Perkins Engine 4012-46A Service Manual

Operation and Maintenance Manual

SEBU8191-01

November 2011

4012-46A Industrial Engine

(Engine)

S12

Important Safety Information

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

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

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

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

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

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

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

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

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

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

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

replacement parts.

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

death.

SEBU8191-01 3

Table of Contents

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

Safety Section

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

General Hazard Information ................................... 5

Burn Prevention ...................................................... 7

Fire Prevention and Explosion Prevention .............. 7

Crushing Prevention and Cutting Prevention .......... 9

Mounting and Dismounting ..................................... 9

Before Starting Engine .......................................... 10

Engine Starting ..................................................... 10

Engine Stopping ................................................... 10

Electrical System ................................................... 11

Index Section

Index ............................... ...................................... 74

Engine Electronics ................................................. 11

Product Information Section

General Information .............................................. 12

Model Views ......................................................... 13

Product Identiﬁcation Information ........................ 17

Operation Section

Lifting and Storage ................................................ 19

Features and Controls .......................................... 20

Engine Starting ..................................................... 23

Engine Operation .................................................. 25

Engine Stopping ................................................... 26

Maintenance Section

Reﬁll Capacities .................................................... 27

Maintenance Interval Schedule ............................ 40

Warranty Section

Warranty Information ............................................ 73

4 SEBU8191-01 Foreword

Foreword

Literature Information

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

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

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

Safety

This safety section lists basic safety precautions. In addition, this section identiﬁes hazardous,

g situations. Read and understand the basic

warnin precautions listed in the safety section before operating or performing lubrication, maintenance and

on this product.

repair

ntains safety, operation instructions,

re holder or literature storage area. Read,

ency.

ls or attachments that may be different

nt and advancement of product design

garding your engine, or this manual, please

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

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

ive maintenance program is followed, a

imize operating costs through cost

rvice should be performed at the

lso governs the Maintenance Interval

t lubrication and maintenance than is

Maintenance Intervals

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

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

nce schedules be reproduced and displayed

f the engine's permanent record.

utor can assist you in adjusting your

Overhaul

Opera

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

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

tion

. They assist with developing the skills and

lop as the operator gains knowledge of the

peration section is a reference for operators.

stopping the engine. This section also includes a

Maintenance

e maintenance section is a guide to engine care.

Th The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance

tervals. Items in the maintenance schedule are

in referenced to detailed instructions that follow.

Major engine overhaul details are not covered in the Operation and Maintenance Manual except

e interval and the maintenance items in that

for th interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer

r Perkins distributor offers a variety of options

or you regarding overhaul programs. If you experience a major engine failure, there are also numerous

r failure overhaul options available. Consult with

afte your Perkins dealer or your Perkins distributor for information regarding these options.

California Proposition 65 Warning

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

th defects, and other reproductive harm. Battery

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

SEBU8191-01 5

Safety Section

Safety Messages

Safety Section

i03835895

Safety Message s

There may be engine. The exact location and a description of the warning signs are reviewed in this section. Please become fam

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

Replace missing.Ifawarningsignisattachedtoapartofthe engine that is replaced, install a new warning sign on the rep distributor can provide new warning signs.

lacement part. Your Perkins dealer or your

several speciﬁc warning signs on your

iliar with all warning signs.

g signs or replace the warning signs if

ng signs. Do not use solvents, gasoline, or

signs. The warning signs that are loosened

any warning sign that is damaged or

(2) Hot Coolant

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loose the cap slowly to relieve the pressure.

(1) Universal Warning

Do not operate or work on this equipment unless

ave read and understand the instructions

you h and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or

the warnings could result in serious injury

heed or death.

Illustration 1

g01231164

Illustration 2

g01231165

i02328435

General Hazard Information

Illustration 3

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment.

g00104545

6 SEBU8191-01 Safety Section General Hazard Information

Illustration 4

Wear a hard hat, protective glasses, and other protective equipment, as required.

Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine.

Make sure that all protective guards and all covers are secured in place on the engine.

Keep the engine free from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps.

g00702020

When pressuriz cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protectiv

The maximum air pressure for cleaning purposes must be below water pressure for cleaning purposes must be below 275 kPa (40 psi).

ed air and/or water is used for

efaceshield.

205 kPa (30 psi). The maximum

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydra escape rapidly if the pressure is not relieved correctly.

Do not remo until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic componen or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve t

ulic ﬂuid or items such as pipe plugs to

ve any hydraulic components or parts

ts or parts until pressure has been relieved

he hydraulic pressure.

Never put maintenance ﬂuids into glass containers. Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Report all necessary repairs.

Do not allow unauthorized personnel on the equipment.

Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs.

Perform maintenance on the engine with the equipment in the servicing position. Refer to the OEM information for the procedure for placing the equipment in the servicing position.

Pressure Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury.

The direct application of pressurized air or pressurized water to the body could result in personal injury.

Illustration 5

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

g00687600

Containing Fluid Spillage

Care must be taken in order to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjusting and repair of the engine. Make provision to collect the ﬂuid with a suitable container before any compartment is opened or before any component is disassembled.

Only use the tools that are suitable for collecting

•

ﬂuids and equipment that is suitable for collecting ﬂuids.

SEBU8191-01 7

Safety Section

Burn Prevention

Only use the too

•

ﬂuids and equipment that is suitable for containing ﬂuids.

Obey all local regulations for the disposal of liquids.

ls that are suitable for containing

i02334785

Burn Prevention

Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine.

Contact with high pressure fuel may cause ﬂuid penetration and burn hazards. High pressure fuel spray may cause a ﬁre hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines.

Oils

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

Batteries

Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.

i0232072

Fire Prevention an d Explosion Preventi

Allow the pressure to be purged in the air system, in the hydraulic system, in the lubrication system, or in the cooling system before any lines, ﬁttings or related items are disconnected.

Coolant

When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.

Check the coolant level after the engine has stopped and the engine has been allowed to cool.

Ensure that the ﬁller cap is cool before removing the ﬁller cap. The ﬁller cap must be cool enough to touch withabarehand.Removetheﬁller cap slowly in order to relieve pressure.

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

stration 6

Illu

All fuels, most lubricants, and some coolant mixtures

ammable.

are ﬂ

Flammable ﬂuids that are leaking or spilled onto hot

faces or onto electrical components can cause

sur a ﬁre. Fire may cause personal injury and property damage.

After the emergency stop button is operated ensure that you allow 15 minutes, before the engine covers

e removed.

Determinewhethertheenginewillbeoperatedinan

vironment that allows combustible gases to be

en drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury,

roperty damage, or engine damage could result.

If the application involves the presence of combustible

ases, consult your Perkins dealer and/or your

g Perkins distributor for additional information about suitable protection devices.

g00704000

8 SEBU8191-01 Safety Section Fire Prevention and Explosion Prevention

Remove all ﬂamm

able combustible materials or conductive materials such as fuel, oil, and debris from the engine. Do not allow any ﬂammable combustible materials or c

onductive materials to accumulate on

the engine.

Store fuels a

nd lubricants in correctly marked containers away from unauthorized persons. Store oily rags and any ﬂammable materials in protective containers

. Do not smoke in areas that are used for

storing ﬂammable materials.

Do not expos

e the engine to any ﬂame.

Exhaust shields (if equipped) protect hot exhaust component

s from oil or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be installed correctly.

Do not weld on lines or tanks that contain ﬂammable

ﬂuids. Do not ﬂame cut lines or tanks that contain ﬂammable

ﬂuid. Clean any such lines or tanks

thoroughly with a nonﬂammable solvent prior to welding or ﬂame cutting.

