Perkins Engine 4012, Perkins 4012, 4016 Gas, 4016 Service Manual

TSL4187E, Issue 1
February 1998

User’s
Handbook

Perkins 4012 and 4016 Gas

4012TESI
4016TESI

WARNING

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND
WARNINGS MENTIONED IN THIS MANUAL.

IMPROPER OPERATION OR MAINTENANCE PROCEDURES
COULD RESULT IN A SERIOUS AC CIDEN T OR DAMAGE TO THE
EQUIPMENT CAUSING INJURY OR DEATH.

NON-COMPLIANCE WITH THESE INSTRUCTIONS AND THOSE
INCLUDED IN THE INSTALLATION MANUAL TSL4200 MAY
INVALIDATE THE WARRANTY OFFERED WITH THE ENGINE.

MAKE QUITE CERTAIN THAT THE ENGINE CANNOT BE
STARTED IN ANY WAY BEFORE UNDERTAKING ANY
MAINTENANCE, PARTICULARLY IN THE CASE OF
AUTOMATICALLY STARTING GENERATING SETS.

4012/16 Gas, February 1998

INTRODUCTION

The purpose of this Manual is to enable the operator to carry out routine servicing of the engine.
Before undertaking any work on the engine the appropriate section in the Workshop Manual should be read
fully and completely understood prior to starting work.
The information contained within the manual is based on such information as was available at the time of going
to print. In line with Perkins Engines (Stafford) Limited policy of continual development and improvement that
information may change at any time without notice. The engine user should therefore ensure that he has the
latest information before starting work.
The instructions contained in this Manual will, provided that they are correctly carried out, ensure the safe
operation of the equipment.
Users are respectfully advised that it is their responsibility to employ competent persons to operate, maintain
and service the equipment in the interest of safety.
Certain overhaul operations are impracticable without the use of special tools, and those operators who are
not equipped to undertake major repairs are urged to consult their Perkins distributor.
When not working on the engine, ensure that all covers, blank flanges, doors, etc., are refitted to openings to
prevent the ingress of dirt, etc.
Please quote the engine type and serial number with all your enquiries. This will help us to help you. The type
and serial number are on a plate fitted to the crankcase.
If any doubt exists regarding the installation, use or application of the engine, the Installation Manual should
be consulted for further advice contact Applications Department at Perkins Engines (Stafford) Ltd.
Oil change intervals may be changed according to operating experience by agreement with Perkins Engines
(Stafford) Limited and subject to oil analysis being carried out at regular intervals.
Please note that this 4000 Series manual also covers SE engines dispatched from the factory from 1 March

1996. A table of equivalent engine designations is given on page 2.

PERKINS COMPANIES
Perkins Group of Companies

Perkins Engines (Peterborough) Ltd.

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

Perkins Engines (Shrewsbury) Ltd.

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

Perkins Engines (Stafford) Ltd.

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

Perkins Powerpart Distribution Centre

Frank Perkins W ay,
Northbank Industrial Park, Irlam,
Manchester, M44 5PP, England.
Tel: [phone]
Specifications Help Desk
Tel: [phone]
Fax: [phone]
Specifications Help Desk
Tel: [phone]
Telex: 32501 PERKEN G

Perkins I nternational - North America

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

Perkins Engines Latin America Inc

999 Ponce de Leon Boulevard,
Suite 710, Coral Gables,
Florida 33134, U.S.A.
Tel: [phone]
Telex: 32501 PERKEN G
Fax: [phone]

Perkins En gines Australia Pty Ltd

Suite 2 , 364 Main Street, Mornington
3931, V i ctoria, Australia.
Tel: [phone]
Telex: 30816
Fax: [phone]

Motori Perkins SpA

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

Perkins Motoren GmbH

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

Moteurs Perkins SA

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

Perkins International Ltd.

Varity Asia/Pacific
Suite 3301, Convention Plaza,
1 Harbour Road, Wanchai,
Hong Kong.
Tel: [phone]
Fax: [phone]

Perkins Engines (Far East) Pte Ltd.

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

In addition to the above companies, there are Perkins distributors in most countries. Perkins Engines
(Peterborough) Limited or one of the above companies can provide distributor handbooks Publication No. 1407/4/97.

Publication TSL4187
Published by the Technical Publications Department, Stafford.
© 1998 Perkins Engines (Stafford) Limited.

4012/16 Gas, February 1998 1

INTRODUCTION

PERKINS ENGINES (STAFFORD)

ENGINE DESIGNATIONS

4000 SERIES AND SE SERIES

EQUIVALENT TERMS

4000 SERIES SE SERIES

4012TESI 12SETCWG
4016TESI 16SETCWG

2 4012/16 Gas, February 1998

CONTENTS

Page

INTRODUCTION 1
ENGINE DESIGNATIONS 2

BRIEF DESCRIPTION OF THE 4012/16 GAS ENGINES 4
PHOTOGRAPHS INSERTS
GENERAL INFORMATION 5
GAS ENGINE DATA 7 - 10

TORQUE SETTINGS 11 - 13
LUBRICATING OIL 14 - 16
COOLANT CORROSION INHIBITORS, ANTI-FREEZE 17
GAS SPECIFICATION 18 - 19

OPERATING INSTRUCTIONS 20 - 21

PREPARATION FOR INITIAL START 20
PRIMING THE TURBOCHARGER 20
BATTERIES 21
FILLING THE COOLING SYSTEM 21
INSTRUMENT PANEL (ENGINE MOUNTED) 22 - 24
EXHAUST TEMPERATURE GAUGE (OPTIONAL) 24
FINAL CHECKS AND INITIAL START UP 25 - 26
GAS ENGINE START/STOP SEQUENCE (AUTOMATIC) 27

MAINTENANCE PROCEDURES 28 - 41

OVERHAUL PERIODS & CONTINUOUS DUTY CHECKLIST 42 - 44
FAULT TRACING CHART 45

WIRING DIAGRAMS

4012/16TESI (MINNOX) WITH CAV STARTER AND PROTECTION SWITCHES 46
4012/16 (GAS) MINNOX ENGINE STARTING CIRCUIT WITH BUTEC

STARTERS AND OPTIONAL INSTRUMENT PANEL 47
EARLY 4012 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM 48
CURRENT 4012 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM 49
4012/16 (GAS) MINNOX ENGINE WIRING DIAGRAM OF STANDARD
PROTECTION PACK AND OPTIONAL BRITISH GAS COUNCIL

PROTECTION EQUIPMENT 50
EARLY 4016 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM 51

CURRENT 4016 SERIES GAS IGNITION AND HEINZMAN WIRING SYSTEM 52
4012/16 LUBRICATING OIL FLOW DIAGRAM TP315
4012/16TESI FRESH AND RAW WATER CIRCULATION DIAGRAM TP381

(HEAT EXCHANGER COOLED)
4012TESI FRESH AND RAW WATER CIRCULATION DIAGRAM TP384

(RADIATOR COOLED)
4012/16TESI ENGINE IGNITION AND GAS FLOW DIAGRAM TP351

4012/16 Gas, February 1998 3

BRIEF DESCRIPTION OF THE 4012/16 GAS ENGINES

4012TESI
(MINNOX)

4012TESI
(MINNOX) 200 L.C.

4012TESI
(MINNOX) 140 L.C.

4012TESI
(MINNOX) 140 H.C.

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pumpandcoolingcircuit, lean burn, low NOx emission levels, 9.5:1
compression ratio

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pumpandcoolingcircuit,leanburn,withNOx emission of less than
200 g/GJ, 9.5:1 compression ratio.

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pumpandcoolingcircuit,leanburn,withNOx emission of less than
140 g/GJ, 9.5:1 compression ratio.

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pumpandcoolingcircuit,leanburn,withNOx emission of less than
140 g/GJ, 11.5:1 compression ratio.

4016TESI
(MINNOX) 200 L.C.

4016TESI
(MINNOX) 140 L.C.

4016TESI
(MINNOX) 140 H.C.

4016TESI
(MINNOX) 90 H.C.

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pumpandcoolingcircuit,leanburn,withNOx emission level of 200
g/GJ or less, 9.5:1 compression ratio.

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pump and cooling circuit, lean burn, with NOx emission of 140 g/
GJ or less, 9.5:1 compression ratio.

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pump and cooling circuit, lean burn, with NOx emission of 140 g/
GJ or less, 11.5:1 compression ratio.

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pump and cooling circuit, lean burn, with NOx emission of 90 g/GJ
or less, 11.5:1 compression ratio.

4 4012/16 Gas, February 1998

4012TESI (MINNOX)

4012TESI (MINNOX)

4016TESI (MINNOX)

4016TESI (MINNOX)

SAFETY
Engine lift equipment

Use only the lift equipment which is designed
for the engine.

Use lift equipment or obtain assistance to lift
heavy engine components such as the
cylinder block, cylinder head, flywheel
housing, crankshaft and flywheel.

Check the engine lift brackets for security
before the engine is lifted.

Asbestos joints

Some joints and gaskets contain
compressed asbestos fibres see Warning
labelFig.1in a rubber compound or in a
metal outer cover. The 'white' asbestos
(Chrysotile) which is used is a safer type of
asbestos and the danger of damage to
health is extremely small.

Contact with asbestos particles normally
occurs at joint edges or where a joint is
damaged during removal, or where a joint is
removed by an abrasive method.

To ensure that the risk is kept to a minimum,
the procedures given below must be
followed when an engine which has
asbestos joints is dismantled or assembled.

●

Work in an area with good ventilation.

●

Do NOT smoke.

●

Useahandscrapertoremovethejoints

- do NOT use a rotary wire brush.

●

Ensure that the joint to be removed is

wet with oil or water to contain any loose

particles.

●

Sprayall asbestosdebriswithwaterand

placeitinaclosedcontainerwhichcan

be sealed for safe disposal.

Dangers from used engine oils

Prolongedand repeated contact with mineral
oil will result in the removal of natural oils
from the skin, leading to dryness, irritation
and dermatitis. The oil also contains
potentially harmful contaminants which may
result in skin cancer.

