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Perkins 400 Series User Handbook
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T
S
L4186E, Issue 1
February 1998
User’s
H
andbook
4000 Series
Diesel
4016 TAG1
4016 TAG2
2
Table of Contents
Table of Contents
5
Brief Description of the 4012/16 Series Diesel Engines
8
Safety
9
General Information
9
Engine Lift Equipment
9
Asbestos Joints
9
Dangers from Used Engine Oils
9
Environmental Protection
10
Viton Seals
10
Diesel Engine Data
11
Typical Cooling System Data
12
Fuel System Data
12
Governors Data
12
Exhaust System Data
13
Flywheel Data
13
Lubrication System Data
13
Induction System Data
13
Typical Dry Weight
14
Holding down Bolt Holes
14
Electrical System Data
14
Protection Equipment Data
15
Air Starting Data
15
Instrument Panel (Engine Mounted) Data
15
Coolant Jacket Heating Data
15
Torque Settings
16
General Torque Loadings
18
Viscosity of Oil
19
Oil Change Periods
19
Quantity of Oil
19
Lubricating Oil Recommendations
19
Engine Operation and Lubrication
20
Approved Industrial Oil A1 Specifications BSEN 590
20
Engine Cooling System
21
Water Quality
21
Additives to Water
21
Maintenance of Coolant
21
Engine Fuels Information
22
Fuel Specification
22
Preparing for Initial Start
23
Filling the Engine with Oil
23
Priming the Turbochargers on Engines Fitted with the Electronic Governor
23
Operating Instructions
23
Priming the Turbochargers on Engines Fitted with a Woodward Type EG10 or 3161 Hydraulic Governor
24
Priming the Turbochargers on Engines Fitted with Regulateurs Europa or Hydraulic Governors
24
Batteries (Supplied Dry Charged)
25
Priming and Venting the Fuel System as Fitted on the Earlier 12 & 16 Cylinder Engines
26
Filling the Cooling Systems
27
Priming and Venting the Fuel System as Fitted on Later 12 & 16 Cylinder Engines
27
Earlier Engines Not Fitted with an Engine Stop Lever
28
Initial Starting of the Engine When Fitted with the Electronic Governod
28
Later Engines Fitted with an Engine Stop Lever
28
Initial Starting of the Engine When Fitted with the Regulateurs Europa 2100 Hydraulic Governor
29
Normal Starting Procedure
30
Engine Shutdown
31
Light Load Operation and Standby Generating Sets
32
Instrument Panel (Engine Mounted)
33
Ammeter (Ampere)
34
Engine Oil Pressure Gauge (Pounds Per Square Inch/Kilopascal X 100)
34
Engine Oil Temperature Gauge
34
Engine Water Temperature Gauge (Fahrenheit/Centigrade)
34
Instrument Panel
34
Engine Tachometer and Hour Counter
35
Key Switch (3 Position) (Off/Run/Start)
35
Fuse Holder
35
Exhaust Temperature Gauge (Optional)
36
Air Filter Maintenance
39
Maintenance Schedule and Checklists
39
Coolant Level
39
Daily Inspection/Lubricating Oil Level
39
Daily Inspection
41
Draining the Water Trap/Sedimenter (Where Fitted)
41
After 50 Hours Only - Fenner Taper Lock Bushes
41
After First 100 Hours - New or Rebuilt Engines
41
Every 250 Hours or 6 Months - Centrifugal Oil Filter
42
Every 250 Hours or 6 Months - Alternator Drive Belt
43
Maintenance of Cooling System
43
Fan Belts Maintenance
43
Every 250 Hours or 6 Months - Bearing and Belts (Covrad Radiator)
44
Fan Bearings and Belts (Bearward Radiator) Maintenance
44
Every 250 Hours or 6 Months - Crankcase Breather, Earlier Engines (Radiator Cooled)
45
Every 250 Hours or 6 Months - Crankcase Breather (Heat Exchanger Cooled Engines)
46
Every 250 Hours or 6 Months - Crankcase Breather (Radiator or Heat Latest Exchanger Cooled Engines)
47
Every 250 Hours or 6 Months - Close Circuit Breather System
48
Every 250 Hours or Every 6 Months
49
Every 250 Hours or Every 6 Months - Changing Engine Oil and Oil Filters
50
Changing the Optional Changeover Lubricants Oil Filters
50
Every 250 Hours or 6 Months - Changing the Filter Elements When the Engine Is Stopped
51
Every 250 Hours or 6 Months - Changing the Change over Filter Elements Without Stopping the Engine
52
Every 250 Hours or 6 Months - Changing Fuel Filter Elements
53
Horizontal Fuel Filter (Early Engines)
53
Fuel Filter and Water Separator (4012 Engines Only)
53
Strainer (4016 Engines Only)
53
Fuel Supply and Priming Circuits Maintenance
54
Hand Priming Pump (Optional)
54
Cleaning Water Trap/Sedimenter (Where Fitted)
54
Every 250 Hours or 6 Months - Changing the Change over Fuel Filter Elements
54
Every 250 Hours or 6 Months - Equalise Rocker Bridges and Setting Valve Clearances
55
Resetting the Valve Clearances with Engine Cold
58
Linkage from the Governor to the Control Shafts
58
Overhaul Periods
59
Cylinder Head
59
Valve Guides
59
Valves
59
Valve Seat Inserts
60
Valve Springs
60
Rockers and Rocker Bridges
60
First Major Overhaul
60
Schedule for Engines in Stand-By Duty
61
Preventive Maintenance
61
Schedule for Engines in Continuous Duty
62
4012/4016 Engine Fault Tracing
63
4012 Starting Circuit, Single Starter with Repeater Relay (Early Engines)
64
4012/16 Staring Circuit, Starters and Twin Start Relays (Early Engines)
65
4012/16 Wiring Diagram, Starter, Electronic Governor (Early Engines)
66
4012/16 Wiring Diagram, Twin Starters and Relays, Electronic Governor (Early Engines)
67
4012/16 Wiring Diagram, Single Starter and Hydraulic Governor (Early Engines)
68
4012/16 Wiring Diagram, Twin Starters, Single Start Relay, Original Air Shut off Valves
69
4012/16 Wiring Diagram, Twin Starters, Single Start Relay, Electronic Governor (Later Engines)
70
4012/16 Wiring Diagram, Twin Starters, Electronic Governor (Intermediate Engines)
71
4016 Wiring Diagram, Twin Starters, Electronic Governor (Intermediate Engines)
72
4012 Wiring Diagram Twin Starters and Electronic Governor (Current Engines)
73
4016 Wiring Diagram, Twin Starters and Electronic Governor (Current Engines)
74
California Proposition 65 Warning
75
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Perkins 400 Series Specifications
General
Configuration
Inline
Engine Type
Diesel
Aspiration
Turbocharged
Cooling System
Liquid-cooled
Emission Standards
Tier 4 Final, Stage V
Cylinders
4
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