Perkins 4000 Series Vee-Form Gas 4012 and 4016 Series Engines USER’S HANDBOOK (1998)

INTRODUCTION

The purpose of this Manual 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 read

fully and completely understood prior to starting work.

The information contained within the manual is based on such information as was available at the time of going

to print. In line with Perkins Engines (Stafford) Limited policy of continual development and improvement that

information may change at any time without notice. The engine user should therefore ensure that he has the

latest information before starting work.

The instructions contained in this Manual will, provided that they are correctly carried out, ensure the safe

operation of the equipment.

Users are respectfully advised that it is their responsibility to employ competent persons to operate, maintain

and service the equipment in the interest of safety.

Certain overhaul operations are impracticable without the use of special tools, and those operators who are

not 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 to

prevent 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 type

and 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 should

be 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 March

1996. A table of equivalent engine designations is given on page 2.

PERKINS COMPANIES

Perkins Group of Companies

Perkins International - North America

Moteurs Perkins SA

Perkins Engines (Peterborough) Ltd.

12025 Tech Center Drive,

Parc de Reflets - Paris Nord II,

Frank Perkins Way, Eastfield,

Livonia, Michigan 48150,

165 Avenue du Bois de la Pie, BP 40064,

Peterborough, PE1 5NA, England.

U.S.A.

95913 Roissy CDG Cedex, France

Tel:

(01733) 583000

Tel:

313 266 5427

Tel:

00 33 149 90 71 72

Telex: 32501 PERKEN G

Fax: 313 266 2700

Fax: 00 33 149 90 71 90

Fax: (01733) 582240

Perkins Engines Latin America Inc

Perkins International Ltd.

Perkins Engines (Shrewsbury) Ltd.

999 Ponce de Leon Boulevard,

Varity Asia/Pacific

Lancaster Road, Shrewsbury,

Suite 710, Coral Gables,

Suite 3301, Convention Plaza,

SY1 3NX, England.

Florida 33134, U.S.A.

1 Harbour Road, Wanchai,

Tel:

(01743) 212000

Tel:

(305) 442 7413

Hong Kong.

Telex: 35171/2 PESL G

Telex:

32501 PERKEN G

Tel:

852 2588 1883

Fax: (01743) 212700

Fax: (305) 442 7419

Fax: 852 2827 2311

Perkins Engines (Stafford) Ltd.

Perkins Engines Australia Pty Ltd

Perkins Engines (Far East) Pte Ltd.

Tixall Road, Stafford, ST16 3UB, England.

Suite 2, 364 Main Street, Mornington

39 Tuas Avenue 13,

Tel:

(01785) 223141

3931, Victoria, Australia.

Singapore 638999.

Telex: 36156 PERKEN G

Tel:

(059) 75 1877

Tel:

(65) 861 1318

Fax: (01785) 215110

Telex:

30816

Fax: (65) 861 6252

Fax: (059) 75 1305

Perkins Powerpart Distribution Centre

Frank Perkins Way,

Motori Perkins SpA

Northbank Industrial Park, Irlam,

Via Socrate. 8,22070 Casnate

Manchester, M44 5PP, England.

Con Bernate (Como), Italy.

Tel:

(0161) 776 5000

Tel:

031 56 46 25 / 031 56 46 33

Specifications Help Desk

Telex:

380658 PERKIT I

Tel:

(0161) 776 5151

Fax: 031 24 90 92 / 031 56 41 45

Fax: (0161) 776 5200

Specifications Help Desk

Perkins Motoren GmbH

Tel:

(0161) 776 5100

D-63801 Kleinostheim,

Telex: 32501 PERKEN G

Saalackerstrasse 4, Germany.

Tel:

(49)

(6027) 5010

Fax: (49) (6027) 501130

In addition to the above companies, there are Perkins distributors

most countries. Perkins Engines

(Peterborough) Limited or one of the above companies can provide distributor handbooks Publication No. 1407/4/97.

Publication TSL4187

Published by the Technical Publications Department, Stafford.

4012/16 Gas, February 1998

CONTENTS

Page

INTRODUCTION

ENGINE DESIGNATIONS

BRIEF DESCRIPTION OF THE 4012/16 GAS ENGINES

PHOTOGRAPHS

INSERTS

GENERAL INFORMATION

GAS ENGINE DATA

TORQUE SETTINGS

LUBRICATING OIL

COOLANT CORROSION INHIBITORS, ANTI-FREEZE

GAS SPECIFICATION

OPERATING INSTRUCTIONS

PREPARATION FOR INITIAL START

PRIMING THE TURBOCHARGER

BATTERIES

FILLING THE COOLING SYSTEM

INSTRUMENT PANEL (ENGINE MOUNTED)

EXHAUST TEMPERATURE GAUGE (OPTIONAL)

FINAL CHECKS AND INITIAL START UP

GAS ENGINE START/STOP SEQUENCE (AUTOMATIC)

MAINTENANCE PROCEDURES

OVERHAUL PERIODS & CONTINUOUS DUTY CHECKLIST

FAULT TRACING CHART

WIRING DIAGRAMS

4012/16TESI (MINNOX) WITH CAV STARTER AND PROTECTION SWITCHES

4012/16 (GAS) MINNOX ENGINE STARTING CIRCUIT WITH BUTEC

STARTERS AND OPTIONAL INSTRUMENT PANEL

EARLY 4012 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM

CURRENT 4012 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM

4012/16 (GAS) MINNOX ENGINE WIRING DIAGRAM OF STANDARD

PROTECTION PACK AND OPTIONAL BRITISH GAS COUNCIL

PROTECTION EQUIPMENT

EARLY 4016 SERIES GAS IGNITION AND HEINZMANN WIRING SYSTEM

CURRENT 4016 SERIES GAS IGNITION AND HEINZMAN WIRING SYSTEM

4012/16 LUBRICATING OIL FLOW DIAGRAM

TP315

4012/16TESI FRESH AND RAW WATER CIRCULATION DIAGRAM

TP381

(HEAT EXCHANGER COOLED)

4012TESI FRESH AND RAW WATER CIRCULATION DIAGRAM

TP384

(RADIATOR COOLED)

4012/16TESI ENGINE IGNITION AND GAS FLOW DIAGRAM

TP351

4012/16 Gas, February 1998

BRIEF DESCRIPTION OF THE 4012/16 GAS ENGINES

4012TESI

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,

(MINNOX)

turbo-charged, water cooled charge air cooler with separate water

pump and cooling circuit, lean burn, low NOx emission levels, 9.5:1

compression ratio

4012TESI

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,

(MINNOX)

200

L.C.

turbo-charged, water cooled charge air cooler with separate water

pump and cooling circuit, lean burn, with NOx emission of less than

200 g/GJ, 9.5:1 compression ratio.

4012TESI

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,

(MINNOX)

140

L.C.

turbo-charged, water cooled charge air cooler with separate water

pump and cooling circuit, lean burn, with NOx emission of less than

140 g/GJ, 9.5:1 compression ratio.

4012TESI

12 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,

(MINNOX)

140

H.C.

turbo-charged, water cooled charge air cooler with separate water

pump and cooling circuit, lean burn, with NOx emission of less than

140 g/GJ, 11.5:1 compression ratio.

4016TESI

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,

(MINNOX)

200

L.C.

turbo-charged, water cooled charge air cooler with separate water

pump and cooling circuit, lean burn, with NOx emission level of 200

g/GJ or less, 9.5:1 compression ratio.

4016TESI

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,

(MINNOX)

140

L.C.

turbo-charged, water cooled charge air cooler with separate water

pump and cooling circuit, lean burn, with NOx emission of 140 g/

GJ or less, 9.5:1 compression ratio.

4016TESI

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,

(MINNOX)

140

H.C.

turbo-charged, water cooled charge air cooler with separate water

pump and cooling circuit, lean burn, with NOx emission of 140 g/

GJ or less, 11.5:1 compression ratio.

4016TESI

16 cylinder, ‘V’ form, 4 stroke, gas engine, water cooled,

(MINNOX)

90 H.C.

turbo-charged, water cooled charge air cooler with separate water

pump and cooling circuit, lean burn, with NOx emission of 90 g/GJ

or less, 11.5:1 compression ratio.

4012/16 Gas, February 1998

GENERAL INFORMATION

SAFETY

Engine lift equipment

Use only the lift equipment which is designed

for the engine.

Use lift equipment or obtain assistance to lift

heavy engine components such as the

cylinder block, cylinder head, flywheel

housing, crankshaft and flywheel.

Check the engine lift brackets for security

before the engine is lifted.

Fig. 1

Asbestos joints

The following is a list of 'Health Protection

Some joints and gaskets contain

Precautions', suggested to minimise the risk

compressed asbestos fibres see Warning

of contamination.

label Fig. 1 in a rubber compound or in a

metal outer cover. The 'white' asbestos

Avoid prolonged and repeated contact

(Chrysotile) which is used is a safer type of

with used engine oils.

asbestos and the danger of damage to

Wear protective clothing, including

health is extremely small.

impervious gloves where applicable.

Contact with asbestos particles normally

Do not put oily rags into pockets.

occurs at joint edges or where a joint is

Avoid contaminating clothes, particularly

damaged during removal, or where a joint is

underwear, with oil.

removed by an abrasive method.

Overalls must be cleaned regularly.

To ensure that the risk is kept to a minimum,

Discard unwashable clothing and oil

the procedures given below must be

impregnated footwear.

followed when an engine which has

First aid treatment should be obtained

asbestos joints is dismantled or assembled.

immediately for open cuts and wounds.

● Work in an area with good ventilation.

Apply barrier creams before each period

● Do NOT smoke.

of work to aid the removal of mineral oil

● Use a hand scraper to remove the joints

from the skin.

- do NOT use a rotary wire brush.