Adequate means of skin protection and
washing facilities should be readily available.

GENERAL INFORMATION

Fig. 1

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

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

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

3. Do not put oily rags into pockets.

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

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

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

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

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

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

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

11. Degrease components before handling
if practicable.

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

4012/16 Gas, February 1998 5

GENERAL INFORMATION

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm. Battery
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.

Environmental protection

There is legislation to protect the
environment from the incorrect disposal of
used lubricating oil. To ensure that the
environment is protected, consult your Local
Authority who can give advice.

Viton seals

Some seals used in engines and in
components fitted to engines are made from
Viton.

Viton is used by many manufacturers and is
a safe material under normal conditions of
operation.

If Viton is burned, a product of this burnt
material is an acid which is extremely
dangerous. Never allow this burnt material
to come into contact with the skin or with the
eyes.

If it is necessary to come into contact with
components which have been burnt, ensure
that the precautions which follow are used:

●

Ensure that the components have
cooled.

●

Use Neoprene gloves and discard the
gloves safely after use.

●

Wash the area with a calcium hydroxide
solution and then with clean water.

●

Disposal of gloves and components
which are contaminated, must be in
accordance with local regulations.

Practical Information
To clean components

It is important that the work area is kept clean
and that the components are protected from
dirt and debris. Ensure that dirt does not
contaminate the fuel system.

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

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

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

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

If there is contamination of the skin or eyes,
wash the affected area with a continuous
supply of clean water or with a calcium
hydroxide solution for 15-60 minutes. Obtain
immediate medical attention.

6 4012/16 Gas, February 1998

GAS ENGINE DATA

The figures quoted are based on engines set to meet the ISO 3046/1 1981 Condition.
For full technical data please refer to the Product Information Manual.
Type (Gas) 12 cylinder and 16 cylinder (MINNOX)'V' form, water cooled, turbocharged,wet
exhaust manifolds with separate raw water cooled charge air cooler.

RANGE 4012TESI (MINNOX) 4016TESI (MINNOX)

Cycle 4 stroke
Configuration ‘V’ form
Bore 160 mm
Stroke 190 mm
Total swept volume 45.842 litres 61.123 litres
Compression ratio 9.5:1 or 11.5:1
Rotation Anti-clockwise looking on flywheel end

Firing order
Cylinder numbering Cylinder 1 furthest from flywheel

Cylinders designated A are on the left side of the engine when viewed from opposite end to the flywheel, with
cylinders designated B on the right hand side of the engine.
NOTE: This is NOT the same as the British Standard and ISO designation.

Valve clearances Exhaust 0.4 mm (0.016”)
Valve dia (mm) inlet & exhaust 48
Valve timing See Workshop Manual Section U7
Valve setting See page 39 onwards
Ignition timing See engine number plate
Piston speeds

1A,6B,5A,2B,3A,4B
6A,1B,2A,5B,4A,3B

Engine r/min

1000
1200
1500

1A,1B,3A,3B,7A,7B,5A,5B
8A,8B,6A,6B,2A,2B,4A,4B

m/s (ft/min)

6.33 (1247)

7.60 (1496)

9.50 (1870)

TYPICAL COOLING SYSTEM

Approved coolants See page 17
Total capacity engine including

charge air cooler & wet exhaust
manifolds

Total capacity engine and radiator 239 litres (52.6 gals)
Total capacity engine and heat

exchanger
Engine shut down temperature 96°C

Max. temperature into engine
Thermostat opening temperature 71°C (nat. gas) 85°C (landfill or biogas) 92°C (HC engines)

System pressure 0.5 - 0.7 bar
Maximum pressure at jacket

coolant pump outlet

To be determined from heat dissipated and water flow through each

81 litres (17.8 gals) 110 litres (24.3 gals)

278 litres (61.3 gals)

153 litres (33.7 gals) 183 litres (40.3 gals)

particular engine model

2.5 bar max

4012/16 Gas, February 1998 7

GAS ENGINE DATA

GAS SYSTEM

4012TESI (MINNOX) 4016TESI (MINNOX)

Approved gas British Natural Gas
Lower calorific value 34.71 MJ/nm
Carburettor mixing unit Deltec 200 - 11
Carburettor throttle body Deltec 100 - 11 Deltec 140 - 11
Gascontrolvalve Deltec36mmdia. Deltec45mmdia.

Deltec 38 mm dia. 4016TESI (minnox 140 HE) ONLY
Gas pressure min. 15 m bar (1.5 kPa)
Gas pressure max. 50 m bar (5 kPa)
Regulator type (Zero pressure) Dungs FRS 220, 5065 or 5100
Later engines or Kromschroder GI50 R02 or GI65 R02

If above 50 mbar (5kPa), an additional regulator should be used in

Supply pressure

Additional items to meet The Instituion of Gas Engineers procedures IGE/UP/3 for 4012/16 (Minnox)
Low pressure detector
Gas solenoid valves Not Perkins supply

Spit back detector PerkinsPart No. (see Spares Book)
Manual gas shut-off valve Perkins Part No. (see Spares Book) (if fitted)

order to bring the supply pressure to between the max. & min.

figures given above

Perkins Part No. (see Spares Book)

(low pressure gas supply only)

3

IGNITION SYSTEM

Ignition unit type Altronic DISN 800
Ignition coil type Altronic 501 061 (L.C. engines) Altronic 591 010 (H.C. engines)

Spark plug type

Spark plug gap

CHAMPION RN79G 14mm (earlier L.C. engines)

CHAMPION RB77 WPC 18mm (later engines)

RN79G 0.5 mm (0.020”)

RB77WPC 0.4 mm (0.015”)

GOVERNOR

Make Heinzmann Electronic
Type 2 x E6V 2 x E10

LUBRICATION SYSTEM

Recommended oil See pages 14 - 16
Type of system Wet sump, external mounted oil pump
Total oil capacity (oil cooler and filter) 178 litres (39 gals) 238 litres (51 gals)
Sump capacity (dipstick) min. 136 litres (30 gals) 147 litres (32 gals)
Sump capacity (dipstick) max. 159 litres (35 gals) 214 litres (47 gals)

2

Min.oilpressure (ratedspeed)to bearings 340 kPa (49 lb/in
Crankcase pressure max 25 mm water gauge
Max. oil temperature in sump 105°C
Lubricating oil filter disposable canister type
Crankcase breather Closed circuit

)

8 4012/16 Gas, February 1998

INDUCTION SYSTEM

4012TESI (MINNOX) 4016TESI (MINNOX)

Air cleaner Twin
Type (paper element) S551A
Max. air intake depression 543 mm H

406 mm H

Air restriction Indicator setting 380 mm H
Turbocharger

Twin Garrett (4016TESI 140 H.C. only)

Twin Schwitzer (all other engines)

O (40 mm Hg) (L.C. engines)

2

O (30 mm Hg) (H.C. engines)

2

O

2

EXHAUST SYSTEM

Manifold type WET
Exhaust outlet flange Vertical (twin)
Mating flange 2 x 6” Table D
Max. exhaust back pressure 40 mm Hg
Max. exhaust temperature (°C)

(after turbocharger)

See Product Information Manual

FLYWHEEL

SAE Size 18”
No. of teeth on ring gear 156

GAS ENGINE DATA

FLYWHEEL HOUSING

SAE Size ‘00’

CRANKSHAFT

Maximum overhung weight on rear
bearing

T.V. damper 1 x 18” 2 x 20”
NOTE: Subject to torsional vibration investigation different T.V. dampers may be fitted.

1700 Kg

DRY WEIGHT

Dry weight 4380 kg 5520 kg
Wet weight 4680 kg 5820 kg

HOLDING DOWN BOLT HOLES

Bolt size (engine feet) 22 mm
No. off 8

ELECTRICAL SYSTEM

Voltage 24
Alternator type Prestolite LNA4024/5 with internal regulator
Alternator output (amps) 30 at a stabilised output of 28 volts
Starter motor type (Twin) Prestolite/Butec MS1/108 MS7/5
No. of teeth (gear ring) 156
No. of teeth (starter motor) 12
Battery capacity cold cranking amps

to IEC Standard at 0°C (32°F)
Battery (lead acid) 24 V (2 x 12 V) at 0°C (32°F) (286 Ah)

286 (each battery) 286 (each battery)

4012/16 Gas, February 1998 9

GAS ENGINE DATA

PROTECTION EQUIPMENT

Before resetting protection equipment, it must be established whether special settings (for that individual

2

)

high water

²)

engine) have been specified in the engine sales contract. This is particularly important with ALL
temperature settings, and ALL
Standard
High air manifold pressure switch 172 kPa (25.1 lb/in

Shutdown switches Alarm Shutdown

High oil temperature 115°C 120°C
Low oil pressure 2.06 bar (30 lb/in
High water temperature
71°C Thermostat

85°C Thermostat
96°C Thermostat

Caution: The above standard settings do not
Overspeed 15% (on 1500 rev/min only)
High air manifold bursting disc pressure

(Early engines only)

settings for protection equipment are as follows:

Cogen applications.

supercede any settings specified in the engine sales contract.

²)

91°C
96°C

100°C

75 lb/in²at 42°C or 58 lb/in²at 120°C

1.93 bar (28 lb/in

96°C
101°C
105°C

AIR STARTING

Air Starter Pressure 150 lb/in²(1034 kPa)
Compressed air supply 170 lb/in²(1172 kPa)
Type Ingersoll-Rand Type SS815

INSTRUMENT PANEL (ENGINE MOUNTED)

Normal operation
Oil pressure Between 300 - 560 kPa (42.6 - 80 lb/in
Oil temperature Between 80 - 90°C(176 - 194°F)
Water temperature Between 65 - 85°C(149 - 185°F)
Exhaust temperature See Product Information Manual
Boost pressure See Test Certificate

COOLANT JACKET HEATING

Heater 2 x 4 kw

²)

10 4012/16 Gas, February 1998

TORQUE SETTINGS

WARNING

IT IS ESSENTIAL THAT THE CORRECT LENGTH OF SCREW OR

BOLT IS USED. INSUFFICIENT THREAD MAY RESULT IN THE
THREAD BEING STRIPPED. WHEREAS TOO LONG A THREAD MAY RESULT IN
BOTTOMING IN A BLIND HOLE, OR CATCHING ON ADJACENT COMPONENTS.

