Perkins Engine 4006 TRS Gas, 4008 TRS Gas Service Manual

Operation and
Maintenance
Manual

SEBU8190-00

April 2006

4006 TRS Gas and 4008 TRS Gas
Industrial Engines

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or
pictorially presented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Perkins is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Perkins dealers or Perkins distributors have the most current information available.

When replacement parts are required for this
product Perkins recommends using Perkins

replacement parts.

Failure to heed this warning can lead to prema­ture failures, product damage, personal injury or
death.

SEBU8190 3

Table of Contents

Table of Contents

Foreword ............................................. .................... 4

Safety Section

Safety Messages .................................................... 5

General Hazard Information ................................... 7

Burn Prevention ...................................................... 9

Fire Prevention and Explosion Prevention .............. 9

Crushing Prevention and Cutting Prevention ......... 11

Mounting and Dismounting .................................... 11

Ignition Systems .................................................... 11

Before Starting Engine ........................................... 11

Engine Starting ..................................................... 12

Engine Stopping ................................................... 12

Index Section

Index ..................................................................... 68

Electrical System .................................................. 12

Product Information Section

Model Views and Specifications ........................... 14

Product Identification Information ........................ 20

Operation Section

Lifting and Storage ................................................ 22

Gauges and Indicators .......................................... 23

Features and Controls .......................................... 24

Engine Starting ..................................................... 27

Engine Operation .................................................. 30

Engine Stopping ................................................... 31

Maintenance Section

Refill Capacities .................................................... 33

Maintenance Interval Schedule ............................ 36

Reference Information Section

Reference Materials .............................................. 64

4 SEBU8190
Foreword

Foreword

Literature Information

This manual con
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literatur
study and keep it with the literature and engine
information.

English is the primary language for all Perkins
publications. The English used facilitates translation
and consiste

Some photographs or illustrations in this manual
show details
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvemen
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises reg
consult with your Perkins dealer or your Perkins
distributor for the latest available information.

Safety

This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning si
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on

this product.

tains safety, operation instructions,

e holder or literature storage area. Read,

ncy.

or attachments that may be different

t and advancement of product design

arding your engine, or this manual, please

tuations. Read and understand the basic

Recommended se
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine a
Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
more frequen
specified in the Maintenance Interval Schedule may
be necessary.

The maintenance schedule items are organized for
a preventive maintenance management program. If
the prevent
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should mini
avoidances resulting from reductions in unscheduled
downtime and failures.

ive maintenance program is followed, a

mize operating costs through cost

rvice should be performed at the

lso governs the Maintenance Interval

t lubrication and maintenance than is

Maintenance Intervals

Perform maintenance on items at multiples of
the original requirement. We recommend that the
maintenan
near the engine as a convenient reminder. We also
recommend that a maintenance record be maintained
as part of

Your authorized Perkins dealer or your Perkins
distribu
maintenance schedule to meet the needs of your
operating environment.

ce schedules be reproduced and displayed

the engine’s permanent record.

tor can assist you in adjusting your

Overhaul

Operatio

Operating techniques outlined in this manual are
basic. Th
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop
engine and its capabilities.

The oper
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and sto
discussion of electronic diagnostic information.

n

ey assist with developing the skills and

as the operator gains knowledge of the

ation section is a reference for operators.

pping the engine. This section also includes a

Maintenance

The mai
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
interv
referenced to detailed instructions that follow.

ntenance section is a guide to engine care.

als. Items in the maintenance schedule are

Major engine overhaul details are not covered in
the Operation and Maintenance Manual except
for the i
interval. Major repairs should only be carried out by
Perkins authorized personnel. Your Perkins dealer
or your P
regarding overhaul programs. If you experience
a major engine failure, there are also numerous
after f
your Perkins dealer or your Perkins distributor for
information regarding these options.

nterval and the maintenance items in that

erkins distributor offers a variety of options

ailure overhaul options available. Consult with

California Proposition 65 Warning

Diesel engine exhaust and some of its c onstituents
are known to the State of California to cause cancer,

defects, and other reproductive harm. Battery

birth
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.

SEBU8190 5

Safety Section

Safety Messages

Safety Section

i02409464

Safety Messages

Illustration 1

Typical example

(1) E ngine Derate (2) Universal warning (3) Engine Oil Level

There may be several specific warning signs on your
engine. The exact location and a description of the
warning signs are reviewed in this section. Please
become familiar with all warning signs.

Ensure that all of the warning signs are legible. Clean
the warning signs or replace the warning signs if
the words cannot be read or if the illustrations are
not visible. Use a cloth, water, and soap to clean
the warning signs. Do not use solvents, gasoline, or
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
warning signs. The warning signs that are loosened
could drop off of the engine.

Replace any warning sign that is damaged or
missing. If a warning sign is attached to a part of the
engine that is replaced, install a new warning sign on
the replacement part. Your Perkins dealer or your
distributor can provide new warning signs.

The safety messages that may be attached on the
engine are illustrated .

g01269446

6 SEBU8190
Safety Section
Safety Messages

(1) Engine Derate

Illustration 2

Typical example

The warning label for derating engine information (1)
is located on the governor control unit. The governor
control unit is located on the right hand side of the
engine.

(2) Universal Warning

Do not operate or work on this equipment unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.

g01241021

The Universal Warning label (2) is located on the
fuse box for the ignition system. The fuse box for
the ignition system is located on the right hand side
of the engine.

Illustration 3

Typical example

g01234595

SEBU8190 7

Safety Section

General Hazard Information

(3) Engine Oil Level

Illustration 4

Typical example

The warning label for checking the engine oil Level
(3) is located on the inlet manifold. The inlet manifold
islocatedontherighthandsideoftheengine.

i02414560

General Hazard Information

Illustration 5

Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine
is repaired.

g00104545

g01241033

Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.

Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.

Filler caps

•

Grease fittings

•

Pressure taps

•

Breathers

•

Drain plugs

•

Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.

Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.

8 SEBU8190
Safety Section
General Hazard Information

Pressure Air and Water

Illustration 6

Wear a hard hat, protective glasses, and other

•

protective equipment, as required.

When work is performed around an engine that is

•

operating, wear protective devices for ears in order
to help prevent damage to hearing.

Do not wear loose clothing or jewelry that can snag

•

on controls or on other parts of the engine.

Ensure that all protective guards and all covers are

•

securedinplaceontheengine.

g00702020

Pressurized ai
and/or hot water to be blown out. This could result in
personal injury.

When pressure air and/or pressure water is used for
cleaning, wear protective clothing, protective shoes,
and eye prote
oraprotectivefaceshield.

The maximum a
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 ps

Fluid Penetr

r and/or water can cause debris

ction. Eye protection includes goggles

ir pressure for cleaning purposes

i).

ation

Never put maintenance fluids into glass containers.

•

Glass containers can break.

Use all cleaning solutions with care.

•

Report all necessary repairs.

•

Unless other instructions are provided, perform
the maintenance under the following conditions:

The engine is stopped. Ensure that the engine

•

cannot be started.

Disconnect the batteries when maintenance

•

is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.

Do not attempt any repairs that are not understood.

•

Use the proper tools. Replace any equipment that
is damaged or repair the equipment.

If work is carried out on the fuel system obey the

•

local regulations for isolation of the gas supply.

California Proposition 6 5 Warning

Some constituents of engine exhaust are known to
the State of California to cause cancer, birth defects,
and other reproductive harm.

Illustration 7

Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.

g00687600

Containing Fluid Spillage

Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.

Tools that are suitable for collecting fluids and

•

equipment that is suitable for collecting fluids

Tools that are suitable for containing fluids and

•

equipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

SEBU8190 9

Safety Section

Burn Prevention

Dispose of Waste Properly

Illustration 8

Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed o

Always use leakproof containers when you drain
fluids. Do
drain, or into any source of water.

f according to local regulations.

not pour waste onto the ground, down a

g00706404

i02414602

Burn Prevention

Oils

Hot oil and hot lubricating components can cause
personal injury . Do not allow hot oil or hot components
to contact the skin.

If the application has a makeup tank, remove the cap
for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.

Batteries

The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolytetocontacttheskinortheeyes.

Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.

Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.

i02415237

Fire Prevention and Explosion
Preventio

n

Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure in
the appropriate system before any lines, fittings or
related items are disconnected.

Coolant

When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator, the heat exchanger, the
heater and lines contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns.
Allow cooling system components to cool before the
cooling system is drained.

Check the coolant level after the engine has stopped
and the engine has been allowed to cool. Ensure
that the filler cap is cool before removing the filler
cap. The filler cap must be cool enough to touch with
a bare hand. Remove the filler cap slowly in order
to relieve pressure.

Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.

Illustration 9

All fuels, most lubricants, and some c oolant mixtures
are flammable.

Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.

A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
an emergency shutdown.

g00704000

10 SEBU8190
Safety Section
Fire Prevention and Explosion Prevention

Determine whet
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engi
property damage, or engine damage could result.

If the applic
gases, consult your Perkins dealer for additional
information about suitable protection devices. All
local regula

Remove all flammable materials such as fuel, oil, and
debris from t
materials to accumulate on the engine.

Store fuels a
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers
storing flammable materials.

Do not expo

Exhaust shields (if equipped) protect hot exhaust
component
a hose, or a seal failure. Exhaust shields must be
installed correctly.

Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines that contain flammable
fluid. Cle
nonflammable solvent prior to welding or flame
cutting.

Wiring must be kept in good condition. All electrical
wires must be properly routed and securely attached.
Check all
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all elec

Eliminate all wiring that is unattached or unnecessary.
Do not us
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.

Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintai
or sparking.

Inspec
deterioration. The hoses must be properly routed.
The lines and hoses must have adequate support
and sec
recommended torque. Leaks can cause fires.

Oil fil
The filter housings must be tightened to the proper
torque.

trical connections.

ned battery cables will help to prevent arcing

t all lines and hoses for wear or for

ure clamps. Tighten all connections to the

ters and fuel filters must be properly installed.

her the engine will be operated in an

ne to overspeed. Personal injury,

ation involves the presence of combustible

tions must be observed.

he engine. Do not allow any flammable

nd lubricants in properly marked

. Do not smoke in areas that are used for

setheenginetoanyflame.

s from oil or fuel spray in case of a line,

an any such lines thoroughly with a

electrical wires daily. Repair any wires

e any wires or cables that are s maller than

Illustration 10

Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.

Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
ahydrometer.

Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.

Do not charge a frozen battery. This may cause an
explosion.

The batteries must be kept clean. The covers
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.

g00704135

Fire Extinguisher

Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

Lines, Tubes and Hoses

Donotbendhighpressurelines.Donotstrikehigh
pressure lines. Do not install any lines that are bent
or damaged.

SEBU8190 11

Safety Section

Crushing Prevention and Cutting Prevention

Repair any line
can cause fires. Consult your Perkins dealer for
repair or for replacement parts.

Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to
to the recommended torque.

Replace the p
are present:

End fittings

•

Outer coverings are chafed or cut.

•

Wires are exposed.

•

Outer coveri

•

Flexible part of the hoses are kinked.

•

Outer covers have embedded armoring.

•

End fittings

•

Make sure that all clamps, guards, and heat shields
are installe
will help to prevent vibration, rubbing against other
parts, and excessive heat.

s that are loose or damaged. Leaks

check for leaks. Tighten all connections

arts if any of the following conditions

are damaged or leaking.

ngs are ballooning.

are displaced.

d correctly. During engine operation, this

i02143194

i02453744

Mounting and Dismounting

The steps or han
engine. Refer to the OEM for information before any
maintenance or repair is performed.

Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these

Mount the engine and dismount the engine only at
locations th
climb on the engine, and do not jump off the engine.

Face the engi
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use o
controls as handholds.

Do not stand
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment w

Do not carry tools or supplies when you mount the
engine or w
line to raise and lower tools or supplies.

dholds may not be installed on the

items in good repair.

at have steps and/or handholds. Do not

ne in order to mount the engine or

ne foot and two hands. Do not use any

on components which cannot support

ill not move.

hen you dismount the engine. Use a hand

Crushing Prevention and
Cutting Prevention

Support th
the component is performed.

Unless oth
never attempt adjustments while the engine is
running.

Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is perfor
reinstall the guards.

Keep obje
blades will throw objects or cut objects.

When obje
order to avoid injury to the eyes.

Chips or o
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.

e component correctly when work beneath

er maintenance instructions are provided,

med. After the maintenance is performed,

cts away from moving fan blades. The fan

cts are struck, wear protective glasses in

ther debris may fly off objects when objects

i02415253

Ignition

Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and
wiring.

Systems

i02453806

Before Starting Engine

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.

Ensure that the engine is equipped with a lighting
system that is suitable for the conditions. Ensure that
all lights work properly.

12 SEBU8190
Safety Section
Engine Starting

All protective
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that
around the parts carefully.

Do not bypass
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are
engine damage.

The initial s
has been serviced make provision to shut the engine
off, in order to stop an overspeed. This may be
accomplish
engine, or shutting off the ignition system.

Engine Star

If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the contro
thewarningtagbeforetheengineisstarted.

guards and all protective covers must

is caused by parts in rotation, work

the automatic shutoff circuits. Do not

also provided in order to help prevent

tart-up of a new engine or a engine that

ed by shutting off the fuel supply to the

i02426322

ting

ls. Consult with the person that attached

i00659907

Engine Stopping

To avoid overhe
wear of the engine components, stop the engine
according to the instructions in this Operation and
Maintenance M
(Operation Section).

Use the Emerge
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency st
problem that caused the emergency stop has been
corrected.

On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop
the engine i
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.

ating of the engine and accelerated

anual, “Engine Stopping” topic

ncy Stop Button (if equipped) ONLY

op, DO NOT start the engine until the

f an overspeed occurs. This may be

i02436641

Electrical System

All protec
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident
around the parts carefully.

If there i
the exhaust system, refer to the purge procedure in
this Operation and Maintenance Manual, “Engine
Starting

Always start the engine according to the procedure
that is de
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent
Knowing the procedure will also help to prevent
personal injury.

