Perkins 4006-23 Operation And Maintenance Manual Download Page 50

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i06682467

Maintenance

Interval

Schedule

When

Required

“ Battery - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 52

“ Battery or Battery Cable - Disconnect” . . . . . . . . . 53

“ Engine - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

“ Engine Air Cleaner Element - Replace” . . . . . . . . 61

“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . . 66

“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . . 69

“Overhaul (Major)” . . . . . . . . . . . . . . . . . . . . . . . . . . 77

“Overhaul (Top End)” . . . . . . . . . . . . . . . . . . . . . . . . 78

“ Severe Service Application - Check” . . . . . . . . . . 79

Daily

“ Cooling System Coolant Level - Check”. . . . . . . . 60

“ Driven Equipment - Check” . . . . . . . . . . . . . . . . . . 61

“ Engine Air Cleaner Service Indicator - Inspect” . . 62

“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . . 65

“ Fuel Tank Water and Sediment - Drain” . . . . . . . . 71

“Walk-Around Inspection” . . . . . . . . . . . . . . . . . . . . 81

Every 50 Service Hours or Weekly

“ Fuel Tank Water and Sediment - Drain” . . . . . . . . 71

Initial 100 Service Hours

“ Alternator Pulley - Check” . . . . . . . . . . . . . . . . . . . 51

“ Engine Valve Lash - Inspect/Adjust” . . . . . . . . . . . 68

“ Fan Drive Pulley - Check” . . . . . . . . . . . . . . . . . . . 68

Every 500 Service Hours

“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . . 66

“ Engine Valve Lash - Inspect/Adjust” . . . . . . . . . . . 68

Every 500 Service Hours or 1 Year

“ Battery Electrolyte Level - Check” . . . . . . . . . . . . 52

“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 53

“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 55

“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . . 56

“ Engine Crankcase Breather - Clean” . . . . . . . . . . 63

“ Fuel System Filter - Replace” . . . . . . . . . . . . . . . . 70

“ Hoses and Clamps - Inspect/Replace”. . . . . . . . . 73

Every Year

“ Crankshaft Vibration Damper - Inspect” . . . . . . . . 60

“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . . 65

“ Engine Protective Devices - Check” . . . . . . . . . . . 68

“ Governor Actuator - Check” . . . . . . . . . . . . . . . . . 73

“ Speed Sensor - Clean/Inspect”. . . . . . . . . . . . . . . 80

Every 1000 Service Hours

“ Aftercooler Core - Inspect” . . . . . . . . . . . . . . . . . . 51

“ Radiator - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Every 5000 Service Hours

“ Fuel Injector - Inspect/Adjust” . . . . . . . . . . . . . . . . 69

Every 6000 Service Hours or 3
Years

“ Cooling System Coolant Extender (ELC) -
Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Every 7500 Service Hours

“ Alternator - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 51

“ Engine Oil Pump - Inspect” . . . . . . . . . . . . . . . . . . 65

“ Fuel Transfer Pump (Lift Pump) - Inspect” . . . . . . 72

“ Starting Motor - Inspect” . . . . . . . . . . . . . . . . . . . . 81

“ Turbocharger - Inspect” . . . . . . . . . . . . . . . . . . . . . 81

“ Water Pump - Inspect”. . . . . . . . . . . . . . . . . . . . . . 82

Every 12 000 Service Hours or 6
Years

“ Cooling System Coolant (ELC) - Change” . . . . . . 58

Overhaul

“ Engine Crankcase Breather - Clean” . . . . . . . . . . 64

SEBU9077-01

Maintenance Section
Maintenance Interval Schedule

Summary of Contents for 4006-23

Page 1: ...Operation and Maintenance Manual 4006 23 and 4008 30 Industrial Engines SD8 Engine SD6 Engine DGBH Engine SEBU9077 01 en us September 2016...

Page 2: ...ing 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 canno...

Page 3: ...ngine Starting 16 Engine Stopping 16 Electrical System 16 Engine Electronics 17 Product Information Section Model Views 18 Product Identification Information 25 Operation Section Lifting and Storage 2...

Page 4: ...d to detailed instructions that follow Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule The actual operating environment of the en...

Page 5: ...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 the engi...

Page 6: ...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 The universal warning labels 1 a...

Page 7: ...o protect your skin The hot surface warning labels 2 are located in two locations The oil cooler and heat shield of the coolant rail 4 Hot Fluid Under Pressure Illustration 6 g01371640 Pressurized sys...

Page 8: ...372254 Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury Ether warning label 4 is on the support bracket for the air cleaners 6 Rotating...

Page 9: ...be started The protective locks or the controls are in the applied position Engage the secondary brakes or parking brakes Block the vehicle or restrain the vehicle before maintenance or repairs are pe...

Page 10: ...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 r...

