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User’s Handbook, TSL 4230, Issue 4

iii

4016-E61TRS

Contents

1 General information

Introduction  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..  1

Safety precautions  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..   2

How to care for your engine  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..  5

Dangers from used engine oils  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..  6

Environmental protection   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..  6

Danger from ‘fluorosilicone’ (Viton) ‘O’ ring seals  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..  7

Practical information for cleaning components  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..  7

Engine preservation   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..  8

Parts and service   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..  8

Service tools  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..  9

Engine identification  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...   10

Engine specifications  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...   11

Performance data  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...   14

2 Engine views

Introduction  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  15

3 Operating instructions

Introduction  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  17

How to fill the engine with oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...   18

How to fill a CHP type cooling system   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...   19

This document has been printed from SPI². Not for Resale

Содержание 4016-E61TRS

Страница 1: ...TSL 4230E Issue 4 Proprietary information of Perkins Engines Company Limited all rights reserved The information is correct at the time of print Published in December 2002 by Technical Publications Pe...

Страница 2: ...eneral information 2 Engine views 3 Operation instructions 4 Preventive maintenance 5 Gas and engine fluids specification 6 Fault diagnosis The following pages contain a detailed table of contents Thi...

Страница 3: ...fluorosilicone Viton O ring seals 7 Practical information for cleaning components 7 Engine preservation 8 Parts and service 8 Service tools 9 Engine identification 10 Engine specifications 11 Perform...

Страница 4: ...check the air cleaner restriction indicator 31 How to change the air filter element and clean the gas mixer 32 How to change the oxygen sensor 33 How to remove a spark plug 34 How to clean set and fit...

Страница 5: ...erms left side and right side apply when the engine is seen from the flywheel end Special tools are required to perform certain operations A list of those required for the operations described in this...

Страница 6: ...iller changing the lubricating oil filter or changing the electrolyte in the battery l Always wear ear protection when working in an enclosed engine room l Always wear suitable eye protection when usi...

Страница 7: ...system for leaks l Ensure that the engine room is correctly ventilated l Check that all the guards are fitted l Check that the pipework allows the exhaust gas to escape upwards l Check that the pipewo...

Страница 8: ...nd correct footwear Waste disposal l Do not leave oil covered cloths on or near the engine l Do not leave loose items on or near the engine l Always provide a fireproof container for oil contaminated...

Страница 9: ...rial number with all your enquiries see Engine identification on page 10 If any doubt exists regarding the installation use or application of the engine the Installation Manual should be consulted For...

Страница 10: ...otwear 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...

Страница 11: ...te medical attention Practical information for cleaning components Use suitable gloves for protection when components are degreased Keep the work area clean and ensure that components are protected fr...

Страница 12: ...oated with Valvoline Tectyl 506 preservative Parts and service Service literature Workshop manuals installation drawings and other service publications are available from your Perkins distributor Trai...

Страница 13: ...adjustment 1 17 mm Combination spanner bridge piece adjuster locknut 1 19 mm Combination spanner rocker adjuster locknut 1 Feeler gauge set to set bridge piece and valve clearance 1 Strap wrench oil f...

Страница 14: ...ine identification The engine number and its build specification details are given on its data plate The data plate is fastened to the crankcase above the flywheel housing on cylinder No 8 A Bank A1 T...

Страница 15: ...al Gas UK Lower calorific value 34 710 kJ Sm3 45 671 kJ kg Density 0 76 kg Sm3 Stoichiometric air requirement 16 kg kg Minimum methane number 75 Cooling system Recommended coolant 50 inhibited ethylen...

Страница 16: ...t gear pump Normal operating angles Fore and aft 5 Side tilt 10 Fuel system Recommended fuel Natural Gas LHV at 34 71 MJ m3 Gas supply pressure 6 kPa to 10 kPa at full rated flow conditions Carburetto...

Страница 17: ...system controlling l Speed governing l Air Fuel ratio l Start Stop sequence l Anti knock l Engine protection and diagnostics Ignition system Primary voltage 24 volts Polarity Negative earth Ignition...

Страница 18: ...rical efficiency 38 2 39 2 Mean piston speed m s 9 5 9 5 Charge coolant flow l s 10 10 Nominal excess air factor Lambda 1 80 1 75 Typical Gen Set 25 C 100 kPa electrical output unit 1 0pf kW 1008 1008...

Страница 19: ...ngine views 2 Introduction Perkins engines are built for specific applications and the views which follow do not necessarily match your engine specification B Bank gearcase end A Bank flywheel end Thi...

Страница 20: ...This page is intentionally blank This document has been printed from SPI Not for Resale...

Страница 21: ...which controls all functions on the engine including oil circuit priming starting and stopping sequences is given in the OEM Application Installation and Commissioning Manual TSL 4232 and the Diagnos...

Страница 22: ...e correct grade of lubricating oil as specified in Lubricating oil recommendations on page 42 4 Refit the oil filler plug Quantity of oil Maximum 257 litres Minimum 147 litres Total system 286 litres...

Страница 23: ...of clean water and anti freeze or clean water and corrosion inhibitor must be used in the cooling system Refer to Coolant specification on page 43 Warning Always stop the engine and allow the pressur...

Страница 24: ...ion of clean water and anti freeze or clean water and corrosion inhibitor must be used in the cooling system Refer to Coolant specification on page 43 Warning Always stop the engine and allow the pres...

Страница 25: ...cing will be necessary particularly in respect of the lubricating oil and air cleaners Correct and regular maintenance will help prolong engine life Warnings l Make quite certain that the engine canno...

