Perkins 4000 Gas Engine
Perkins 4000 Gas Engine
In-line Gas
4006 and 4008 Series engines
USER’S HANDBOOK
i
This publication is divided into six chapters:
1 General information
2 Engine views
3 Operation instructions
4 Preventive maintenance
6 Fault diagnosis
ii
4006/4008 In-line Gas
Contents
1 General information
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1
How to care for your engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2
Safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Practical information for cleaning components ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6
Engine preservation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6
Parts and service ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7
Service tools ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7
Engine identification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8
Engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9
Protection equipment .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12
Electrical system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12
Electrical wiring diagrams ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 13
Perkins companies .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 19
2 Engine views
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 21
6 cylinder engines ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 21
8 cylinder engines ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 22
3 Operating instructions
Introduction .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23
Instrument panel .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24
Instrument operation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25
How to fill the engine with oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
How to prime the lubrication system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
How to fill a CHP type cooling system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
How to fill a radiator type cooling system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29
Final checks and first engine start ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30
Typical engine start sequence . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
Typical engine stop sequence . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32
4 Preventive maintenance
Maintenance procedures . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
Service schedules ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
How to check the oil level ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
How to check the coolant level ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
How to check and clean the radiator (if fitted) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
How to check the radiator fan drive belts (if fitted) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39
How to check the battery charging alternator (if fitted) ... ... ... ... ... ... ... ... ... ... ... ... ... 40
How to change the engine oil and filters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41
How to change the change-over filters (if fitted) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42
How to clean the open circuit crankcase breather ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43
How to clean the closed circuit breather system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44
How to check the air cleaner restriction indicator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45
How to change the air filter element ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45
How to remove a spark plug ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46
How to clean, set and fit a spark plug .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47
Preparation for equalising bridge pieces and setting valve clearances ... ... ... ... ... ... ... 48
How to equalise bridge pieces . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50
How to set valve clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51
How to check valve and seat recession .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52
6 Fault diagnosis
Problems and possible causes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 57
List of possible causes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 58
1
General information 1
Introduction
The 4006 and 4008 gas engines are a family of 6 and 8 cylinder turbocharged gas engines, designed by
Perkins Engines Company Limited, Stafford, a world leader in the design and manufacture of high-
performance gas engines. They form part of the 4000 Series range of engines.
Perkins approved assembly and quality standards, together with the latest technology, have been applied to
the manufacture of your engine to give you reliable and economic power.
To ensure that you use the correct information for your specific engine type refer to "Engine identification" on
page 8.
The terms ‘left side’ and ‘right side’ apply when the engine is seen from the flywheel end.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.
Start-up
When working on the engine always ensure that the battery has been disconnected, and that any other
means of accidental start-up has been disabled.
Never start the engine with the governor linkage disconnected.
Do not hold the stop lever in the run position when starting the engine.
Always hold the stop lever in the stop position when cranking only.
Electrical equipment
Always check that electrics are earthed to local safety standards.
Always disconnect the electrical supply to the jacket water heater (if fitted) before working on the engine.
Take care to prevent any danger of electric shock.
Never re-adjust the settings of electronic equipment without reference to the Workshop Manual.
Freezing or heating components
Always use heat resistant gloves and use the correct handling equipment.
Exhaust system
Check the system for leaks.
Ensure that the engine room is correctly ventilated.
Check that all the guards are fitted.
Check that the pipework allows the exhaust gas to escape upwards.
Check that the pipework is supported.
Stopping the engine
1 Disengage the engine load.
2 Run the engine on NO LOAD for 5 to 7 minutes before stopping.
Note: This will allow the circulating lubricating oil to dissipate heat from the bearings, pistons, etc. It will also
allow the turbochargers, which run at a very high speed, to slow down while there is still oil flow through the
bearings.
Ensure that the engine is stopped before performing any of the following operations:
Changing the lubricating oil.
Filling or topping up the cooling system.
Beginning any repair work on the engine.
Adjusting belts (where fitted).
Adjusting bridge pieces / valve clearance.
Changing spark plugs.
Changing air or oil filters.
Tightening any fixing bolts.
