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Perkins 4012-46A User Manual

Perkins 4012-46A
78 pages
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SEBU8191-01
November 2011
Operation and
Maintenance
Manual
4012-46A Industrial Engine
S12
(Engine)

Table of Contents

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Perkins 4012-46A Specifications

General IconGeneral
Engine Model4012-46A
Number of Cylinders12
Speed1500 RPM
Lubrication SystemWet sump
Engine TypeDiesel
AspirationTurbocharged
Bore160 mm
Stroke190 mm
Fuel SystemElectronic Unit Injector (EUI)
Cooling SystemLiquid-cooled

Summary

Foreword

Literature Information

Explains the manual's content, importance of reading, and proper storage.

Safety

Directs users to the safety section for essential precautions and hazard identification.

Operation

Outlines basic operating techniques and procedures for efficient engine use.

Maintenance

Guides engine care, including service intervals and recommended procedures.

Safety Section

Safety Messages

Details warning signs, their meaning, and proper usage for hazard awareness.

General Hazard Information

Covers protective equipment, fluid hazards, pressure safety, and fluid penetration risks.

Burn Prevention

Warns about hazards associated with hot components, coolant, oils, and batteries.

Fire Prevention and Explosion Prevention

Discusses flammable materials, sparks, fire hazards, and safe refueling practices.

Crushing Prevention and Cutting Prevention

Addresses hazards from moving parts and safe handling of lines, tubes, and hoses.

Mounting and Dismounting

Provides safety guidelines for engine installation, removal, and safe access.

Before Starting Engine

Outlines essential safety checks and procedures before initiating engine startup.

Engine Starting

Details safe procedures and necessary precautions for starting the engine.

Engine Stopping

Covers standard and emergency procedures for safely stopping the engine.

Electrical System

Highlights safety precautions related to the engine's electrical system and wiring.

Engine Electronics

Contains safety warnings regarding tampering with engine electronic control systems.

Product Information Section

General Information

Provides an overview and specific procedures, such as welding on electronic systems.

Model Views

Introduces engine component identification through detailed illustrations.

Engine Description

Describes the engine model, its configuration, and aspiration type.

Engine Specifications

Lists key engine performance data, including bore, stroke, and configuration.

Engine Cooling and Lubrication

Explains the engine's cooling system components and the lubrication process.

Product Identification Information

Guides users on identifying engine models and serial numbers for parts.

Operation Section

Lifting and Storage

Provides guidelines for safely lifting and storing the engine and its components.

Features and Controls

Describes the engine's operational features, control systems, and sensor locations.

Engine Starting

Covers procedures and safety precautions for starting the engine, including cold weather.

Engine Operation

Provides guidance on efficient and economical engine operation and fuel conservation.

Engine Stopping

Covers standard and emergency procedures for safely stopping the engine.

Maintenance Section

Refill Capacities

Specifies fluid capacities for lubrication, cooling, and fuel systems.

Maintenance Interval Schedule

A comprehensive schedule of required maintenance tasks and their intervals.

Actuator Control Linkage - Lubricate

Instructions for lubricating the governor actuator linkages to ensure smooth operation.

Aftercooler Core - Clean/Test

Procedure for cleaning and testing the engine aftercooler core for optimal performance.

Aftercooler Core - Inspect

Guidelines for inspecting the aftercooler for damage, corrosion, and debris.

Alternator - Inspect

Procedure for inspecting the engine alternator and charging system for proper function.

Alternator Pulley - Check

Steps for checking the condition and tension of the alternator pulley and belt.

Battery - Replace

Instructions for safely replacing a vehicle battery, including disposal guidelines.

Battery Electrolyte Level - Check

How to check and maintain the correct electrolyte level in batteries for optimal performance.

Battery or Battery Cable - Disconnect

Safe procedures for disconnecting battery terminals and cables to prevent electrical hazards.