To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
proper
temperature during heater operation.

Engine
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. I
vent the engine exhaust to the outside.

tive guards and all protective covers must

that is caused by parts in rotation, work

s a possibility that unburned gas remains in

” topic in the Operation Section.

scribed in the Operation and Maintenance

major damage to the engine components.

ly , check the water temperature and the oil

exhaust contains products of combustion

f the engine is started in an enclosed area,

Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible
gases that are produced by some batteries, the
negative “í” cable should be connected last from the
external power source to the negative “í” terminal
of the starting motor. If the starting motor is not
equipped with a negative “í” terminal, connect the
cabletotheengineblock.

Check the electrical wires daily for wires that
are loose or frayed. Tighten all loose electrical
connections before the engine is started. Repair all
frayed electrical wires before the engine is started.
See the Operation and Maintenance Manual for
specific starting instructions.

Grounding Practices

Note: All ground lines must return to the battery

ground.

SEBU8190 13

Safety Section

Electrical System

Illustration 11

Typical example

(1) Starting motor to ground
(2) Battery negative to engine

g01217202

Correct grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Incorrect grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.

Uncontrolled electrical circuit paths can result in
damage to the crankshaft bearing journal surfaces
and to aluminum components.

The connections for the grounds should be tight and
free of corrosion. The engine alternator must be
grounded to the negative “-” battery terminal with
a wire that is adequate to handle the full charging
current of the alternator.

The power supply connections and the ground
connections for the engine electronics should always
be from the isolator to the battery.

14 SEBU8190
Product Information Section
Model Views and Specifications

Product Information
Section

Model Views and
Specifications

i02415298

Model View Illustrations

The illustrations show various typical features of
4000 Series TRS Engine. The illustrations do not
show all of the options that are available.

SEBU8190 15

Product Information Section

Model Views and Specifications

Illustration 1 2

Typical example

(1) Air filter
(2) Governor control unit
(3) Fuses for the ignition system
(4) Ignition

(5) Water temperature regulator
(6) O il filler cap
(7) Alternator
(8) Oil level gauge (dipstick)

g01207301

(9) Engine oil filters
(10) Relay
(11) Starting motor
(12) Charge air cooler

16 SEBU8190
Product Information Section
Model Views and Specifications

Illustration 1 3

Typical example

(13) Ignition coil
(14) Zero pressure regulator
(15) Turbocharger

(16) Closed breather system
(17) The inspection cover for the Crankcase
(18) Drain plug

i02430841

Product Description

The Perkins Engines were developed in order to
provide gas engines for generator set applications.
The engines have the ability to burn a wide variety of
gaseous fuels.

Fuel System

The fuel is delivered to the zero pressure regulator.
The gas must be at a constant pressure and the gas
must be stable. The pressure must be within a range
of1.5to5kPa(0.21to0.72psi).Higherpressurewill
need to be reduced with an additional gas regulator.

g01215253

(19) Secondary water pump

The venturi must be selected for the engine. This
selection is based on the composition of the gas that
will be used.

Any change in the composition of the gas may require
a change to the venturi.

Theventuriislocatedinthegasmixerbody
immediately before the turbocharger. As air is
accelerated through the venturi gas is mixed with the
air. This mixture is compressed by the turbocharger.
the mixture passes through the charge cooler and
into the inlet manifold. The speed and the load is
governed by an electronically controlled throttle valve.

The air/fuel ratio is adjustable by the main adjustment
screw. This screw is located on the gas mixer body
before the venturi. This is the only means of adjusting
the exhaust emissions at full load.

SEBU8190 17

Product Information Section

Model Views and Specifications

Ignition System

The engine is equipped with an Electronic Ignition
System (EIS). The EIS provides dependable firing
and low maintenance. The EIS provides precise
control of the following factors:

Voltage

•

Duration of the spark

•

Ignition timing

•

The TRS2 engine is equipped with protection from
detonation. The TRS1 engine may be equipped with
protection for detonation as an option.

The ignition timing is retarded when excessive
detonation is sensed. If detonation continues after full
retardation, then the engine must be shut down.

Lubrication System

The engine lubrication oil is supplied by a pump
that is driven by a gear. The oil is cooled and the
oil is filtered. A bypass valve provides unrestricted
flow of lubrication oil to the engine parts if the
oil filter elements become plugged. The bypass
valve will open if the oil filter differential pressure
reaches 34.4 to 48.2 kPa (5 to 7 psi). The engine oil
pressure operates in a range of 413.6 to 448.1 kPa
(60to65psi).

Battery chargi

•

The system is used when recovery of heat is not an
important fac

Cogeneration

Cogeneration uses energy from heat which would
otherwisebew

The following items are not supplied:

Water pumps

•

Water tempera

•

All water tube assemblies

•

This system is the responsibility of the OEM.

ng alternator

tor.

engine

asted.

ture regulator ( thermostat)

Engine Service Life

Engine effic
performance depend on adherence to proper
operation and maintenance recommendations. This
includes the
and coolants.

For the engin
refer to the Operation and Maintenance Manual,
“Maintenance Interval Schedule” in the Maintenance
Section.

iency and maximum utilization of engine

use of recommended lubricants, fuels,

e maintenance that is required,

Note: The engine lubrication oil is not filtered when
the bypass valve is open. Do not allow the engine
to operate when the bypass valve is open. This can
damage the engine components.

Cooling System

The water enters the engine from the oil cooler and
the water is passed through the cylinder block. The
water exits the cylinder head into the rail. The water
exits the engine from the water outlet.

Electrounit

This type of engine is supplied with the following
components:

Jacket water coolant pump

•

Water temperature regulator (thermostat)

•

Coolant pipe for the charge cooler

•

A water pump for the charge cooler

•

A water temperature regulator (thermostat) that

•

controls the system for the charge cooler

Specificat

ions

General Engine Specifications

Illustration 14

Six c ylinder

(A) Inlet v a lves
(B) E xhaus t valves

i02415458

g01216853

18 SEBU8190
Product Information Section
Model Views and Specifications

Table 1

4006 Engine Specifications

Rated rpm 1500

Cylinders and arrangement In-line six cylinders

Bore 160 mm (6.2992 inch)

Stroke 190 mm (7.4803 inch)

Displacement

Compression ratio

Aspiration Turbocharged

Rotation (flywheel end) Counterclockwise

Inlet valve lash (cold) 0.40 mm (0.0157 inch)

Exhaust valve lash (cold) 0.40 mm (0.0157 inch)

Firing order 1,5,3,6,2,4

22.9 L (1397.4436 in3)

12:1

Illustration 15

Eight cylinder

(A) Inlet valves
(B) Exhaust valves

Table 2

g01207434

4008 Engine Specifications

Rated rpm 1500

Cylinders and arrangement

Bore

In-line eight cylinder

160 mm (6.2992 inch)

Stroke 190 mm (7.4803 inch)

Displacement

30.56 L

(1864.8855 in

Compression ratio 12:1

Aspiration Turbocharged

ion (flywheel end)

Rotat

Count

erclockwise

Inlet valve lash (cold) 0.40 mm (0.0157 inch)

Exhaust valve lash (cold) 0.40 mm (0.0157 inch)

ng order

Firi

7,6,8,5,2,3

1,4,

3

)

SEBU8190 19

Product Information Section

Model Views and Specifications

Piston Positions for Valve Lash
Setting

Table 3

The six cylinder engine

Table 4

Top Center Position

1-6 6 1

2-5 2 5

3-4 4 3

1-6 1 6

2-5 5 2

3-4 3 4

Top Center Position

1-8 8 1

4-5 5 4

2-7 2 7

3-6 3 6

1-8 1 8

4-5 4 5

2-7 7 2

3-6 6 3

Engine cylinder with valves

on the rock

The eight cylinder engine

Engine cylinder with valves

on the rock

Set the bridge adjustment and

set valve lash.

Set the bridge adjustment and

set valve lash.

20 SEBU8190
Product Information Section
Product Identification Information

Product Identification
Information

i02531889

Plate Locations and Film
Locations

Engine Identification

Perkins engines are identified by an engine serial
number.

A typical example of an engine serial number is
DGE F**** U00001M.

_________________________________________ MadeinStafford

D

G

____________________________________ Application (Table 5)

E

________________________________Type of engine (Table 6)

Perkins dealer
these numbers in order to determine the components
that were included in the engine. This permits
accurate iden

Serial Number

s and Perkins distributors require all of

tification of replacement part numbers.

Plate

_________________________ Number of cylinders (Table 7)

F

*****

_________________________________ _ Fixed build number

U

____________________________Built in the United Kingdom

00001

M

Table 5

Table 6

____________________________________Engine Number

____________________________________ Year of Manufacture

Application

G Genset

I

F TESI Gas Unit

E TESI Combined Heat and Power Unit

G 4016-E61 TRS

H

J

Gas

Type of engine (Gas)

TRS Combined Heat and Power Unit

TRS Gas Unit

Illustration 16

Serial number plate

The engine serial number plate contains the following
information:

Place of manufacture

•

Telephone number of manufacturer

•

Fax number of manufacturer

•

Type of engine

•

Engine serial number

•

Rated speed

•

Power output

•

Engine timing

•

Rating

•

g01266904

Table 7

Number of Cylinders

F 6

H 8

SEBU8190 21

Product Information Section

Product Identification Information

Illustration 17

Location of the serial number plate for in-line engines

g01212991

The serial number plate (1) on an in-line engine is
located on the right side of the cylinder block. See
Illustration 17.

22 SEBU8190
Operation Section
Lifting and Storage

Operation Section

Lifting and Storage

Product Lifting

i02427136

Some removals r
obtain proper balance and safety.

To remove the e
are on the engine.

Lifting eyes a
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obs
that proper lifting devices are provided. Consult your
Perkins dealer for information regarding fixtures for
proper engin

equire lifting fixtures in order to

ngine ONLY, use the lifting eyes that

re designed and installed for the specific

olete. If alterations are made, ensure

elifting.

i02427139

Product Storage

Refer to Perkins Engine Company limited, Stafford
for information on engine storage.

There is three different levels of engine storage.
Level “A, B and C”.

Illustration 18

Typical example

NOTICE
Never ben
the eyebolts and the brackets under tension. Remem­ber that the capacity of an eyebolt is less as the angle
between
comes less than 90 degrees.

When it i
angle, only use a link bracket that is properly rated for
the weight.

d the eyebolts and the brackets. Only load

the supporting members and the object be-

s necessary to remove a component at an

g01203936

Level “A ”

Level “A” will give protection for six month for diesel
engines and protection for one year for gas engines.
This is for engines that are transported by a container
or a truck.

Level “B ”

This level is additional to level “A”. Level “B ” will
give protection under normal storage condition from
í15° to +55°C (5.0000° to 99.0000°F) and “90%”
relative humidity for one year.

Level “C ”

This level is additional to level “B”. Level “C” will give
protection for five year in tropical temperatures or
arctic climates. Level “C” also meets MOD NES 724
level “J” for europe, when engines are stored in a
unheated building or in the open under waterproof
covers.

Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
suppor
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted

ting members (chains and cables) should be

.

SEBU8190 23

Operation Section

Gauges and Indicators

Gauges and Indicators

i02427382

Gauges and Indicators

Your engine m
the gauges that are described. For more information
about the gauge package, see the OEM information.

Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine th
the gauges over a period of time.

Noticeable c
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if the r
Determine and correct the cause of any significant
change in the readings. Consult your Perkins dealer
or your Per

If no oil pressure is indicated, STOP the engine. If
maximum co
the engine. Engine damage can result.

ay not have the same gauges or all of

e normal operating range by observing

hanges in gauge readings indicate

eadings are within specifications.

kins distributor for assistance.

NOTICE

olant temperature is exceeded, STOP

Engine Oil

the engine oil pressure is 415 to 450 kPa
(60to65psi).

Pressure – The range for

Jacket Wat

Typical water temperature into the engine

is 71°C (160°F). Higher temperatures
may occur
temperature reading may vary according to load. The
reading should never exceed 96°C (204°F).

1. Ahighwat

cooling system.

indicator should be to the right side of “0” (zero).

under certain conditions. The water

er temperature switch is installed in the

Tachomet

speed (rpm).

Ammeter – This gauge indicates the

amount of charge or discharge in the

battery charging circuit. Operation of the

Service Hour Meter – The gauge indicates

operating hours of the engine.

er Coolant Temperature –

er – This gauge indicates engine

24 SEBU8190
Operation Section
Features and Controls

Features and Controls

i02427696

Performance Parameters

Air/Fuel Ratio

The correct air/fuel ratio is very important for the
following considerations:

Margin of detonation

•

Control of emissions

•

Achieving optimum service life for the engine

•

If the air/fuel ratio is not appropriate for the fuel and
the operating conditions, a failure of the engine may
occur. The service life of the turbocharger, the valves,
and other components may be reduced.

Fuel Supply Pressure and Temperature

The fuel supply for the zero pressure regulator
must be at a constant pressure of 1.5 to 5 kPa
(0.21to0.72psi).Ifahigherpressureisrequireda
separate gas regulator must be installed into the fuel
line.

The minimum temperature for the gas into ZPR is
5 °C (41.0 °F). The maximum temperature into the
ZPRis40°C(104.0°F).

Zero Gas Pressure Regulator

The zero gas pressure regulator is a control valve that
operates on demand. The pitot tube in the regulator
outlet controls the flow. As the air is drawn through
the venturi a depression is created. Gas at higher
pressure is drawn in. This is mixed into the air flow.
This mixture then passes through the turbocharger.
As the engine load increases the pressure at the
outlet of the ZPR is reduced and the valve opens
supplying more gas.

i02427718

Sensors and Electrical
Components

Electronic Ignition System (EIS)

The Electronic Ignition System includes the following
components:

The control module for the ignition

•

Timing sensor

•

Ignition coil on each cylinder

•

Spark plugs

•

Ignition har

•

The ignition system generates high voltage. Do
not come in contact with the ignition system with
the engine in
personal injury or death.

