Perkins 4016-61 TRG Operation And Maintenance Manual Download

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Operation and
Maintenance
Manual

4016-61 TRG Industrial Engine

SEBU8604-02 (en-us)

October 2022

Summary of Contents for 4016-61 TRG

Page 1: ...Operation and Maintenance Manual 4016 61 TRG Industrial Engine SEBU8604 02 en us October 2022 ...

Page 2: ...zard 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 satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use including site specific rules and precautions applicable to the...

Page 3: ...oduct Information Section General Information 21 Model Views 22 Product Identification Information 26 Operation Section Lifting and Storage 28 Features and Controls 31 Engine Starting 36 Engine Operation 39 Engine Stopping 40 Maintenance Section Refill Capacities 41 Maintenance Interval Schedule Engines in Base Load Applications 49 Maintenance Interval Schedule Engines in Standby Applications 51 M...

Page 4: ...s 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 section lists basic safety precautions In addition this section identifies hazardous warning situations Read and understand the basic precautions listed in the safety section before operating or performi...

Page 5: ...r 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 distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment Overhaul Major engine overhaul details are not covered in the Operation and Maintenance Man...

Page 6: ... 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 the engine Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine that is repla...

Page 7: ...s Position Bank A Illustration 1 g06595920 Typical example 1 Universal warning 2 No step warning 3 Hot surface warning 4 Hot fluid under pressure warning 5 Ether warning SEBU8604 02 7 Safety Section Safety Messages ...

Page 8: ...s Position Bank B Illustration 2 g06595921 Typical example 1 Universal warning 2 No step warning 3 Ether warning 4 Hot fluid under pressure warning 5 Hot surface warning 8 SEBU8604 02 Safety Section Safety Messages ...

Page 9: ...ance Manuals Failure to follow the instructions or heed the warnings could result in serious injury or death The universal warning labels 1 are installed on both banks of the engine The universal warning labels 1 are installed on two valve mechanism covers front and rear of each engine bank Ether Warning Do not use aerosol types of starting aids such as ether Such use could result in an explosion ...

Page 10: ...r compo nents to contact your skin Use protective cloth ing or protective equipment to protect your skin The hot surface warning labels are on the oil coolers that are on both banks of the engine Hot Fluid Under Pressure Illustration 8 g01371640 Pressurized system Hot coolant can cause seri ous burns injury or death To open the cooling system filler cap stop the engine and wait until the cooling s...

Page 11: ...l Messages Illustration 10 g06249496 Typical example The labels will be installed on both engine oil coolers A special starting procedure may be required Refer to this Operation and Maintenance Manual Before Starting Engine for the correct procedure i08335488 General Hazard Information Illustration 11 g00104545 Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to ...

Page 12: ...ery If equipped disconnect the connectors for the unit injectors that are located on the valve cover base This action will help prevent personal injury from the high voltage to the unit injectors Do not come in contact with the unit injector terminals while the engine is operating Do not attempt any repairs or any adjustments to the engine while the engine is operating Do not attempt any repairs t...

Page 13: ...ection includes goggles or a protective face shield The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if ...

Page 14: ...nts Avoid death or serious injury from fire or explosion Consult with your fuel or fuel system supplier to ensure the delivery system is in compliance with fueling standards for proper grounding and bonding practices Inhalation Illustration 14 g00702022 Exhaust Use caution Exhaust fumes can be hazardous to health If you operate the equipment in an enclosed area adequate ventilation is necessary He...

Page 15: ...n these components is usually bound in a resin or sealed in some way Normal handling is not hazardous unless airborne dust that contains asbestos is generated If dust that may contain asbestos is present there are several guidelines that should be followed Never use compressed air for cleaning Avoid brushing materials that contain asbestos Avoid grinding materials that contain asbestos Use a wet m...

Page 16: ... information Viton Seals If Viton is burned a product of this burnt material is an acid which is hazardous Do not allow burnt material to come into contact with the skin or with the eyes Use the appropriate set of Personal Pro tective Equipment to protect your skin and eyes Failure to follow the instructions or heed the warning could result in serious injury or death If there is need to come into ...