Flammable fluids
Ensure that these are never stored near the engine.
Ensure that they are never used near a naked light.
Clothing
Do not wear loose clothing, ties, jewellery, etc.
Always wear steel toe cap shoes/boots.
Always wear the correct head, eye and ear protection.
Always wear suitable overalls.
Always replace a spillage contaminated overall immediately.
Environmental protection
There is legislation to protect the environment from the incorrect disposal of used lubricating oil. To ensure that
the environment is protected, consult your Local Authority who can give advice.
Engine preservation
Ex-works preservation treatment
The preservation treatment will give up to 12 months shipping and storage protection under normal enclosed
storage conditions of -15 °C to +55 °C and up to 90% relative humidity.
1 The oil used on engine test will give protection for up to 12 months after despatch from the works.
2 After test the oil is then drained from the sump.
3 The corrosion inhibited anti-freeze at 50% dilution with clean water used on engine test will give protection
for up to 12 months after despatch from the works.
4 After spray painting, all openings in the engine (including points where pipework has been removed and air
cleaner inlets, etc.), are sealed with plastic plugs or covers.
5 The drive face of the flywheel is coated with Valvoline Tectyl 506 preservative.
Service tools
The following tools and equipment are required to carry out the operations described in this handbook.
Part No. Description
699/2 Feeler gauge set
61008 8 mm Allen key (*)
5
348/3 /8 Allen key (*)
483/25 Strap wrench (*)
2710190 Spark plug removal tool (*)
SE253 Engine cranking device
687/1 Tool box (*)
477/1 Screwdriver set (*)
T6253/312 Valve seat recession checking tool
483/28 19 mm Combination spanner (*)
Note: Items marked (*) are supplied as a tool kit under part number SE671E.
Engine identification
The engine number and its build specification details are given on its data plate (A1) which is fitted to the right
side of the crankcase by the oil filters.
A reference code and engine description is given in the table below.
Reference
Description
Code
6 cylinder, in-line, 4 stroke, turbocharged, spark ignition gas engine, with water based engine
4006TESI
coolant and oil cooler, raw water pump and separate cooling system for charge air
200 LC
intercooler. With NOx emission of 200g/GJ or less.
6 cylinder, in-line, 4 stroke, turbocharged, spark ignition gas engine, with water based engine
4006TESI
coolant and oil cooler, raw water pump and separate cooling system for charge air
140 LC
intercooler. With NOx emission of less than 140g/GJ.
6 cylinder, in-line, 4 stroke, turbocharged, spark ignition gas engine, with water based engine
4006TESI coolant and oil cooler, raw water pump and separate cooling system for charge air
140 HC intercooler. With NOx emission of less than 140g/GJ, and higher thermal efficiency than the
4006TESI 140 LC.
6 cylinder, in-line, 4 stroke, turbocharged, spark ignition gas engine, with water based engine
4006TESI
coolant and oil cooler, raw water pump and separate cooling system for charge air
90 HC
intercooler. With NOx emission of less than 90g/GJ.
8 cylinder, in-line, 4 stroke, turbocharged, spark ignition gas engine, with water based engine
4008TESI
coolant and oil cooler, raw water pump and separate cooling system for charge air
200 LC
intercooler. With NOx emission of 200g/GJ or less.
8 cylinder, in-line, 4 stroke, turbocharged, spark ignition gas engine, with water based engine
4008TESI
coolant and oil cooler, raw water pump and separate cooling system for charge air
140 LC
intercooler. With NOx emission of less than 140g/GJ.
8 cylinder, in-line, 4 stroke, turbocharged, spark ignition gas engine, with water based engine
4008TESI coolant and oil cooler, raw water pump and separate cooling system for charge air
140 HC intercooler. With NOx emission of less than 140g/GJ, and higher thermal efficiency than the
4006TESI 140 LC.
8 cylinder, in-line, 4 stroke, turbocharged, spark ignition gas engine, with water based engine
4008TESI
coolant and oil cooler, raw water pump and separate cooling system for charge air
90 HC
intercooler. With NOx emission of less than 90g/GJ.
