Perkins Engine 4012, Perkins 4012, 4016 Gas, 4016 Service Manual

TSL4187E, Issue 1
February 1998

User’s
Handbook

Perkins 4012 and 4016 Gas

4012TESI
4016TESI

WARNING

READ AND UNDERSTAND ALL SAFETY PRECAUTIONS AND
WARNINGS MENTIONED IN THIS MANUAL.

IMPROPER OPERATION OR MAINTENANCE PROCEDURES
COULD RESULT IN A SERIOUS AC CIDEN T OR DAMAGE TO THE
EQUIPMENT CAUSING INJURY OR DEATH.

NON-COMPLIANCE WITH THESE INSTRUCTIONS AND THOSE
INCLUDED IN THE INSTALLATION MANUAL TSL4200 MAY
INVALIDATE THE WARRANTY OFFERED WITH THE ENGINE.

MAKE QUITE CERTAIN THAT THE ENGINE CANNOT BE
STARTED IN ANY WAY BEFORE UNDERTAKING ANY
MAINTENANCE, PARTICULARLY IN THE CASE OF
AUTOMATICALLY STARTING GENERATING SETS.

4012/16 Gas, February 1998

INTRODUCTION

The purpose of this Manual is to enable the operator to carry out routine servicing of the engine.
Before undertaking any work on the engine the appropriate section in the Workshop Manual should be read
fully and completely understood prior to starting work.
The information contained within the manual is based on such information as was available at the time of going
to print. In line with Perkins Engines (Stafford) Limited policy of continual development and improvement that
information may change at any time without notice. The engine user should therefore ensure that he has the
latest information before starting work.
The instructions contained in this Manual will, provided that they are correctly carried out, ensure the safe
operation of the equipment.
Users are respectfully advised that it is their responsibility to employ competent persons to operate, maintain
and service the equipment in the interest of safety.
Certain overhaul operations are impracticable without the use of special tools, and those operators who are
not equipped to undertake major repairs are urged to consult their Perkins distributor.
When not working on the engine, ensure that all covers, blank flanges, doors, etc., are refitted to openings to
prevent the ingress of dirt, etc.
Please quote the engine type and serial number with all your enquiries. This will help us to help you. The type
and serial number are on a plate fitted to the crankcase.
If any doubt exists regarding the installation, use or application of the engine, the Installation Manual should
be consulted for further advice contact Applications Department at Perkins Engines (Stafford) Ltd.
Oil change intervals may be changed according to operating experience by agreement with Perkins Engines
(Stafford) Limited and subject to oil analysis being carried out at regular intervals.
Please note that this 4000 Series manual also covers SE engines dispatched from the factory from 1 March

1996. A table of equivalent engine designations is given on page 2.

PERKINS COMPANIES
Perkins Group of Companies

Perkins Engines (Peterborough) Ltd.

Frank Perkins Way, Eastfield,
Peterborough, PE1 5NA, England.
Tel: [phone]
Telex: 32501 PERKEN G
Fax: [phone]

Perkins Engines (Shrewsbury) Ltd.

Lancaster Road, Shrewsbury,
SY1 3 NX, England.
Tel: [phone]
Telex: 35171/2 PESL G
Fax: [phone]

Perkins Engines (Stafford) Ltd.

Tixall Road, Stafford, ST16 3UB, England.
Tel: [phone]
Telex: 36156 PERKEN G
Fax: [phone]

Perkins Powerpart Distribution Centre

Frank Perkins W ay,
Northbank Industrial Park, Irlam,
Manchester, M44 5PP, England.
Tel: [phone]
Specifications Help Desk
Tel: [phone]
Fax: [phone]
Specifications Help Desk
Tel: [phone]
Telex: 32501 PERKEN G

Perkins I nternational - North America

12025 Tech Center Drive,
Livonia, M ichigan 48150,
U.S.A.
Tel: [phone]
Fax: [phone]

Perkins Engines Latin America Inc

999 Ponce de Leon Boulevard,
Suite 710, Coral Gables,
Florida 33134, U.S.A.
Tel: [phone]
Telex: 32501 PERKEN G
Fax: [phone]

Perkins En gines Australia Pty Ltd

Suite 2 , 364 Main Street, Mornington
3931, V i ctoria, Australia.
Tel: [phone]
Telex: 30816
Fax: [phone]

Motori Perkins SpA

Via Socrate. 8,22070 Casnate
Con Bernate (Como), Italy.
Tel: [phone]
Telex: 380658 PERKIT I
Fax: [phone]

Perkins Motoren GmbH

D-63801 Kleinostheim,
Saalackerstrasse 4, Germany.
Tel: (49) (6027) 5010
Fax: (49) (6027) 501130

Moteurs Perkins SA

Parc de Reflets - Pa ris Nord II,
165 Avenue du Bois de la Pie, BP 40064,
95913 Roissy CDG Cedex, France
Tel: [phone]
Fax: [phone]

Perkins International Ltd.