Wiring must be kept in good condition. All electrical wires must be correctly routed and securely attached. Check al

l electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Clean all electrical connections and tighten all elec

trical connections.

Oil ﬁlters and f

uel ﬁlters must be correctly installed. The ﬁlter housings must be tightened to the correct torque. Refer to the Disassembly and Assembly manual for mor

Illustration 7

e information.

g00704059

Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open ﬂames or sparks. Always stop the engine before refueling.

Eliminate all wiring that is unattached or unnecessary. Do not u

se any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or circuit breakers.

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

ained battery cables will help to prevent arcing

maint or sparking.

Contact with high pressure fuel may cause ﬂuid

tration and burn hazards. High pressure fu-

pene el spray may cause a ﬁre hazard. Failure to follow these inspection, maintenance and service in-

uctions may cause personal injury or death.

str

After the engine has stopped, you must wait for 60

conds in order to allow the fuel pressure to be

se purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines.

Ensure that the engine is stopped. Inspect all lines and hoses for wear or for deterioration. The hoses

ust be correctly routed. The lines and hoses must

m have adequate support and secure clamps.

Illustration 8

g00704135

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

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

SEBU8191-01 9

Safety Section

Crushing Prevention and Cutting Prevention

Incorrect jump an explosion that can result in injury. Refer to the Operation Section of this manual for speciﬁc instructions

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

The batteries must be kept clean. The covers (if equippe recommended cables, connections, and battery box covers when the engine is operated.

er cable connections can cause

d) must be kept on the cells. Use the

Fire Extinguisher

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

e ﬁre extinguisher and service the ﬁre

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are damaged

Leaks can cause ﬁres. Consult your Perkins dealer or your P

Replace the parts if any of the following conditions are pre

erkins distributor for replacement parts.

sent:

i02143194

Crushing Prevention and Cutting Preve

Support the component correctly when work beneath the component is performed.

Unless other maintenance instructions are provided, never attempt adjustments while the engine is running.

Stay clear of all rotating parts and of all moving parts. Lea is performed. After the maintenance is performed, reinstall the guards.

Keep objects away from moving fan blades. The fan blades will throw objects or cut objects.

When objects are struck, wear protective glasses in order to avoid injury to the eyes.

Chips or other debris may ﬂy off objects when objects are struck. Before objects are struck, ensure that no one will

ve the guards in place until maintenance

be injured by ﬂying debris.

ntion

i02235492

Mounting and Dismounting

High pressure fuel line or lines are removed.

•

End ﬁttings are damaged or leaking.

•

coverings are chafed or cut.

Outer

•

Wires are exposed.

•

Outer coverings are ballooning.

•

ible part of the hoses are kinked.

Flex

•

Outer covers have embedded armoring.

•

End ﬁttings are displaced.

•

e sure that all clamps, guards, and heat shields

Mak are installed correctly. During engine operation, this will help to prevent vibration, rubbing against other

ts, and excessive heat.

par

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

Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds.

Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.

Do not carry tools or supplies when you mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies.

10 SEBU8191-01 Safety Section Before Starting Engine

i02813489

Before Starting Engine

Before the ini serviced or repaired, make provision to shut the engine off, in order to stop an overspeed. This may be accomplis supply to the engine.

Overspeed s engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop buttonino

Inspect the engine for potential hazards.

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

If equipped, ensure that the lighting system for the engine is lights work correctly, if equipped.

tial start-up of an engine that is new,

hed by shutting off the air and/or fuel

hutdown should occur automatically for

rder to cut the fuel and/or air to the engine.

ee of personnel.

suitable for the conditions. Ensure that all

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

Always start that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Kn prevent major damage to the engine components. Knowing the procedure will also help to prevent personal in

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

Note: Do not use Lube oil heaters.

