Perkins Engine 4016-61TRS1, 4016-61TRS2 Service Manual

Operation and
Maintenance
Manual

SEBU8430-00

August 2008

4016-61TRS1 and 4016-61TRS2 Gas
Engines

(Engine)

G16

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.

SEBU8430 3

Table of Contents

Table of Contents

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

Safety Section

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

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

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

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

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

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

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

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

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

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

Index Section

Index ............................... ...................................... 69

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

Product Information Section

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

Product Identification Information ........................ 18

Operation Section

Lifting and Storage ................................................ 20

Gauges and Indicators .......................................... 21

Features and Controls .......................................... 22

Engine Starting ..................................................... 25

Engine Operation .................................................. 28

Engine Stopping ................................................... 29

Maintenance Section

Refill Capacities .................................................... 30

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

Reference Information Section

Reference Materials .............................................. 65

4 SEBU8430
Foreword

Foreword

Literature Information

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

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

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

Safety

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

this product.

tains safety, operation instructions,

e holder or literature storage area. Read,

ncy.

or attachments that may be different

t and advancement of product design

arding your engine, or this manual, please

tuations. Read and understand the basic

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

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

ive maintenance program is followed, a

mize operating costs through cost

rvice should be performed at the

lso governs the Maintenance Interval

t lubrication and maintenance than is

Maintenance Intervals

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

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

ce schedules be reproduced and displayed

the engine’s permanent record.

tor can assist you in adjusting your

Overhaul

Operatio

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

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

n

ey assist with developing the skills and

as the operator gains knowledge of the

ation section is a reference for operators.

pping the engine. This section also includes a

Maintenance

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

ntenance section is a guide to engine care.

als. Items in the maintenance schedule are

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

nterval and the maintenance items in that

erkins distributor offers a variety of options

ailure overhaul options available. Consult with

California Proposition 65 Warning

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

defects, and other reproductive harm. Battery

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

SEBU8430 5

Safety Section

Safety Messages

Safety Section

i02885759

Safety Me ssage s

Illustration 1

Typical example

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

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

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

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

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

g01530454

6 SEBU8430
Safety Section
Safety Messages

(1) Engine Oil Level

Illustration 2

Typical example

The warning label for checking the engine oil Level
(1) is located on the inlet manifold on the left side of
the engine. Refer to illustration 1.

(2) Universal Warning

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

g01241033

The Universal Warning label (2) is located on the
inlet manifold on the right side of the engine. Refer
to illustration 1.

Illustration 3

Typical example

g01234595

SEBU8430 7

Safety Section

General Hazard Information

(3) Engine Derate

Illustration 4

Typical example

The warning label for derating engine information
(3) is located on the control box. Refer to OEM
information for the location of the control box.

i03139708

General Hazard Information

Illustration 5

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

g00104545

g01241021

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

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

Filler caps

•

Grease fittings

•

Pressure taps

•

Breathers

•

Drain plugs

•

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

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

8 SEBU8430
Safety Section
General Hazard Information

Pressurized Air and Water

Illustration 6

Wear a hard hat, protective glasses, and other

•

protective equipment, as required.

When work is performed around an engine that is

•

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

Do not wear loose clothing or jewelry that can snag

•

on controls or on other parts of the engine.

Ensure that all protective guards and all covers are

•

securedinplaceontheengine.

g00702020

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

When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and ey
goggles or a protective face shield.

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

Fluid Penetr

r and pressurized water can cause

eprotection.Eyeprotectionincludes

ir pressure for cleaning purposes

i).

ation

Never put maintenance fluids into glass containers.

•

Glass containers can break.

Use all cleaning solutions with care.

•

Report all necessary repairs.

•

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

The engine is stopped. Ensure that the engine

•

cannot be started.

Disconnect the batteries when maintenance

•

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

Do not attempt any repairs that are not understood.

•

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

If work is carried out on the fuel system obey the

•

local regulations for isolation of the gas supply.

California Proposition 65 Warning

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

Illustration 7

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

g00687600

Containing Fluid Spillage

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

Tools that are suitable for collecting fluids and

•

equipment that is suitable for collecting fluids

Tools that are suitable for containing fluids and

•

equipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

SEBU8430 9

Safety Section

Burn Prevention

Dispose o f Waste Properly

Illustration 8

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

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

f according to local regulations.

ot pour waste onto the ground, down a

g00706404

i03116980

Burn Prevention

Oils

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

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

Batteries

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

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

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

i02415237

Fire Prevention and Explosion
Preventio

n

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

Coolant

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

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

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

Illustration 9

All fuels, most lubricants, and some coolant mixtures
are flammable.

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

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

g00704000

10 SEBU8430
Safety Section
Fire Prevention and Explosion Prevention

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

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

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

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

Do not expo

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

Do not weld on lines or tanks that contain flammable

fluids. Do not flame cut lines that contain flammable
fluid. Clea

nonflammable solvent prior to welding or flame
cutting.

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

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

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

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

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

trical connections.

ned battery cables will help to prevent arcing

t all lines and hoses for wear or for

ure clamps. Tighten all connections to the

ers and fuel filters must be properly installed.

her the engine will be operated in an

ne to overspeed. Personal injury,

ation involves the presence of combustible

tions must be observed.

he engine. Do not allow any flammable

nd lubricants in properly marked

. Do not smoke in areas that are used for

setheenginetoanyflame.

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

n any such lines thoroughly with a

electrical wires daily. Repair any wires

e any wires or cables that are smaller than

Illustration 10

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

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

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

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

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

g00704135

Fire Extinguisher

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

Lines, Tubes and Hoses

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

SEBU8430 11

Safety Section

Crushing Prevention and Cutting Prevention

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

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

Replace the p
are present:

End fittings a

•

Outer coverings are chafed or cut.

•

Wires are exposed.

•

Outer coveri

•

Flexible part of the hoses are kinked.

•

Outer covers have embedded armoring.

•

End fittings a

•

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

s that are loose or damaged. Leaks

check for leaks. Tighten all connections

arts if any of the following conditions

re damaged or leaking.

ngs are ballooning.

re displaced.

d correctly. During engine operation, this

i02143194

i02453744

Mounting and Dismounting

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

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

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

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

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

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

dholds may not be installed on the

items in good repair.

at have steps and/or handholds. Do not

ne in order to mount the engine or

ne foot and two hands. Do not use any

on components which cannot support

ill not move.

hen you dismount the engine. Use a hand

Crushing Prevention and
Cutting Prevention

Support th
the component is performed.

Unless oth
never attempt adjustments while the engine is
running.

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

Keep obje
blades will throw objects or cut objects.

When obje
order to avoid injury to the eyes.

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

e component correctly when work beneath

er maintenance instructions are provided,

med. After the maintenance is performed,

cts away from moving fan blades. The fan

cts are struck, wear protective glasses in

ther debris may fly off objects when objects

i02415253

Ignition

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

Systems

i02453806

Before Starting Engine

Inspect the engine for potential hazards.

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

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

12 SEBU8430
Safety Section
Engine Starting

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

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

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

Engine Star

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

guards and all protective covers must

is caused by parts in rotation, work

the automatic shutoff circuits. Do not

also provided in order to help prevent

tart-up of a new engine or a engine that

ed by shutting off the fuel supply to the

i03101447

ting

ls. Consult with the person that attached

i00659907

Engine Stopping

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

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

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

ating of the engine and accelerated

anual, “Engine Stopping” topic

ncy Stop Button (if equipped) ONLY

op, DO NOT start the engine until the

f an overspeed occurs. This may be

i02436641

Electrical S ys tem

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

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

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

To ensure that the jacket water heater (if equipped) is
working properly, check the water temperature and
the oil

Engine exhaust contains products of combustion
which c
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent th

tive guards and all protective covers must

that is caused by parts in rotation, work

s a possibility that unburned gas remains in

” topic in the Operation Section.

scribed in the Operation and Maintenance

major damage to the engine components.

temperature during heater operation.

an be harmful to your health. Always start the

e engine exhaust to the outside.

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

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

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

Grounding Practices

Note: All ground lines must return to the battery

ground.

SEBU8430 13

Safety Section

Electrical System

Illustration 11

Typical example

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

g01217202

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

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

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

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

14 SEBU8430
Product Information Section
Model Views and Specifications

Product Information
Section

Model Views and
Specifications

i02885828

Model View Illustrations

The illustrations show various typical features of
4016 Series TRS Engine. The illustrations do not
show all of the options that are available.

Illustration 12

Typical example

(1) Ignition coils
(2) Air filter
(3) Charge air cooler

(4) E ngine oil filters
(5) The inspection cover for the Crankcase
(6) Oil level gauge (dipstick)

g01525185

(7) Oil filler cap

SEBU8430 15

Product Information Section

Model Views and Specifications

Illustration 13

Typical example

(8) Tumbulator
(9) Turbocharger
(10) Gas control valve

(11) Rail for the engine wiring
(12) Throttle
(13) O il drain plug

i02885810

Product Description

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

Fuel System

The fuel is delivered to the gas control valve. The gas
must be at a constant pressure and the gas pressure
must be stable. The pressure must be within a range
of5to25kPa(0.72to3.6psi).Higherpressurewill
need to be reduced with an additional gas regulator.

g01525189

(14) Ope n breather system

Theventuriislocatedinthegasmixerbody
immediately before the turbocharger. As air is
accelerated through the venturi gas is mixed with the
air. This mixture is compressed by the turbocharger.
The mixture passes through the tumbulator, and the
charge coolers, and into the inlet manifolds. The
speed and the load is governed by electronically
controlled throttle valves.

A digitally controlled gas valve maintains the air/fuel
ratio. This system is adjustable. Refer to Systems
Operation, Testing and Adjusting for details. This is
the only means of adjusting the exhaust emissions.

Ignition System

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

16 SEBU8430
Product Information Section
Model Views and Specifications

Voltage

•

Duration of the spark

•

Ignition timing

•

Level of energ

•

All 4016TRS gas engines are equipped with a device
to detect deto
the ignition system. This device automatically retards
the ignition timing.

The ignition timing is retarded when excessive
detonation is sensed. If detonation continues after full
retardation

Lubrication

The engine lubrication oil is supplied by a pump
that is drive
oil is filtered. A bypass valve provides unrestricted

flow of lubrication oil to the engine parts if the oil
filter eleme

will open if the oil filter differential pressure reaches

34.4to48.2kPa(5to7psi).Theengineoilpressure
operates in

Note: The engine lubrication oil is not fi ltered when
the bypass v
to operate when the bypass valve is open. This can
damage the engine components.

y of the ignition

nation which is connected directly into

, then the engine must be shut down.

System

n by a gear. The oil is cooled and the

nts become plugged. The bypass valve

a range of 415 to 450 kPa (60 to 65 psi).

alve is open. Do not allow the engine

Cooling System

The system is us
important factor.

ed when recovery of heat is not an

Cogeneration engine

Cogeneration
otherwisebewasted.

The following

Water pumps

•

Water temperature regulator ( thermostat)

•

All water tube

•

This system is the responsibility of the OEM.

uses energy from heat which would

items are not supplied:

assemblies

Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on adherence to proper
operation an
includes the use of recommended lubricants, fuels,
and coolants.

For the engine maintenance that is required,
refer to the Operation and Maintenance Manual,
“Maintenan
Section.

d maintenance recommendations. This

ce Interval Schedule” in the Maintenance

i02885756

Specifications

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

ts the cylinder head into the rail. The water

Electrounit

This type
components:

Jacket wa

•

Water temperature regulator (thermostat)

•

Coolant pipe for the charge cooler

•

A water pu

•

A water temperature regulator (thermostat) that

•

controls
cooler

Battery c

•

of engine is supplied with the following

ter coolant pump

mp for the charge cooler

the water inlet temperature for the charge

harging alternator

General Eng

Illustration 14

Sixteen cylinder

(X) Inlet valves
(Y) Exhaust valves

ine Specifications

g01210841

SEBU8430 17

Product Information Section

Model Views and Specifications

Table 1

4016 Engine Specifications

Rated rpm 1500

Number of Cylinders

Configuration Vee-form

Bore

160 mm (6.299 inch)

Stroke 190 mm (7.480 inch)

Displacement

61.123 L (3729.954 in

Compression ratio

Aspiration Turbocharged

Rotation (flyw

heel end)

Counterclock

Inlet valve lash (cold) 0.40 mm (0.016 inch)

Exhaust valve lash (cold) 0.40 mm (0.016 inch)

Firing order 1A-1B-3A-3B-7A-7B-

5A-5B-8A-8B-6A-6B-

16

13:1

wise

2A-2B-4A-4B

3

)

18 SEBU8430
Product Information Section
Product Identification Information

Product Identification
Information

i02978102

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
DIH R**** U10001S.