The EIS contr
serviceable parts. The timing sensor uses the
magnets that are mounted on the camshaft in order
to generate
cylinder plus an index magnet in order to indicate the
start of each cycle. The EIS control module has a
output to e
each cylinder, the EIS sends a pulse to the primary
winding of the ignition coil. The coil increases the
voltage on
spark across the spark plug electrode.

The electr
following activities:

Ignition t

•

Protection from detonation (if equipped)

•

ness

operation. This voltage can ca use

ol module is a sealed unit with no

thetimingpulses.Onepulseforeach

ach ignition coil. To initiate combustion in

the secondary winding which creates a

onic ignition system provides control for the

iming

Air, Charge Cooler Water
Temperature and Altitude

Refer to technical date sheet for the charts for
the derate in order to determine the maximum
temperatures into the engine and the altitude derate.

Switches

The engine is installed with the following switches.

High cool

•

Low oil pressure switch

•

Overspeed switch and magnetic pickup

•

High press

•

ing water temperature switch

ureswitchforthemanifold

SEBU8190 25

Operation Section

Features and Controls

Governor

The engine is installed with a digital governor that
includes the following components:

Digital governor

•

Actuator and throttle valve

•

Magnetic pickup

•

Wiring harness

•

The governor uses the magnetic pickup to sense
engine speed from the flywheel gear teeth. This
signal is fed into the governor, which drives an
actuator. This is connected to the throttle valve in
order to control the amount of combustion gas/air.

A Pandaros Packager service tool and cable are
required in order to make any adjustments to the
system.

Detonation System ( If Equipped)

The equipment for the detonation system is available
to sense detonation or knock which may be caused
by poor gas or may be caused by high combustion
temperatures.

The detonation system includes the following
components:

Detonation sensor on each cylinder

•

Control module for detonation

•

Wiring harness

•

The detonation system operates by measuring
vibrations on the crankcase. The signal is processed
in order to eliminate normal engine vibrations. If
detonation above a predetermined level is detected
the engine timing is retarded. If the engine continues
detonation the detonation system will operate in order
to stop the engine. If detonation ceases, the ignition
timing that is retarded will be gradually brought back
to a normal value.

i02427728

Alarms and Shutoffs

Engines may be e
protective devices that are not included in this section.
This section contains some general information about
thefunctiono

Alarms and shutoffs are electronically controlled.
The operatio
components which are actuated by a sensing unit.
The alarms and shutoffs are set at critical operating
temperature
protect the engine from damage.

The alarms fu
when an abnormal operating condition occurs. The
shutoffs function in order to shut down the engine
whenamorec
occurs. The shutoffs help to prevent damage to the
engine.

Shutoffs may cause unburned gas to remain in the
air inlet and in the exhaust manifold.

Unburned gas in the air inlet and exhaust system
may ignite
injury and/or property damage may result.

Before sta
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging u
section.

If an engi
always determine the cause of the shutoff. Make
the necessary repairs before attempting to start the
engine.

Become familiar with the following information:

Types of the alarm and shutoff controls

•

Location

•

Conditions which cause each control to function

•

Resetting procedure that is required before starting

•

the engine

rting an engine that may contain un-

nburned gas in the “Starting the Engine”

ne protective device shuts off the engine,

s of the alarm and shutoff controls

quipped with optional engine

f typical engine protective devices.

n of all alarms and shutoffs utilize

s, pressures, or speeds in order to

nction in order to warn the operator

ritical abnormal operating condition

when the engine is started. Personal

Testing Alarms and Shutoffs

The OEM will supply this system. Refer to the OEM
for more information.

Alarms must function properly in order to provide
timely warning to the operator. Shutoffs help to
prevent
to determine if the engine protective devices are
in good working order during normal operation.
Malfun
engine protective devices.

damage to the engine. It is impossible

ctions must be simulated in order to test the

26 SEBU8190
Operation Section
Features and Controls

NOTICE
During testing
simulated.

, abnormal operating conditions must be

The tests must b
vent possible damage to the engine.

Periodic test
proper operation is recommended maintenance. To

prevent damage to the engine, only authorized
service perso

e performed correctly in order to pre-

ingofengineprotectivedevicesfor

nnel should perform the tests.

i02452757

Control Panel

Refer to the O
that is installed.

EM for information on the control panel

SEBU8190 27

Operation Section

Engine Starting

Engine Starting

i02452805

Before Starting Engine

Before the en
daily maintenance and any other periodic
maintenance that is due. Refer to the Operation
and Maintena
Schedule” for more information.

For the maxim

•

thorough inspection within the engine compartment
before the engine is started. Look for the following
items: oil l
excessive dirt and/or grease. Remove any excess
dirt and/or grease buildup. Repair any faults that
were ident

Inspect the cooling system hoses for cracks and

•

for loose c

Inspect the alternator and accessory drive belts for

•

cracks, b r

Inspect the wiring for loose connections and for

•

worn wires

Open the fuel supply valve (if equipped).

•

Do not start the engine or move any of the controls

•

if there is a “DO NOT OPERATE” warning tag or
similar w
to the controls.

gine is started, perform the required

nce Manual, “Maintenance Interval

um service life of the engine, make a

eaks, coolant leaks, loose bolts, and

ified during the inspection.

lamps.

eaks, and other damage.

or frayed wires.

arning tag attached to the start switch or

If the engine is

•

maintain the coolant level within 13 mm (0.5 inch)
of the bottom of the filler pipe. If the engine is
equipped with
level in the sight glass.

Observe the a

•

the air cleaner when the diaphragm enters the red
zone, or when the red piston locks in the visible
position.

Remove any electrical loads.

•

not equipped with a header tank

a sight glass, maintain the coolant

ir cleaner service indicator. Service

i02427758

Cold Weather Starting

A jacket water heater is required for starting when the
temperature is below 10 °C (50 °F). The temperature
of the jacket water should be maintained at 40 °C
(104 °F).

Note: A oil pan immersion heater must not be
installed.

Extra battery capacity may be necessary in order to
start the engine.

Consult your Perkins dealer for more information on
the starting aids that are available for cold weather
starting.

i02427781

Starting

the Engine

Ensure th

•

clear.

All of the

•

damaged guards or for missing guards. Repair
any damaged guards. Replace damaged guards
and/or m

Check electrical cables and check the battery for

•

poor con

Reset all of the shutoffs or alarm components (if

•

equippe

Check the engine lubrication oil level. Maintain the

•

oil leve
mark on the engine oil level gauge.

Check th

•

in the header tank (if equipped). Maintain the
coolant level to the “FULL” mark on the header
tank.

at the areas around the rotating parts are

guards must be put in place. Check for

issing guards.

nections and for corrosion.

d).

l between the “ADD” mark and the “FULL”

e coolant level. Observe the coolant level

Engine exhaust contains products of combustion
which may
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside

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
fuel supply and/or the ignition to the engine.

be harmful to your health. Always start

.

NOTICE

28 SEBU8190
Operation Section
Engine Starting

Purging Unburned Gas

Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal
injury and/or property damage may result.

Before starting an engine that may contain un­burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.

The OEM will supply this system. Refer to the OEM
for more information.

Note: Using the “EMERGENCY STOP” button will
shut off both the fuel and the ignition.

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.

Ensure that no one will be endangered before the
engine is started and when the engine is started.

Perform the procedures that are described in this
Operation and Maintenance Manual, “Before Starting
Engine” (Operation Section).

The following events cause unburned gas to remain
in the air inlet and in the exhaust manifold:

Emergency stop

•

Engine overspeed

•

Unsuccessful successive attempts to start the

•

engine

Unburned gas may remain in the air inlet and exhaust
system after several unsuccessful attempts to start
the engine. The unburned gas may increase to a
concentration that may ignite during a successive
attempt to start the engine.

Perform the following procedure in order to purge
the unburned gas:

1. Turn the manual gas shutoff valve to the CLOSED

position.

2. Disable the ignition system. Remove the fuses

from the ignition.

3. Turn the engine control switch to the START

position. Crank the engine for a minimum of six
seconds.

Final Checks and First Engine Start

Note: The fuel system must comply with all local

regulations.

The OEM will supply this system. Refer to the OEM
for more information.

1. The starting and the stopping of the engine must

be on no load.

2. The procedure for starting and stopping a radiator

cooled and CHP gas engine will be determined
by the OEM relative to each individual engine
installation.

3. Operate the engine at rated speed for ten minutes.

4. Inspect the engine for leaks in the oil system and

the coolant systems.

5. Stop the engine and check the engine oil and the

engine coolant level.

6. Operate the engine under normal working

conditions. Check the gauges in order to see the
condition of the engine.

7. If the engine fails to start after two attempts turn

off the gas supply and investigate the cause.

4. Enable the ignition by connecting the fuses that

was disconnected in Step 2.

5. Turn the manual gas shutoff valve to the OPEN

position.

6. Start the engine. Refer to the engine starting

procedure and refer to OEM in order to start the
engine.

Engine Starting Procedure

Note: The starting procedure may differ because of

the OEM system that is installed.

1. The signal is received.

2. Check that the gas pressure is in limits. If the gas

pressure is incorrect a warning is activated and
the electrical system will shut down. If the gas
pressure is in limits, go to the next step.

3. Activate the governor.

4. Activate the starter.

5. Operate the engine for three seconds in order to

purge the system.

SEBU8190 29

Operation Section

Engine Starting

6. Activate the ga

Continue to operate the starter.

1. After the engi

Note: If the engine fails to start after the maximum

cranking time

2. The engine is now operating.

s valve and activate the ignition.

ne is started disengage the starter.

, the engine will be shut down.

Operation o f the Generator Set
Control Panel

For informati
set control panel, refer to the Operation and
Maintenance Manual for the generator and the
control pane

Automatic St

When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid personal
injury, alw
the engine is in the AUTOMATIC mode.

on on operation for a specific generator

l.

arting

ays remain clear of the the engine when

Manual starting

Refer to the
controls in order to manually start the engine.

OEM manual for information on the

i02428473

Starting with Jump Start
Cables

Do not use jump start cables in order to start the
engine. Charge the batteries or replace the batteries.
Refer to Operation and Maintenance Manual,
“Battery - Replace”.

i024285

After Starting Engine

For new in
rebuilt, carefully monitor the engine in order to detect
any unusual engine performance.

stallations and engines that are recently

29

Check for leaks in the air and in the fluid systems.

30 SEBU8190
Operation Section
Engine Operation

Engine Operation

i02428569

Engine Operation

Proper opera
attaining the maximum service life and economy for
the engine. Follow the instructions in this Operation
and Maintena
operatingcostsandmaximizetheservicelifeofthe
engine.

Observe the gauges frequently while the engine is
operating. Record the data from the gauges in a log
regularly.
for normal engine operation. Comparing the data
over time will help to detect changes in engine
performan

Investigate any significant change in the gauge
readings.
action when discrepancies are found.

tion and maintenance are key factors in

nce Manual in order to minimize

Compare the data to the specifications

ce.

Monitor the engine operation and take

Partial load and Low Load
Operation

Extended operation at low load or reduced load will
cause the f

Carbon formation in the cylinder

•

ollowing results:

Detonation

•

Power los

•

Poor performance

•

Accelerated wear of components

•

Increase

•

The cylinder bore to glaze

•

s

d oil consumption

SEBU8190 31

Operation Section

Engine Stopping

Engine Stopping

i02428635

Emergency Stopping

The OEM will s

Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT us
controls for normal stopping procedure.

Pressing the
unburned gas to remain in the air inlet and in the
exhaust manifold.

Unburned gas in the air inlet and exhaust system
may ignite w
injury and/or property damage may result.

Before star
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unb
section.

upply the system.

NOTICE

e emergency shutoff devices or

Emergency Stop Button may cause

hen the engine is started. Personal

ting an engine that may contain un-

urned gas in the “Starting the Engine”

2. With the engine

and switch off the governor.

3. If an overspee

gas valve and the governor..

4. If another eng

valve.

stopped, switch off the ignition

d occurs, switch off the ignition, the

ine fault occurs switch off the gas

i02453745

Manual Stop Procedure

In order to manually stop the engine, refer to the
OEM for infor
the system that has been installed.

Stopping the
been operating under a load can result in overheating
and accelerated wear of the engine components.

Allow the engine to gradually cool before stopping the
engine.

mation. The procedure will depend on

NOTICE

engine immediately after the engine has

The emergen
for normal engine operation. Push the button for
emergency stopping. This shuts off both the fuel
and the ign
button is locked. To reset the button, turn the button
clockwise. The spring-loaded button will return to the
OUT posit

Do not use this method to stop the engine unless
an emergency has occurred. Continuous emergency
shutdownscancausedamagetosomeenginecom­ponents. This will leave unburned fuels in the combus­tion chambers and in the exhaust system. If an emer­gency shutdown occurs, purge the system by cranking
the engine for 5 to 10 seconds with the ignition shutoff.

cy stop button is in the OUT position

ition. The engine will not start when the

ion.

NOTICE

Typical Procedure in Order to Stop
the Engine

Note: The stopping procedure will differ because

of the different types of OEM controls that can be
installed.

1. In order to stop the engine, switch off the gas

valve.

32 SEBU8190
Operation Section
Engine Stopping

i02508920

After Stopping Engine

Check the engin

•

the oil level between the “ADD” and “FULL” marks
on the “ENGINE STOPPED” side of the oil level
gauge.

If necessary, perform minor adjustments. Repair

•

any leaks and t

Note the service hour reading. Perform the

•

maintenance
and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section).

Only use antifreeze/coolant mixtures recommended in
the Refill Capacities and Recommendations section of
this manual.
age.

Allow the en

•

If freezing temperatures are expected, check the

•

coolant for
system must be protected against freezing to the
lowest expected outside temperature. Add the
proper cool

e crankcase oil level. Maintain

ighten loose bolts.

that is scheduled in this Operation

NOTICE

Failure to do so can cause engine dam-

gine to cool. Check the coolant level.

protection against freezing. The cooling

ant/water mixture, if necessary.

