARTING THE
ENGINE.

Having rotated the engine to the correct
position, check that the inlet and exhaust
rockers have clearance before continuing
with the next operation. Loosen the lock nut
(1) on each bridge piece, screw the adjuster
(2) out until the fixed side of the bridge piece
rests on its valve, hold the top edge down
with onehand, then screwthe adjuster down
until you feel it touch the valve, thereby
equalising valve lift. Tighten the lock nut
without moving the adjuster (see Fig. 44).

SETTING VALVE CLEARANCES

With both bridge pieces equalised check the
valve clearance of 0.4 mm (0.016") inlet and
exhaust using a feeler gauge (1). If
adjustment is required loosen the lock nut (2)
and using the adjuster screw (3) set the
clearance (see Fig. 45). Tighten the lock nut
without moving the adjuster. The feeler
gauge should be a slide fit between the
rocker and bridge piece thereby giving the
correct clearance. Refit the rocker cover with
a new gasket.

2
1

Fig. 44

Fig. 45

32.3

33.3

Engine 4006 Valves Rocking on Set Bridge Piece and Valve

T.D.C. Cylinder No. Clearance on Cylinder No.

1and6 6 1
2and5 2 5
3and4 4 3
1and6 1 6
2and5 5 2
3and4 3 4

Engine 4008 Valves Rocking on Set Bridge Piece and Valve

T.D.C. Cylinder No. Clearance on Cylinder No.

1and8 8 1
4and5 5 4
2and7 2 7
3and6 3 6
1and8 1 8
4and5 4 5
2and7 7 2
3and6 6 3

44 4006/8 Diesel, May 1998

PREVENTIVE MAINTENANCE

SCHEDULE FOR ENGINES IN STAND-BY DUTY

For engines which are in use for a total of less than 400 hours in every twelve months, the
schedule below must be used:
The preventive maintenance operations must be applied at the interval (hours or months)
which occurs first.

A-Monthly
B-3 Months
C-Every 200 hours or 6 months
D-Every 1,000 hours or 12 months

ABCDOperation

●

Check the amount of coolant

●

●

●

●

●

●

●

Check the lubricating oil level
Check the restriction indicators for the air filters and, when

necessary, renew the filter elements
Start and run the engine on load until normal temperature

of operation is reached
Drain any water/sediment from the primary fuel filter

●

Check the condition and the tension of all drive belts

●

Check the specific gravity and the pH value of the coolant
Renew the lubricating oil and filter

●

Check radiator air restriction (visual)
Clean centrifugal oil filter
Renew the canister of the main fuel filter
Ensure thatthe fuel injectors arechecked and corrected or

●

renewed, if necessary*

●

Equalise bridge pieces and check valve clearances

NOTE: All bolts, hose clips, terminal connections, pipes and joints must be checked for
tightness and leaks e very 3 months unless stated otherwise.

* By a person who has had the correct training.

4006/8 Diesel, May 1998 45

PREVENTIVE MAINTENANCE

SCHEDULE FOR ENGINES IN CONTINUOUS DUTY

The preventive maintenance operations must be applied at the interval (hours or months)
which occurs first.

A-Daily
B-Every 250 hours or 6 months
C-Every 2500 hours or 12 months

A B C Operation

●

Check the coolant level

●

●

●

●

●

●

●

●

●

●

●

●

Check the lubricating oil level
Check the restriction indicators for the air filters and, when

necessary, renew the filter elements
Drain any water/sediment from the primary fuel filter
Check the condition and the tension of all drive belts
Check the specific gravity and the pH value of the coolant
Renew the lubricating oil and filter
Visually check for radiator air restriction
Clean centrifugal oil filter
Renew the canister of the main fuel filter
Clean the water trap sedimenter
Equalise bridge pieces and check valve clearances
Checkthat theair chargecooler andthe radiator areclean andfree

from debris

●

Drain and flush the coolant system and renew coolant mixture
Ensure that the fuel injectors are checked and corrected or

●

renewed, if necessary *

* By a person who has had the correct training.

46 4006/8 Diesel, May 1998

4006/4008 ENGINE FAULT TRACING

Fig. 46

4006/8 Diesel, May 1998 47

WIRING DIAGRAM, CAV STARTER WITH REPEATER RELAY

Key
(Fig. 47)

1. Repeater relay

2. 24 volt starting batteries

3. CAV Starter motor

4. Start relay

5. Fuel stop solenoid

35.0 Amps inrush

0.75 Amps holding
Energised to run

6. NOTE: Aux terminal gives a battery
negative signal when solenoid is fully
energised. To enable engine to run
immediately on depressing start button
F.P.S. must be fed positive +ve

7. Fuel stop solenoid relay

8. Start button

Fig. 47

48 4006/8 Diesel, May 1998

WIRING DIAGRAM, CAV STARTER WITHOUT REPEATER RELAY

Key
(Fig. 48)

1. 24 volt starting batteries

2. CAV Starter motor

3. Start relay

4. Fuel stop solenoid

35.0 Amps inrush

0.75 Amps holding
Energised to run

5. Fuel stop solenoid relays

6. NOTE: Aux terminal gives a battery
negative signal when solenoid is fully
energised. To enable engine to run
immediately on depressing start button
F.P.S. must be fed positive +ve