Belts - Inspect/Adjust/Replace (Fan Drive Belts)

Guide for inspecting, adjusting, and replacing fan drive belts for proper tension.

Belts - Inspect/Adjust/Replace (Alternator Belt)

Guide for inspecting, adjusting, and replacing the alternator belt.

Cooling System Coolant (ELC) - Change

Procedures for changing the Extended Life Coolant (ELC) in the cooling system.

Cooling System Coolant - Change (Inhibitor)

Guidelines for changing coolant with inhibitors, including system cleaning.

Cooling System Coolant Level - Check

How to properly check the engine coolant level and inspect the filler cap.

Driven Equipment - Check

Maintenance recommendations for connected driven equipment as per OEM specifications.

Engine - Clean

Procedures and benefits of cleaning the engine to improve maintenance and heat transfer.

Engine Air Cleaner Element - Replace

Steps for replacing the engine air filter element to prevent engine damage.

Engine Air Cleaner Service Indicator - Inspect

How to check and reset the air cleaner service indicator for timely filter replacement.

Engine Crankcase Breather - Clean

Instructions for cleaning the engine crankcase breather to ensure proper ventilation.

Engine Mounts - Inspect

How to inspect engine mounts for wear, misalignment, and vibration issues.

Engine Oil Filter (Auxiliary) - Change

Procedure for changing auxiliary engine oil filters, referring to oil sampling.

Engine Oil Level - Check

How to check and maintain the engine oil level within the recommended range.

Engine Oil Pump - Inspect

Procedure for inspecting the engine oil pump for wear and potential damage.

Engine Oil Sample - Obtain

Guidelines for collecting engine oil samples for analysis to monitor condition.

Engine Oil and Filter - Change

Comprehensive guide for changing engine oil and filters, including draining procedures.

Engine Protective Devices - Check

Procedures for testing engine safety systems, alarms, and shutdown devices.

Engine Valve Lash - Inspect/Adjust (Valves and Valve Bridges)

Instructions for inspecting and adjusting engine valve lash for optimal performance.

Fuel Injector - Inspect/Adjust

Procedures for inspecting and adjusting fuel injectors for engine efficiency.

Fuel System - Prime

Steps to purge air from the fuel system before starting the engine.

Fuel System Filter - Replace

Procedure for replacing the fuel system filter to ensure clean fuel supply.

Fuel System Primary Filter/Water Separator - Drain

How to drain the primary fuel filter and water separator to remove contaminants.

Fuel Tank Water and Sediment - Drain

Procedure for draining water and sediment from the fuel tank to maintain fuel quality.

Fuel Tank

Information on fuel quality, water contamination, and maintenance of fuel tanks.

Fuel Transfer Pump (Lift Pump) - Inspect

How to inspect the fuel transfer pump for leaks and proper operation.

Governor Actuator - Check

Procedures for checking and calibrating the governor actuator for correct control.

Hoses and Clamps - Inspect/Replace

Guidelines for inspecting and replacing fuel system hoses and clamps to prevent leaks.

Overhaul (Major)

Covers major engine overhauls, scheduling factors, and component inspection.

Overhaul (Top End)

Focuses on servicing engine cylinder heads, pistons, and related parts.

Severe Service Application - Check

Identifies conditions of severe service and required checks for engine reliability.

Speed Sensor - Clean/Inspect (Engine Speed Sensor and Overspeed Sensor)

Instructions for cleaning and inspecting speed and overspeed sensors for accurate signals.

Starting Motor - Inspect

Guidelines for inspecting the engine starting motor to ensure reliable starting.

Turbocharger - Inspect

Procedures for inspecting the turbocharger for damage and proper operation.

Walk-Around Inspection

Daily pre-operation checks to ensure the engine is in good condition.

Water Pump - Inspect

How to inspect the water pump for leaks and proper function to prevent overheating.

Warranty Section

Warranty Information

General information regarding engine warranties and coverage.

Emissions Warranty Information

Details on coverage for engine emissions compliance and certification.

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