D

_________________________________________ Made in Stafford

______________________________________Application (Table 2)

I

_______________________________ Type of engine (Table 3)

H

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.

Serial Nu mber Plate

_________________________ Number of cylinders (Table 4)

R

_________________________________ _ Fixed build number

*****

____________________________Built in the United Kingdom

U

00001

S

Table 2

Table 3

____________________________________Engine Number

_____________________________________ Year of Manufacture

Application

G Genset

I

F

E

G 4016-E61-TRS

H TRS Combined Heat and Power Unit

J TRS Gas Unit

Gas

Type of engine (Gas)

TESI Gas unit

TESI Combined Heat and Power unit

Illustration 15

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

•

g01266904

Rated speed

•

Power output

•

Engine timing

•

Rating

•

SEBU8430 19

Product Information Section

Product Identification Information

Illustration 16

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

g01229580

The serial number plate (1) on a vee-form engine is
located on the rear face of the cylinder block (bank
A). See Illustration 16.

20 SEBU8430
Operation Section
Lifting and Storage

Operation Section

Lifting and Storage

i02885807

Product 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 correct
your Perkins dealer or your Perkins distributor for
information regarding fixtures for correct engine
lifting.

gine ONLY, use the lifting eyes

gements. Alterations to the lifting eyes

lifting devices are provided. Consult

i03139740

Product S t orag e

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

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

ration 17

Illust

Typical example

Level “A ”

Level “A” will give protection for 12 month for diesel
engines and 12 month protection for gas engines.
This is for engines that are transported by a container
or a truck. Level “A” is for the transportation of items
that are within the United kingdom and within Europe.

Level “B ”

This level is additional to level “A”. Level “B ” will
give protection under normal storage condition
from −15° to +55°C (5° to 99°F) and “90%”
relative humidity for two years. Level “B” is for the
transportation of items overseas.

Level “C ”

In order to protect the product to Level “C”, contact
Perkins Engines Company Limited Stafford.

g01230422

Use a hoist to remove heavy components. Use a
lifting beam (A) to lift the engine. All supporting
member
to each other. The chains and cables should be
perpendicular to the top of the object that is being
lifted

s (chains and cables) should be parallel

.

SEBU8430 21

Operation Section

Gauges and Indicators

Gauges and Indicators

i02917145

Gauges and Indicators

Gauges are su
information about the gauge package, see the OEM
information.

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

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

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

pplied by the OEM. For more

e normal operating range by observing

hanges in gauge readings indicate

eadings are within specifications.

kins distributor for assistance.

NOTICE

olant temperature is exceeded, STOP

Engine Oil

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

Pressure – The range for

Jacket Wat

Typical water temperature into the engine

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

1. Ahighwat

cooling system.

2. Alowoilp

gallery of the engine.

3. Ahighpre

inlet manifold of the engine.

under certain conditions. The water

er temperature switch is installed in the

ressure switch is installed in the oil

ssure Backfire switch is installed to the

er Coolant Temperature –

22 SEBU8430
Operation Section
Features and Controls

Features and Controls

i02885816

Performance Param eters

Air/Fuel Ratio

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

Margin of detonation

•

Control of emissions

•

Engine performance

•

Achieving optimum service life for the engine

•

Compliance with legal requirements

•

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

Fuel Supply Pressure and Temperature

The gas supply to the control valve for the air/fuel
ratiomustbebetween5to25kPa(0.72to3.6psi).
If a higher pressure is required a separate gas
regulator must be installed into the fuel line.

The temperature of the gas into the air/fuel ratio
controlsystemmustbebetween5to40°C
(41 to 104°F).

Note: No zero pressure regulator is required with
the air/fuel ratio control system for the 4016-61TRS
engine.

Air, Charge Cooler Water
Temperatur e and Altitude

i02894958

Sensors and Electrical
Components

Electronic Ignition System (EIS)

The Electronic Ignition System includes the following
components:

The control module for the ignition

•

Timing sensor

•

Ignition coil on each cylinder

•

Spark plugs

•

Ignition har

•

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

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

The electr
following activities:

Ignition t

•

ness

ol module is a sealed unit with no

thetimingpulses.Onepulseforeach

ach ignition coil. To initiate combustion in

the secondary winding which creates a

onic ignition system provides control for the

iming

operation. This voltage can cause

Refer to technical date sheet for the charts for
thederateinordertodeterminethemaximum
temperatures into the engine and the altitude derate.

Ignition energy

•

Protection from detonation

•

Switches

The engin

High cooling water temperature switch

•

Low oil pressure switch

•

High press

•

e is installed with the following switches.

ureswitchforthemanifold

SEBU8430 23

Operation Section

Features and Controls

Governor

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

Digital governor

•

Actuators and throttle valves

•

Magnetic pickup

•

Wiring harness

•

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

A DC Desk service tool with the appropriate software
key and cable are required in order to perform any
adjustments to the system.

Detonation System

The equipment for the detonation system senses
detonation or knock which may be caused by
poor gas or may be caused by high combustion
temperatures.

The detonation system includes the following
components:

Detonation sensor on each cylinder

•

Control module for detonation

•

Wiring harness

•

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

i02427728

Alarms a

nd Shutoffs

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

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

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

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

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

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

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

Become familiar with the following information:

Types of the alarm and shutoff controls

•

Location

•

Conditions which cause each control to function

•

Resetting procedure that is required before starting

•

the engine

rting an engine that may contain un-

nburned gas in the “Starting the Engine”

ne protective device shuts off the engine,

s of the alarm and shutoff controls

quipped with optional engine

f typical engine protective devices.

n of all alarms and shutoffs utilize

s, pressures, or speeds in order to

nction in order to warn the operator

ritical abnormal operating condition

when the engine is started. Personal

Testing Alarms and Shutoffs

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

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

damage to the engine. It is impossible

ctions must be simulated in order to test the

24 SEBU8430
Operation Section
Features and Controls

NOTICE
During testing
simulated.

, abnormal operating conditions must be

The tests must b
vent possible damage to the engine.

Periodic test
proper operation is recommended maintenance. To

prevent damage to the engine, only authorized
service perso

e performed correctly in order to pre-

ingofengineprotectivedevicesfor

nnel should perform the tests.

i02918497

Control Panel

All 4016TRS e
mounted control panel. This unit contains the
following components and integrated wiring.

Ignition system

•

Detonation

•

The system for governing engine speed

•

The control panel is connected to the engine via 4
harness assemblies.

ngines are supplied with a remote

system

Illustration 18

g01544873

SEBU8430 25

Operation Section

Engine Starting

Engine Starting

i02894959

Before Start ing Engine

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

For the maxim

•

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

Inspect the cooling system hoses for cracks and

•

for loose c

Inspect the alternator and accessory drive belts for

•

cracks, br

gine is started, perform the required

nce Manual, “Maintenance Interval

um service life of the engine, make a

eaks, coolant leaks, loose bolts, and

ified during the inspection.

lamps.

eaks, and other damage.

Observe the air

•

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

Remove any electrical loads.

•

cleaner service indicator. Service

i02982579

Cold Weather Starting

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

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

The 4016-61TRS engine is equipped with Multitorch
spark plugs. Under certain circumstances, it is
possible for condensation to develop within the
nozzle for the spark plug. This may cause difficulty in
engine starting. If this occurs, conduct the following
procedure:

Inspect the wiring for loose connections and for

•

worn wires

Open the fuel supply valve (if equipped).

•

Do not start the engine or move any of the controls

•

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

Ensure th

•

clear.

All of the

•

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

Check electrical cables and check the battery for

•

poor con

Reset all of the shutoffs or alarm components (if

•

equippe

Check the engine lubrication oil level. Maintain the

•

oil leve
mark on the engine oil level gauge.

Check th

•

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

or frayed wires.

arning tag attached to the start switch or

at the areas around the rotating parts are

guards must be put in place. Check for

issing guards.

nections and for corrosion.

d).

l between the “Min” mark and the “Max”

e coolant level. Observe the coolant level

1. Remove the spark plugs from four of the engines
cylinders, refer to Disassembly and Assembly,
“Spark Plugs - Remove and Install”

2. Use a suitable tool in order to heat the tip of the
spark plug.

3. Replace the spark plugs, refer to Disassembly and
Assembly, “Spark Plugs - Remove and Install”

4. Start the engine.

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

i02894960

Starting

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

the Engine

y be harmful to your health. Always start

.

26 SEBU8430
Operation Section
Engine Starting

NOTICE
For initial sta
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This ma
fuel supply and/or the ignition to the engine.

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

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

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

Note: The OEM must ensure that using the
“EMERGENCY STOP” button will shut off both the
fuel and the ignition.

rt-up of a new or rebuilt engine, and for

y be accomplished by shutting off the

5. Stop the engine
engine coolant level.

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

7. If the engine fails to start after two attempts turn
off the gas supply and investigate the cause.

and check the engine oil and the

gine under normal working

Purging Unburned Gas

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

Emergency stop

•

Engine overs

•

Unsuccessful successive attempts to start the

•

engine

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

peed

several unsuccessful attempts to start

tart the engine.

Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or to
the controls.

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

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

Final Checks and First Engine Start

Note: The fuel system must comply with all local

regulations.

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

1. The starting and the stopping of the engine must
be on no load.

2. The procedure for starting and stopping a radiator
cooled and CHP gas engine will be determined
by the OEM relative to each individual engine
installation.

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

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

the coolant systems.

Perform the following procedure in order to purge
the unburne

1. Turn the manual gas shutoff valve to the CLOSED
position.

2. Disable the ignition system.

3. Turn the engine control switch to the START

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

4. Enable the ignition system.

5. Turn the manual gas shutoff valve to the OPEN

position.

6. Start the engine. Refer to the engine starting
procedure and refer to OEM in order to start the
engine.

Engine St

Note: If the engine fails to start after the maximum

cranking
attempting to restart the engine, investigate the
cause. Follow the procedure for purging unburned
gas once t

Note: The starting procedure may differ because of
the OEM sy

1. The signal is received.

d gas:

arting Procedure

time, the engine will be shut down. Before

he cause has been detected.

stem that is installed.

SEBU8430 27

Operation Section

Engine Starting

2. Check that the g
pressure is incorrect a warning is activated and
the electrical system will shut down. If the gas
pressure is in

3. Activate the governor.

4. Activate the starting motor.

5. Operate the st

order to purge the system.

6. Activate the
Continue to operate the starting motor.

7. After the eng
motor.

Note: If the e
cranking time, the engine will be shut down.

8. Theengineis

Operation of

as pressure is in limits. If the gas

limits, go to the next step.

arting motor for three seconds in

gas valve and activate the ignition.

ine is started disengage the starting

ngine fails to start after the maximum

now operating.

the Generator Set

Control Panel

i02978143

After Starting Engine

For new install
rebuilt, check and adjust the air/fuel ratio, refer to
Systems Operation Testing and Adjusting, “Air/Fuel
Ratio Control
detect any unusual engine performance through the
load range of the engine.

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

ations and engines that are recently

- Adjust”. Monitor the engine in order to

For information on operation for a specific generator
set control panel, refer to the Operation and
Maintenanc
control panel.

e Manual for the generator and the

Automatic Starting

When the engine is in the AUTOMATIC mode, the
engine can
injury, always remain clear of the the engine when
the engine is in the AUTOMATIC mode.

start at any moment. To avoid personal

Manual starting

Refer to the OEM manual for information on the
controls in order to manually start the engine.

i02428473

Starting with Jump Start
Cables

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

28 SEBU8430
Operation Section
Engine Operation

Engine Operation

i02894963

Engine Operation

Proper opera
attaining the maximum service life and economy for
the engine. Follow the instructions in this Operation
and Maintena
Testing and Adjusting in order to minimize operating
costs and maximize the service life of the engine.

