400 Series Perkins

TSL4186E, Issue 1February 1998UsersHandbook4000 Series Diesel4016 TAG14016 TAG2 Downloaded from www.Manualslib.com manuals search engine 4012/16 Diesel, February 1997WARNINGREAD AND UNDERSTAND ALL SAFETY PRECAUTIONS ANDWARNINGS MENTIONED IN THIS MANUAL.IMPROPER OPERATION OR MAINTENANCE PROCEDURES COULDRESULT INA SERIOUS ACCIDENT ORDAMAGE TOTHEEQUIPMENTCAUSING INJURY OR DEATH.NON-COMPLIANCE WITH THESE INSTRUCTIONS AND THOSEINCLUDED IN THE INSTALLATION MANUAL TSL4068 MAYINVALIDATE THE WARRANTY OFFERED WITH THE ENGINE.MAKE QUITE CERTAIN THAT THE ENGINE CANNOT BE STARTED INANY WAY BEFORE UNDERTAKING ANY MAINTENANCE,PARTICULARLY IN THE CASE OF AUTOMATICALLY STARTINGGENERATING SETS.Downloaded from www.Manualslib.com manuals search engine INTRODUCTION4012/16 Diesel, February 1997 1The purpose of this Operators Handbook 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 readfully and completely understood prior to starting work.The information contained within this Operators Handbook is based on such information as was available atthe time of going to print. In line with Perkins Engines (Stafford) Limited policy of continual development andimprovement that information may change at any time without notice. The engine user should therefore ensurethat he has the latest information before starting work.The instructions contained in this Operators Handbook will, provided that they are correctly carried out, ensurethe safe operation of the equipment.Users are respectfully advised that it is their responsibility to employ competent persons to operate, maintainand service the equipment in the interest of safety.Certain overhaul operations are impracticable without the use of special tools, and those operators who arenot 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 toprevent 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 typeand 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 shouldbe 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 March1996. A table of equivalent engine designations is given on page 2.PERKINS COMPANIESPerkins Group of CompaniesPerkins Engines (Peterborough) Ltd.Frank Perkins Way, Eastfield,Peterborough, PE1 5NA, England.Tel: (01733) 67474Telex: 32501 PERKEN GFax: (01733) 582240Perkins Engines (Shrewsbury) Ltd.Lancaster Road, Shrewsbury,SY1 3NX, England.Tel: (01743) 212000Telex: 35171/2 PESL GFax: (01743) 212700Perkins Engines (Stafford) Ltd.Tixall Road, Stafford, ST16 3UB, England.Tel: (01785) 223141Telex: 36156 PERKEN GFax: (01785) 215110Perkins Powerpart Distribution CentreFrank Perkins Way,Northbank Industrial Park, Irlam,Manchester, M44 5PP, England.Tel: (0161) 776 5000Specifications Help DeskTel: (0161) 776 5151Fax: (0161) 776 5200Specifications Help DeskTel: (0161) 776 5100Telex: 32501 PERKEN GPerkins International - North America12025 Tech Center Drive,Livonia, Michigan 48150,U.S.A.Tel: 313 266 5427Fax: 313 266 2700Perkins Engines Latin America Inc999 Ponce de Leon Boulevard,Suite 710, Coral Gables,Florida 33134, U.S.A.Tel: (305) 442 7413Telex: 32501 PERKEN GFax: (305) 442 7419Perkins Engines Australia Pty LtdSuite 2, 364 Main Street, Mornington3391, Victoria, Australia.Tel: (059) 75 1877Telex: 30816Fax: (059) 75 1305Motori Perkins SpAVia Socrate. 8,22070 CasnateCon Bernate (Como), Italy.Tel: 031 56 46 25 / 031 56 46 33Telex: 380658 PERKIT IFax: 031 24 90 92 / 031 56 41 45Perkins Motoren GmbHD-63801 Kleinostheim,Saalackerstrasse 4, Germany.Tel: (49) (6027) 5010Fax: (49) (6027) 501130Moteurs Perkins SA9 Avenue Michelet, 93583 Saint Quen,Cedex, France.Tel: (1) 40 10 71 / (1) 40 10 42 49Telex: 234 924Fax: (1) 40 10 42 45A/S Perkins Engines (Denmark) LtdIndustrihaven 1, DK-3300Frederiksvaerk, Denmark.Tel: (45) 47 771055Fax: (45) 47 771981Perkins International Ltd.Varity Asia/PacificSuite 3301, Convention Plaza,1 Harbour Road, Wanchai,Hong Kong.Tel: 852 2588 1883Fax: 852 2827 2311Varity (Japan) K.K.5th Floor, Reinanzaka Building,14-2 Akasaka 1 - Chome,Minato-Ku Tokyo 107, Japan.Tel: (03) 3586 7377Telex: PERKOIL 12424823Fax: (03) 3582 1596Perkins Engines (Far East) Pte Ltd.39 Tuas Avenue 13,Singapore 638999.Tel: (65) 861 1318Fax: (65) 861 6252In addition to the above companies, there are Perkins distributors in most countries. Perkins Engines(Peterborough) Limited or one of the above companies can provide details.Publication TSL4186Published by the Technical Publications Department, Stafford. 1997 Perkins Engines (Stafford) Limited.Downloaded from www.Manualslib.com manuals search engine ENGINE DESIGNATIONS2 4012/16 Diesel, February 1997PERKINS ENGINES (STAFFORD)ENGINE DESIGNATIONS4000 SERIES AND SE SERIESEQUIVALENT TERMS4000 SERIES SE SERIES4012TWG 12SETCR4012TAG 12SETCR24012TAG1 12SETCA4012TA2 12SETCA14012TEG 12SETCA24012TEG2 12SETCW4016TWG 12SETCW24016TWG2 16SETCR4016TAG 16SETCR24016TAG1 16SETCA4016TAG2 16SETCA24016TEG 16SETCW4016TEG2 16SETCW2Downloaded from www.Manualslib.com manuals search engine CONTENTS4012/16 Diesel, February 1997 3PAGEINTRODUCTION 1-2CONTENTS 3SAFETY PRECAUTIONS INSERTPHOTOGRAPHS 6-7BRIEF DESCRIPTION OF THE 4012 & 4016 ENGINES 8GENERAL INFORMATION 9-10ENGINE DATA 11-15TORQUE SETTINGS 16-18LUBRICATING OIL 19-20COOLANT CORROSION INHIBITORS AND ANTI-FREEZE 21FUEL SPECIFICATION 22OPERATING INSTRUCTIONS 23-32PREPARATION FOR INITIAL START 23PRIMING THE TURBOCHARGERS 23-24BATTERIES 25PRIMING THE FUEL SYSTEM 26-27FILLING THE COOLING SYSTEM 27INITIAL STARTING OF THE ENGINE 28NORMAL STARTING PROCEDURE 30ENGINE SHUTDOWN 31LIGHT LOAD OPERATION AND STANDBY GENERATOR SETS 32INSTRUMENT PANEL 33-35EXHAUST TEMPERATURE GAUGE 36-38MAINTENANCE SCHEDULE AND CHECKLIST 39-60PREVENTIVE MAINTENANCE 61-62STANDBY DUTY CHECKLIST 61CONTINUOUS DUTY CHECKLIST 62FAULT TRACING 634012 STARTING CIRCUIT, SINGLE STARTER (EARLY ENGINES) 644012/16 STARTING CIRCUIT, STARTERS AND START RELAYS (EARLY ENGINES) 654012/16 WIRING DIAGRAM, STARTER, GOVERNOR (EARLY ENGINES) 664012/16 WIRING DIAGRAM, STARTERS & RELAYS, GOVERNOR (EARLY ENGINES) 674012/16 WIRING DIAGRAM, SINGLE STARTER, GOVERNOR (EARLY ENGINES) 684012/16 WIRING DIAGRAM, TWIN STARTERS, SINGLE START RELAY,ORIGINAL AIR SHUT OFF VALVES 694012/16 WIRING DIAGRAM, TWIN STARTERS, SINGLE START RELAY,ELECTRONIC GOVERNOR (LATER ENGINES) 704012/16 WIRING DIAGRAM, TWIN STARTERS, ELECTRONIC GOVENOR,(INTERMEDIATE ENGINES) 714016 WIRING DIAGRAM, TWIN STARTERS, ELECTRONIC GOVENOR(INTERMEDIATE ENGINES) 724012 WIRING DIAGRAM, TWIN STARTERS, ELECTRONIC GOVENOR(CURRENT ENGINES) 734016 WIRING DIAGRAM, TWIN STARTERS, ELECTRONIC GOVENOR(CURRENT ENGINES) 744012/16 SERIES LUBRICATION OIL DIAGRAM TP3154012/16TAG WATER CIRCULATION DIAGRAM TP3724012/16TWG WATER CIRCULATION DIAGRAM TP3734012/16TEG WATER CIRCULATION DIAGRAM TP3744012 SERIES FUEL SYSTEM DIAGRAM TP3214016 SERIES FUEL SYSTEM DIAGRAM TP375Downloaded from www.Manualslib.com manuals search engine PHOTOGRAPHS6 4012/16 Diesel, February 19974012 TAG4012 TAGDownloaded from www.Manualslib.com manuals search engine PHOTOGRAPHS4012/16 Diesel, February 1997 74016 TAG4016 TAGDownloaded from www.Manualslib.com manuals search engine BRIEF DESCRIPTION OF THE 4012/16 SERIES DIESEL ENGINES8 4012/16 Diesel, February 19974012TWG 12 cylinder "V" formdiesel engine, water cooled, turbocharged (twinturbochargers), jacket water cooledchargeair coolersandoil coolersinengine cooling circuit. Earlier engines with vertical air cleaners, later engineswith horizontal air cleaners.4012TWG2 Up rated version of the 4012TWG 12 cylinder "V" form diesel engine, watercooled, turbocharged(twinturbochargers) jacket water cooledchargeaircoolers in engine cooling circuit. Horizontal air cleaners.4012TAG 12 cylinder "V" formdiesel engine, water cooled, turbocharged (twinturbochargers), aircooled charge airintercoolerin radiator. Oilcoolersinengine cooling circuit. Earlier engines with vertical air cleaners, later engineswith horizontal air cleaners.4012TAG1 Up rated version of the 4012TAG 12 cylinder "V" form diesel engine, watercooled, turbocharged (twin turbochargers) air cooled charge air intercooler inradiator. Oil coolers in engine cooling circuit. Horizontal air cleaners.4012TAG2 Up rated version of the 4012TAG1 12 cylinder "V" form diesel engine, watercooled, turbocharged (twin turbochargers), air cooled charge air intercooler inradiator. Oil coolers in engine cooling circuit. Horizontal air cleaners.4012TEG 12 cylinder "V" formdiesel engine, water cooled, turbocharged (twinturbochargers), raw water cooled charge air coolers with raw water pump andseparate cooling circuit. Oil coolers in engine cooling circuit. Earlier engineswith vertical air cleaners, later engines with horizontal air cleaners.4012TEG2 12 cylinder "V" formdiesel engine, water cooled, turbocharged (twinturbochargers), raw water cooled charge air coolers with raw water pump andseparate cooling circuit. Oil coolers in engine cooling circuit. Horizontal aircleaners.4016TWG 16 cylinder "V" formdiesel engine, water cooled, turbocharged (twinturbochargers), jacket water cooledair coolersandoil coolersinenginecooling circuit. Horizontal air cleaners.4016TWG2 Up rated version of the 4016TWG 16 cylinder "V" form diesel engine, watercooled, turbocharged(fourturbochargers), jacket watercooledchargeaircoolers and oil coolers in engine cooling circuit. Horizontal air cleaners.4016TAG 16 cylinder "V" formdiesel engine, water cooled, turbocharged (twinturbochargers), aircooled charge airintercoolerin radiator. Oilcoolersinengine cooling circuit. Earlier engines with vertical air cleaners, later engineswith horizontal air cleaners.4016TAG1 Up rated version of the 4016TAG 16 cylinder "V" form diesel engine, watercooled, turbocharged (four turbochargers) air cooled charge air intercooler inradiator. Oil coolers in engine cooling circuit. Horizontal air cleaners.4016TAG2 Up rated version of the 4016TAG1 16 cylinder "V" form diesel engine, watercooled, turbocharged (four turbochargers) air cooled charge air intercooler inradiator. Oil coolers in engine cooling circuit. Horizontal air cleaners.4016TEG 16 cylinder "V" formdiesel engine, water cooled turbocharged (twinturbochargers) raw water cooled charge air coolers with raw water pump andseparate cooling circuit. Oil coolers in engine cooling circuit. Earlier engineswith vertical air cleaners, later engines with horizontal air cleaners.4016TEG1AND4016TEG2Uprated versions of the 4016TEG 16 cylinder "V" form diesel engine, watercooled, turbocharged(four turbochargers), rawwater cooledchargeaircoolerswithrawwater pumpandseparatecoolingcircuit. Oil coolersinengine cooling circuit. Horizontal air cleaners.Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION4012/16 Diesel, February 1997 9SAFETYEngine lift equipmentUse only the lift equipment which is designedfor the engine.Use lift equipment or obtain assistance to liftheavy engine components such as thecylinder block, cylinder head, flywheelhousing, crankshaft and flywheel.Checktheenginelift bracketsfor securitybefore the engine is lifted.Asbestos jointsSome joints and gaskets containcompressedasbestosfibresseeWarninglabel Fig. A in a rubber compound or in ametal outer cover. The'white' asbestos(Chrysotile) which is used is a safer type ofasbestos and the danger of damage tohealth is extremely small.Contact with asbestos particles normallyoccursat joint edgesor whereajoint isdamaged during removal, or where a joint isremoved by an abrasive method.To ensure that the risk is kept to a minimum,the procedures given below must befollowed when an engine which hasasbestos joints is dismantled or assembled. Work in an area with good ventilation. Do NOT smoke. Use a hand scraper to remove the joints- do NOT use a rotary wire brush. Ensure that the joint to be removed iswet with oil or water to contain any looseparticles. Spray all asbestos debris with water andplace it in a closed container which canbe sealed for safe disposal.Dangers from used engine oilsProlonged and repeated contact with mineraloilwill result in the removalof natural oilsfromthe skin, leading to dryness, irritationand dermatitis. The oil also containspotentially harmful contaminants which mayresult in skin cancer.Adequate means of skin protection andwashing facilities should be readily available.The following is a list of 'Health ProtectionPrecautions', suggested to minimise the riskof contamination.1 Avoid prolonged and repeated contactwith used engine oils.2 Wear protective clothing, includingimpervious 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 oilimpregnated footwear.6 First aid treatment should be obtainedimmediately for open cuts and wounds.7 Apply barrier creams before each periodof work to aid the removal of mineral oilfrom the skin.8 Wash with soap and hot water, oralternatively use a skin cleanser and anail brush, to ensure that all oil isremovedfromtheskin. Preparationscontaining lanolin willhelp replace thenatural skin oils which have beenremoved.9 DoNOTusepetrol, kerosene, dieselfuel, gasoil, thinnersor solvents forwashing the skin.10 If skin disorder appears, medical advicemust be taken.11 Degrease components before handlingif practicable.12 Where there is the possibility of a risk tothe eyes, goggles or a face shieldshould be worn. An eye wash facilityshould be readily available.Fig. ADownloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION4012/16 Diesel, February 1997 10Environmental protectionThere is legislation to protect theenvironment fromtheincorrect disposal ofusedlubricatingoil. Toensurethat theenvironment is protected, consult your LocalAuthority who can give advice.Viton sealsSome seals used in engines and incomponents fitted to engines are made fromViton.Viton is used by many manufacturers and isa safe materialunder normalconditions ofoperation.If Vitonisburned, aproduct of thisburntmaterial is an acid which is extremelydangerous. Never allow this burnt materialto come into contact with the skin or with theeyes.If it is necessary to come into contact withcomponents which have been burnt, ensurethat the precautions which follow are used: Ensure that the components havecooled. Use Neoprene gloves and discard thegloves safely after use. Wash the area with a calcium hydroxidesolution and then with clean water. Disposal of gloves and componentswhich are contaminated, must be inaccordance with local regulations.If there is contamination of the skin or eyes,washtheaffectedareawithacontinuoussupply of clean water or with acalciumhydroxide solution for 15-60 minutes. Obtainimmediate medical attention.Downloaded from www.Manualslib.com manuals search engine DIESEL ENGINE DATA4012/16 Diesel, February 1997 11For full technical data please refer to the Product Information Manual.Type: Water-cooled, turbocharged, charge cooled, industrial diesel engine.RANGE 4012 4016Cycle 4 stroke 4 strokeNo. of cylinders 12 16Configuration V-form V-formBore 160 mm 160 mmStroke 190 mm 190 mmTotal swept volume 45,84 litres 61,123 litresCompression ratio 13,6:1 13,6:1Rotation Anti-clockwise looking on flywheel endFiring order1A-6B-5A-2B-3A-4B-6A-1B-2A-5B-4A-3B1A-1B-3A-3B-7A-7B-5A-5B-8A-8B-6A-6B-2A-2B-4A-4BValve Timinginlet valve opens 60 BTDCinlet valve closes 46 ABDCexh valve opens 46 BBDCexh valve closes 60 ATDCCylinder numbering Cylinder 1 furthest from flywheelCylinders designated A are on the right hand side of the engine, when viewed from the fly-wheel end and cylindersdesignated B are on the left hand side of the engine.Valve Clearances exhaust 0,40 mm (0,016)(Engine cold) inlet 0,40 mm (0,016)Valve dia. (mm) inlet and exhaust 48 48(52 on 4012TAG1/2 AND 4016TAG1/2)Valve Timing See Workshop Manual Sections U4 and U5Injection Timing See engine nameplatePiston Speeds Engine r/min m/s (ft/min)1000 6,33 (1247)1200 7,60 (1496)1500 9,50 (1870)1800 11,40 (2244)Fig. BA BANKB BANKDownloaded from www.Manualslib.com manuals search engine DIESEL ENGINE DATA12 4012/16 Diesel, February 1997TYPICAL COOLING SYSTEM* Engine only** Engine with heat exchangerFUEL SYSTEMGOVERNORS4006 4008Approved Coolants) See page 21Total water capacity Ltrs Gals Spec Ltrs Gals Spec200 44 TAG 255 56.1 TAG232 51 TAG1 316 70 TAG1232 51 TAG2 316 70 TAG2185 40 TWG 95 21 TWG*205 45 TWG2 95 21 TWG2*82 18 TEG** 108 23.7 TEG**Max radiator top tank temperature 93CMax water temperature into engine 80CThermostat opening temperature 71CSystem pressure 0.5 to 0.7 bar4012 4016Approved fuels See page 20Minimum size fuel tank 14000 litres (3000 gal.) 18000 litres (4000 gal.)Relief valve setting 310 kPA (45 psi)Inferior nozzle pressure 225-235 atmInjection equipment Lucas-Bryce unit injectorFilter/water separator Spin-on expandable canister(s)Fuel lift pump Maximum suction lift 1 metreFuel flow 20.457 litre/min. (4.5 gpm) @ 1800 r/min4012 4016Type Electronic ElectronicType Hydraulic HydraulicDownloaded from www.Manualslib.com manuals search engine DIESEL ENGINE DATA4012/16 Diesel, February 1997 13LUBRICATION SYSTEMINDUCTION SYSTEMEXHAUST SYSTEMFLYWHEELFLYWHEEL HOUSING4012 4016Recommended oilSee pages 19 and 20Type of system Wet sump, external engine mounted oil pumpTotal oil capacity (including cooler and filter) 178 litre (39.2 gal) 238 litre (53 gal)Sump capacity (dipstick)Min. 136 litre (30 gal) 147 litre (33 gal)Max. 159 litre (35 gal) 214 litre (47 gal)Crankcase pressure (max) 25 mm (1) water gaugeLubricating oil temperature max. to bearings 105CLubricating oil pressure at 80C temp. to bearings 0.34 mPaMax. oil temperature in sump 115CMin. oil pressure (1500 rpm)(at filter head) 200 kPa (30 lb/in)Oil filter Disposable canister typeOil pump location A Bank4012 4016Air cleaners (earlier)(current)Twin vertical air cleanersTwin horizontal air cleanersType Paper elementAir restriction indicator setting 380 mm H20Turbochargers x2 off x4 off4012 4016Manifold Type Dry or water cooledExhaust outlet flange Vertical (Twin)Mating flangeSee Installation ManualMax. exhaust back pressureSee Product Information ManualMax. exhaust temperature4012 4016Drive size SAE 18SAE 21 Optional4012 4016SAE size 00Downloaded from www.Manualslib.com manuals search engine DIESEL ENGINE DATA14 4012/16 Diesel, February 1997TYPICAL DRY WEIGHTHOLDING DOWN BOLT HOLESELECTRICAL SYSTEM4012 4016Dry weight (engine) 4360 kg 4012TAG 5500 kg 4016TAG4360 kg 4012TAG1 5750 kg 4016TAG14400 kg 4012TAG2 5750 kg 4016TAG24975 kg 4012TWG 5940 kg 4016TWG/25315 kg 4012TWG2 5820 kg 4016TEG4680 kg 4012TEG2Dry weight engine & tropical radiator 5280 kg 4012TAG 6900 kg 4016TAG5760 kg 4012TAG1 8010 kg 4016TAG15800 kg 4012TAG2 8010 kg 4016TAG24995 kg 4012TWG5315 kg 4012TWG/2Dry weight engine & heat exchanger 4860 kg 4012TEG 6000 kg 4016TEG4012 4016Hole dia. (Engine feet) 22 mmNo. off 8Hole dia. (Radiator feet) 18 mm x 6 4012TAG 22 mm x 6 4016TAG/2Turbochargers 22 mm x 6 4012TAG222 mm x 6 4012TWG/14012 4016Voltage 24VAlternator Belt DrivenAlternator output 30AStarter motorSingle CAV(Earlier Engines)Twin Prestolite(Current Engines)Twin PrestoliteNo. of teeth (gear ring)144 (Early Engines)156 (Current Engines)156No. of teeth (starter pinion) 12Battery (lead acid) 24V DC (2 x 12V)Capacity down to 0C (32F) 286 AhDownloaded from www.Manualslib.com manuals search engine DIESEL ENGINE DATA4012/16 Diesel, February 1997 15PROTECTION EQUIPMENTBefore resetting protection equipment, it must be established whether special settings (forthat individual engine) have been specified in the engine sales contract. This is particularlyimportant with ALL high water temperature settings, and ALL Cogen applications.Standard settings for protection equipment are as follows:-Caution: The above standard settings do not supersede any settings specified in the enginesales contract.AIR STARTINGINSTRUMENT PANEL (ENGINE MOUNTED)COOLANT JACKET HEATINGAlarm ShutdownHigh Oil temperature (in sump) 110C 115CLow oil pressure 2.06 bar (30 lb/in) 1.93 bar (28 lb/in)High water temperature71C Thermostat 91C 96C85C Thermostat 96C 101C96C Thermostat 100C 105COverspeed15% above max. running speed(Except 1800 r/min which is 7%)4012 4016Air starterSee Installation ManualAir starter pressure 150 lb/in2(10.34 bar)Compressed air supply 170 lb/in2(11.72 bar)Normal OperationOil pressure Between 276-413 kPa (40-60 lb/in)Oil temperature Between 80-90C (176-194F)Water temperature Between 65-85C (149-185F)Exhaust temperatureSee Product Information Manual4012 4016Heater 2 x 4 kWVoltage 210-250V acDownloaded from www.Manualslib.com manuals search engine TORQUE SETTINGS16 4012/4016 Diesel, February 1997NOTE: * Bolt heads and threads must be lubricated with clean engine oil.