NOTE: * Bolt and threads must be lubricated with clean engine oil.

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

on the threads with P.B.C. (Poly-Butyl-Cuprysil) grease. Important: See Section R10 in

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

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

TORQUE SETTINGS
CYLINDER HEAD GROUP Ibf.ft Nm

** Cylinder head bolt (early type) M24 550 750

See Section R14

** Cylinder head bolt (later (waisted) type) M24 530 723
Rocker shaft bolt/nut M16 90 120
Rocker adjuster nut inlet/exhaust M12 35 50
Rocker box bolt M10 35 50
Air manifold bolt M10 35 50
Exhaust manifold bolt M10 50 70
Turbocharger V-band clamp nuts - (Schwitzer) 7 9.5

(Mitsubishi) 7 9.5
(Garrett) 10 13.5

Sandwich plate r etaining capscrew (if fitted) M10 40 57

CRANKCASE AND CRANKSHAFT GROUPS

* Main bearing bolt M24 580 783
Side bolts (main bearing caps) M16 124 168
Bolts sump to crankcase M10 40 57
* Connecting rod bolt M16 210 285
Viscous damper bolts to crankshaft M16 250 340
Flywheel bolt to crankshaft M16 250 340
Front drive adaptor bolts to crankshaft M16 250 340
Balance weight bolt M16 250 340
Front crankshaft pulley bolt M 16 250 340
Piston cooling jet setscrew M10 35 50
Flywheel housing bolt M10 35 50

LUBRICATING OIL PUMP

Bolts, pump housing to gearcase plate M10 35 50
Thin nut gear to drive shaft M24 175 237

4012/16 Gas, February 1998 11

TORQUE SETTINGS

Ibf.ft Nm

CAMSHAFT GROUP

Camshaft gear bolt M12 110 150
Camshaft thrust plate bolt M10 35 50
Camshaft follower housing capscrew M10 50 70
Cam follower housing bolt M10 35 50
Idler gear hub bolts M10 35 50

WATER PUMP AND OIL PUMP GROUPS

Water pump/oil pump gear units M24 170 230
Water header to oil cooler bolts M10 35 50
Water header to gearcase bolts M10 35 50
Raw water pump gear securing nut (non lubricated thread) M35 184 250
Engine Feet M12 70 95

GOVERNOR

Control shaft mounting plate bolt M10 35 50

FAN DRIVE

Fan driven pulley taper lock bush screw

1

/2"BSW 35 50

5

/8" BSW 124 170

ALTERNATOR

Drive pulley taper lock bush screws

3

/8"BSW 14 20

IGNITION SYSTEM

Sparkplug M18x1.5 35 50
Adaptor clamp capscrew M12 100 136
Adaptor clamp screw (earlier engines) M10 50 68
Retaining bolt for timing disc cover M10 35 50
Timing disc housing to mounting plate bolt M10 35 50
Drive gear screw M10 50 70
Drive coupling capscrew M6 10 13.5
Driven gear capscrew M10 50 70
Magnet disc to shaft nut M12 35 50
Disc shaft flange to camshaft bolt M12 120 171

FLEXIBLE COUPLING (HOLSET)

Flexible coupling cover screw M12 or1/2" UNC 90 129
Coupling driving flange screws (coupling size 2.15) M12 or1/2" UNC 90 129
toflywheel (couplingsize3.86) M16or5/8" UNC 175 250

12 4012/16 Gas, February 1998

TORQUE SETTINGS

GENERAL TORQUE LOADINGS

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

Thread Size (mm) Ibf.ft Nm

81825
10 35 50

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

4012/16 Gas, February 1998 13

LUBRICATING OIL

QUANTITY OF OIL

4012TESI 4016TESI
The total system capacity 178 litres (39 gallons) 238 litres (52 gallons)
The maximum sump capacity 159 litres (35 gallons) 214 litres (47 gallons)
The minimum dipstick mark indicates 136 litres (30 gallons) 147 litres (32 gallons)

CAUTION
In order to select a suitable lubricating oil for a gas engine it is necessary to consider
the fuel quality.

NATURAL GAS ENGINES (NO ACIDIC PRODUCTS PRESENT)

The oil should be a grade that is specifically formulated by all the major oil companies for
turbocharged and charge cooled natural gas engines. The oil should contain anti-wear and
detergent/dispersant additives. The oil is to have high resistance to oxidation and have
good thermal stability. Modern gas engine oils do not rely on a high total base number to
achieve long life and the special additive packages that are now available from many of the
major oil suppliers now meet this criteria.
Engines fitted with oxidizing catalysts (2 way) require a lubricant that is low in zinc and
phosphorus, it is essential that the oil supplier confirms that the brand of oil supplied is
compatible with the catalyst.

BIOGAS ENGINES (CONTAINING ACIDIC PRODUCTS AT LEVELS APPROVED BY PERKINS ENGINES (STAFFORD) LTD

These engine require a lubricating oil that has more reserve alkalinity than the natural gas
engine and therefore the TBN should be more than 8 and less than 10 with the sulphated
ash in the range of 0.5 to 1.1%. The oil supplier will assist with the selection of suitable oils
when presented with the gas analysis. (TBN = Total Base Number).

NATURAL GAS BIOGAS ENGINES

Where gas engines oils are not available, please consult Perkins Engines (Stafford) Ltd for
advice.

GRADE OF OIL

The viscosity of the oil used should be either SAE 30 or SAE 40. In general SAE 30 is used
at temperature less than 30°C average ambient temperature and SAE 40 more than 30°C.
As these engine are generally operating continuously, it is possible to use higher viscosity
oils as sluggishness in starting is not generally critical.
The use of SAE40 will give reduced oil consumption but under certain conditions it will also
give reduced oil change periods.

OIL CHANGE PERIOD (NATURAL GAS ENGINES)

For normal operation of gas engines, change the oil after the first 500 hours, after which the
oil change period is 800 hours or annually which ever is the sooner.
It may be possible to extend the oil change period, where an oil change programme has
been approved by Perkins Engines (Stafford) Ltd, based upon the analysis of oil samples
taken during the first 1000 hours of engine use. However even if an analysis is showing a
satisfactory oil quality, the oil life should not be extended above 1000 hours.

14 4012/16 Gas, February 1998

LUBRICATING OIL

The following should be regarded as critical parameters:
Viscosity at 100°C 16.5 cSt maximum
Insolubles 1.5 maximum
Total Acid Number (TAN) less than 4 times the TAN value for new oil.
Total Base Number (TBN) 50% less than new oil value.
Total base number (TBN) and total acid number (TAN) must not cross over.
Nitration 25 maximum
Oxidation 25 maximum
Water 0.2% maximum
Iron Less than 20ppm*
Copper Less than 40ppm*
NB Oil samples should be taken from the mean level in the engine sump never from the
sump drain plug.
Should there be a lubricating oil supply problem or a high sulphur content in the gas, Perkins
Engines (Stafford) Ltd should be contacted to give advice in selecting suitable formulations.

OIL CHANGE PERIOD (BIOGAS ENGINES)

Engines that are operated on either digester gas or landfill gas are to be subjected to special
conditions regarding the oil change periods.
When the engine/s are first commissioned an analysis of the site gas is to be submitted to
Perkins Engines (Stafford) (this is addition to the analysis supplied at the order stage) and
a description of the proposed lubricating oil that is to be used.
When the engine starts operating it is essential that oil samples are taken at intervals of
every 150 hours with the result of the a nalysis being sent to Perkins Engines (Stafford) at
the earliest opportunity.
This course of action is necessary because of the variability of the gas. If the oil is allowed
to be used after it has deteriorated beyond the limits specified below then the engine may
be damaged. The warranty on the engine is dependant on the oil being maintained in
satisfactory condition. To meet this requirement it is necessary to continue the oil analysis
programmethroughout the warrantyperiod. The frequency of the analysis can be extended
but it must show that at the oil change point that the oil is still in acceptable limits.

CRITICAL PARAMETERS

Maximum viscosity at 100°C 16.5 cSt
Total acid number and total base number must not cross over
TBN must not reduce to less than 50% the value of new oil
Nitration must not exceed 25
Oxidation must not exceed 30
Insolubles >3 µ must not exceed 1.5
Water max % 0.2
Silicon max ppm 100
Sodium max ppm 50
Iron max ppm 35*
Copper max ppm 35*

4012/16 Gas, February 1998 15

LUBRICATING OIL

During the early life of the engine it will be found that the parameters marked * will have
higher levels as a result of the running in procedure.

UNDER NO CIRCUMSTANCES IS THE OIL TO BE USED FOR MORE THAN 900 HOURS
EVEN IF THE ANALYSIS SHOWS THAT THE OIL IS IN ACCEPTABLE CONDITION.

NOTE: When operating on methane based fuels, approximately one litre of water is

produced for every cubic metre of methane burnt. It is essential to ensure that the piston
blow by can not condense e ither in the crankcase or in any pipes associated with the
breather. Water has a devastating effect on o il life due to the attack on the additive package
in the oil. It i s essential that the engine breather is functioning effectively. Water should be
drained from the sump weekly.

WARNING

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY
RESULT IN ENGINE DAMAGE.

