Warning Labels Position Bank A
Illustration 1
g07083386
Typical example
(1) Universal warning(2) Ether warning
(3) No step warning(4) Hot surface warning
(5) Hot fluid under pressure warning
SEBU8430-02
7
Safety Section
Safety Messages
Page 1: ...Operation and Maintenance Manual 4016 61TRS1 and 4016 61TRS2 Gas Engines SEBU8430 02 en us June 2022...
Page 2: ...ard The warnings in this publication and on the product are therefore not all inclusive You must not use this product in any manner different from that considered by this manual without first satisfyi...
Page 3: ...g 19 Engine Stopping 19 Electrical System 19 Product Information Section Model Views and Specifications 21 Product Identification Information 25 Operation Section Lifting and Storage 27 Gauges and Ind...
Page 4: ...manual Whenever a question arises regarding your engine or this manual please consult with your Perkins dealer or your Perkins distributor for the latest available information Safety This safety sect...
Page 5: ...the engine as a convenient reminder Perkins also recommends that a maintenance record be maintained as part of the permanent record of the engine Your authorized Perkins dealer or your Perkins distri...
Page 6: ...h 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 warn...
Page 7: ...Position Bank A Illustration 1 g07083386 Typical example 1 Universal warning 2 Ether warning 3 No step warning 4 Hot surface warning 5 Hot fluid under pressure warning SEBU8430 02 7 Safety Section Sa...
Page 8: ...Illustration 2 g07083440 Typical example 1 Universal warning 2 No step warning 3 Ether warning 4 Hot fluid under pressure warning 5 Hot surface warning 6 Rotating shaft hand crush hazard 8 SEBU8430 02...
Page 9: ...er Such use could result in an explosion and personal injury Illustration 4 g01154809 Typical example The ether warning labels are installed on both banks of the engine underneath the engine air clean...
Page 10: ...system pressure cap slowly in order to relieve the pressure Read and understand the Operation and Maintenance Manual before per forming any cooling system maintenance The hot fluids under pressure la...
Page 11: ...ard Engine Oil Level Illustration 9 g01241033 Typical example On earlier engines the warning label for checking the engine oil level is located on the inlet manifold on the left side of the engine Eng...
Page 12: ...the starting controls Do not allow unauthorized personnel on the engine or around the engine when the engine is being serviced Tampering with the engine installation or tampering with the OEM supplied...
Page 13: ...ller 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...
Page 14: ...llect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids Dispose of all fluids according to local regulations and mandates Inhalation Il...
Page 15: ...bestos materials A vacuum cleaner that is equipped with a high efficiency particulate air filter HEPA can also be used Use exhaust ventilation on permanent machining jobs Wear an approved respirator i...
Page 16: ...that can cause personal injury Do not allow electrolyte to contact the skin or the eyes Do not smoke while checking the battery electrolyte levels Batteries give off flammable fumes which can explode...
Page 17: ...rks 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 a hydrometer Improper ju...
Page 18: ...k platform Secure the climbing equipment so that the equipment will not move Do not carry tools or supplies when you mount the engine or when you dismount the engine Use a hand line to raise and lower...
Page 19: ...ergency Stop Button if equipped ONLY in an emergency situation Do not use the Emergency Stop Button for normal engine stopping After an emergency stop DO NOTstart the engine until the problem that cau...
Page 20: ...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 sup...
Page 21: ...es TRS Engine The illustrations do not show all of the options that are available Illustration 20 g01525185 Typical example 1 Ignition coils 2 Air filter 3 Charge air cooler 4 Engine oil filters 5 The...
Page 22: ...gulator The venturi is located in the gas mixer body immediately before the turbocharger As air is accelerated through the venturi gas is mixed with the air This mixture is compressed by the turbochar...
Page 23: ...ylinder block The water exits the cylinder head into the rail The water exits the engine from the water outlet Electrounit This type of engine is supplied with the following components Jacket water co...