Page 11: ...lt with your fuel or fuel system supplier to ensure that the delivery system complies with fueling standards for proper grounding and bonding Avoid static electricity risk when fueling Ultra low sulfu...

Page 12: ...Allow cooling system components to cool before the cooling system is drained Check that the coolant level after the engine has stopped and the engine has been allowed to cool Ensure that the filler ca...

Page 13: ...quipped protect hot exhaust components from oil or fuel spray if there was a line a tube or a seal failure Exhaust shields must be installed correctly Do not carry out any work on the fuel lines or ta...

Page 14: ...Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter or a hydrometer Incorrect jumper cable connections can cause an explosion that can result in injury...

Page 15: ...ured by flying debris i05875651 Mounting and Dismounting Do not climb on the engine The engine has not been designed with mounting or dismounting locations Refer to the OEM for the location of foot an...

Page 16: ...NOTstart the engine until the problem that caused the emergency stop has been corrected Stop the engine if an overspeed condition occurs during the initial start up of a new engine or an engine that h...

Page 17: ...nt adjusters if equipped Sensors Wiring Harness System Description The system is controlled by an Electronic control Unit ECU The ECU contains a microprocessor that has an Electronic Programmable Read...

Page 18: ...ons Engine Views for the Six and Eight Cylinder 4000 Series Engines The following model views show typical features of the engine Due to individual applications your engine may appear different from t...

Page 19: ...differences on six cylinder engine to an eight cylinder engine are shown in illustration 17 These differences are air cleaner end cap design the crankcase breather design The adjustment plate The bel...

Page 20: ...Typical example 1 Radiator lifting eyes 2 Radiator pressurized filler cap 3 Radiator 4 Radiator drain 5 Fuel cooler 6 Air charge cooler 20 SEBU9077 01 Product Information Section Engine Views for the...

Page 21: ...ator 5 Front lifting eye 6 Thermostat housing 7 Stop solenoid 8 Oil filler cap 9 Coolant pump 10 Primary fuel filter 11 Fuel priming pump 12 Oil gauge Dipstick 13 Oil drain location 14 Oil filters 15...

Page 22: ...ypical example 17 Twin turbochargers 18 Right side rear lifting eye 19 Left side rear lifting eye 20 Crankcase breather 22 SEBU9077 01 Product Information Section Engine Views for the Six and Eight Cy...

Page 23: ...ilable with turbocharged aftercooled aspiration The 4006 23 and the 4008 30 industrial engines are designed as a constant speed engine Engine Specifications The front end of the engine is opposite the...

Page 24: ...m consists of the following components Gear driven water pump Water temperature regulators Gear driven oil pump rotor type Oil cooler The engine lubricating oil is supplied by a gear driven pump The l...

Page 25: ...le 1 Engine serial number plate 2 Emission label location Illustration 24 g06016214 Typical example 1 Engine serial number plate Your Perkins distributor needs all the number from the plate when servi...

Page 26: ...lift the engine All supporting members chains and cables should be parallel to each other The chains and cables should be perpendicular to the top of the object that is being lifted To remove the engi...

Page 27: ...xample 1 Rear lifting eye 2 Rear lifting eye 3 Front lifting eye Radiator Lifting Only Illustration 26 g06006867 Typical example 1 Radiator lifting eye 2 Radiator lifting eye SEBU9077 01 27 Operation...

Page 28: ...ed in a container or by a truck Level B This level is additional to level A Level B will give protection under normal conditions of storage from 15 to 55 C 5 to 99 F and 90 relative humidity for a max...

Page 29: ...pressure Engine speed Engine overspeed The throttle control is also monitored and controlled i06518694 Sensors and Electrical Components The illustration within the section shows the typical locations...

Page 30: ...lant temperature switch 2 Stop solenoid 3 Alternator 4 Oil pressure switch 5 Starter relay 6 Starting motor 7 Inlet manifold air pressure sensor 8 Electronic governor control unit 30 SEBU9077 01 Opera...

Page 31: ...Illustration 28 g06006921 Typical example 9 Oil pressure switch 10 Overspeed sensor SEBU9077 01 31 Operation Section Sensors and Electrical Components...

Page 32: ...ition for an extra 10 seconds Only crank the engine for 30 seconds when building engine oil pressure After 30 seconds stop cranking and allow 2 minutes for the starter to cool Note The keyswitch is pa...

Page 33: ...d up The fuel may overflow from the fuel tank Inspect fuel lines for leaks Repair the fuel lines as needed Be aware of the properties of the different fuels Use only the recommended fuels Avoid unnece...

Page 34: ...gine for at least 10 minutes in order to allow the engine oil to return to the oil pan If the engine is equipped with a service hour meter note the reading Perform the maintenance that is in the Opera...