APPROVED LUBRICATING OILS (NATURAL GAS ENGINES)
(Suitable for British and Durch natural gas)
Oil Company Type

MOBIL Pegasus 480 (Suitable for catalyst equipped engines)
MOBIL Pegasus 489
ESSO Estor Supreme LA 40
ESSO Estor Protec LA 40
TEXACO Geotex LA or HD
SHELL Mysella MA 40
CASTROL NG404-408

APPROVED LUBRICATING OILS (BIOGAS AND OTHER GASES)
Oil Company Type

MOBIL Pegasus 489 + *EM/PA programme
*EM/PA = Equipment Maintenance through Progressive Analysis

CATALYST EQUIPPED GAS ENGINES

These require oils with sulphated ash limited to 0.5%, zinc limited to 0.04% and
phosphorous limited to 0.09% by weight,

(see theabovetable)

.

16 4012/16 Gas, February 1998

COOLANT

WARNING

ALWAYS STOP

THE ENGINE AND
ALLOW THE PRESSURISED SYSTEM
TO COOL BEFORE REMOVING THE
FILLER CAP. AVOID SKIN CONTACT
WITH ANTIFREEZE BY WEARING
HAND PROTECTION.

ENGINE COOLING SYSTEM

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

Caution: untreated water is not suitable.
WATER QUALITY

The water that is mixed with the additive
must have the following characteristics:
Chloride less than 80 PPMV (parts per
million by volume)
Sulphateslessthan80PPMV
Total hardness less than 200 PPMV pH of
water between 7 to 7.5 (i.e. neutral to slightly
alkaline)

ADDITIVES TO WATER

Due to the complexity of the cooling system
it is necessary to use an additive that
contains a balanced package of corrosion
inhibitors.
To achieve the required solution a 50/50 mix
of Shell Safe Premium anti-freezewith water
should be used at all times, even in areas
where frost is unlikely.
This mixture will give frost protection down to

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

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

MAINTENANCE OF COOLANT

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

This is not a measure of protection
against corrosion.

WARNING

FAILURE TO

FOLLOW THE
ABOVE RECOMMENDATIONS MAY
RESULT IN ENGINE DAMAGE AND
WILL INVALIDATE THE ENGINE

4012/16 Gas, February 1998 17

GAS SPECIFICATION

A new engine will be set to operate on clean natural gas conforming to the British natural
gas specifications having a lower calorific value of 34.71 MJ/Sm³ (930 BTU/Sft³).
Thedifferencebetweenhighcalorificvalue(HCV)and low calorific value (LCV) is that (HCV)
is the total amount of heat given off by the gas during combustion and the (LCV) is the high
calorific value less the amount of heat used to vaporize the water content of the gas. Since
the amount of heat lost in vaporizing the water is different for different gases, the lower
calorific value of the gas is chosen as the basis for fuel consumption data. There must be
no liquid hydrocarbon fractions in the gas.

WARNING

IF THE ENGINE IS NOT SET TO SUIT THE SITE GAS,
UNECONOMICAL RUNNING, LOSS OF POWER OR DAMAGE

MAY OCCUR, WHICH COULD RESULT IN INJURY.

Where gases other than British Natural Gas are to be used, such as wellhead gas, digester
gas and landfill gas, it is essential that a detailed analysis of the gas is submitted to Perkins
Engines (Stafford) Ltd. as resetting or changing the standard gas equipment may be
necessary.

Limiting Values for British Natural Gas:

4012/16TESI (MINNOX)

200 &140 L.C. 140 & 90 H. C.

1) Methane number must exceed 65 80

2) Combustible constituents must exceed 85% 95%

3) Calorific value (LHV) to exceed 31.7 MJ/Nm
(850 BTU/Sf3)(912BTU/Sft

4) Ethane 6% 4.5%

5) Hydrogen content not to exceed 0.2% 0.1%

6) Propane must not exceed 2% 1%

7) Isobutane content not to exceed 0.2% 0.2%

8) Normal butane not to exceed 0.2% 0.2%

9) Normal pentane and higher fractions

(hexane, heptane, etc.).
The summation must not exceed. 0.02% 0.02%

10) Gas pressure at inlet to regulators 15 mbar 15 mbar

must exceed (1.5 kPa) (1.5 kPa)

11) Gas pressure not to exceed without 50 mbar 50 mbar

additional pressure regulators (5 kPa) (5 kPa)

12) Hydrogen sulphide not to exceed 0.01% 0.01%

or 100 ppm or 100 ppm

3

34 MJ/Nm

3

3

)

NOTE: The rating may be reduced if lower calorific value of the fuel is lower than 34.71 MJ/
Nm³ (930 BTU/Sft³). Also pressure must be constant to maintain emissions and stability. If
any of the above parameters are not met, Perkins Engines (Stafford) Ltd should be
consulted for advice.

GAS SAFETY REGULATIONS

There are legal requirements that within the U.K. gas fittings and equipment are installed
and used in accordance with the GAS SAFETY (INSTALLATION AND USE)
REGULATIONS. Only competent persons should i nstall this equipment. Reference should
be made to the Institute of gas engineers IGE UP/3. Outside the UK anyone undertaking
work on the engine or associated with the engine and its gas equipment in particular should
check with local and national regulations to ensure compliance.

18 4012/16 Gas, February 1998

DERATING

GAS SPECIFICATION

WARNING

IT IS ESSENTIAL

THAT FULL
ACCOUNT IS TAKEN OF ALL DERATING
INFLUENCES WHETHER GAS
SPECIFICATION, ALTITUDE, AMBIENT
TEMPERATURE OR HUMIDITY. WHERE
ANY OF THESE DEVIATE FROM THE
STANDARD SPECIFIED IN THIS
MANUAL THE RATING OF THE GAS
ENGINE MUST BE ADJUSTED AS
INSTRUCTED BELOW.

SETTING ENGINE POWER TO SUIT ACTUAL SITE CONDITIONS

Derating means reducing the power output
of an engine from its normal rating at normal
temperature and pressure conditions to
allow for adverse effects of site conditions
e.g. altitude and ambient temperature.
Perkins Engines (Stafford) Ltd. may be
unaware of the final destination of an engine
at the time of despatch from the works. The
engine will be set to give the power output at
normal temperature and pressure under ISO
3046 standard conditions, using gas
conforming to British Natural Gas
Specification, having a lower calorific value
of 34.71 MJ/Nm³ (930 BTU/Sft³), which when
operating under the actual site conditions,
could result in severe damage to the engine

(refer to page 18).

Providing that the actual gas being used
meets with the above conditions, then the
engine need only be derated for altitude and
ambient temperature conditions.
Any engine so supplied must be derated in
accordance with the published percentage
derate figure as shown in the Product

Information manual, by the Equipment

Manufacturer on his premises, or even on
site.
To derate, calculate, (using the above
percentage derate figure) the new reduced
power output of the engine, and run the
engine or generating set on this load.
Where possible this maximum load limit
should be set and locked in the engine
control panel.

4012/16 Gas, February 1998 19

OPERATING INSTRUCTIONS

PREPARATION FOR INITIAL START FILLING THE ENGINE WITH OIL

Remove the drain plug to ensure sump is
clean and empty, refit and tighten the plug.
Remove the oil filler plug situated on the left
hand side of the gearcase by rotating T-bar
anti-clockwise and pulling Fig. 2.Fillthe
sump to maximum mark on the dipstick with
the appropriate grade and quality of oil
specified,see Pages14-16and replace the
plug, rotating the T-bar to tighten and seal it.

PRIMING THE TURBOCHARGER

Beforestartingthe engine for thefirsttime, or
if it has been stood idle for more than three
months, the turbocharger bearings should
be primed. Ensure that the gas supply is
turned off,also the switch in thecontrol panel
is in the stop position, and the ignition is
turned off.
Locate the semi-rotary hand pump which
may be found immediately in front of the oil
pump (see Fig. 3). Operating the pump
coveys oil from the sump via a one wayvalve
to the crankcase,pressurising the lubricating
system through t he oil filters. Pump until
approximately 35 kPa (5lb/in²) is indicated
on the oil pressure gauge. Continue
pumping for a further 20 seconds to ensure
that oil has reached the turbocharger.

Fig. 2

Fig. 3

20 4012/16 Gas, February 1998

BATTERIES (PERKINS BATTERIES ARE
SUPPLIED DRY CHARGED. SEE

INSTALLATION MANUAL TSL4200)

OPERATING INSTRUCTIONS

WARNING

WHEN CHECKING ELECTROLYTE
LEVELIN THEBATTERY.INFLAMMABLE
GAS IS GIVEN OFF BY THE BATTERY.
DO NOT CHECK WITH A NAKED FLAME.

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

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

WARNING

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

HAND PROTECTION
MUST BE WORN

NEVER CONNECT
A BATTERY INTO

Fig. 4

After installation and before the first start
remove the radiator cap Fig. 4 by rotating it
anti-clockwise. Fill the cooling system with
the required coolant. Should the engine be
fitted with water cooled exhaust manifolds
then these may need bleeding (see

Workshop Manual Section F7).Runthe

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

FILLING THE COOLING SYSTEM

WARNING

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

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

to page 17.

4012/16 Gas, February 1998 21

THE COOLING
SYSTEM IS

INSTRUMENT PANEL (ENGINE MOUNTED)

DESCRIPTION

The instrument panel is flexibly mounted on
the side of the engine between the air
manifold flanges. Some instruments are
duplicated giving readings for A and B bank
(see Fig. 5).

(1) Battery charging rate
(2) Coolant temperature 'A' bank
(3) Lubricating oil temperature 'A' bank
(4) Lubricating oil p ressure 'A' bank
(5) Taco and hours run
(6) Keyswitch
(7) Fuse holder
(8) Coolant temperature 'B' bank
(9) Lubricating oil temperature 'B' bank
(10) Lubricating oil pressure 'B' bank
(11) Exhaust temperature gauge (when

fitted)

Fig. 5

22 4012/16 Gas, February 1998

Engine water temperature gauge

(Fahrenheit/Centigrade) Fig. 6
The coolant temperature during normal
operation should be between 65°C - 85°C
(149°F - 185°F). If the temperature should
rise above 93°C (200°F) for a prolonged
period of time, stop the engine and investi­gate the cause. The engine should, on the
other hand, not be r un at too low a tempera­ture for long periods either .

