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 ACCIDENT 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 International - North America	Moteurs Perkins SA
Perkins Engines (Peterborough) Ltd.	12025 Tech Center Drive,	Parc de Reflets - Paris Nord II,
Frank Perkins Way, Eastfield,	Livonia, Michigan 48150,	165 Avenue du Bois de la Pie, BP 40064,
Peterborough, PE1 5NA, England.	U.S.A.	95913 Roissy CDG Cedex, France
Tel: [phone]	Tel: [phone]	Tel: [phone]
Telex: 32501 PERKEN G	Fax: [phone]	Fax: [phone]
Fax: [phone]

	Perkins Engines Latin America Inc	Perkins International Ltd.
Perkins Engines (Shrewsbury) Ltd.	999 Ponce de Leon Boulevard,	Varity Asia/Pacific
Lancaster Road, Shrewsbury,	Suite 710, Coral Gables,	Suite 3301, Convention Plaza,
SY1 3NX, England.	Florida 33134, U.S.A.	1 Harbour Road, Wanchai,
Tel: [phone]	Tel: [phone]	Hong Kong.
Telex: 35171/2 PESL G	Telex: 32501 PERKEN G	Tel: [phone]
Fax: [phone]	Fax: [phone]	Fax: [phone]

Perkins Engines (Stafford) Ltd.	Perkins Engines Australia Pty Ltd	Perkins Engines (Far East) Pte Ltd.
Tixall Road, Stafford, ST16 3UB, England.	Suite 2, 364 Main Street, Mornington	39 Tuas Avenue 13,
Tel: [phone]	3931, Victoria, Australia.	Singapore 638999.
Telex: 36156 PERKEN G	Tel: [phone]	Tel: [phone]
Fax: [phone]	Telex: 30816	Fax: [phone]
	Fax: [phone]
Perkins Powerpart Distribution Centre

Frank Perkins Way,	Motori Perkins SpA
Northbank Industrial Park, Irlam,	Via Socrate. 8,22070 Casnate
Manchester, M44 5PP, England.	Con Bernate (Como), Italy.
Tel: [phone]	Tel: [phone]
Specifications Help Desk	Telex: 380658 PERKIT I
Tel: [phone]	Fax: [phone]
Fax: [phone]
Specifications Help Desk	Perkins Motoren GmbH
Tel: [phone]	D-63801 Kleinostheim,
Telex: 32501 PERKEN G	Saalackerstrasse 4, Germany.
	Tel:	(49) (6027) 5010
	Fax:	(49) (6027) 501130

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	12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
(MINNOX)	turbo-charged, water cooled charge air cooler with separate water
	pump and cooling circuit, lean burn, low NOx emission levels, 9.5:1
	compression ratio
4012TESI	12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
(MINNOX) 200 L.C.	turbo-charged, water cooled charge air cooler with separate water
	pump and cooling circuit, lean burn, with NOx emission of less than
	200 g/GJ, 9.5:1 compression ratio.
4012TESI	12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
(MINNOX) 140 L.C.	turbo-charged, water cooled charge air cooler with separate water
	pump and cooling circuit, lean burn, with NOx emission of less than
	140 g/GJ, 9.5:1 compression ratio.
4012TESI	12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
(MINNOX) 140 H.C.	turbo-charged, water cooled charge air cooler with separate water
	pump and cooling circuit, lean burn, with NOx emission of less than
	140 g/GJ, 11.5:1 compression ratio.
4016TESI	16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
(MINNOX) 200 L.C.	turbo-charged, water cooled charge air cooler with separate water
	pump and cooling circuit, lean burn, with NOx emission level of 200
	g/GJ or less, 9.5:1 compression ratio.
4016TESI	16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
(MINNOX) 140 L.C.	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.
4016TESI	16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
(MINNOX) 140 H.C.	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.
4016TESI	16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
(MINNOX) 90 H.C.	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)

GENERAL INFORMATION

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 label Fig. 1 in 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.

●Use a hand scraper to remove the joints

- 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.

●Spray all asbestos debris with water and place it in a closed container which can be sealed for safe disposal.

Dangers from used engine oils

Prolonged and 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.

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

	Environmental protection	Practical Information
	There is legislation to protect the	To clean components
	environment from the incorrect disposal of	It is important that the work area is kept clean
	used lubricating oil. To ensure that the	and that the components are protected from
	environment is protected, consult your Local	dirt and debris. Ensure that dirt does not
	Authority who can give advice.	contaminate the fuel system.
		Before a component is removed from the
	Viton seals	engine, clean around the component and
	Some seals used in engines and in	ensure that all openings, disconnected
	components fitted to engines are made from	hoses and pipes are sealed.
	Viton.	Remove, clean and inspect each component
		carefully. If it is usable, put it in a clean dry
	Viton is used by many manufacturers and is
	a safe material under normal conditions of	place until needed. Ball and roller bearings
		must be cleaned thoroughly and inspected. If
	operation.	the bearings are usable, they must be
	If Viton is burned, a product of this burnt
		flushed in low viscosity oil and protected with
	material is an acid which is extremely	clean paper until needed.
	dangerous. Never allow this burnt material	Before the components are assembled,
	to come into contact with the skin or with the	ensure that the area is free from dust and dirt
	eyes.	as possible. Inspect each component
	If it is necessary to come into contact with
		immediately before it is fitted, wash all pipes
	components which have been burnt, ensure	and ports and pass dry compressed air
	that the precautions which follow are used:	through them before connections are made.