Wash with soap and hot water, or

● Ensure that the joint to be removed is

alternatively use a skin cleanser and a

wet with oil or water to contain any loose

nail brush, to ensure that all oil is

particles.

removed from the skin. Preparations

● Spray all asbestos debris with water and

containing lanolin will help replace the

place it in a closed container which can

natural skin oils which have been

be sealed for safe disposal.

removed.

Do NOT use petrol, kerosene, diesel

fuel, gas oil, thinners or solvents for

Dangers from used engine oils

washing the skin.

Prolonged and repeated contact with mineral

10.

If skin disorder appears, medical advice

oil will result in the removal of natural oils

must be taken.

from the skin, leading to dryness, irritation

and dermatitis.

The oil also contains

11.

Degrease components before handling

potentially harmful contaminants which may

if practicable.

result in skin cancer.

12.

Where there is the possibility of a risk to

Adequate means of skin protection and

the eyes, goggles or a face shield

washing facilities should be readily available.

should be worn. An eye wash facility

should be readily available.

4012/16 Gas, February 1998

GENERAL INFORMATION

Environmental protection

Practical Information

There is legislation to protect the

To clean components

environment from the incorrect disposal of

It is important that the work area is kept clean

used lubricating oil. To ensure that the

and that the components are protected from

environment is protected, consult your Local

dirt and debris. Ensure that dirt does not

Authority who can give advice.

contaminate the fuel system.

Before a component is removed from the

engine, clean around the component and

Viton seals

ensure that all openings, disconnected

Some seals used in engines and in

hoses and pipes are sealed.

components fitted to engines are made from

Remove, clean and inspect each component

Viton.

carefully. If it is usable, put it in a clean dry

Viton is used by many manufacturers and is

place until needed. Ball and roller bearings

a safe material under normal conditions of

must be cleaned thoroughly and inspected. If

operation.

the bearings are usable, they must be

If Viton is burned, a product of this burnt

flushed in low viscosity oil and protected with

material is an acid which is extremely

clean paper until needed.

dangerous. Never allow this burnt material

Before the components are assembled,

to come into contact with the skin or with the

ensure that the area is free from dust and dirt

eyes.

as possible. Inspect each component

If it is necessary to come into contact with

immediately before it is fitted, wash all pipes

components which have been burnt, ensure

and ports and pass dry compressed air

that the precautions which follow are used:

through them before connections are made.

● Ensure that the components have

Use suitable gloves for protection when

cooled.

components are degreased or cleaned with

● Use Neoprene gloves and discard the

trichloroethylene,

white

spirit,

etc.

gloves safely after use.

Degreasing solutions which are basically

● Wash the area with a calcium hydroxide

trichloroethane are not recommended.

solution and then with clean water.

● Disposal of gloves and components

which are contaminated, must be in

accordance with local regulations.

If there is contamination of the skin or eyes,

wash the affected area with a continuous

supply of clean water or with a calcium

hydroxide solution for 15-60 minutes. Obtain

immediate medical attention.

4012/16 Gas, February 1998

GAS ENGINE DATA

The figures quoted are based on engines set to meet the ISO 3046/1 1981 Condition.

For full technical data please refer to the Product Information Manual.

Type (Gas) 12 cylinder and 16 cylinder (MINNOX) 'V' form, water cooled, turbocharged, wet

exhaust manifolds with separate raw water cooled charge air cooler.

RANGE

4012TESI (MINNOX)

4016TESI (MINNOX)

Cycle

4 stroke

Configuration

‘V’ form

Bore

160 mm

Stroke

190 mm

Total swept volume

45.842 litres

61.123 litres

Compression ratio

9.5:1 or 11.5:1

Rotation

Anti-clockwise looking on flywheel end

1A,6B,5A,2B,3A,4B

1A,1B,3A,3B,7A,7B,5A,5B

Firing order

6A,1B,2A,5B,4A,3B

8A,8B,6A,6B,2A,2B,4A,4B

Cylinder numbering

Cylinder 1 furthest from flywheel

Cylinders designated A are on the left side of the engine when viewed from opposite end to the flywheel, with

cylinders designated B on the right hand side of the engine.

NOTE: This is NOT the same as the British Standard and ISO designation.

Valve clearances

Exhaust 0.4 mm (0.016”)

Valve dia (mm) inlet & exhaust

Valve timing

See Workshop Manual Section U7

Valve setting

See page 39 onwards

Ignition timing

See engine number plate

Piston speeds

Engine r/min

m/s (ft/min)

1000

6.33

(1247)

1200

7.60

(1496)

1500

9.50

(1870)

TYPICAL COOLING SYSTEM

Approved coolants

See page 17

Total capacity engine including

charge air cooler & wet exhaust

81 litres (17.8 gals)

110 litres (24.3 gals)

manifolds

Total capacity engine and radiator

239 litres (52.6 gals)

278 litres (61.3 gals)

Total capacity engine and heat

153 litres (33.7 gals)

183 litres (40.3 gals)

exchanger

Engine shut down temperature

96°C

To be determined from heat dissipated and water flow through each

Max. temperature into engine

particular engine model

Thermostat opening temperature

71°C (nat. gas) 85°C (landfill or biogas) 92°C (HC engines)

System pressure

0.5 - 0.7 bar

Maximum pressure at jacket

2.5 bar max

coolant pump outlet

4012/16 Gas, February 1998

GAS ENGINE DATA

GAS SYSTEM

4012TESI (MINNOX)

4016TESI (MINNOX)

Approved gas

British Natural Gas

Lower calorific value

34.71 MJ/nm³

Carburettor mixing unit

Deltec 200 - 11

Carburettor throttle body

Deltec 100 - 11

Deltec 140 - 11

Gas control valve

Deltec 36 mm dia.

Deltec 45 mm dia.

Deltec 38 mm dia. 4016TESI (minnox 140 HE) ONLY

Gas pressure min.

15 m bar (1.5 kPa)

Gas pressure max.

50 m bar (5 kPa)

Regulator type (Zero pressure)

Dungs FRS 220, 5065 or 5100

Later engines

or Kromschroder GI50 R02 or GI65 R02

If above 50 mbar (5kPa), an additional regulator should be used in

Supply pressure

order to bring the supply pressure to between the max. & min.

figures given above

Additional items to meet The Instituion of Gas Engineers procedures IGE/UP/3 for 4012/16 (Minnox)

Perkins Part No. (see Spares Book)

Low pressure detector

(low pressure gas supply only)

Gas solenoid valves

Not Perkins supply

Spit back detector

Perkins Part No. (see Spares Book)

Manual gas shut-off valve

Perkins Part No. (see Spares Book) (if fitted)

IGNITION SYSTEM

Ignition unit type

Altronic DISN 800

Ignition coil type

Altronic 501 061 (L.C. engines) Altronic 591 010 (H.C. engines)

CHAMPION RN79G 14mm (earlier L.C. engines)

Spark plug type

CHAMPION RB77 WPC 18mm (later engines)

RN79G 0.5 mm (0.020”)

Spark plug gap

RB77WPC 0.4 mm (0.015”)

GOVERNOR

Make

Heinzmann Electronic

Type

2 x E6V

2 x E10

LUBRICATION SYSTEM

Recommended oil

See pages 14 - 16

Type of system

Wet sump, external mounted oil pump

Total oil capacity (oil cooler and filter)

178 litres (39 gals)

238 litres (51 gals)

Sump capacity (dipstick) min.

136 litres (30 gals)

147 litres (32 gals)

Sump capacity (dipstick) max.

159 litres (35 gals)

214 litres (47 gals)

Min. oil pressure (rated speed) to bearings

340 kPa (49 lb/in2)

Crankcase pressure max

25 mm water gauge

Max. oil temperature in sump

105°C

Lubricating oil filter

disposable canister type

Crankcase breather

Closed circuit

4012/16 Gas, February 1998

GAS ENGINE DATA

INDUCTION SYSTEM

4012TESI (MINNOX)

4016TESI (MINNOX)

Air cleaner

Twin

Type (paper element)

S551A

Max. air intake depression

543 mm H₂O (40 mm Hg) (L.C. engines)

406 mm H₂O (30 mm Hg) (H.C. engines)

Air restriction Indicator setting

380 mm H₂O

Twin Garrett (4016TESI 140 H.C. only)

Turbocharger

Twin Schwitzer (all other engines)

EXHAUST SYSTEM

Manifold type

WET

Exhaust outlet flange

Vertical (twin)

Mating flange

2 x 6” Table D

Max. exhaust back pressure

40 mm Hg

Max. exhaust temperature (°C)

See Product Information Manual

(after turbocharger)

FLYWHEEL

SAE Size

18”

No. of teeth on ring gear

156

FLYWHEEL HOUSING

SAE Size

‘00’

CRANKSHAFT

Maximum overhung weight on rear

1700 Kg

bearing

T.V. damper

1 x 18”

2 x 20”

NOTE: Subject to torsional vibration investigation different T.V. dampers may be fitted.

DRY WEIGHT

Dry weight

4380 kg

5520 kg

Wet weight

4680 kg

5820 kg

HOLDING DOWN BOLT HOLES

Bolt size (engine feet)

22 mm

No. off

ELECTRICAL SYSTEM

Voltage

Alternator type

Prestolite LNA4024/5 with internal regulator

Alternator output (amps)

30 at a stabilised output of 28 volts

Starter motor type (Twin) Prestolite/Butec

MS1/108

MS7/5

No. of teeth (gear ring)

156

No. of teeth (starter motor)

Battery capacity cold cranking amps

286

(each battery)

286

(each battery)

to IEC Standard at 0°C (32 °F)

Battery (lead acid)

24 V (2 x 12 V) at 0°C (32 °F) (286 Ah)

4012/16 Gas, February 1998

GAS ENGINE DATA

PROTECTION EQUIPMENT

Before resetting protection equipment, it must be established whether special settings (for that individual

engine) have been specified in the engine sales contract. This is particularly important with ALL high water

temperature settings, and ALL Cogen applications.