Observe the gauges and the instrument panel
frequently during engine operation and record
the data in a
the specifications for normal engine operation.
Comparing the data over time will help to detect
changes in

Investigate any significant change in the readings.
Monitor th
discrepancies are found.

tion and maintenance are key factors in

nce Manual and Systems Operation,

log regularly. Compare the data to

engine performance.

e engine operation and take action when

Partial load and Low Load
Operation

Extended operation below 50% of the base power
load will c

Carbon formation in the cylinder

•

ause the following results:

Detonation

•

Power los

•

Poor performance

•

Accelerated wear of components

•

Increase

•

Glazing of the cylinder bore

•

s

d oil consumption

SEBU8430 29

Operation Section

Engine Stopping

Engine Stopping

i02978181

Emergency Stopping

The OEM will s

In the event of an emergency or in the event of an
engine overs
valve and the governor.

Emergency sh
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.

Pressing the Emergency Stop Button may cause
unburned gas to remain in the air inlet and in the
exhaust man

Unburned ga
may ignite when the engine is started. Personal
injury and/or property damage may result.

Before starting an engine that may contain un­burned gas, purge the unburned gas from the air
inlet and e
purging unburned gas in the “Starting the Engine”
section.

upply the system.

peed, switch off the ignition, the gas

NOTICE

utoff controls are for EMERGENCY use

ifold.

s in the air inlet and exhaust system

xhaust system. Refer to the topic on

i02453745

Manual Stop Procedure

In order to manu
OEM for information. The procedure will depend on
the system that has been installed.

Stopping the engine immediately after the engine has
been operating under a load can result in overheating
and accelerat

Allow the engine to gradually cool before stopping the
engine.

After Stoppi

Check the engine oil level. Maintain the oil level

•

between the “MIN” and “MAX” marks on the oil
level gauge.

If necessary, perform minor adjustments. Repair

•

any leaks and

Note the service hour reading. Perform the

•

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

ally stop the engine, refer to the

NOTICE

ed wear of the engine components.

i02978201

ng Engine

tighten loose bolts.

that is scheduled in this Operation

Typical Procedure in Order to Stop
the Engine

Note: The s

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

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

2. With the engine stopped, switch off the ignition
and switch off the governor.

If another engine fault occurs switch off the gas valve.

topping procedure will differ because

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

Allow the en

•

If freezing temperatures are expected, check the

•

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

Perform all required periodic maintenance on all

•

driven equ
provided by the OEM of the driven equipment.

. Failure to do so can cause engine dam-

gine to cool. Check the coolant level.

protection against freezing. The cooling

lant/water mixture, if necessary.

ipment. Refer to the instructions that are

30 SEBU8430
Maintenance Section
Refill Capacities

Maintenance Section

Refill Capacities

i02887773

Fluid Recommendations

General Lubricant Information

Engine Oil

The engine oil recommendation for an application
can change due to advances in the specification of
the oil. For a list of recommended lubricating oils,
refer to the latest issue of Perkins service bulletin 48.

Oil analysis

The oil analysis will complement the preventive
maintenance program.

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

The Wear Rate Analysis monitors the wear of the

•

engine’s metals. The amount of wear metal and
type of wear metal that is in the oil is analyzed. The
increase in the rate of engine wear metal in the
oil is as important as the quantity of engine wear
metal in the oil.

Tests are conducted in order to detect

•

contamination of the oil by water, glycol or fuel.

The Oil Condition Analysis determines the loss of

•

the oil’s lubricating properties. An infrared analysis
is used to compare the properties of new oil to the
properties of the used oil sample. This analysis
allows technicians to determine the amount of
deterioration of the oil during use. This analysis
also allows technicians to verify the performance
oftheoilaccordingtothespecification during the
entire oil change interval.

i02984445

Fluid Recommendations
(Coolant Speci

fications)

General Coolant Information

NOTICE
Never add coolant to an overheated engine. Engine
damage could re

If the engine is to be stored in, or shipped to an area
with below freezing temperatures, the cooling system
must be either protected to the lowest outside temper­ature or drained completely to prevent damage.

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

Clean the cooling system for the following reasons:

Contamination of the cooling system

•

Overheating of the engine

•

Foaming of the coolant

•

Never operate an engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
proper operating temperature. Cooling system prob­lems can develop without water temperature regula­tors.

The following problems are related to cooling system
failures: Overheating, leakage of the water pump,
and plugged radiators or heat exchangers.

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

sult. Allow the engine to cool first.

NOTICE

NOTICE

NOTICE

Coolant is normally composed of three elements:
Water, additives, and glycol.

Water

Waterisusedinthecoolingsysteminorderto
transfer heat.

SEBU8430 31

Maintenance Section

Refill Capacities

Distilled wate
recommended for use in engine cooling systems.

DO NOT use the f
systems: Hard water, softened water that has been
conditioned with salt, and sea water.

If distilled water or deionized water is not available,
use water with the properties that are listed in Table 5.

Table 5

Property Maximum Limit

Chloride (Cl) 40 mg/L

Sulfate (SO4) 100 mg/L

Total Hardness 170 mg/L

Total Solids 340 mg/L

For a water analysis, consult one of the following
sources:

Local water utility company

•

Agricultural agent

•

Independent laboratory

•

r or deionized water is

ollowing types of water in cooling

Acceptable Wa

Acidity pH of 5.5 to 9.0

ter

Additives

Additives help to protect the metal surfaces of
the cooling system. A lack of coolant additives or
insufficient amounts of additives enable the following
conditions to occur:

Corrosion

•

Formation of mineral deposits

•

Rust

•

Scale

•

Foaming of the coolant

•

Many additives are depleted during engine operation.
These additives must be replaced periodically.

Additives must be added at the correct concentration.
Overconcentration of additives can cause the
inhibitors to drop out-of-solution. The deposits can
enable the following problems to occur:

Formation of gel compounds

•

Reduction of heat transfer

•

Plugging of rad

•

iators, coolers, and small passages

Glycol

Glycol in the coolant helps to provide protection
against the following conditions:

Boiling

•

Freezing

•

Cavitation of the water pump

•

For optimum performance, Perkins recommends a
1:1 mixture of a water/glycol solution.

Note: Use a mixture that will provide protection
against the lowest ambient temperature.

Note: 100 percent pure glycol will freeze at a
temperature of −23 °C (−9°F).

Most conventional antifreezes use ethylene glycol.
Propylene glycol may also be used. In a 1:1 mixture
with water, e
similar protection against freezing and boiling. See
Tables 6 and 7.

Table 6

Concentration Freeze Protection

50 Percent −36 °C (−33 °F)

60 Percent

Do not use propylene glycol in concentrations that ex­ceed 50 percent glycol because of propylene glycol’s
reduced heat transfer capability. Use ethylene glycol
in conditions that require additional protection against
boiling or freezing.

Table 7

Concentration Freeze Protection

50 Percent −29 °C (−20 °F)

To check the concentration of glycol in the coolant,
measure the specific gravity of the coolant.

thylene and propylene glycol provide

Ethylene Glycol

−51 °C (−60 °

NOTICE

Propylene Glycol

F)

Coolant Recommendations

ELC____________________________ Extended Life Coolant

•

SCA___________________ Supplement Coolant Additive

•

Leakage of the water pump seal

•

32 SEBU8430
Maintenance Section
Refill Capacities

ASTM D4985 ____

•

_______________________ _________

ASTM

specification for coolant specification

The following

two coolants are used in Perkins diesel

engines:

Preferred – Pe

rkins ELC

Acceptable – A commercial heavy-duty antifreeze
that meets “AS

TM D4985” specifications

NOTICE
Do not use a commercial coolant/antifreeze that on­ly meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light automotive appli­cations.

Perkins recommends a 1:1 mixture of water and
glycol. This mixture of water and glycol will provide
optimum heavy-duty performance as a antifreeze.
Thisratiomaybeincreasedto1:2watertoglycolif
extra freezing protection is required.

Note: A commercial heavy-duty antifreeze that
meets “ASTM D4985” specifications MAY require a
treatment with an SCA at the initial fill. Read the label
or the instructions that are provided by the OEM of
the product.

In stationary engine applications and marine engine
applications that do not require anti-boil protection
or freeze protection, a mixture of SCA and water
is acceptable. Perkins recommends a six percent
to eight percent concentration of SCA in those
cooling systems. Distilled water or deionized water
is preferred. Water which has the recommended
properties may be used.

Table 8

Coolant Service Life

Coolant Type Service Life

Perkins ELC

Commercial Heavy-Duty

Antifreeze that meets

“ASTM D4985”

Perkins POWERPART

Commerc

SCA

ial SCA and

Water

6,000 Service Hours or

Three Years

3000 Service Hours or

Two Years

3000 Service Hours or

Two Years

3000 Ser

vice Hours or

Two Years

Heavy-duty die

•

Automotive applications

•

sel engines

The anti-corrosion package for ELC is different from
the anti-corrosion package for other coolants. ELC
is an ethylene

glycol base coolant. However, ELC
contains organic corrosion inhibitors and antifoam
agents with low amounts of nitrite. Perkins ELC
has been form

ulated with the correct amount of
these additives in order to provide superior corrosion
protection for all metals in engine cooling systems.

ELC is available in a premixed cooling solution with
distilled water. ELC is a 1:1 mixture. The Premixed
ELC provides

freeze protection to −36 °C (−33 °F).
The Premixed ELC is recommended for the initial
fill of the cooling system. The Premixed ELC is also
recommende

dfortoppingoffthecoolingsystem.

Containers of several sizes are available. Consult
your Perki

ELC Coolin

ns distributor for the part numbers.

g System Maintenance

Correct additions to the Extended Life
Coolant

NOTICE
Use only Perkins products for pre-mixed or concen­trated coolants.

Mixing Extended Life Coolant with other products re­duces the Extended Life Coolant service life. Failure to
follow the recommendations can reduce cooling sys­tem components life unless appropriate corrective ac­tion is performed.

In order t
the antifreeze and the additives, you must maintain
the recommended concentration of ELC. Lowering
the propo
additive. This will lower the ability of the coolant to
protect the system from pitting, from cavitation, from
erosion

Do not use a conventional coolant to top-off a cooling
system that is filled with Extended Life Coolant (ELC).

When using Perkins (ELC), do not use standard SCA’s
or SCA filters.

o maintain the correct balance between

rtion of antifreeze lowers the proportion of

, and from deposits.

NOTICE

ELC

Perkins provides ELC for use in the following
applications:

Heavy-duty spark ignited gas engines

•

SEBU8430 33

Maintenance Section

Refill Capacities

ELC Cooling Sys

Note: If the cooling system is already using ELC,

cleaning agen
the specified coolant change interval. Cleaning
agents are only required if the system has been
contaminate
coolant or by cooling system damage.

Clean water i
when ELC is drained from the cooling system.

After the coo
system is refilled, operate the engine until the coolant
level reaches the normal operating temperature and
until the coo
thecoolantmixtureinordertofill the system to the
specified level.

ts are not required to be used at

d by the addition of some other type of

s the only cleaning agent that is required

ling system is drained and the cooling

lant level stabilizes. As needed, add

tem Cleaning

Changing to Perkins ELC

To change fr
ELC, perform the following steps:

Care must be
contained during performance of inspection, main­tenance, testing, adjusting and the repair of the
product. B
containers before opening any compartment or dis­assembling any component containing fluids.

Dispose of all fluids according to local regulations and
mandates.

1. Drain the c

om heavy-duty antifreeze to the Perkins

NOTICE

takentoensurethatallfluids are

e prepared to collect the fluidwithsuitable

oolant into a suitable container.

NOTICE
Incorrect or in
can result in damage to copper and other metal com­ponents.

To avoid damage to the cooling system, make sure to
completely flush the cooling system with clear water.
Continue to flu
cleaning agent are gone.

7. Drain the cool

and flushthecoolingsystemwithcleanwater.

Note: The cool
flushed from the cooling system. Cooling system
cleaner that is left in the system will contaminate the
coolant. The
system.

8. Repeat Step

completely clean.

9. Fill the coo

ELC.