** Cylinder head bolts to be lubricated under the heads, under the washers and onthe threads with PBC (Poly-Butyl-Cuprysil)grease. Important:See WorkshopManualSection R11 before fitting. However, dry threads are required for connecting rod bolts andthe raw water pump shaft nut, but all other threads only to be lubricated with clean engineoil and care must be taken NOT to oil the heads or faces.TORQUE SETTINGSCYLINDER HEAD GROUP lbf.ft NmCylinder head bolt ** (early type) M24 550 750Cylinder head bolt ** (later waisted type) M24 530 720Rocker shaft capscrew/nut M16 90 120Rocker adjuster nuts inlet/exhaust M12 35 50Rocker adjuster nuts pump injectors M14 50 70Injector clamp capscrews M12 70 95Bridge piece adjuster nuts M10 25 35Injector clamp to cylinder head capscrews M12 70 95Rocker box bolts M10 35 50Air manifold bolt M10 35 50Exhaust manifold bolts M10 50 70Exhaust bellows to exhaust manifold (16 cyl only)prevailing torque bolts / nuts M10 45 60Exhaust Y piece (16 cyl only) prevailing torque bolts M10 38 50Schwitzer turbocharger 'V'-band clamp nuts M8 8 11Sandwich plate retaining capscrews M10 35 50CRANKCASE AND CRANKSHAFT GROUPSMain bearing bolts * See Section W4 M24 580 786Lateral capscrews, main bearing caps for sequence M16 124 168Bolts sump to crankcase M10 40 54New connecting rod bolts (must be fitted with dry threads) M16 210 285Inspection covers M10 35 50Viscous damper bolts M16 250 340Flywheel bolts See Section X3 for sequence M16 250 340Front drive adaptor bolts(12 cylinder engines only) M16 250 340Front drive adaptor bolts(16 cylinder engines only) M20 380 520Balance weight bolts M16 250 340Crankshaft pulley bolts M16 250 340Piston cooling jet screws M10 20 27Flywheel housing bolts M10 35 50Lifting bracket Durlock screws M10 50 70WARNINGIT IS ESSENTIAL THAT THE CORRECT LENGTH OF SCREW ORBOLT IS USED. INSUFFICIENT LENGTHMAY RESULT IN THETHREAD BEING STRIPPED, WHEREAS TOO LONG A THREAD MAY RESULT INBOTTOMING IN A BLIND HOLE, OR CATCHING ON ADJACENT COMPONENTS.Downloaded from www.Manualslib.com manuals search engine TORQUE SETTINGS4012/4016 Diesel, February 1997 17LUBRICATING OIL PUMP lbf.ft NmBolts, pump housing to gearcase plate M10 35 50Thin nut, gear to drive shaft M30 175 237CAMSHAFT GROUPCamshaft gear bolt M12 110 150Camshaft thrust plate bolt M10 35 50Camshaft follower housing bolt M10 35 50Idler gear hub bolts M10 35 50WATER PUMPWater pump gear nut M24 170 230Water header to oil cooler bolts M10 35 50Water pump to gearcase bolts M10 35 50Raw water pump gear securing nut, dry thread M35 180 244ENGINE FEETEngine feet to base frame bolts M20 350 475Engine feet to cushion feet bolts M16 160 215Engine feet to gearcase and suspension plate bolt M12 70 95GOVERNORControl shaft mounting plate bolt M10 35 50FANFan driven pulley taper lock bush screws 1/2" BSW 35 50Fan driven pulley taper lock bush screws 5/8" BSW 65 90ALTERNATORDrive pulley taper lock bush screw 3/8" BSW 15 20FUEL PUMP/INJECTORSInjector capscrew clamp to cylinder head, early engines M10 50 70Injector capscrew clamp to cylinder head, later engines M12 70 95Injector nozzle nut to holder M27 150 203Fuel pump control linkage screw 2BA 6 8Unit injector control lever capscrews M5 6 8FLEXIBLE COUPLINGFlexible coupling cover screw M12 or 1/2" UNC 47 64Coupling driving flange screws (coupling size 2.15) M12 or 1/2" UNC 47 64Coupling driving flange screws (coupling size 3.86) M16 or 5/8" UNC 114 155Downloaded from www.Manualslib.com manuals search engine TORQUE SETTINGS18 4012/4016 Diesel, February 1997GENERAL TORQUE LOADINGSThe following torque loadings are general for metric coarse threads and for grade 8.8 steel,but do not supersede the figures quoted above.THREAD lbf ft NmM5 5 7M6 9 12M8 21 28M10 41 56M12 72 98M16 180 244M20 351 476M24 606 822GENERAL NOTE:M10 - 12.9 Steel 50 70TIGHTENING TORQUESThese are based on 85% of the proof loads designated in BS3692.Downloaded from www.Manualslib.com manuals search engine LUBRICATING OIL RECOMMENDATIONS4012/16 Diesel, February 1997 19QUANTITY OF OILTYPE OF OILThe industrial diesel engine should be lubricated with a good quality oil conforming to APICD or CCMC D4 specifications. All the major oil companies formulate oils to the abovespecifications.VISCOSITY OF OILUse oil of:SAE10W/30 in starting temperatures below -15C (without sump heater)SAE10W/40 in starting temperatures from -15C to 0CSAE30 in starting temperatures from 0C to 32C or Mobil Devlac SuperSAE40 in starting temperatures above 32C 1300 SAE 15W/40OIL CHANGE PERIODSFor normal operation of the engine the oil should be changed every 250 hours or annuallywhichever is the sooner.Under certain circumstances where a centrifugal oil filter is fitted to the engine and an oilanalysis programme has been carried out with the oil supplier over a period of 1000 hoursof engine operation, it may be possible to extend the oil change period up to maximum of350 hours.To achieve this extended oil change period, a centrifugal oil filter must be fitted and cleanedevery 250 hours between routine oil changes, and at every oil change point i.e. 350 hoursmaximum.As the oil deteriorates it is essential that the following parameters must not be exceeded atthe oil change point:1 The viscosity of the oil must not increase by more than 10cSt at 100C.2 The total base number of the oil should not reduce to less than 50% of the value of newoil.3 The flash point of the oil should exceed 180C.4 The water content of the oil must not exceed 1%.5 The fuel content of the oil must not exceed 1%.6 Oil samples should be taken from the mean sump oil level of the engine.Sump Capacity Dipstick 4012 4016Minimum 136 litre(30 gal) 147 litre (33 gal)Maximum 159 litre (35 gal) 214 litre (47 gal)Downloaded from www.Manualslib.com manuals search engine LUBRICATING OIL RECOMMENDATIONS20 4012/16 Diesel, February 1997ENGINE OPERATIONExcessive periods of idling or repeated cold starts should be avoided, as they will causeexcessive dilution of the oil by fuel, requiring more frequent oil changes and dangerouslylowering the flash point of the oil.Should there be a lubricating oil supply problem, or if the fuel being used contains more than0.5%sulphur, PerkinsEngines(Stafford) Limitedmust beconsultedtogiveadviceinselecting a suitable grade.The following list gives details of some of the oils that meet the required specifications. Notethat the brand names may change as oils are upgraded or reformulated.An up-to-date list is maintained by Perkins Engines (Stafford) Limited of major oil companiesproducts and information, which can be obtained from Perkins Engines (Stafford) ServiceDepartment.APPROVED INDUSTRIAL OIL A1 SPECIFICATIONS BSEN 590(Suitable for fuel to Class A2 specifications BS2869 Part 2).Oil Company TypeCASTROL CRH/RX SuperELF Multiperfo XCKUWAIT OIL Co Q8 T400MOBIL Delvac 13Delvac Super 1300 (15W/40)SHELL Rimula XESSO Essolube XD 3+TEXACO Ursa Super LAWARNINGFAILURE TO COMPLY WITH THESE INSTRUCTIONS WILLINVALIDATE THE WARRANTY OFFERED WITH THE ENGINE, ASIT MAY RESULT IN ENGINE DAMAGE.Downloaded from www.Manualslib.com manuals search engine COOLANT4012/16 Diesel, February 1997 21ENGINE COOLING SYSTEMThecoolingsystemof anenginecontainsmany different materials e.g. cast iron,aluminium, copper, solder, rubber(varioustypes). To prevent deterioration of thesematerials, it is essential to use a very goodquality coolant. Untreated water is notsuitable. It isessential that thewater istreated with an additive that gives thenecessary protection.WATER QUALITYThe water to be mixed with the additive musthave the following characteristics:Chlorides less than 80 PPMV(PPMV = parts per million by volume)Sulphates less than 80 PPMVTotal hardness less than 200 PPMVpH of water between 7 to 7.5(neutral to slightly alkaline)ADDITIVES TO WATERDue to the complexity of the cooling systemit is necessary to use an additive thatcontainsabalancedpackageof corrosioninhibitors.To achieve the required solution a 50/50 mixof Shell Safe Premium antifreeze with watershould be used at alltimes, even in areaswhere frost is unlikely.**The 50/50 mixture willgive frost protectiondown to -35C. In areas where Shell SafePremiumis not availablecontact PerkinsEngines(Stafford)Limitedforadviceonarecommended alternative.Under no circumstances should an additivecontaining nitrites, borates, phosphates,chromates, nitrates, or silicates be used, astheyarenot compatible withthe materialsused in the cooling system.When mixing the antifreeze with the wateralways follow the manufacturer'srecommendation to add the antifreeze in thecorrect proportion before introducing it intothe engine cooling system. Adding water toantifreeze can lead to the formation of a gelin the mixture, which can cause blockage ofthewater passagesandsubsequent localoverheating.MAINTENANCE OF COOLANTThe water/antifreeze mixture should beregularlyreplacedinoperatingenginesatleast once a year.In engines used for standby duty it isessential to maintainthewater/antifreezemixture at the correct alkalinity level i.e. thepH should not increase above 7.5. Ahydrometer only shows the proportionofethylene glycol, not the degree of corrosionprotection.4012TWG2onlytothisruleiswhentwosectionradiators areusedinconjunctionwith charge air coolers under tropicalconditions. It may be necessary to reducetheantifreezecontent of thecoolant from50%to10%toachieve anadequateheattransfer coefficient.WARNINGALWAYS STOP THEENGINE AND ALLOWTHE PRESSURISED SYSTEM TO COOLBEFORE REMOVING FILLER CAP.AVOID SKIN CONTACT WITHANTIFREEZE BY WEARING HAND, ETC.WARNINGFAILURETOFOLLOWTHE ABOVERECOMMENDATIONS MAY RESULT INDAMAGE TO THE ENGINE, AND WILLINVALIDATE THE ENGINE WARRANTY.Downloaded from www.Manualslib.com manuals search engine FUEL SPECIFICATION22 4012/16 Diesel, February 1997Fuel should be wholly hydrocarbon oil derived from petroleum, with which small quantitiesof additives may be incorporated for the improvement of ignition or other characteristics andshould conform to British Standard Specification 2869. Class A1 or A2.If fuels other than the above classes are considered, the operator must consult PerkinsEngines (Stafford) Limited, and ensure that a suitable grade of lubricating oil is used.BS2869 REQUIREMENTS FOR ENGINE FUELProperty Class A1 Class A2Viscosity, Kinematic at 40C, cSt *Min. 1.5 1.5Max. 5.0 5.5Cetane number, min. 50 45Carbon residue, Ramsbottom on 10% residue, % (m/m), max. 0.20 0.20Distillation, recovery at 350C, % (V/V), min. 56C 56CSulphur content, % (V/V), max. 0.05 0.05Sediment, % (m/m), max. 0.01 0.01Ash, %(m/m), max. 0.01 0.01Sulphur content, % (m/m), max. 0.30++ 0.50++Copper corrosion test, max. 1 1Cold filter plugging point C, max.Summer (March/September inclusive) -4 -4Winter (October/February inclusive) -15 -12* cSt = 1 mm/s.