Standard settings for protection equipment are as follows:

High air manifold pressure switch

172 kPa (25.1 lb/in²)

Shutdown switches

Alarm

Shutdown

High oil temperature

115°C

120°C

Low oil pressure

2.06 bar (30 lb/in²)

1.93 bar (28 lb/in²)

High water temperature

71°C Thermostat

91°C

96°C

85°C Thermostat

96°C

101°C

96°C Thermostat

100°C

105°C

Caution: The above standard settings do not supercede any settings specified in the engine sales contract.

Overspeed

15% (on 1500 rev/min only)

High air manifold bursting disc pressure

75 lb/in² at 42°C or 58 lb/in² at 120°C

(Early engines only)

AIR STARTING

Air Starter Pressure

150 lb/in² (1034 kPa)

Compressed air supply

170 lb/in² (1172 kPa)

Type

Ingersoll-Rand Type SS815

INSTRUMENT PANEL (ENGINE MOUNTED)

Normal operation

Oil pressure

Between 300 - 560 kPa (42.6 - 80 lb/in²)

Oil temperature

Between 80 - 90 °C (176 - 194 °F)

Water temperature

Between 65 - 85 °C (149 - 185 °F)

Exhaust temperature

See Product Information Manual

Boost pressure

See Test Certificate

COOLANT JACKET HEATING

Heater

2 x 4 kw

4012/16 Gas, February 1998

TORQUE SETTINGS

IT IS ESSENTIAL THAT THE CORRECT LENGTH OF SCREW OR

WARNING

BOLT IS USED. INSUFFICIENT THREAD MAY RESULT IN THE

THREAD BEING STRIPPED. WHEREAS TOO LONG A THREAD MAY RESULT IN

BOTTOMING IN A BLIND HOLE, OR CATCHING ON ADJACENT COMPONENTS.

NOTE:

* Bolt and threads must be lubricated with clean engine oil.

** Cylinder head bolts to be lubricated under the heads, under the washers and

on the threads with P.B.C. (Poly-Butyl-Cuprysil) grease. Important:

See Section R10 in

the Workshop Manual before fitting. All other bolt threads only to be lubricated with clean

engine oil. Care must be taken not to oil the heads and faces.

TORQUE SETTINGS

CYLINDER HEAD GROUP

Ibf.ft

** Cylinder head bolt (early type)

M24

550

750

See Section R14

** Cylinder head bolt (later (waisted) type)

M24

530

723

Rocker shaft bolt/nut

M16

120

Rocker adjuster nut inlet/exhaust

M12

Rocker box bolt

M10

Air manifold bolt

M10

Exhaust manifold bolt

M10

Turbocharger V-band clamp nuts - (Schwitzer)

9.5

(Mitsubishi)

9.5

(Garrett)

13.5

Sandwich plate retaining capscrew (if fitted)

M10

CRANKCASE AND CRANKSHAFT GROUPS

* Main bearing bolt

M24

580

783

Side bolts (main bearing caps)

M16

124

168

Bolts sump to crankcase

M10

* Connecting rod bolt

M16

210

285

Viscous damper bolts to crankshaft

M16

250

340

Flywheel bolt to crankshaft

M16

250

340

Front drive adaptor bolts to crankshaft

M16

250

340

Balance weight bolt

M16

250

340

Front crankshaft pulley bolt

M16

250

340

Piston cooling jet setscrew

M10

Flywheel housing bolt

M10

LUBRICATING OIL PUMP

Bolts, pump housing to gearcase plate

M10

Thin nut gear to drive shaft

M24

175

237

4012/16 Gas, February 1998

TORQUE SETTINGS

Ibf.ft

CAMSHAFT GROUP

Camshaft gear bolt

M12

110

150

Camshaft thrust plate bolt

M10

Camshaft follower housing capscrew

M10

Cam follower housing bolt

M10

Idler gear hub bolts

M10

WATER PUMP AND OIL PUMP GROUPS

Water pump/oil pump gear units

M24

170

230

Water header to oil cooler bolts

M10

Water header to gearcase bolts

M10

Raw water pump gear securing nut (non lubricated thread)

M35

184

250

Engine Feet

M12

GOVERNOR

Control shaft mounting plate bolt

M10

FAN DRIVE

Fan driven pulley taper lock bush screw

¹/2" BSW

⁵/8" BSW

124

170

ALTERNATOR

Drive pulley taper lock bush screws

³/8" BSW

IGNITION SYSTEM

Spark plug

M18 x 1.5

Adaptor clamp capscrew

M12

100

136

Adaptor clamp screw (earlier engines)

M10

Retaining bolt for timing disc cover

M10

Timing disc housing to mounting plate bolt

M10

Drive gear screw

M10

Drive coupling capscrew

13.5

Driven gear capscrew

M10

Magnet disc to shaft nut

M12

Disc shaft flange to camshaft bolt

M12

120

171

FLEXIBLE COUPLING (HOLSET)

Flexible coupling cover screw

M12 or¹/2" UNC

129

Coupling driving flange screws

(coupling size

2.15)

M12 or¹/2" UNC

129

to flywheel

(coupling size

3.86)

M16 or⁵/8" UNC

175

250

4012/16 Gas, February 1998

LUBRICATING OIL

QUANTITY OF OIL

4012TESI

4016TESI

The total system capacity

178 litres (39 gallons)

238 litres (52 gallons)

The maximum sump capacity

159 litres (35 gallons)

214 litres (47 gallons)

The minimum dipstick mark indicates

136 litres (30 gallons)

147 litres (32 gallons)

CAUTION

In order to select a suitable lubricating oil for a gas engine it is necessary to consider

the fuel quality.

NATURAL GAS ENGINES (NO ACIDIC PRODUCTS PRESENT)

The oil should be a grade that is specifically formulated by all the major oil companies for

turbocharged and charge cooled natural gas engines. The oil should contain anti-wear and

detergent/dispersant additives. The oil is to have high resistance to oxidation and have

good thermal stability. Modern gas engine oils do not rely on a high total base number to

achieve long life and the special additive packages that are now available from many of the

major oil suppliers now meet this criteria.

Engines fitted with oxidizing catalysts (2 way) require a lubricant that is low in zinc and

phosphorus, it is essential that the oil supplier confirms that the brand of oil supplied is

compatible with the catalyst.

BIOGAS ENGINES (CONTAINING ACIDIC PRODUCTS AT LEVELS APPROVED BY

PERKINS ENGINES (STAFFORD) LTD

These engine require a lubricating oil that has more reserve alkalinity than the natural gas

engine and therefore the TBN should be more than 8 and less than 10 with the sulphated

ash in the range of 0.5 to 1.1%. The oil supplier will assist with the selection of suitable oils

when presented with the gas analysis. (TBN = Total Base Number).

NATURAL GAS BIOGAS ENGINES

Where gas engines oils are not available, please consult Perkins Engines (Stafford) Ltd for

advice.

GRADE OF OIL

The viscosity of the oil used should be either SAE 30 or SAE 40. In general SAE 30 is used

at temperature less than 30°C average ambient temperature and SAE 40 more than 30°C.

As these engine are generally operating continuously, it is possible to use higher viscosity

oils as sluggishness in starting is not generally critical.

The use of SAE40 will give reduced oil consumption but under certain conditions it will also

give reduced oil change periods.

OIL CHANGE PERIOD (NATURAL GAS ENGINES)

For normal operation of gas engines, change the oil after the first 500 hours, after which the

oil change period is 800 hours or annually which ever is the sooner.

It may be possible to extend the oil change period, where an oil change programme has

been approved by Perkins Engines (Stafford) Ltd, based upon the analysis of oil samples

taken during the first 1000 hours of engine use. However even if an analysis is showing a

satisfactory oil quality, the oil life should not be extended above 1000 hours.

4012/16 Gas, February 1998

LUBRICATING OIL

The following should be regarded as critical parameters:

Viscosity at 100°C

16.5 cSt maximum

Insolubles

1.5 maximum

Total Acid Number (TAN)

less than 4 times the TAN value for new oil.

Total Base Number (TBN)

50% less than new oil value.

Total base number (TBN) and total acid number (TAN) must not cross over.

Nitration

25 maximum

Oxidation

25 maximum

Water

0.2% maximum

Iron

Less than 20ppm*

Copper

Less than 40ppm*

NB Oil samples should be taken from the mean level in the engine sump never from the

sump drain plug.

Should there be a lubricating oil supply problem or a high sulphur content in the gas, Perkins

Engines (Stafford) Ltd should be contacted to give advice in selecting suitable formulations.

OIL CHANGE PERIOD (BIOGAS ENGINES)

Engines that are operated on either digester gas or landfill gas are to be subjected to special

conditions regarding the oil change periods.

When the engine/s are first commissioned an analysis of the site gas is to be submitted to

Perkins Engines (Stafford) (this is addition to the analysis supplied at the order stage) and

a description of the proposed lubricating oil that is to be used.

When the engine starts operating it is essential that oil samples are taken at intervals of

every 150 hours with the result of the analysis being sent to Perkins Engines (Stafford) at

the earliest opportunity.

This course of action is necessary because of the variability of the gas. If the oil is allowed

to be used after it has deteriorated beyond the limits specified below then the engine may

be damaged. The warranty on the engine is dependant on the oil being maintained in

satisfactory condition. To meet this requirement it is necessary to continue the oil analysis

programme throughout the warranty period. The frequency of the analysis can be extended

but it must show that at the oil change point that the oil is still in acceptable limits.