ELC Cooling

Mixing ELC with other products reduces the effective­ness of the ELC and shortens the ELC service life.
Use only Perkins Products for premixed or concen­trate coolants. Failure to follow these recommenda­tions can result in shortened cooling system compo­nent life.

complete flushing of the cooling system

sh the system until all the signs of the

ing system into a suitable container

ing system cleaner must be thoroughly

cleaner may also corrode the cooling

s6and7untilthesystemis

ling system with the Perkins Premixed

System Contamination

NOTICE

2. Dispose of the coolant according to local
regulatio

3. Flush the system with clean water in order to
remove an

4. Use Perkins cleaner to clean the system. Follow
the instr

5. Drain the cleaner into a suitable container. Flush
the cooli

6. Fill the cooling system with clean water and
operate t
49° to 66°C (120° to 150°F).

ns.

ydebris.

uction on the label.

ng system with clean water.

he engine until the engine is warmed to

ELC cooling systems can withstand contamination to
a maximum of ten percent of conventional heavy-duty
antifreeze or SCA. If the contamination exceeds ten
percent of the total system capacity, perform ONE of
the following procedures:

Drain the cooling system into a suitable container.

•

Dispose of the coolant according to local
regulations. Flush the system with clean water. Fill
the system with the Perkins ELC.

Drain a portion of the cooling system into a suitable

•

container according to local regulations. Then, fill
the cooling system with premixed ELC. This should
lower the contamination to less than 10 percent.

Maintain the system as a conventional Heavy-Duty

•

Coolant. Treat the system with an SCA. Change
the coolant at the interval that is recommended for
the conventional Heavy-Duty Coolant.

34 SEBU8430
Maintenance Section
Refill Capacities

Commercial Hea

vy-Duty Antifreeze and

SCA

NOTICE
Commercial Heavy-Duty Coolant which contains
Amine as part of the corrision protection system must
not be used.

NOTICE
Never operate a

n engine without water temperature
regulators in the cooling system. Water temperature
regulators help to maintain the engine coolant at the
correct opera

ting temperature. Cooling system prob­lems can develop without water temperature regula­tors.

Check the anti

freeze (glycol concentration) in
order to ensure adequate protection against boiling
or freezing. Perkins recommends the use of a
refractomet

er for checking the glycol concentration.

Perkins engine cooling systems should be tested at
500 hour inte

rvals for the concentration of SCA.

Additions of SCA are based on the results of the test.
An SCA that is

liquid may be needed at 500 hour

intervals.

Refer to Tab

le 9 for part numbers and for quantities

of SCA.

Table 9

Perkins Liquid SCA

Part Number

21825735 10

Quantity

Adding the SCA t o Heavy-Duty Coolant
at the Initial Fill

Commercial heavy-duty antifreeze that meets “ASTM
D4985” specifications MAY require an addition of
SCA at the initial fill. Read the label or the instructions
that are provided by the OEM of the product.

Use the equation that is in Table 10 to determine the
amount of Perkins SCA that is required when the
cooling system is initially filled.

Table 10

Equation For Adding The SCA To The Heavy-Duty

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Coolant At The Initial Fill

V × 0.045 = X

Table11isanex

ample for using the equation that

is in Table 10.

Table 11

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant At The Initial Fill

Total Volume

of the Cooling

System (V)

15 L (4 US gal)

Multiplication

Factor

×0.045

Amount of

SCA that is

Required (X)

0.7 L (24 oz)

Adding The SCA to The Heavy-Duty
Coolant For Maintenance

Heavy-duty antifreeze of all types REQUIRE periodic
additions of an SCA.

Test the antifreeze periodically for the concentration
of SCA. For the interval, refer to the Operation
and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section). Test the
concentration of SCA.

Additions of SCA are based on the results of the
test. The size of the cooling system determines the
amount of SCA that is needed.

Use the equation that is in Table 12 to determine the
amount of Perkins SCA that is required, if necessary:

Table 12

Equation Fo

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Table 13 is an example for using the equation that
is in Table 12.

Table 13

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant For Maintenance

Total Volume

of the Cooling

System (V)

15 L (4 US gal)

r Adding The SCA To The Heavy-Duty
Coolant For Maintenance

V×0.014=X

Multiplication

Factor

×0.014

Amount of

SCA that is

Required

0.2 L (7 oz)

(X)

SEBU8430 35

Maintenance Section

Refill Capacities

Cleaning the Sy

stem of Heavy-Duty

Antifreeze

Perkins cooli
to clean the cooling system of harmful scale
and corrosion. Perkins cooling system cleaners
dissolve min
contamination and sludge.

Clean the coo

•

drained or before the cooling system is filled with
new coolant.

Clean the cooling system whenever the coolant is

•

contaminated or whenever the coolant is foaming.

ng system cleaners are designed

eral scale, corrosion products, light oil

ling system after used coolant is

i02885763

Refill C apaci ties

Lubrication System

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

4016-61TRS

Table 15

4016-61 TRS

Refill Capacities

Compartment or System Liters Quarts

Engine block only 95 100

4016-61TRS

Table 14

4016-61 TRS

Refill Capacities

Compartment or System

Crankcase Oil Sump 257 271

Total Lubrication System 286 302

Liters

Quarts

Cooling System

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

36 SEBU8430
Maintenance Section
Maintenance Interval Schedule

i02896508

Maintenance Interval Schedule

Note: These int

powered by natural gas only. For other gases, consult
Perkins Applications Engineering (Stafford ) for more
information.

When Required

Battery - Repl

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

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

Engine Oil Fil

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

Fuel Filtration S ystem - Service ............................ 56

Overhaul (In-F

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

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

Overhaul Consi

Radiator - Clean .................................................... 62

Water Temperature Regulator - Replace .............. 63

Daily

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

Cooling System C
Driven Equipment - Inspect/Replace/Lubricate ... 44

Engine Air Cleaner Service Indicator - Inspect ..... 45

Engine Oil Level

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

Exhaust Piping - Inspect ....................................... 55

Fuel System Fuel

Check .................................................................. 56

Hoses and Clamps - Inspect/Replace .................. 56

Walk-Around Ins

ervals apply for engines that are

ace .................................................. 38

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

rame) ............................................. 59

derations ...................................... 61

oolant Level - Check ................ 42

- Check ...................................... 50

Filter Differential Pressure -

pection ........................................ 62

Every 500 Servi

Battery Electrolyte Level - Check .......................... 39

Belts - Inspect

Belts - Inspect/Adjust/Replace .............................. 39

ce Hours or 1 Year

/Adjust/Replace .............................. 39

Every 1000 Service Hours

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

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

Every 1000 Serv

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

Every 2000 Serv

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

Engine Air Clea

Engine Crankcase Breather - Clean/Replace ....... 47

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

Engine Oil Filt

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

Ignition System Spark Plugs - Inspect/Replace

iceHoursor1Year

ice Hours

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

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

Every Year

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

Engine Speed/Ti

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

Every 4000 Service Hours

Cylinders - Insp

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

Ignition System Timing - Check/Adjust ................. 58

Inlet Air System -

ect ................................................ 44

Inspect ...................................... 58

Every 7500 Service Hours

Water Pump - Insp

ect ........................................... 63

Every Week

Jacket Water Heat

er - Check ................................ 58

Initial 100 Service Hours

Alternator Pulle

Fan Drive Pulley - Check ...................................... 55

y - Check ...................................... 37

Every 250 Service Hours

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

Initial 500 Service Hours

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

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

Engine Oil Filter

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

Ignition System Spark Plugs - Inspect/Replace

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

Every 8000 Service Hours

Aftercooler Cor

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

e - Inspect/Clean .......................... 37

Every 8000 Service Hours or 1 Year

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

Every 16 000 Service Hours or 6 Years

Turbocharger - Inspect .......................................... 62

SEBU8430 37

Maintenance Section

Alternator - Inspect

i03178662

Alternator - Inspect

This section re
the battery. For information about the generator
alternator, refer to the OEM for the appropriate
information.

Perkins recommends a scheduled inspection of
the alternato
connections and correct battery charging. Check the
ammeter (if equipped) during engine operation in
order to ensu
correct performance of the electrical system. Make
repairs, as required.

Check the alternator and the battery charger for
correct operation. If the batteries are correctly
charged, th
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects th
the battery will not crank the engine. When the
engine is not run for long periods of time or if the
engine is r
fully charge. A battery with a low charge will freeze
more easily than a battery with a full charge.

fers to the alternator for charging

r. Inspect the alternator for loose

re correct battery performance and/or

eammeterreadingshouldbeverynear

e cranking power. If the battery is too cold,

un for short periods, the batteries may not

6. Flush the core t
residue and remaining debris. Flush the core with
clean, fresh water until the water that is exiting the
core is clear a

Personal inj

Personal injury ca n result without following prop­er procedure
tective face shield and protective clothing.

Maximum air p
than 205 kPa (30 psi) for cleaning purposes.

7. Dry the core w

the reverse direction of the normal flow.

8. Prior to inst
for damage. If necessary, replace the O-rings or
seals.

9. Inspect the core for trapped debris and
cleanliness. If it is necessary, remove the debris
and repeat t

10. Inspect the core for damage and perform a
pressure te

horoughly in order to remove

nd free of debris.

ury can result from air pressure.

. When using pressure air, wear a pro-

ressure at the nozzle must be less

ith compressed air. Direct the air in

allation, inspect any O-rings or seals

he cleaning procedure.

st in order to detect leaks.

i03109422

Aftercooler Core ­Inspect/Clean
(Air Charge Cooler)

1. Remove the core. Refer to the Disassembly and

Assembly Manual, “Aftercooler Core - Remove”
for the procedure.

2. Turn the aftercooler core on one side in order
to remove debris. Remove the debris that is
accessible.

3. Remov e the drain plug.

4. Steam clean the core in order to remove any

residue. Flush the fins of the aftercooler core.
Remove any other trapped debris from the inside
and from the outside of the core.

Note: Do not use high pressure when the fins are
cleaned. High pressure can damage the fins.

11. Install the core. Refer to Disassembly and
Assembly Ma
the procedure.

For more in
your Perkins dealer.

nual, “Aftercooler Core - Install” for

formation on cleaning the core, consult

Alternator Pulley - Check

1. Isolate the electrical supply to the engine.

i02888334

5. Wash the core with hot, soapy water.

38 SEBU8430
Maintenance Section
Battery - Replace

i02429553

Battery - Replace

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

his can result in severe personal in-

Illustration 19

Typical example

g01237956

2. Remove the guard (3) in order to gain access to
the drive pulley (1) for the alternator (2).

ion 20

Illustrat

Typical example

g01233693

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

4. Install the guard (3).

5. Restore th

e electrical supply to the engine.

Ensure prope

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

es. Do not smoke when batteries are

serviced.

1. Refer to the O

EM for instruction for switching the

engine to the OFF position.

2. Turn off any

battery chargers. Disconnect any

battery chargers.

3. The NEGATIV

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

terminal is disconnected first.

4. The POSITIVE “+” cable connects the POSITIVE
“+” battery

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

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

facility.

5. Remove the used battery.

6. Ensure that all the battery connections are clean

and free from corrosion.

7. Install the new battery.

Note: Befo

re the cables are connected, ensure that

theenginestartswitchisOFF.

8. Connect t

he cable from the starting motor to the

POSITIVE “+” battery t erminal.

9. Connect t

he NEGATIVE “-” cable to the NEGATIVE

“-” battery terminal.

SEBU8430 39

Maintenance Section

Battery Electrolyte Level - Check

i02747977

Battery Electrolyte Level ­Check

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

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

1. Remove the fi

level to the “FULL” mark on the battery.

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

echarge. Ensure a full charge in order

ero, when the engine is in operation.

rotective clothing w hen working on or

ller caps. Maintain the electrolyte

ion of water is necessary, use distilled

ater.

i03104621

Belts - Inspect/Adjust/Replace
(Alternator Be

Inspection

1. Isolate the electrical supply to the engine.

Illustration 21

Typical example

2. Remove the bolts (2) and remove the guard (3).

lt)

g01233715

2. Check the condition of the electrolyte with a
suitable b

3. Install the caps.

4. Keep the batteries clean.

Clean the b
cleaning solutions:

Use a solut

•

and 1 L (1 qt) of clean water.