Page 17: ...ng must be kept in good condition Ensure that all electrical wires are correctly installed and securely attached Check all electrical wires daily Repair any wires that are loose or frayed before you operate the engine Clean all electrical connections and tighten all electrical connections Eliminate all wiring that is unattached or unnecessary Do not use any wires or cables that are smaller than th...

Page 18: ...s and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install any lines that are damaged Leaks can cause fires Consult your Perkins distributor for replacement parts Replace the parts if any of the following conditions are present End fittings are damaged or leaking Outer coverings are chafed or cut Wires are exposed Outer coverings are ballooning Flexible parts of t...

Page 19: ...e the Service Manual for repairs and for adjustments i06545901 Engine Starting Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury If a warning tag is attached to the engine start switch or to the controls DO NOTstart the engine or move the controls Consult with the person that attached the warning tag before the engine is started All p...

Page 20: ...olled electrical circuit paths can result in damage to main bearings to crankshaft bearing journal surfaces and to aluminum components Engines that are installed without engine to frame ground straps can be damaged by electrical discharge To ensure that the engine and the engine electrical systems function properly an engine to frame ground strap with a direct path to the battery must be used This...

Page 21: ...e battery If a battery disconnect switch is provided open the switch 3 Disconnect the connectors from the ECM Illustration 19 g01324562 Use the example above The current flow from the welder to the ground clamp of the welder will not cause damage to any associated components 1 Engine 2 Welding rod 3 Keyswitch in the OFF position 4 Battery disconnect switch in the open position 5 Disconnected batte...

Page 22: ...owing model views show typical features of the engine Due to individual applications engines may appear different from the Illustrations Note Only serviced components are identified on the following Illustrations 22 SEBU8604 02 Product Information Section Model Views ...

Page 23: ...g A Bank 3 Electronic governor actuator 4 Thermostat housing B Bank 5 Engine crankcase breather B Bank 6 Air shutoff valve B Bank 7 3x Oil filters B Bank 8 Oil cooler 9 Oil level gauge Dipstick 10 Oil filler 11 Water pump 12 Stop solenoid SEBU8604 02 23 Product Information Section Model View Illustrations ...

Page 24: ...ine Description The 4016 61 TRG engine model is designed for power generation The engine is available with turbocharged aftercooled aspiration Engine Specifications Note The number 1 cylinders are to the front The front of the engine is farthest from the flywheel Bank A cylinders are on the right hand side of the engine Bank B cylinders are on the left hand side of the engine To determine the left...

Page 25: ...ngine coolant temperature Gear driven oil pump gear type Oil coolers The engine lubricating oil is supplied by a gear driven pump The lubrication oil is cooled and filtered Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high Bypass valves can also provide unrestricted flow of lubrication oil to the engine parts if the oil filter element should ...

Page 26: ...G1 B TAG2 D TAG3 M TWG K TWG2 N TWG3 P TRG1 R TEG2 S TEG3 W TRG2 X TGR3 Table 4 Number of Cylinders F 6 H 8 M 12 R 16 Perkins dealers and Perkins distributors require all of these numbers to determine the components that were included in the engine This permits accurate identification of replacement part numbers Serial Number Plate Illustration 23 g01266904 Serial number plate The engine serial nu...

Page 27: ...ustration 24 g02029586 Typical example The serial number plate 1 on an engine is on the left side of the cylinder block bank B SEBU8604 02 27 Product Information Section Plate Locations and Film Locations ...

Page 28: ...e brackets under ten sion Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees Illustration 25 g02126835 Typical example Use a hoist to remove heavy components Use a lifting beam A to lift the engine All supporting members chains and cables should be parallel to each other The chains and cables should be perpendicu...

Page 29: ...ngine components Lifting eyes are designed and installed for specific 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 provided Consult your Perkins dealer or your Perkins distributor for information regarding fixtures for correct engine lifting i03781209 Eng...

Page 30: ...ve protection under normal conditions of storage from 15 to 55 C 5 to 99 F and 90 relative humidity for a maximum of 2 year Level C This level is additional to level B Level C will give protection for five years in tropical or in arctic climates Level C also meets MOD NES 724 Level J for Europe when engines are stored in an unheated building or in the open under a waterproof cover 30 SEBU8604 02 O...