Perform all required periodic maintenance on all

•

driven equ
provided by the OEM of the driven equipment.

ipment. Refer to the instructions that are

SEBU8190 33

Maintenance Section

Refill Capacities

Maintenance Section

Refill Capacities

i02478642

Refill Capacities

Lubrication System

The refill capacities for the engine crankcase reflect
the approximate capacity of the crankcase or sump
plus standard oil filters. Auxiliary oil filter systems will
require additional oil. Refer to the OEM specifications
for the capacity of the auxiliary oil filter. Refer to this
Manual, “Maintenance Section” for more information
on fluid recommendations.

TRS 4006

Table 8

TRS 4006

Refill Capacities

Compartment or System Liters Quarts

Crankcase Oil Sump

Total Lubrication System

(1)

These values are the approximate capacities for the crankcase
oil sump which includes the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil
filter.

(2)

The Total Lubrication System includes the capacity for the
Crankcase Oil Sump plus the capacity of factory installed oil
filters and other filters added to the lubrication system. Enter
the value for the capacity of the Total Lubrication Sy stem in
this row.

TRS 4008

Table 9

Compartment or System Liters Quarts

Crankcase Oil Sump

Total Lubrication System

(1)

These values are the approximate capacities for the crankcase
oil sump which includes the standard factory installed oil filters.
Engines with auxiliary oil filters will require additional oil. Refer
to the OEM specifications for the capacity of the auxiliary oil
filter.

(2)

The Total Lubrication System includes the capacity for the
Crankcase Oil Sump plus the capacity of factory installed oil
filters and other filters added to the lubrication system. Enter
the value for the capacity of the Total Lubrication Sy stem in
this row.

(1)

(2)

122.7 129.6

TRS 4008

Refill Capacities

(1)

(2)

166.6 176

Cooling System

To maintain the cooling system, the Total Cooling
System capacity must be known. The approximate
capacity is for the engine cooling system. External
System capacities will vary among applications.
Refer to the OEM specifications for the External
System capacity. This capacity information will be
needed in order to determine the amount of coolant
that is required for the Total Cooling System.

TRS 4006

Table 10

TRS 4006

Refill Capacities

Compartment or System Liters Quarts

Engine bloc

External System Per OEM

Total Cooling System

(1)

The E xternal System includes a radiator or an expansion
tank with the following components: heat exchanger and
piping. Refer to the OEM specifications. Enter the value for the
capacity of the External System in this row.

(2)

he Total Cooling System capacity includes the capacity of

T
he Engine plus the External System. Enter the value for the

t

apacity of the Total Cooling System in this row.

c

TRS 4008

able 11

T

Compartment or System Liters Quarts

Engine block only 48 64.4

External System Per OEM

Total Cooling System

(1)

The E xternal System includes a radiator or an expansion
tank with the following components: heat exchanger and
piping. Refer to the OEM specifications. Enter the value for the
capacity of the External System in this row.

(2)

The Total Cooling System capacity includes the capacity of
the Engine plus the External System. Enter the value for the
capacity of the Total Cooling System in this row.

k only

Refill Capacities

36 42.3

(1)

(2)

TRS 4008

(1)

(2)

34 SEBU8190
Maintenance Section
Refill Capacities

i02481783

Fluid Recommendations

General Lubricant Information

Engine Oil

The engine oil recommendation for an application
can change due
of the oil. Refer to Perkins Engines Stafford for the
latest information.

Multigrade oils must not be used.

Recommendati

Engines that operate on natural gas should be
lubricated b
of 0.5% by weight. The total base number must be
between 5 and 7. The following SAE40 monograde
engine oils

Mobil Pegasus 705

•

Texaco/Caltex Geotex LA

•

Q8 Mahler MA

•

Castrol Duratec L

•

The oil change interval for Mobil Pegasus HPC40

•

is up to 2000 hours. Use scheduled oil analysis in
order to det

Mobil Pegasus 805

•

BP Energas NGL

•

Shell Mysel

•

Total Nateria MH40

•

Chevron HPLX low ash

•

to advances in the specification

on

y oils that have a nominal ash content

comply:

ermine the oil change interval.

la LA

Oil analysis

The oil analysis will complement the preventive
maintenance p

The oil analysis is a diagnostic tool that is used to
determine oil
rates. Contamination can be identified and measured
through the use of the oil analysis. The oil analysis
includes the

The Wear Rate Analysis monitors the wear of the

•

engine’s met
type of wear metal that is in the oil is analyzed. The
increase in the rate of engine wear metal in the
oil is as impo
metal in the oil.

Tests are co

•

contamination of the oil by water, glycol or fuel.

The Oil Cond

•

the oil’s lubricating properties. An infrared analysis
is used to compare the properties of new oil to the
propertie
allows technicians to determine the amount of
deterioration of the oil during use. This analysis
also allow
of the oil according to the specification during the
entire oil change interval.

rogram.

performance and component wear

following tests:

als. The amount of wear metal and

rtant as the quantity of engine wear

nducted in order to detect

ition Analysis determines the loss of

s of the used oil sample. This analysis

s technicians to verify the performance

Fuel Specification

A new engin
that conforms to the British natural gas specifications.
Refer to Perkins Engines Stafford in order to use a
differen

Cooling S

e is set to operate with clean natural gas

t specification of gas.

ystem Specifications

General Coolant Information

NOTICE
Never add coolant to an overheated engine. Engine
damage could result. Allow the engine to cool first.

Chevron/Ca

•

The oil has a lower total base number than the
recommended minimum value. The additive will
give the eq

The oil change interval for any of the oils must be

•

approved b

Engines which operate on landfill gas must use

•

the oil tha
Engines Stafford. These oils have a higher ash
content.

ltex HDAX 0% and 0.5% sulfated ash.

uivalent performance.

y Perkins Engines Stafford.

t is currently recommended by Perkins

NOTICE
If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be ei
ature or drained completely to prevent damage.

Frequently check the specific gravity of the coolant for
proper freeze protection or for anti-boil protection.

Clean the cooling system for the following reasons:

ther protected to the lowest outside temper-

NOTICE

SEBU8190 35

Maintenance Section

Refill Capacities

Contamination

•

Overheating of the engine

•

Foaming of the coolant

•

Never operate
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operat
lems can develop without water temperature regula­tors.

Many engine fa
system. The following problems are related to cooling
system failures: Overheating, leakage of the water
pump, and plu

These failures can be avoided with correct cooling
system maint
as important as maintenance of the fuel system and
the lubrication system. Quality of the coolant is as
important a
oil.

of the cooling system

NOTICE

an engine without water temperature

ing temperature. Cooling system prob-

ilures are related to the cooling

gged radiators or heat exchangers.

enance. Cooling system maintenance is

s the quality of the fuel and the lubricating

Use 21825735 po
systems that operate in temperatures above 10 °C
(50 °F). This cooling system must use clean soft
water.

21825735 powerpart innibitor can be used in
systems that

Refer to Perkins Engines Stafford for the correct
coolant for y
will damage the cooling system.

our cooling system. The incorrect coolant

werpart inhibitor for cooling

use combined heat and power.

Coolant is n
Water, additives, and glycol.

ormally composed of three elements:

Water

Water is used in the cooling system in order to
transfer he

Distilled water or deionized water is
recommend

DO NOT use the following types of water in cooling
systems: H
conditioned with salt, and sea water.

For a water
sources:

Local wate

•

Agricultural agent

•

Independent laboratory

•

Coolant R

at.

ed for use in engine cooling systems.

ard water, softened water that has been

analysis, consult one of the following

r utility company

ecommendations

Use 50 percent ethylene glycol and 50 percent clean
soft wate
percent propylene glycol and 50 percent clean soft
water in the cooling system. Also use an inhibitor in
the cooli

rinthecoolingsystem.Youcanuse50

ng system.

36 SEBU8190
Maintenance Section
Maintenance Interval Schedule

i02451168

Maintenance Interval Schedule

When Required

Battery - Replace .................................................. 39

Cooling System Coolant - Change ....................... 40

Engine Air Prec

Engine Oil - Change ............................................. 48

Engine Oil Filter (Auxiliary) - Change ................... 48

Engine Oil Filt

Fuel Filtration System - Service ............................ 54

Ignition System Timing - Check/Adjust ................. 57

Overhaul (In-Fr

Overhaul (Major) ................................................... 59

Overhaul (Top End) ............................................... 60

Overhaul Conside

Radiator - Clean .................................................... 61

Water Temperature Regulator - Replace .............. 62

Daily

Alternator and Fan Belts - Inspect ........................ 37

Control Panel - In

Cooling System Coolant Level - Check ................ 42

Driven Equipment - Inspect/Replace/Lubricate ... 44
Engine Air Cleane

Engine Oil Level - Check ...................................... 49

Engine Protective Devices - Check ...................... 51

Exhaust Piping - In
Fuel System Fuel Filter Differential Pressure -

Check .................................................................. 54

Hoses and Clamps -

Walk-Around Inspection ........................................ 61

Initial 100 Service Hours

Alternator Pulley - Check ...................................... 38

Fan Drive Pulley - Check ...................................... 54

leaner - Clean .............................. 46

er - Change .................................... 49

ame) ............................................. 58

rations ...................................... 60

spect ......................................... 40

r Service Indicator - Inspect ..... 45

spect ....................................... 53

Inspect/Replace .................. 54

Initial 1000 Se

Crankshaft Vibration Damper - Inspect ................. 43

Every 1000 Serv

Engine - Clean ...................................................... 44

Every 1000 Ser

Crankshaft Vibration Damper - Inspect ................. 43

Every 2000 Ser

Alternator - Inspect ............................................... 37

Engine Crankca

Engine Oil - Change ............................................. 48

Engine Oil Filter (Auxiliary) - Change ................... 48

Engine Oil Filt

Engine Valve Lash and Bridge - Adjust ................ 52

Ignition System Spark Plugs - Check/Adjust/

Replace ............................................................... 55

rvice Hours or 1 Year

ice Hours

vice Hours or 1 Year

vice Hours

se Breather - Clean/Replace ....... 46

er - Change .................................... 49

Every Year

Carburetor Air

Engine Speed/Timing Sensor - Clean/Inspect ...... 51

/Fuel Ratio - Check/Adjust ............. 40

Every 4000 Service Hours

Cylinders - Inspect ................................................ 44

Driven Equipment - Check .................................... 44

Gas Pressure Reg

Ignition System Timing - Check/Adjust ................. 57

Inlet Air System - Inspect ...................................... 58

Every 5000 Serv

Battery Electrolyte Level - Check .......................... 40

Every 7500 Servi

Water Pump - Inspect ........................................... 62

ulator - Check .......................... 54

ice Hours

ce Hours

Every 250 Service H

Engine Oil Sample - Obtain .................................. 50

Initial 500 Servic

Engine Oil - Change ............................................. 48

Engine Oil Filter

Engine Oil Filter - Change .................................... 49

Engine Valve Lash and Bridge - Adjust ................ 52

Ignition System Sp

Replace ............................................................... 55

(Auxiliary) - Change ................... 48

ours

e Hours

ark Plugs - Check/Adjust/

Every 500 Service Hours

Alternator and Fan Belts - Replace ....................... 37

Battery Electrolyte Level - Check .......................... 40

Engine Air Cleaner

Element - Replace ................. 45

Every 8000 Servi

Cooling System Coolant - Test/Add ...................... 42

Every 8000 Servi

Engine Mounts - Check ........................................ 47

Every 16 000 Ser

Turbocharger - Inspect .......................................... 61

ce Hours

ce Hours or 1 Year

vice Hours or 6 Years

SEBU8190 37

Maintenance Section

Alternator - Inspect

i02322311

Alternator - Inspect

Perkins recomm
the alternator. Inspect the alternator for loose
connections and correct battery charging. Check the
ammeter (if eq
order to ensure correct battery performance and/or
correct performance of the electrical system. Make
repairs, as r

Check the alternator and the battery charger for
correct oper
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries s
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. When the
engine is no
engine is run for short periods, the batteries may not
fully charge. A battery with a low charge will freeze
more easil

ends a scheduled inspection of

uipped) during engine operation in

equired.

ation. If the batteries are correctly

hould be kept warm because temperature

t run for long periods of time or if the

y than a battery with a full charge.

i02449716

Alternator and Fan Belts ­Replace

Alternator

i02449713

Alternator and Fan Belts ­Inspect

To maximize the engine performance, inspect the
belts for wear and for cracking. Replace belts that are
worn or damaged.

Refer to this manual, “Alternator and Fan Belts ­Replace”.

Illustration 19

Typical example

1. Remove the fasteners (5) and the plate (6).

Remove the fastener (3) and remove the fasteners
(1 and 4).

2. Remove the guard (2).

3. Loosen the fastener (8) and remove the fastener

(9) in order to remove the belt.

4. Install the new belt and install the fastener (9).

g01222905

38 SEBU8190
Maintenance Section
Alternator Pulley - Check

Fan Drive Belts

Illustration 20

Typical example

g01222934

5. Tension the belt. Apply pressure of 15.6 N (3.5 lb)

between the two pulleys (7). The correct deflection
of the belt is 1.5 mm (0.0591 inch). Tighten the
fasteners (8 and 9) securely.

6. Install the guard and tighten all the fasteners

securely.

Illustration 21

Typical example

1. Remove the

guards.

g0122295

2. Loosen the fastener (1) and loosen the belt

tensione

r (2). Remove the belts.

3. Install new belts. Adjust the belt tensioner in order

to give th

ecorrecttensiontothebelts.

Note: Change the belts as a set.

4. Tighten the fastener (1) securely. Ensure that the

deflection on the belts is correct.

5. Apply hand pressure to the belts between the

pulleys (3). The correct deflection for the belts is

12.5 mm (0

.4921 inch) .

3

6. Install the guards and tighten all fasteners

securel

y.