Страница 26: ...codes record and rectify Oil and filter change UH Clean the filter gauze for the piston cooling jet oil gallery UH Equalise bridge pieces and set valve clearances UH Check and clean spark plugs reset...

Страница 27: ...t WM Test sensors and protection systems annually DM Check coolant anti freeze inhibitor strength annually UH Calibrate oxygen sensor renew if necessary UH DM Calibrate turbine inlet temperature inter...

Страница 28: ...record DM Check EMS logged diagnostic codes record and rectify Equalise bridge pieces and set the valve clearances UH Check valve and seat recession UH Check and clean spark plugs reset gap WM Breathe...

Страница 29: ...Check coolant anti freeze inhibitor strength annually WM Calibrate oxygen sensor renew if necessary UH DM Calibrate interface module for turbine inlet temperature WM DM Check emissions adjust if nece...

Страница 30: ...e same grade and specification as that already in the system Caution Do NOT overfill How to check the coolant level Warning Always stop the engine and allow the pressurised system to cool before remov...

Страница 31: ...rs using a strap wrench turning the filter anti clockwise A 5 Clean the sealing faces and the threaded bosses of the oil filter header 6 Lightly lubricate the sealing ring of the new filters with engi...

Страница 32: ...solvent if necessary use compressed air to remove small particles from the gauze 3 Refit the plug filter A1 complete with a new sealing washer part number 036620 A2 and tighten to a torque of 70 Nm 5...

Страница 33: ...rviceable condition 2 When the filter reaches its contamination limit the red restriction indicator button will show At this point the filter element must be renewed see To change the filter element o...

Страница 34: ...own from the filter body and discard it 4 Clean the oil deposits from the filter container and the filter body 5 Fit the sealing retaining O ring A5 to the new filter element A6 6 Push the filter elem...

Страница 35: ...tion 2 When the filter reaches its contamination limit the restriction indicator will sense the change in manifold pressure and the middle section will change to red 3 At this point the air filter mus...

Страница 36: ...t the filter element A3 3 Clean any dust accumulation from inside the air filter body and the gas mixer A4 using a clean cloth If necessary remove the coupling hose A5 to give access 4 Fit a new filte...

Страница 37: ...ensor interface A2 2 Remove the oxygen sensor A3 from the turbocharger outlet 3 Fit the new oxygen sensor into the turbocharger outlet tighten it down to 25 Nm 18 lbf ft 4 Reconnect the multi pin plug...

Страница 38: ...3 Pull the combined ignition coil plug cap A3 out of the rocker cover 4 Remove the spark plug B Note Store the spark plugs in their cylinder order as the combustion deposits on the plugs will give a g...

Страница 39: ...centre and ground electrodes of the spark plug are tipped with a hard surface which must not be filed or cleaned using abrasive paper 4 Every time a spark plug is refitted the sealing washer A3 must...

Страница 40: ...g B6 7 To rotate the engine to the positions required for this procedure fit the engine cranking device to the spare starter motor mounting in the flywheel housing C 8 Using a socket and ratchet wrenc...

Страница 41: ...from the front of the engine the crankshaft damper turbocharger end T D C Top Dead Centre Valves rocking on cylinder No Set bridge piece and valve clearance on cylinder No A1 A8 A8 A1 B1 B8 B8 B1 A3...

Страница 42: ...exhaust rockers have clearance on the bridge piece 2 Loosen the locknut on the bridge piece A1 3 Screw the adjuster A2 out until the fixed side of the bridge piece rests on its valve 4 Hold the top ed...

Страница 43: ...and bridge piece 4 Screw the adjuster A3 up or down making the feeler gauge a slide fit 5 Tighten the locknut to a torque of 50 Nm 35 lbf ft without moving the adjuster 6 Refit the spark plug cover tu...

Страница 44: ...tainers 2 The clearance between the legs and valve spring retainers indicates the valve life left A leg touching a valve spring retainer indicates the need for a cylinder head overhaul 3 To check the...

Страница 45: ...any of the above parameters are not met Perkins Engines Company Limited should be consulted for advice Gas safety regulations There are legal requirements that within the U K gas fittings and equipme...

Страница 46: ...eriod oil analysis will show higher levels of iron and copper than the acceptable contamination parameters marked in the list below As the engine continues to run the levels will drop within the speci...

Страница 47: ...of coolant Warning Always stop the engine and allow the pressurised system to cool before removing the filler cap Avoid skin contact with the coolant mixture The coolant mixture should be changed at 8...

Страница 48: ...This page is intentionally blank This document has been printed from SPI Not for Resale...

Страница 49: ...ce tools TIPSS EST To locate problems within the engine and its systems refer to the Diagnostic Manual TSL 4233 Caution Do not use mobile phones within 2 meters of the engine as the transmitted signal...

Страница 50: ...10 11 12 13 15 26 27 28 29 30 44 46 Misfire 7 8 9 13 15 26 27 28 29 30 High gas consumption 7 9 12 26 27 28 29 44 46 The engine knocks 13 20 26 27 29 30 32 33 38 The engine runs erratically 7 8 9 12 2...

Страница 51: ...in engine mounting or flywheel housing 21 Too much lubricating oil in sump 22 Restriction in air or coolant passages of radiator 23 Electric coolant pump failure 24 Restriction in breather 25 Insuffic...

Страница 52: ...on the engine 42 Spare 43 Restriction in sump strainer 44 Turbocharger impeller is damaged or dirty 45 Lubricating oil seal of turbocharger leaks 46 Faulty engine management system 47 Faulty sensor 48...

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