Varity Asia/Pacific
Suite 3301, Convention Plaza,
1 Harbour Road, Wanchai,
Hong Kong.
Tel: [phone]
Fax: [phone]

Perkins Engines (Far East) Pte Ltd.

39 Tuas Avenue 13,
Singapore 638999.
Tel: [phone]
Fax: [phone]

In addition to the above companies, there are Perkins distributors in most countries. Perkins Engines
(Peterborough) Limited or one of the above companies can provide distributor handbooks Publication No. 1407/4/97.

Publication TSL4187
Published by the Technical Publications Department, Stafford.
© 1998 Perkins Engines (Stafford) Limited.

4012/16 Gas, February 1998 1

INTRODUCTION

PERKINS ENGINES (STAFFORD)

ENGINE DESIGNATIONS

4000 SERIES AND SE SERIES

EQUIVALENT TERMS

4000 SERIES SE SERIES

4012TESI 12SETCWG
4016TESI 16SETCWG

2 4012/16 Gas, February 1998

CONTENTS

Page

INTRODUCTION 1
ENGINE DESIGNATIONS 2

BRIEF DESCRIPTION OF THE 4012/16 GAS ENGINES 4
PHOTOGRAPHS INSERTS
GENERAL INFORMATION 5
GAS ENGINE DATA 7 - 10

TORQUE SETTINGS 11 - 13
LUBRICATING OIL 14 - 16
COOLANT CORROSION INHIBITORS, ANTI-FREEZE 17
GAS SPECIFICATION 18 - 19

OPERATING INSTRUCTIONS 20 - 21

PREPARATION FOR INITIAL START 20
PRIMING THE TURBOCHARGER 20
BATTERIES 21
FILLING THE COOLING SYSTEM 21
INSTRUMENT PANEL (ENGINE MOUNTED) 22 - 24
EXHAUST TEMPERATURE GAUGE (OPTIONAL) 24
FINAL CHECKS AND INITIAL START UP 25 - 26
GAS ENGINE START/STOP SEQUENCE (AUTOMATIC) 27

MAINTENANCE PROCEDURES 28 - 41

OVERHAUL PERIODS & CONTINUOUS DUTY CHECKLIST 42 - 44
FAULT TRACING CHART 45

WIRING DIAGRAMS

4012/16TESI (MINNOX) WITH CAV STARTER AND PROTECTION SWITCHES 46
4012/16 (GAS) MINNOX ENGINE STARTING CIRCUIT WITH BUTEC

STARTERS AND OPTIONAL INSTRUMENT PANEL 47
EARLY 4012 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM 48
CURRENT 4012 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM 49
4012/16 (GAS) MINNOX ENGINE WIRING DIAGRAM OF STANDARD
PROTECTION PACK AND OPTIONAL BRITISH GAS COUNCIL

PROTECTION EQUIPMENT 50
EARLY 4016 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM 51

CURRENT 4016 SERIES GAS IGNITION AND HEINZMAN WIRING SYSTEM 52
4012/16 LUBRICATING OIL FLOW DIAGRAM TP315
4012/16TESI FRESH AND RAW WATER CIRCULATION DIAGRAM TP381

(HEAT EXCHANGER COOLED)
4012TESI FRESH AND RAW WATER CIRCULATION DIAGRAM TP384

(RADIATOR COOLED)
4012/16TESI ENGINE IGNITION AND GAS FLOW DIAGRAM TP351

4012/16 Gas, February 1998 3

BRIEF DESCRIPTION OF THE 4012/16 GAS ENGINES

4012TESI
(MINNOX)

4012TESI
(MINNOX) 200 L.C.

4012TESI
(MINNOX) 140 L.C.

4012TESI
(MINNOX) 140 H.C.