Alternator Pulley - Check

1. Isolate the electrical supply to the engine.

i02530854

SEBU8190 39

Maintenance Section

Battery - Replace

i02429553

Battery - Replace

Batteries give off combustible gases which can
explode. A spark can cause the combustible gas­es to ignite. T
jury or death.

his can result in severe personal in-

Illustration 22

Typical example

g01237956

2. Remove the guard (3) in order to gain access to

the drive pulley (1) for the alternator (2).

ion 23

Illustrat

Typical example

g01233693

3. Tighten the grub screws (4) to a torque of 20 N·m

(15 lb ft).

4. Install the guard (3).

5. Restore th

e electrical supply to the engine.

Ensure prope

r ventilation for batteries that are in
an enclosure. Follow the proper procedures in or­der to help prevent electrical arcs and/or sparks
near batter i

es. D o not smoke when batteries are

serviced.

1. Refer to the O

EM for instruction for switching the

engine to the OFF position.

2. Turn off any

battery chargers. Disconnect any

battery chargers.

3. The NEGATIV

E “-” cable connects the NEGATIVE
“-” battery terminal to the NEGATIVE “-” terminal
on the starting motor. Ensure that the NEGATIVE
“-” battery

terminal is disconnected first.

4. The POSITIVE “+” cable connects the POSITIVE

“+” battery

terminal to the POSITIVE “+” terminal
on the starting motor. Disconnect the cable from
the POSITIVE “+” battery terminal.

Note: Always recycle a battery. Never discard a
battery. Dispose of used batteries to an appropriate
recycling

facility.

5. Remove the used battery.

6. Ensure that all the battery connections are clean

and free from corrosion.

7. Install the new battery.

Note: Befo

re the cables are connected, ensure that

the engine start switch is OFF.

8. Connect t

he cable from the starting motor to the

POSITIVE “+” b atte ry terminal.

9. Connect t

he NEGATIVE “-” cable to the

NEGATIVE “-” battery terminal.

40 SEBU8190
Maintenance Section
Battery Electrolyte Level - Check

i02322318

Battery Electrolyte L evel ­Check

When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully r
to help prevent the battery from freezing. If batteries
are correctly charged, the ammeter reading should
be very near z

All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
shield and p
near batteries.

1. Remove the f

level to the “FULL” mark on the battery.

If the addit
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened w

2. Check the condition of the electrolyte with a

suitable b

echarge. Ensure a full charge in order

ero, when the engine is in operation.

rotective clothing when working on or

iller caps. Maintain the electrolyte

ion of water is necessary, use distilled

ater.

attery tester.

Ensure that the
so that the air/fuel ratio is correct.

adjustment screw is adjusted properly

i02450196

Control Panel - Inspect

Inspect the condition of the panel. If a component is
damaged, ensu
that the component is replaced. If equipped, ensure
that the electronic displays are operating properly.
Inspect the w
wiring connections are secure.

Refer to the O

Cooling Syst

re that the component is repaired or

iring for good condition. Ensure that the

EM for more information.

i02462593

em Coolant -

Change

Refer to the OEM for information on cogeneration
engines.

Drain

3. Install the caps.

4. Keep the batteries clean.

Clean the b
cleaning solutions:

Amixtureo

•

baking soda and 1 L (1 qt) of clean water

Amixtureo

•

(1 qt) of clean water

Thoroughl

attery case with one of the following

f 0.1 kg (0.2 lb) of washing soda or

f 0.1 L (0.11 qt) of ammonia and 1 L

y rinse the battery case with clean water.

i02450166

Carburetor Air/Fuel Ra tio ­Check/Adjust

An engine failure may occur if the air/fuel ratio is
not appropriate for the fuel and for the operating
conditions. The service life of the turbocharger, of the
valves, and of the other components may be reduced.

Illustration 24

Typical example

1. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.

g01228758

SEBU8190 41

Maintenance Section

Cooling System Coolant - Change

2. Open the drain c

ock or remove the drain plug on

the radiator.

3. Open the drain

cock or remove the drain plug (1)

on the engine.

Illustration 25

Typical example

g01230401

4. Open the drain cock (2) on the engine oil cooler.

Illustration 26

Typical examp le

g01228755

Note: The cooling system must be filled slowly. Refer
to Perkins engines Stafford for more information.

2. If equipped, loosen the vent screw (3). Fill the

cooling system until coolant free of air flows from
the vent screw.

5. If equipped, open the drain cock or remove the

drainplug(4)onthecooler.

Allow the system to drain.

Fill

Refer to the OEM for information on cogeneration
engines.

1. Close the drain cock or install the drain plug in the

engine. Close the drain cock or install the drain
plug on the radiator. Close the drain cock on the
engine oil cooler. If equipped, close the drain cock
or install the drain plug (4) on the cooler.

3. Stop filling the cooling system. Tighten the vent

screw securely. Check that the coolant level is
within 25 mm (1.0 inch) of the bottom of the filler
pipe.

4. Install the cooling system filler cap.

5. Start the engine. Operate the engine until the

engine is at the correct operating temperature.
Inspect the cooling system for leaks.

6. Stop the engine and allow the engine to cool.

Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Check that the level of coolant
is correct. If necessary, add more coolant. Refer
to this manual, “ Cooling System Coolant Level
Check”.

7. In order to check the specific gravity of the coolant,

refer to this manual , “Coolant System Coolant ­Te s t/ Ad d” .

42 SEBU8190
Maintenance Section
Cooling System Coolant - Test/Add

i02460258

Cooling System Coolant ­Test/Add

Check the specific gravity o f the
coolant

4. Remove the fill

5. Drain some of the coolant from the cooling system

into a suitabl

6. Use a special hydrometer that will check the

temperature a
and follow the manufacturer’s instructions.

Note: If a spec
not available, put an hydrometer and a separate
thermometer into the antifreeze mixture and check
the readings
readings with the data in illustration 27.

Note: If nece
coolant in the system with premixed coolant of the
correct strength. Perkins POWERPART antifreeze
withaconce
against frost to a temperature of í35 °C (í31 °F).
Thesolutionwillalsoprotectagainstcorrosion.This
is especia
components in the cooling circuit.

7. Adjust the

lly important when there are aluminum

er cap of the cooling system.

e container.

nd the specific gravity of the coolant,

ial thermo-hydrometer for coolant is

on both instruments. Compare the

ssary, fill the system or replenish the

ntration of 50% will give protection

strength of the mixture if it is necessary.

Illustration 27

The char t for the S pecific gravity

A = Percentage of antifreeze by volume

B = The temperature of the mixture in °F

C = Specific gravity

D = The temperature of the solution in °C

The following procedure must be used to measure
coolant that contains antifreeze:

1. Operate the engine until the coolant temperature

opens the thermostat. Continue to run the engine
until the coolant has circulated around the cooling
system.

2. Stop the engine.

3. Allow the engine to cool until the temperature is

below60°C(140°F).

g00997964

i02460267

Cooling System Coolant Level

- Check

Pressurized System: Hot coolant can cause seri­ous burns. 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.

Refer to the OEM for information on cogeneration
engines.

Check the coolant level when the engine is stopped
and cool.

Pressurized System: Hot coolant can cause seri­ous burns. 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.

SEBU8190 43

Maintenance Section

Crankshaft Vibration Damper - Inspect

Illustration 28

Typical example

1. Remove the cooling system filler cap (1) or (2)

slowly in order to relieve pressure.

g01228685

3. Clean the cooli

gasket. If the gasket is damaged, discard the old
filler cap and install a new filler cap. If the gasket
is not damaged
in order t o pressure test the filler cap. The correct
pressure is stamped on the face of the filler cap. If
the filler ca
install a new filler cap.

Crankshaft

ng system filler cap and inspect the

,useasuitablepressurizingpump

p does not retain the correct pressure,

i02450294

Vibration Damper

-Inspect

The crankshaft vibration damper limits the torsional
vibration o
a weight that is located inside a fluid filled case.

Damage to t
of the damper can increase torsional vibrations. This
can result in damage to the crankshaft and to other
engine com
cause excessive gear train noise at variable points
in the speed range.

f the crankshaft. The visconic damper has

he crankshaft vibration damper or failure

ponents. A deteriorating damper can

Illustration 29

Typical example

2. Maintain the coolant level within 25 mm (1.0 inch)

of the bottom of the filler pipe.

g01229602

A damper that is hot is due to excessive torsional
vibration. Monitor the temperature of the damper
during op

Note: If you use an infrared thermometer to monitor
the tempe
during operation with similar loads and speeds. Keep
a record of the data. If the temperature begins to rise,
reduce t

If the temperature of the damper reaches 100 °C
(212 °F)

Inspect the damper for evidence of dents, cracks,
and leak

If a fluid leak is found, replace the damper. The fluid
in the da
characteristics: transparent, viscous, smooth, and
sticky.

Inspect the damper and replace the damper for any
of the following reasons.

The damper is dented, cracked, or leaking.

•

The pai

•

eration.

rature of the damper, use the thermometer

he interval for inspecting the damper.

, consult your Perkins dealer.

s of the fluid.

mper is silicone. Silicone has the following

nt on the damper is discolored from heat.

The engine has had a failure because of a broken

•

•

haft.

cranks

There is a large amount of gear train wear that is
not cau

sed by a lack of oil.

44 SEBU8190
Maintenance Section
Cylinders - Inspect

i02450387

Cylinders - Inspect

Use a borescope
inspection will provide information about the internal
condition of the engine.

Aborescopewithalensthatcanbeangledupand
down is recommended. This type of borescope
provides a cle
of the bottom deck of the cylinder head. Photographic
documentation or video documentation is also
recommended
information on available borescopes.

To perform th
through the openings for the spark plugs. Use the
borescope to look for the following conditions:

Valve wea r

•

Deposits on

•

Deposits on the valve face

•

Polishing of the cylinder walls

•

Scratching

•

to inspect the cylinders. The

ar view of the combustion chamber and

. Consult your Perkins dealer for

is procedure, insert the borescope

the valve seat

of the cylinder walls

i02453750

Driven Equipment ­Inspect/Repl

Observe the driven equipment during operation. Look
for the following items:

Unusual noise and vibration

•

Loose connect

•

Damaged parts

•

Perform any maintenance that is recommended
by the OEM of the driven equipment. Refer to the
literature of
following service instructions.

Inspection

•

Lubricating grease and lubricating oil requirements

•

Specifications for adjustment

•

Replacement

•

Requirements for ventilation

•

the OEM of the driven equipment for the

ace/Lubricate

ions

of components

Deposits on the cylinder walls that are above the

•

upper limit

Note: If you use a borescope be aware of the effect
of magnific
be misunderstood. This can result in unnecessary
maintenance.

of the piston stroke

ation. Minor scratches and marks can

i02453747

Driven Equipment - Check

To minimiz
engine crankshaft and the driven equipment, the
alignment between the engine and driven equipment
must be ma

Check the alignment according to the instructions
that are p

OEM of the coupling

•

OEM of the driven equipment

•

e bearing problems and vibration of the

intained properly.

rovided by the following manufacturers:

i02453751

Engine - Clean

Personal in
age.

Moisture co
tivity.

Make sure th
utility and/or other generators), locked out and
tagged "Do Not Operate".

Water or condensation can cause damage to gen­erator components. Protect all electrical components
from exposure to water.

Acleaneng

jury or death can result from high volt-

uld create paths of electrical conduc-

e unit is off line (disconnec t ed from

NOTICE

ine provides the following benefits:

Easy detection of fluid leaks

•

Maximum heat transfer characteristics

•

SEBU8190 45

Maintenance Section

Engine Air Cleaner Element - Replace

Ease of mainten

•

Engine Air Clea

ance

i02450440

ner Element -

Replace

NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner eleme
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components.
borne debris from entering the air inlet.

Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

Renew the air filter element if the service indicator is
triggered. Refer to this manual, “Engine Air cleaner
Service Indicator - Inspect” for more information.

Clean the air intake precleaner before maintenance
is performed on the air filter. Refer to , “Engine Air
Precleaner - Check/Clean” for more information.

Operating condition may require more frequent
service of the air filter.

nt. Do not use air cleaner elements with

Air cleaner elements help to prevent air-

NOTICE

2. Remove the old e

element in a safe place.

Note: Ensure t
assembly.

3. Install a new e

Install the cover (2) and install the washer and
wing nut (3). Tighten the wing nut securely.

lement (1). Dispose of the old

hat dirt can not enter the air filter

lement into the air filter assembly.

i02451134

Engine Air Cleaner Service
Indicator - Inspect

Some engines may be equipped with a different
service indicator.

Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.

The service indicator may be mounted on the air
cleaner element or in a remote location.

Observe the service indicator.

Illustration 30

Typical example

1. Remove the wing nut and the washer (3). Remove

the cover (2).

g01223389

Replace the air filter element if the indicator is
triggered by the following event:

The red piston locks in the visible position.

•

Test the S ervice Indicator

Service indicators are important instruments.

46 SEBU8190
Maintenance Section
Engine Air Precleaner - Clean

Illustration 31

Typical service indicator

In order to reset the indicator, you must press the
button (1).

g01223729

Note: Ensure th
assembly.

2. Ensure that th

the precleaner.

Engine Crank

at dirt can not enter the air filter

e precleaner is clean and dry. Install

i02478561

case Breather -

Clean/Replace

Open Breathe

1. Ensure that the power supply is disconnected

from the engi

2. Remove the wing nut (1) and the cover (2).

r

ne.

If the service indicator does not reset easily, the
service indicator should be replaced.

The service indicator may need to be replaced
frequently in environments that are severely dusty.

i02451208

Engine A ir Precleaner - Clean

Illustration 32

Typical example

The precleaner (1) must be cleaned when a new
element is installed in the air filter assembly.

1. Remove the precleaner from the air filter assembly

and wash the precleaner.

g01224873

Illustration 33

Typical example

3. Remove the filter elements (3) from the breather

body (4).

4. By using a suitable cleaning fluid, clean the filter

elements (3) and dry the filter elements. Inspect
the filter elements for damage or deterioration. If
necessary, replace the filter elements.

5. Clean the cover and clean the body of the

breather.

6. Install the filter elements (3) to the breather body

(4).

