Perkins Engine 4016-61 TRG Service Manual
Operation and
Maintenance
Manual
SEBU8604
March 2010
4016-61 TRG Industrial Engine
(Engine)
S16
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.
SEBU8604 3
Table of Contents
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 ..................................................................... 77
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 .......................................... 22
Engine Starting ..................................................... 26
Engine Operation .................................................. 28
Engine Stopping ................................................... 29
Maintenance Section
Refill Capacities .................................................... 30
Maintenance Interval Schedule ............................ 42
Warranty Section
Warranty Information ............................................ 76
4 SEBU8604
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.
SEBU8604 5
Safety Section
Safety Messages
Safety Section
i03835895
Safety Me ssage 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 SEBU8604
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 fl uid 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.
SEBU8604 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 ca use 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 and Explosion
Preventi
on
1
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.
ar
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.
p
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 SEBU8604
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.
SEBU8604 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 SEBU8604
Safety Section
Before Starting Engine
i02813489
Before Start ing 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. To 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 Stopping
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.
SEBU8604 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 Electron ics
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 SEBU8604
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 m inimum 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 sw itch in the open position
(5) Disconnected battery cables
(6) Battery
(7) Electrical/Electronic component
(8) Maximum distance between the component that is being
welded and any electrical/electronic component
(9) The component that is being welded
(10) Current 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.
SEBU8604 13
Product Information Section
Model Views
Model Views
i03754000
Model View Illustrations
4016-61TRG
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 SEBU8604
Product Information Section
Model Views
Illustration 1 0
Left side view of engine
(1) Engine crankcase brea ther ( A Bank)
(2) Thermostat housing (A Bank)
(3) Electronic governor actuator
(4) Thermostat housing (B Bank)
(5) Engine crankcase breather (B Bank)
(6) Air shutoff valve (B Bank)
(7) 3x Oil fi lters (B B ank)
(8) Oil cooler
g02029553
(9) Oil level gauge (Dipstick)
(10) Oil filler
(11) Water pump
(12) Stop solenoid
SEBU8604 15
Product Information Section
Model Views
Illustration 11
Right side view of engine
(13) Air cleaner
(14) Restriction indicator for air cleaner
(15) Turbocharger
(16) Electronic governor control unit
(17) Alternator
(18) Fuel filters
(19) Oil drain plug
(20) Fuel priming pump
(21) Oil cooler (A B ank)
(22) 3x Oil filters (A Bank)
i03754029
Engine Description
The 4016-61 TRG engine model is designed for
power generation. The engine is available with
turbocharged aftercooled aspiration.
g02029554
(23) Starter relay
(24) Starting m otor
(25) Aftercooler
Engine Specifications
Note: The number 1 cylinders are to the front. The
front of the engine is farthest from the flywheel.
nk A cylinders are on the right hand side of the
Ba
engine. Bank B cylinders are on the left hand side of
the engine. To determine the left and right sides of
he engine, stand behind the flywheel and face the
t
dampers.
16 SEBU8604
Product Information Section
Model Views
Illustration 12
4016-61 TRG engine model
(A) Bank
(B) Bank
(X) Inlet valves
(Y) Exhaust valves
Table 1
4016-61 Engine Specifications
Cycle 4 Stroke
Number of
Cylinders
Configuration Vee-form
Bore 160 mm (6.299 inch)
e
Strok
Displacement
Compression
Ratio
Rotation
(flywheel end)
Firing Order
Inlet Valve Lash
(Cold)
Exhaust Valve
Lash (Cold)
190 mm
61.123 L (3729.954 in
Counterclockwise
1A-1B-3A-3B-7A-7B-5A-5B-8A-8B-
6A-6B-2A-2B-4A-4B
0.40 mm (0.016 inch)
0.40 mm (0.016 inch)
16
(7.480 inch)
13:1
g01210841
3
)
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
•
SEBU8604 17
Product Information Section
Product Identification Information
Product Identification
Information
i03754088
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 R**** U00001M.
D
_________________________________________ Made in Stafford
____________________________________ Application (Table 2)
G
________________________________ Type of engine (Table 3)
B
_________________________ Number of cylinders(Table 4)
R
__________________________________Fixed build number
*****
____________________________ Built in the United Kingdom
U
Table 3
Type of engine (Diesel)
F TG
L
A
B
D
M
K
N
P
R
S TEG3
W TRG2
X TGR3
F
E
G 4016-E61-TRS
H
J
TAG
TAG1
TAG2
TAG3
TWG
TWG2
TWG3
TRG1
TEG2
Type of engine (Gas)
Gas unit
TESI
TESI Combined Heat and Power unit
TRS Combined Heat and Power Unit
TRS Gas Unit
00001
M
Table 2
____________________________________Engine Number
____________________________________ Year of Manufacture
Application
G Genset
I
Gas
Table 4
Number of Cylinders
F 6
H 8
M 12
R 16
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 SEBU8604
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
•
g01266904
Illustration 14
Typical example
The serial number plate (1) on a engine is located on
the left side of the cylinder block (bank B).