Page 31: ...speed Sensor or Switch i08246361 Sensors and Electrical Components Sensor Locations Illustration 28 g02088773 1 Electronic control unit ECU 2 Coolant temperature switch 3 Boost pressure sensor 4 Oil pressure switch A bank 5 High turbine inlet temperature shutdown sensor A bank 6 Thermocouple 7 Speed sensor 8 Overspeed sensor 9 High turbine inlet temperature shutdown sensor B bank 10 Oil pressure s...

Page 32: ...tions Coolant Temperature Switch Illustration 29 g02088775 Coolant temperature switches The coolant temperature switches 2 monitor the engine coolant temperature The switches are supplied for connecting to an OEM supplied panel Boost Pressure Sensors Illustration 30 g02125658 Boost pressure sensor 32 SEBU8604 02 Operation Section Sensors and Electrical Components ...

Page 33: ...nk 10 Oil pressure switch B Bank if equipped On earlier engines an oil pressure switch is installed on both side of the engine The engine oil pressure switches are mounted in the main oil gallery On later engines an oil pressure switch is installed on one side of the engine A Bank The engine oil pressure switch is mounted in the main oil gallery SEBU8604 02 33 Operation Section Sensors and Electri...

Page 34: ...nel High Turbine Inlet Temperature Shutdown Sensor Illustration 32 g02124274 5 High turbine inlet temperature shutdown sensor A bank 8 High turbine inlet temperature shutdown sensor B bank Illustration 33 g02123434 Thermocouple 34 SEBU8604 02 Operation Section Sensors and Electrical Components ...

Page 35: ...Inspect Failure of the Speed Sensor If the ECU 1 does not receive a signal from the speed sensor 4 the engine cannot run If the ECU does not receive a signal from the speed sensor 7 the engine will shut down A faulty speed sensor should be replaced Note Intermittent failure of the speed sensor will cause the engine to run erratically This may also cause overspeed Overspeed Sensor Illustration 35 g...

Page 36: ...ion Hold the keyswitch in this position until the oil pressure gauge indicates 100 kPa 14 5040 psi Continue to hold the keyswitch in the START position for an additional 10 seconds Note The keyswitch is part of the OEM supplied panel The exact procedure for starting may vary Refer to OEM supplied instructions for the correct starting procedure c Turn the keyswitch to the STOP position d Reconnect ...

Page 37: ...oad 8 Gradually remove all the engine load over a 60 second time period 9 Operate the engine off load for a time period of 4 minutes to reduce the operating temperature of the engine 10 Stop the engine Inspect the engine for leaks from the fuel coolant and lubricating oil systems Engine Starting Procedure for Engines in Standby Applications or Engines with Low Hours of Operation Note When possible...

Page 38: ...w will improve cold starting and reduce white smoke emissions Startability will be improved at temperatures below 10 C 50 F from the use of a jacket water heater The use of space heaters No load operation and or multiple start stop events in colder ambient conditions can cause the emission of white smoke from the exhaust The emission of white smoke from the exhaust is a result of partly unburnt fu...

Page 39: ...ed 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 unnecessary running at a low load If the engine is not under load the engine should be shut down Observe the air cleaner service indicator frequently The air cleaner elements should be replaced when the ai...

Page 40: ...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 Operation and Maintenance Manual Maintenance Interval Schedule Check the crankcase oil level Maintain the oil level between the MIN mark and the MAX mark on the engine oil level gauge If necessary perform minor adjustments Repair any leaks fro...

Page 41: ... specifications for additional information on the capacity of the Fuel System Table 7 Engine Refill Capacities Compartment or System 4016 Minimum Capacity of Fuel Tank 22500 L 4949 Imp gal i08267149 Fluid Recommendations General Coolant Information General Coolant Information NOTICE Never add coolant to an overheated engine Engine damage could result Allow the engine to cool first NOTICE If the en...

Page 42: ...ty can be affected by various factors including malfunctioning purification equipment earthquakes and droughts Additives Additives help to protect the metal surfaces of the cooling system A lack of coolant additives or insufficient amounts of additives enable the following conditions to occur Corrosion Formation of mineral deposits Rust Scale Pitting and erosion from cavitation of the cylinder lin...