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pumpandcoolingcircuit, lean burn, low NOx emission levels, 9.5:1
compression ratio

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pumpandcoolingcircuit,leanburn,withNOx emission of less than
200 g/GJ, 9.5:1 compression ratio.

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pumpandcoolingcircuit,leanburn,withNOx emission of less than
140 g/GJ, 9.5:1 compression ratio.

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pumpandcoolingcircuit,leanburn,withNOx emission of less than
140 g/GJ, 11.5:1 compression ratio.

4016TESI
(MINNOX) 200 L.C.

4016TESI
(MINNOX) 140 L.C.

4016TESI
(MINNOX) 140 H.C.

4016TESI
(MINNOX) 90 H.C.

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pumpandcoolingcircuit,leanburn,withNOx emission level of 200
g/GJ or less, 9.5:1 compression ratio.

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pump and cooling circuit, lean burn, with NOx emission of 140 g/
GJ or less, 9.5:1 compression ratio.

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pump and cooling circuit, lean burn, with NOx emission of 140 g/
GJ or less, 11.5:1 compression ratio.

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,
turbo-charged,water cooled charge air cooler with separate water
pump and cooling circuit, lean burn, with NOx emission of 90 g/GJ
or less, 11.5:1 compression ratio.

4 4012/16 Gas, February 1998

4012TESI (MINNOX)

4012TESI (MINNOX)

4016TESI (MINNOX)

4016TESI (MINNOX)

SAFETY
Engine lift equipment

Use only the lift equipment which is designed
for the engine.

Use lift equipment or obtain assistance to lift
heavy engine components such as the
cylinder block, cylinder head, flywheel
housing, crankshaft and flywheel.

Check the engine lift brackets for security
before the engine is lifted.

Asbestos joints

Some joints and gaskets contain
compressed asbestos fibres see Warning
labelFig.1in a rubber compound or in a
metal outer cover. The 'white' asbestos
(Chrysotile) which is used is a safer type of
asbestos and the danger of damage to
health is extremely small.

Contact with asbestos particles normally
occurs at joint edges or where a joint is
damaged during removal, or where a joint is
removed by an abrasive method.

To ensure that the risk is kept to a minimum,
the procedures given below must be
followed when an engine which has
asbestos joints is dismantled or assembled.

●

Work in an area with good ventilation.

●

Do NOT smoke.

●

Useahandscrapertoremovethejoints

- do NOT use a rotary wire brush.

●

Ensure that the joint to be removed is

wet with oil or water to contain any loose

particles.

●

Sprayall asbestosdebriswithwaterand

placeitinaclosedcontainerwhichcan

be sealed for safe disposal.

Dangers from used engine oils

Prolongedand repeated contact with mineral
oil will result in the removal of natural oils
from the skin, leading to dryness, irritation
and dermatitis. The oil also contains
potentially harmful contaminants which may
result in skin cancer.

Adequate means of skin protection and
washing facilities should be readily available.

GENERAL INFORMATION

Fig. 1

The following is a list of 'Health Protection
Precautions', suggested to minimise the risk
of contamination.

1. Avoid prolonged and repeated contact
with used engine oils.

2. Wear protective clothing, including
impervious gloves where applicable.

3. Do not put oily rags into pockets.

4. Avoid contaminating clothes, particularly
underwear, with oil.

5. Overalls must be cleaned regularly.
Discard unwashable clothing and oil
impregnated footwear.

6. First aid treatment should be obtained
immediately for open cuts and wounds.

7. Apply barrier creams before each period
of work to aid the removal of mineral oil
from the skin.

8. Wash with soap and hot water, or
alternatively use a skin cleanser and a
nail brush, to ensure that all oil is
removed from the skin. Preparations
containing lanolin will help replace the
natural skin oils which have been
removed.

9. Do NOT use petrol, kerosene, diesel
fuel, gas oil, thinners or solvents for
washing the skin.

10. If skin disorder appears, medical advice
must be taken.

11. Degrease components before handling
if practicable.

12. Where there is the possibility of a risk to
the eyes, goggles or a face shield
should be worn. An eye wash facility
should be readily available.

4012/16 Gas, February 1998 5

GENERAL INFORMATION

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm. Battery
posts, terminals and related accessories contain lead
and lead compounds. Wash hands after handling.