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SEBU8604 19
Operation Section
Lifting and Storage
Operation Section
Lifting and Storage
i03880885
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.
lustration 15
Il
Typical examp le
Use a hoist to remove heavy components. Use a
lifting beam (A) to lift the engine. All supporting
embers (chains and cables) should be parallel
m
to each other. The chains and cables should be
perpendicular to the top of the object that is being
lifted.
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20 SEBU8604
Operation Section
Lifting and Storage
Illustration 1 6
(1) Front lifting eyes (2) Rear lifting eye
ToremovetheengineONLY,usetheliftingeyesthat
are shown in illustration 16. If necessary, remove
engine components in order to avoid damage from
the lifting device.
g02131153
Lifting eyes are designed and installed for specific
engine arrangements. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that correct lifting devices are provided. Consult
your Perkins dealer or your Perkins distributor for
information regarding fixtures for correct engine
lifting.
Illustration 17
g02130795
Note: The lifting eye (3) must NOT b e used in
order to lift the engine. The lifting eye (3) has
not been designed in order to lift the engine. The
lifting eye is used in factory assembly of engine
components.
SEBU8604 21
Operation Section
Lifting and Storage
i03781209
Engine Storage
Refer to Perki
ST16 3UB for information on engine storage.
There are thr
Level “A, B and C”.
ns Engine Company Limited, Stafford,
ee different levels of engine storage.
Level “A ”
Level “A” wi
engines and for gas engines. This level is used for
engines that are transported in a container or by a
truck.
ll give protection for 12 months for diesel
Level “B ”
This level is additional to level “A”. Level “B ” will
give prot
from −15° to +55°C (5° to 99°F) and “90%” relative
humidity, for a maximum of 2 year.
ection under normal conditions of storage
Level “C ”
This level is additional to level “B”. Level “C” will
give protection for five years in tropical or in arctic
es. Level “C” also meets MOD NES 724
climat
Level “J” for Europe, when engines are stored in an
unheated building or in the open under a waterproof
cover.
22 SEBU8604
Operation Section
Features and Controls
Features and Controls
i03882309
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 Sensors
•
Engine speed (Sensor)
•
Engine overspeed (Sensor or Switch)
•
Sensors and Electrical
Components
Sensor Locations
i03781211
Illustration 1 8
(1) Electronic control unit (ECU)
(2) Coolant tempe rature sensor
(3) Boost pressure sensor
(4) Oil pressure switch
(5) High turbine inlet temperature shutdown
sensor (A bank)
(6) Thermocouple
(7) Speed sensor
g02088773
(8) Overspeed sensor
(9) High turbine inlet te mperature shutdown
sensor (B bank)
(10) Oil pressure switch
SEBU8604 23
Operation Section
Features and Controls
The Illustrati
ons show the typical locations of the
sensors on the engine. Specific engines may appear
different from the illustrations due to differences in
applications
Coolant Tempe
.
rature Sensor
The boost press
ure sensor (3) measures the
pressure in the inlet air manifold. A signal is sent to
the ECU (1).
Illustration 19
Coolant temperature switches
g02088775
The coolant temperature switches (2) monitor the
engine coolant temperature. The switches are
supplied for connecting to an OEM supplied panel.
Boost Pressure Sensors
llustration 20
I
Boost pressure sensor
g02125658
24 SEBU8604
Operation Section
Features and Controls
Engine Oil Pressure Switch
Illustration 2 1
Engine oil pressure sensor
(4) Oil pressure sensor (A Bank) (9) Oil pressure sensor (B Bank)
An oil pressure sensor is installed on both side of
the engine. The engine oil pressure sensors are
mounted in the main oil gallery. The engine oil
pressure sensors are supplied for connecting to an
OEM supplied panel.
High Turbine Inlet Temperature
Shutdown Sensor
g02041294
Illustration 2 2
(5) High turbine inlet temperature shutdown
sensor (A bank)
(8) High turbine inlet temperature shutdown
sensor (B bank)
02124274
g
SEBU8604 25
Operation Section
Features and Controls
Illustration 23
Thermocouple
g02123434
Four thermocouples are installed. One thermocouple
is installed in each of the exhaust manifolds. There
are two high turbine inlet temperature shutdown
sensors. One sensor monitors each engine bank.
A sensor monitors two thermocouples. If high
temperatures are indicated the engine will be
shutdown.
The speed senso
r(7)shouldbeservicedat
the required maintenance interval. Refer to the
Operation and Maintenance Manual, “Speed Sensor,
Clean/Inspec
t”.
Failure of the Speed Sensor
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 (7), the engine will shut down. A faulty speed
sensor shou
ld be replaced.
Note: Intermittent failure of the speed sensor will
cause the e
ngine to run erratically. This may also
cause overspeed.
Overspeed Sensor
Speed Sensor
Illustration 24
eed sensor
Sp
g02123433
Illustration 25
Overspeed sensor
g01231518
The signal from the overspeed sensor (8) is
connected to the overspeed switch or the overspeed
circuit in the OEM supplied panel.
The location of the sensor can vary depending on
the application.
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