CRITICAL PARAMETERS

Maximum viscosity at 100°C

16.5 cSt

Total acid number and total base number must not cross over

TBN must not reduce to less than 50% the value of new oil

Nitration must not exceed

Oxidation must not exceed

Insolubles >3 µ must not exceed

1.5

Water max %

0.2

Silicon max ppm

100

Sodium max ppm

Iron max ppm

35*

Copper max ppm

35*

4012/16 Gas, February 1998

LUBRICATING OIL

During the early life of the engine it will be found that the parameters marked * will have

higher levels as a result of the running in procedure.

UNDER NO CIRCUMSTANCES IS THE OIL TO BE USED FOR MORE THAN 900 HOURS

EVEN IF THE ANALYSIS SHOWS THAT THE OIL IS IN ACCEPTABLE CONDITION.

NOTE: When operating on methane based fuels, approximately one litre of water is

produced for every cubic metre of methane burnt. It is essential to ensure that the piston

blow by can not condense either in the crankcase or in any pipes associated with the

breather. Water has a devastating effect on oil life due to the attack on the additive package

in the oil. It is essential that the engine breather is functioning effectively. Water should be

drained from the sump weekly.

FAILURE TO COMPLY WITH THESE INSTRUCTIONS MAY

WARNING

RESULT IN ENGINE DAMAGE.

APPROVED LUBRICATING OILS (NATURAL GAS ENGINES)

(Suitable for British and Durch natural gas)

Oil Company

Type

MOBIL

Pegasus 480 (Suitable for catalyst equipped engines)

MOBIL

Pegasus 489

ESSO

Estor Supreme LA 40

ESSO

Estor Protec LA 40

TEXACO

Geotex LA or HD

SHELL

Mysella MA 40

CASTROL

NG404-408

APPROVED LUBRICATING OILS (BIOGAS AND OTHER GASES)

Oil Company

Type

MOBIL

Pegasus 489 + *EM/PA programme

*EM/PA = Equipment Maintenance through Progressive Analysis

CATALYST EQUIPPED GAS ENGINES

These require oils with sulphated ash limited to

0.5%, zinc limited to

0.04%

and

phosphorous limited to 0.09% by weight, (see the above table).

4012/16 Gas, February 1998

COOLANT

When mixing the anti-freeze with the water

ALWAYS STOP

WARNING

always

the

manufacturer's

THE ENGINE AND

recommendation which is to add the anti-

ALLOW THE PRESSURISED SYSTEM

freeze to water and mix thoroughly before

TO COOL BEFORE REMOVING THE

adding the mixture to the engine cooling

FILLER CAP. AVOID SKIN CONTACT

system.

WITH ANTIFREEZE BY WEARING

Mixing water to the anti-freeze can lead to

HAND PROTECTION.

the formation of gel in the mixture, due to

over concentration, and this can lead to

ENGINE COOLING SYSTEM

blockage of water passages and subsequent

To protect the engine cooling system against

loss of water flow causing overheating.

corrosion it is essential that the engine

coolant contains suitable additives which will

MAINTENANCE OF COOLANT

give the necessary protection.

The water/anti-freeze mixture should be

Caution: untreated water is not suitable.

replaced in operating engines at least once a

year.

WATER QUALITY

It is essential to maintain the coolant at the

The water that is mixed with the additive

correct alkalinity level i.e. the pH should not

must have the following characteristics:

increase above

7.5. A hydrometer only

Chloride less than

80 PPMV (parts per

shows the proportion of ethylene glycol.

million by volume)

This is not a measure of protection

Sulphates less than 80 PPMV

against corrosion.

Total hardness less than 200 PPMV pH of

water between 7 to 7.5 (i.e. neutral to slightly

FAILURE TO

alkaline)

WARNING

FOLLOW THE

ABOVE RECOMMENDATIONS MAY

ADDITIVES TO WATER

RESULT IN ENGINE DAMAGE AND

Due to the complexity of the cooling system

WILL INVALIDATE THE ENGINE

it is necessary to use an additive that

contains a balanced package of corrosion

inhibitors.

To achieve the required solution a 50/50 mix

of Shell Safe Premium anti-freeze with water

should be used at all times, even in areas

where frost is unlikely.

This mixture will give frost protection down to

-35°C. In areas where Shell anti-freeze is

unobtainable contact Perkins Engines

(Stafford) Ltd for advice.

Under no circumstances should an additive

containing nitrites, borates, phosphates,

chromates, nitrates or silicates be used, as

these materials are not compatible with the

materials used in the cooling system.

4012/16 Gas, February 1998

GAS SPECIFICATION

A new engine will be set to operate on clean natural gas conforming to the British natural

gas specifications having a lower calorific value of 34.71 MJ/Sm³ (930 BTU/Sft³).

The difference between high calorific value (HCV) and low calorific value (LCV) is that (HCV)

is the total amount of heat given off by the gas during combustion and the (LCV) is the high

calorific value less the amount of heat used to vaporize the water content of the gas. Since

the amount of heat lost in vaporizing the water is different for different gases, the lower

calorific value of the gas is chosen as the basis for fuel consumption data. There must be

no liquid hydrocarbon fractions in the gas.

IF THE ENGINE IS NOT SET TO SUIT THE SITE GAS,

WARNING

UNECONOMICAL RUNNING, LOSS OF POWER OR DAMAGE

MAY OCCUR, WHICH COULD RESULT IN INJURY.

Where gases other than British Natural Gas are to be used, such as wellhead gas, digester

gas and landfill gas, it is essential that a detailed analysis of the gas is submitted to Perkins

Engines (Stafford) Ltd. as resetting or changing the standard gas equipment may be

necessary.

Limiting Values for British Natural Gas:

4012/16TESI (MINNOX)

200 &140 L.C.

140 & 90 H. C.

Methane number must exceed

Combustible constituents must exceed

85%

95%

Calorific value (LHV) to exceed

31.7 MJ/Nm³

34 MJ/Nm³

(850 BTU/Sf³)

(912 BTU/Sft³)

Ethane

4.5%

Hydrogen content not to exceed

0.2%

0.1%

Propane must not exceed

Isobutane content not to exceed

0.2%

Normal butane not to exceed

0.2%

Normal pentane and higher fractions

(hexane, heptane, etc.).

The summation must not exceed.

0.02%

10) Gas pressure at inlet to regulators

15 mbar

must exceed

(1.5 kPa)

11) Gas pressure not to exceed without

50 mbar

additional pressure regulators

(5 kPa)

12) Hydrogen sulphide not to exceed

0.01%

or 100 ppm

NOTE: The rating may be reduced if lower calorific value of the fuel is lower than 34.71 MJ/

Nm³ (930 BTU/Sft³). Also pressure must be constant to maintain emissions and stability. If

any of the above parameters are not met, Perkins Engines (Stafford) Ltd should be

consulted for advice.

GAS SAFETY REGULATIONS

There are legal requirements that within the U.K. gas fittings and equipment are installed

and used in accordance with the GAS SAFETY

(INSTALLATION AND USE)

REGULATIONS. Only competent persons should install this equipment. Reference should

be made to the Institute of gas engineers IGE UP/3. Outside the UK anyone undertaking

work on the engine or associated with the engine and its gas equipment in particular should

check with local and national regulations to ensure compliance.

4012/16 Gas, February 1998

GAS SPECIFICATION

DERATING

IT IS ESSENTIAL

WARNING

THAT FULL

ACCOUNT IS TAKEN OF ALL DERATING

INFLUENCES WHETHER GAS

SPECIFICATION, ALTITUDE, AMBIENT

TEMPERATURE OR HUMIDITY. WHERE

ANY OF THESE DEVIATE FROM THE

STANDARD SPECIFIED IN THIS

MANUAL THE RATING OF THE GAS

ENGINE MUST BE ADJUSTED AS

INSTRUCTED BELOW.

SETTING ENGINE POWER TO SUIT

ACTUAL SITE CONDITIONS

Derating means reducing the power output

of an engine from its normal rating at normal

temperature and pressure conditions to

allow for adverse effects of site conditions

e.g. altitude and ambient temperature.

Perkins Engines

(Stafford) Ltd. may be

unaware of the final destination of an engine

at the time of despatch from the works. The

engine will be set to give the power output at

normal temperature and pressure under ISO

3046

standard conditions, using gas

conforming to British Natural Gas

Specification, having a lower calorific value

of 34.71 MJ/Nm³ (930 BTU/Sft³), which when

operating under the actual site conditions,

could result in severe damage to the engine

(refer to page 18).

Providing that the actual gas being used

meets with the above conditions, then the

engine need only be derated for altitude and

ambient temperature conditions.

Any engine so supplied must be derated in

accordance with the published percentage

derate figure as shown in the Product

Information manual, by the Equipment

Manufacturer on his premises, or even on

site.

To derate, calculate,

(using the above

percentage derate figure) the new reduced

power output of the engine, and run the

engine or generating set on this load.

Where possible this maximum load limit

should be set and locked in the engine

control panel.

4012/16 Gas, February 1998

OPERATING INSTRUCTIONS

PREPARATION FOR INITIAL START

FILLING THE ENGINE WITH OIL

Remove the drain plug to ensure sump is

clean and empty, refit and tighten the plug.

Remove the oil filler plug situated on the left

hand side of the gearcase by rotating T-bar

anti-clockwise and pulling Fig.

2. Fill the

sump to maximum mark on the dipstick with

the appropriate grade and quality of oil

specified, see Pages 14 - 16 and replace the

plug, rotating the T-bar to tighten and seal it.

Fig.

PRIMING THE TURBOCHARGER

Before starting the engine for the first time, or

if it has been stood idle for more than three

months, the turbocharger bearings should

be primed. Ensure that the gas supply is

turned off, also the switch in the control panel

is in the stop position, and the ignition is

turned off.