1
A 1665.2
Engine weight
4006TESI LC 4008TESI LC
Engine model
4006TESI HC 4008TESI HC
Dry weight (engine) 2420 kg 3350 kg
Dry weight (engine including charge cooler and
2574 kg 3558 kg
wet exhaust manifolds)
Coolant jacket
4006TESI LC 4008TESI LC
Engine model
4006TESI HC 4008TESI HC
Heater (when fitted) 1 x 2 kw 1 x 4 kw
Gas system
4006TESI LC 4008TESI LC
Engine model
4006TESI HC 4008TESI HC
Approved gas British Natural Gas
Lower calorific value (at 15 °C and 1,013 bar) 34,71 MJ/Nm3
Carburettor type mixing unit Check fuel specification
Main adjusting screw Deltec (2”) VM5394
Gas pressure min. 1,5 kPa (15 mb)
Gas pressure max. 5 kPa (50 mb)
Regulator type (zero pressure) Dungs FRS520 or KROM SCHRODER
Supply pressure 50 mbar (5 kPa) maximum
Additional items to meet the Institution of Gas Engineers Procedures IGE UP3
Low pressure detector To engines specification
Gas solenoid valves Not Perkins supply
Ignition system
4006TESI LC 4008TESI LC
Engine model
4006TESI HC 4008TESI HC
Ignition unit type Altronic DISN 800
Altronic 501061 LC
Ignition coil type
Altronic 591010 HC
Spark plug type (18 mm) Champion RB77WPC
Spark plug gap 0,4 mm (0.015 in)
Governor
4006TESI LC 4008TESI LC
Engine model
4006TESI HC 4008TESI HC
Type Electronic
Make Heinzmann E6 (6 cyl) Heinzmann E10 (8 cyl)
Note: The governor specification may alter due to application and speed.
Induction system
4006TESI LC 4008TESI LC
Engine model
4006TESI HC 4008TESI HC
Air cleaner Single (paper element)
Type S551A
Max. Air intake depression Refer to relevant Technical Data sheet
Air restriction indicator setting 380 mm H2O
SCHWITZER HC GARRETT HC
Turbocharger make and type S4T-114.58 AE-1.3N5 TV94/44/T18A/1.32G
SCHWITZER LC SCHWITZER LC
Exhaust system
4006TESI LC 4008TESI LC
Engine model
4006TESI HC 4008TESI HC
Manifold type Wet
Exhaust outlet flange Vertical (single)
Mating flange 1 x 6” Table D
Max. exhaust back pressure Refer to relevant Technical Data sheet
Crankshaft
4006TESI LC 4008TESI LC
Engine model
4006TESI HC 4008TESI HC
End float 0,13 - 0,48 mm
Max additional load applied to flywheel due to all rotating
Maximum overhung weight on rear bearing
components 650 kg
T.V. Damper 1 x 14” 1 x 20”
Tuning Disc 1 x 18”
Note: Subject to a satisfactory torsional vibration investigation different T.V. dampers may be fitted.
Engine fixing bolt
4006TESI LC 4008TESI LC
Engine model
4006TESI HC 4008TESI HC
Bolt size (engine feet) 20 mm
No. off 6
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:.
Shutdown switches Alarm Shutdown
2
High air manifold pressure switch 172 kPa (25.1 lb/in )
High Oil temperature 115 °C 120 °C
2
Low oil pressure 2,06 bar (30 lb/in ) 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
Overspeed 15% (on 1500 rev/min only)
Caution: The above standard settings do not supersede any settings specified in the engine sales contract.