Use a solut

•

Thoroughly rinse the battery case with clean water.

attery tester.

attery case with one of the following

ion of 0.1 kg (0.2 lb) baking soda

ion of ammonium hydroxide.

i03104600

Belts - Inspect/Adjust/Replace
(Fan Drive Belts)

The OEM supplies this system. Refer to the OEM for
the appropriate information.

3. Inspect the belt (1) for cracks. Inspect the belt
for contamination. If necessary, replace the belt.
Refer to “Replacement” for more information.

Illustration 22

4. Apply 15.6 N (3.5 lb) of pressure at point (X).

The total deflection should not exceed 1.5 mm
(0.06 inch).

Replace the belt if the total deflection exceeds

1.5 mm (0.06 inch). Refer to “Replacement” for
more information.

g01239310

5. Install the guard (3) and bolts (2).

40 SEBU8430
Maintenance Section
Carburetor Air/Fuel Ratio - Check/Adjust

6. Restore the ele

ctrical supply to the engine.

Adjustment

The alternator belt is a toothed belt. The belt tension
is not adjusta
Light tension will ensure that the belt is a snug fiton
the pulleys.

ble. The belt does not require a preload.

Replacement

Removal of the Alternator Belt

1. If necessary

engine and remove the guards.

, Isolate the electrical supply to the

4. Check the tensi
for the correct procedure.

5. If necessary,
engine and install the guards.

on of the belt. Refer to “Inspection”

restore the electrical supply to the

i02894971

Carburetor Air/Fuel Ratio ­Check/Adjust

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

Refer to the Systems Operation, Testing and
Adjusting for the correct procedure.

i02450196

Control Pan el - Insp ect

Illustration 23

Typical example

2. Remove nut (5) and bolt (4).

3. Loosen nut (7) and push the alternator (6) toward

the engine.

4. Remove the belt (1).

g01239580

Installation of the Alternator Belt

1. Install the belt (1) over the pulleys.

Note: Ensure that the teeth on the belt are engaged

with the teeth on the pulleys.

2. Pull the alternator (6) away from the engine. Install
bolt (4) and nut (5).

3. Tighten nuts (5) and (7).

Inspect the
damaged, ensure that the component is repaired or
that the component is replaced. If equipped, ensure
that the el
Inspect the wiring for good condition. Ensure that the
wiring connections are secure.

Refer to the OEM for more information.

condition of the panel. If a component is

ectronic displays are operating properly.

i02888193

Cooling System Coolant ­Change

Refer to t
engines.

Jacket Water System Drain

1. Stop the e

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

2. Open the drain cock or remove the drain plug on
the radi

he OEM for information on cogeneration

ngine and allow the engine to cool.

ller cap.

ator or the heat exchanger.

SEBU8430 41

Maintenance Section

Cooling System Coolant - Change

Charge Water System Drain

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

the charge water drain cock (OEM installation).

2. Remove the drain plugs (2 & 3) on each of the
charge coolers and remove the cooling system
filler cap.

Illustration 24

Typical example

g01515804

3. Open the drain cock (1) on the engine oil cooler.

4. Allow the system to drain.

Jacket Water System Fill

Refer to the OEM for information on cogeneration
engines.

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

1. Close the drain cock or install the drain plug on
the radiator or the heat exchanger. Close the drain
cock on the engine oil cooler (1).

2. Slowly refill the cooling system. Check that the
coolant level is within 25 mm (1.0 inch) of the
bottom of the filler pipe.

3. Install the cooling system filler cap.

4. Start the engine. Operate the engine until the

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

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

Illustration 25

Typical example

g01515913

3. Allow the system to drain.

Charge Water System Fill

Note: The cooling system must be filled slowly. Refer

to Perkins engines Stafford for more information.

1. Close the drain cock on the charge water circuit
(OEM installation). Install the drain plugs (2 & 3)
into each charge cooler.

2. Loosen the vent plug (2) in order to release any
air from the system. When the coolant runs free of
air, tighten the vent plug.

3. Install the charge water system filler cap.

4. Follow steps 4 to 6 on jacket water system in order

to complete charge water refill.

6. In order to check the specific gravity of the coolant,
refer to this manual , “Coolant System Coolant ­Test/Add”.

42 SEBU8430
Maintenance Section
Cooling System Coolant - Test/Add

i02894972

Cooling System Coolant ­Test/Add

Check the specific gravity of the
coolant

4. Remove the fille

5. Drain some of the coolant from the cooling system

into a suitabl

6. Use a special hydrometer that will check the
temperature a
and follow the manufacturer’s instructions.

Note: If a spec
not available, put an hydrometer and a separate
thermometer into the antifreeze mixture and check
the readings
readings with the data in illustration 26.

Note: If nece
the coolant in the system with premixed
coolant of the correct strength. Refer to the
Operation a
recommendations”.Perkins POWERPART antifreeze
with a concentration of 50% will give protection
against fr
Thesolutionwillalsoprotectagainstcorrosion.This
is especially important when there are aluminum
component

7. Adjust the strength of the mixture if it is necessary.

nd Maintenance Manual, “Fluid

ost to a temperature of −35 °C (−31 °F).

s in the cooling circuit.

r cap of the cooling system.

e container.

nd the specific gravity of the coolant,

ial thermo-hydrometer for coolant is

on both instruments. Compare the

ssary, fill the system or replenish

Illustration 26

The chart for the Specificgravity

A = Per centage of antifreeze by volume

B = The temperature of the mixture in °F

C = Specificgravity

D = The temperature of the solution in °C

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

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

2. Stop the engine.

3. Allow the engine to cool until the temperature is

below60°C(140°F).

Pressurized System: Hot coolant can cause seri­ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres­sure.

g00997964

i02888192

Cooling Sys tem Coolant Level

- Check

Pressurized System: Hot coolant can cause seri­ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres­sure.

Refer to the OEM for information on cogeneration
engines.

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

SEBU8430 43

Maintenance Section

Crankshaft Vibration Damper - Inspect

Illustration 27

Typical example

1. Remove the cooling system filler cap (1) or (2)
slowly in order to relieve pressure.

g01228685

3. Clean the cooli
gasket. If the gasket is damaged, discard the old
filler cap and install a new filler cap. If the gasket
is not damaged
in order to pressure test the filler cap. The correct
pressure is stamped on the face of the filler cap. If
the filler cap
install a new filler cap.

Crankshaft

-Inspect

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

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

f the crankshaft. The visconic damper has

ng system filler cap and inspect the

, use a suitable pressurizing pump

does not retain the correct pressure,

i02895011

Vibration Damper

he crankshaft vibration damper or failure

ponents. A deteriorating damper can

Illustration 28

Typical example

2. Maintain the coolant level within 25 mm (1.0 inch)
of the bottom of the filler cap.

g01229602

A damper that gets hot could be due to excessive
torsional vibration. Monitor the temperature of the
damper du

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

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

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

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

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

The damper is dented, cracked, or leaking.

•

The pai

•

ring operation.

rature of the damper, use the thermometer

he interval for inspecting the damper.

, consult your Perkins dealer.

softhefluid.

mper is silicone. Silicone has the following

nt on the damper is discolored from heat.

The engine has had a failure because of a broken

•

•

haft.

cranks

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

sed by a lack of oil.

44 SEBU8430
Maintenance Section
Cylinders - Inspect

The damper has b

•

een dropped.

i02978267

Cylinders - Ins pect

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

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

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

Valve we ar

•

Marks on th

•

Deposits on the valve seat

•

Deposits on the valve face

•

Polishing o

•

Scratching of the cylinder walls

•

Deposits on the cylinder walls that are above the

•

upper limit of the piston stroke

e to inspect the cylinders. The

ear view of the combustion chamber and

d. Consult your Perkins dealer for

his procedure, insert the borescope

epistoncrown

f the cylinder walls

i02453750

Driven Equipment ­Inspect/Repl

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

Unusual noise and vibration

•

Loose connect

•

Damaged parts

•

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

Inspection

•

Lubricating grease and lubricating oil requirements

•

Specifications for adjustment

•

Replacement

•

Requirements for ventilation

•

the OEM of the driven equipment for the

ace/Lubricate

ions

of components

i02895015

Engine - C lean

Note: If you use a borescope be aware of the effect

of magnification. Minor scratches and marks can
be misunde
maintenance.

rstood. This can result in unnecessary

i02453747

Driven Equipm ent - Check

To minimize bearing problems and vibration of the
engine cr
alignment between the engine and driven equipment
must be maintained properly.

Check the alignment according to the instructions
that are provided by the following manufacturers:

OEM of the coupling

•

OEM of the

•

ankshaft and the driven equipment, the

driven equipment

Personal in
age.

Moisture co
tivity.

Make sure th
utility and/or other generators), locked out and
tagged "Do N ot Operate".

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

Do not point high pressure water cleaners directly on
to electrical components.

jury or death can result from high volt-

uld create paths of electrical conduc-

e unit is off line (disconnected from

NOTICE

NOTICE

SEBU8430 45

Maintenance Section

Engine Air Cleaner Element - Replace

A clean engine p

Easy detection of fluid leaks

•

Maximum heat transfer characteristics

•

Ease of mainte

•

Engine Air Cle
Replace

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

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

rovides the following benefits:

nance

i02947520

aner Element -

NOTICE

nt. Do not use air cleaner elements with

Air cleaner elements help to prevent air-

NOTICE

Illustration 29

Typical example

1. Remove the retaining clips (3). Remove the cover
(4).

2. Remove the old element (2). Dispose of the old
element.

g01461009

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

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

severe operating conditions may require more
frequent service of the air filter.

Note: Ensure that dirt can not enter the air filter
assembly.

3. Install a new element into the air filter housing (1).
Install the cover (4). Fit the retaining clips (3).

i02888185

Engine Air Cleaner Service
Indicator - Inspect

Some engines may be equipped with a different
service indicator.

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

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

46 SEBU8430
Maintenance Section
Engine Crankcase Breather - Clean/Replace

Observe the ser

Replace the air filter element if the indicator is
triggered by t

The red piston locks in the visible position.

•

vice indicator.

he following event:

Test the Service Indicator

Service indicators are important instruments.

Illustration 31

Typical example

3. Remove the filter elements (3) from the breather
body (4).

g01224945

Illustration 30

Typical service indicator

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

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

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

g01223729

i02888182

Engine Crankcase Breather ­Clean/Replace

Open Breather

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

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

5. Clean the cover and clean the body of the
breather.

6. Install the filter elements (3) to the breather body
(4).

7. Ensure that the seal in the cover (2) is free from
damage. If necessary, replace the seal.

8. Align the cover (2) with the dowel (5). Install the
cover to the breather body (4).

9. Install the wing nut (1). Tighten the wing nut
securely.

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

1. Ensure that the power supply is disconnected
from the engine.

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

SEBU8430 47

Maintenance Section

Engine Crankcase Breather - Clean/Replace

i02978569

Engine Crankcase Breather ­Clean/Replac

Closed Breather System

Ensure that the power supply is disconnected from
the engine.

e

Illustration 32

Typical example

1. Release the four clips (1). Remove the bowl (2)
and remove the old filter element. Discard the old
filter element in accordance with local regulations.

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

2. Ensure that the seal (3) is installed onto the new
filter element (4).

g01224943

Illustration 33

Typical example

3. Install the new filter element. Align the clips (1).
Install the bowl (2).

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

g01235923

i03032640

Engine Mo unts - Check

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

Improper mounting

•

Loose bolts

•

Deterioration of the isolators

•

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

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

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

48 SEBU8430
Maintenance Section
Engine Oil - Change

i02888179

Engine Oil - Change

Note: Refer to t

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

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

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

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

1. Remove the drain plug and the sealing washer
(4). Allow t

2. Replace the sealing washer, if necessary . Install
the drain p

he Operation and Maintenance

te particles settle on the bottom of

in the oil pan with the oil warm. This

ubrication system with the new oil.

llect the waste oil.

he engine oil to drain.

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

Illustration 35

Typical example

4. Remove the filler cap (1). Fill the engine with the
required amount of engine oil. Refer to Operation
and Maintenance Manual, “Refill Capacities”.