Page 43: ...tions ELC Extended Life Coolant A coolant that relies on organic inhibitors for corrosion and cavitation protection Also known as Organic Acid Technology OAT coolant ELI Extended Life Inhibitor SCA Supplement Coolant Additive concentrated inorganic inhibitor package ASTM American Society for Testing and Materials The following three glycol based coolants are recommended for use in Perkins diesel e...

Page 44: ... of SAE J754 Some classifications follow SAE J183 abbreviations and some classifications follow the EMA Recommended Guideline on Diesel Engine Oil In addition to Perkins definitions there are other definitions that will be of assistance in purchasing lubricants Refer to Perkins Diesel Engines Fluids Recommendations M0113102 for additional information that relates to oil Perkins Diesel Engine Oils ...

Page 45: ... 1 ACEA E9 1 ACEA E7 ECF 3 API CJ 4 1 ECF 2 API CI 4 ECF 1a API CH 4 1 Use of API CK 4 API CJ 4 ACEA E9 oil specification is subject to ULSD LSD fuel or fuel with a sulphur content of less than 1000 ppm parts per million mg kg Note API engine oil categories are backwards compatible except for API FA 4 oil specification Perkins DEO ULS API CK 4 oil can be used in all engines with some restrictions ...

Page 46: ... 3 API CK 4 Non Perkins commercial oils are as a group an acceptable choice of oils Aftermarket Oil Additives Perkins does not recommend the use of aftermarket additives in oil Aftermarket additives are not necessary to achieve the maximum service life of the engine or rated performance of the engine Fully formulated finished oils consist of base oils and of commercial additive packages These addi...

Page 47: ...e oil with distillate fuel and some marine diesel fuel These fuels are not suitable for use in all engine applications The acceptability of these fuels for use is determined on a case by case basis A complete fuel analysis is required Consult your Perkins distributor for further information Biodiesel fuel is permissible for use in Perkins engines NOTICE Use of permissible fuels can result in highe...

Page 48: ...consumption Perkins Diesel Fuel System Cleaner addresses the deposits formed due to the use of degraded diesel fuel poor quality diesel fuel and diesel fuel containing high quantities of high molecular weight compounds Perkins Diesel Fuel System Cleaner addresses deposits formed due to the use of biodiesel biodiesel blends and biodiesel that does not meet the appropriate quality specifications Con...

Page 49: ...l Level Check 70 Fuel System Primary Filter Water Separator Drain 77 Walk Around Inspection 84 Every 50 Service Hours or Weekly Fuel Tank Water and Sediment Drain 77 Initial 500 Service Hours Engine Valve Lash Inspect Adjust 74 Every 500 Service Hours or 1 Year Actuator Control Linkage Lubricate 55 Alternator Pulley Check 56 Battery Electrolyte Level Check 57 Belts Inspect Adjust Replace 59 Belts ...

Page 50: ...nd 80 Commissioning Actuator Control Linkage Lubricate 55 Alternator Inspect 56 Alternator Pulley Check 56 Belts Inspect Adjust Replace 59 Belts Inspect Adjust Replace 58 Cooling System Coolant Level Check 66 Driven Equipment Check 66 Engine Crankcase Breather Clean 68 Engine Mounts Inspect 69 Engine Oil Level Check 70 Engine Protective Devices Check 73 Fan Drive Pulley Check 74 Fuel System Prime ...

Page 51: ...ator Drain 77 Walk Around Inspection 84 Every 50 Service Hours or Weekly Fuel Tank Water and Sediment Drain 77 Initial 500 Service Hours or 24 Months Engine Valve Lash Inspect Adjust 74 Every 500 Service Hours or 24 Months Actuator Control Linkage Lubricate 55 Alternator Pulley Check 56 Battery Electrolyte Level Check 57 Belts Inspect Adjust Replace 59 Belts Inspect Adjust Replace 58 Engine Crankc...

Page 52: ...ning Fan Drive Pulley Check 74 Fuel System Prime 75 Jacket Water Heater Check 79 Severe Service Application Check 82 Cooling System Coolant Level Check 66 Driven Equipment Check 66 Engine Oil Level Check 70 Fuel System Primary Filter Water Separator Drain 77 Alternator Pulley Check 56 Engine Crankcase Breather Clean 68 Actuator Control Linkage Lubricate 55 Belts Inspect Adjust Replace 58 Belts Ins...