Electrical system
4006TESI LC 4008TESI LC
Engine model
4006TESI HC 4008TESI HC
Voltage 24V
Alternator type (when fitted) PRESTOLITE (BUTEC) with internal regulator
Alternator output (amps) 30 at a stabilised output of 28 volts
PRESTOLITE/
Starter motor type MS7/3A
BUTEC MS1/105
No. of teeth (gear ring) 190
No. of teeth (starter motor) 12
Battery capacity cold cranking amps to IEC
540 (each battery) 600 (each battery)
Standard at 0 °C (32 °F)
24 V (2 x 12 V) a 0 °C (32 °F)
Battery (lead acid)
143 Ah 178 Ah
2
W
D+
1 +
-
220W 5w
3 4
6
9
45.0 AMPS INRUSH
0.75 HOLDING
Aux -
5 7 8
10
+
B+ FPS
11 +VE
12
A 323.4
2
W
D+
1 +
-
220W 5w
3 4
6
+ 10
45.0 AMPS INRUSH
5 7 8 9 0.75 HOLDING
-
-
6 5 4 3 2 1
11
FPS
+VE
13
SMC
B+
12
A 324.4
Note: GET knock sensing protection equipment can be wired into this system. Refer to the wiring diagram on
page 16.
8 5 16 12
17
1
3 2
6
13 18
7
14
15
10
11
9
4
A 1800.1
Warning! When GET knock sensing system is fitted, remove the engine terminal box links A2 - A1, C2 - C1,
add links C5 - E5, B5 - D5.
3
2
J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J
8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 13 13 13 13 13 13 13 13 13 13
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10
GOV
A5 B5 C5 D5 E5 G C2 B2 A2 A1 B1 C1 D S0 S0 Ign
+ -
Ign
A3 B3 E3SC3 B- +
1 2 3 4 PU+ PU- SC1 SW1 SW2 SCR
6
A 1802.1
Note: GET knock sensing protection equipment can be wired into this system. Refer to the wiring diagram on
page 18.
8 5 16 12
17
1
3 2 6
13 18
7
15 14
10
11
9
4
A 1801.1
Warning! When GET knock sensing system is fitted, remove the engine terminal box links A2 - A1, C2 - C1,
add links C5 - E5, B5 - D5.
3
2
J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J
8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 13 13 13 13 13 13 13 13 13 13
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10
6
A 1803.1
Australia Singapore
Perkins Engines Australia Pty. Ltd, Perkins Engines Asia Pacific Ltd,
Suite 4, 13A Main Street, 20 Harbour Drive, 07-06A PSA Vista,
Mornington, Victoria 3931, Australia. Singapore 117612.
Telephone: 0061 (0) 597 51877 Telephone: [65] (874) 77 12
Telex: Perkoil AA30816 Fax: [65] (874) 77 22
Fax: 0061 (0) 597 1305
United Kingdom
China Perkins Engines Company Limited,
Perkins Engines (Tianjin) Ltd, Eastfield, Peterborough, PE1 5NA, England.
Jin Wei Road, Beichen District, Telephone: 0044 (0) 1733 583000
Tianjin, 300402, PR China. Telex: 32501 Perken G
Telephone: (86) (22) 2699 2288 Fax: 0044 (0) 1733 582240
Fax: (86) (22) 2699 3784
Perkins Engines Company Limited,
France Tixall Road, Stafford, ST16 3UB, England.
Moteurs Perkins S.A., Telephone: 0044 (0) 1785 223141
Paris Nord II - Parc des reflets, Fax: 0044 (0) 1785 215110
165 Avenue du Bois de la Pie, BP 40064,
F-95913 Roissy - CDG Cedex, France. Perkins Engines Company Limited,
Telephone: 0033 (01) 49-90-7168 Lancaster Road, Shrewsbury, SY1 3NX, England.
Fax: 0033 (01) 49-90-7190 Telephone: 0044 (0) 1743 212000
Fax: 0044 (0) 1743 212700
Germany
Perkins Motoren GmbH, United States of America
Saalaeckerstrasse 4, Perkins Engines Inc,
D-63801 Kleinostheim, Germany. 26200 Town Centre Drive, Suite 280, Novi,
Telephone: 0049 6027 5010 Michigan 48375, USA
Fax: 0049 6027 501130 Telephone: 001 248 374 3100
Fax: 001 248 374 3100
India
Perkins Engines Company Limited Perkins Engines Latin America Inc,
17, S-1 International Trade Tower, Nehru Place, 701 Waterford Way (NW 62nd Avenue), Suite 200,
New Delhi - 19 India. Miami, FL 33126, U.S.A.