5. Check the oil gauge (dipstick) (2). Ensure that the
engine oil is on the correct mark.

6. Operate the engine and check for engine oil leaks.
Stop the engine. Check the engine oil level. Add
engine oil, if necessary. Refer to Operation and
Maintenance Manual, “Engine Oil Level - Check”.

g01441988

Illustration 34

Typical example

3. Replace the engine oil filters (3). Refer to
Operation and Maintenance Manual, “Engine Oil
Filter - Change or Engine Oil Filter (Auxiliary) ­Change” in order to change the engine oil filter.

g01441987

i02888172

Engine Oil Filter (Auxiliary) ­Change

Note: Refer to the Operation and Maintenance

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

Change the Filter with the Engine
in Operation

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

SEBU8430 49

Maintenance Section

Engine Oil Filter - Change

i02888171

Engine Oil Filter - Change

Illustration 36

Typical example

The changeover valve (1) has three positions.

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

•

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

•

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

•

g01233078

Note: Refer to O

peration and Maintenance Manual,
“Engine Oil sample - Obtain” before performing
maintenance.

Replace the Oil Filter

Table 16

Required Tool

Too l

A

Part

Number

-

NOTICE
Perkins oil filters are manufactured to Perkins Engine
Company LTD specifications. Use of an oil filter that is
not recommended by Perkins Engine Company LTD
could result in severe damage to the engine. Large
particles from unfiltered engine oil will cause damage
to the engine. Do not use oil filters that are not recom­mended by Perkins Engine Company LTD.

Note: All six oil filters must be changed as a set.

s

Part Name Qty

Strap Wrench 1

1. Rotate the changeover valve to position B. By
using a suitable tool (2), remove the right hand
oil filter.

Note: Oil flow direction (D and E ).

2. Ensure that the sealing face on the housing is

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

3. Rotate the changeover valve to position C. By
using a suitable tool, remove the left hand oil filter.

4. Ensure that the sealing face on the housing is
clean. Fill the new oil filter with clean engine oil.
Install the new oil filter. Apply hand pressure
only in order to install the oil filter. Rotate the
changeover valve to position A. Check for oil
leaks.

5. Clean any spillage of engine oil.

Illustration 37

Typical example

1. Use Toolin

g (A) in order to remove the oil filters (1).

g0144202

2. Ensure that the sealing face of the filter base (3)
is clean.

2

50 SEBU8430
Maintenance Section
Engine Oil Level - Check

3. Lubricate the s
oil.

4. Install the ne

Note: Apply hand pressure only in order to tighten

the oil filters

Fill the Oil Pa

Refer to Operation and Maintenance Manual, “Fluid
Recommendati

1. Remove the oil filler cap.

2. Fill the oil pan with the correct amount of new

engine lubricating oil. Refer to Operation and
Maintenance
information.

If equipped with an auxilliary oil filter system or a re­mote filter sy
facture’s remonmendations. Under filling or over filling
the crankcase with oil can cause engine damage.

Note: Before starting the engine, crank the engine on
the starter in order to obtain oil pressure.

3. Start the engine and run the engine for two
minutes. Perform this procedure in order to ensure
that the lub
filters are filled.

4. Inspect the

5. Stop the engine. Check the engine oil level. Add

engine oil
Maintenance Manual, “Engine Oil Level - Check”

ealing rings (2) with clean engine

woilfilters (1).

.

n

ons” for information on suitable oils.

Manual, “Refill Capacities” for more

NOTICE

stem, follow the OEM or the filter manu-

rication system has oil and that the oil

oil filters for oil leaks.

, if necessary. Refer to Operation and

Illustration 38

(Y) “ Min” mark. (X) “Max” mark.

NOTICE

Perform this maintenance with the engine stopped.

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

1. Maintain the oil level between the “MIN” mark (Y)
and the “MAX
Do not fill the crankcase above the “MAX” mark
(X).

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

before checking the oil level.

” mark (X) on the engine oil dipstick.

NOTICE

stobedippedinoil.Ifyoudrivethecrank-

ubbles will be created w hen the crankshaft

ss of power.

g01165836

i02888170

Engine Oil Level - Check

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

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

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

i02888169

Engine Oil Sample - Obtain

Replacement Pro gram for the
Engine Oil and Filter

The life of the lubricating oil and filter is governed by
the engine load and quality of the gas that is supplied.

SEBU8430 51

Maintenance Section

Engine Protective Devices - Check

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

rmine the optimum program for the

Initiating an Oil analysis Program

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

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

must be taken from the mean level in

This is shown in the list that follows. As

Every 250 Hou rs

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

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

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

eforthefirst 500 hours. Replace the

rvice program for the engine.

t 2000 hours.

Critical Parameters for the Lubricating
Oil

i02430590

Engine Protective Devices ­Check

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

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

During testing, abnormal operating conditions must be
simulated.

The tests must be performed correctly in order to pre­vent possib

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

age to the engine. It is impossible

s must be simulated in order to test the

n check of the engine protective devices

functioning properly.

NOTICE

le damage to the engine.

sonnel or your Perkins dealer should

viscosity at 100 °C cSt max 20% above original

•

value

Insolubles 1.5% wt.max

•

Total base number 60% less than new oil value

•

Nitration

•

Oxidation 30 abs/cm max

•

Water 0.2% vol max

•

Iron - Fe le

•

Copper - Cu less than 40 ppm

•

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

30 abs/cm max

ss than 20 ppm

Visual Inspection

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

heck the condition of all gauges, sensors

nts should be repaired or replaced

i02948519

Engine Speed /Timing Sensor ­Clean/Inspect

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

Table 17

Too l

A SE252 Engine cranking device 1

Part

Number

Required Tools

Part Name Qty

52 SEBU8430
Maintenance Section
Engine Valve Lash and Bridge - Adjust

Speed Sensor

Illustration 39

Typical example

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

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

3. Install tooling (A).

4. Rotate the engine in order to align one teeth to the

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

5. Tighten the locknut. Do not allow the sensor to
rotate. Connect the connection (3).

6. Remove tooling (A).

g01234089

Timing Sensor

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

Illustration 40

Typical example

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

3. Install tooling (A).

4. Screw in the timing sensor by hand until light

contact is made with the timing disc. unscrew the
sensor. Unscrew one complete turn in order to
give a clearance of 1 mm (0.04 inch).

5. Tighten the locknut. Do not allow the sensor to
rotate. Connect the connection for the timing
sensor.

6. Remove tooling (A).

Connect the power to the engine.

g01554776

i02888165

Engine Valve Lash and Bridge

-Adjust

1. Remove the connection for the timing sensor (not

shown). Loosen the locknut (1).

Ensure that all power is disconnected to the engine.

SEBU8430 53

Maintenance Section

Engine Valve Lash and Bridge - Adjust

Monitoring the Valve Recession

Table 18

Required Tools

Tool Part

Number

A

B

Every 1000 ser

-

-

vice hours record the valve lash. The
monitoring of the valve seat wear should be carried
out before any adjustment of the valve lash.

In order to measure the protrusion of the valve stems,
use the following procedure:

1. Remove the valve mechanism covers from all

cylinders.

2. Removethebridgeassemblyforalltheinlet

valves.

3. Removethebridgeassemblyforalltheexhaust

valves.

4. Remove the rocker assemblies.

5. Install Too

ling (A) to the stud for the bridge

assembly.

Note: To ol i

ng (A) must be located correctly onto the

cylinder head.

6. To oli ng ( B )

is used in order to measure the
distance from the top of Tooling (A) to the top of
the valve stem.

7. Record this measurement for all valves.

Also, reco

rd the average engine load factor for

the previous 1000 hours.

When you fit

a new cylinder head assembly,
conduct the measurement procedure in order to
establish a baseline for the protrusion of the valve
stem. Kee

p a log of the protrusions of the valve
stems over the life of the engine. Plan for a top
end overhaul as the valve recession approaches
the follo

wing maximum limits:

Part Name

Val v e
recession
measurement
tool

Depth
micrometer

Qty

1

1

The recorded va

lues can be used to identify any
excessive valve seat wear on individual valves. The
recorded values can be used to schedule a top end
overhaul.

An example of recorded valve lash

Table 19

Hours Recorded clea

on A1 cylinder

Inlet Exhaust Inlet Exhaust

500 0.4mm 0.4mm 0 0

1000 0.4 0.4 0 0

1500 0.35 0.35 0.05 0.05

2000 0.35 0.35 0.1 0.1

2500 0.3 0.3 0.2 0.2

3000 0.25 0.3 0.35 0.3

3500 0.25 0.35 0.5 0.35

4000 0.25 0.3 0.65 0.45

rances

Tot a l v alv e w e

ar

After 4000 hours running, the total valve recession
on the inlet i

s 0.65 mm (0.026 inch) and the exhaust

is 0.45 mm (0.018 inch).

In this examp

le, the valves are still serviceable after

4000 hours running.

When the valv

es approach the maximum wear limit,
the rockers can be removed and a measurement
fromthecylinderheadfacetothetopofthevalve
stems can be

taken. When a new valve is installed
the protrusion of the valve stem would be 29.75 mm
(1.171 inch). therefore, a maximum wear limit would
be 30.75 mm

Adjusting

(1.211 inch).

the Valve Lash and

Bridge

Table 20

ools

Part Name

Engine
cranking
device

Qty

1

Too l Pa rt

C

Number

SE252

Required T

Inlet valves 2 mm (0.08 inch)

•

Exhaust valves 1 mm (0.04 inch)

•

54 SEBU8430
Maintenance Section
Engine Valve Lash and Bridge - Adjust

Illustration 41

Typical example

g01235020

1. Remove the spark plug. Refer to this
manual, “Ignition System Spark Plugs ­Check/Adjust/Replace”.

2. Remove the setscrews (1) and remove the cover
(2). Discard the old joint.

3. Ensure that the

re is clearance between the rocker

arm and bridge pad.

Illustration 43

Typical example

g01235021

4. Loosen the locknut (3). Adjust the screw (2) so
that the fixed side of the bridge contacts the
valve. Apply hand pressure to the bridge. Refer to
illustration 43.

3. Remove the spark plug tube (3).

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

Adjust the bridge

Illustration 42

Typical example

1. Use the timing pointer (1) in order to set the
engine to top dead center. Refer to this manual,
“Specifications” for the sequence of piston position
for valve lash.

2. Rotate the crankshaft to the required position.

g01235025

5. Adjust the screw so that light contact is made with
the valve. Tighten the locknut (3) to a torque of
35 N·m (25 lb ft). Ensure that the screw has not
rotated.

Valve lash

Illustration 44

Typical example

g01235023

SEBU8430 55

Maintenance Section

Exhaust Piping - Inspect

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

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

2. Use a suitable feeler gauge in order to check the
valve lash. If adjustment is required loosen the
locknut (1).
clearance is obtained.

3. Tighten the l
(25 lb ft).

kshaft to the required position.

Adjust the screw (2) so that the correct

ockscrewtoatorqueof35N·m

Install the Cover

1. Install the s

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

head. Insta

3. Install the lead for the spark plug.

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

to the engine.

park plug tube.

ll the setscrew and tighten securely.

Fan Drive Pulley - Check

1. Isolate the ele

ctrical supply to the engine.

i02887782

i02430592

Exhaust Piping - Inspect

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

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

Damage

•

Cracks

•

Leaks

•

Loose connections

•

Consult your Perkins dealer for assistance.

Illustration 45

Typical example

2. Remove the guards (not shown) in order to gain
access to the fan drive pulley (1).

Illustration 46

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

4. Install the guards (not shown).

5. Restore the electrical supply to the engine.

g01238304

g01238305

56 SEBU8430
Maintenance Section
Fuel Filtration System - Service

i02478666

Fuel Filtration Syste m - Service

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

e bio-gas may require special

eOEMoftheequipment.

Do not bend or st
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks c
and hoses carefully. Tighten all connections to the rec­ommended torque.

Check for the following conditions:

an cause fires. Inspect all lines, tubes

NOTICE

rike high pressure lines. Do not in-

i02478685

Fuel System Fuel Filter
Differential Pressure - Check

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

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

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

For the service of the fuel filter on the low pressure

•

gas fuel system, refer to the OEM for information.