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

guards and all protective covers must

is caused by parts in rotation, work

theengineaccordingtotheprocedure

owing the correct procedure will help to

jury.

correctly, check the water temperature

haust contains products of combustion

he engine is started in an enclosed area,

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

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

See th adjustments.

ective guards and all protective covers must

t that is caused by parts in rotation, work

ypass the automatic shutoff circuits. Do not

its are also provided in order to help prevent

e Service Manual for repairs and for

i02414669

Engine Starting

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

i02414676

Engine St opp ing

Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping” in order to avoid overheating of the engine and accelerated wear of the engine components.

Use the Emergency Stop Button ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected.

Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has been overhauled. In the event of an overspeed condition, the air shutoff valves will operate. After operation, the air shutoff valves must be manually reset.

If a warning tag is attached to the engine start switch or to the controls DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.

SEBU8191-01 11

Safety Section

Electrical System

i02414678

Electrical System

Never disconn circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that ar

To help prevent sparks from igniting combustible gases that a negative “−” cable should be connected last from the external power source to the negative “−” terminal of the starti

Check the electrical wires daily for wires that arelooseo connections before the engine is started. Repair all frayed electrical wires before the engine is started. See the Op speciﬁc starting instructions.

Engines t ground straps can be damaged by electrical discharge.

ect any charging unit circuit or battery

e produced by some batteries to ignite.

re produced by some batteries, the

ng motor.

r frayed. Tighten all loose electrical

eration and Maintenance Manual for

hat are installed without engine-to-frame

Setpoint adjus

•

Sensors

•

Wiring Harness

•

ters (if equipped)

System Description

The system is (ECU). The ECU contains a microprocessor that has an Electronic Programmable Read Only Memory (EPROM). Th are stored in the EPROM. The actuator is connected to the fuel injectors via a mechanical linkage.

A laptop computer is used to set the operating parameters of the governor. The laptop computer is connected operating parameters for the governor should only be modiﬁed by a trained Perkins representative. Refer to the Speci for more information.

controlled by an Electronic control Unit

e operating parameters for the governor

to the governor via an interface cable. The

al Instruction, “Pandoras Digital Governor”

To ensure that the engine and the engine electrical systems function correctly, an engine-to-frame ground s used. This path may be provided by way of a direct engine ground to the frame.

The connections for the grounds should be tight and free of corrosion. The engine alternator must be groun a wire that is adequate to handle the full charging current of the alternator.

trap with a direct path to the battery must be

ded to the negative “-” battery terminal with

i0241

4684

Engine Electronics

Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engine damage.

The engine is controlled by a digital Pandoras governor. The control system includes the following components.

Control unit

•

Actuator

•

12 SEBU8191-01 Product Information Section General Information

Product Information Section

General Infor mation

i02640420

Welding on Engines with Electronic Controls

NOTICE Proper welding procedures are necessary in order to avoid damage to the engine's ECM, sensors, and associated components. When possible, remove the component from the unit and then weld the component. If removal of the component is not possible, the following procedure must be followed when you weld with a unit that is equipped with an Electronic Engine. The following procedure is considered to be the safest procedure to weld a component. This procedure should provide a minimum risk of damage to electronic components.

NOTICE Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic components, electrical components, and other components.

Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. This will help reduce the possibility of damage.

1. Stop the engine. Turn the switched power to the

OFF position.

2. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is provided, open the switch.

Illustration 9

Use the example above. The current ﬂow from the welder to the ground clamp of the welder will not cause damage to any associated components.

(1) Engine (2) Welding rod (3) Keyswitch in the OFF position (4) Battery disconnect switch in the open position (5) Disconnected battery cables (6) Battery (7) Electrical/Electronic component (8) Maximum distance between the c ompo nent that is being

welded and any electrical/electronic component (9) The component that is being welded (10) Cur rent path of the welder (11) Ground clamp for the welder

4. Connect the welding ground cable directly to the

part that will be welded. Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings, hydraulic components, electrical components, and ground straps.