++ This limit is set in accordance with the legislative requirements for gas oil of the 'CouncilDirective (75/716/EEC of the European Economic Community) on the approximation of thelaws of Member States relating to the sulphur content of certain liquid fuels'.Incountrieswherethislegislationdoesnot apply, it ispermissibletorun4000Seriesengines on fuels with up to 1.0% sulphur. (See page 20 "Engine Operation").ENGINE FUELS1 The two classes of fuel specified in the table are marketed specifically as oil enginefuels. Class A1 is of higher quality and is intended primarily as an automotive dieselfuel, whilst Class A2 is intended as a general purpose diesel fuel. Classes A1 and A2are distillate grades and are so specified as to prevent the inclusion of residuum.2 The specifications for Classes A1 and A2 include limits for cold filter plugging pointchosen to cover seasonal requirements in the United Kingdom.3 Ignition quality is specified in terms of cetane number, but the calculated cetane indexis referred to as an alternative for routine purposes with fuels not containing ignitionimprover additives.NOTE: If local supply problems dictate that fuels which fall outside the above specificationare to be used, our Service Department must be consulted prior to use.Downloaded from www.Manualslib.com manuals search engine OPERATING INSTRUCTIONS4012/16 Diesel, February 1997 23PREPARING FOR INITIAL STARTFILLING THE ENGINE WITH OILRemovethedrainplugtoensurethat thesump is clean and empty. Refit and tightenthe plug. Remove the oil filler situated on theleft hand side of the crankcase, by rotatingtheT-bar anti-clockwise and pulling up (Fig.1). Fill the sump to the maximum mark onthe dipstick with the appropriate grade andquantity of oil (see page 19 & 20).NOTE:If the engine has been overhauledensurethat, withthegovernorinthestopposition, the pump injectorsareset in the'NO FUEL' position.PRIMING THE TURBOCHARGERS ONENGINES FITTED WITH THEELECTRONIC GOVERNORBefore starting the engine for the first time, orif it has stood idle for more than threemonths, theturbocharger bearingsshouldbe primed. To prime the turbocharger, theengineneedstobemotoredover onthestarter. In order that the engine does not runup to speed when operating the key switch(i.e. energising the stop solenoids) it will benecessary to hold the governor lever in thestop position (see Fig. 13) but ensure thatthe air shut-off valves have been manuallyset to the run position (see Fig. 12).Key(Fig. 2 & Fig. 3)1. Electronic plugWARNINGNEVER OPERATETHE ENGINE WHENTHE OIL LEVEL IS BELOW THEMINIMUM MARK OR ABOVE THEMAXIMUM. ALWAYS WEARPROTECTIVE GLOVES WHENHANDLING ENGINE OIL.Fig. 1Fig. 21Fig. 31Downloaded from www.Manualslib.com manuals search engine OPERATING INSTRUCTIONS24 4012/16 Diesel, February 1997For earlier enginesnot fittedwithastoplever, disconnect the battery leads andremove the electric plug from the governorby unscrewing the locking collar and pullingthe plug out of its socket. (See Fig. 2 & Fig.3).Operatethestartingcontrol or keyswitchand motor the engine over on the starter untilan oil pressure of approximately 40 kPa (5 lb/in) is indicated on the pressure gauge.Continue for a further 10 seconds to ensurethat the oil has reached the turbochargers,and stop the engine by releasing the startcontrol. Disconnect thebatteryleadsandreconnect the electric plug in the actuator.Reconnect the battery leads.PRIMING THE TURBOCHARGERS ONENGINES FITTEDWITHREGULATEURSEUROPA OR HYDRAULIC GOVERNORSLet the engine run without load for about 5minutes ensuring the lubricating oil hasreached the turbochargers.PRIMING THE TURBOCHARGERS ONENGINESFITTEDWITHAWOODWARDTYPE UG10 OR 3161 HYDRAULICGOVERNORNOTE: It is recommendedthat for initialstarting of new or overhauled engines, thattheloadisdisengaged, withthegovernorspeed control leverin the minimumspeedposition, the shutdown solenoid in the STOPposition and the air shut-off valves manuallyset to the run position (see Fig. 4 and Fig.11).Checktheoil level bymeansof thesightgauge. If necessary, addnewSAE30orSAE15W/40 engine oil (after lifting the fillercap) to bring the oil up to the correct level(see Fig. 2). Ensure that the fuel supply tothe engine is turned off.Key(Fig. 4)1 Low speed stop2 Oil filler3 Compensation adjustment4 Oil drain plug5 Compensating needle valve6 High speed stop7 Oil level gaugeWith the speed control unit set in the idlingposition, (for generator dutythegovernorminimumandmaximumspeedstops arefactory set) ensure that the governor speedlever is in the minimum speed position. Turnthe key in the instrument panel from the stopposition to the start position and motor theengine over on the starter until the oilpressure gauge registers approximately 40kPa (5 lb/in). Continue cranking for a further10 seconds to ensure that the oil hasreached the turbochargers.WARNINGTHE OPERATORMUST BE IN A TOPRESS THE EMERGENCY STOPBUTTON IN THE EVENT OF APROTECTION EQUIPMENT FAILURE.Fig. 41234567Downloaded from www.Manualslib.com manuals search engine OPERATING INSTRUCTIONS4012/16 Diesel, February 1997 25BATTERIES (SUPPLIED DRY CHARGED)See Installation ManualCheck the level of electrolyte in each batterycell whichshouldbeapproximately8mmabove the plates. Using a hydrometer, checkthat the batteries are fully charged. A fullycharged battery will have a specific gravity of1.27 to 1.285, assuming the air temperatureis below 32C. For higher temperatures thespecific gravity will be 1.24 to 1.255. Whentoppingupthebatteriesalwaysusepuredistilled water and always replace the plugsafter filling.WARNINGHAND PROTECTIONMUST BE WORNWHEN CHECKING THE BATTERYELECTROLYTE. NEVER CHECK WITH ANAKED FLAME.WARNINGNEVER CONNECT ABATTERY INTO THESYSTEM WITHOUT FIRST CHECKINGTHE POLARITY AND VOLTAGE. NEVERDISCONNECT THE BATTERY WHILSTTHE ENGINE IS RUNNING. NEVERFLASH CONNECTIONS TO CHECK FORCURRENT FLOW.Downloaded from www.Manualslib.com manuals search engine OPERATING INSTRUCTIONS26 4012/16 Diesel, February 1997PRIMING AND VENTING THE FUELSYSTEMAS FITTED ON THE EARLIER 12& 16 CYLINDER ENGINES.Loosen the union nut on the fuel feed pipefrom the fuel filter, Fig. 5.Operate the priming pump by pressing therubber button Fig. 6. Continue priming untilair free fuel flows from the union. Re-tightenthe union nut.Then slacken off the vent plugs located atthe oppositeto flywheel end of 'A' and'B'bankfuel returnrails, Fig. 7 andcontinuepriming until air free fuel flows. Tighten thevent plugs.When priming a fuel systemfitted withchangeoverfuel filters, undotheleft handbleed screws 'L'(see Fig. 8). Operate thepriming pump by pressing the rubber button(see Fig. 6), until air free fuel flows from thebleed screws. Retighten the left bleedscrews 'L'. Repeat the above operation withthe right hand bleed screws 'R' until all fourfilters have been primed with fuel.Slacken off the vent plugs located at the frontend of both fuel return rails (see Fig. 7) andcontinuepriminguntil air freefuel flows.Retighten the vent plugs.Key(Fig. 6 & Fig. 7)1 Priming pump2 Strainer3 Vent plugFig. 5Fig. 612Fig. 73Fig. 8L L RRDownloaded from www.Manualslib.com manuals search engine OPERATING INSTRUCTIONS4012/16 Diesel, February 1997 27PRIMING AND VENTING THE FUELSYSTEM AS FITTED ON LATER 12 & 16CYLINDER ENGINESLoosen the union nut on the fuel feed pipe tothe front cylinder head on the fuel rail Fig. 9.NOTE: The fuel system should not be bledfrom the water trap/sedimenter filter (iffitted), since this is on the suction side of thelift pump. Fig. 10. However, it is important todrain the water from this unit periodically. Donot operate the priming pump but unscrewthe valve at the bottom of the filter about 4turnsuntil it dropsdownabout 25mm(1inch). Allow the water to drain out and thenscrew the valve back in until it is hand tight.Operate the priming pump by pressing therubber button Fig. 10. Continue priming untilair free fuel flows from the union. Re-tightenthe union nut.FILLING THE COOLING SYSTEMSThe use of non-inhibited water is notrecommended owing to chemicalreactionswhich can result in corrosion and furring-upof thecoolingsystem. Asolutionof eitheruniversal anti-freeze or corrosionpreventative and water must be used. Referto page 21.After installationandbeforethefirst startremove the radiator cap, see Fig. 11. Fill thecooling system and run the engine off-loadfor one minute to ensure that the system iscompletely filled. Stop the engine and top upthe system to within 25 mm (1") of the top ofthe filler neck then replace the cap. Shouldthe engine be fitted with water cooledexhaust manifolds, these will need bleeding.(Older engines without vent pipes only).(See Workshop Manual Section Q3).Key(Fig. 10 & Fig. 11)1 Normal fuel flow2 Priming circuit3 Water trap/sedimenter4 Drain valve - DONOT open whenengine running5 Radiator capWARNINGTHE COOLINGSYSTEM ISPRESSURISED - DO NOT REMOVE THEFILLER CAP FROM THE RADIATORWHILE THE ENGINE IS HOT. HANDPROTECTION MUST BE WORN.Fig. 9Fig. 101234Fig. 115Downloaded from www.Manualslib.com manuals search engine OPERATING INSTRUCTIONS28 4012/16 Diesel, February 1997INITIAL STARTING OF THE ENGINEWHEN FITTED WITH THE ELECTRONICGOVERNORWith the load disengaged, ensure that thestop control on engine/panel is in the 'stop'position, and that the air shut-off valves havebeen manually set to the 'run' position (seeFig. 12) typical installation.EARLIER ENGINES NOT FITTED WITHAN ENGINE STOP LEVERDisconnect the battery leads and remove theelectric plug from the Heinzmann actuator byunscrewing the locking collar and pulling theplug out of its socket.Press theemergency stopbutton tode-energise the stop solenoids, to prevent thegovernor levers moving into the 'run'position.Reconnect the battery leads.LATER ENGINES FITTED WITH ANENGINE STOP LEVERIn order to prevent the engine running up toits rated speed when operating the keyswitch, it will be necessary to hold the stoplever in the 'stop' position. Fig. 13.Key(Fig. 12 & Fig. 13)1 Closed (stop)2 Latched in (run)3 Governor lever4 Stop position5 Run position6 Solenoid energised7 Solenoid de-energisedWARNINGALWAYS BE IN APOSITION TOMANUALLY STOP THE ENGINE IN THEEVENT OF A MALFUNCTION BYOPERATING THE EMERGENCY STOPBUTTON.Fig. 1212Fig. 133 4675Downloaded from www.Manualslib.com manuals search engine OPERATING INSTRUCTIONS4012/16 Diesel, February 1997 29INITIAL STARTING OF THE ENGINEWHEN FITTED WITH THEREGULATEURS EUROPA 2100HYDRAULIC GOVERNORNOTE: It is recommendedthat for initialstarting of new or overhauled engines, anyautomatic starting or control systems are by-passed and the engine is controlledmanually with the load disengaged, but withtheairshut-off valvesmanuallyset tothe'run' position (see Fig. 12).Remove the filler plug from the top face ofthe governor and fill with oil to the line in thesight glass (see Fig. 14). Refer toWorkshop Manual, Section AA41 for thecorrect grade of oil. Replace the plug.Ensure that the fuel supply to the engine isturned off.Rotate the engine using the cranking device,as describedonpage55, inthecorrectdirectionof rotationfor tworevolutionstoensure that all working parts are free.Disengage or remove the cranking deviceimmediately after use.NOTE: When the engine is fitted with threestarter motorsi.e. twoelectricandmaybeone air starter then on early engines one ofthestarters may needtoberemovedtoenable the cranking device to be fitted.Theminimumandmaximumspeedstopsare factory set. Reduce the governor speedsetting by turning the hand wheel clockwiseuntil thereisnofurther movement of theoutput levers.Key(Fig. 14)1 Locknut2 Solenoid energised to stop3 Minimum speed stop screw4 Maximum speed stop screw5 Oil filler plug6 Hand control wheel7 Oil level sight glassEnsure the starting batteries are fullycharged. Energisetheshutdownsolenoid('stop'position) and motor the engine overonthestarteruntil theoil pressuregaugeregisters approximately 40kPa(5lb/in).Continue cranking for a further 10 seconds,to ensure that the oil has reached theturbochargers. Stop the engine by releasingthe start control and visually check theengine for fuel or oil leaks, rectifying wherenecessary. Turn on the fuel supply and bleedthe fuel system. Ensuring that the shutdownsolenoid is de-energised ('run' position)crank the engine on the starter. The engineshouldstart andrunuptotheminimumspeed setting. Increase the engine speed byturning the hand wheelanti-clockwise untilthere is no further movement of the outputlevers. Withtheenginerunninguptothemaximumspeedsetting, adjust thehandwheel to obtain the desired operating speed.Check the engine for fuel and oil leaks. Applyload.WARNINGUNDER