For the service of the fuel filter on the high pressure

•

gas fuel system, refer to the OEM for information.

i0243059

Hoses and Clamps ­Inspect/

Replace

End fittings that are damaged or leaking

•

Outer covering that is chafed or cut

•

Exposedwirethatisusedforreinforcement

•

Outer covering that is ballooning locally

•

Flexible part of the hose that is kinked or crushed

•

Armoring that is embedded in the outer covering

•

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

Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.

Each installation application can be different. The
differences depend on the following factors:

Type of hose

•

Type of fitting material

•

3

Anticipated expansion and contraction of the hose

•

Anticipated expansion and contraction of the

•

fittings

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

Cracking

•

Softness

•

Loose clamps

•

Replace hoses that are cracked or soft. Tighten any
loose clamps.

Replace the Hoses and the Clamps

Pressuriz
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
componen
pressure cap slowly in order to relieve the pres­sure.

1. Stop the engine. Allow the engine to cool.

ed System: Hot coolant can cause seri-

ts are cool. Loosen the cooling system

SEBU8430 57

Maintenance Section

Ignition System Spark Plugs - Inspect/Replace

2. Loosen the cool

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

Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.

3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.

4. Remove the hose clamps.

5. Disconnect t

he old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

8. Refill the cool

ing system.

9. Clean the cooling system filler cap. Inspect the
cooling syst

em filler cap’s gaskets. Replace
the cooling system fi ller cap if the gaskets are
damaged. Install the cooling system filler cap.

10. Start the engine. Inspect the cooling system for
leaks.

Illustration 47

g01507793

1. Remove the lead (1) for the spark plug f rom the
ignition coil.

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

i02887646

Ignition System Spark Plugs ­Inspect/Re

place

Table 21

Required To

Tool

A 484/49 Spark plug removal tool 1

Part

Number

Inspect the S park Plug

Inspect the spark plug closely for damage. The
condition of the spark plug can indicate the operating
condition of the engine.

ols

Part Name Qty

Replace the Spark P lug

The spark plug is not a serviceable part. A
replacement spark plug must be used.

Table 22

Required Tools

Tool

B

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

Install the spark plug by using tooling (A). Tighten the
spark plug by hand and then tighten the spark plug to
atorqueof50N·m(36lbft).

On the initial start-up of a new engine or an engine
that has been serviced, it is possible for condensation
to have built up in the spark plugs. If this occurs, refer
to this manual, “Cold Weather Starting”.

Part

Number

27610178

Part Name Qty

Cylinder head spark plug
thread cleaning tool

1

58 SEBU8430
Maintenance Section
Ignition System Timing - Check/Adjust

i02887641

Ignition System Timing ­Check/Adjust

After maintenance has been performed on the
ignition system, check the timing of the ignition
system. Adjus

The optimum ignition timing for a gas engine varies
according to

Compression ratio of the engine

•

Inlet air temperature

•

Methane numbe

•

Note: Refer to this manual, “Plate Locations and Film
Locations” i
for the engine.

1. Install a tim
cylinder for the 4016TRS Gas.

Note: The lea
contact with the exhaust manifold.

t the timing, if necessary.

several factors:

n order to find the correct ignition timing

ing light to the lead on number One A

ds for the timing light must not come in

r of the gas

4. Install the cap
Removethetiminglight.

Rotating the s

•

ignition timing.

Rotating the s

•

the ignition timing.

when the ignition timing is correct.

crew (1) clockwise retards the

crew (1) counterclockwise advances

i02895042

Inlet Air System - Inspect

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

Cracks

•

Leaks

•

Loose connections

•

Inspect the following components:

Piping between the air cleaner and the

•

turbochargers

Turbochargers

•

Illustration 48

Typical example

2. Operate the engine and check the timing marks
on the flywheel.

3. If necessary, adjust the ignition timing. Remove
the cap (not shown) that covers the screw for
timing adjustment (1). By using a suitable tool,
rotate the screw (1) in order to adjust the ignition
timing.

g01521796

Piping between the turbochargers and the

•

aftercoolers

Aftercoolers

•

Piping between the air/fuel ratio and the gas mixer

•

units

Piping between the closed circuit breather and the

•

turbochargers

Connection of the aftercooler to the air inlet

•

manifolds

Connection of the air inlet manifolds to the cylinder

•

heads

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

i03140143

Jacket Water Heater - Check

Jacket wat
ambient temperatures that are below 10 °C (50 °F).
All installations that require automatic starting should
have jack

er heaters help to improve startability in

et water heaters.

SEBU8430 59

Maintenance Section

Overhaul (In-Frame)

Check the opera
an ambient temperature of 0 °C (32 °F), the heater
should maintain the jacket water coolant temperature
at approximat

tion of the jacket water heater. For

ely 40 °C (104 °F).

i02895045

Overhaul (In-Frame)

Scheduling an In-Frame Overhaul

Scheduling an in-frame overhaul normally depends
on the following conditions:

An increase of oil consumption

•

An increase of crankcase blowby

•

A decrease or a variation of cylinder compression

•

A reduction in the detonation margin

•

An increase in throttle position

•

In-Frame Overhaul Information

An in-frame overhaul includes all of the work that is
done for a top end overhaul. Additionally, some other
components that wear are replaced. The condition
of components is inspected. Those components are
replaced, if necessary.

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

i02895678

Overhaul (Major)

Scheduling a Major Overhaul

Generally, a major overhaul is performed at 32000
hours. The need for a major overhaul is determined
by several factors. Some of those factors are the
same factors that determine the in-frame overhaul:

Each individual condition may not indicate a need for
an overhaul. However, evaluating these conditions
together is the most accurate method of determining
when an overhaul is necessary.

The engine does not require an overhaul if the
engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder
compression.

Periodically measure each of these conditions. The
first measurement should occur during the engine
commissioning. This establishes a baseline for
future measurements. Additional measurements are
scheduled at regular intervals in order to determine a
schedule for the next in-frame overhaul.

Note: Oil consumption will be initially high. This will
be reduced when the rings are seated to the bore.

Note: These indications do not require an engine
to be shut down for service. These indications
only mean that an engine should be scheduled for
service in the near future. If the engine operation
is satisfactory, an immediate overhaul is not a
requirement.

Monitor the engine as the engine accumulates
service hours.

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

An increase of oil consumption

•

An increase of crankcase blowby

•

A decrease and variation of cylinder compression

•

A reduction in the detonation margin

•

An increase in throttle position

•

Other factors must also be considered for determining
a major overhaul:

The service hours of the engine

•

The wear metal analysis of the lube oil

•

An increase in the levels of noise and vibration

•

An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
need to be serviced. An increase in the levels of
noise and vibration indicates that rotating parts
require service.

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

Monitor the engine as the engine accumulates
service hours. Consult your Perkins dealer about
scheduling a major overhaul.

60 SEBU8430
Maintenance Section
Overhaul (Top End)

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

n equipment may also require service

Major Overhaul Information

A major overhaul includes all of the work that is done
for top end overhauls and in-frame overhauls. In
some cases, t
Components that wear are disassembled and
inspected. If necessary, the parts are replaced. The
crankshaft i
may require regrinding. Alternatively, the crankshaft
may be replaced with a Perkins replacement part.
Your Per k in
components. Y our Perkins dealer can ensure that
the components are operating within the appropriate
specificati

If you elect to perform an overhaul without the
services o
recommendations.

Replacing

Replace the following components during the major
overhaul.

he engine is relocated for disassembly.

s measured for wear. The crankshaft

s dealer can provide these services and

ons.

f a Perkins dealer, be aware of the following

of Components

Chargecooler

•

Camshafts

•

Camshaft bearings

•

Camshaft foll

•

Connecting rods

•

Crankshaft

•

Gear train and

•

Governor

•

Inlet air piping

•

Oil cooler

•

Pistons

•

Ignition coils

•

Val v e t r ain th

•

owers

bearings

at includes the rocker gear

i02960029

Connecting rod bearings

•

Cylinder liners

•

Piston rin

•

Turbochargers

•

Cylinder heads

•

Oil pump

•

Joints and bolts

•

Gaskets and seals

•

Main beari

•

Water temperature regulators

•

gs

ngs

Rebuilding or Replacing of Components

Rebuild t
overhaul.

Carburet

•

Engine Water pumps

•

he following components during the major

or

Inspecting Components

Inspect t

he following components:

Overhaul (Top End)

Scheduling a Top End Overhaul

Table 23

Required Tools

Too l P a rt

A

B

Top end overhauls are scheduled according to the
valve recession. Valve recessions are calculated
by measuring the protrusions of the valve stems.
Measure the valve recession at every 1000 running
hours. This measurement gives an accurate
indication of valve wear. This information can be used
to predict when a cylinder head must be replaced.

Anticipated replacement intervals for the cylinder
head are 12,000 hours for the 4016-61TRS2 engine,
and 16,000 hours for the 4016-61TRS1 engine.

Inordertomeasuretheprotrusionofthevalvestems,
use the following procedure:

Number

-

-

Part Name

Valve
recession
measurement
tool

Depth
micrometer

Qty

1

1

SEBU8430 61

Maintenance Section

Overhaul Considerations

1. Remove the valv
cylinders.

2. Remove the bri
valves.

3. Remove the bri
valves.

4. Remove the roc

5. Install Tooling (A) to the stud for the bridge

assembly.

Note: Tooling (A) must be located correctly onto the
cylinder hea

6. Tooling (B) is used in order to measure the
distance fro
the valve stem.

7. Record this m

Also, record the average engine load factor for
the previou

When you fit a new cylinder head assembly,
conduct the
establish a baseline for the protrusion of the valve
stem. Keep a log of the protrusions of the valve
stems over t
end overhaul as the valve recession approaches
the following maximum limits:

d.

e mechanism covers from all

dge assembly for all the inlet

dge assembly for all the exhaust

ker assemblies.

m the top of Tooling (A) to the top of

easurement for all valves.

s 1000 hours.

measurement procedure in order to

he life of the engine. Plan for a top

Cleaning of the

•

and the engine block

It is not pract
symptoms of excessive wear or failure. It is not less
costly to wait. A planned overhaul before failure may
be the best va

Costly unplanned downtime can be avoided.

•

Many original parts can be reused according to the

•

guidelines for reusable parts.

The service life of the engine can be extended

•

without the risk of a major catastrophe due to
engine failu

Achieve the best cost/value relationship per hour

•

of extended s

internal passages of the engine

ical to wait until the engine exhibits

lue for the following reasons:

re.

ervice life.

Overhaul Intervals

Top end overhauls are determined by the recession
of the valves. In-frame overhauls are determined by
the followi

An increase of oil consumption

•

An increase of crankcase blowby

•

A decrease o

•

A reduction in the detonation margin

•

ng conditions:

r a variation of cylinder compression

Inlet valves 2 mm (0.08 inch)

•

Exhaust va

•

Do not allow the recession of the valves to exceed
these limi

Overhaul C

lves 1 mm (0.04 inch)

ts.

onsiderations

i02896454

Overhaul Information

An overhaul is replacing the major worn components
of the engine. An overhaul is a maintenance interval
that is pl
rebuilt parts or new parts that replace the worn parts.

An overha

•

•

anned. The engine is rebuilt with certain

ul also includes the following maintenance:

Inspection of all the parts that are visible during
the disas

Replacement of the seals and gaskets that are
removed

sembly

An increase in the throttle position

•

Major overh
tests, and by results of oil analysis.

Some other f
the overhaul intervals include the following
considerations:

Performance of preventive maintenance

•

Use of reco

•

Use of recommended coolants

•

Use of recommended fuels

•

Operating

•

Operation within acceptable limits

•

Engine load

•

Engine spe

•

auls are determined by the in-frame

actors that are important for determining

mmended lubricants

conditions

ed

62 SEBU8430
Maintenance Section
Radiator - Clean

Overhaul Inspe

If the parts are not within the inspection specifi cations,
the parts shou
are not in wear limits could result in unscheduled
downtime and/or costly repairs. This can also
contribute t
reduction of engine efficiency.

Your Per k in s
needed to rebuild the engine at the least possible
cost.

o increased fuel consumption and

ction

ld be replaced. The use of parts that

dealer can provide the parts that are

Overhaul recommendation

Perkins reco
to minimize downtime. A scheduled overhaul will
provide the lowest cost and the greatest value.
Schedule an

mmends a scheduled overhaul in order

overhaul with your Perkins dealer.

i02481257

Radiator - Clean

Note: Adjust the frequency of cleaning according to

the effects of the operating environment.