Note: If electrical/electronic components are used as a ground for the welder, or electrical/electronic components are located between the welder ground and the weld, current ﬂow from the welder could severely damage the component.

g01324562

3. Disconnect the connectors from the ECM.

5. Protect the wiring harness from welding debris

and spatter.

6. Use standard welding practices to weld the

materials.

SEBU8191-01 13

Product Information Section

Model Views

i03754026

Model View Illustrations

4012-46A

The following model views show typical features of the engine. may appear different from the Illustrations.

Due to individual applications, engines

Note: Only the following Illustrations.

serviced components are identiﬁed on

14 SEBU8191-01 Product Information Section Model Views

Illustration 10

Typical example

Left side view of engine

(1) Radiator cap (2) Thermostat housing (3) C oolant temperature switch (4) Air cleaner (5) Res triction indicator for air cleaner

(6) Air shutoff valve (7) Timing inspection hole (8) Inspection covers for crankcase (9) 3x Oil ﬁlters (10) Oil cooler

g02090055

(11) Oil drain plug (12) O il level gauge (13) Oil ﬁ ller (14) Crankshaft damper (15) Engine crankcase breather

SEBU8191-01 15

Product Information Section

Model Views

Illustration 11

Typical example

Right side view of engine

(1) Air shutoff valve (2) Res triction indicator for air cleaner (3) Air cleaner (4) Electronic governor control unit (5) C oolant temperature switch (6) Thermostat housing

(7) Aftercooler (8) Radiator (9) Engine crankcase breather (10) Alternator (11) Primary fuel ﬁlter/water separator (12) Oil pump

i03754051

Engine De script ion

The 4012-46A Engine model is designed for power generation. The engine is available with turbocharged aftercooled aspiration.

g02090056

(13) Fuel priming pump (14) Oil pan drain plug (15) Oil cooler (16) 3x Oil ﬁlters (17) Starter relay (18) 2x Starting motors

Engine Speciﬁcations

te: The number 1 cylinders are to the front. The

front of the engine is farthest from the ﬂywheel. Bank A cylinders are on the right-hand side of the

ngine. Bank B cylinders are on the left-hand side of

e the engine. To determine the left and right sides of the engine, stand behind the ﬂywheel and face the

ampers.

16 SEBU8191-01 Product Information Section Model Views

Illustration 12

4012-46A Engine model

(A) Bank (B) Bank (X) Inlet valves (Y) Exhaust valves

Table 1

4012-46A Engine Speciﬁcations

Cycle 4 Stroke

Number of Cylinders

Conﬁguration Vee-form

Bore 160 mm (6.299 inch)

Strok

Displacement

Compression Ratio

Rotation (ﬂywheel end)

Firing Order

Inlet Valve Lash (Cold)

Exhaust Valve Lash (Cold)

190 mm

45.84 L (2797.328 in

Counterclockwise

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

0.40 mm (0.016 inch)

(7.480 inch)

13:1

5B-4A-3B

g01210840

)

The engine lubr

icating oil is supplied by a gear-driven pump. The lubrication oil is cooled and ﬁltered. Bypass valves provide unrestricted ﬂow of lubrication oil to the engi

nepartswhenoilviscosityishigh. Bypass valves can also provide unrestricted ﬂow of lubrication oil to the engine parts if the oil ﬁlter element shou

ld become plugged.

Engine efﬁciency, efﬁciency of emission controls, and engine perf

ormance depend on adherence to proper operation and maintenance recommendations. Engine performance and efﬁciency also depend on the use of re

commended fuels, lubrication oils, and coolants. Refer to this Operation and Maintenance Manual, “Maintenance Interval Schedule” for more informati

on on maintenance items.

Engine Cooling and Lubrication

The cooling system consists of the following components:

Gear-driven water pumps

•

Water temperature regulators which regulate the

•

engine coolant temperature

Gear-driven oil pump (gear type)

•

Oil coolers

•

SEBU8191-01 17

Product Information Section

Product Identiﬁcation Information

i03754093

Plate Locations and Film Locations

Engine Identiﬁcation

Perkins engines are identiﬁed by an engine serial number.