NORMALCONDITIONSGENERATINGSETS MUST NOT BE RUNAT LESS THAN THEIR NORMALOPERATING SPEED. OPERATIONBELOW THIS SPEED WILL DAMAGETHE AUTOMATIC VOLTAGEREGULATOR (AVR) THEREFOREISOLATE THE AVR BEFORE REDUCINGTHE ENGINE SPEED.Fig. 142345671Downloaded from www.Manualslib.com manuals search engine OPERATING INSTRUCTIONS30 4012/16 Diesel, February 1997NORMAL STARTING PROCEDUREWHEN FITTED WITH THEREGULATEURS EUROPA 2100GOVERNOR AND A WOODWARD TYPEUG10 OR 3161Ensure that where possible the load is off.Set the engine switch to the 'run' position andpress the starter button, the engine shouldstart immediately and run up to full speed.If theenginedoesnot start withinafewseconds, do not keep the starter engaged,let the engine come to rest and begin again.Allow 15 seconds between start attempts. Ifthe engine fails to start after severalattempts, do not persist in motoring theengine but investigate the cause. Check oilpressure, for fuel and oil leaks and that theammeter in the instrument panel is showingchargetotheenginebatteries. Allowtheengine to run for 5 minutes. Checkinstruments are reading correctly. Applyload.NORMAL STARTING PROCEDUREWHEN FITTED WITH THE HEINZMANNE16AND WOODWARD PROACT IIELECTRONIC GOVERNOROperate the start control, which will energisethe solenoid and allow the governor lever tomove to the 'run' position Fig. 11, the engineshould then start immediately. Again checkthe oil pressure, for any fuel or oil leaks, andthat the ammeter in the instrument panel isshowing charge to the engine batteries.Allowtheenginetorunfor fiveminutes,checking that instruments are readingcorrectly. Apply load.Downloaded from www.Manualslib.com manuals search engine OPERATING INSTRUCTIONS4012/16 Diesel, February 1997 31ENGINE SHUTDOWNThe engine is normally stopped by operatingan electric stop control via a key switch. Inthis case it is only necessary to turn the keyin an anti-clockwise direction which de-energises thestopsolenoids tostoptheengine. The solenoids remain de-energiseduntil the engine is started up again.NOTE: For engines fitted with RegulateursEuropa2100, WoodwardUG10or 3161hydraulic governors, the 'stop' solenoids arebuilt into the governors and they areenergised to stop (ETS) the engine and de-energised shortly after the engine stops.Should the engine stop due to the air shut-offvalves being operated, it is imperative thatthe cause of the fault be investigatedimmediately.It is essential to allow the engine to run at noloadfor 3- 5minutesbeforestoppingtoallow the circulating lubricating oil to take theheat away from the bearings and shafts, etc.This is especially important withturbocharged engines where extremely hightemperatures are experienced within theturbocharger. Heat rise by suddenlystopping an engine on load can causeseizure of bearings and damage to oil seals.NOTE: Excessive idling of the engine willresult in only partial burning of the fuel,causing high carbon build-up on injectornozzles, valves, pistonrings, etc. Alsounburnt fuel will tend to wash thelubricatingoil fromcylinder boresanddilute the oil in the sump. This caneventually cause inefficient lubrication ofbearings and result in seizure.WARNINGDO NOT RUN THEENGINE AT LOWSPEEDS OR LOADS. IF THE ENGINE ISNOT BEING USED SHUT IT DOWN.Downloaded from www.Manualslib.com manuals search engine LIGHT LOAD OPERATION & STANDBY GENERATING SETS32 4012/16 Diesel, February 1997If an engine is operated on a load less than25-30%of its rated output, certain symptomswill be observed which may give cause forconcern.The usual results of this operation areheavier than normal lubricating oilconsumption, and oil leaks from the air andexhaust manifolds. This condition isparticularlyevident onstand-bygeneratorset applications where a weekly exercise onno load is the usual practice.These phenomena are due to the fact that:1 Turbocharger oil seals are not fullyeffective on light load which results in oilbeing delivered together with the air intothe engine air manifolds.2 The cylinder temperatures are too lowtoensure complete burning of all the fueldelivered. This results in an unsightlydrip from the exhaust manifoldjunctions. Afurther result is that ofabnormal carbon build-up on the valves,piston crowns and exhaust ports, thusthe normal service interval of 2500hours between top overhauls may haveto be reduced. Fuel dilution of thelubricating oil will also occur.To alleviate this condition the followingrecommendations are made:-1 Running on light load should be avoidedorreduced to the minimumperiod. Ifweekly exercising on no load is carriedout, the running period should be keptdowntosay, 10minutes, or until thebattery charging rate returns to normal.Periodically site load should be applied(min 25%) through the year.2 Every year the engine or generator setshould be run for four hours, to burn offaccumulations of carbon in the engineand exhaust system. This will requirethe use of a 'dummy load', whichshould be built up gradually from zero tothe maximum over a four hour run.On standby sets, air cleaner elementsshould be changed annually.Lubricatingoil andfuel filterelementsshouldbechangedeverysixmonths.The fuel pump injectors should bechecked every 2 years.Downloaded from www.Manualslib.com manuals search engine INSTRUMENT PANEL (ENGINE MOUNTED)4012/16 Diesel, February 1997 33DESCRIPTIONThe instrument panel is flexibly mounted on the engine (see Fig. 15). The basic enginemounted panel includes the instruments associated with the engine only, which show thereadings for the following conditions:1 Cooling water temperature 4 Battery charging rate 7 Fuse holder2 Lubricating oil temperature 5 Speed and hours run 8 Exhaust temperature3 Lubricating oil pressure 6 Keyswitch gauge (when fitted)Fig.15123 4867 1 2 3 5Downloaded from www.Manualslib.com manuals search engine INSTRUMENT PANEL34 4012/16 Diesel, February 19971 Engine water temperature gauge(Fahrenheit/Centigrade) Fig. 16The coolant temperature during normaloperationshouldbebetween65C-85C (149F - 185F). If the temperatureshouldriseabove93C(200F) foraprolonged period of time, stop theengine and investigate the cause. Theengine should, on the other hand, not berunat toolowatemperaturefor longperiods either.2 Engine oil temperature gauge(Fahrenheit/Centigrade) Fig. 17Thelubricatingoil temperatureshouldbe between 80C - 90C (176F -194F)whentheengineishot. If thetemperatureshouldriseabove115C(240F), stoptheengineimmediatelyand investigate the cause.3 Engine oil pressure gauge Fig. 18(poundsper squareinch/kiloPascal x100)Thelubricatingoil pressureshouldbebetween 276 - 413 kPa (40 - 60 lb/in2)when the engine is hot. If the pressureshould drop below 200 kPa (30 lb/in2) athigher engine speeds than idling, stopthe engine immediately and investigatethe cause.4 Ammeter (Ampere) Fig. 19The ammeter indicates at what chargingcurrent the battery is being charged bythe alternator, or to what extent currentistakenfromthebatterywithout thebattery being recharged.Fig. 16Fig. 17Fig.18Fig. 19Downloaded from www.Manualslib.com manuals search engine INSTRUMENT PANEL4012/16 Diesel, February 1997 355 Engine tachometer and hour counter(revolutions per minute x 1000 andhours) Fig. 20The electrically operated tachometer/hour counter showsthespeedof theengine in r/min. and the actual operatinghours the engine has run. Thetachometer/hour counter startsoperating from an alternator voltage of12 V onwards, which has already beenreached at engine idling speed.6 Key switch (3 position) (Off/run/start)The hand operated keyswitch withswitch lock is moved by a separate keytothepositionsshown, (seeFig. 21)viewed from front of switch.7 Fuse holderTo protect the instrument panel a 2 ampfuseis fittedtoremovethefuse(1)unscrew its holder (2) (see Fig. 21.1).Key(Fig. 21)1 Off2 Run3 StartFig. 20Fig. 21123Fig. 21.112Downloaded from www.Manualslib.com manuals search engine EXHAUST TEMPERATURE GAUGE (OPTIONAL)36 4012/16 Diesel, February 1997DESCRIPTIONAllexhaust temperature gauges are of thehigh accuracy type with digital LCD display,and are powered by the engine 24 voltsystem.Atwo-point gaugemaybefittedtotheseengines, measuring the exhausttemperature of both banks after theturbocharger (see Fig. 22, Fig. 23 and Fig24).NOTE: These gauges are wired with 'A' bankdefined as 'the left hand bank as viewed fromthe FRONT (free end) of the engine'.Key(Fig. 22)1 Red terminal2 Compensating cables3 Red terminal4 Locknuts5 Mounting bracket6 Exhaust temperature gauge7 Mounting bracket8 Nylon connector9 Armour braided cable10 Exhaust bend11 Thermocouple12 ProbeFig. 2212563 47 81112910Downloaded from www.Manualslib.com manuals search engine EXHAUST TEMPERATURE GAUGE (OPTIONAL)4012/16 Diesel, February 1997 37SPECIFICATIONTemperature range -20/+800CResolution 1CAccuracy + 0.5% F.S.D.Probe fitting 3/8" BSPTerminal size to suit 4BA eyelet connectorCable size 2 core 7 strand 0.1 mm dia.Type of cable Compensating type Ki.e. nickel/chrome ornickel/alumel to BritishStandard 4937 alternativelycopper/constantanSupply 24V DCor PP3 lithiumbattery(earlier engines)Key(Fig. 23)1 Pushbuttontoread(batterypoweredonly)2 Switch(Fig. 24)1 24V DC SupplyFig. 2312Fig. 241Downloaded from www.Manualslib.com manuals search engine EXHAUST TEMPERATURE GAUGE (OPTIONAL)38 4012/16 Diesel, February 1997A four point gauge may also be fitted whichmeasures the exhaust temperature of bothbanks before as well as after theturbocharger (see Fig. 25 and Fig. 26).NOTE: Thesegaugesarewiredwith'A'bank defined as 'the left hand bank asviewedfromtheFRONT(freeend) of theengine'.With both the above gauges, a thermocoupleis inserted into each exhaust at the point tobe measured, and is connected via armourbraided cable to a nylon terminal connector.TypeKcompensatingcablesareusedtoconnect the nylon terminal connector to thegauge. (see Fig. 22).Wiring is quite straightforward, with thepositive (red) terminal on the nylon terminalconnector, connectedtoitscorrespondingpositive(red) terminal at thebackof thegauge (see Figs. 22, 24 and 26).Key(Fig. 26)1 24V DC SuppyFig. 