Locate the semi-rotary hand pump which

may be found immediately in front of the oil

pump (see Fig. 3). Operating the pump

coveys oil from the sump via a one way valve

Fig.

to the crankcase, pressurising the lubricating

system through the oil filters. Pump until

approximately 35 kPa (5lb/in²) is indicated

on the oil pressure gauge. Continue

pumping for a further 20 seconds to ensure

that oil has reached the turbocharger.

4012/16 Gas, February 1998

OPERATING INSTRUCTIONS

BATTERIES (PERKINS BATTERIES ARE

SUPPLIED DRY CHARGED. SEE

INSTALLATION MANUAL TSL4200)

HAND PROTECTION

WARNING

MUST BE WORN

WHEN CHECKING ELECTROLYTE

LEVELIN THE BATTERY. INFLAMMABLE

GAS IS GIVEN OFF BY THE BATTERY.

DO NOT CHECK WITH A NAKED FLAME.

Fig. 4

Check the level of electrolyte in each of the

battery cells; it should be 8-16 mm above the

After installation and before the first start

plates. Using a hydrometer, check that the

remove the radiator cap Fig. 4 by rotating it

batteries are fully charged. A fully charged

anti-clockwise. Fill the cooling system with

battery will have a specific gravity of 1.27 to

the required coolant. Should the engine be

1.285, assuming the air temperature is

fitted with water cooled exhaust manifolds

below 32°C. For higher temperatures the

then these may need bleeding

(see

specific gravity will be 1.24 to 1.255. When

Workshop Manual Section F7). Run the

topping up the batteries always use pure

engine off-load for one minute to ensure that

distilled water and always replace the plugs

the system is completely filled, then stop the

after filling.

engine and top up the system to 25 mm (1")

below the top of the filter neck then replace

the cap.

NEVER CONNECT

WARNING

A BATTERY INTO

THE SYSTEM WITHOUT FIRST

CHECKING THE POLARITY AND

VOLTAGE.

NEVER DISCONNECT THE BATTERY

WHILST THE ENGINE IS RUNNING.

NEVER FLASH CONNECTIONS TO

CHECK FOR CURRENT FLOW.

FILLING THE COOLING SYSTEM

THE COOLING

WARNING

SYSTEM IS

PRESSURISED - DO NOT REMOVE THE

FILLER CAP FROM THE RADIATOR

WHILST THE ENGINE IS HOT. HAND

PROTECTION MUST BE WORN.

The use of plain drinking water is not

recommended owing to chemical reactions

which can result in corrosion and furring-up

of the cooling system. A solution of either

water and universal anti-freeze or water and

corrosion preventative must be used. Refer

to page 17.

4012/16 Gas, February 1998

INSTRUMENT PANEL

Engine water temperature gauge

(Fahrenheit/Centigrade) Fig. 6

The coolant temperature during normal

operation should be between 65°C - 85°C

(149°F - 185°F). If the temperature should

rise above 93°C (200°F) for a prolonged

period of time, stop the engine and investi-

gate the cause. The engine should, on the

other hand, not be run at too low a tempera-

ture for long periods either.

Fig.

Engine oil temperature gauge (Fahrenheit/

Centigrade) Fig. 7

The lubricating oil temperature should be

between 80°C - 90°C (176°F - 194°F) when

the engine is hot. If the temperature should

rise above 115°C (240°F), stop the engine

immediately and investigate the cause.

Engine oil pressure gauge Fig. 8

(pounds per square inch/kiloPascal x 100)

The lubricating oil pressure should be

between 300 - 350 kPa (45 - 50 lb/in²) when

the engine is hot. If the pressure should

Fig.

drop below 200 kPa (30 lb/in²) at higher

engine speeds than idling, stop the engine

immediately and investigate the cause.

Ammeter (Ampere) Fig. 9

The ammeter indicates at what charging

current the battery is being charged by the

alternator, or to what extent current is taken

from the battery without the battery being

recharged.

Fig. 8

Fig. 9

4012/16 Gas, February 1998

INSTRUMENT PANEL

Engine tachometer and hour counter

(revolutions per minute x 1000 and hours)

(see Fig. 10).

The electrically operated tachometer/hour

counter shows the speed of the engine in

rev per min. and the actual operating hours

the engine has run. The tachometer/hour

counter starts operating from an alternator

voltage of 12 V onwards, which has already

been reached at engine idling speed.

Fig.

Exhaust temperature gauge (optional)

Temperature range -20 +800°C

The gauge shows readings of turbine outlet

temperature and is switched from A to B

bank using the button (1) (see Fig. 11).

NOTE: Early engines may require a dry cell

9 volt battery.

Key switch (3 position) (Off/run/start)

The hand operated keyswitch with switch

lock is moved by a separate key to the posi-

tions shown, (see Fig. 12) viewed from front

of switch.

Fig.

Fuse holder

To protect the instrument panel a 2 amp fuse

is fitted to remove the fuse (1) unscrew its

holder (2) (see Fig. 13).

Fig. 12

Fig. 13

4012/16 Gas, February 1998

OPERATING INSTRUCTIONS

Starting (manual)

FINAL CHECKS AND INITIAL STARTUP

Gas supply train must comply with British

3.1)

Turn on gas at manual valve.

gas Code IM17. See Fig. 1 page 16 in the

3.2)

Press start button/turn ignition

Workshop Manual. Also gas pipework up to

key.

the solenoid operated valves must be tested

3.3)

Governor now energised.

at twice working pressure to ensure gas

3.4)

Starter engages, starts to crank.

tightness and any leaks rectified.

Automatic 3 second purge time

determined by control panel.

3.5)

Ignition on, gas solenoid valves

IMPROPER

WARNING

open.

OPERATION OF A

3.6)

Engine starts, starter disengages,

GAS ENGINE CAN BE DANGERHOUS.

runs up to rated speed.

BE PREPARED TO CHECK FOR GAS

3.6.1)

If engine fails to start, investigate

LEAKS AFTER THE SOLENOID VALVES

the following probable causes:

AS SOON AS THE ENGINE STARTS,

High or low gas pressure.

USING A LEAK DETECTING FLUID.

Ignition system grounded.

STOP THE ENGINE AND RECTIFY ANY

Governor failed to energise.

LEAK FOUND.

Low cranking speed.

3.6.2)

Try again once more only

1. Starting and stopping must be on no

commencing with 3.2 above.

load.

3.7)

When engine is running, check oil

pressure, warm engine through

2. For automatic start and stop sequence

and apply the load.

see Fig. 14 on page 27.

3.8)

Check engine condition

at full

load, oil pressure,

jacket

coolant

IF THE ENGINE

WARNING

and charge

air

coolant

FAILS TO START

temperatures.

AFTER TWO ATTEMPTS, TURN OFF

THE GAS SUPPLY AND INVESTIGATE

THE CAUSE. BEFORE ATTEMPTING

TO RESTART THE ENGINE IT MUST

BE PURGED OF GAS. TO DO THIS,

WITH THE GAS SUPPLY AND THE

IGNITION SYSTEM TURNED OFF,

CRANK THE ENGINE WITH THE

STARTER FOR NO MORE THAN 30

SECONDS. THIS SHOULD REMOVE

ANY BUILD-UP OF GAS FROM THE

ENGINE AND EXHAUST SYSTEM.

ALTERNATIVELY THE SYSTEM MAY

BE PURGED WITH COMPRESSED

AIR. ALWAYS BE IN A POSITION TO

STOP THE ENGINE IN THE EVENT OF

A MALFUNCTION BY TURNING OFF

THE GAS SUPPLY OR IN AN

EMERGENCY BY PRESSING THE

RED BUTTON, WHICH REMAINS OFF

UNTIL RESET.

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

Towards the rear of this section there is a

check list sheet for continuous duty

generator sets which is to be used as a

guide for operators and maintenance

personnel.

The following schedule details some of the

maintenance to be carried out as in the

maintenance check lists, however not all are

detailed. In these cases please refer to the

Workshop Manual.

The schedule within this section will be

Fig. 15

perfectly suitable for an engine working

under average conditions. If your engine is

COOLANT LEVEL

working under particularly dirty or dusty

conditions, more frequent servicing will be

THE COOLING

WARNING

necessary particularly in respect of the

SYSTEM IS

lubricating oil and air cleaners. Correct and

PRESSURISED - DO NOT REMOVE THE

regular maintenance will help prolong

FILLER CAP WHEN THE ENGINE IS

engine life.

HOT. HAND PROTECTION MUST BE

WORN.

MAKE QUITE

WARNING

CERTAIN THE

ENGINE CANNOT BE STARTED

With the engine stopped remove the

BEFORE UNDERTAKING ANY

radiator cap; the coolant should be 25 mm

MAINTENANCE, PARTICULARLY IN THE

(1") below the top of the filler neck. If the

CASE OF AUTOMATICALLY STARTING

level is low top up with a solution of water

GENERATING SETS OR REMOTE

and inhibitor or water and anti-freeze similar

to that already in the engine. Refer to

STARTING ENGINES.

Engine Data section pages 7 to 10.

DAILY INSPECTION

LEAKS

LUBRICATING OIL LEVEL

Visually check the engine for gas, oil,

With the engine stopped for at least 5 min-

coolant and exhaust leaks, repairing where

utes:-

necessary.

Withdraw the dipstick and wipe clean.

ii)

Re-insert the dipstick fully into the

WEEKLY

sump.

Deal with items under DAILY INSPECTION.

iii) Wait for at least

5 seconds, withdraw

and check the oil level in relation to the

AIR CLEANER RESTRICTION INDICATOR

two marks on the dipstick.