A typical example of an engine serial number is DGB M**** U00001V.

_________________________________________ Made in Stafford

____________________________________ Application (Table 2)

________________________________ Type of engine (Table 3)

________________________ Number of cylinders (Table 4)

__________________________________Fixed build number

*****

____________________________ Built in the United Kingdom

Table 3

F TG

S TEG3

W TRW2

X TRW3

Table 4

F 6

H 8

M 12

R 16

Type of engine (Diesel)

TAG

TAG1

TAG2

TAG3

TWG

TWG2

TWG3

TRG1

TEG2

Number of Cylinders

00001

Table 2

____________________________________Engine Number

_____________________________________ Year of Manufacture

Application

G Genset

Perkins dealers and Perkins distributors require all of these numbers in order to determine the components that were included in the engine. This permits accurate identiﬁcation of replacement part numbers.

18 SEBU8191-01 Product Information Section Product Identiﬁcation Information

Serial Number Plate

Illustration 13

Serial number plate

The engine serial number plate contains the following information:

Place of manufacture

•

Telephone number of manufacturer

•

Fax number of manufacturer

•

Type of engine

•

Engine serial number

•

Rated speed

•

Power output

•

Engine timing

•

Rating

•

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Illustration 14

The location of the serial number plate for vee-form engines

The serial number plate (1) on a vee-form engine is located on the rear face of the cylinder block (bank A). See Illustration 14.

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SEBU8191-01 19

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i02414727

Engine Lifting

NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees.

When it is necessary to remove a component at an angle, only use a link bracket that is properly rated for the weight.

To re m ov e t he e n that are on the engine. If necessary, remove engine components in order to avoid damage from the lifting device.

Lifting eyes are designed and installed for speciﬁc engine arran and/or the engine make the lifting eyes and the lifting ﬁxtures obsolete. If alterations are made, ensure that correc your Perkins dealer or your Perkins distributor for information regarding ﬁxtures for correct engine lifting.

t lifting devices are provided. Consult

gine ONLY, use the lifting eyes

gements. Alterations to the lifting eyes

i03781209

Engine Storage

Refer to Perkins Engine Company Limited, Stafford, ST16 3UB for information on engine storage.

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

lustration 15

Level “A ”

Level “A” will give protection for 12 months for diesel engines and for gas engines. This level is used for engines that are transported in a container or by a truck.

Level “B ”

This level is additional to level “A”. Level “B ” will give protection under normal conditions of storage from −15° to +55°C (5° to 99°F) and “90%” relative humidity, for a maximum of 2 year.

Level “C ”

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

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Use a hoist to remove heavy components. Use a

ifting beam (A) to lift the engine. All supporting

l members (chains and cables) should be parallel to each other. The chains and cables should be

erpendicular to the top of the object that is being

p lifted.

20 SEBU8191-01 Operation Section Features and Controls

Features and Controls

i02415217

Monitoring System

The engine is equipped with sensors or switches to monitor the following parameters:

Coolant temperature (Switch)

•

Oil pressure (Switch)

•

Intake manifold boost pressure (Sensor)

•

Exhaust temperature (if equipped)

•

Engine speed (Sensor)

•

Engine overspeed (Sensor or Switch)

•

Sensors and Electrical Components

i02415219

Illustration 16

Right side view of engine

(1) Electronic control unit (ECU) (2) C oolant temperature switch (3) B oost pressure sensor (4) Speed sensor (5) Oil pressure switch

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Sensor Locations

trations 16 and 17 show the typical locations

Illus of the sensors on the engine. Speciﬁc engines may appear different from the illustrations due to

erences in applications. Illustration 16 shows the

diff location of the Electronic Control Unit (ECU).