Telephone: [91](11) 644 2595 Telephone: 001 305 442 7413
Fax: [91](11) 623 1598 Telex: 32501 Perken G
Fax: 001 305 442 7419
Italy
Motori Perkins S.p.A.,
Via Socrate 8,
22070 Casnate con Bernate (Como), Italy.
Telephone: 0039 (0) 31 564633/564625
Fax: 0039 (0) 31 565480/564145/396001
Japan
Perkins Engines Inc (Japan Branch)
Address Building 8th Floor, 2-2-19 Akasaka,
Minato-ku, Tokyo, 107-0052 Japan.
Telephone: [81](3) 3560 3877
Fax: [81](3) 3560 3878
Note: In addition to the above companies, there are Perkins distributors in most countries. Perkins Engines
Company Limited, Stafford or one of the above companies can provide details.
2
Engine views 2
Introduction
Perkins engines are built for specific applications and the views which follow do not necessarily match your
engine specification.
6 cylinder engines
Left side of engine (gearcase end)
A
Right side of engine (flywheel end)
8 cylinder engines
Left side of engine (gearcase end)
A
Right side of engine (flywheel end)
3
Operating instructions 3
Introduction
Information for the mechanical maintenance of the 4006/8 gas engines is given in this User’s Handbook
(Publication TSL 4185E) , the Workshop Manual (Publication TSL 4078E) and also the manual for the anti-
knock control system (supplied by Gas Engine Technology Bv) when fitted.
These publications should be understood and used together for the safe operation of the engine.
Note: For oil and coolant details refer to Chapter 5, Gas and engine fluids specification.
Instrument panel
CHP engines
The siting of instruments on CHP engines will vary with each individual installation.
The instruments are normally the same as on a radiator cooled engine, refer to "Instrument operation" on page
25, with the exception of an ammeter, as a battery charging alternator is not usually fitted to CHP engines.
Radiator cooled engines
The instrument panel is mounted on the air inlet manifold.
The individual components of the instrument panel are shown in (A), and listed below:
A1 Exhaust temperature gauge (if fitted)
A2 Coolant temperature gauge
A3 Lubricating oil temperature gauge
A4 Lubricating oil pressure gauge
A5 Battery charging rate gauge
A6 RPM and hours run indicator
A7 Fuse holder
1 2 3 4 5 6 7
A 299.5
A 300.3 B 301.3
C 302.3 D 303.3
A 304.3 B 307.3
1 2
C 1066.4
A 2.3 B 312.3
C 903.3 D 302.3
2
1
A 1486.1 B 1300.1
C 1301.2
A 11.4 B 1300.1
C 1301.2
Warnings!
If the engine fails to start after two attempts, turn off the gas supply and investigate the cause. Before
attempting to restart the engine it must be purged of gas. Disconnect the ignition system and gas supply
and crank the engine over for six seconds maximum.
The cooling system is pressurised - DO NOT remove the filler cap from the radiator while the engine is hot.
Personal protective equipment must be worn.
Start signal
received
Is gas
pressure NO Low gas pressure
within alarm & lockout
limits?
YES
Energise
governor
Energise starter
motor & crank
timer
Crank for 3
seconds
(Purge system)
Energise gas
valves & ignition
continue cranking
NO
Has Max
engine NO cranking YES Fail to start
time lockout
started ? reached?
YES
De-energise
starter
motor
Engine
running
A 623.4
Engine
running
A 623.5
4
Preventive maintenance 4
Maintenance procedures
These maintenance procedures are suitable for an engine working under average conditions.
If your engine is working under particularly dirty or dusty conditions, more frequent servicing will be necessary
particularly in respect of the lubricating oil and air cleaners.
Correct and regular maintenance will help prolong engine life.
Warnings!
Make quite certain that the engine cannot be started before undertaking any maintenance.
This is particularly important in the case of automatically starting generating sets or remote starting
engines.
Personal protective equipment must always be worn.
Service schedules
The following service schedules are applicable to engines running on both natural and biogas. Extra work
required for biogas engines only is indicated (*).
Oil and filter change intervals
For engines running on gas to the specification given in "Gas specifications" on page 53 and using approved
lubricating oils as specified in "Approved lubricating oils" on page 54, the oil and filters must be changed after
the first 500 hours of operation.