Environmental protection

There is legislation to protect the
environment from the incorrect disposal of
used lubricating oil. To ensure that the
environment is protected, consult your Local
Authority who can give advice.

Viton seals

Some seals used in engines and in
components fitted to engines are made from
Viton.

Viton is used by many manufacturers and is
a safe material under normal conditions of
operation.

If Viton is burned, a product of this burnt
material is an acid which is extremely
dangerous. Never allow this burnt material
to come into contact with the skin or with the
eyes.

If it is necessary to come into contact with
components which have been burnt, ensure
that the precautions which follow are used:

●

Ensure that the components have
cooled.

●

Use Neoprene gloves and discard the
gloves safely after use.

●

Wash the area with a calcium hydroxide
solution and then with clean water.

●

Disposal of gloves and components
which are contaminated, must be in
accordance with local regulations.

Practical Information
To clean components

It is important that the work area is kept clean
and that the components are protected from
dirt and debris. Ensure that dirt does not
contaminate the fuel system.

Before a component is removed from the
engine, clean around the component and
ensure that all openings, disconnected
hoses and pipes are sealed.

Remove, clean and inspect each component
carefully. If it is usable, put it in a clean dry
place until needed. Ball and roller bearings
mustbe cleaned thoroughlyand inspected. If
the bearings are usable, they must be
flushed in low viscosity oil and protected with
clean paper until needed.

Before the components are assembled,
ensurethat the area is free fromdust and dirt
as possible. Inspect each component
immediately before it is fitted, wash all pipes
and ports and pass dry compressed air
through them before connections are made.

Use suitable gloves for protection when
components are degreased or cleaned with
trichloroethylene, white spirit, etc.
Degreasing solutions which are basically
trichloroethane are not recommended.

If there is contamination of the skin or eyes,
wash the affected area with a continuous
supply of clean water or with a calcium
hydroxide solution for 15-60 minutes. Obtain
immediate medical attention.

6 4012/16 Gas, February 1998

GAS ENGINE DATA

The figures quoted are based on engines set to meet the ISO 3046/1 1981 Condition.
For full technical data please refer to the Product Information Manual.
Type (Gas) 12 cylinder and 16 cylinder (MINNOX)'V' form, water cooled, turbocharged,wet
exhaust manifolds with separate raw water cooled charge air cooler.

RANGE 4012TESI (MINNOX) 4016TESI (MINNOX)

Cycle 4 stroke
Configuration ‘V’ form
Bore 160 mm
Stroke 190 mm
Total swept volume 45.842 litres 61.123 litres
Compression ratio 9.5:1 or 11.5:1
Rotation Anti-clockwise looking on flywheel end

Firing order
Cylinder numbering Cylinder 1 furthest from flywheel

Cylinders designated A are on the left side of the engine when viewed from opposite end to the flywheel, with
cylinders designated B on the right hand side of the engine.
NOTE: This is NOT the same as the British Standard and ISO designation.

Valve clearances Exhaust 0.4 mm (0.016”)
Valve dia (mm) inlet & exhaust 48
Valve timing See Workshop Manual Section U7
Valve setting See page 39 onwards
Ignition timing See engine number plate
Piston speeds

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

Engine r/min

1000
1200
1500

1A,1B,3A,3B,7A,7B,5A,5B
8A,8B,6A,6B,2A,2B,4A,4B

m/s (ft/min)

6.33 (1247)

7.60 (1496)

9.50 (1870)

TYPICAL COOLING SYSTEM

Approved coolants See page 17
Total capacity engine including

charge air cooler & wet exhaust
manifolds

Total capacity engine and radiator 239 litres (52.6 gals)
Total capacity engine and heat

exchanger
Engine shut down temperature 96°C

Max. temperature into engine
Thermostat opening temperature 71°C (nat. gas) 85°C (landfill or biogas) 92°C (HC engines)

System pressure 0.5 - 0.7 bar
Maximum pressure at jacket

coolant pump outlet

To be determined from heat dissipated and water flow through each

81 litres (17.8 gals) 110 litres (24.3 gals)

278 litres (61.3 gals)

153 litres (33.7 gals) 183 litres (40.3 gals)

particular engine model

2.5 bar max

4012/16 Gas, February 1998 7

GAS ENGINE DATA

GAS SYSTEM

4012TESI (MINNOX) 4016TESI (MINNOX)

Approved gas British Natural Gas
Lower calorific value 34.71 MJ/nm
Carburettor mixing unit Deltec 200 - 11
Carburettor throttle body Deltec 100 - 11 Deltec 140 - 11
Gascontrolvalve Deltec36mmdia. Deltec45mmdia.

