Perkins Engine 4006-23, 4008-30 Service Manual
Operation and
Maintenance
Manual
SEBU9077-01 (en-us)
September 2016
4006-23 and 4008-30 Industrial Engines
SD8 (Engine)
SD6 (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.
When replacement parts are required for this
product Perkins recommends using Perkins
replacement parts.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
SEBU9077-01
3
Table of Contents
Table of Contents
Foreword ........................................................... 4
Safety Section
Safety Messages............................................... 5
General Hazard Information.............................. 9
Burn Prevention............................................... 12
Fire Prevention and Explosion Prevention...... 13
Crushing Prevention and Cutting Prevention.. 15
Mounting and Dismounting ............................. 15
Before Starting Engine .................................... 15
Engine Starting................................................ 16
Engine Stopping .............................................. 16
Warranty Section
Warranty Information....................................... 83
Index Section
Index................................................................ 84
Electrical System............................................. 16
Engine Electronics........................................... 17
Product Information Section
Model Views .................................................... 18
Product Identification Information ................... 25
Operation Section
Lifting and Storage .......................................... 26
Features and Controls..................................... 29
Engine Starting................................................ 32
Engine Operation ............................................ 33
Engine Stopping .............................................. 34
Maintenance Section
Refill Capacities............................................... 35
Maintenance Interval Schedule....................... 50
4
Foreword
SEBU9077-01
Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance information. This
manual should be stored in or near the engine area in
a literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.
English is the primary language for all Perkins
publications. The English used facilitates translation
and consistency.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have been
removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Perkins dealer or your Perkins
distributor for the latest available information.
Safety
This safety section lists basic safety precautions. In
addition, this section identifies hazardous, warning
situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe, dusty,
wet or freezing cold operating conditions, more
frequent lubrication and maintenance than is
specified in the Maintenance Interval Schedule may
be necessary.
The maintenance schedule items are organized for a
preventive maintenance management program. If the
preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. We recommend that the
maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engine's permanent record.
Your authorized Perkins dealer or your Perkins
distributor can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs should only be carried out by Perkins
authorized personnel. Your Perkins dealer or your
Perkins distributor offers a variety of options
regarding overhaul programs. If you experience a
major engine failure, there are also numerous after
failure overhaul options available. Consult with your
Perkins dealer or your Perkins distributor for
information regarding these options.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm. Battery
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.
SEBU9077-01
Safety Section
i06712726
Safety Messages
There may be several specific warning signs on your
engine. The exact location and a description of the
warning signs are reviewed in this section. Become
familiar with all warning signs.
Ensure that all the warning signs are legible. Clean
the warning signs or replace the warning signs if the
words cannot be read or if the illustrations are not
visible. Use a cloth, water, and soap to clean the
warning signs. Do not use solvents, gasoline, or
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning signs. The warning signs that are loosened
could drop off the engine.
5
Safety Section
Safety Messages
Replace any warning sign that is damaged or
missing. If a warning sign is attached to a part of the
engine that is replaced, install a new warning sign on
the replacement part. Your Perkins distributor can
provide new warning signs.
Illustration 1 g06086932
(1) Universal warning label locations
(2) Do not step
(3) Hot surface label location
(4) Hot fluid under pressure label locations
(5) Ether warning label location
6
Safety Section
Safety Messages
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Illustration 2 g06093786
(1) Universal warning label location
(3) Hot surface label location
(6) Rotating shaft hand crush hazard label
location
1 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.
The universal warning labels (1) are installed in two
locations. One universal warning label is installed on
the coolant rail. The other universal warning label is
installed on the control box.
2 Do Not Step
This safety message is located in the center of the
Illustration 3 g06019365
Universal Warning label
intake manifold.
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Illustration 4 g01393287
Do not use this surface as a step or platform. This
surface may not support additional weight or may
be slippery. Serious injury or death could occur
from a fall.
7
Safety Section
Safety Messages
The hot surface warning labels (2) are located in two
locations. The oil cooler and heat shield of the
coolant rail.