7. Ensure that the seal in the cover (2) is free from

damage. If necessary, replace the seal.

g01224945

SEBU8190 47

Maintenance Section

Engine Mounts - Check

8. Align the cover

(2) with the dowel (5). Install the

cover to the breather body (4).

9. Install the wi

ng nut (1). Tighten the wing nut

securely.

10. Connect the po

wer supply to the engine. Operate

the engine and check for leaks.

Closed Breather System

Ensure that th
the engine.

e power supply is disconnected from

Illustration 35

Typical example

g01235923

3. Install the new filter element. Align the clips (1).

Install the bowl (2).

Illustration 34

Typical example

g01224943

1. Release the four clips (1). Remove the bowl (2)

and remove the old filter element. Discard the old
filter element in accordance with local regulations.

Note: The filter element is removed by pulling down
on the filter element.

2. Ensure that the seal (3) is installed onto the new

filter element (4).

Connect the power supply to the engine. Operate the
engine and check for leaks.

i02463642

Engine Mounts - Check

Misalignment of the engine and the driven equipment
will cause extensive damage. Excessive vibration
can lead to misalignment. Excessive vibration of the
engine and the driven equipment can be caused by
the following conditions:

Improper mounting

•

Loose bolts

•

Deterioration of the isolators

•

Ensure that the mounting bolts are tightened to the
proper torque.

Ensure that the isolators are free of oil and
contamination. Inspect the isolators for deterioration.
Ensure that the bolts for the isolators are tightened to
the correct torque.

Replace any isolator that shows deterioration. For
more information, see the literature that is provided
bytheOEMoftheisolators.

48 SEBU8190
Maintenance Section
Engine Oil - Change

i02468905

Engine Oil - C h a nge

Note: Refer to t

Manual, “Engine Oil Sample - Obtain” before
performing maintenance.

Do not drain the engine lubricating oil when the
engine is cold. As the engine lubricating oil cools,
suspended was
the oil pan. The waste particles are not removed with
draining cold oil. Drain the oil pan with the engine
stopped. Dra
draining method allows the waste particles that are
suspended in the oil to be drained properly.

Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
theenginel

Ensure that the vessel that will be used is large
enough to co

1. Remove the drain plug and the sealing washer

(1). Allow t

2. Replace the sealing washer, if necessary. Install

the drain p

he Operation and Maintenance

te particles settle on the bottom of

in the oil pan with the oil warm. This

ubrication system with the new oil.

llect the waste oil.

he engine oil to drain.

lug. Tighten the plug to 68 N·m (50 lb ft).

Illustration 37

Typical example

5. Remove the filler cap (3). Fill the engine with the

required amount of engine oil.

6. Check the oil gauge (dipstick) (2). Ensure that the

engine oil is on the correct mark.

7. Operate the engine and check for engine oil leaks.

Stop the engine. Check that engine oil level. Add
engine oil, if necessary. Refer to this manual,
“Engine Oil Level - Check”.

g01231267

Illustration 36

Typical example

3. Replace the engine oil filters.

4. Refer to this manual, “Engine Oil Filter - Change

or Engine Oill Filter (Auxiliary) - Change” in order
to change the engine oil filter.

g01231597

i02472513

Engine Oil Filter (Auxiliary) ­Change

Note: Refer to the Operation and Maintenance

Manual, “Engine Oil Sample - Obtain” before
performing maintenance.

Change the Filter with the Engine
in Operation

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.

SEBU8190 49

Maintenance Section

Engine Oil Filter - Change

i02472515

Engine Oil Filter - Change

Illustration 38

Typical example

g01233078

The changeover valve (1) has three positions.

(A) The oil flow is to both oil filters.

•

(B) The oil flow is to the left hand oil filter.

•

(C) The oil flow is to the right hand oil filter.

•

1. Rotate the changeover valve to position B. By

using a suitable tool (2), remove the right hand
oil filter.

Note: Oil flow direction (D and E ).

Note: Refer to t

he Operation and Maintenance
Manual, “Engine Oil Sample - Obtain” before
performing maintenance.

Illustration 39

Typical example

g01233082

All three oil filters must be changed as a set.

1. Use a suitable tool in order to remove the oil filter

(2). Ensure that the sealing housing is clean.

2. Ensure that the sealing face on the housing is

clean. Fill the new oil filter with clean engine oil.
Install the new oil filter. Rotate the changeover
valve to position A. Check for oil leaks.

3. Rotate the changeover valve to position C. By

using a suitable tool, remove the left hand oil filter.

4. Ensure that the sealing face on the housing is

clean. Fill the new oil filter with clean engine oil.
Install the new oil filter. Apply hand pressure
only in order to install the oil filter. Rotate the
changeover valve to position A. Check for oil
leaks.

5. Clean any spillage of engine oil.

2. Lubricate the sealing ring (1). Install the new oil

filter. Apply hand pressure only in order to install
the oil filter.

3. When all three oil filters have been installed fill

the engine with engine oil. Refer to this manual,
“Engine Oil - Change”.

i02463768

Engine Oil Level - Check

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.

50 SEBU8190
Maintenance Section
Engine Oil Sample - Obtain

Illustration 40

(Y) “Min” mark. (X) “Max” mark.

NOTICE

Perform this maintenance with the engine stopped.

Note: After the engine has been switched OFF, wait
for ten minutes in order to allow the engine oil to drain
to the oil pan

1. Maintain the oil level between the “ADD” mark (Y)

and the “FUL
Do not fill the crankcase above the “FULL” mark
(X).

If you operate the engine with the oil level above the
“FULL” mark, this may cause your crankshaft and bal­ance weight
shaft and balance weights through oil, excessive drag
will occur and this will increase the load on the en­gine. Air b
and balance weights are driven through oil. This will
reduce the lubricating characteristics of the oil and re­sult in a lo

before checking the oil level.

L” mark (X) on the engine oil dipstick.

NOTICE

stobedippedinoil.Ifyoudrivethecrank-

ubbles will be created when the crankshaft

ss of power.

g01165836

In order to dete
oil and filter service, use the oil analysis program
that follows.

rmine the optimum program for the

Initiating an Oil analysis Program

The oil sample
the engine oil pan. Do not take an oil sample from
the drain plug.

Oil analysis in the first 500 hours will show higher
levels of iron and copper than the acceptable
parameters.
the engine continues to operate the levels will drop
within the specified parameters.

must be taken from the mean level in

This is shown in the list that follows. As

Every 250 Hours

Run the engin
engine oil and the engine oil filter. Every 250 hours
obtain an oil sample.

A trend can be established by analyzing the results
of the oil sampling. Each individual operator can
develop a se

Note: The engine oil and the engine oil filter must be
replaced a

e for the first 500 hours. Replace the

rvice program for the engine.

t 2000 hours.

Critical Parameters for the Lubricating
Oil

viscosity at 100 °C cSt max 20% above original

•

value

Insolubles 1.5% wt.max

•

Total base number 60% less than new oil value

•

Nitration

•

30 abs/cm max

2. Remove the oil filler cap and add oil, if necessary.

Clean the oil filler cap. Install the oil filler cap.

i02472647

Engine Oil Sample - O btain

Replacement Program for the
Engine Oil and Filter

Thelifeofthelubricatingoilandfilterisgovernedby
the engine load and quality of the gas that is supplied.

Oxidation 30 abs/cm max

•

Water 0.2% vol max

•

Iron - Fe le

•

Copper - Cu less than 40 ppm

•

Note: Perkins Engines Stafford must agree to the
maintenance schedule.

ss than 20 ppm

SEBU8190 51

Maintenance Section

Engine Protective Devices - Check

i02430590

Engine Protective Devices ­Check

Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent dam
to determine if the engine protective devices are
in good working order during normal operation.
Malfunction
engine protective devices.

Acalibratio
will ensure that the alarms an d shutoffs activate
at the setpoints. Ensure that the engine protective
devices are

During testing, abnormal operating conditions must be
simulated.

The tests must be performed correctly in order to pre­vent possib

To prevent damage to the engine, only authorized
service per
perform the tests.

age to the engine. It is impossible

s must be simulated in order to test the

ncheckoftheengineprotectivedevices

functioning properly.

NOTICE

le damage to the engine.

sonnel or your Perkins dealer should

Visual Inspection

Visually c
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
or compone
immediately.

heck the condition of all gauges, sensors

nts should be repaired or replaced

i02473236

Engine Speed/Timing Sensor -

Speed Sensor

Illustration 41

Typical example

1. Remove the connection (3). Loosen the locknut

(1).

2. Remove the sensor (2). Clean any debris from

the sensor.

3. Install tooling (A).

4. Rotatetheengineinordertoalignoneteethtothe

tapped hole. By hand, install the sensor. When
light contact is made with the teeth you must stop.
Unscrew the sensor half of one turn. This will give
a clearance of 0.5 to 0.8 mm (0.02 to 0.03 inch).

5. Tighten the locknut. Do not allow the sensor to

rotate. Connect the connection (3).

6. Remove tooling (A).

g01234089

Clean/Inspect

Ensure that all power is disconnected to the engine
before performing these procedures.

Table 12

Required Tools

Tool

A

Part

Number

SE252

Part Name Qty

Engine cranking device 1

Timing Sensor

The timing sensor is a hall effect sensor that is
located in the gear case.

1. Remove the connection (3). Loosen the locknut

(1).

52 SEBU8190
Maintenance Section
Engine Valve Lash and Bridge - Adjust

Remove the Cover

Illustration 42

Typical example

g01236930

2. Remove the sensor (2). Clean any debris from

the sensor.

3. Install tooling (A).

4. Rotate the engine in order to align a magnet to the

tapped hole. By hand, install the sensor. When
light contact is made with the magnet you must
stop. Unscrew the sensor. Unscrew one complete
turn. This will give a clearance of 1 mm (0.04 inch).

5. Tighten the locknut. Do not allow the sensor to

rotate. Connect the connection (3).

6. Remove tooling (A).

Connect the power to the engine.

i02474878

Engine Valve Lash and Bridg e

- Adjust

Illustration 43

Typical example

g01235020

1. Remove the lead for the spark plug. Refer to

this manual, “Ignition SystemSpark Plugs ­Check/Adjust/Replace”.

2. Remove the setscrews (1) and remove the cover

(2). Discard the old joint.

3. Remove the spark plug tube (3).

4. Install tooling (A) in order to rotate the crankshaft.

Adjust the bridge

Ensure that all power is disconnected to the engine.

Table 13

Required Tools

Tool

A SE252 Engine cranking device 1

Part

Number

Part Name

Qty

Illustration 44

Typical example

g01235025

1. Use the timing pointer (1) in order to set the

engine to top dead center. Refer to this manual,
“Specifications” for the sequence of piston position
for valve lash.

SEBU8190 53

Maintenance Section

Exhaust Piping - Inspect

2. Rotate the cran

Illustration 45

Typical example

3. Loosen the locknut (3). Adjust the screw (2) so

that the fixed side of the bridge contacts the
valve. Apply hand pressure to the bridge. Refer to
illustration 45.

4. Adjust the screw so that light contact is made with

thevalve.Tightenthelocknut(3)toatorqueof
35 N·m (25 lb ft). Ensure that the screw has not
rotated.

kshaft to the required position.

g01235021

1. Rotate the cran

Refer to this manual, “Specifications” for the
sequence of piston position for valve lash.

Note: The bridge adjustment must be checked before
adjustment is performed on the valve lash.

2. Use a suitable feeler gauge in order to check the

valve lash. If adjustment is required loosen the
locknut (1).
clearance is obtained.

3. Tighten the l

(25 lb ft).

kshaft to the required position.

Adjust the screw (2) so that the correct

ockscrewtoatorqueof35N·m

Install the Cover

1. Install the s

2. Install a new joint. Align the cover to the cylinder

head. Insta

3. Install the lead for the spark plug.

4. Remove tooling (A). Connect the power supply

to the engine.

park plug tube.

ll the setscrew and tighten securely.

i02430592

Exhaust Piping - Inspect

Valve lash

Illustration 46

Typical example

g01235

023

Hot engine components can cause injury from
burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.

Inspect the components of the exhaust system.
Repair the components or replace the components if
any of the following conditions occur:

Damage

•

Cracks

•

Leaks

•

Loose connections

•

Consult your Perkins dealer for assistance.

54 SEBU8190
Maintenance Section
Fan Drive Pulley - Check

i02463729

Fan Drive Pulley - Ch eck

1. Isolate the ele

Illustration 47

Typical example

2. Remove the guards (not shown) in order to gain

access to the fan drive pulley (1).

ctrical supply to the engine.

g01238304

i02478666

Fuel Filtration System - Service

Engines that us
equipment for processing the fuel. Service the fuel
filtration system according to the instructions that are
provided by th

e bio-gas may require special

e OEM of the equipment.

i02478685

Fuel System Fuel Filter
Differential Pressu re - Check

A fuel filter differential pressure gauge may be
installed in order to determine when the fuel filter
requires service.

A fuel filter dif ferential pressure gauge indicates the
difference in fuel pressure between the inlet side
and the outlet side of the fuel filter. The differential
pressure increases as the fuel filter becomes
plugged.

Operate the engine at the rated speed and at the
normal operating temperature. Check the fuel filter
differential pressure. Service of the fuel filter depends
on the pressure of the fuel system:

For the service of the fuel filter on the low pressure

•

gas fuel system, refer to the OEM for information.

Illustration 48

3. Tighten the grub screws (2) to a torque of 90 N·m

(66 lb ft).

4. Install the guards (not shown).

5. Restore the electrical supply to the engine.

g01238305

For the service of the fuel filter on the high pressure

•

gas fuel system, refer to the OEM for information.

i0247548

Gas Pressure Regulator ­Check

Before the regulator is set the supply pressure must
be checked. The supply pressure must be1.5 to 5 kPa
(0.2 to 0

.7 psi).

i02430593

Hoses and Clamps ­Inspect/Replace

Inspect all hoses for leaks that are caused by the
following conditions:

9

SEBU8190 55

Maintenance Section

Ignition System Spark Plugs - Check/Adjust/Replace

Cracking

•

Softness

•

Loose clamps

•

Replace hoses
loose clamps.

