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
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