Deltec 38 mm dia. 4016TESI (minnox 140 HE) ONLY
Gas pressure min. 15 m bar (1.5 kPa)
Gas pressure max. 50 m bar (5 kPa)
Regulator type (Zero pressure) Dungs FRS 220, 5065 or 5100
Later engines or Kromschroder GI50 R02 or GI65 R02

If above 50 mbar (5kPa), an additional regulator should be used in

Supply pressure

Additional items to meet The Instituion of Gas Engineers procedures IGE/UP/3 for 4012/16 (Minnox)
Low pressure detector
Gas solenoid valves Not Perkins supply

Spit back detector PerkinsPart No. (see Spares Book)
Manual gas shut-off valve Perkins Part No. (see Spares Book) (if fitted)

order to bring the supply pressure to between the max. & min.

figures given above

Perkins Part No. (see Spares Book)

(low pressure gas supply only)

3

IGNITION SYSTEM

Ignition unit type Altronic DISN 800
Ignition coil type Altronic 501 061 (L.C. engines) Altronic 591 010 (H.C. engines)

Spark plug type

Spark plug gap

CHAMPION RN79G 14mm (earlier L.C. engines)

CHAMPION RB77 WPC 18mm (later engines)

RN79G 0.5 mm (0.020”)

RB77WPC 0.4 mm (0.015”)

GOVERNOR

Make Heinzmann Electronic
Type 2 x E6V 2 x E10

LUBRICATION SYSTEM

Recommended oil See pages 14 - 16
Type of system Wet sump, external mounted oil pump
Total oil capacity (oil cooler and filter) 178 litres (39 gals) 238 litres (51 gals)
Sump capacity (dipstick) min. 136 litres (30 gals) 147 litres (32 gals)
Sump capacity (dipstick) max. 159 litres (35 gals) 214 litres (47 gals)

2

Min.oilpressure (ratedspeed)to bearings 340 kPa (49 lb/in
Crankcase pressure max 25 mm water gauge
Max. oil temperature in sump 105°C
Lubricating oil filter disposable canister type
Crankcase breather Closed circuit

)

8 4012/16 Gas, February 1998

INDUCTION SYSTEM

4012TESI (MINNOX) 4016TESI (MINNOX)

Air cleaner Twin
Type (paper element) S551A
Max. air intake depression 543 mm H

406 mm H

Air restriction Indicator setting 380 mm H
Turbocharger

Twin Garrett (4016TESI 140 H.C. only)

Twin Schwitzer (all other engines)

O (40 mm Hg) (L.C. engines)

2

O (30 mm Hg) (H.C. engines)

2

O

2

EXHAUST SYSTEM

Manifold type WET
Exhaust outlet flange Vertical (twin)
Mating flange 2 x 6” Table D
Max. exhaust back pressure 40 mm Hg
Max. exhaust temperature (°C)

(after turbocharger)

See Product Information Manual

FLYWHEEL

SAE Size 18”
No. of teeth on ring gear 156

GAS ENGINE DATA

FLYWHEEL HOUSING

SAE Size ‘00’

CRANKSHAFT

Maximum overhung weight on rear
bearing

T.V. damper 1 x 18” 2 x 20”
NOTE: Subject to torsional vibration investigation different T.V. dampers may be fitted.

1700 Kg

DRY WEIGHT

Dry weight 4380 kg 5520 kg
Wet weight 4680 kg 5820 kg

HOLDING DOWN BOLT HOLES

Bolt size (engine feet) 22 mm
No. off 8

ELECTRICAL SYSTEM

Voltage 24
Alternator type Prestolite LNA4024/5 with internal regulator
Alternator output (amps) 30 at a stabilised output of 28 volts
Starter motor type (Twin) Prestolite/Butec MS1/108 MS7/5
No. of teeth (gear ring) 156
No. of teeth (starter motor) 12
Battery capacity cold cranking amps

to IEC Standard at 0°C (32°F)
Battery (lead acid) 24 V (2 x 12 V) at 0°C (32°F) (286 Ah)

286 (each battery) 286 (each battery)