Page 24: ...480 inch Displacement 61 123 L 3729 954 in3 Compression ratio 13 1 Aspiration Turbocharged Rotation flywheel end Counterclockwise Inlet valve lash cold 0 40 mm 0 016 inch Exhaust valve lash cold 0 40...
Page 25: ...t and Power unit G 4016 E61 TRS H TRS Combined Heat and Power Unit J TRS Gas Unit Table 4 Number of Cylinders F 6 H 8 M 12 R 16 Perkins dealers and Perkins distributors require all of these numbers in...
Page 26: ...e serial number plate for vee form engines The serial number plate 1 on a vee form engine is located on the rear face of the cylinder block bank A See Illustration 24 26 SEBU8430 02 Product Informatio...
Page 27: ...ecific engine arrangements Alterations to the lifting eyes and or the engine make the lifting eyes and the lifting fixtures obsolete If alterations are made ensure that correct lifting devices are pro...
Page 28: ...Perkins dealer or your Perkins distributor for assistance NOTICE If no oil pressure is indicated STOP the engine If maximum coolant temperature is exceeded STOP the engine Engine damage can result Eng...
Page 29: ...ne the maximum temperatures into the engine and the altitude derate Contact your Perkins distributor or Perkins dealer for more information i02894958 Sensors and Electrical Components Electronic Ignit...
Page 30: ...operate in order to stop the engine i02427728 Alarms and Shutoffs The OEM will supply this system Refer to the OEM for more information Engines may be equipped with optional engine protective devices...
Page 31: ...l operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine Periodic testing of engine protective devices for proper operation is...
Page 32: ...oil level gauge Check the coolant level Observe the coolant level in the header tank if equipped Maintain the coolant level to the FULL mark on the header tank Observe the air cleaner service indicato...
Page 33: ...t no one will be endangered before the engine is started and when the engine is started Perform the procedures that are described in this Operation and Maintenance Manual Before Starting Engine Operat...
Page 34: ...ails to start after the maximum cranking time the engine will be shut down 8 The engine is now operating Operation of the Generator Set Control Panel For information on operation for a specific genera...
Page 35: ...ecord the data in a log regularly Compare the data to the specifications for normal engine operation Comparing the data over time will help to detect changes in engine performance Investigate any sign...
Page 36: ...to manually stop the engine refer to the OEM for information The procedure will depend on the system that has been installed NOTICE Stopping the engine immediately after the engine has been operating...
Page 37: ...ubrication system Quality of the coolant is as important as the quality of the fuel and the lubricating oil Coolant is normally composed of three elements Water additives and glycol Water Water is use...
Page 38: ...Boiling protection is increased with the use of a pressurized ra diator A system with a 1 bar 14 5 psi pressure cap at sea lev el will increase the final boiling point of 50 percent coolant to 130 C...
Page 39: ...is provided for all metals that are in engine cooling systems ELC is an ethylene glycol base coolant However ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite...
Page 40: ...he product Be prepared to collect the fluid with suitable containers before opening any compartment or disas sembling any component containing fluids Dispose of all fluids according to local regulatio...
Page 41: ...types of coolant Do NOT mix brands or types of SCA and or brands or types of in hibitors Different brands or types may use different additive packages to meet the cooling system re quirements Differen...
Page 42: ...s Operation and Maintenance Manual Then refill the cooling system with a mixture of 7 5 Perkins ELI in water that meets the Perkins Minimum Acceptable Water Requirements table in this Operation and Ma...
Page 43: ...ins coolants refer to the coolant manufacturer for information on a compatible SCA Check the antifreeze glycol concentration to ensure adequate protection against boiling or freezing Perkins recommend...
Page 44: ...a 1 0 L 1 0 qt sample of coolant from the engine while in operation into a clear container Take the sample shortly after start up while the coolant is not yet hot The coolant should be adequately mix...
Page 45: ...er or deionized water is not available use water that meets or exceeds the minimum requirements that are listed in the Perkins Minimum Acceptable Water Requirements table for recommended water propert...