The middle section of the restriction indicator

iv) Repeat operation

(i)

(ii)

(iii) at least

'A' will remain clear while the air cleaner is in

twice, until identical readings are

a serviceable condition. When the filter

observed.

reaches its contamination limit the restriction

If the oil level is below the top mark add

indicator will sense the change in manifold

sufficient of the same grade as that already

pressure and middle section 'A' will change

in the engine to bring the oil level up to the

to red. At this point the air filter must be

top mark.

changed (see Operators Handbook page

Always replace the filler plug immediately

37). When the air filters have been changed

replenishment is completed.

reset the indicator by pressing button 'B'.

(See Fig. 15).

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

BATTERIES

HAND PROTECTION

WARNING

MUST BE WORN

WHEN CHECKING ELECTROLYTE

LEVEL IN THE BATTERY. INFLAMMABLE

GAS IS GIVEN OFF BY THE BATTERY.

DO NOT CHECK WITH A NAKED FLAME.

Remove the plugs or 'quick fill' covers and

check the level of electrolyte. It should be

Fig. 16

13.3

approximately 3 mm above the top of the

plates. If it is low, top-up with pure distilled

NEW OR REBUILT ENGINES

water. Replace the plugs and wipe the top

It is essential to carry out the following

of the battery clean and dry (see page 21

maintenance procedure after the initial 100

for fuller information).

hours.

NOTE: Check the specific gravity

(see

Maintenance Schedule).

FLANGES AND FASTENENERS

Check the torque on all external fasteners

RADIATOR

including the exhaust manifold and

If the engine is working in dirty or dusty

turbocharger flanges. Tighten all hose clips

conditions check that the air passages in the

and pipe unions.

radiator are not becoming choked. They can

be cleaned out by blowing compressed air in

EQUALISE BRIDGE PIECES AND CHECK

the direction opposite to that of the normal

VALVE CLEARANCES

air flow.

(see page

39).

DRAINING WATER FROM THE SUMP

(FOR ENGINE OPERATING ON

LANDFILL GAS)

Unscrew the drain plug in the sump and

drain off the accumulated water content until

oil flows. Tighten the plug, check the oil

level and add the required oil.

FENNER TAPE LOCK BUSHES

MAINTENANCE INSTRUCTIONS

Experience has shown that taper lock

bushes as fitted in the fan pulleys and battery

alternator driven pulley can work loose

shortly after being put into service. Check

using a hexagon wrench to tighten allen

screws (1) Fig. 16 gradually and alternately

until all are tightened to the required torque

(see Torque Settings on pages 11 - 13).

Full details of taper lock pulley see Section

B2 & Section U1 of the Workshop Manual.

Replace any guards removed before running

the engine (see Fig. 16).

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

TURBOCHARGERS

If the engine has been overhauled and a

filter joint fitted to the turbocharger oil feed,

this should now be removed and replaced

with the standard joint. See Service

Bulletin 301 (Revised) and 1.

FOR ENGINES OPERATING ON BIOGAS,

LANDFILL GAS, ETC.

SPARK PLUGS

Clean and reset gaps as described in

Fig.

Section N9 of the Workshop manual.

ENGINE OIL AND SPIN-ON FILTERS,

ALSO CENTRIFUGAL OIL FILTER

(WHERE FITTED)

Change engine oil and disposable filters

(see page 34) clean centrifugal filter (see

page 33).

ENGINE ALTERNATOR DRIVE BELT

DISCONNECTING

WARNING

BATTERIES OR ANY

OTHER MEANS OF STARTING.

Remove the small mesh guard (1) around

the alternator. The toothed belt used to drive

the alternator relies on tooth engagement to

transmit to load. It does not require

preloading, however a slight initial tension to

ensure that the belt fits snugly round the

pulleys is desirable. Using light pressure

midway between the two pulleys a total

deflection of 1.5 mm (¹/₁₆”) is satisfactory

(see Fig. 17). Refit the guard.

SPARK PLUGS

Reset the plug gap as described in Section

N9 and N12 of the Workshop Manual.

ENGINE OIL AND FILTERS

On completion of the first

500 hours

running, change the engine oil and

filters.

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

FAN BEARINGS AND BELTS

To adjust slacken the jockey pulley pivot and

adjuster bolts, and operate the jockey pulley

lever.

DISCONNECT

WARNING

Moving the jockey pulley lever outwards will

BATTERIES OR ANY

tension the belts and inwards will slacken

OTHER MEANS OF STARTING.

the belts.

The correct tension is obtained by measur-

Remove the mesh guard around the fan

ing the deflection at the mid point between

belts, grease the fan and jockey pulley

the fan pulley and the crankshaft pulley

bearings Fig. 18 using high melting point

when the above force is applied.

lithium based grease

(e.g. Shell Alvania

To apply the force place a rule across the

R.A.)

outside width of the belts and attach spring

Check the tension and condition of the fan

balance as shown Fig. 18 pull on the spring

belts. Using a spring balance and rule, or a

balance until the required force is reached

belt tension indicator, check that the force

and measure the belt deflection.

compares with the kgf (lbf) values shown

Adjust the position of the jockey pulley lever

below for the correct belt deflection. See

until the force on the spring balance and the

Fig. 18.

belt deflection agree with the figures given.

Deflection

kg Force

lb Force

Key

11 mm

3 - 4.3

6,67 - 9.47

(Fig. 18)

1. Force

Fan belts if worn, should be replaced as a

2. Deflection

complete, matching set. Individual belts

should NOT be replaced.

Fig. 18

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

DISCONNECT

WARNING

BATTERIES OR ANY

OTHER MEANS OF STARTING. WHEN

USING COMPRESSED AIR OR

CLEANING AGENTS ALWAYS WEAR

EYE PROTECTION, AND PROTECTIVE

GLOVES.

CRANKCASE BREATHER (IMPROVED

DESIGN) FITTED TO LATER ENGINES

Fig.

The crankcase breather is mounted on the

side of the thermostat housing Fig. 19 and

is connected to the engine via a flexible pipe

and elbow fitted on the front of the gearcase

(see Fig. 20).

To clean the breather remove the top cover

and withdraw the two wire mesh elements

and wash thoroughly using a suitable

cleaning agent. Shake as dry as possible,

finally blow dry with an compressed air.

Refit the elements into the breather body,

and fit the top cover firmly.

NOTE: When replacing the cover check the

sealing gasket is in good condition and the

cover has located on its dowel

Fig. 20

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

DISCONNECT

WARNING

BATTERIES OR ANY

OTHER MEANS OF STARTING. ALWAYS

WEAR PROTECTIVE GLOVES.

FOR EXTENDED OIL CHANGE PERIOD

(WITH OIL ANALYSIS PROGRAMME) SEE

PAGES 14 - 16 ON ENGINES OPERATING

ON BIO GAS AND OTHER GASES (NOT

BRITISH NATURAL GAS)

CLEANING THE CENTRIFUGAL

LUBRICATING OIL FILTER

Stop the engine, and allow time for

lubricating oil to drain back to sump.

Slacken safety clamp (1) unscrew cover

nut and lift off cover (A).

(See Fig. 21).

Lift off rotor assembly

(B) having

allowed oil to drain from nozzles. The

rotor should be removed and replaced

on the spindle with extreme care in

order to ensure that bearings are not

damaged.

Secure rotor in dismantling tool T6253/

292. Unscrew rotor cover nut (3) and

Fig.

separate rotor cover from body.

Remove standtube (4) using extraction

tool T6253/293 and clean.

Reassemble

filter

complete

checking

Remove sludge from inside the rotor by

that rotor revolves

freely then replace

means of a spatula and wipe clean.

filter body cover. Tighten cover nut and

Ensure that all rotor components are

secure safety clamp. The clamp ring

thoroughly cleaned and free from

should be securely fitted at all times and

deposits of dirt before reassembling the

the filter should not be run without the

rotor. Failure to do so could cause an

clamp ring fitted.

out-of-balance condition which will

10.

With engine running check all joints for

accelerate bearing spindle wear.

leakage. Check for excessive vibration.

Clean nozzle with brass wire. Examine

'O' ring (5) and renew if damaged.

Reassemble rotor complete and tighten

top nut. IMPORTANT: Ensure that the

rotor cover and rotor body are always

matched by balance reference number

and pin location.

DO NOT INTERCHANGE ROTOR

COVERS.

Examine spindle journals, if damaged

or worn replace with body assembly

complete.

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

NOTE: It is suggested that oil analysis tests

are carried out at regular intervals to check

that these maintenance intervals are

satisfactory.

CHANGING ENGINE OIL AND

STANDARD SPIN-ON TYPE

LUBRICATING OIL FILTERS

DISCONNECT

WARNING

BATTERIES OR ANY

OTHER MEANS OF STARTING. ALWAYS

WEAR PROTECTIVE GLOVES.

With the engine stopped, place a suitable

container of at least 150 to 250 litres (33 to

55 gal) beneath the drain plug. Remove the

drain plug and allow the oil to drain. This

operation is best carried out while the

engine is still warm as the thinner oil will

drain more efficiently. While the oil is

draining remove the three oil filters per

bank, turning them anti-clockwise using a

strap wrench see Fig. 22.

Fig.

NOTE: Removal of the oil filters will allow an

escape of oil from the filter manifolds, it is

See page 20

for instructions on priming with

therefore recommended that a suitable

the semi-rotary pump.

container of at least 5 litres (1 gal) capacity

Stop cranking the engine and visually check

is positioned under each filter prior to

the engine for oil leaks, top up the oil level.

removal.

Wipe clean the sealing faces and threaded

bosses of the oil header. Smear engine oil

on the captive rubber sealing ring and

carefully screw each new filter up to the oil

header using firm hand pressure only.

Use only genuine Perkins oil filters. The use

of other filters may cause serious damage to

the engine.