4012/16 Gas, February 1998 9

GAS ENGINE DATA

PROTECTION EQUIPMENT

Before resetting protection equipment, it must be established whether special settings (for that individual

2

)

high water

²)

engine) have been specified in the engine sales contract. This is particularly important with ALL
temperature settings, and ALL
Standard
High air manifold pressure switch 172 kPa (25.1 lb/in

Shutdown switches Alarm Shutdown

High oil temperature 115°C 120°C
Low oil pressure 2.06 bar (30 lb/in
High water temperature
71°C Thermostat

85°C Thermostat
96°C Thermostat

Caution: The above standard settings do not
Overspeed 15% (on 1500 rev/min only)
High air manifold bursting disc pressure

(Early engines only)

settings for protection equipment are as follows:

Cogen applications.

supercede any settings specified in the engine sales contract.

²)

91°C
96°C

100°C

75 lb/in²at 42°C or 58 lb/in²at 120°C

1.93 bar (28 lb/in

96°C
101°C
105°C

AIR STARTING

Air Starter Pressure 150 lb/in²(1034 kPa)
Compressed air supply 170 lb/in²(1172 kPa)
Type Ingersoll-Rand Type SS815

INSTRUMENT PANEL (ENGINE MOUNTED)

Normal operation
Oil pressure Between 300 - 560 kPa (42.6 - 80 lb/in
Oil temperature Between 80 - 90°C(176 - 194°F)
Water temperature Between 65 - 85°C(149 - 185°F)
Exhaust temperature See Product Information Manual
Boost pressure See Test Certificate

COOLANT JACKET HEATING

Heater 2 x 4 kw

²)

10 4012/16 Gas, February 1998

TORQUE SETTINGS

WARNING

IT IS ESSENTIAL THAT THE CORRECT LENGTH OF SCREW OR

BOLT IS USED. INSUFFICIENT THREAD MAY RESULT IN THE
THREAD BEING STRIPPED. WHEREAS TOO LONG A THREAD MAY RESULT IN
BOTTOMING IN A BLIND HOLE, OR CATCHING ON ADJACENT COMPONENTS.

NOTE: * Bolt and threads must be lubricated with clean engine oil.

** Cylinder head bolts to be lubricated under the heads, under the washers and

on the threads with P.B.C. (Poly-Butyl-Cuprysil) grease. Important: See Section R10 in

the Workshop Manual before fitting. All other bolt threads only to be lubricated with clean

engine oil. Care must be taken not to oil the heads and faces.

TORQUE SETTINGS
CYLINDER HEAD GROUP Ibf.ft Nm

** Cylinder head bolt (early type) M24 550 750

See Section R14

** Cylinder head bolt (later (waisted) type) M24 530 723
Rocker shaft bolt/nut M16 90 120
Rocker adjuster nut inlet/exhaust M12 35 50
Rocker box bolt M10 35 50
Air manifold bolt M10 35 50
Exhaust manifold bolt M10 50 70
Turbocharger V-band clamp nuts - (Schwitzer) 7 9.5

(Mitsubishi) 7 9.5
(Garrett) 10 13.5

Sandwich plate r etaining capscrew (if fitted) M10 40 57

CRANKCASE AND CRANKSHAFT GROUPS

* Main bearing bolt M24 580 783
Side bolts (main bearing caps) M16 124 168
Bolts sump to crankcase M10 40 57
* Connecting rod bolt M16 210 285
Viscous damper bolts to crankshaft M16 250 340
Flywheel bolt to crankshaft M16 250 340
Front drive adaptor bolts to crankshaft M16 250 340
Balance weight bolt M16 250 340
Front crankshaft pulley bolt M 16 250 340
Piston cooling jet setscrew M10 35 50
Flywheel housing bolt M10 35 50

LUBRICATING OIL PUMP

Bolts, pump housing to gearcase plate M10 35 50
Thin nut gear to drive shaft M24 175 237

4012/16 Gas, February 1998 11

TORQUE SETTINGS

Ibf.ft Nm

CAMSHAFT GROUP

Camshaft gear bolt M12 110 150
Camshaft thrust plate bolt M10 35 50
Camshaft follower housing capscrew M10 50 70
Cam follower housing bolt M10 35 50
Idler gear hub bolts M10 35 50