Page 46: ...by oils that have a nominal sulphated ash content of 0 6 by weight Sour gas engines should be lubricated by oils that have a nominal sulphated ash level of 0 6 to 1 by weight Oil sampling can be carri...
Page 47: ...nt of 15 mg kg of oil Maximum humidity relative 80 percent At lowest inlet temperature no condensation in inlet manifold and gas train allowed Min max gas pressure 4006TRS and 4008TRS engines 15 to 50...
Page 48: ...in variation frequency 5 h Min max gas temperature 10 to 50 C 50 to 122 F The gas specification requirements are to be used as a guide only Perkins require a full gas analysis to be supplied at the in...
Page 49: ...apacity is for the engine cooling system External System capacities will vary among applications Refer to the OEM specifications for the External System capacity This capacity information will be need...
Page 50: ...Differential Pressure Check 69 Hoses and Clamps Inspect Replace 70 Walk Around Inspection 76 Every Week Jacket Water Heater Check 72 Initial 100 Service Hours Alternator Pulley Check 52 Fan Drive Pul...
Page 51: ...eck 60 Ignition System Timing Check Adjust 71 Inlet Air System Inspect 72 Every 6000 Service Hours or 3 Years Cooling System Coolant ELC Change 55 Every 7500 Service Hours Water Pump Inspect 76 Every...
Page 52: ...10 Inspect the core for damage and perform a pressure test in order to detect leaks 11 Install the core Refer to Disassembly and Assembly Manual Aftercooler Core Install for the procedure For more in...
Page 53: ...ions are clean and free from corrosion 7 Install the new battery Note Before the cables are connected ensure that the engine start switch is OFF 8 Connect the cable from the starting motor to the POSI...
Page 54: ...rmation Illustration 30 g01239310 4 Apply 4 3 to 8 7 N 1 to 1 9 lb of pressure at point X The total deflection should not exceed 2 75 mm 0 10 inch Replace the belt if the total deflection exceeds 2 75...
Page 55: ...lves and of the other components may be reduced Refer to the Systems Operation Testing and Adjusting for the correct procedure i02450196 Control Panel Inspect Inspect the condition of the panel If a c...
Page 56: ...coolant refer to Operation and Maintenance Manual Coolant System Coolant Test Add Charge Water System Drain 1 Stop the engine and allow the engine to cool Open the charge water drain cock OEM installa...
Page 57: ...r cap slowly in order to relieve any pressure Remove the cooling system filler cap Check that the level of coolant is correct If necessary add more coolant Refer to this manual Cooling System Coolant...
Page 58: ...e temperature and the specific gravity of the coolant and follow the manufacturer s instructions Note If a special thermo hydrometer for coolant is not available put an hydrometer and a separate therm...
Page 59: ...e components A deteriorating damper can cause excessive gear train noise at variable points in the speed range A damper that gets hot could be due to excessive torsional vibration Monitor the temperat...
Page 60: ...nt the alignment between the engine and driven equipment must be maintained properly Check the alignment according to the instructions that are provided by the following manufacturers OEM of the coupl...
Page 61: ...emove the cover 4 2 Remove the old element 2 Dispose of the old element Note Ensure that dirt can not enter the air filter assembly 3 Install a new element into the air filter housing 1 Install the co...
Page 62: ...leaning fluid clean the filter elements 3 and dry the filter elements Inspect the filter elements for damage or deterioration If necessary replace the filter elements 5 Clean the cover and clean the b...
Page 63: ...olators for deterioration Ensure that the bolts for the isolators are tightened to the correct torque Replace any isolator that shows deterioration For more information see the literature that is prov...
Page 64: ...Ensure that the engine oil is on the correct mark 6 Operate the engine and check for engine oil leaks Stop the engine Check the engine oil level Add engine oil if necessary Refer to Operation and Main...
Page 65: ...ecifications Use of an oil filter that is not recommended by Perkins Engine Company LTD could result in severe damage to the engine Large particles from unfiltered engine oil will cause damage to the...