Subsequent oil and filter changes must be determined using an oil analysis program. For further details refer
to "Oil and filter change program" on page 54.
Warning! If oil analysis is not used to establish the oil change intervals, it is essential that Perkins Engines
Company Limited, Stafford are consulted. Failure to do so could affect engine warranty.
Using Manuals
Users Handbook (Publication TSL 4185E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UH
Workshop Manual (Publication TSL 4078E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WM
A service - First 500 hours
Description Manual
Oil and filters - change UH
Equalise bridge pieces and set valve clearance UH
Spark plugs - clean and re-gap UH
Fan and battery charging alternator drive belts - check WM
Fan and battery charging alternator taperlock drive pulleys - check UH
B service - 1,000, 2,000, 4,000, 5,000, 7,000, 8,000, 10,000, 11,000, 13,000, 14,000, 16,000, 17,000, 19,000,
20,000, 22,000 and 23,000 hours
Description Manual
Equalise bridge pieces, set valve clearance and check valve seat recession UH
Spark plugs - check, clean and re-gap UH
Breather systems - clean or replace element UH
Air filter - replace (subject to environmental conditions) UH
Governor actuator - lubricate ball joints WM
Notes:
Maintenance schedule from 24,000 hrs to 48,000 hrs is the same as 1,000 to 24,000 hrs.
At 48,000 hrs operation consult Perkins Engines Company Limited, Stafford reference major overhaul and
service exchange engine components.
Under normal operating conditions the radiator cooling fins should be inspected for a build up of dust and oil
contamination every 3 months.
Caution: If adverse site conditions exist inspections must be increased.
Cleaning the radiator cooling fins
Note: To clean the cooling fins on the fan side of the radiator, the fan, its supports and the cowling must first
be removed.
1 Dry dust and general contamination can be blown from the cooling fins using compressed air at a maximum
pressure of 100 - 300 kPa.
2 To clean oil / dirt contamination, brush an industrial liquid detergent onto the fins.
Warning! The detergent manufacturers instructions must be followed.
3 Use a steam jet at a maximum pressure of 500 - 700 kPa to remove the contamination.
1
3
A 476.4
2 1
3
6
4
2
A 1026.4
A 1026.4
5
4
A 2 1 3 4 5 80.6
A 974.4
3
B 1304.1
A 966.4 C 1005.3
A 948.4
3 2 1
4
B 27.4
A 1020.3 B 1663.1
1 Clean any carbon / ash deposits from the spark plug thread and ceramic insulator using a suitable solvent
and a dry cloth.
2 A light coating of ash evenly deposited on the electrodes indicates the plug is in good condition with a clean
burning mixture.
3 Clean any loose ash deposit from the end of the spark plug (A1) using a nylon brush.
Caution: Do not use a metal brush to clean a spark plug as the porcelain around the centre electrode will be
scratched, allowing ash deposits to build rapidly on the roughened surface, causing plug failure.
4 Set the spark plug gap to 0,4 mm (0.0015”) (A2).
Caution: The centre and ground electrodes of the spark plug are tipped with a hard surface which must not
be filed or cleaned using abrasive paper.
5 Every time a spark plug is refitted the sealing washer (A3) must be replaced. Use sealing washer part
number Y98/00038.
Warning! The spark plug should be finger tightened into the cylinder head, if resistance is felt clean the plug
thread in the cylinder head using a thread chaser. NEVER use a thread tap.
6 Apply a very small amount of Poly Butyl Cuprysil grease to the thread of the spark plug (A4).
7 Fit the spark plug carefully locating it in the cylinder head. Tighten down finger tight, then torque to 50 Nm
(35 lbf ft).
8 Refit the spark plug lead (B1).
1 2
1
4
A 1332.1 B 1020.3
Warning! Make sure the engine cannot be started before any maintenance is carried out.
1 Remove the spark plug lead from the cylinder head.
2 Take out the four capscrews (A1) holding the rocker box cover (A2).
3 Lift off the rocker box cover (A2).
4 Pull the plug lead tube (A3) out of the cylinder head.
5 To rotate the engine to the positions required for this procedure fit the engine cranking device to the spare
starter motor mounting in the flywheel housing (B).