WATER PUMP AND OIL PUMP GROUPS

Water pump/oil pump gear units M24 170 230
Water header to oil cooler bolts M10 35 50
Water header to gearcase bolts M10 35 50
Raw water pump gear securing nut (non lubricated thread) M35 184 250
Engine Feet M12 70 95

GOVERNOR

Control shaft mounting plate bolt M10 35 50

FAN DRIVE

Fan driven pulley taper lock bush screw

1

/2"BSW 35 50

5

/8" BSW 124 170

ALTERNATOR

Drive pulley taper lock bush screws

3

/8"BSW 14 20

IGNITION SYSTEM

Sparkplug M18x1.5 35 50
Adaptor clamp capscrew M12 100 136
Adaptor clamp screw (earlier engines) M10 50 68
Retaining bolt for timing disc cover M10 35 50
Timing disc housing to mounting plate bolt M10 35 50
Drive gear screw M10 50 70
Drive coupling capscrew M6 10 13.5
Driven gear capscrew M10 50 70
Magnet disc to shaft nut M12 35 50
Disc shaft flange to camshaft bolt M12 120 171

FLEXIBLE COUPLING (HOLSET)

Flexible coupling cover screw M12 or1/2" UNC 90 129
Coupling driving flange screws (coupling size 2.15) M12 or1/2" UNC 90 129
toflywheel (couplingsize3.86) M16or5/8" UNC 175 250

12 4012/16 Gas, February 1998

TORQUE SETTINGS

GENERAL TORQUE LOADINGS

The following torque loadings are general for metric coarse threads for grade 8.8 steel and
do not supersede the figures quoted above.

Thread Size (mm) Ibf.ft Nm

81825
10 35 50

M10-12.9 steel 50 70
These are based to BS 3692.

4012/16 Gas, February 1998 13

LUBRICATING OIL

QUANTITY OF OIL

4012TESI 4016TESI
The total system capacity 178 litres (39 gallons) 238 litres (52 gallons)
The maximum sump capacity 159 litres (35 gallons) 214 litres (47 gallons)
The minimum dipstick mark indicates 136 litres (30 gallons) 147 litres (32 gallons)

CAUTION
In order to select a suitable lubricating oil for a gas engine it is necessary to consider
the fuel quality.

NATURAL GAS ENGINES (NO ACIDIC PRODUCTS PRESENT)

The oil should be a grade that is specifically formulated by all the major oil companies for
turbocharged and charge cooled natural gas engines. The oil should contain anti-wear and
detergent/dispersant additives. The oil is to have high resistance to oxidation and have
good thermal stability. Modern gas engine oils do not rely on a high total base number to
achieve long life and the special additive packages that are now available from many of the
major oil suppliers now meet this criteria.
Engines fitted with oxidizing catalysts (2 way) require a lubricant that is low in zinc and
phosphorus, it is essential that the oil supplier confirms that the brand of oil supplied is
compatible with the catalyst.

BIOGAS ENGINES (CONTAINING ACIDIC PRODUCTS AT LEVELS APPROVED BY PERKINS ENGINES (STAFFORD) LTD

These engine require a lubricating oil that has more reserve alkalinity than the natural gas
engine and therefore the TBN should be more than 8 and less than 10 with the sulphated
ash in the range of 0.5 to 1.1%. The oil supplier will assist with the selection of suitable oils
when presented with the gas analysis. (TBN = Total Base Number).

NATURAL GAS BIOGAS ENGINES

Where gas engines oils are not available, please consult Perkins Engines (Stafford) Ltd for
advice.

GRADE OF OIL

The viscosity of the oil used should be either SAE 30 or SAE 40. In general SAE 30 is used
at temperature less than 30°C average ambient temperature and SAE 40 more than 30°C.
As these engine are generally operating continuously, it is possible to use higher viscosity
oils as sluggishness in starting is not generally critical.
The use of SAE40 will give reduced oil consumption but under certain conditions it will also
give reduced oil change periods.

OIL CHANGE PERIOD (NATURAL GAS ENGINES)

For normal operation of gas engines, change the oil after the first 500 hours, after which the
oil change period is 800 hours or annually which ever is the sooner.
It may be possible to extend the oil change period, where an oil change programme has
been approved by Perkins Engines (Stafford) Ltd, based upon the analysis of oil samples
taken during the first 1000 hours of engine use. However even if an analysis is showing a
satisfactory oil quality, the oil life should not be extended above 1000 hours.

14 4012/16 Gas, February 1998