4 Hot Fluid Under Pressure
Illustration 6 g01371640
3 Hot Surface
Illustration 5 g01372256
Hot parts or hot components can cause burns or
personal injury. Do not allow hot parts or components to contact your skin. Use protective clothing or protective equipment to protect your skin.
Pressurized system! Hot coolant can cause serious burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order
to relieve the pressure. Read and understand the
Operation and Maintenance Manual before performing any cooling system maintenance.
8
Safety Section
Safety Messages
SEBU9077-01
The hot fluids under pressure labels (3) have two
positions. One label is on the end cover of the oil
cooler. Perkins recommends that the other hot fluid
under pressure label is installed on the radiator, next
to the coolant filler cap.
5 Ether Warning
Illustration 7 g01372254
Ether warning label (4) is on the support bracket for
the air cleaners.
6 Rotating Shaft Hand Crush
Hazard
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
Illustration 8 g02781437
Rotating shaft pinch hazard. The shaft under this
cover is rotating anytime the engine is running.
Contact with a rotating shaft could cause injury
or death. Keep hands away.
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9
Safety Section
General Hazard Information
The rotating shaft hand crush hazard label (5) is on
the cover of the crankshaft vibration damper.
i06106934
General Hazard Information
Illustration 9 g00104545
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. Attach the warning tags to the engine and
to each operator control station. When appropriate,
disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
• Tampering with the engine installation or
tampering with the OEM supplied wiring can be
dangerous. Personal injury, death and/or engine
damage could result.
• Vent the engine exhaust to the outside when the
engine is operated in an enclosed area.
• If the engine is not running, do not release the
secondary brake or the parking brake systems
unless the vehicle is blocked or unless the vehicle
is restrained.
• Wear a hard hat, protective glasses, and other
protective equipment, as required.
• When work is performed around an engine that is
operating, wear protective devices for ears in
order to help prevent damage to hearing.
• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.
• Ensure that all protective guards and all covers
are secured in place on the engine.
• Never put maintenance fluids into glass
containers. Glass containers can break.
• Use all cleaning solutions with care.
• Report all necessary repairs.
Unless other instructions are provided, perform the
maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot be started.
• The protective locks or the controls are in the
applied position.
• Engage the secondary brakes or parking brakes.
• Block the vehicle or restrain the vehicle before
maintenance or repairs are performed.
• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks. If
equipped, allow the diesel exhaust fluid to be
purged before disconnecting the battery.
• If equipped, disconnect the connectors for the unit
injectors that are located on the valve cover base.
This action will help prevent personal injury from
the high voltage to the unit injectors. Do not come
in contact with the unit injector terminals while the
engine is operating.
• Do not attempt any repairs or any adjustments to
the engine while the engine is operating.
• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.
• For initial start-up of a new engine or for starting
an engine that has been serviced, make
provisions to stop the engine if an overspeed
occurs. The stopping of the engine may be
accomplished by shutting off the fuel supply and/
or the air supply to the engine. Ensure that only
the fuel supply line is shut off. Ensure that the fuel
return line is open.
• Start the engine from the operators station (cab).
Never short across the starting motor terminals or
the batteries. This action could bypass the engine
neutral start system and/or the electrical system
could be damaged.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
10
Safety Section
General Hazard Information
SEBU9077-01
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.
• Disconnect the batteries when maintenance is
performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• Do not attempt any repairs that are not
understood. Use the proper tools. Replace any
equipment that is damaged or repair the
equipment.
Pressurized Air and Water
Pressurized air and/or water can cause debris and/or
hot water to be blown out. This action could result in
personal injury.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration
Illustration 10 g00702020
• Wear a hard hat, protective glasses, and other
protective equipment, as required.
• When work is performed around an engine that is
operating, wear protective devices for ears in
order to help prevent damage to hearing.
• Do not wear loose clothing or jewelry that can
snag on controls or on other parts of the engine.
• Ensure that all protective guards and all covers
are secured in place on the engine.