Page 35: ...S gal Table 5 4008 30 Engine and Engine with Radiator Engine Only 48 L 10 5 Imp gal Engine and Radiator 140 L 30 8 Imp gal Fuel System Refer to the OEM specifications for additional information on the...

Page 36: ...e replaced periodically Additives must be added at the correct concentration Over concentration of additives can cause the inhibitors to drop out of solution The deposits can enable the following prob...

Page 37: ...he correct amount of these additives 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...

Page 38: ...Contamination NOTICE Mixing ELC with other products reduces the effective ness of the ELC and shortens the ELC service life Use only Perkins Products for premixed or concen trate coolants Failure to f...

Page 39: ...ssary Table 12 Equation For Adding The SCA To The Heavy Duty Coolant For Maintenance V 0 014 X V is the total volume of the cooling system X is the amount of SCA that is required Table 13 is an exampl...

Page 40: ...The footnotes are a key part of the Perkins Specifica tion for Distillate Diesel Fuel Table Read ALL of the footnotes Table 14 Perkins Specification for Distillate Diesel Fuel Property UNITS Requirem...

Page 41: ...quirements at 40 C 104 F of either the ASTM D445 test method or the ISO 3104 test method If a fuel with a low viscosity is used cooling of the fuel may be required to maintain 1 4 cSt or greater visco...

Page 42: ...the correct power output Lighter fuels are acceptable but these fuels will not produce the rated power Sulfur The level of sulfur is governed by emissions legislations Regional regulation national reg...

Page 43: ...ments that are listed in Table 14 The lubricity of these fuels must not exceed wear scar diameter of 0 46 mm 0 01811 inch as per ISO 12156 1 Refer to Lubricity and Perkins Diesel Fuel Conditioner Note...

Page 44: ...el will also cause fuel filters to become blocked more quickly Therefore the regular service interval should be reduced to 250 hours When biodiesel fuel is used crank case oil and aftertreatment syste...

Page 45: ...els are intended for use in temperatures that can be as low as 54 C 65 2 F Refer to Group 1 Preferred Fuels for detail and conditions of use of the aviation kerosene fuels Mixing alcohol or gasoline w...

Page 46: ...nliness level or cleaner as dispensed into the engine or application fuel tank should be used This recommendation will help to reduce power loss fuel system failures and related down time of engines T...

Page 47: ...Perkins designed and produced filtration products i06693368 Fluid Recommendations Engine Oil Specification General Lubricant Information Because of government regulations regarding the certification...

Page 48: ...mulated finished oils consist of base oils and of commercial additive packages These additive packages are blended into the base oils at precise percentages to help provide finished oils with performa...

Page 49: ...il by water glycol or fuel The Oil Condition Analysis determines the loss of the oils lubricating properties An infrared analysis is used to compare the properties of new oil to the properties of the...

Page 50: ...Hours or 1 Year Battery Electrolyte Level Check 52 Belts Inspect Adjust Replace 53 Belts Inspect Adjust Replace 55 Belts Inspect Adjust Replace 56 Engine Crankcase Breather Clean 63 Fuel System Filte...

Page 51: ...alternator and the battery charger for correct operation If the batteries are correctly charged the ammeter reading should be very near zero All batteries should be kept charged The batteries should...

Page 52: ...Remove the used battery 6 Install the new battery Note Before the cables are connected ensure that the engine start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery t...

Page 53: ...Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can ca...

Page 54: ...ation 4 Tighten the locknut 4 to a torque of 120 N m 88 5 lb ft Tighten bolts 5 securely 5 Ensure that the electrical supply to the engine is isolated Install the guards Replacement Note Fan drive bel...

Page 55: ...e the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged To check accurately the belt tension a suitable gauge should be used 1 Isolate the electrica...

Page 56: ...e electrical power to the engine Replace Refer to Disassembly and Assembly Manual V Belts Fan Drive V Belts Remove and Install for more information i06729752 Belts Inspect Adjust Replace Alternator Be...

Page 57: ...the belt is a snug fit on the pulleys Replacement Removal of the Alternator Belt 1 Ensure that the electrical supply to the engine is isolated Remove the guards refer to Inspection for more informati...

Page 58: ...is contaminated Note When the cooling system is cleaned only clean water is needed when the Extended Life Coolant ELC is drained and replaced Note Inspect the water pump and the water temperature reg...

Page 59: ...engine and allow the engine to cool Isolate the electrical supply to the engine Loosen the cooling system filler cap 1 slowly to relieve any pressure Remove the cooling system filler cap Open the drai...

Page 60: ...em components are cool Loosen the cooling system pressure cap slowly in order to relieve the pressure Check the coolant level when the engine is stopped and cool Illustration 46 g01211179 1 Remove the...