Page 53: ...il Level Check 70 Fuel System Primary Filter Water Separator Drain 77 Walk Around Inspection 84 Every 50 Service Hours or Weekly Fuel Tank Water and Sediment Drain 77 Initial 500 Service Hours Engine Valve Lash Inspect Adjust 74 Every 500 Service Hours or 1 Year Actuator Control Linkage Lubricate 55 Alternator Pulley Check 56 Battery Electrolyte Level Check 57 Belts Inspect Adjust Replace 59 Belts...

Page 54: ...d 80 Commissioning Actuator Control Linkage Lubricate 55 Alternator Inspect 56 Alternator Pulley Check 56 Belts Inspect Adjust Replace 58 Belts Inspect Adjust Replace 59 Cooling System Coolant Level Check 66 Driven Equipment Check 66 Engine Crankcase Breather Clean 68 Engine Mounts Inspect 69 Engine Oil Level Check 70 Engine Protective Devices Check 73 Fan Drive Pulley Check 74 Fuel System Prime 7...

Page 55: ...ethod for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes 2 Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 27...

Page 56: ...d run the engine This will help in drying of the core Stop the engine Inspect these items for good condition Welds mounting brackets air lines connections clamps and seals Make repairs if necessary i02322311 Alternator Inspect Perkins recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and correct battery charging Check the ammeter if equipped during en...

Page 57: ...OSITIVE battery terminal to the POSITIVE terminal on the starting motor Disconnect the cable from the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Dispose of used batteries to an appropriate recycling facility 6 Remove the used battery 7 Install the new battery Note Before the cables are connected ensure that the engine start switch is OFF 8 Connect the cable fro...

Page 58: ... until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit correctly Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly 6 Tape the cable connections to help prevent accidental starting 7 Proceed with necessary system repairs 8 To connect the battery connect the positive connection bef...

Page 59: ...rs for the air pipes and remove the guards 2 Loosen the locknut 4 3 Rotate the rod 3 until the pulley 2 is toward the center of the engine 4 Remove the belts 1 Installation of the Fan Drive Belts 1 Install the belts 1 over the pulleys 2 Rotate the rod 3 in order to achieve the correct tension of belts 1 The total deflection should not exceed 12 5 mm 0 5 inch 3 Tighten the locknut 4 to a torque of ...

Page 60: ...ement Removal of the Alternator Belt 1 If necessary isolate the electrical supply to the engine and remove the guards Illustration 47 g01239580 Typical example 2 Remove nut 5 and bolt 4 3 Loosen nut 7 and push the alternator 6 toward the engine 4 Remove the belt 1 Installation of the Alternator Belt 1 Install the belt 1 over the pulleys Note Ensure that the teeth on the belt are engaged with the t...

Page 61: ...tered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is needed when the ELC is drained and replaced Note Inspect the water pumps and the water temperature regulators after the cooling system has been drained This is a good opportunity to replace the water pumps the water temperature regulators and the hoses if necessary Drain Pressurized...

Page 62: ... not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 3 Fill the cooling system with clean water Loosen the air vent 4 in the aftercoolers Fill the cooling system until coolant free of air flows from the vent Tighten the air vent securely Install the cooling system filler cap 1 4 Start the engine Operate the engin...

Page 63: ...ngine and operate the engine Inspect the cooling system for leaks Ensure that the cooling system operates at the correct temperature i08246768 Cooling System Coolant Change NOTICE Care must be taken to ensure that fluids are con tained during performance of inspection mainte nance testing adjusting and repair of the product Be prepared to collect the fluid with suitable contain ers before opening ...

Page 64: ...ure Remove the cooling system filler cap Illustration 54 g01211160 Typical example 2 Open the drain cock or remove the drain plug 2 in the cylinder block 3 Open the drain cock or remove the drain plug on the radiator Illustration 55 g01211161 Typical example 4 Open the drain cocks or remove the drain plugs 3 in the oil coolers Illustration 56 g02126488 Typical example Note In some applications ope...