• Never put maintenance fluids into glass
containers. Glass containers can break.
• Use all cleaning solutions with care.
• Report all necessary repairs.
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved
correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
information for any procedures that are required to
relieve the hydraulic pressure.
Unless other instructions are provided, perform
the maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot be started.
SEBU9077-01
Illustration 11 g00687600
Always use a board or cardboard when you check for
a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
11
Safety Section
General Hazard Information
Avoid static electricity risk when fueling. Ultralow sulfur diesel fuel (ULSD fuel) poses a greater
static ignition hazard than earlier diesel formulations with a higher sulfur contents. Avoid death
or serious injury from fire or explosion. Consult
with your fuel or fuel system supplier to ensure
the delivery system is in compliance with fueling
standards for proper grounding and bonding
practices.
Inhalation
Containing Fluid Spillage
Care must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.
Static Electricity Hazard when
Fueling with Ultra-low Sulfur Diesel
Fuel
The removal of sulfur and other compounds in ultralow sulfur diesel fuel (ULSD fuel) decreases the
conductivity of ULSD and increases the ability of
ULSD to store static charge. Refineries may have
treated the fuel with a static dissipating additive.
Many factors can reduce the effectiveness of the
additive over time. Static charges can build up in
ULSD fuel while the fuel is flowing through fuel
delivery systems. Static electricity discharge when
combustible vapors are present could result in a fire
or explosion. Ensure that the entire system used to
refuel your machine (fuel supply tank, transfer pump,
transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system
complies with fueling standards for proper grounding
and bonding.
Illustration 12 g00702022
Exhaust
Use caution. Exhaust fumes can be hazardous to
health. If you operate the equipment in an enclosed
area, adequate ventilation is necessary.
Asbestos Information
Perkins equipment and replacement parts that are
shipped from Perkins engine company limited are
asbestos free. Perkins recommends the use of only
genuine Perkins replacement parts. Use the following
guidelines when you handle any replacement parts
that contain asbestos or when you handle asbestos
debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.
12
Safety Section
Burn Prevention
SEBU9077-01
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
particles in the air.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i06545886
Burn Prevention
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the
cooling system is drained.
Check that the coolant level after the engine has
stopped and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly to
relieve pressure. Refer to this Operation and
Maintenance Manual, Cooling System Coolant Level
- Check for more information.
Dispose of Waste Properly
Illustration 13 g00706404
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Skin may be irritated following repeated or prolonged
exposure to mineral and synthetic base oils. Refer to
your suppliers Material Safety Data Sheets for
detailed information. Hot oil and lubricating
components can cause personal injury. Do not allow
hot oil to contact the skin. Appropriate personal
protective equipment should be used.
Diesel Fuel
Diesel may be irritating to the eyes, respiratory
system, and skin. Prolonged exposure to diesel may
cause various skin conditions. Appropriate personal
protective equipment should be used. Refer to
supplier Material safety Data sheets for detailed
information.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Do not smoke whilst checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.
SEBU9077-01
13
Safety Section
Fire Prevention and Explosion Prevention
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
i06545894
Fire Prevention and Explosion
Prevention
Illustration 14 g00704000
All fuels, most lubricants, and some coolant mixtures
are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. Fire may cause personal injury and property
damage.
After the emergency stop button is operated, ensure
that you allow 15 minutes, before the engine covers
are removed.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray if there was a line,
a tube, or a seal failure. Exhaust shields must be
installed correctly.
Do not carry out any work on the fuel lines or tanks
that could ignite residual fuel. Grinding, welding,
cutting, chiseling, and sawing have the potential to
create a source of ignition must be avoided.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.
Wiring must be kept in good condition. Ensure that all
electrical wires are correctly installed and securely
attached. Check all electrical wires daily. Repair any
wires that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or
unnecessary. Do not use any wires or cables that are
smaller than the recommended gauge. Do not
bypass any fuses and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and correctly
maintained battery cables will help to prevent arcing
or sparking.