25Fig. 261Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 39Towards therear of thissectionaretwocheck sheets, one for continuous duty setsand one for standby duty sets, which are tobe used as a guide for operators andmaintenance personnel. The followingschedule details some of the maintenance tobe carried out as in the maintenance checklists. However, not all are detailed. In thesecases please refer to the WorkshopManual. TheSchedulewithinthissectionwill be perfectly suitable for an engineworking under average conditions. If yourengine is working under particularly arduous,dirty or dusty conditions, it will be necessaryto undertake more frequent servicing,particularly in respect of the lubricating oil,fuel systems and air cleaners. Correct andregular maintenance will help prolong the lifeof your engine.The periods referred to throughout thismaintenance section are true engine runninghours as indicated on the hour recorder fittedin the instrument panel.DAILY INSPECTIONLUBRICATING OIL LEVELWith the engine stopped for at least 5minuteswithdrawthedipstick, wipecleanand re-insert into the sump. After waiting 5 -10seconds for the oil level tostabilise,withdraw and check the oil level in relation tothe two marks on the dipstick. If the level isbelow the top mark, remove the oil filler capand add the correct grade of oil to bring thelevel up to the top mark. Always replace thefiller cap immediately replenishment iscompleted.COOLANT LEVELWith the engine stopped, remove radiatorcap; the coolant should be 25 mm (1") belowthe top of the filler neck. If the level is low topup with a solution of water and inhibitor orwater and anti-freeze similar to that alreadyin the engine. Refer to page 21.LEAKSVisually check the engine for fuel, oil, coolantand exhaust leaks, repairing wherenecessary.AIR FILTER MAINTENANCE(See Section A4 Maintenance Manual)The middle section of the restriction indicator'A' will remain clear while the air cleaner is ina serviceablecondition. When thefilterreaches its contamination limit the restrictionindicator willsense the change in manifoldpressure and middle section 'A' will changetored. At thispoint theairfiltermust bechanged. Whentheair filtershavebeenchanged reset the indicator by pressingbutton 'B'. (See Fig. 26.1). Check this signaldaily.WARNINGMAKE QUITECERTAIN THEENGINE CANNOT BE STARTEDBEFORE UNDERTAKING ANYMAINTENANCE, PARTICULARLY IN THECASE OF AUTOMATICALLY STARTINGGENERATING SETS.Fig. 26.1ABWARNINGTHE COOLINGSYSTEM ISPRESSURISED - DO NOT REMOVE THEFILLERCAPWHENTHEENGINEISHOT.HAND PROTECTION MUST BE WORN.Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS40 4012/16 Diesel, February 1997AIR FILTER MAINTENANCEGENERAL SERVICING INSTRUCTIONSServicing procedures include replacing thefilter element, cleaning the filter housing, andassuring that all piping and hoseconnections fromthe filter outlet to theturbocharger intake are sealed and airtight.(See Fig. 27).Key(Fig. 27)1 Mesh guard2 Element3 End cover4 Pre-cleaner (Cyclone unit) (Optional)WARNINGREPLACE ANYELEMENT WHICH ISDAMAGED. NEVER EXCEEDRECOMMENDED MAXIMUM. NEVERBLOW DIRT OUT OF THE FILTERHOUSING. THIS MAY INTROSUCEDUST INTO THE ENGINE. INSTEAD,USE A CLEAN, DAMP CLOTH. DO NOTOIL THE ELEMENT. ALWAYS USE EYEPROTECTION WHEN USINGCOMPRESSED AIR.WARNINGDISCONNECTBATTERIES OR ANYOTHER MEANS OF STARTING ENGINE.Fig. 271234Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 41DAILY INSPECTIONDRAINING THE WATER TRAP/SEDIMENTER (WHERE FITTED)There are no moving parts orelements toservice, however daily open the drain plug toremove collected water and sediment. Theplugisself retaining, unscrewuntil loose.Leave open until clean fuel is seen. Screwback in (see Fig. 28).AFTER FIRST 50 HOURS ONLYFENNER TAPER LOCK BUSHESMaintenance InstructionsExperience has shown that taper lockbushes, asfittedinthefanandalternatordriven pulleys, can work loose shortly afterbeing put into service. After a bush has beenrun for the first 50 hours, check the tightnessof the screws. Tighten the screws graduallyand alternately until tightened to the requiredtorque (see Torque Settings). Replace anyguards removed before running the engine(see Fig. 29).AFTER FIRST 100 HOURSNEW OR REBUILT ENGINESIt is essential to carry out the followingmaintenance procedure after the initial 100hours.Equalise bridge pieces and check valveclearances (see pages 55-58).EVERY 250 HOURS OR EVERY 6MONTHSENGINE OIL AND FILTERSChange engine oil and filter (see page 48).Equalise bridge pieces and check valveclearances (see pages 55-58).Key(Fig. 29)1 Locating screwWARNINGDISCONNECTBATTERIES OR ANYOTHER MEANS OF STARTING. ALWAYSWEAR PROTECTIVE GLOVES.Fig. 28Fig. 29Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS42 4012/16 Diesel, February 1997EVERY 250 HOURS OR 6 MONTHSCENTRIFUGAL OIL FILTER (IF FITTED)Stop the engine, and allow time for the oil todrain back to the sump. Refer to Fig. 30.1 Slacken safety clamp (1) unscrew covernut and lift off cover.2 Lift off rotor assembly (2) havingallowed oilto drain from nozzles. Therotor should be removed and replacedon the spindle withextreme care inorder toensurethat bearingsarenotdamaged.3 Secure rotor in dismantling tool T6253/292. Unscrewrotor cover nut (3) andseparate rotor cover from body.4 Remove standtube (4) using extractiontool T6253/293 and clean.5 Remove sludge from inside the rotor bymeans of aspatulaandwipeclean.Ensurethat all rotor componentsarethoroughly cleaned and free fromdeposits of dirt before reassembling therotor. Failure to do so could cause anout-of-balance condition which willaccelerate bearing spindle wear.6 Clean nozzle with brass wire. Examine'O'-ring (5) and renew if damaged.7 Reassemble rotor completely andtighten top nut.IMPORTANT:Ensurethat rotorcoverand rotor body are always matched bybalance reference number and pinlocation.DO NOT INTERCHANGE ROTORCOVERS.8 Examine spindle journals, if damaged orworn replace with body assemblycomplete.9 Reassemble filter completely, checkingthat rotor revolves freely, then replacefilter body cover. Tighten cover nut andsecuresafetyclamp. Theclampringshould be securely fitted at all times andthe filter should not be run without theclamp ring fitted.10 With engine running check all joints forleakage. Check for excessive vibration.See page 19 for oil change periods.WARNINGDISCONNECTBATTERIES OR ANYOTHER MEANS OF STARTING.ALWAYS WEAR PROTECTIVE GLOVES.Fig. 3021345Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS43 4012/16 Diesel, February 1997EVERY 250 HOURS OR EVERY 6MONTHSALTERNATOR DRIVE BELTRemove the smallmesh guard around thealternator. The toothed belt used to drive thealternator relies on tooth engagement totransmit load. It does not require pre-loading,however a slight initial tension to ensure thatthe belt fits snugly round the pulleys isdesirable. Using light pressure midwaybetween the two pulleys a total deflection of1.5 mm (1/16") is satisfactory (see Fig. 31).Refit the guard.Key(Fig. 31)1 Pulley guard2 Tensioning arm3 Drive guard4 Pivot bracket and boltMAINTENANCE OF COOLANTCOOLING SYSTEMCheck the specific gravity and the pH valueof the coolant (see page 25 of theWorkshop Manual). Visually check theradiator core for debris causing airrestriction.FAN BELTSFan belts should be checked for wear andcondition, particularly the following faults:a Small cracks on 'V'-belt side and base.Generally caused by lack of belt tensionbut excessive heat and/or chemicalfumes can also give same failure.b 'V'-belt swelling or softening.Caused by excessive contamination byoil, certain cutting fluids or rubbersolvent.c Whipping during running.Usually caused by incorrect tensioning,principallyonlong centredrives. If aslightlyhigher(orlower)tensiondoesnot cure the problem, there may be acritical vibration frequency in thesystem, which requires re-design or theuse of a banded belt.WARNINGDISCONNECTBATTERIES OR ANYOTHER MEANS OF STARTING THEENGINE.Fig. 31123Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 44EVERY 250 HOURS OR EVERY 6 MONTHSBEARINGS AND BELTS (COVRADRADIATOR)Removethemeshguardaroundthefanbelts, grease the fan bearings (2) and jockeypulley bearings (4) Fig. 32, using highmelting point lithium LM grease at greasingpoints (5).Check the tension and wear of the fan belts.Using moderate thumb pressure midwaybetweenthecrankshaft andfanpulley, atotal deflection of 12.5 mm (1/2") issatisfactory.If the fan belts are worn, the complete setshouldbereplacedandthefanpulleytocrankshaft pulley alignment checked.If adjustment isfoundnecessary, slackenthe two adjusting screws (3) and using a tubeextension(6) fittedover either thefanorjockey pulley adjusting tag (1), moveoutwards to tension the belts and inwards toslacken the belts. Having set the tension ofthebelts, tightentheadjustingscrews(3)and refit the fan belt guard.FAN BEARINGS AND BELTS(BEARWARD RADIATOR)Removethemeshguardaroundthefanbelts. The fan bearings (1) and jockey pulleybearings (2) do not need greasing as theseare of the pre-packed type.Check the tension and wear of the fan belts.Using moderate thumb pressure midwaybetween the crankshaft and fan pulley (1), atotal deflection of 12.5 mm (1/2") issatisfactory (see Fig. 33). If one or more fanbelts are faulty, a complete set mustalways be fitted, and the fan pulley tocrankshaft pulley alignment checked. Ifadjustment is found necessary slacken thelocking bolts (3) and adjust nut (4) either wayretighten locking bolts (3) and adjusting nut(4).WARNINGDISCONNECTBATTERIES OR ANYOTHER MEANS OFSTARTING THEENGINE.Fig. 321 23456Fig. 331234Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS45 4012/16 Diesel, February 1997EVERY 250 HOURS OR EVERY 6 MONTHSCRANKCASE BREATHER, EARLIERENGINES (RADIATOR COOLED)An extension pipe runs fromboth sides of theenginegearcasetotheenginebreathers,whicharemountedoneachsideof theradiator Fig. 34 and Fig. 35. Unscrew eachbreather by turning it anti-clockwise. Wash itthoroughly. Shake it as dry as possible,finally blow it dry with compressed air andscrew the breather firmly back into position.WARNINGDISCONNECTBATTERIES OR ANYOTHER MEANS OF STARTING. ALWAYSWEAR EYE PROTECTION ANDPROTECTIVE GLOVES WHENCLEANING BREATHER.Fig. 34Fig. 35Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 46EVERY 250 HOURS OR EVERY 6 MONTHSCRANKCASE BREATHER (HEATEXCHANGER COOLED ENGINES)Thecrankcasebreathersaremountedonthe side of each thermostat housing and areconnectedtotheengineviaanextensionpipeandbendfittedoneachsideof thegearcase (see Fig. 37). To clean a breather,unscrew the cap see Fig. 36 by turning anti-clockwise and wash it thoroughly. Shake itas dry as possible, blow dry withcompressed air and screw it firmly back intoposition.AS FITTED ON 4012 (EARLIER ENGINES)Fig. 36Fig. 37Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS47 4012/16 Diesel, February 1997EARLY 250 HOURS OR 6 MONTHSCRANKCASE BREATHER (RADIATOROR HEAT LATEST EXCHANGERCOOLED ENGINES)Thecrankcasebreathersaremountedonthe side of the thermostat housings and areconnectedtotheengineviaanextensionpipeandbendfittedoneachsideof thegearcase (see Fig. 39). To clean thebreather remove the top cover see Fig. 38and withdraw the two wire mesh elementsand wash thoroughly. Shake as dry aspossible, finallyblowdrywithanair line.Refit theelementsintothebreatherbody,and fit the top cover firmly back into position.NOTE: When replacing the cover check thesealing gasket is in good condition and thecover has located on its dowel.AS FITTED ON ALL 4016 ENGINES AND4012 (CURRENT ENGINES)Fig. 38Fig. 39Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 48EVERY 250 HOURS OR EVERY 6 MONTHSCLOSED CIRCUIT BREATHER SYSTEM(IF FITTED)The closed circuit separators are mountedjust behindthethermostat housingviaanexpansion pipe and hose bend which is fittedon each side of the gearcase and isconnectedtotheairinlet viathebreathervalve see Fig. 41.To clean the breather separator remove thecomplete unit fromthe engine remove thetopcover andwithdrawthefoamelement(see Fig. 40), check for oil saturation washthoroughly (with a suitable detergent), shakeas dry as possible and finally blow dry withcompressed air. Check the lower body forsludge contamination build up and clean asabove. Finally refit in reverse order.Fig. 40Fig. 41Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS49 4012/16 Diesel, February 1997EVERY 250 HOURS OR EVERY 6 MONTHSTwobreather valves aremountedinthecircuit. To remove release the pipe clips andpull away from the valve manifold. Wash thebreather thoroughly (with a suitabledetergent) paying particular attention to anydeposits on the internal area of the breather.Shake as dry as possible and blow dry withcompressed air.Beforerefittingensurethat thecupat thebase of the two breather valves are fullofclean engine oil (see Fig. 42).Key(Fig. 42)1 Breather valve2 Fill with clean engine oilFig. 