Engine oil temperature gauge (Fahrenheit/ Centigrade) Fig. 7 The lubricating oil temperature should be between 80°C - 90°C (176°F - 194°F) when the engine is hot. If the temperature should rise above 115°C (240°F), stop the engine immediately and investigate the cause.

INSTRUMENT PANEL

Fig. 6

Engine oil pressure gauge Fig. 8

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

Ammeter (Ampere) Fig. 9

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

Fig. 7

Fig. 8

Fig. 9

4012/16 Gas, February 1998 23

INSTRUMENT PANEL

Engine tachometer and hour counter

(revolutions per minute x 1000 and hours)
(see Fig. 10).
The electrically operated tachometer/hour
counter shows the speed of the engine in
rev per min. and the actual operating hours
the engine has run. The tachometer/hour
counter starts operating from an alternator
voltage of 12 V onwards, which has already
been reached at engine idling speed.

Exhaust temperature gaug e (optional)

Temperature range -20 +800°C
The gauge shows readings of turbine outlet
temperature and is switched from A to B
bank using the button (1) (see Fig. 11).
NOTE: Early engines may require a dry cell
9 volt battery.

Fig. 10

1

Key switch (3 position) (Off/run/start) The hand operated keyswitch with switch lock is moved by a separate key to the posi­tions shown, (see Fig. 12)viewedfromfront of switch.

Fuse holder

To protect the instrument panel a 2 amp fuse
is fitted to remove the fuse (1) unscrew its
holder (2) (see Fig. 13).

Fig. 11

Fig. 12

2

1

2

3

1

Fig. 13

24 4012/16 Gas, February 1998

OPERATING INSTRUCTIONS

FINAL CHECKS AND INITIAL STARTUP

Gas supply train must comply with British
gas Code IM17. See Fig. 1 page 16 in the

Workshop Manual. Also gas pipework up to

the solenoid operated valves must be tested
at twice working pressure to ensure gas
tightness and any leaks rectified.

WARNING

IMPROPER

OPERATION OF A

GAS ENGINE CAN BE DANGERHOUS.
BE PREPARED TO CHECK FOR GAS
LEAKS AFTER THE SOLENOID VALVES
AS SOON AS THE ENGINE STARTS,
USING A LEAK DETECTING FLUID.
STOP THE ENGINE AND RECTIFY ANY
LEAK FOUND.

1. Starting and stopping must be on no
load.

2. For automatic start and stop sequence

see Fig. 14 on page 27.

WARNING

IF THE ENGINE

FAILS TO START
AFTER TWO ATTEMPTS, TURN OFF
THE GAS SUPPLY AND INVESTIGATE
THE CAUSE. BEFORE ATTEMPTING
TO RESTART THE ENGINE IT MUST
BE PURGED OF GAS. TO DO THIS,
WITH THE GAS SUPPLY AND THE
IGNITION SYSTEM TURNED OFF,
CRANK THE ENGINE WITH THE
STARTER FOR NO MORE THAN 30
SECONDS. THIS SHOULD REMOVE
ANYBUILD-UPOFGASFROMTHE
ENGINE AND EXHAUST SYSTEM.
ALTERNATIVELY THE SYSTEM MAY
BE PURGED WITH COMPRESSED
AIR. ALWAYS BE IN A POSITION TO
STOPT HE ENGINE IN THE EVENT OF
A MALFUNCTION BY TURNING OFF
THE GAS SUPPLY OR IN AN
EMERGENCY BY PRESSING THE
RED BUTTON, WHICH REMAINS OFF
UNTIL RESET.

3. Starting (manual)

3.1) Turn on gas at manual valve.

3.2) Press start button/turn ignition
key .

3.3) Governor now energised.

3.4) Starter engages, starts to crank.
Automatic 3 second purge time
determined by control panel.

3.5) Ignition on, gas solenoid valves
open.

3.6) Engine starts, starter disengages,
runs up to rated speed.

3.6.1) If engine fails to start, investigate
the following probable causes:

a) High or low gas pressure.
b) Ignition system grounded.
c) Governor failed to energise.
d) Lo w cranking speed.

3.6.2) Try again once more only
commencing with 3.2 above.

3.7) When engine is running, check oil
pressure, warm engine through
and apply the load.

3.8) Check engine condition at full
load, oil pressure, jacket coolant
and charge air coolant
temperatures.

4012/16 Gas, February 1998 25

OPERATING INSTRUCTIONS

4. Stopping

4.1) Remove load, run for 3 to 5
minutes to reduce combustion
system temperatures and
localised boiling of coolant and
to prevent oil carburizing in the
turbocharger bearing housing.

4.2) Stop engine by de-energising
gas solenoid valves and
governor. DO NOT press the
red stop button for normal
stopping procedure. If the
ignition is switched off the
system will be left full of gas, and
must be purged.

WARNING

DO NOT RUN THE

ENGINE
EXCESSIVELY AT RATED SPEED ON
NO LOAD. IF THE ENGINE IS NOT
BEING USED, SHUT IT DOWN.

Excessive running of the engine at rated
speed no load resultsin a high depression in
thecylinders,leadingto high oil consumption
and a build up of deposits on spark plugs,
valves and pistons.

26 4012/16 Gas, February 1998

OPERATING INSTRUCTIONS

GAS ENGINE START/STOP SEQUENCE (AUTOMATIC)

START SIGNAL

RECEIVED

IS GAS

PRESSURE

WITHIN

LIMITS?

YES

ENERGISE

GOVERNOR

ENERGISE STARTER

MOTOR & CRANK

TIMER

CRANK FOR
3 SECONDS

(PURGE SYSTEM)

NO

LOW GAS PRESSIRE

ALARM & LOCKOUT

NO

ENGINE

RUNNING

OVER SPEED

FAULT?

OTHER
ENGINE
FAULT?

STOP

ENGINE?

NO

YES

YES

YES

SWITCH OFF
IGNITION SYSTEM
&DE-ENGERGISE

GAS VALVES

DE-ENERGISE

GAS VALVES

DE-ENERGISE

GAS VALVES

ENERGISE GAS

VALVES & IGNITION

CONTINUE
CRANKING

HAS ENG INE

STARTED?

YES

DE-ENERGISE

STARTER MOTOR

ENGINE

RUNNING

NO

NO

MAX CRANKING

TIME REACHED?

YES

FAIL TO START

LOCKOUT

Fig. 14

4012/16 Gas, February 1998 27

MAINTENANCE PROCEDURES

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

Workshop Manual.

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

WARNING

MAKE QUITE

CERTAIN THE
ENGINE CANNOT BE STARTED
BEFORE UNDERTAKING ANY
MAINTENANCE, PARTICULARLY IN THE
CASE OF AUTOMATICALLY STARTING
GENERATING SETS OR REMO TE
STARTING ENGINES.

A

B

Fig. 15

COOLANT LEVEL

WARNING

THE COOLING

SYSTEM IS
PRESSURISED - DO NOTREMOVETHE
FILLER CAP WHEN THE ENGINE IS
HOT. HAND PROTECTION MUST BE
WORN.

With the engine stopped remove the
radiator cap; the coolant should be 25 mm
(1") below the top of the filler neck. If the
levelislowtopupwithasolutionofwater
and inhibitor or water and anti-freeze similar
to that already in the engine. Refer to

Engine Data section pages 7 to 10.

DAILY INSPECTION
LUBRICATING OIL LEVEL

With the engine stopped for at least 5 min­utes:­i) Withdraw the dipstick and wipe clean.
ii) Re-insert the dipstick fully into the

sump.

iii) Wait for at least 5 seconds, withdraw

and check the oil level in relation to the
two marks on the dipstick.

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

twice, until identical readings are

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

LEAKS

Visually check the engine for gas, oil,
coolant and exhaust leaks, repairing where
necessary.

WEEKLY

Deal with items under DAILY INSPECTION.

AIR CLEANER RESTRICTION INDICATOR

The middle section of the restriction indicator
'A' will remain clear while the air cleaner is in
a serviceable condition. When the filter
reaches its contamination limit the restriction
indicator will sense the change in manifold
pressure and middle section 'A' will change
to red. At this point the air filter must be
changed (see Operators Handbook page

37). When the air filters have been changed

reset the indicator by pressing button 'B'.
(See Fig. 15).

28 4012/16 Gas, February 1998

BATTERIES

MAINTENANCE PROCEDURES

WARNING

HAND PROTECTION

MUST BE WORN
WHEN CHECKING ELECTROLYTE
LEVEL IN THE BATTERY. INFLAMMABLE
GASISGIVENOFFBYTHEBATTERY.
DO NOT CHECK WITH A NAKED FLAME.

Remove the plugs or 'quick fill' covers and
check the level of electrolyte. It should be
approximately 3 mm above the top of the
plates. If it is low, top-up with pure distilled
water. Replace the plugs and wipe the top
of the battery clean and dry (see page 21

for fuller information).

NOTE: Check the specific gravity (see

Maintenance Schedule).

RADIATOR

If the engine is working in dirty or dusty
conditionscheck that the air passages in the
radiator are not becoming choked. They can
be cleaned out by blowing compressed air in
the direction opposite to that of the normal
air flow.

Fig. 16

13.3

NEW OR REBUILT ENGINES

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

FLANGES AND FASTENENERS

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

EQUALISE BRIDGE PIECES AND CHECK VALVE CLEARANCES

(see page 39).

DRAINING WATER FROM THE SUMP
(FOR ENGINE OPERATING ON
LANDFILL GAS)

Unscrew the drain plug in the sump and
drain off the accumulated water content until
oil flows. Tighten the plug, check the oil
level and add the required oil.

FENNER TAPE LOCK BUSHES
MAINTENANCE INSTRUCTIONS

Experience has shown that taper lock
bushesasfittedinthefanpulleysandbattery
alternator driven pulley can work loose
shortly after being put into service. Check
using a hexagon wrench to tighten allen
screws (1) Fig. 16 gradually and alternately
until all are tightened to the required torque

(see Torque Settings on pages 11 - 13).