Ensure that the engine is stopped. Inspect all lines
and hoses for wear damage, leakage or for
deterioration. Ensure that the hoses are correctly
routed. The lines and hoses must have adequate
support and secure clamps.
Oil filters and fuel filters must be installed correctly.
The filter housings must be tightened to the correct
torque. Refer to the Disassembly and Assembly
manual for more information.
If the application involves the presence of
combustible gases, consult your Perkins dealer and/
or your Perkins distributor for additional information
about suitable protection devices.
Remove all flammable combustible materials or
conductive materials such as fuel, oil, and debris
from the engine. Do not allow any flammable
combustible materials or conductive materials to
accumulate on the engine.
Store fuels and lubricants in correctly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
14
Safety Section
Fire Prevention and Explosion Prevention
SEBU9077-01
Illustration 15 g00704059
Use caution when you are refueling an engine. Do
not smoke whilst you are refueling an engine. Do not
refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Avoid static electricity risk when fueling. Ultra-low
Sulfur Diesel fuel (ULSD fuel) poses a greater static
ignition hazard than earlier diesel formulations with a
higher sulfur content. Avoid death or serious injury
from fire or explosion. Consult your fuel or fuel
system supplier to ensure that the delivery system is
in compliance with fueling standards for proper
grounding and bonding practices.
Illustration 16 g00704135
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or a
hydrometer.
Incorrect jumper cable connections can cause an
explosion that can result in injury. Refer to the
Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. A frozen battery may
cause an explosion.
The batteries must be kept clean. The covers (if
equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Ether
Ether is flammable and poisonous.
Do not smoke whilst you are replacing an ether
cylinder or whilst you are using an ether spray.
SEBU9077-01
15
Safety Section
Crushing Prevention and Cutting Prevention
Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders in
direct sunlight or in temperatures above 49° C
(120° F). Keep ether cylinders away from open
flames or sparks.
Lines, Tubes, and Hoses
Do not bend high-pressure lines. Do not strike highpressure lines. Do not install any lines that are
damaged.
Leaks can cause fires. Consult your Perkins
distributor for replacement parts.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible parts of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation,
correct installation will help to prevent vibration,
rubbing against other parts, and excessive heat.
i05875651
Mounting and Dismounting
Do not climb on the engine. The engine has not been
designed with mounting or dismounting locations.
Refer to the OEM for the location of foot and hand
holds for your specific application.
i04257031
Before Starting Engine
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
air and/or fuel supply to the engine.
Engine exhaust contains products of combustion
which may be harmful to your health. Always
start and operate the engine in a well ventilated
area and, if in an enclosed area, vent the exhaust
to the outside.
Inspect the engine for potential hazards.
i02143194
Crushing Prevention and
Cutting Prevention
Support the component correctly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving parts.
Leave the guards in place until maintenance is
performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
Do not start the engine or move any of the controls if
there is a “DO NOT OPERATE” warning tag or similar
warning tag attached to the start switch or to the
controls.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
If equipped, ensure that the lighting system for the
engine is suitable for the conditions. Ensure that all
lights work properly, if equipped.
All protective guards and all protective covers must
be installed if the engine must be started in order to
perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Do not start an engine when the governor linkage is
disconnected.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
16
Safety Section
Engine Starting
SEBU9077-01
i06545901
Engine Starting
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
If a warning tag is attached to the engine start switch,
or to the controls DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started to perform
service procedures.
Start the engine from the operators compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
Ensure that the jacket water heater (if equipped) is
working correctly, check the water temperature
reading on the control panel of the original engine
manufacture.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the
Emergency Stop Button for normal engine stopping.
After an emergency stop, DO NOT start the engine
until the problem that caused the emergency stop
has been corrected.
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled. This may be
accomplished by shutting off the fuel supply to the
engine and/or shutting off the air supply to the
engine.