Page 65: ...coolers Remove the drain plugs 5 in the aftercoolers Allow the water to drain Flush the cooling system with clean water Fill 1 Close the drain cock or install the drain plug 2 in the cylinder block Close the drain cock or install the drain plug on the radiator Close the drain cocks or install the drain plugs 3 in the oil coolers Install the drain plugs 5 in the aftercoolers NOTICE Do not fill the ...

Page 66: ...t the filler cap The correct pressure is stamped on the face of the filler cap If the filler cap does not retain the correct pressure replace the filler cap Install the cooling system filler cap 4 Inspect the cooling system for leaks i08246734 Crankshaft Vibration Damper Inspect Depending on the engine variant the engine can be equipped with one or two crankshaft vibration dampers The crankshaft v...

Page 67: ...ction of cables into the rear of the connectors Avoid electrical components such as the alternator the starting motors and the ECU Ensure that care is taken that the safety labels emission label and any information labels are not removed during engine cleaning i08233550 Engine Air Cleaner Element Replace NOTICE Never run the engine without an air cleaner element installed Never run the engine with...

Page 68: ...242332 When the air filter element requires replacement the center section of the service indicator 1 is red Service Indicator Reset Illustration 63 g01242328 Once 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 service indicator does not reset easily t...

Page 69: ...essive vibration of the engine and the driven equipment can be caused by the following conditions Improper mounting Loose bolts Deterioration of the isolators Ensure that the mounting bolts are tightened to the correct torque Ensure that the isolators are free of oil and contamination Inspect the isolators for deterioration Ensure that the bolts for the isolators are tightened to the correct torqu...

Page 70: ... 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 ten minutes in order to allow the engine oil to drain to the oil pan before checking the oil level NOTICE Operating your engine when the oil level is above the Max mark could cause your crankshaft to dip into the oil The air bubbles created from the cr...

Page 71: ...ative of the oil in the crankcase obtain a warm well mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean The sample can be checked for the following the quality of the oil the existence of any coolant in the oil the existence of any ferrous metal particles in the oil and the existence of any nonferrous metal pa...

Page 72: ... Remove the drain plug 3 Allow the engine oil to drain Note Ensure that the vessel that will be used is large enough to collect the waste oil 2 Remove the sealing washer from the drain plug 3 Discard the sealing washer 3 Install a new sealing washer to the drain plug 3 Install the drain plug to the engine oil pan Tighten the plug to a torque of 68 N m 50 lb ft Replace the Oil Filter Table 14 Requi...

Page 73: ...p the engine and allow the oil to drain back to the oil pan for a minimum of 10 minutes Illustration 70 g01165836 Y Min mark X Max mark 5 Remove the engine oil level gauge 2 to check the oil level Maintain the oil level between the MIN and MAX marks on the engine oil level gauge i02461963 Engine Protective Devices Check Alarms and shutoffs must function properly Alarms provide timely warning to th...

Page 74: ...life Note The valve bridges must be equalized before the valve lash is adjusted Record the valve clearance Refer to Systems Operation Testing and Adjusting Valve Lash Adjust for the correct procedure Note The valve depth is to be measured at every service The valve recession can then be calculated A valve recession tool has been designed to give service personnel a good indication of the cylinder ...

Page 75: ...fuel system from the water separator if equipped 1 Ensure that the fuel system is in working order Check that the fuel supply from the fuel day tank is in the ON position Illustration 73 g01280510 Typical example 2 Place a suitable container below the tee piece 2 in order to catch any fuel that might be spilled Note Clean up any spillage of fuel immediately 3 Loosen the connection 1 at the tee pie...

Page 76: ...n mainte nance testing adjusting and repair of the product Be prepared to collect the fluid with suitable contain ers before opening any compartment or disassem bling any component containing fluids Dispose of all fluids according to local regulations and mandates NOTICE The water separator can be under suction during nor mal engine operation Ensure that the drain valve is tightened securely to he...

Page 77: ...mal engine operation Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system 1 Place a suitable container under the water separator to catch any fuel that might spill Note Clean up any spilled fuel immediately Illustration 76 g02126453 2 Loosen the drain plugs 1 Allow the fluid to drain into the container until clean fuel can be seen 3 Tighten the drain ...