6 Using a 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. Refer to the relevant table for 6 or 8 cylinder
engines on page 49.
7 The flywheel markings are viewed through an inspection hole in the flywheel housing. To get an accurate
reading align by eye the tip of both pointers with the marks on the flywheel (C).
2 1
A 316.3 B 1096.4
C 1224.2
8 cylinder engines
T.D.C. Valves rocking on Set bridge piece and valve
(top dead centre) cylinder No. clearance on cylinder No.
1&8 8 1
4&5 5 4
2&7 2 7
3&6 3 6
1&8 1 8
4&5 4 5
2&7 7 2
3&6 6 3
2
1
A 317.5
3 2
A 318.5
Using tool T6253/312, an indication of valve and seat wear (recession) can be obtained without removing a
cylinder head. The tool is to be used as part of the bridge piece and valve clearance setting sequence.
Warning! This check should be done at 3,000 hours and every service when setting bridge pieces and valve
clearances, up to the cylinder heads being replaced.
The inlet valves are easily checked but insufficient clearance means only one exhaust valve can be checked.
1 Place the tool on the rocker box face around the bolt (A1).
2 Position the legs of the tool above the inlet valve spring retainers. The clearance between the legs and valve
spring retainers indicates the valve life left.
3 A leg touching a valve spring retainer indicates the need for a cylinder head overhaul.
4 To check the exhaust valve, place the tool around bolt (A2).
From engine serial number DGB061220U0678F (6 cylinder engines) and DGB080702U0680F (8 cylinder
engines) the following improvements have been introduced:
The rocker box to cylinder head joint has been improved using a graphite material which is 0,7 mm thicker
than the joint it has replaced.
Capscrews have replaced the retaining bolts (A1) and (A2).
To check valve seat recession on these engines use a 0,7 mm feeler gauge (A3) in conjunction with the
recession tool (A4).
2
1 3
A 1199.6
5
Gas and engine fluids specification 5
Gas specifications
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 (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.
Warning! If the engine is not set to suit the site gas, 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, a detailed analysis of the gas must be submitted to Perkins Engines Company Limited, Stafford as
resetting or changing the standard gas equipment may be necessary.
4006/8TESI 4006/8TESI
Limiting values for British Gas
200 & 140 LC 140 & 90 HC
Methane number must exceed 65 80
Combustible constituents must exceed 85% 95%
31,7 MJ/Nm3 34 MJ/Nm3
Calorific value (LCV) to exceed
(850 BTU/Sft ) (912 BTU/Sft3)
3
Ethane 6% 4.5%
Hydrogen content not to exceed 0.2% 0.1%
Propane must not exceed 2.0% 1.0%
Isobutane content not to exceed 0.2% 0.2%
Normal butane not to exceed 0.2% 0.2%
Normal pentane and higher fractions (hexane, heptane, etc).
0.02% 0.02%
The summation must not exceed
15 mbar 15 mbar
Minimum gas pressure at inlet to regulators
(1.5 kPa) (1.5 kPa)
50 mbar 50 mbar
Gas pressure not to exceed without additional pressure regulators
(5 kPa) (5 kPa)
0.01% 0.01%
Hydrogen sulphide not to exceed
or 100 ppm 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 Company Limited, Stafford should be consulted for advice.
Gas safety regulations
There are legal requirements that within the U.K. gas fittings and equipment must be installed only by
competent persons and in accordance with the Institution of Gas Engineers Procedures IGE UP3. Outside the
U.K. 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.
Maintenance of coolant
Warning! Always stop the engine and allow the pressurised system to cool before removing the filler cap.
Prevent skin contact with the coolant mixture.
The coolant mixture should be changed at 12,000 hours or 18 months and checked at 3,000 hours or 6 month
intervals for the correct alkalinity level. The pH should not be above 7.5.
Note: A hydrometer only shows the proportion of ethylene glycol. This is not a measure of protection against
corrosion.
Warning! Failure to follow the above recommendations may result in engine damage and will invalidate the
engine warranty.
6
Fault diagnosis 6