Illustration 17

Left side view of engine

) Coolant temperature switch

) Boost pressure sensor

) Oil pressure switch

) Overspeed sensor

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231520

SEBU8191-01 21

Operation Section

Features and Controls

Coolant Temperature Switches

Illustration 18

Coolant temperature switch

The coolant temperature switches (2) monitor the engine coolant temperature. The switches are supplied for connecting to an OEM supplied panel.

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Boost Pressure Sensors

Speed Sensor

Illustration 20

Speed sensor

The speed sensor (4) should be serviced at the required maintenance interval. Refer to the Operation and Maintenance Manual, “Speed Sensor, Clean/Inspect”.

Failure of the Speed Sensor

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Illustration 19

Boost pressure sensor

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The boost pressure sensor (3) measures the pressure in the inlet air manifold. A signal is sent to the ECU (1).

If the ECU (1) does not receive a signal from the speed sensor (4), the engine cannot run.

If the ECU does not receive a signal from the speed sensor (4), the engine will shut down. A faulty speed sensor should be replaced.

Note: Intermittent failure of the speed sensor will cause the engine to run erratically. This may also cause overspeed.

22 SEBU8191-01 Operation Section Features and Controls

Engine Oil Pressure Switch

Illustration 21

Engine oil pressure switch

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The engine oil pressure switch (5) is mounted in the main oil gallery. The engine oil pressure switches are supplied for connecting to an OEM supplied panel (1).

Overspeed Sensor

Illustration 22

Overspeed sensor

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The signal from the overspeed sensor (6) is connected to the overspeed switch or the overspeed circuit in the OEM supplied panel.

SEBU8191-01 23

Operation Section

Engine Starting

i02415220

Before Starting Engine

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

Note: Do no controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the c

1. Open the fuel supply valve (if equipped).

2. If the engine has not been started for several

weeks, fuel may have drained from the fuel system. some air pockets will be trapped in the engine. In these instances, prime the fuel system. Refer to the O System-Prime”formoreinformation.

ngine is started, perform the required

nance Manual, “Maintenance Interval

t start the engine or move any of the

ontrols.

Also, when fuel ﬁlters have been changed,

peration and Maintenance Manual, “Fuel

b. Turn the keyswi

Hold the keyswitch in this position until the oil pressure gauge indicates 100 kPa (14.5040 psi) in the START position for an additional 10 seconds.

Note: The keyswitch is part of the OEM supplied panel. The exact procedure for starting may vary. Refer to OEM starting procedure.

c. Turn the key

d. Reconnect the speed pickup connector.

The engine is now ready to run.

supplied instructions for the correct

tch to the START position.

. Continue to hold the keyswitch

switch to the STOP position.

i02415221

Starting the Eng ine

Normal Engine Starting Procedure

Note: When possible, ensure that the engine is not

started under load.

Illustration 23

3. Ensure that the two air shutoff valves (1) are in

the OPEN position.

4. If the engine has not been started for more than

three months, the engine oil system must be primed. Follow Steps 4.a through 4.d in order to prime the engine oil system.

a. Ensure that the governor stays in the STOP

position by disconnecting the speed pickup connector on the governor control.

g01230837

1. Turn the keyswitch to the START position. The engine should start immediately.

2. Allow the keyswitch to return to the RUN position after the engine starts.

If the engine does not start after 10 seconds, return the keyswitch in the RUN position for 10 seconds. Then repeat Steps 1 and 2.

Note: If the engine fails to start after three attempts, investigate the cause.

3. After the engine has started follow Steps 3.a through 3.d.

a. Check the oil pressure.

b. Inspect the engine for leaks.

c. Ensure that the batteries for the engine are

receiving a charge.

d. After the engine has run for ﬁve minutes, check

the engine monitoring systems. Ensure that the engine is operating correctly before the load is applied.

24 SEBU8191-01 Operation Section Engine Starting

i02415223

Cold Weather Starting

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

Startability will be improved at temperatures below +10 °C (+50 °F) from the use of a jacket water heater or extra battery capacity.

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