Do not bend or strike high pressure lines. Do not in­stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec­ommended torque.

Check for the

End fittings that are damaged or leaking

•

Outer covering that is chafed or cut

•

Exposed wire

•

Outer covering that is ballooning locally

•

that are cracked or soft. Tighten any

NOTICE

following conditions:

that is used for reinforcement

Replace the Hoses and the Clamps

Pressurized System: Hot coolant can cause seri­ous burns. To o
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap
sure.

1. Stop the engi

2. Loosen the cooling system filler cap slowly in

order to reli
system filler cap.

Note: Drain
container. The coolant can be reused.

3. Drain the co

level that is below the hose that is being replaced.

4. Remove the h

5. Disconnect the old hose.

pen the cooling system filler cap,

slowly in order to relieve the pres-

ne. Allow the engine to cool.

eve any pressure. Remove the cooling

the coolant into a suitable, clean

olant from the cooling system to a

ose clamps.

Flexible part of the hose that is kinked or crushed

•

Armoring tha

•

A constant torque hose clamp can be used in place
of any standa
torque hose clamp is the same size as the standard
clamp.

Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
This can res
clamp will help to prevent loose hose clamps.

Each instal
differences depend on the following factors:

Type of hos

•

Type of fitting material

•

Anticipated expansion and contraction of the hose

•

Anticipat

•

fittings

t is embedded in the outer covering

rd hose clamp. Ensure that the constant

ult in leaks. A constant torque hose

lation application can be different. The

e

ed expansion and contraction of the

6. Replace the old hose with a new hose.

7. Install the

8. Refill the cooling system.

9. Clean the cooling system filler cap. Inspect the

cooling system filler cap’s gaskets. Replace
the coolin
damaged. Install the cooling system filler cap.

10. Start the e

leaks.

hose clamps with a torque wrench.

g system filler cap if the gaskets are

ngine. Inspect the cooling system for

i02475603

Ignition System Spark Plugs ­Check/Adjust/Replace

Table 14

Required Tools

Too l

A T6253/265Spark plug removal tool 1

Part

Number

Part Name Qty

56 SEBU8190
Maintenance Section
Ignition System Spark Plugs - Check/Adjust/Replace

Check the Spark Plug

Illustration 49

g01235566

1. Remove the lead (1) for the spark plug from the

cylinder head.

Illustration 50

g01235

2. Install tooling (A). Remove the spark plug (2).

569

Illustration 51

Typical examp le

g01264908

Faint marks may extend from shell (2) onto the
insulator (1). The marks may be a result of corona
that forms at the top of the shell. The conductor will
develop a corona when a very high voltage potential
ionizes the air. This is a normal condition. This is not
an indication of leakage between the shell and the
insulator.

Inspect shell (2) for damage. Cracks can be caused
by overtightening the spark plug. Overtightening can
also loosen the shell. Discard any spark plug that has
a shell that is cracked or loose.

Install a new sealing washer (3) before installing the
old spark plug.

1. Clean the spark plug by using a nylon brush.

Note: The electrodes (5) must not be damaged. If the

electrodes are damaged replace the spark plug. Do
not file the electrodes or use abrasive paper in order
to clean the electrodes.

2. If necessary, adjust the gap on the spark plug. Set

thegapto0.25mm(0.0098inch).

Check the Plug and Adjust the Plug

t the spark plug closely for damage. The

Inspec
condition of the spark plug can indicate the operating
condition of the engine.

SEBU8190 57

Maintenance Section

Ignition System Timing - Check/Adjust

Illustration 52

Typical example

Replace the Plug

Table 15

Required Tools

Tool

B 27610178

Part

Number

Cylinder head spark plug
thread cleaning tool

g01235576

Part Name Qty

1

Note: Refer to t

his manual, “Plate Locations and Film

Locations” in order to find the ignition timing.

1. Install a timi

ng light to the lead on number six
cylinder 4006TRS or number eight cylinder
4008TRS.

Note: The leads for the timing light must not come in
contact with the exhaust manifold.

Ensure that the threads in the cylinder head are not
damaged. Clean the threads in the cylinder head by
using tooling (B).

Ensure that the gap of the spark plug is set correctly.
Ensurethatthesparkplugisinaworkingcondition.

Install the spark plug by using tooling (A). Tighten the
spark plug by hand and then tighten the spark plug to
a torque of 50 N·m (36 lb ft).

i02477244

Ignition System Timing ­Check/Adjust

After maintenance has been performed on the
ignition system, check the timing of the ignition
system. Adjust the timing, if necessary .

The optimum ignition timing for a gas engine varies
according to several factors:

Compression ratio of the engine

•

Inlet air temperature

•

Illustration 53

Typical e

xample

g01237060

2. Operate the engine and check the timing marks

on the fl

ywheel.

3. If necessary, adjust the ignition timing. Remove

the cap (

1). By using a suitable tool, rotate the

screw (2) in order to adjust the ignition timing.

4. Ensure t

hat the cap (3) is not removed. This is set

for the application in the factory.

5. Install

the cap (1) when the ignition timing is

correct. Remove the timing light.

Rotatin

•

g the screw (2) clockwise advances the

ignition timing.

Rotatin

•

g the screw (2) counterclockwise retards

the ignition timing.

Methane number of the gas

•

58 SEBU8190
Maintenance Section
Inlet Air System - Inspect

Note: For engin
sensor, the timing is controlled by the detonation
system. refer to a separate manual.

es that are installed with a detonation

i02477819

Inlet Air System - Inspect

Inspect the components of the air inlet system for
the following conditions:

Cracks

•

Leaks

•

Loose connections

•

Inspect the following components:

Piping between the air cleaner and the turbocharger

•

Turbocharger

•

Piping between the turbocharger and the

•

aftercooler

Aftercooler

•

Connection of the aftercooler to the air inlet

•

manifold

Connection of the air inlet manifold to the cylinder

•

head

Ensure that all of the connections are secure. Ensure
that the components are in good condition.

The engine does
engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder
compression.

Periodically measure each of the three conditions.
The first mea
engine commissioning. This establishes a baseline
for future measurements. Additional measurements
are schedule
determine a schedule for the next in-frame overhaul.

The followin
normally require a scheduled overhaul:

An increase i

•

An increase in crankcase blowby

•

A loss of cylinder compression

•

Note: Oil co
be reduced when the rings are seated to the bore.

Note: These
to be shut down for service. These indications
only mean that an engine should be scheduled for
service in t
is satisfactory, an immediate overhaul is not a
requirement.

Monitor the engine as the engine accumulates
service hours.

Usually, an in-frame overhaul does not require
removal of the engine. Instead, the service is
performe

he near future. If the engine operation

d with the engine in place.

In-Frame

not require an overhaul if the

surement should occur during the

d at regular intervals in order to

g changes in the three conditions

n oil consumption

nsumption will be initially high. This will

indications do not require an engine

Overhaul Information

i02484880

Overhaul (In-Frame)

Scheduling an In-Frame Overhaul

Schedulin
on the following conditions:

An increas

•

An increase of crankcase blowby

•

A decrease or a variation of cylinder compression

•

Each indiv
for an overhaul. However, evaluating the three
conditions together is the most accurate method of
determini

g an in-frame overhaul normally depends

e of oil consumption

idual condition may not indicate a need

ng when an overhaul is necessary.

An in-frame overhaul includes all of the work that is
done for a
components that wear are replaced. The condition
of components is inspected. Those components are
replaced

Your Perkins dealer can provide these services and
componen
the components are operating within the appropriate
specifications.

top end overhaul. Additionally, some other

, if necessary.

ts. Your Perkins dealer can ensure that

SEBU8190 59

Maintenance Section

Overhaul (Major)

i02484872

Overhaul (Major)

Scheduling a Major Overhaul

Generally, a m
hours. The need for a major overhaul is determined
by several factors. Some of those factors are the
same factors t

An increase of oil consumption

•

An increase of crankcase blowby

•

A decrease and

•

Other factors must also be considered for determining
a major overh

The service hours of the engine

•

The wear metal analysis of the lube oil

•

An increase i

•

ajor overhaul is performed at 32000

hat determine the in-frame overhaul:

variation of cylinder compression

aul:

n the levels of noise and vibration

Major Overhaul Information

A major overhaul includes all of the work that is done
for top end overhauls and in-frame overhauls. In
some cases, the engine is relocated for disassembly.
Components that wear are disassembled and
inspected. If necessary, the parts are replaced. The
crankshaft is measured for wear. The crankshaft
may require regrinding. Alternatively, the crankshaft
may be replaced with a Perkins replacement part.
Your Perkins dealer can provide these services and
components. Your Perkins dealer can ensure that
the components are operating within the appropriate
specifications.

If you elect to perform an overhaul without the
services of a Perkins dealer, be aware of the following
recommendations.

Replacing of Components

Replace the following components during the major
overhaul.

Connecting rod bearings

•

Cylinder liners

•

An increase of wear metals in the lube oil indicates
that the bear
need to be serviced. An increase in the levels of
noise and vibration indicates that rotating parts
require serv

Note: It is possible for oil analysis to indicate a
decrease of
liners may be worn so that polishing of the bore
occurs. Also, the increased use of lube oil will dilute
the wear me

Monitor the engine as the engine accumulates
service ho
scheduling a major overhaul.

Note: The d
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.

ings and the surfaces that wear may

ice.

wear metals in the lube oil. The cylinder

tals.

urs. Consult your Perkins dealer about

riven equipment may also require service

Piston rings

•

Cylinder heads

•

Joints and bolts

•

Gaskets and seals

•

Main bearings

•

Water temperature regulators

•

Rebuilding or Replacing of Components

Rebuild the following components during the major
overhaul.

Carburetor

•

Gas regulator

•

Turbochargers

•

Engine Water pumps

•

Inspecting Components

Inspect the following components:

Chargecooler

•

Camshafts

•

60 SEBU8190
Maintenance Section
Overhaul (Top End)

Camshaft beari

•

Camshaft followers

•

Connecting rods

•

Crankshaft

•

Gear train and bearings

•

Governor

•

Inlet air pipi

•

Oil cooler

•

Oil pump

•

Pistons

•

Transformers

•

Valve train that includes the rocker gear

•

ngs

ng

Overhaul (Top End)

i02484906

i02484859

Overhaul Considerations

Overhaul Information

An overhaul is
of the engine. An overhaul is a maintenance interval
that is planned. The engine is rebuilt with certain
rebuilt parts

An overhaul also includes the following maintenance:

Inspection of all the parts that are visible during

•

the disassembly

Replacement of the seals and gaskets that are

•

removed

Cleaning of the internal passages of the engine

•

and the engine block

It is not practical to wait until the engine exhibits
symptoms of excessive wear or failure. It is not less
costly to wa
be the best value for the following reasons:

replacing the major worn components

or new parts that replace the worn parts.

it. A planned overhaul before failure may

Scheduling a Top End Overhaul

Top end overhauls are scheduled according to the
valve recession. This is achieved by recording the
valve clearance at each service and calculating
the valve recession. This measurement provides
an accurate indication of the rate of valve wear.
This measurement can be used to predict when a
cylinder head must be replaced. Plan for the top end
overhaul as the valve stem projection approaches
the maximum limit 1 mm (0.04 inch). Do not allow the
recession of the valves to exceed this limit.

Note: Generally, cylinder heads wear out at different
rates. In some cases, servicing the cylinder heads at
different times may be the most economic decision.
This depends on the valve recession of the individual
cylinders. However, this decision must include the
costs of additional downtime that is caused by this
procedure. Perform an economic analysis in order to
determine if cylinder heads should be serviced as a
group or divided into smaller groups.

Note: The generator or the driven equipment may
also require service when the engine overhaul is
performed.

Costly unpl

•

Many original parts can be reused according to the

•

guidelines

The service life of the engine can be extended

•

without the
engine failure.

Achieve th

•

of extended service life.

Overhaul I

Top end overhauls are determined by the recession
of the valv
cylinder compression, crankcase blowby, and oil
consumption. Major overhauls are determined by the
in-frame t

Some other factors that are important for determining
the overh
considerations:

Performa

•

Use of recommended lubricants

•

anned downtime can be avoided.

for reusable parts.

risk of a major catastrophe due to

e best cost/value relationship per hour

ntervals

es. In-frame overhauls are determined by

ests, and by results of oil analysis.

aul intervals include the following

nce of preventive maintenance

Use of recommended coolants

•

Use of rec

•

ommended fuels

SEBU8190 61

Maintenance Section

Radiator - Clean

Operating cond

•

Operation within acceptable limits

•

Engine load

•

Engine speed

•

itions

Overhaul Inspection

If the parts are not within the inspection specifications,
the parts should be replaced. The use of parts that
are not in wear
downtime and/or costly repairs. This can also
contribute to increased fuel consumption and
reduction of

Your Perkins dealer can provide the parts that are
needed to reb
cost.

Overhaul re

Perkins recommends a scheduled overhaul in order
to minimize
provide the lowest cost and the greatest value.
Schedule an overhaul with your Perkins dealer.

limits could result in unscheduled

engine efficiency.

uild the engine at the least possible

commendation

downtime. A scheduled overhaul will

Pressurized wa
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). In order to clean
a radiator wit
removed from the radiator. This will allow access to
both sides of the core.

Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with deterge
core with clean water.

Inspect the f
repaired. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and

ter may also be used for cleaning.

h dual cores, one core will need to be

nt and hot water. Thoroughly rinse the

ins for damage. Bent fins may be

seals. Make repairs, if necessary.

i02479722

Turbocharger - Inspect

Do not inspect the turbocharger. The turbocharger
must be replaced.

i02484850

i02481257

Radiator - Clean

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.

Personal injury can result from air pressure.

Personal injury can result without following prop­er procedure. When using pressure air, wear a pro­tective face shield and protective clothing.

Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.

Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
of the fan’s air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move the
air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.