Full details of taper lock pulley see Section

B2 & Section U1 of the WorkshopManual.

Replace any guards removed before running
the engine (see Fig. 16).

4012/16 Gas, February 1998 29

MAINTENANCE PROCEDURES

TURBOCHARGERS

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

Bulletin 301 (Revised) and 1.

FOR ENGINES OPERATING ON BIOGAS,
LANDFILL GAS, ETC.
SPARK PLUGS

Clean and reset gaps as described in

Section N9 of the Workshop manual.

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

Change engine oil and disposable filters

(see page 34) clean centrifugal filter (see

page 33).

Fig. 17

ENGINE ALTERNATOR DRIVE BELT

WARNING

DISCONNECTING
BATTERIES OR ANY

OTHER MEANS OF STARTING.

Remove the small mesh guard (1) around
the alternator. The toothed belt used to drive
the alternator relies on tooth engagement to
transmit to load. It does not require
preloading, however a slight initial tension to
ensure that the belt fits snugly round the
pulleys is desirable. Using light pressure
midway between the two pulleys a total
deflection of 1.5 mm (1/16”) is satisfactory
(see Fig. 17). Refit the guard.

SPARK PLUGS

Reset the plug gap as described in Section

N9 and N12 of the Workshop Manual.

ENGINE OIL AND FILTERS
On completion of the first 500 hours
running, change the engine oil and
filters.

30 4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

FAN BEARINGS AND BELTS

WARNING

DISCONNECT

BATTERIES OR ANY
OTHER MEANS OF STARTING.

Remove the mesh guard around the fan
belts, grease the fan and jockey pulley
bearings Fig. 18 using high melting point
lithium based grease (e.g. Shell Alvania
R.A.)
Check the tension and condition of the fan
belts. Using a spring balance and rule, or a
belt tension indicator, check that the force
compares with the kgf (lbf) values shown
below f or the correct belt deflection. See
Fig. 18.

Deflection

11 mm

kg Force

3-4.3

lb Force

6,67 - 9.47

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

To adjust slacken the jockey pulley pivot and
adjuster bolts, and operate the jockey pulley
lever.
Moving the jockey pulley lever outwards will
tension the belts and inwards will slacken
the belts.
The correct tension is obtained by measur­ing the deflection at the mid point between
the fan pulley and the crankshaft pulley
when the above force is applied.
To apply the force place a rule across the
outside width of the belts and attach spring
balance as shown Fig. 18 pull on the spring
balance until the required force is reached
and measure the belt deflection.
Adjust the position of the jockey pulley lever
until the force on the spring balance and the
belt deflection agree with the figures given.

Key
(Fig. 18)

1. Force

2. Deflection

Fig. 18

4012/16 Gas, February 1998 31

MAINTENANCE PROCEDURES

WARNING

DISCONNECT

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

CRANKCASE BREATHER (IMPROVED DESIGN) FITTED TO LATER ENGINES

The crankcase breather is mounted on the
side of the thermostat housing Fig. 19 and
is connected to the engine via a flexible pipe
and elbow fitted on the front of the gearcase
(see Fig. 20).
To clean the breather remove the top cover
and withdraw the two wire mesh elements
and wash thoroughly using a suitable
cleaning agent. Shake as dry as possible,
finally blow dry with an compressed air.
Refit the elements into the breather body,
andfitthetopcoverfirmly.
NOTE: When replacing the cover check the
sealing gasket is i n good condition and the
cover has located on its dowel

Fig. 19

Fig. 20

32 4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

WARNING

DISCONNECT

BATTERIES OR ANY
OTHERMEANS OF STARTING. ALWAYS
WEAR PROTECTIVE GLOVES.

FOR EXTENDED OIL CHANGE PERIOD
(WITH OIL ANALYSIS PROGRAMME) SEE

PAGES 14 - 16 ON ENGINES OPERATING

ON BIO GAS AND OTHER GASES (NOT
BRITISH NATURAL GAS)
CLEANING THE CENTRIFUGAL
LUBRICATING OIL FILTER

Stop the engine, and allow time for
lubricating oil to drain back to sump.

1. Slacken safety clamp (1) unscrew cover
nut and lift off cover (A). (See Fig. 21).

2. Lift off rotor assembly (B) having
allowed oil to drain from nozzles. The
rotor should be removed and replaced
on the spindle with extreme care in
order to ensure that bearings are not
damaged.

3. Secure rotor in dismantling tool T6253/

292. Unscrew rotor cov er nut (3) and
separate rotor cover from body.

4. Remove standtube (4) using extraction
tool T6253/293 and clean.

5. Remove sludge from inside the rotor by
means of a spatula and wipe clean.
Ensure that all rotor components are
thoroughly cleaned and free from
deposits of dirt before reassembling the
rotor. Failuretodosocouldcausean
out-of-balance condition which will
accelerate bearing spindle wear.

6. Clean nozzle with brass wire. Examine
'O' ring (5) and renew if damaged.

7. Reassemble rotor complete and tighten
top nut. IMPORTANT: Ensure that the
rotor cover and rotor body are always
matched by balance reference number
and pin location.
DO NOT INTERCHANGE ROTOR
CO VERS.

8. Examine spindle journals, if damaged
or worn replace with body assembly
complete.

Fig. 21

9. Reassemble filter complete checking
that rotor revolves freely then replace
filter body cover. Tighten cover nut and
secure safety clamp. The clamp ring
should be securely fitted at all times and
the filter should not be run without the
clampringfitted.

10. With engine running check all joints for
leakage. Check for excessive vibration.

4012/16 Gas, February 1998 33

MAINTENANCE PROCEDURES

Fig

NOTE: It is suggested that oil analysis tests

are carried out at regular intervals to check
that these maintenance intervals are
satisfactory.

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

WARNING

DISCONNECT

BATTERIES OR ANY
OTHERMEANS OF STARTING. ALWAYS
WEAR PROTECTIVE GLOVES.

With the engine stopped, place a suitable
container of at least 150 to 250 litres (33 to
55 gal) beneath the drain plug. Remove the
drain plug and allow the oil to drain. This
operation is best carried out while the
engine is still warm as the thinner oil will
drain more efficiently. While the oil is
draining remove the three oil filters per
bank, turning them anti-clockwise using a
strapwrenchseeFig. 22.
NOTE: Removal of the oil filters will allow an
escape of oil from the filter manifolds, it is
therefore recommended that a suitable
container of at least 5 litres (1 gal) capacity
is positioned under each filter prior to
removal.
Wipe clean the sealing faces and threaded
bosses of the oil header. Smear engine oil
on the captive rubber sealing ring and
carefully screw each new filter up to the oil
header using firm hand pressure only.
Use only genuine Perkins oil filters. The use
of other filters may cause serious damage to
the engine.
Refit the drain plug and fill the engine with
the appropriate grade of new oil (see pages

11-13). Ensure that the gas supply is turned

off, also the switch on the control panel is in
the stop position, and the ignition is
grounded to prevent the engine fir ing. Turn
the keyswitch to the start position, and crank
the engine over until the oil pressure gauge
registers 0.4 kg/cm² (5 lb/in²).
Continue cranking for a further 10 seconds
which will ensure the oil has reached the
turbocharger bearings.

.22

See page 20 for instructions on priming with

the semi-rotary pump.
Stop cranking the engine and visually check
the engine for oil leaks, top up the oil level.

34 4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

WARNING

DISCONNECT

BATTERIES OR ANY
OTHERMEANS OF STARTING. ALWAYS
WEAR PROTECTIVE GLOVES.

CHANGING THE OPTIONAL CHANGE­OVER LUBRICATING OIL FILTERS

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

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

Fig. 24 on page 36. Failure to change fil-

ters when due can also lead to trouble from
unfiltered oil.

CHANGING THE FILTER ELEMENTS WHENTHEENGINEISSTOPPED

All that is necessary is to unscrew the
canisters with a strap wrench as shown in
Fig. 23, without moving the change-over
valve, as there is no pressure in the system
when the engineis stationary. The underside
of the header is then wiped clean, and a
smear of oil applied to the sealing rings on
the new canisters, before screwing them up
by hand and tightening them by no more
than three quarters of a turn after the seals
contact the header. Check the filter for leaks
after the engine is restarted.

Fig. 23

4012/16 Gas, February 1998 35

MAINTENANCE PROCEDURES

WARNING

REDUCE ENGINE

SPEEDTOIDLINGIF
CHANGING THE FILTERS WHILST
ENGINE IS RUNNING.

CHANGING THE FILTER ELEMENTS WITHOUT STOPPING THE ENGINE

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

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

Key
(Fig. 24)

1. Change right filter

2. Normal

3. Change left filter

4. Dirty oil into filter

5. Clean oil into engine

Fig. 24

36 4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

WARNING

DISCONNECT

BATTERIES OR ANY
OTHER MEANS OF STARTING THE
ENGINE.

CHANGING AIR FILTER (SEE SECTION

A1 IN THE WORKSHOP MANUAL)

STANDARD

Remove the end cover (3) of the air filter
housing, after unscrewing the retaining wing
nut, carefully lift out the paper air filter
element (1). For servicing the element see

General Servicing Instructions below.

When all servicing procedures are
completed, fit the new or cleaned element
into the housing. When fitting the end cover
ensure it has seated fully in the housing
before tightening the wing nut. Inspect and
tighten all air filter connection bef ore
resumingequipmentoperation(seeFig. 25).