Page 66: ...re driven through oil This will reduce the lubricating characteristics of the oil and result in a loss of power 2 Remove the oil filler cap and add oil if necessary Clean the oil filler cap Install th...
Page 67: ...are functioning properly NOTICE During testing abnormal operating conditions must be simulated The tests must be performed correctly in order to pre vent possible damage to the engine To prevent damag...
Page 68: ...is maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool...
Page 69: ...iltration System Service Engines that use bio gas may require special equipment for processing the fuel Service the fuel filtration system according to the instructions that are provided by the OEM of...
Page 70: ...ion application can be different The differences depend on the following factors Type of hose Type of fitting material Anticipated expansion and contraction of the hose Anticipated expansion and contr...
Page 71: ...ft On the initial start up of a new engine or an engine that has been serviced it is possible for condensation to have built up in the spark plugs If this occurs refer to this manual Cold Weather Sta...
Page 72: ...he operation of the jacket water heater For an ambient temperature of 0 C 32 F the heater should maintain the jacket water coolant temperature at approximately 40 C 104 F i02895045 Overhaul In Frame S...
Page 73: ...analysis may indicate a decrease of wear metals in the lube oil The cylinder liners may be worn so that polishing of the bore occurs Also the increased use of lube oil will dilute the wear metals Moni...
Page 74: ...he required service interval record the valve lash 1 Remove the rocker covers 2 Refer to Operation and Maintenance Manual Engine Valve Lash and Bridge Adjust 3 On all engine cylinders record the clear...
Page 75: ...n unscheduled downtime and or costly repairs This can also contribute to increased fuel consumption and reduction of engine efficiency Your Perkins dealer can provide the parts that are needed to rebu...
Page 76: ...els more often than recommended until the leak is found or fixed or until the suspicion of a leak is proved to be unwarranted NOTICE Accumulated grease and oil on an engine is a fire hazard Keep the e...
Page 77: ...ainer Note If the valve 1 is open at ambient temperature the elements must be renewed 2 Heat the coolant gradually Use a thermometer 2 to check the temperature of the coolant The opening temperature o...
Page 78: ...ds can be used for a variety of other business decisions that are related to engine maintenance Maintenance records are a key element of a maintenance program that is well managed Accurate maintenance...
Page 79: ...ble 23 Engine Model Serial Number Service Hours Cylinder Cylinder Pressure Valve Location Current Measure Reset size Wear 1 Inlet Inlet Exhaust Exhaust 2 Inlet Inlet Exhaust continued SEBU8430 02 79 R...
Page 80: ...Inlet Exhaust Exhaust 6 Inlet Inlet Exhaust Exhaust 7 Inlet Inlet Exhaust Exhaust 8 Inlet Inlet Exhaust Exhaust 9 Inlet Inlet Exhaust Exhaust 10 Inlet Inlet Exhaust Exhaust 11 Inlet Inlet Exhaust Exh...
Page 81: ...ust Inlet Exhaust Exhaust i02885737 Warranty Information The engine installation and the service interval for the engine must be approved The engine must be operated with the approved fuel lubricant a...
Page 82: ...r System Fill 56 Jacket Water System Drain 55 Jacket Water System Fill 56 Cooling System Coolant Level Check 58 Crankshaft Vibration Damper Inspect 59 Crushing Prevention and Cutting Prevention 18 Cyl...
Page 83: ...Air and Water 13 H Hoses and Clamps Inspect Replace 70 Replace the Hoses and the Clamps 70 I Ignition System Spark Plugs Inspect Replace 70 Inspect the Spark Plug 71 Replace the Spark Plug 71 Ignition...
Page 84: ...Lubrication System 48 S Safety Messages 6 Do Not Step 9 Engine Derate 11 Engine Oil Level 11 Ether Warning 9 Hot Fluid Under Pressure 10 Hot Surface 9 Rotating Shaft Hand Crush Hazard 10 Universal War...
Page 85: ...aintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Inf...
Page 86: ...SEBU8430 2022 Perkins Engines Company Limited All Rights Reserved 86 June 2022...