Page 78: ...gine fuel tank If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle before filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used i08246207 Fuel Transfer Pump Lift ...

Page 79: ... engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pressure 1 Stop the engine Allow the engine to cool 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suitable clean container The coolant can be reused 3 Drain the coolant...

Page 80: ...Contact your Perkins distributor or Perkins dealer for more information An inspection of the components by the Perkins distributor or Perkins dealer can help to determine when a major overhaul is required as well as the other factors Note The driven equipment may also require service when the engine is overhauled Refer to the literature that is provided by the OEM of the driven equipment Major Ove...

Page 81: ...ote For earlier engines the maximum permitted inlet and exhaust valve seat wear is 1 00 mm 0 040 inch Note For later engines the maximum permitted inlet and exhaust valve seat wear is 2 mm 0 080 inch Do not allow the recession of the valves to exceed these limits i02415302 Radiator Clean Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the radiato...

Page 82: ...ine is frequently started and stopped in very cold temperatures Extremely hot intake air reduces engine performance Quality of the air The engine may be exposed to extended operation in an environment that is dirty or dusty unless the equipment is cleaned regularly Mud dirt and dust can encase components Maintenance can be very difficult The buildup can contain corrosive chemicals Buildup Compound...

Page 83: ...he sensor 2 until light contact is made with the ring gear Note Do not tighten the sensor Illustration 78 g01237854 7 Unscrew the sensor 2 by half of one full turn in order to obtain a clearance X of 0 5 to 0 8 mm 0 02 to 0 03 inch 8 Tighten the locknut 1 Do not allow the sensor 2 to rotate Connect the connection 3 9 Remove Tooling A 10 Restore the electrical supply to the engine Overspeed Sensor ...

Page 84: ...flywheel ring gear must be in good condition in order for the engine to start properly The engine will not start if the starting motor pinion does not engage the flywheel ring gear The teeth of the starting motor pinion and the flywheel ring gear can be damaged because of irregular engagement Inspect the starting motors for proper operation Listen for grinding when the engine is started Inspect th...

Page 85: ...may indicate the need to replace a water pump Refer to Operation and Maintenance Manual Water Pump Inspect for more information If necessary consult your Perkins dealer or your Perkins distributor Inspect the lubrication system for leaks at the front crankshaft 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...

Page 86: ...seous 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 if your engine is emissions certified and if your engine is subject to an Emissions Warranty 86 SEBU8604 02 Warranty Section Warranty Information ...

Page 87: ...Practices 20 Emergency Stopping 40 Emissions Warranty Information 86 Engine Clean 67 Engine Air Cleaner Element Replace 67 Engine Air Cleaner Service Indicator Inspect 68 Service Indicator Check 68 Service Indicator Reset 68 Engine Crankcase Breather Clean 68 Engine Description 24 Engine Cooling and Lubrication 25 Engine Specifications 24 Engine Electronics 20 System Description for Engines with E...

Page 88: ...Drain 77 Drain the Water and the Sediment 78 Fuel Storage Tanks 78 Fuel Tank 77 Fuel Transfer Pump Lift Pump Inspect 78 G General Hazard Information 11 Containing Fluid Spillage 13 Dispose of Waste Properly 15 Fluid Penetration 13 Inhalation 14 Pressurized Air and Water 13 Static Electricity Hazard when Fueling with Ultra low Sulfur Diesel Fuel 14 General Information 21 Governor Actuator Check 78 ...

Page 89: ... Radiator Clean 81 Refill Capacities 41 Cooling System 41 Fuel System 41 Lubrication System 41 S Safety Messages 6 6 Rotating Shaft Hand Crush Hazard 11 Do Not Step 10 Ether Warning 9 Hot Fluid Under Pressure 10 Hot Surface 10 Universal Warning 9 Warning Labels Position Bank A 7 Safety Section 6 Sensors and Electrical Components 31 Boost Pressure Sensors 32 Coolant Temperature Switch 32 Engine Oil...

Page 90: ......

Page 91: ...Maintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Information Customer Equipment Number Dealer Equipment Number Dealer Information Name Branch Address Dealer Contact Phone Number Hours Sales Parts Service ...

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