1

2

3

4

Fig. 25

(b) Dust accumulation on the inlet side of

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

HEAVY DUTY

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

GENERAL SERVICING INSTRUCTIONS

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

FILTER ELEMENT SERVICE

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

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

WARNING

REPLACE ANY

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

ELEMENT CLEANING

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

Page 28) has not been triggered, the

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

4012/16 Gas, February 1998 37

MAINTENANCE PROCEDURES

CLOSED CIRCUIT BREATHER

The closed circuit breather separators (1)
are mounted on each side of the gearcase
and are connected to the carburettor mixer
inlet via the breather valve (2). To clean the
breather separator remove the complete
unit from the engine (see Fig. 26).
Release the retaining clips and remove the
top cover (4) from the filter body . Remove
the foam element (5) check it for oil sludge
saturation wash thoroughly in a suitable
cleaning agent, shake of excess solvent and
blow dry with compressed air. Clean any oil
sludge deposits from the filter body re­assemble and fit to engine.
The breather valve (2) is mounted at the
flywheel end of the engine directly under the
air filter. To remove release the pipe clips
(see Fig. 27) and pull away from the valve
manifold. Wash the breather thoroughly in a
suitable solvent paying particular attention
to any deposits on the internal are of the
breather. Shake as dry as possible and
blow dry with compressed air.
Before refitting ensure that the cup (A) at the
base of the two breather valves are full of
clean engine oil (see Fig. 27).

Fig. 26

Fig. 27

2

1

Fig. 28

38 4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

EQUALISING BRIDGE PIECES AND SETTING VALVE CLEARANCES

NOTE: The bridge pieces must be set before

attempting to set the valve clearances.

WARNING

DISCONNECT
BATTERIES OR ANY

OTHER MEANS OF STARTING.

Remove the 4 screws (1) from the rocker
cover (2), lift off the cover peel off and throw
awa y the old gasket (3) Pull the spark plug
lead tube (4) from the spark plug bush (see
Fig. 29).
To equalise the bridge pieces the
appropriate valves must be rocking, use the
table below.
In order that the engine may be rotated
while the batteries are disconnected a
special cranking device (SE253) can be
fitted to the spare starter motor hole in the
flywheel housing (see Fig. 30). Using a
socket and ratchet wrench press against the
spring loaded bolt head until the pinion
engages with the flywheel gear then crank
the engine to the desired position.
If the valves required to be rocking are
closed rotate the engine one revolution
which will bring these valves to the rocking
position. The flywheel housing has an
inspection hole directly below the
turbocharger through which the flywheel
markings may be seen to line up with the
pointer set in the flywheel housing (see Fig.

31).
The flywheel is marked: T.D.C. (Top Dead

Centre)

4012TESI 4016TESI

A1-A6 A1-A8
A5-A2 A3-A6
A3-A4 A7-A2
B1-B6 A5-A4
B5-B2 B1-B8
B3-B4 B3-B6

B7-B2
B5-B4

Fig. 29

Fig. 30

Fig. 31

1

2

4

3

2

1

4012/16 Gas, February 1998 39

MAINTENANCE PROCEDURES

EQUALISING THE BRIDGE PIECES

WARNING

DISCONNECT

BATTERIES OR ANY
OTHER MEANS OF STARTING THE
ENGINE.

Having rotated the engine to the correct
position, check that the inlet and exhaust
rockers have clearance before continuing
with the next operation. Loosen the lock nut
(1)oneachbridgepiece,screwtheadjuster
(2) out until the fixed side of the bridge piece
rests on its valve, hold the top edge down
with one hand then screw the adjuster down
until you feel it touch the valve, thereby
equalising valve lift. Tighten the lock nut
without moving the adjuster (see Fig. 32).

SETTING VALVE CLEARANCE

With both bridge pieces equalised check the
valv e clearance of 0.4 mm (0.016") inlet and
exhaustusing a feelergauge (1). If adjustment
is required loosen the lock nut (2) and using
the adjuster screw (3) set the clearance.
Tighten the lock nut without moving the
adjuster (see Fig. 33). The feeler gauge
should be a slide fit between the rocker and
bridge piece thereby giving the correct
clearance. Refit the rocker cover with a new
gasket.

Fig. 32

Fig. 33

2

1

3

2

1

ENGINE 4012TESI

T.D.C.

A1 & A6 A6 A1
B1 & B6 B1 B6
A2 & A5 A2 A5
B2 & B5 B5 B2
A3 & A4 A4 A3
B3 & B4 B3 B4
A1 & A6 A1 A6
B1 & B6 B6 B1
A2 & A5 A5 A2
B2 & B5 B2 B5
A3 & A4 A3 A4
B3 & B4 B4 B3

VALVES ROCKING ON

CYLINDER NO.

SET BRIDGE PIECE

AND VALVE CLEARANCE

ON CYLINDER NO.

40 4012/16 Gas, February 1998

ENGINE 4016TESI

MAINTENANCE PROCEDURES

SET BRIDGE PIECE

AND VALVE CLEARANCE

ON CYLINDER NO.

T.D.C.

VALVES ROCKING ON

CYLINDER NO.

A1 & A8 A8 A1
B1 & B8 B8 B1
A3 & A6 A6 A3
B3 & B6 B6 B3
A7 & A2 A2 A7
B7 & B2 B2 B7
A5 & A4 A4 A5
B5 & B4 B4 B5
A1 & A8 A1 A8
B1 & B8 B1 B8
A3 & A6 A3 A6
B3 & B6 B3 B6
A7 & A2 A7 A2
B7 & B2 B7 B2
A5 & A4 A5 A4
B5 & B4 B5 B4

4012/16 Gas, February 1998 41

MAINTENANCE PROCEDURES

BRITISH NATURAL GAS, BIOGAS AND OTHER GASES
CONTINUOUS DUTY CHECK LIST (BASED ON ENGINES RUNNING AT 1500 RPM NORMAL
OPERATION AND STANDARD OIL CHANGE PERIOD)

CONTINUOUS DUTY MAINTENANCE OPERATIONS TO BE PERFORMED

ABCDEFG

▲

SYSTEM OPERATION DESCRIPTION

Lubricating Check

Change
Clean
Change

Cooling Check

Change
Grease

Change
Clean

Air Check

Change

Gas Check

Exhaust Check

Engine
Related

Electrical Check Battery charging system, ignition system

Check
Check
Renew
Check
Clean
Adjust
Change

Clean
Check

Check
Check
Check
Overhaul
Re-ring
Overhaul

For leaks and oil pressure
Engine oil level
Full flow filters (normal or change-over)
Engine oil
Crankcase Breather (and centrifugal oil filter, if fitted)
Closed circuit crankcase breather
Closed circuit crankcase breather separator elements

For radiator air restriction
Operationof coolant heater
Hoses and connections for leaks
Coolant level and operating temperature
Antifreeze & inhibitor concentration
Belt condition & tension
Fan and alternator belts
Fan hub & jockey pulley bearing

Coolant
Cooling system

For leaks
Air cleaner restriction
Pipes and connection
Air cleaner element

For leaks
Governor linkage
Gas lines & connections
Diaphragmin regulator
Wiring (incl. high tension lead, renew if required)
Spark plugs (reset)
Bridge pieces and valves First 100 hours and then
Spark plugs

For leaks
For exhaust restrictions
Turbocharger comp wheel & diffuser
Turbocharger bearing clearances

Fenner taper lock bush (First 50 hours)
Vibration damper
Engine mountings
Cylinder heads
Piston (if necessary)
Engine (new pistons, liners, etc.)

Battery electroylte level, specific gravity
Belt condition & tension
Clean & reset magnetic pick-ups
Protection switches & alarms
Startermotor mounting bolts & terminals

FIRST 100

HOURS DAILY

DAILY

WEEKLY/50

HRS ✼

EVERY 500 HRS★

EVERY 1000 HRS

•

•••••

•

•

•

••

••••••••

•

•

•••••

•

•

•

EVERY 12 MONTHS

•••■•

•••

•

•

•

★

•

★

•

★

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

■

•

•

•

•

•

•

•

•

•

EVERY 3000 HRS

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

EVERy 6000 HRS✛EVERy 12000 HRS

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

NOTE: All bolts, hose clips, terminal connections, pipes and joints, should be checked for tightness and leaks after the first 100 hrs and every 3 months
thereafter.

★ First 500 hours then every 1,000 hours for British Natural Gas. For Biogas and other gases, first 250 hrs then every 400 hrs.

■ Clean at first 500 hrs then every 1,000 hrs for British Natural Gas. For Biogas and other gases first 250 hrs then every 400 hrs. Change every 2,000

hrs for British Natural Gas and every 1,000 hrs for Biogas and other gases.

✛ Major inspection at 12,000 hrs for British Natural Gas. For Biogas and other gases at 6,000 hrs check front and rear crankshaft oil seals
▲ Major overhaul at 20,000 hrs for British Natural Gas. For Biogas and other gases at 12,000 hrs
✼ Whichever is sooner.

NOTE: On landfill gas engines drain condensate from sump every week.

42 4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

BRITISH NATURAL GAS
CONTINUOUS DUTY CHECK LIST (BASED ON ENGINES RUNNING AT 1500 RPM NORMAL
OPERATION AND EXTENDED OIL CHANGE PERIOD)

CONTINUOUS DUTY MAINTENANCE OPERATIONS TO BE PERFORMED

ABCDEFG

SYSTEM OPERATION DESCRIPTION

Lubricating Check

Change
Clean
Change

Cooling Check

Change
Grease
Change
Clean

Air Check

Change

Gas Check

Exhaust Check

Engine
Related

Electrical Check Battery charging system, ignition system

Check
Check
Renew
Check
Clean
Adjust

Change

Clean
Check

Check
Check
Check
Overhaul
Re-ring
Overhaul

For leaks and oil pressure
Engineoil level
Full flow filters (normal or change-over)
Engineoil
Crankcase Breather (and centrifugal oil filter, if fitted)
Closed circuit crankcase breather
Closed circuit crankcase breather separator elements

For radiator air restriction
Operation of coolant heater
Hoses and connections for leaks
Coolant level and operating temperature
Antifreeze & inhibitor concentration
Belt condition & tension
Fan and alternator belts
Fan hub & jockey pulley bearing
Coolant
Cooling system

For leaks
Air cleaner restriction
Pipes and connection
Air cleaner element

For leaks
Governor linkage
Gas lines & connections
Diaphragm in regulator
Wiring (incl. high tension lead, renew if required)
Spark plugs (reset) First 500 hours and then
Bridgepieces and valves First100 hours and then

Spark plugs
For leaks

For exhaust restrictions
Turbocharger comp wheel & diffuser
Turbocharger bearing clearances

Fenner taper lock bush (First 50 hours)
Vibration damper
Enginemountings
Cylinder heads
Piston (if necessary)
Engine (new pistons, liners, etc.)