●Ensure that the components have Use suitable gloves for protection when

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.

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.

components are degreased or cleaned with trichloroethylene, white spirit, etc.

Degreasing solutions which are basically trichloroethane are not recommended.

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	1A,6B,5A,2B,3A,4B		1A,1B,3A,3B,7A,7B,5A,5B
	6A,1B,2A,5B,4A,3B		8A,8B,6A,6B,2A,2B,4A,4B
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	Engine r/min			m/s (ft/min)
	1000			6.33 (1247)
	1200			7.60 (1496)
	1500			9.50 (1870)

TYPICAL COOLING SYSTEM

	Approved coolants	See page 17
	Total capacity engine including
	charge air cooler & wet exhaust	81 litres (17.8 gals)		110 litres (24.3 gals)
	manifolds
	Total capacity engine and radiator	239 litres (52.6 gals)		278 litres (61.3 gals)
	Total capacity engine and heat	153 litres (33.7 gals)		183 litres (40.3 gals)
	exchanger
	Engine shut down temperature	96°C
	Max. temperature into engine	To be determined from heat dissipated and water flow through each
		particular engine model
	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	2.5 bar max
	coolant pump outlet

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/nm3
	Carburettor mixing unit	Deltec 200 - 11
	Carburettor throttle body	Deltec 100 - 11	Deltec 140 - 11
	Gas control valve	Deltec 36 mm dia.	Deltec 45 mm dia.
		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	order to bring the supply pressure to between the max. & min.
		figures given above
	Additional items to meet The Instituion of Gas Engineers procedures IGE/UP/3 for 4012/16 (Minnox)
	Low pressure detector	Perkins Part No. (see Spares Book)
		(low pressure gas supply only)
	Gas solenoid valves	Not Perkins supply
	Spit back detector	Perkins Part No. (see Spares Book)
	Manual gas shut-off valve	Perkins Part No. (see Spares Book) (if fitted)

	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	CHAMPION RN79G 14mm (earlier L.C. engines)
		CHAMPION RB77 WPC 18mm (later engines)
	Spark plug gap	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)
	Min. oil pressure (rated speed) to bearings	340 kPa (49 lb/in2)
	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

						GAS ENGINE DATA
INDUCTION SYSTEM
		4012TESI (MINNOX)				4016TESI (MINNOX)
Air cleaner			Twin
Type (paper element)			S551A
Max. air intake depression			543 mm H2O (40 mm Hg) (L.C. engines)
			406 mm H2O (30 mm Hg) (H.C. engines)
Air restriction Indicator setting			380 mm H2O
Turbocharger			Twin Garrett (4016TESI 140 H.C. only)
			Twin Schwitzer (all other engines)
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)			See Product Information Manual
(after turbocharger)
		FLYWHEEL
SAE Size			18”
No. of teeth on ring gear		156
FLYWHEEL HOUSING
SAE Size			‘00’
		CRANKSHAFT
Maximum overhung weight on rear			1700 Kg
bearing
T.V. damper			1 x 18”			2 x 20”
NOTE: Subject to torsional vibration investigation different T.V. dampers may be fitted.
		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			286 (each battery)			286 (each battery)
to IEC Standard at 0°C (32°F)
Battery (lead acid)			24 V (2 x 12 V) at 0°C (32°F) (286 Ah)

4012/16 Gas, February 1998

9

172 kPa (25.1 lb/in2)

GAS ENGINE DATA

PROTECTION EQUIPMENT

Before resetting protection equipment, it must be established whether special settings (for that individual engine) have been specified in the engine sales contract. This is particularly important with ALL high water temperature settings, and ALL Cogen applications.

Standard settings for protection equipment are as follows: High air manifold pressure switch

Shutdown switches	Alarm	Shutdown
High oil temperature	115°C	120°C
Low oil pressure	2.06 bar (30 lb/in²)	1.93 bar (28 lb/in²)
High water temperature
71°C Thermostat	91°C	96°C
85°C Thermostat	96°C	101°C
96°C Thermostat	100°C	105°C

Caution: The above standard settings do not supercede any settings specified in the engine sales contract.

Overspeed	15% (on 1500 rev/min only)
High air manifold bursting disc pressure	75 lb/in² at 42°C or 58 lb/in² at 120°C
(Early engines only)

	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/in²)
Oil temperature		Between 80 - 90°C (176 - 194°F)
Water temperature		Between 65 - 85°C (149 - 185°F)
Exhaust temperature		See Product Information Manual
Boost pressure		See Test Certificate
	COOLANT JACKET HEATING
Heater		2 x 4 kw

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)			See Section R14	M24	550	750
** Cylinder head bolt (later (waisted) type)				M24	530	723
Rocker shaft bolt/nut				M16	90	120
Rocker adjuster nut inlet/exhaust				M12	35	50
Rocker 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 retaining 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				M16	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

CAMSHAFT GROUP				Ibf.ft	Nm
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			1/2" BSW
Fan driven pulley taper lock bush screw				35	50
			5/8" BSW	124	170
ALTERNATOR			3/8" BSW
Drive pulley taper lock bush screws				14	20
IGNITION SYSTEM
Spark plug			M18 x 1.5	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)		M12 or 1/2" UNC
Flexible coupling cover screw				90	129
Coupling driving flange screws	(coupling size 2.15)	M12 or 1/2" UNC		90	129
to flywheel	(coupling size 3.86)	M16 or 5/8" 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
8	18	25
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