Refit the drain plug and fill the engine with

the appropriate grade of new oil (see pages

11-13). Ensure that the gas supply is turned

off, also the switch on the control panel is in

the stop position, and the ignition is

grounded to prevent the engine firing. Turn

the keyswitch to the start position, and crank

the engine over until the oil pressure gauge

registers 0.4 kg/cm² (5 lb/in²).

Continue cranking for a further 10 seconds

which will ensure the oil has reached the

turbocharger bearings.

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

NOTE: If the flexible connections to the filter

DISCONNECT

WARNING

are removed for any reason, it is essential

BATTERIES OR ANY

that they are reconnected correctly to avoid

OTHER MEANS OF STARTING. ALWAYS

unfiltered oil getting into the engine. See

WEAR PROTECTIVE GLOVES.

Fig. 24 on page 36. Failure to change fil-

ters when due can also lead to trouble from

CHANGING THE OPTIONAL CHANGE-

unfiltered oil.

OVER LUBRICATING OIL FILTERS

These special duplex filters are normally

CHANGING THE FILTER ELEMENTS

intended for use on long running engines, or

WHEN THE ENGINE IS STOPPED

where a servicing requirement may occur

All that is necessary is to unscrew the

when it is impractical to stop the engine. For

canisters with a strap wrench as shown in

this reason they are fitted with a three way

Fig.

23, without moving the change-over

change-over valve in the head which enables

valve, as there is no pressure in the system

the elements to be changed, one at a time,

when the engine is stationary. The underside

whilst the engine continues to run. They are

of the header is then wiped clean, and a

normally mounted on the engine, but may be

smear of oil applied to the sealing rings on

remotely mounted, and connected to the

the new canisters, before screwing them up

engine by means of flexible pipes.

by hand and tightening them by no more

than three quarters of a turn after the seals

contact the header. Check the filter for leaks

after the engine is restarted.

Fig. 23

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

NOTE: Prepare for a small spillage of oil

REDUCE ENGINE

WARNING

from the filter as each canister is removed,

SPEED TO IDLING IF

by placing a container of about

litres

CHANGING THE FILTERS WHILST

gallon capacity under the filter.

ENGINE IS RUNNING.

Key

CHANGING THE FILTER ELEMENTS

(Fig. 24)

WITHOUT STOPPING THE ENGINE

1. Change right filter

The normal position of the change-over

2. Normal

valve is with marking on the valve spindle for

3. Change left filter

the spanner showing the leg of the inverted

4. Dirty oil into filter

T pointing upwards when both filter elements

5. Clean oil into engine

are in circuit. Turning the valve with the

spanner provided so that the leg of the T

points to the left, puts the right hand filter out

of service, so that it may be exchanged for a

new one, fill the new filter with clean oil

before fitting. Turning the valve so that the

leg points to the right, puts the left hand filter

out of service, so that this one can now be

exchanged for a new filter canister. The valve

is then returned to its original position, so

that both elements of the filter are back in

service. Check for oil leaks.

Fig. 24

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

DISCONNECT

WARNING

BATTERIES OR ANY

OTHER MEANS OF STARTING THE

ENGINE.

CHANGING AIR FILTER (SEE SECTION

A1 IN THE WORKSHOP MANUAL)

STANDARD

Remove the end cover (3) of the air filter

housing, after unscrewing the retaining wing

Fig. 25

nut, carefully lift out the paper air filter

element (1). For servicing the element see

(b) Dust accumulation on the inlet side of

General Servicing Instructions below.

the housing is usually caused by

When all servicing procedures are

leaking gaskets and/or damaged gasket

completed, fit the new or cleaned element

surfaces. If this condition exists, leaking

into the housing. When fitting the end cover

gaskets should be replaced and

ensure it has seated fully in the housing

damaged gasket surfaces should be

before tightening the wing nut. Inspect and

repaired before placing the unit back

tighten all air filter connection before

into service.

resuming equipment operation (see Fig. 25).

REPLACE ANY

HEAVY DUTY

WARNING

ELEMENT WHICH IS

The heavy duty air filter incorporates a

DAMAGED.

cyclone unit (4) fitted to the air intake of the

NEVER “BLOW” DIRT OUT OF THE

filter

(replacing the mesh guard (2)). To

FILTER HOUSING. THIS MAY

clean the cyclone unit remove it from the air

INTRODUCE DUST INTO THE ENGINE.

filter and blow out any foreign matter within

INSTEAD, USE A CLEAN, DAMP CLOT,

the unit. Changing the paper air filter

DO NOT OIL THE ELEMENT.

element the procedure is the same as for the

WHEN USING COMPRESSED AIR

standard air filter above.

ALWAYS WEAR EYE PROTECTION.

GENERAL SERVICING INSTRUCTIONS

ELEMENT CLEANING

Servicing procedures include cleaning or

If the filter element is in good condition with

replacing the filter element, cleaning the filter

light dust contamination on its outer surface

housing, and assuring that all piping and

and the air flow restriction indicator

(see

hose connection from the filter outlet to the

Page

28) has not been triggered, the

turbocharger intake are sealed airtight.

element can be cleaned using a vacuum

cleaner or compressed air.

FILTER ELEMENT SERVICE

Clean the exterior of the filter housing and

then carefully remove the element. Inspect

the "clean air side" of the element and the

outlet side of the filter housing for any

unusual dust accumulations.

(a) Dust accumulations on the clean air side

of the element usually indicates a rupture

in the filter medium.

Immediate

replacement of the element is

necessary.

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

CLOSED CIRCUIT BREATHER

The closed circuit breather separators (1)

are mounted on each side of the gearcase

and are connected to the carburettor mixer

inlet via the breather valve (2). To clean the

breather separator remove the complete

unit from the engine (see Fig. 26).

Release the retaining clips and remove the

top cover (4) from the filter body. Remove

the foam element (5) check it for oil sludge

saturation wash thoroughly in a suitable

Fig.

cleaning agent, shake of excess solvent and

blow dry with compressed air. Clean any oil

sludge deposits from the filter body re-

assemble and fit to engine.

The breather valve (2) is mounted at the

flywheel end of the engine directly under the

air filter. To remove release the pipe clips

(see Fig. 27) and pull away from the valve

manifold. Wash the breather thoroughly in a

suitable solvent paying particular attention

to any deposits on the internal are of the

breather. Shake as dry as possible and

blow dry with compressed air.

Fig.

Before refitting ensure that the cup (A) at the

base of the two breather valves are full of

clean engine oil (see Fig. 27).

Fig. 28

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

EQUALISING BRIDGE PIECES AND

SETTING VALVE CLEARANCES

NOTE: The bridge pieces must be set before

attempting to set the valve clearances.

DISCONNECT

WARNING

BATTERIES OR ANY

OTHER MEANS OF STARTING.

Fig.

Remove the 4 screws (1) from the rocker

cover (2), lift off the cover peel off and throw

away the old gasket (3) Pull the spark plug

lead tube (4) from the spark plug bush (see

Fig. 29).

To equalise the bridge pieces the

appropriate valves must be rocking, use the

table below.

In order that the engine may be rotated

while the batteries are disconnected a

special cranking device

(SE253) can be

fitted to the spare starter motor hole in the

flywheel housing (see Fig. 30). Using a

Fig.

socket and ratchet wrench press against the

spring loaded bolt head until the pinion

engages with the flywheel gear then crank

the engine to the desired position.

If the valves required to be rocking are

closed rotate the engine one revolution

which will bring these valves to the rocking

position. The flywheel housing has an

inspection hole directly below the

turbocharger through which the flywheel

markings may be seen to line up with the

pointer set in the flywheel housing (see Fig.

31).

Fig.

The flywheel is marked: T.D.C. (Top Dead

Centre)

4012TESI

4016TESI

A1-A6

A1-A8

A5-A2

A3-A6

A3-A4

A7-A2

B1-B6

A5-A4

B5-B2

B1-B8

B3-B4

B3-B6

B7-B2

B5-B4

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

EQUALISING THE BRIDGE PIECES

DISCONNECT

WARNING

BATTERIES OR ANY

OTHER MEANS OF STARTING THE

ENGINE.

Having rotated the engine to the correct

position, check that the inlet and exhaust

rockers have clearance before continuing

with the next operation. Loosen the lock nut

Fig.

(1) on each bridge piece, screw the adjuster

(2) out until the fixed side of the bridge piece

rests on its valve, hold the top edge down

with one hand then screw the adjuster down

until you feel it touch the valve, thereby

equalising valve lift. Tighten the lock nut

without moving the adjuster (see Fig. 32).

SETTING VALVE CLEARANCE

With both bridge pieces equalised check the

valve clearance of 0.4 mm (0.016") inlet and

exhaust using a feeler gauge (1). If adjustment

is required loosen the lock nut (2) and using

Fig.

the adjuster screw (3) set the clearance.

Tighten the lock nut without moving the

adjuster

(see Fig.

33). The feeler gauge

should be a slide fit between the rocker and

bridge piece thereby giving the correct

clearance. Refit the rocker cover with a new

gasket.

ENGINE 4012TESI

SET BRIDGE PIECE

VALVES ROCKING ON

AND VALVE CLEARANCE

CYLINDER NO.

T.D.C.

ON CYLINDER NO.