Use a degreaser
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clea

Inspect the fins for damage. Bent fins may be
repaired. In
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.

and steam for removal of oil and

nwater.

spect these items for good condition:

i02885745

Turbocharger - Insp ect

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

i02885738

Walk-Around Inspection

Inspect the Engine for Leaks and
for Loose Connections

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

Personal injury can result from air pressure.

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

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

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

Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). In order to clean
a radiator with dual cores, one core will need to be
removed from the radiator. This will allow access to
both sides of the core.

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

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

The guards must be in the proper place. Repair

•

damaged guards or replace missing guards.

Wipe all caps and plugs before the engine is

•

serviced in order to reduce the chance of system
contamination.

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

NOTICE
Accumulatedgreaseandoilonanengineisafire haz­ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.

SEBU8430 63

Maintenance Section

Water Pump - Inspect

Ensure that coo

•

Check for leaks. Check the condition of all pipes.

Inspect the wa

•

this manual, “Water Pump - Inspect”.

Note: The wate
in the cooling system. It is normal for a small amount
of leakage to occur when the engine cools and the
parts contra

Inspect the lubrication system for leaks at the front

•

crankshaft s
pan, the oil filters and the valve covers.

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

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

Check the fuel system for leaks. Look for loose fuel

•

line clamps.

ling lines are properly clamped.

ter pumps for coolant leaks. Refer to

r pump seal is lubricated by coolant

ct.

eal, the rear crankshaft seal, the oil

i02885734

Water Temperature Regulator ­Replace

If Equipped, Remove the
Water Temperature Regulator
(Thermostat

1. Drain sufficient coolant from the cooling system in

order to remo
(4). Remove the outlet hose (1).

)

ve the water temperature regulator

Inspect the piping for the air inlet system and the

•

elbows for cracks and for loose clamps.

Inspect the wiring and the wiring harnesses for

•

loose connections and for worn wires or frayed
wires.

Inspect the ground straps for good connections

•

and for good condition.

Check the condition of the gauges. Replace any

•

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

Inspect the exhaust system for leaks. If a leak is

•

found, make repairs.

i02885735

Water Pump - Inspect

A failed water pump might cause severe engine
overheating problems that could result in cracks in
the cylinder heads, a piston seizure or other potential
damage to the engine.

Refer to the latest issue of Perkins service bulletin
157formoreinformationoninspectingthewater
pump.

Illustration 49

example

Typical

2. Remove the retaining nuts (7) and lift off the top

cover (2

3. Remove the setscrew and washer (6). Then

remove t

). Discard the joint (3).

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

g01240519

Check

Visually inspect the elements for damage.

1. Fill a suitable container with coolant. Place the

element in the container.

64 SEBU8430
Maintenance Section
Water Temperature Regulator - Replace

Note: If the val

ve (1) is open at ambient temperature

the elements must be renewed.

Illustration 50

Typical example

g01240533

2. Heat the coolant gradually. Use a thermometer (2)
in order to check the temperature of the coolant.
The opening temperature of the valve is 71 °C
(160 °F). Ensure that the valve starts the process
of opening at this temperature. Ensure that the
valve opens to the full amount.

3. If the valve does not open or the valve does not
open to the full amount discard the old element.

Replace

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

clean the mating face of the cover (2).

Illustration 51

Typical ex

ample

g01240519

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

rew and washer (6).

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

rque all the retaining nuts (7) to a torque

of 50 N·m (37 lb ft).

4. Install t

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

5. Fill the cooling system with the correct amount of
coolant.

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

SEBU8430 65

Reference Information Section

Reference Materials

Reference Information
Section

Reference Materials

i02484851

Maintenance Records

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

Determine operating costs.

•

Establish maintenance schedules for other engines

•

that are operated in the same environment.

Show compliance with the required maintenance

•

practices and maintenance intervals.

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

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

66 SEBU8430
Reference Information Section
Reference Materials

i02481255

Maintenance Log

Table 24

Engine Model

Serial Number

Service

Hours

Quantity

Of Fuel

Service Item Date Authorization

Customer Identifier

Arrangement Number

SEBU8430 67

Reference Information Section

Reference Materials

i02885832

Valve Data S heet

Table 25

Engine Model

Cylinder

1

2

3

4

5

6

7

8

Cylinder

Pressure

Serial Number Service Hours

Valve Location

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Current

Measure

Reset size Wear

-

(continued)

68 SEBU8430
Reference Information Section
Reference Materials

(Table 25, contd)

9

10

11

12

13

14

15

16

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Inlet

Exhaust

Exhaust

Inlet

Exhaust

Inlet

Exhaust

Exhaust

Inlet

Exhaust

Exhaust

i02885737

Warranty Information

The engine installation and the service interval for
the engine mu
be operated with the approved fuel, lubricant and
coolant. Refer to Perkins Engines Stafford for more
information

st be approved. The engine must

.

SEBU8430 69

Index Section

Index

A

After Startin

After Stopping Engine............................................ 29

Aftercooler Core - Inspect/Clean (Air Charge

Cooler) ................................................................. 37

Alarms and Shutoffs .............................................. 23

Testing Alarms and Shutoffs .............................. 23

Alternator - I

Alternator Pulley - Check....................................... 37

B

Battery - Repl

Battery Electrolyte Level - Check .......................... 39

Before Starting Engine ..................................... 11, 25

Belts - Inspec

Adjustment ......................................................... 40

Inspection........................................................... 39

Replacement...................................................... 40

Belts - Inspect/Adjust/Replace (Fan Drive Belts)... 39

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

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

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

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

C

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

Cold Weather Starting ........................................... 25

Control Panel......................................................... 24

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

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

Charge Water Sys

Charge Water System Fill .................................. 41

Jacket Water System Drain ............................... 40

Jacket Water Syst

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

Check the specific gravity of the coolant............ 42

Cooling System Co

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

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

Cylinders - Inspec

D

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

Driven Equipment

E

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

Grounding Practi

g Engine ............................................. 27

nspect ................................................ 37

ace................................................... 38

t/Adjust/Replace (Al ternator Belt) .... 39

tem Drain .............................. 41

em Fill ................................... 41

olant Level - Check ................. 42

t................................................. 44

- Inspect/Replace/Lubricate ..... 44

ces .......................................... 12

Emergency Stopping ............................................. 29

Typical Procedure in Order to Stop the Engine .. 29
Engine - Clean

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

Engine Air Cleaner Service Indicator - Inspect ...... 45

Test the Servi
Engine Crankcase Breather - Clean/Replace .. 46–47

Closed Breather System .................................... 47

Open Breather ................................................... 4

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

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

Engine Oil Filte

Fill the Oil Pan.................................................... 50

Replace the Oil Filter ......................................... 49

Engine Oil Filte

Change the Filter with the Engine in Operation.. 48

Engine Oil Level - Check ....................................... 50

Engine Oil Sampl

Replacement Program for the Engine Oil and

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

Engine Operatio

Partial load and Low Load Operation................. 28

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

Visual Inspectio

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

Speed Sensor .................................................... 52

Timing Sensor.................................................... 52

Engine Starting ................................................ 12, 25

Engine Stopping .............................................. 12, 29

Engine Valve Lash a

Adjust the bridge ................................................ 54

Adjusting the Valve Lash and Bridge ................. 53

Install the Cover ................................................. 5

Monitoring the Valve Recession......................... 53

Valve lash........................................................... 54

Exhaust Piping - Ins

F

Fan Drive Pulley - Check....................................... 55

Features and Contro

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

Fire Extinguisher ................................................ 10

Lines, Tubes and Hos

Fluid Recommendations........................................ 30

General Lubricant Information ........................... 30

Fluid Recommendati

ELC Cooling System Maintenance .................... 32

General Coolant Information.............................. 30

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

California Proposition 65 Warning ....................... 4

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

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

Maintenance Interv als.......................................... 4

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

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

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

....................................................... 44

ce Indicator................................... 46

r - Change ..................................... 49

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

e - Obtain ................................... 50

n................................................... 28

n................................................ 51

nd Bridge - Adjust ................. 52

pect........................................ 55

ls ........................................... 22

es .................................... 10

ons (Coolant Specifications).. 30

6

5

70 SEBU8430
Index Section

Fuel Filtratio
Fuel System Fuel Filter Differential Pressure -

Check................................................................... 56

G

Gauges and Indicators .......................................... 21

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

Containing Fl

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

Fluid Penetration.................................................. 8

Pressurized Ai

H

Hoses and Clamps - Inspect/Replace ................... 56

Replace the Hos

I

Ignition System Spark Plugs - Inspect/Replace..... 57

Inspect the Spa

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

Ignition System Timing - Check/Adjust .................. 58

Ignition Syste

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

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

J

n System - Service............................. 56

uid Spillage ..................................... 8

r and Water ................................... 8

es and the Clamps .................. 56

rk Plug....................................... 57

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

Overhaul (Majo

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

Scheduling a Major Overhaul............................. 59

Overhaul (Top E

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

Overhaul Considerations ....................................... 61

Overhaul Infor

P

Performance Parameters .................. .................... 22

Air, Charge Coo

Altitude ............................................................. 22

Air/Fuel Ratio ..................................................... 22

Plate Locations

Engine Identification........................................... 18

Serial Number Plate........................................... 18

Product Descrip

Cogeneration engine.......................................... 16

Cooling System .................................................. 16

Electrounit .......................................................... 16

Engine Service Life ............................................ 16

Fuel System ....................................................... 15

Ignition System .................................................. 1

Lubrication System ............................................ 16

Product Identification Information .......................... 18

Product Informat

Product Lifting........................................................ 20

Product Storage..................................................... 20

Level “A ” ........................................................... 20

Level “B ” ........................................................... 20

Level “C ” .......................................................... 20

r).................................................... 59

nd) ............................................... 60

mation ......................................... 61

ler Water Temperature and

and Film Locations ....................... 18

tion ............................................... 15

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

5

Jacket Water Heater - Check ................................ 58

L

Lifting and Sto

M

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

Maintenance Lo

Maintenance Records............................................ 65

Maintenance Secti on ............................................. 30

Manual Stop Pro

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

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

Mounting and Di

O

Operation Section.................................................. 20

Overhaul (In-Fr

In-Frame Overhaul Information.......................... 59

Scheduling an In-Frame Overhaul ..................... 59

rage ................................................ 20

g ................................................... 66

cedure......................................... 29

smounting..................................... 11

ame) .............................................. 59

R

Radiator - Clean .................................................... 62

Reference Information Section .............................. 65

Reference Materia

Refill Capacities ............................................... 30, 35

Cooling System .................................................. 35

Lubrication System

S

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

(1) Engine Oil Level

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

(3) Engine Derate................................................. 7

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

Sensors and Electrical Components ..................... 22

Detonation System............................................. 23

Electronic Ignitio

Governor ............................................................ 23

Switches............................................................. 22

Speci

fications ........................................................ 16

General Engine Specifications........................... 16

ls .............................................. 65

............................................ 35

............................................. 6

n System (EIS ) ........................ 22

SEBU8430 71

Index Section

Starting the En

Automatic Starting.............................................. 27

Engine Starting Procedure................................. 26

Final Checks an

Manual starting .................................................. 27

Operation of the Generator Set Control Panel ... 27
Purging Unburn

Starting with Jump Start Cables ............................ 27

T

Table of Conten

Turbocharger - Inspect .......................................... 62

V

Valve Data Shee

W

Walk-Around Inspection ........................................ 62

Inspect the Eng

Connections ..................................................... 62

Warranty Information ............................................. 68

Water Pump - Ins

Water Temperature Regulator - Replace............... 63

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

If Equipped, Rem

Regulator (Thermostat) .................................... 63

Replace.............................................................. 64

gine ................................................ 25

d First Engine Start .................. 26

ed Gas ...................................... 26

ts........................... .......................... 3

t................................................... 67

ine for Leaks and for Loose

pect............................................ 63

ove the Water Temperature

72 SEBU8430
Index Section

Product and Dealer Information

Note: For product identification plate locations, see the section “Product Identification Information” in the Operation

and Maintenance Manual.

Delivery Date:

Product Information

Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information

Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:

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