7. Start button

Fig. 48

4006/8 Diesel, May 1998 49

WIRING DIAGRAM, CAV STARTER WITH REPEATER RELAY FOR REMOTE OR AUTOMATIC START

Key
(Fig. 49)

1. Charge alternator

2. Oil pressure switch

3. Resistor

4. Water temperature gauge

5. Oil temperature gauge

6. Oil pressure gauge

7. Ammeter

8. Tachometer

9. Fuse

10.Governor actuator

11.Repeator relay

12.Aux terminal gives a battery negative
signal fully energised

13.Water temperatur sender

14.Oil temperature sender

15.Oil pressure sender

16.Oil pressure sender

17.Key switch if required

18.Starter motor

19.Start relay

20.Fuel solenoid relay

21.Fuel solenoid energised to run

45.0 Amps inrush

0.75 Amps holding

22.Combined engine faults switch

23.Water temperature

24.Oil pressure

25.Magnetic pick-up

26.Engine flywheel

27.24 volt starting batteries

28.Typical terminal block

29.Two switch speed unit

30.Switch 2 overspeed

31.Switch 1 speed ref

32.To enable engine to run immediately on
depressing start button both FPS and GOV+
must be fed 24 volt +ve. To stop break thus
+ve supply

33.Speed trim pot

34.If speed trim pot is not required remove
and connect thus

35.Wire sizes

Fig. 49

50 4006/8 Diesel, May 1998

WIRING DIAGRAM, ENGINE WITHOUT REPEATER (MANUAL START)

Key
(Fig. 50)

1. Charging alternator

2. Oil pressure switch

3. Resistor

4. Water temperature gauge

5. Oil temperature gauge

6. Oil pressure gauge

7. Ammeter

8. Tachometer

9. 2 Amp fuse

10.Governor actuator

11.Aux terminal gives a battery negative
signal fully energised

12.Fuel solenoid energised to run

45.0 Amps inrush

0.75 Amps holding

13.Combined engine fault switch

14.Water temperature

15.Oil pressure

16.Key switch if required

17.Governor control box

18.Magnetic pick-ups

19.Engine flywheel

20.Starter motor

21.Starter relay

22.Fuel solenoid relay

23.24 volt starting relay

24.Typical terminal block

25.Two switch speed box

26.Switch 2 overspeed

27.Switch 1 speed ref

28.Wire sizes

29.Toenableenginetorunimmediatelyon
depressing start button both GOV and FPS
must be fed 24 volt +ve to stop break +ve
supply

30.Speed trim pot

31.If speed trim pot is not required remove
and connect thus

Fig. 50

4006/8 Diesel, May 1998 51

WIRING DIAGRAM, PRESTOLITE STARTER WITH REPEATER RELAY

Key
(Fig. 51)

1. Charging alternator

2. Signal for tacho

3. Ammeter

4. Oil pressure switch

5. Resistor

6. 24 volt starting batteries

7. Starter motor

8. Starter relay

9. Fuel solenoid relay

10.Repeat start unit

11.Fuel stop solenoid energised to stop

45.0 Amps inrush

0.75 Amps holding

12.Start button

13.To stop

Fig. 51

52 4006/8 Diesel, May 1998

WIRING DIAGRAM, PRESTOLITE STARTER WITHOUT REPEATER RELAY

Key
(Fig. 52)

1. Charging alternator

2. Signal for tacho

3. Oil pressure switch

4. Resistor

5. Ammeter

6. 24 volt starting batteries

7. Starter motor

8. Starter relay

9. Relay to allow fuel solenoid to energise
before crank

10.Fuel stop solenoid energised to stop
45 Amps inrush

11.Start button

12.Must be +ve immediately on start

Fig. 52

4006/8 Diesel, May 1998 53

WIRING DIAGRAM WITH HEINZMANN GOVERNOR & PRESTOLITE STARTER FOR MANUAL OR AUTOMATIC START

Key
(Fig. 53)

1. Charge alternator (CAV)
1A.Charge alternator (BUTEC)

2. Oil pressure switch

3. Water temperature gauge

4. Oil temperature gauge

5. Oil pressure gauge

6. Ammeter

7. Tachometer

8. Fuse

9. Key switch if required

10.Governor actuator

11.Resistor

12.Sender water temperature

13.Sender oil temperature

14.Sender oil pressure

15.Governor control box

16.Fuel solenoid energised to run

17.Magnetic pick-up

18.Engine flywheel

19.24 volt starting batteries

20.Starter motor

21.Start relay

22.Fuel solenoid relay

23.Combined engine faults switch

24.Water temperature

25.Oil pressure

26.Two switch speed unit

27.Switch 2 overspeed

28.Switch 1 speed ref

29.Wire sizes

30.To enable engine to run immediately on
depressing start button both FPS and GOV+
must be fed 24 volt +ve. To stop break thus
+ve supply

31.Typical terminal block

32.Speed trim pot

33.If speed trim pot is not required remove
and connect thus

Fig. 53

54 4006/8 Diesel, May 1998

© 1998 Perkins Engines Company Limited
All Rights Reserved