A1 & A6

B1 & B6

A2 & A5

B2 & B5

A3 & A4

B3 & B4

A1 & A6

B1 & B6

A2 & A5

B2 & B5

A3 & A4

B3 & B4

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

BRITISH NATURAL GAS, BIOGAS AND OTHER GASES

CONTINUOUS DUTY CHECK LIST (BASED ON ENGINES RUNNING AT 1500 RPM NORMAL

OPERATION AND STANDARD OIL CHANGE PERIOD)

CONTINUOUS DUTY MAINTENANCE

OPERATIONS TO BE PERFORMED

A B C D E F G

SYSTEM

OPERATION

DESCRIPTION

Lubricating

Check

For leaks and oil pressure

•

Engine oil level

•

Change

Full flow filters (normal or change-over)

•

★

•

Engine oil

•

★

•

Clean

Crankcase Breather (and centrifugal oil filter, if fitted)

★

•

Closed circuit crankcase breather

•

Change

Closed circuit crankcase breather separator elements

•

Cooling

Check

For radiator air restriction

•

Operation of coolant heater

•

Hoses and connections for leaks

•

Coolant level and operating temperature

•

Antifreeze & inhibitor concentration

•

Belt condition & tension

•

Change

Fan and alternator belts

•

Grease

Fan hub & jockey pulley bearing

•

Change

Coolant

EVERY 12 MONTHS

Clean

Cooling system

Air

Check

For leaks

•

Air cleaner restriction

•

Pipes and connection

•

Change

Air cleaner element

•

Gas

Check

For leaks

•

Check

Governor linkage

•

Check

Gas lines & connections

•

Renew

Diaphragm in regulator

•

Check

Wiring (incl. high tension lead, renew if required)

•

Clean

Spark plugs (reset)

■

•

Adjust

Bridge pieces and valves

First 100 hours and then

•

Change

Spark plugs

■

•

Exhaust

Check

For leaks

•

For exhaust restrictions

•

Clean

Turbocharger comp wheel & diffuser

•

Check

Turbocharger bearing clearances

•

Engine

Check

Fenner taper lock bush (First 50 hours)

•

Check

Vibration damper

•

Check

Engine mountings

•

Overhaul

Cylinder heads

•

Re-ring

Piston (if necessary)

•

Overhaul

Engine (new pistons, liners, etc.)

•

Electrical

Check

Battery charging system, ignition system

•

Battery electroylte level, specific gravity

•

Belt condition & tension

•

Clean & reset magnetic pick-ups

•

Protection switches & alarms

•

Starter motor mounting bolts & terminals

•

NOTE: All bolts, hose clips, terminal connections, pipes and joints, should be checked for tightness and leaks after the first 100 hrs and every 3

months

thereafter.

★ First 500 hours then every 1,000 hours for British Natural Gas. For Biogas and other gases, first 250 hrs then every 400 hrs.

■ Clean at first 500 hrs then every 1,000 hrs for British Natural Gas. For Biogas and other gases first 250 hrs then every 400 hrs. Change every 2,000

hrs for British Natural Gas and every 1,000 hrs for Biogas and other gases.

✛ Major inspection at 12,000 hrs for British Natural Gas. For Biogas and other gases at 6,000 hrs check front and rear crankshaft oil seals

▲ Major overhaul at 20,000 hrs for British Natural Gas. For Biogas and other gases at 12,000 hrs

✼ Whichever is sooner.

NOTE: On landfill gas engines drain condensate from sump every week.

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

BRITISH NATURAL GAS

CONTINUOUS DUTY CHECK LIST (BASED ON ENGINES RUNNING AT 1500 RPM NORMAL

OPERATION AND EXTENDED OIL CHANGE PERIOD)

CONTINUOUS DUTY MAINTENANCE

OPERATIONS TO BE PERFORMED

A B C D E F G

SYSTEM

OPERATION

DESCRIPTION

Lubricating

Check

For leaks and oil pressure

•

Engine oil level

•

Change

Full flow filters (normal or change-over)

•

★

•

Engine oil

•

★

•

Clean

Crankcase Breather (and centrifugal oil filter, if fitted)

★

•

■

•

Closed circuit crankcase breather

•

Change

Closed circuit crankcase breather separator elements

•

Cooling

Check

For radiator air restriction

•

Operation of coolant heater

•

Hoses and connections for leaks

•

Coolant level and operating temperature

•

Antifreeze & inhibitor concentration

•

Belt condition & tension

•

Change

Fan and alternator belts

•

Grease

Fan hub & jockey pulley bearing

•

Change

Coolant

Clean

Cooling system

EVERY 12 MONTHS

Air

Check

For leaks

•

Air cleaner restriction

•

Pipes and connection

•

Change

Air cleaner element

•

Gas

Check

For leaks

•

Check

Governor linkage

•

Check

Gas lines & connections

•

Renew

Diaphragm in regulator

•

Check

Wiring (incl. high tension lead, renew if required)

•

Clean

Spark plugs (reset)

First 500 hours and then

•

Adjust

Bridge pieces and valves

First 100 hours and then

•

Change

Spark plugs

EVERY 2000 HOURS

Exhaust

Check

For leaks

•

For exhaust restrictions

•

Clean

Turbocharger comp wheel & diffuser

•

Check

Turbocharger bearing clearances

•

Engine

Check

Fenner taper lock bush (First 50 hours)

•

Check

Vibration damper

•

Check

Engine mountings

•

Overhaul

Cylinder heads

•

Re-ring

Piston (if necessary)

•

Overhaul

Engine (new pistons, liners, etc.)

•

Electrical

Check

Battery charging system, ignition system

•

Battery electrolyte level, specific gravity

•

Belt condition & tension

•

Clean & reset magnetic pick-ups

•

Protection switches & alarms

•

Starter motor mounting bolts & terminals

•

NOTE: All bolts, hose clips, terminal connections, pipes and joints, should be checked for tightness and leaks after the first 100 hrs and every 3 months

thereafter.

★ Change at first 500 hrs, then every 1000 hrs, until an extended oil change period has been established, which will depend on the

result of a series of analyses (see pages 14-15).

■ Also check front and rear crankshaft oil seals.

✼ Whichever is sooner.

4012/16 Gas, February 1998

MAINTENANCE PROCEDURES

BIOGAS AND OTHER GASES (NOT BRITISH NATURAL GAS)

CONTINUOUS DUTY CHECK LIST (BASED ON ENGINES RUNNING AT 1500 RPM NORMAL

OPERATION AND EXTENDED OIL CHANGE PERIOD)

CONTINUOUS DUTY MAINTENANCE

OPERATIONS TO BE PERFORMED

A B C D E F G

SYSTEM

OPERATION

DESCRIPTION

Lubricating

Check

For leaks and oil pressure

•

Engine oil level

•

Change

Full flow filter

•

★

•

Engine oil

•

★

•

Clean

Crankcase Breather

•

Closed circuit crankcase breather

•

Change

Closed circuit crankcase breather separator elements

•

Clean

Centrifugal lubricating oil filter

First 250 hours and then

EVERY 400 HOURS

Check

Front and rear crankshaft oil seals

•

Cooling

Check

For radiator air restriction

•

Operation of coolant heater

•

Hoses and connections for leaks

•

Coolant level and operating temperature

•

Antifreeze & inhibitor concentration

•

Belt condition & tension

•

Change

Fan and alternator belts

•

Grease

Fan hub & jockey pulley bearing

•

Change

Coolant

EVERY 12 MONTHS

Clean

Cooling system

Air

Check

For leaks

•

Air cleaner restriction

•

Pipes and connection

•

Change

Air cleaner element

•

Gas

Check

For leaks

•

Check

Governor linkage

•

Check

Gas lines & connections

•

Renew

Diaphragm in regulator

•

Check

Wiring (incl. high tension lead, renew if required)

•

Clean

Spark plugs (reset)

First 250 hours and then

★

•

Adjust

Bridge pieces and valves

First 100 hours and then

•

Change

Spark plugs

•

Exhaust

Check

For leaks

•

For exhaust restrictions

•

Clean

Turbocharger comp wheel & diffuser

•

Check

Turbocharger bearing clearances

•

Engine

Check

Fenner taper lock bush (First 50 hours)

•

Check

Vibration damper

•

Check

Engine mountings

•

Overhaul

Cylinder heads

•

Re-ring

Piston (if necessary)

•

Overhaul

Engine (new pistons, liners, etc.)

•

Electrical

Check

Battery charging system, ignition system

•

Battery electrolyte level, specific gravity

•

Belt condition & tension

•

Clean & reset magnetic pick-ups

•

Protection switches & alarms

•

Starter motor mounting bolts & terminals

•

NOTE: All bolts, hose clips, terminal connections, pipes and joints, should be checked for tightness and leaks every

3 months.

★ Change first 250 hrs, then every 400 hrs, until an extended oil change period has been established, which will depend on a series of analyses (see

pages 14-15). A centrifugal oil filter (see page 29) must be fitted and cleaned after first 250 hrs then every 400 hrs.

NOTE: It is normal practice when operating on gases other than natural gas for the oil to be continuously analysed at intervals of 100/150 hrs.

✼ Whichever is sooner.

4012/16 Gas, February 1998

4012/16 (GAS) MINNOX ENGINE WIRING DIAGRAM OF STANDARD PROTECTION

PACK AND OPTIONAL BRITISH GAS COUNCIL PROTECTION EQUIPMENT

Key

17. Gas solenoid valves not normally

(Fig. 39)

supplied by Perkins can be four off

1. Standard fitted equipment

depending on gas pipe work arrangement

2. Magnetic pick-up

18. Energised to run gas line

solenoid

3. Engine flywheel

valves

4. Two switch speed unit

19. Low water level fault switch

5. Switch 2 over speed

6. Switch 1 speed 600 rpm

7. Engine terminal box

8. NOTE:

1. High manifold gas pressure and gas

spitback can be on the same fault

channel.

2. Manifold out of balance switch

gauges can be earth return type.

9. Left/right banks engine fault switches.

10. Water temp.

11. Oil press

12. Left/right banks manifold out of balance

switch gauges

13. Left/right banks high manifold gas

pressure fault switches

14. Optional equipment

15. Left/right banks gas spitback fault

switches

16. Low gas pressure fault switch

Fig. 39

4012/16 Gas, February 1998