Walk-Around Inspection

Inspect the Engine for Leaks and
for Loose Connections

A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.

For maximum engine service life, thoroughly inspect
the engine room before starting the engine. Look for
items such as leaks, loose bolts, loose connections
and trash buildup. Make repairs, as needed.

The guards must be in the proper place. Repair

•

damaged guards or replace missing guards.

Wipe all caps and plugs before the engine is

•

serviced in order to reduce the chance of system
contamination.

NOTICE
For any type of leak, clean up the fluid. If leaking is ob­served, find the source and correct the leak. If leaking
is suspected, check the fluid levels more often than
recommended until the leak is found or fixed, or until
the suspicion of a leak is proved to be unwarranted.

62 SEBU8190
Maintenance Section
WaterPump-Inspect

i02482020

NOTICE
Accumulated gr
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.

Ensure that cooling lines are properly clamped.

•

Check for leak

ease and oil on an engine is a fire haz-

s. Check the condition of all pipes.

Water Pump - Inspect

A failed water p
overheating problems that could result in cracks in
the cylinder heads, a piston seizure or other potential
damage to the e

ump might cause severe engine

ngine.

Inspect the water pumps for coolant leaks. Refer to

•

this manual, “

Note: The water pump seal is lubricated by coolant
in the cooling
of leakage to occur when the engine cools and the
parts contract.

Inspect the lubrication system for leaks at the front

•

crankshaft seal, the rear crankshaft seal, the oil
pan, the oil

NEVER use a flame to check for gas leaks. Use a
gas detector.

An open flame can ignite mixtures of air and fuel.
This will cause explosion and/or fire which could
result in severe personal injury or death.

Check the fuel system for leaks. Look for loose fuel

•

line clamps.

Inspect the piping for the air inlet system and the

•

elbows for cracks and for loose clamps.

Water Pump - Inspect”.

system. It is normal for a small amount

filters and the valve covers.

Visually inspect the water pump for leaks. If leaking
of the water pu
water pump.

Water Temper

mp seals is observed, replace the

i02484837

ature Regulator -

Replace

Remove the W
Regulator (Thermostat)

1. Drain sufficient coolant from the cooling system in

order to remove the water temperature regulator
(4). Remov

e the outlet hose (1).

ater Temperature

Inspect the wiring and the wiring harnesses for

•

loose connections and for worn wires or frayed
wires.

Inspect the ground straps for good connections

•

and for good condition.

Check the condition of the gauges. Replace any

•

gauge that is damaged. Replace any gauge that
can not be calibrated.

Inspect the exhaust system for leaks. If a leak is

•

found, make repairs.

ration 54

Illust

Typical example

g01240519

SEBU8190 63

Maintenance Section

Water Temperature Regulator - Replace

2. Remove the reta

ining nuts (7) and lift off the top

cover (2). Discard the joint (3).

3. Remove the set

screw and washer (6). Then

remove the elements (4) from the housing (5).

Check

Visually insp

1. Fill a suitable container with coolant. Place the

element in the

Note: If the valve (1) is open at ambient temperature
the elements

ect the elements for damage.

container.

must be renewed.

Illustration 55

Typical example

g01240533

2. Heat the coolant gradually. Use a thermometer

(2) in order to check the temperature of the
coolant. The opening temperature of the valve is
71 °C (159.8 °F). Ensure that the valve starts the
process of opening at this temperature. Ensure
that the valve opens to the full amount.

3. If the valve does not open or the valve does not

open to the full amount discard the old element.

Replace

1. Clean the mating face of the housing (5), and

clean the mating face of the cover (2).

Illustration 56

Typical ex

ample

g01240519

2. Install both elements (4) into the housing. Install

the setsc

rew and washer (6).

3. Install a new joint (3) and install the top cover.

Evenly to

rque all the retaining nuts (7) to a torque

of 50 N·m (37 lb ft).

4. Install t

he outlet hose (1) and tighten the hose clip.

5. Fill the cooling system with the correct amount of

coolant.

Refer to this manual , “Cooling System
Coolant Level - Check”. Operate the engine and
check for leaks.

64 SEBU8190
Reference Information Section
Reference Materials

Reference Information
Section

Reference Materials

i02484851

Maintenance Records

Perkins recommends the retention of accurate
maintenance records. Accurate maintenance records
can be used for the following purposes:

Determine operating costs.

•

Establish maintenance schedules for other engines

•

that are operated in the same environment.

Show compliance with the required maintenance

•

practices and maintenance intervals.

Maintenance records can be used for a variety of
other business decisions that are related to engine
maintenance.

Maintenance records are a key element of a
maintenance program that is well managed. Accurate
maintenance records can help your Perkins dealer to
fine tune the recommended maintenance intervals in
order to meet the specific operating situation. This
should result in a lower engine operating cost.

SEBU8190 65

Reference Information Section

Reference Materials

i02481255

Maintenance Log

Table 16

Engine Model

Serial Numbe

Service

Hours

Quantity

Of Fuel

r

Service Item Date Authorization

Customer Identifier

Arrangement Number

66 SEBU8190
Reference Information Section
Reference Materials

i02484853

Valve Data Sheet

Table 17

Engine Model

Cylinder

1

2

3

4

5

6

7

8

Cylinder

Pressure

Serial Number Service Hours

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhau

Inlet

Inlet

Exhaust

Exhaust

Valve Location

st

Current

Measure

Reset size Wear

-

SEBU8190 67

Reference Information Section

Reference Materials

i02484854

Warranty Information

The engine inst
the engine must be approved. The engine must
be operated with the approved fuel, lubricant and
coolant. Refe
information.

allation and the service interval for

r to Perkins Engines Stafford for more

68 SEBU8190
Index Section

Index

A

After Startin

After Stopping Engine............................................ 32

Alarms and Shutoffs .............................................. 25

Testing Alarm

Alternator - Inspect ................................................ 37

Alternator and Fan Belts - Inspect......................... 37

Alternator and

Alternator ........................................................... 37

Fan Drive Belts .................................................. 38

Alternator Pul

B

Battery - Replace................................................... 39

Battery Electr

Before Starting Engine ..................................... 11, 27

Burn Prevention....................................................... 9

Batteries............................................................... 9

Coolant................................................................. 9

Oils....................................................................... 9

C

Carburetor Air/Fuel Ratio - Check/Adjust .............. 40

Cold Weather Starting ........................................... 27

Control Panel......................................................... 26

Control Panel - Inspect .......................................... 40

Cooling System Coolant - Change ........................ 40

Drain .................................................................. 40

Fill ...................................................................... 41

Cooling System Coolant - Test/Add....................... 42

Check the specif

Cooling System Coolant Level - Check ................. 42

Crankshaft Vibration Damper - Inspect ................. 43

Crushing Prevent

Cylinders - Inspect................................................. 44

D

Driven Equipment

Driven Equipment - Inspect/Replace/Lubricate ..... 44

E

Electrical Syste

Grounding Practices .......................................... 12

Emergency Stopping ............................................. 31

Typ ical Procedur

Engine - Clean....................................................... 44

Engine Air Cleaner Element - Replace.................. 45

Engine Air Cleaner

Test the Service Indicator................................... 45

g Engine ............................................. 29

s and Shutoffs .............................. 25

Fan Belts - Replace ....................... 37

ley - Check ....................................... 38

olyte Level - Check .......................... 40

ic gravity of the coolant............ 42

ion and Cutting Prevention ......... 11

- Check..................................... 44

m ................................................... 12

einOrdertoStoptheEngine.. 31

Service Indicator - Inspect ...... 45

Engine Air Precleaner - Clean ............................... 46

Engine Crankcase Breather - Clean/Replace........ 46

Closed Breath

Open Breather ................................................... 46

Engine Mounts - Check ......................................... 47

Engine Oil - Ch

Engine Oil Filter - Change ..................................... 49

Engine Oil Filter (Auxiliary) - Change .................... 48

Change the Filt

Engine Oil Level - Check ....................................... 49

Engine Oil Sample - Obtain ................................... 50

Replacement Pro

Filter ................................................................. 50

Engine Operation................................................... 30

Partial load and

Engine Protective Devices - Check ....................... 51

Visual Inspection................................................ 51

Engine Speed/Ti

Speed Sensor .................................................... 51

Timing Sensor.................................................... 51

Engine Starting

Engine Stopping .............................................. 12, 31

Engine Valve Lash and Bridge - Adjust ................. 52

Adjust the bridge

Install the Cover ................................................. 53

Remove the Cover............................................. 52

Valve lash........................................................... 53

Exhaust Piping - Inspect ........................................ 53

F

Fan Drive Pulley -

Features and Controls ........................................... 24

Fire Prevention and Explosion Prevention .............. 9

Fire Extinguisher

Lines, Tubes and Hoses .................................... 10

Fluid Recommendations........................................ 34

Cooling System Spe

General Lubricant Information ........................... 34

Foreword ................................................................. 4

California Proposi

Literature Information........................................... 4

Maintenance ........................................................ 4

Maintenance Interv

Operation ............................................................. 4

Overhaul .............................................................. 4

Safety................................................................... 4

Fuel Filtration System - Service............................. 54

Fuel System Fuel Filter Differential Pressure -

Check................................................................... 54

G

Gas Pressure Regulator - Check........................... 54

Gauges and Indicato

er System.................................... 47

ange .............................................. 48

er with the Engine in Operation.. 48

gram for the Engine Oil and

Low Load Operation................. 30

ming Sensor - Clean/Inspect....... 51

................................................ 12, 27

................................................ 52

Check....................................... 54

................................................ 10

cifications........................... 34

tion 65 Warning ....................... 4

als.......................................... 4

rs .......................................... 23

SEBU8190 69

Index Section

General Hazard

Containing Fluid Spillage ..................................... 8

Dispose of Waste Properly .................................. 9

Fluid Penetrat

Pressure Air and Water........................................ 8

H

Hoses and Clamp

Replace the Hoses and the Clamps .................. 55

I

Ignition Syste

Replace................................................................ 55

Check the Plug and Adjust the Plug .................. 56

Check the Spark

Replace the Plug................................................ 57

Ignition System Timing - Check/Adjust .................. 57

Ignition Syste

Important Safety Information ................................... 2

Inlet Air System - Inspect....................................... 58

L

Information ............................ ........ 7

ion.................................................. 8

s - Inspect/Replace ................... 54

m Spark Plugs - Check/Adjust/

Plug ........................................ 56

ms ..................................................... 11

P

Performance Parameters ...................................... 24

Air, Charge Coo

Altitude ............................................................. 2 4

Air/Fuel Ratio ..................................................... 24

Plate Location

Engine Identification........................................... 20

Serial Number Plate........................................... 20

Product Descri

Cogeneration engine.......................................... 17

Cooling System.................................................. 17

Electrounit .......................................................... 17

Engine Service Life............................................ 17

Fuel System....................................................... 16

Ignition System

Lubrication System ............................................ 17

Product Identification Information .......................... 20

Product Informat

Product Lifting........................................................ 22

Product Storage..................................................... 22

Level “A ” ........................................................... 22

Level “B ” ........................................................... 22

Level “C ” .......................................................... 22

R

ler Water Temperature and

s and Film Locations....................... 20

ption ............................................... 16

.................................................. 17

ion Section .................................. 14

Lifting and Storage ................................................ 22

M

Maintenance In

Maintenance Log................................................... 65

Maintenance Records............................................ 64

Maintenance Se

Manual Stop Procedure......................................... 31

Model View Illustrations......................................... 14

Model Views and S

Mounting and Dismounting..................................... 11

O

Operation Secti

Overhaul (In-Frame).............................................. 58

In-Frame Overhaul Information.......................... 58

Scheduling an In-

Overhaul (Major).................................................... 59

Major Overhaul Information ............................... 59

Scheduling a Maj

Overhaul (Top End) ............................................... 60

Scheduling a Top End Overhaul ........................ 60

Overhaul Conside

Overhaul Information ......................................... 60

terval Schedule ............................. 36

ction ............................................. 33

pecifications ............................ 14

on.................................................. 22

Frame Overhaul..................... 58

or Overhaul............................. 59

rations ....................................... 60

Radiator - Clean .................................................... 61

Reference Information Section.............................. 64

Reference Materia

Refill Capacities..................................................... 33

Cooling System.................................................. 33

Lubrication Syste

S

Safety Messages..................................................... 5

(1) Engine Derate................................................. 6

(2) Universal Warning .......................................... 6

(3) Engine Oil Level ............................................. 7

Safety Section ......................................................... 5

Sensors and Electrical Components ..................... 24

Detonation System ( If Equipped) ...................... 25

Electronic Ignitio

Governor ............................................................ 25

Switches............................................................. 24

Specifications ........................................................ 17

General Engine Specifications........................... 17

Piston Positions for Valve Lash Setting ............. 19

Starting the Engine

Automatic Starting.............................................. 29

Engine Starting Procedure................................. 28

Final Checks and Firs

Manual starting .................................................. 29

Operation of the Generator Set Control Panel... 29

Purging Unburned Gas

Starting with Jump Start Cables ............................ 29

ls .............................................. 64

m ............................................ 33

n System (EIS) ........................ 24

................................................ 27

t Engine Start .................. 28

...................................... 28

70 SEBU8190
Index Section

T

Table of Contents..................................................... 3

Turbocharger -

V

Valve Data Sheet................................................... 66

W

Walk-Around Inspection ........................................ 61

Inspect the Engine for Leaks and for Loose

Connections ..................................................... 6

Warranty Information............................................. 67

Water Pump - Inspect............................................ 62

Water T emperat

Check................................................................. 63

Remove the Water Temperature Regulator

(Thermostat)

Replace.............................................................. 63

Inspect .......................................... 61

1

ure Regulator - Replace ............... 62

..................................................... 62

Product and Dealer Information

Note: For product identification plate locations, see the section “Product Identification Information” in the Operation

and Maintenance Manual.

Delivery Date:

Product Information

Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information

Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:

Copyright ©2006Perkins Engines Company Limited
All Rights Reserved Printed in UK