4212Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 50EVERY 250 HOURS OR EVERY 6 MONTHSCHANGINGENGINEOILANDOILFILTERS(STANDARD HORIZONTAL TYPE)Withtheenginestopped, placeasuitablecontainer of at least 214 litres (47 gal)beneath the drain plug (which is situated onthe bottom edge of the sump directly underthedipstick). Removethedrainplugandallow the oil to drain. This operation is bestcarried out while the engine is still warm asthe thinner oil will drain more quickly. Whilethe oil is draining remove all three oil filtersper bank, two on the main header supplyingthe bearings and one on the single headersupplyingthepistonjets, byturningthemanti-clockwise with a strap wrench Fig. 43).NOTE: Removal of the oil filters will allowan escape of oil from the filter headers. It istherefore recommended that a suitablecontainer of at least 5 litres (1 gal) capacity ispositioned under each header prior to filterremoval as the oil filters are of the disposablecanister type they must be thrown away. Filltheoil filterswithcleanengineoil priortofitting. Wipecleanthesealingfacesandthreaded bosses of the header. Smearengine oil on the captive rubber sealing ringand carefully screw each new filter up to theoil header using firm hand pressure only.Having drained the engine oil, refit the drainplug and fill the engine with the appropriategradeofnewoil(seepages19 & 20) .Ensure that the switch on the control paneland fuel stop lever on the engine are both intheir respective 'stop' positions, and that theair shut-off valves have been manually set tothe 'run'position (see Fig. 2). Then motorthe engine over on the starter until apressure of approximately 40 kPa (5lb/in2) isindicated on the pressure gauge, thusensuring that the oilfilters are fulland theturbocharger bearings are primed (see page23).Check the dipstick and add more oil ifnecessary.CHANGING THE OPTIONAL CHANGE-OVER LUBRICATING OIL FILTERSThesespecial duplex filters arenormallyintended for use on long running engines, orwhereaservicingrequirement mayoccurwhen it is impossible to stop the engine tochange the filters. For this reason they arefitted with a three way change over valve inthe head, which enables the elements to bechanged, oneat atimewhilst theenginecontinues to run. They are normally mountedon the engine, but they may also be remotelymountedandconnectedtotheenginebymeans of flexible pipes.NOTE: If the flexible connections to the filterare removed for any reason, it is essentialthat they are reconnected correctly to avoidunfiltered oil getting into the engine. See Fig.44. Failure to change filters when due canalso lead to trouble from unfiltered oil.Alwaysfill areplacement filter withcleanengine oil before fitting.WARNINGDISCONNECTBATTERIES OR ANYOTHER MEANS OF STARTING. WEARPROTECTIVE GLOVES.Fig. 43WARNINGIT IS ESSENTIAL TOPRIME THE SYSTEMAFTER AN OIL AND FILTER CHANGE TOAVOID OIL STARVATION PROBLEMS,WITH AUTOMATICALLY STARTINGGENERATOR SETS, WHICH TAKE FULLLOAD IMMEDIATELY AFTER STARTING.Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS51 4012/16 Diesel, February 1997EVERY 250 HOURS OR 6 MONTHSCHANGING THE FILTER ELEMENTSWHEN THE ENGINE IS STOPPEDAll that is necessary is to unscrewthecanisters with a strap wrench as shown inFig. 44, without movingthechange-overvalve, as there is no pressure in the systemwhen the engine is stationary. The undersideof theheader isthenwipedclean, andasmear of clean oil applied to the sealing ringson the new canisters, before screwing themup by hand and tightening them by no morethan three quarters of a turn after the sealscontact the header. Check for leaks after theengine is restarted.Key(Fig. 44)1 Change right filter2 Normal running3 Change left filterEarly Engines (optional)Fig. 44123Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 52EVERY 250 HOURS OR 6 MONTHSCHANGING THE CHANGE OVER FILTERELEMENTS WITHOUT STOPPING THEENGINEIf the filters must be changed withoutstopping the engine. The normal position ofthe change-over valve is with the leg of the'T' mark pointing upwards, see Fig. 44 or 45,when both filter elements are in circuit.Turning the valve so that the leg of the 'T'points to the left puts the right hand filter outof service, so that it may be exchanged for anew one which should be filled with new oilbeforescrewingthecanister intopositionusing firm hand pressure only. Turning thevalve so that the leg of the 'T' points to theright puts the left hand filter out of service, sothat this one can now be exchanged for anew canister also primed with oil as before.Thevalveisthenreturnedtoits originalposition, so that both elements of the filterare back in service. Check for leaks beforeleaving the engine and increasing its speed.Later Engines (Optional)NOTE: Prepare for some spillage of oilaseach canister is removed, by placing a bowlof about 5 litres or 1 gallon capacity underthe filters.NOTE: If the pipes connecting the change-over oil filters to the engine are removed forany reason, it is essential that they bereconnected correctly to avoid unfiltered oilgetting into the system. See Fig. 44 or 45.Left hand side pipe (A) fitted to the oil coolerheader fits to the front of the oil filter header.Righthandsidepipe(B)fittedtotheoilcooler header fitstotherear of thefilterheader.Key(Fig. 45)1 Change right filter2 Normal running3 Change left filterFig. 45AB1 2 3Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS53 4012/16 Diesel, February 1997EVERY 250 HOURS OR EVERY 6 MONTHSCHANGING FUEL FILTER ELEMENTSNOTE: Ensure complete cleanliness isadhered to.HORIZONTAL FUEL FILTER (EARLYENGINES)First turn off the fuel on installations having anoverhead supply, drain the sediment trap orpre-fuel filter (if fitted) before filter removal.Remove the two fuel filters (one filter on eachbank) locatedat theoppositeendof theengine to the flywheel, by turning them anti-clockwise with a strap wrench Fig. 46.NOTE: Removalof the filters willallow anescape of fuel from the filter housings andpipes, it isthereforerecommendedthat asuitable container of at least 5 litres (1 gal)capacityispositionedundereachhousingprior to filter removal.As the fuel filters are of the non-serviceablecanister typetheymust bethrownaway.Wipe clean the sealing faces and threadedbosses of the housings. Smear clean engineoil onthecaptiverubber sealingringandcarefully screw the newcanisterup to thehousing using firm hand pressure only.Turn on the fuelsupply (if applicable)andvent the fuel system (refer to pages 25-26).the filters for leaks with the engine running.Key(Fig. 46)1 Oil filtersFUEL FILTER AND WATER SEPARATOR(FITTED TO 4012 ENGINES ONLY)First turn off the fuel supply, drain thesediment trap or pre-fuel filter (if fitted)before filter renewal. Remove the fuel filtercanister, which is located on the side of thegearcase, by unscrewing fromthe filterheader with a strap wrench (Fig. 47).STRAINER (FITTED TO 4016 ENGINESONLY)The screen inside the strainer body shouldberemovedfor cleaning(usingasuitablecleaningagent) at thesametimethat thefilter elements are replaced. To remove thescreen, unscrew the cap nut under the bodyand withdraw it, catching any spillage of fuelin a 5 litre (1 gal) container.WARNINGDISCONNECTBATTERIES OROTHER MEANS OF STARTING. ALWAYSWEAR PROTECTIVE GLOVESFig. 461Fig. 47Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 54EVERY 250 HOURS OR EVERY 6 MONTHSCHANGING THE CHANGE OVER FUELFILTER ELEMENTS WHEN THE ENGINEIS STOPPEDAll that is necessary is to unscrewthecanisters with a strap wrench as shown inFig. 48, leaving the change-over lever in thevertical position as there is no pressure in thefuel system with the engine stationary. Thereplacement canistersarescrewedonbyhand, after applying a smear of clean engineoil to the rubber seals, and tightening by firmhand pressure only. Bleed the air from thenewfiltersbyslackeningthevent screwsand operating the priming pump. Check forleaks when the engine is restarted.CHANGING THE CHANGE OVER FUELFILTER ELEMENTS WHEN THE ENGINEIS RUNNINGThe normal position of the change-overvalve lever is vertically upwards, when bothfilters are in circuit. Turning the lever to theleft, puts the right hand filter out of service,so that the right hand canister may beexchanged for a new one, smearing the sealwith clean engine oil and tightening by firmhand pressure only. Bleed the air from thenew filter by means of the vent screw as thelever is returned to the vertical position.Turning the lever so that it points the right,puts the left hand filter out of service so thatit can then be exchanged for a new one, asbefore. Again bleed the air from the new filteras the lever is returned to its normal verticalposition, so that both elements are back incircuit, andcheckforleaksbeforeleavingthe engine.NOTE: Prepare for some spillage of fuel byplacing a bowl of about 5 litres or 1 galloncapacity under the filter when changing thecapacities.CLEANINGWATERTRAP/SEDIMENTER(WHERE FITTED)Opendrainplug(1) toremovecollectedwater and sediment. The plug is selfretaining, leave open until clean fuel is seenthen screw back in see page 41. Removethebowl byunscrewingthreescrews(2).Cleanthoroughlyall componentsanddrywith compressed air. Replace joint washer ifdamaged.FUEL SUPPLY AND PRIMING CIRCUITSMAINTENANCE INSTRUCTIONSFUEL LIFT PUMPFor information on the lift pump see SectionKK1 of the Workshop Manual.HAND PRIMING PUMP (OPTIONAL)The pump requires no maintenance butshould it fail to operate a replacement unit isrequired.WARNINGDISCONNECTBATTERIES OR ANYOTHER MEANS OF STARTING.ALWAYS WEAR PROTECTIVE GLOVES.Fig. 481Fig. 48.121Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS55 4012/16 Diesel, February 1997EVERY 250 HOURS OR 6 MONTHSEQUALISE ROCKER BRIDGES ANDSETTING VALVE CLEARANCESNOTE: The bridge pieces must be set beforeattempting to set the valve clearances.Remove the 4 slot headed screws from eachrocker cover, lift off the covers and peel offand throw away the old gaskets Fig. 49.To set the valve clearances and bridgepieces the appropriate valves must berocking, use the table