Battery electrolyte level, specific gravity
Belt condition & tension
Clean & reset magneticpick-ups
Protection switches & alarms
Starter motor mounting bolts & terminals

FIRST 100

HOURS DAILY

DAILY

WEEKLY/50

HRS ✼

EVERY 500 HRS★

EVERY 1000 HRS

•

•••••

•

•

•

••

••••••••

•

•

•••••

•

•

•

EVERY 12 M ONTHS

••••

EVERY 2000 HOURS

•••

•

•

•

★

•

★

•

★

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

EVERY 3000 HRS

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

■

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

EVERy 12000 HRS

EVERy 20000 HRS

•

•

•

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NOTE: All bolts, hose clips, terminal connections, pipes and joints, should be checked for tightness and leaks after the first 100 hrs and every 3 months
thereafter.
★ Ch ange at first 500 hrs, then every 1000 hrs, until an extended oil change period has been established, which will de pend on the

result of a series of analyses (see pages 14-15).

■ Also check front and rear crankshaft oil seals.
✼ Whichever is sooner.

4012/16 Gas, February 1998 43

MAINTENANCE PROCEDURES

BIOGAS AND OTHER GASES (NOT BRITISH NATURAL GAS)

CONTINUOUS DUTY CHECK LIST (BASED ON ENGINES RUNNING AT 1500 RPM NORMAL
OPERATION AND EXTENDED OIL CHANGE PERIOD)

CONTINUOUS DUTY MAINTENANCE OPERATIONS TO BE PERFORMED

ABCDEFG

SYSTEM OPERATION DESCRIPTION

Lubricating Check

Change
Clean
Change

Clean Centrifugal lubricating oil filter First 250 hours and then EVERY 400 HOURS
Check Front and rear crankshaft oil seals

Cooling Check

Change
Grease

Change
Clean

Air Check

Change

Gas Check

Exhaust Check

Engine
Related

Electrical Check Battery charging system, ignition system

Check
Check
Renew
Check
Clean
Adjust
Change

Clean
Check

Check
Check
Check
Overhaul
Re-ring
Overhaul

For leaks and oil pressure
Engine oil level
Full flow filter
Engine oil
Crankcase Breather
Closed circuit crankcase breather
Closed circuit crankcase breather separator elements

For radiator air restriction
Operation of coolant heater
Hoses and connections for leaks
Coolant level and operating temperature
Antifreeze & inhibitor concentration
Belt condition & tension
Fan and alternatorbelts
Fan hub & jockey pulley bearing

Coolant
Cooling system

For leaks
Air cleaner restriction
Pipes and connection
Air cleaner element

For leaks
Governor linkage
Gas lines & connections
Diaphragm in regulator
Wiring (incl. high tension lead, renew if required)
Spark plugs (reset) First 250 hours and then
Bridge pieces and valves First 100 hours and then
Spark plugs

For leaks
For exhaust restrictions
Turbocharger comp wheel & diffuser
Turbocharger bearing clearances

Fenner taper lock bush (First 50 hours)
Vibration damper
Engine mountings
Cylinderheads
Piston(if necessary)
Engine (new pistons, liners, etc.)

Battery electrolyte level, specific gravity
Belt condition & tension
Clean & reset magnetic pick-ups
Protection switches & alarms
Startermotor mounting bolts & terminals

FIRST 100

HOURS DAILY

DAILY

WEEKLY/50

HRS ✼

EVERY 500 HRS★

EVERY 1000 HRS

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EVERY 12 MONTHS

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EVERy 6000 HRS

EVERy 12000 HRS

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NOTE: All bolts, hose clips, terminal connections, pipes and joints, should be checked for tightness and leaks every 3 months.
★ Change first 250 hrs, then every 400 hrs, until an extended oil change period has been established, which will depend on a series of analyses (see

pages 14-15). A centrifugal oil filter (see page 29) must be fitted and cleaned after first 250 hrs then every 400 hrs.

NOTE: It is normal practice when operating on gases other than natural gas for the oil to be continuously analysed at intervals of 100/150 hrs.

✼ Whichever is sooner.

44 4012/16 Gas, February 1998

4012 & 4016 GAS ENGINES FAULT TRACING CHART

Fig. 34

4012/16 Gas, February 1998 45

4012/16TESI (MINNOX) WIRING DIAGRAM WITH CAV STARTER AND PROTECTION SWITCHES

Key
(Fig. 35)

1. Oil press switch

2. 220Ω5w resistor

3. Charging alternator

4. Repeater relay

5. Start motor

6. ‘Start relay

7. Engine fault switches left/right banks

8. Water temp.

9. Oil press

10. All fault switches close on a fault. One
side of all fault switches are identical. For the
engine to run, immediately on depressing
start button, Gov+ must be fed 24 volt +ve. To
stop the engine break this +ve.

11. Left/right manifold high gas pressure
detector switches

12. Pick-up sensing on flywheel

13. Left/right manifold switch gauges for
manifold out of balance protection

14. Switch speed 700 rpm

15. Switch overspeed

16. Two switch speed unit

Fig. 35

46 4012/16 Gas, February 1998

4012/16 (GAS) MINNOX ENGINE WIRING DIAGRAM STARTING CIRCUIT WITH

Key
(Fig. 36)

1. Charging alternator

2. Ammeter

3. Oil press

4. Oil temp.

5. Water temp.

6. Tacho

7. Oil press

8. Oil temp.

9. Water temp.

10. Gauge senders

11. Oil press switch

12. No. 1 Starter motor

13. Start relay

14. Engine terminal block

15. No. 2 Starter motor

16. 24 Volt Start batteries

BUTEC STARTERS AND OPTIONAL INSTRUMENT PANEL

Fig. 36

4012/16 Gas, February 1998 47

EARLY 4012 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM

Key
(Fig. 37)

1. DISN Unit

2. 19 Pin plug

3. 6 Pin plug

4. Pick-up

5. Engine fitted emergency stop button

6. H.T. Leads

7. Spark plugs

8. Ignition coils

9. Firing order

10. Fused terminals

11. Engine fitted terminal box

12. Heinzmann actuator 'A' bank left

13. Heinzmann actuator 'B' bank right

14. Magnetic pick-ups

15. Engine flywheel

16. Heinzmann control box 'A' bank left

17. Heinzmann control box 'B' bank right

Fig. 37

48 4012/16 Gas, February 1998

CURRENT 4012 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM

Key
(Fig. 38)

1. DISN Unit

2. 19 Pin plug

3. 6 Pin plug

4. Pick-up

5. Engine fitted emergency stop button

6. H.T. Leads

7. Spark plugs

8. Magnetic disc

9. Ignition coils

10. Terminal box

11. Magnetic pick-up

12. Engine flywheel

13. Heinzmann actuator 'A' bank

14. Heinzmann actuator 'B' bank

15. Heinzmann control box 'B' bank right

16. Heinzmann control box 'A' bank left

Fig. 38

4012/16 Gas, February 1998 49

4012/16 (GAS) MINNOX ENGINE WIRING DIAGRAM OF STANDARD PROTECTION PACK AND OPTIONAL BRITISH GAS COUNCIL PROTECTION EQUIPMENT

Key
(Fig. 39)

1. Standard fitted equipment

2. Magnetic pick-up

3. Engine flywheel

4. Two switch speed unit

5. Switch 2 over speed

6. Switch 1 speed 600 rpm

7. Engine terminal box

8. NOTE:

1. High manifold gas pressure and gas
spitback can be on the same fault
channel.

2. Manifold out of balance switch
gauges can be earth return type.

9. Left/right banks engine fault switches.

10. Water temp.

11. Oil press

12. Left/right banks manifold out of balance
switch gauges

13. Left/right banks high manifold gas
pressure fault switches

14. Optional equipment

15. Left/right banks gas spitback fault
switches

16. Low gas pressure fault switch

17. Gas solenoid valves not normally
supplied by Perkins can be four off
depending on gas pipe work arrangement

18. Energised to run gas line solenoid
valves

19. Low water level fault switch

Fig. 39

50 4012/16 Gas, February 1998

EARLY 4016 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM

Key
(Fig. 40)

1. DISN Unit

2. 19 Pin plug

3. 6 Pin plug

4. Pick-up

5. Engine fitted emergency stop button

6. H.T. Leads

7. Spark plugs

8. Ignition coils

9. Firing order

10. Fused terminals

11. Heinzmann actuator 'A' bank left

12. Heinzmann actuator 'B' bank right

13. Magnetic pick-ups

14. Engine fitted terminal box

15. Engine flywheel

16. Heinzmann control box 'A' bank left

17. Heinzmann control box 'B' bank right

Fig. 40

4012/16 Gas, February 1998 51

CURRENT 4016 SERIES GAS IGNITION AND HEINZMAN WIRING SYSTEM

Key
(Fig. 41)

1. DISN Unit

2. 19 Pin plug

3. 6 Pin plug

4. Pick-up

5. Engine fitted emergency stop button

6. HT Leads

7. Spark plugs

8. Ignition Coils

9. Magnetic Disc

10. Heinzmann actuator 'A' bank left

11. Heinzmann actuator 'B' bank right

12. Magnetic pick-ups

13. Engine fitted terminal box

14. Engine flywheel

15. Heinzmann control box 'A' bank left

16. Heinzmann control box 'B' bank right

Fig. 41

52 4012/16 Gas, February 1998

© 1998 Perkins Engines Company Limited
All Rights Reserved