Page 61: ...y detection of fluid leaks Maximum heat transfer characteristics Ease of maintenance Note Caution must be used to prevent electrical components from being damaged by excessive water when the engine is...

Page 62: ...re that both filter elements are replaced at the same time 4006 23 Air Cleaner Illustration 49 g06073787 1 Both the end caps 6 on the 4006 23 engine are secured by one central nut 5 Ensure that both f...

Page 63: ...e the service indicator has been triggered and when the air filter element has been replaced the service indicator must be reset In order to reset the service indicator 1 press the button 2 If the ser...

Page 64: ...ne and check for leaks i06682626 Engine Crankcase Breather Clean 4008 30 Engine Only S N SD81 Up Note The maintenance and maintenance period for the 4008 30 engine is different from the maintenance an...

Page 65: ...l or hot components to contact the skin NOTICE Perform this maintenance with the engine stopped Note After the engine has been switched OFF wait for 10 minutes to allow the engine oil to drain to the...

Page 66: ...the container for the sample is clean and dry Also ensure that the container for the sample is clearly labelled To ensure that the sample is representative of the oil in the crankcase obtain a warm we...

Page 67: ...tall the new oil filter 4 Note Apply hand pressure only to tighten the oil filters 4 Spin on the oil filter until the O ring seal contacts the sealing surface 1 Then rotate the oil filter of a full tu...

Page 68: ...ually check the condition of all gauges sensors and wiring Look for wiring and components that are loose broken or damaged Damaged wiring or components should be repaired or replaced immediately i0378...

Page 69: ...efficiency and also reduce engine component life Refer to Systems Operation Testing and Adjusting Fuel Injector Adjustment for the correct procedures to inspect and adjust the fuel injectors i06530425...

Page 70: ...sition 5 Operate the starting motor and crank the engine After the engine has started run the engine for a minimum of 5 minutes to remove any trapped air within the fuel system i06559454 Fuel System F...

Page 71: ...ents Clean up fuel spills immediately NOTICE Ensure that the engine is stopped before any servic ing or repair is performed NOTICE The water separator can be under suction during nor mal engine operat...

Page 72: ...s use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain th...

Page 73: ...enetration hazard Refer to Operation and Maintenance Manual General hazard Information Inspect all hoses for leaks that are caused by the following conditions Cracking Softness Loose clamps Replace ho...

Page 74: ...e coolant from the cooling system to a level that is below the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose 7 Install the hose...

Page 75: ...tart the engine Inspect the cooling system for leaks Clamps and V Band Locations Illustration 65 g06117407 1 Clamp torque 7 N m 62 lb in SEBU9077 01 75 Maintenance Section Hoses and Clamps Inspect Rep...

Page 76: ...Illustration 66 g06117430 1 Clamp torque 7 N m 62 lb in 2 Clamp torque 9 N m 79 lb in 3 Clamp torque 10 N m 88 lb in 76 SEBU9077 01 Maintenance Section Hoses and Clamps Inspect Replace...

Page 77: ...l 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 th...

Page 78: ...ever this decision must include the costs of additional downtime that is caused by this procedure Perform an economic analysis to determine if cylinder heads should be serviced as a group or divided i...

Page 79: ...rinse the core with clean water After cleaning the radiator and aftercooler start the engine Run the engine This action helps remove debris and the drying of the core Stop the engine Use a light bulb...

Page 80: ...Sensor and Overspeed Sensor When the engine is cranked small metal particles are produced These particles will contaminate the magnetic end of the overspeed sensor Contamination will distort the sign...

Page 81: ...ken or chipped If damaged teeth are found the starting motor pinions and the flywheel ring gear must be replaced Refer to the Disassembly and Assembly Manual for information on removing the starting m...

Page 82: ...ankshaft seal the rear crankshaft seal the oil pan the oil filters and the rocker cover Inspect the piping for the air intake system and the elbows for cracks and for loose clamps Ensure that hoses an...

Page 83: ...eous emission standards that are prescribed by the law at the time of manufacture This engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or distributor to determine...

Page 84: ...gency Stopping 34 Emissions Warranty Information 83 Engine Clean 61 Engine Air Cleaner Element Replace 61 4008 30 Air Cleaner 62 Engine Air Cleaner Service Indicator Inspect 62 Service Indicator Check...

Page 85: ...p Lift Pump Inspect 72 Replacement of the Lift Pump 72 G General Hazard Information 9 Containing Fluid Spillage 11 Dispose of Waste Properly 12 Fluid Penetration 10 Inhalation 11 Pressurized Air and W...

Page 86: ...Under Pressure 7 5 Ether Warning 8 6 Rotating Shaft Hand Crush Hazard 8 Safety Section 5 Sensors and Electrical Components 29 Severe Service Application Check 79 Environmental Factors 79 Incorrect Mai...

Page 87: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...

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