To stop an electronically controlled engine, cut the
power to the engine.
i06088340
Electrical System
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “−” jump-start cable should be connected
last from the external power source to the negative
“−” terminal of the starting motor. If the starting motor
is not equipped with a negative “−” terminal, connect
the jump-start cable to the engine block.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. Refer to
the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.
Note: The engine may be equipped with a device for
cold starting. If the engine will be operated in cold
conditions, then an extra cold starting aid may be
required. Normally, the engine will be equipped with
the correct type of starting aid for your region of
operation.
i01462046
Engine Stopping
Stop the engine according to the procedure in the
Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
the engine components.
Grounding Practices
Proper grounding for the engine electrical system is
necessary for optimum engine performance and
reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
To ensure that the engine and the engine electrical
systems function properly, an engine-to-frame
ground strap with a direct path to the battery must be
used. This path may be provided by way of a starting
motor ground, a starting motor ground to the frame,
or a direct engine ground to the frame.
SEBU9077-01
All grounds should be tight and free of corrosion. The
engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.
i02414684
Engine Electronics
Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/
or engine damage.
The engine is controlled by a digital Pandoras
governor. The control system includes the following
components.
17
Safety Section
Engine Electronics
• Control unit
• Actuator
• Setpoint adjusters (if equipped)
• Sensors
• Wiring Harness
System Description
The system is controlled by an Electronic control Unit
(ECU). The ECU contains a microprocessor that has
an Electronic Programmable Read Only Memory
(EPROM). The operating parameters for the
governor are stored in the EPROM. The actuator is
connected to the fuel injectors via a mechanical
linkage.
A laptop computer is used to set the operating
parameters of the governor. The laptop computer is
connected to the governor via an interface cable. The
operating parameters for the governor should only be
modified by a trained Perkins representative. Refer to
the Special Instruction, “Pandoras Digital Governor”
for more information.
18
Product Information Section
Model Views
Product Information
Section
Model Views
i06681533
Model View Illustrations
(Engine Views for the Six and
Eight Cylinder 4000 Series
Engines)
The following model views show typical features of
the engine. Due to individual applications, your
engine may appear different from the illustrations.
SEBU9077-01
SEBU9077-01
4006-23 Engine Views
19
Product Information Section
Engine Views for the Six and Eight Cylinder 4000 Series Engines
Illustration 17 g06072657
Typical example
(1) Twin air cleaners
(2) Crankcase breather
(3) Adjustment housing
(4) Fan hub pulley
(5) Belts
The major engine differences on six cylinder engine
to an eight cylinder engine are shown in illustration
17 . These differences are, air cleaner end cap
design the crankcase breather design. The
adjustment plate. The belts that drive the fan and the
belt pulley for the fan drive.
20
Product Information Section
Engine Views for the Six and Eight Cylinder 4000 Series Engines
4006-23 Radiator
SEBU9077-01
Illustration 18 g06072687
Typical example
(1) Radiator lifting eyes
(2) Radiator pressurized filler cap
(3) Radiator
(4) Radiator drain
(5) Fuel cooler
(6) Air charge cooler
SEBU9077-01
4008-30 Engine Views
21
Product Information Section
Engine Views for the Six and Eight Cylinder 4000 Series Engines
Illustration 19 g06004723
Typical example
(1) Twin air cleaners
(2) Electronic governor control unit
(3) Oil cooler
(4) Alternator
(5) Front lifting eye
(6) Thermostat housing
(7) Stop solenoid
(8) Oil filler cap
(9) Coolant pump
(10) Primary fuel filter
(11) Fuel priming pump
(12) Oil gauge (Dipstick)
(13) Oil drain location
(14) Oil filters
(15) Starter relay
(16) Starting motor
22
Product Information Section
Engine Views for the Six and Eight Cylinder 4000 Series Engines
SEBU9077-01
Illustration 20 g06004738
Typical example
(17) Twin turbochargers
(18) Right side rear lifting eye
(19) Left side rear lifting eye
(20) Crankcase breather
SEBU9077-01
4008-30 Radiator
23
Product Information Section
Engine Description
Illustration 21 g06005784
Typical example
(1) Radiator assembly lifting eye
(2) After cooler
(3) Radiator
(4) Coolant filler cap
(5) Radiator assembly lifting eye
(6) Fan belts
i06681623
(7) Fan belt pulley adjuster
(8) Coolant drain
(9) Fuel cooler
Engine Description
The 4006-23 and the 4008-30 engines are available
with turbocharged aftercooled aspiration. The 400623 and the 4008-30 industrial engines are designed
as a constant speed engine.