on page 56.NOTE:ForcylinderdesignationseeDataData on page 11.In order that the engine may be rotated whilethebatteriesaredisconnectedanenginerotating device can be fitted to a spare startermotor hole in the flywheel housing Fig. 50.This is fitted with a cover which is removedbyunscrewingtheretainingscrew. Thenusingasocket andratchet wrenchpressagainst the spring loaded bolt head until thepinion engages with the flywheelgear androtate the engine to the desired position byturning in the direction of the arrow. Whenthe engine is fitted with three starters, one ofthem may need to be removed to enable theabove device to be fitted.WARNINGDISCONNECTBATTERIES ANDOTHER MEANS OF STARTING THEENGINE.Fig. 49Fig. 50Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 56Engine 4012T.D.C.Valves Rocking onCylinder No.Set Bridge Piecesand Valve Clearanceson Cylinder no.A1 & A6 A6 A1B1 & B6 B1 B6A2 & A5 A2 A5B2 & B5 B5 B2A3 & A4 A4 A3B3 & B4 B3 B4A1 & A6 A1 A6B1 & B6 B6 B1A2 & A5 A5 A2B2 & B5 B2 B5A3 & A4 A3 A4B3 & B4 B4 B3Engine 4016T.D.C.Valves Rocking onCylinder No.Set Bridge Piecesand Valve Clearanceson Cylinder no.A1 & A8 A8 A1B1 & B8 B8 B1A3 & A6 A6 A3B3 & B6 B6 B3A7 & A2 A2 A7B7 & B2 B2 B7A5 & A4 A4 A5B5 & B4 B4 B5A1 & A8 A1 A8B1 & B8 B1 B8A3 & A6 A3 A6B3 & B6 B3 B6A7 & A2 A7 A2B7 & B2 B7 B2A5 & A4 A5 A4B5 & B4 B5 B4Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS57 4012/16 Diesel, February 1997EVERY 250 HOURS OR EVERY 6 MONTHSIf the valves required to be rocking areclosed, rotatethe engine one revolution,which will bring these valves to the rockingposition.The flywheel housing has an inspection holedirectlybelowthe'B' bankturbocharger(s)through which the flywheel markings may beseen toline upwith thepointerset intheflywheel housing Fig. 51.The flywheel is marked as follows:-4012 4016T.D.C. A1-A6 T.D.C. A1-A8A5-A2 A3-A6A3-A4 A7-A2B1-B6 A5-A4B5-B2 B1-B8B3-B4 B3-B6B7-B2B5-B4EQUALISING THE BRIDGE PIECESHavingrotatedtheenginetothecorrectposition see the table on page 56, check thatthe inlet and exhaust rockers to be adjustedhaveclearancebeforecontinuingwiththenext operation. Loosen the locknut on eachbridge piece adjuster, screw the adjuster outuntil the fixed side of the bridge piece restson its valve, hold the top edge of the bridgepiecedownwithonehandFig. 52, thenscrewtheadjuster downuntil youfeel ittouch the valve, thereby equalising valve lift.Tighten the lock nut without moving theadjuster.WARNINGDISCONNECTBATTERIES AND ALLOTHER MEANS OF STARTING THEENGINE.Fig. 51Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 58EVERY 250 HOURS OR EVERY 6 MONTHSE.g. to adjust valves and bridge pieces onNo. A1 cylinder set No. A6 cylinder valvesrocking for the 4012 engine and No. A8 forthe 4016 engine.RESETTING THE VALVE CLEARANCESWITH ENGINE COLDWithbothbridgepiecesequalised, checkand adjust the valve clearance using a 0.4mm(0.016") feeler gauge for both theexhaust andinlet valveset betweeneachrocker and bridge piece Fig. 53. If requiredscrew the adjuster until the rocker is bearinglightly on the feeler gauge. Tighten the locknut without moving the adjuster. (SeeTorqueSettingspage16).Thefeelergaugeshouldbeaslidefit betweentherocker and bridge piece, thereby giving thecorrect clearance. Refit therocker coverwith a new gasket.For further instructions on maintenanceplease refer to the Maintenance Section ofthe Workshop Manual.LINKAGE FROM THE GOVERNOR TOTHE CONTROL SHAFTSCheckthefreedomof operationof theseimportant linkages, whicharevital totheproper running of the engine.WARNINGFAILURE TOEQUALISE A BRIDGEPIECE MAY RESULT IN ENGINEDAMAGE. ALWAYS CHECK THAT THEPARTS FIT TOGETHER AND MOVEFREELY, BEFORE ASSEMBLY.WARNINGDISCONNECT THEBATTERIES AND ALLOTHER MEANS OF STARTING ENGINE.Fig. 52Fig. 53Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS59 4012/16 Diesel, February 1997OVERHAUL PERIODSThe intervals at which routine overhauls arerequired, to keep an engine in goodoperatingcondition, will varyconsiderablydependinguponoperatingconditions, thequality of lubricating oil and fuels used, andthe engine operating speed.The frequency required for top overhaul willdepend upon the condition of valveseats,and in the case of prolonged light loadoperation, the amount of carbonaccumulated around the valves and on thepiston crowns.A major influence on valve condition istappet clearance and the importance ofchecking tappet clearances every 250 hourscannot be overstressed.After the FIRST 2500 HOURS operation of anew engine it is good practice to remove theunit injectors and check their condition, carryout a compression test, and an endoscopic(borescope) examination of liner and valvecondition. If thereareanyproblems, thenremove TWO cylinder heads to assess thecondition of the valves, cylinder bores andfuel injectors.If all components are in good condition,clean the parts and reassemble the engineleaving the other cylinders alone.This inspection will enable maintenanceengineers to decide upon the requiredfrequency of top overhaul to suit theparticular application.EVERY 2500 HOURS (TOP OVERHAUL IFNECESSARY)A top overhaul may involve some or all of thefollowing operations depending upon thehoursrun, theengineapplicationandtheduty cycle.CYLINDER HEADNOTE: Serviceexchangecylinder headsare available.Remove the cylinder heads from the engineandremovetheinlet andexhaust valves.Soak the cylinder head in a carbon removingfluidor removeall deposits by useof ascraper and wire brush.Check for cracks especially between valveports and the injector hole. Check core plugsand replace if leaking or corroded.When handling, alwaysprotect the bottommachined face from accidental damage.Examine the injector tubes for leaks. Checkthe nozzle seating face.Prioro refitting the valves, wash the headthoroughly and blow off with compressed air.If new core plugs or injector tubes have beenfittedahydraulicpressuretest to6.9bar(100 lb/in) for leaks should be carried outusing hot water at 70-90C (158-194F) .VALVE GUIDESInspect the bores of the guides for wear andcheck the fit of a new valve. Check for pick-up or scoring. Replace if necessary.VALVESRemove carbon and scale by soaking in awater based solvent or by use of a scraperand wire brush. Polish with fine emery cloth.Examine the valve heads for cracks. Inspectvalve seats and true up by grinding to thecorrect angle if required. Check the valvestem tip for wear and reface by grinding ifnecessary. (To a maximum limit of 0.4 mm(0.015").Check the valve stems for wear or scoring.Check valve heads fordistortion by rollingthe stems on a surface table. Scrap any bentvalves. Replace any worn collets and valvespring retainers. Check valve protrusionafter refitting into head.WARNINGDISCONNECT THEBATTERIES AND ALLOTHER MEANS OF STARTING ENGINE.WARNINGWHEN USINGCOMPRESSED AIRALWAYS WEAR EYE PROTECTION.Downloaded from www.Manualslib.com manuals search engine MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 60EVERY 2500 HOURS OR 12 MONTHS IFNECESSARYVALVE SEAT INSERTSExamine the valve seats for pitting and wear.If necessary reface them using a planetarygrinderandthenhandlapthevalvesintotheir seats using grinding paste. In cases ofextremewear or burning, fit newinserts,(see Section R4 in the Workshop Manual).VALVE SPRINGSMeasurethefreelength. Comparewithanewspring(Seepage41inWorkshopManual ScheduleofWearandRenewalLimits). Reject any spring which may havea permanent set.Check the ends of the springs forsquareness.ROCKERS AND ROCKER BRIDGESInspect thebridgepiecesandtheir guidealso each rocker on its shaft forwear andreplace where necessary.INJECTOR TUBESThese do not require replacing unless theyare leaking.PISTONS AND LINERSUsing a blunt scraper, remove excessivecarbon from the piston crown and the linerflange face. Do not use emery cloth. Do notallow any carbon to find its way downbetween the piston and liner. Rotate theengine as required. Wipe the bores clean andlubricate before refitting the cylinder heads.EVERY 2500 HOURS OR 12 MONTHSCOOLING SYSTEMDrain off the coolant in the fresh watersystem using the drain plug fitted in the oilcoolerendcovers.Refillthesystemasdescribed on page 27.GENERAL ATTENTIONAlso carry out all checks and fit replacementparts as listed for each service period in theMaintenance Schedule.EVERY 12 MONTHS CHANGE THEWOODWARD GOVERNOR OILRemove the drain plug from the front of thegovernor whilst the engine is still warm andcollect the1/2gallon/ 2litresof oil inasuitable container. Refit the plug and refillwith a similar quantity of diesel fuel.Reconnect thebatteries, start theengineand run it at a low speed. Cycle the governorby opening the needle valve by two or threeturns. Let the governor hunt for a minute ortwo, thenstoptheengineanddrainthegovernor. Repeat this flushingoperationandthenreplacethediesel fuel withnewSAE30 or SAE15W/40 engine oil.Restart the engine and reset thecompensation adjustment and needle valvesetting. (See Sections AA54-AA75 in theWorkshop Manual for UG10 and 3161governors).FIRST MAJOR OVERHAULIf serviceschedulesareadheredtomajoroverhauls may not be required until 20,000hours of operation have been completed.The charge aircooler and heat exchangerwill alsoneedtobeinspectedat 10,000hours for internal cleaning of the inside andoutside of the tubes, and the maintenanceperiod determined for future overhauls.The FIRST assessment of engine conditionwill enablemaintenanceengineersto planthe time of major overhauls i.e. 10,000 and20,000 hours to be carried out at convenienttimes e.g. to coincidewith annualrefits orfactory shut-downs.The oil change intervals may be alteredaccording to operating experience over 1000hoursbyagreement withPerkinsEngines(Stafford) Limited and subject to oil analysesbeingcarriedout onaregular basis, seepages 19 & 20.WARNINGDISCONNECTBATTERIES AND ALLOTHER MEANS OF STARTING.ALWAYS WEAR PROTECTIVE GLOVESAND GOGGLES.Downloaded from www.Manualslib.com manuals search engine PREVENTIVE MAINTENANCE4012/16 Diesel, February 1997 61SCHEDULE FOR ENGINES IN STAND-BY DUTYFor engines which are in use for a total of less than 400 hours in every twelve months, theschedule below must be used:The preventive maintenance operations must be applied at the interval (hours or months)which occurs first.A MonthlyB 3 MonthsC Every 200 hours or 6 monthsD Every 1,000 hours or 12 monthsNOTE: All bolts, hose clips, terminal connections, pipes and joints must be checked fortightness and leaks every 3 months unless stated otherwise.* By a person who has had the correct training.A B C D Operation Check the amount of coolant Check the lubricating oil levelCheck the restriction indicators for the air filters and, whennecessary, renew the filter elementsStart and run the engine on lad until normal temperature ofoperation is reached Drain any water/sediment from the primary fuel filter Check the condition and the tension of all drive belts Check the specific gravity and the pH value of the coolant Renew the lubricating oil and filter Check radiator air