Engine Specifications
The front end of the engine is opposite the flywheel
end of the engine. The left and the right sides of the
engine are determined from the flywheel end. The
number 1 cylinder is the front cylinder.
Illustration 22 g03897666
Typical example of an 8 cylinder engine
(A) Inlet valves
(B) Exhaust valves
24
Product Information Section
Engine Description
Table 1
4006-23 Engine Specifications
Number of cylinders In-line 6 cylinder
Bore 160 mm (6.29920 inch)
Stroke 190 mm (7.48030 inch)
Displacement 22.921 L ()
Compression Ratio 13.6:1
Firing order 1-5-3-6-2-4
Aspiration Turbocharged after cooled
Valve seat angle 20°
Valve lash 0.4 mm (0.01575 inch)
Cold
Table 2
4008-30 Engine Specifications
SEBU9077-01
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to proper
operation and maintenance recommendations.
Engine performance and efficiency also depend on
the use of recommended fuels, lubrication oils, and
coolants. Refer to this Operation and Maintenance
Manual for more information.
Number of cylinders In-line 8 cylinder
Bore 160 mm (6.29920 inch)
Stroke 190 mm (7.48030 inch)
Displacement
Compression Ratio 13.6:1
Firing order 1-4-7-6-8-5-2-3
Aspiration Turbo charged after cooled
Valve seat angle 20°
Valve lash 0.4 mm (0.01575 inch)
30.56 L
(1864.88549 cubic inch)
Cold
Engine Cooling and Lubrication
The cooling system consists of the following
components:
• Gear-driven water pump
• Water temperature regulators
• Gear-driven oil pump (rotor type)
• Oil cooler
The engine lubricating oil is supplied by a gear-driven
pump. The lubrication oil is cooled and filtered.
Bypass valves provide unrestricted flow of lubrication
oil to the engine parts when oil viscosity is high.
Bypass valves can also provide unrestricted flow of
lubrication oil to the engine parts if the oil filter
element should become plugged.
SEBU9077-01
Product Identification
Information
i06516715
Plate Locations and Film
Locations
The engine serial number plate is on the right side
rear of the engine.
25
Product Information Section
Product Identification Information
Illustration 23 g06017751
Typical example
(1) Engine serial number plate
(2) Emission label location
Illustration 24 g06016214
Typical example
(1) Engine serial number plate
Your Perkins distributor needs all the number from
the plate when service information is required.
Emission Label
The emission label (2) is installed on the inlet
manifold of the engine.
26
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
i06700907
Engine Lifting
(4006-23 and 4008-30 Engines)
Engine Lifting Only
SEBU9077-01
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the
angle between the supporting members and the object becomes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use a
lifting beam to lift the engine. All supporting members
(chains and cables) should be parallel to each other.
The chains and cables should be perpendicular to
the top of the object that is being lifted.
To remove the engine ONLY, use the lifting eyes that
are on the engine. If necessary, remove engine
components to avoid damage from the lifting device.
Lifting eyes are designed and installed for specific
engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure that
correct lifting devices are provided. Consult your
Perkins distributor for information regarding fixtures
for correct engine lifting.
NOTICE
SEBU9077-01
27
Operation Section
4006-23 and 4008-30 Engines
Illustration 25 g06006861
Typical example
(1) Rear lifting eye (2) Rear lifting eye (3) Front lifting eye
Radiator Lifting Only
Illustration 26 g06006867
Typical example
(1) Radiator lifting eye (2) Radiator lifting eye
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