PERKINS Industrial Engine 4016-61 TRG Operation and Maintenance Manual
PERKINS Industrial Engine 4016-61 TRG Operation and Maintenance Manual
PERKINS Industrial Engine 4016-61 TRG Operation and Maintenance Manual
March 2010
Operation and
Maintenance
Manual
4016-61 TRG Industrial Engine
S16 (Engine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
Safety Section
Safety Messages .................................................... 5
Operation Section
Lifting and Storage ................................................ 19
Maintenance Section
Refill Capacities .................................................... 30
Warranty Section
Warranty Information ............................................ 76
4 SEBU8604
Foreword
i03835895
i02328435
g00104545
Illustration 3
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
Illustration 4
g00702020 cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Wear a hard hat, protective glasses, and other
protective equipment, as required. Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
Do not wear loose clothing or jewelry that can snag may occur. Do not disassemble any hydraulic
on controls or on other parts of the engine. components or parts until pressure has been relieved
or personal injury may occur. Refer to the OEM
Make sure that all protective guards and all covers information for any procedures that are required to
are secured in place on the engine. relieve the hydraulic pressure.
Ensure that the power supply is disconnected before Always use a board or cardboard when you check
you work on the bus bar or the glow plugs. for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
Perform maintenance on the engine with the serious injury and possible death. A pin hole leak can
equipment in the servicing position. Refer to the cause severe injury. If fluid is injected into your skin,
OEM information for the procedure for placing the you must get treatment immediately. Seek treatment
equipment in the servicing position. from a doctor that is familiar with this type of injury.
• Only use the tools that are suitable for containing Oils
fluids and equipment that is suitable for containing
fluids. Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
Obey all local regulations for the disposal of liquids. skin. Also, do not allow hot components to contact
the skin.
i02334785
Batteries
Burn Prevention
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
Do not touch any part of an operating engine. batteries. Wash hands after touching the batteries
Allow the engine to cool before any maintenance is and connectors. Use of gloves is recommended.
performed on the engine.
i02320721
Coolant
g00704000
Illustration 6
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under All fuels, most lubricants, and some coolant mixtures
pressure. The radiator and all lines to the heaters or are flammable.
to the engine contain hot coolant.
Flammable fluids that are leaking or spilled onto hot
Any contact with hot coolant or with steam can cause surfaces or onto electrical components can cause
severe burns. Allow cooling system components to a fire. Fire may cause personal injury and property
cool before the cooling system is drained. damage.
Check the coolant level after the engine has stopped After the emergency stop button is operated ensure
and the engine has been allowed to cool. that you allow 15 minutes, before the engine covers
are removed.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch Determine whether the engine will be operated in an
with a bare hand. Remove the filler cap slowly in environment that allows combustible gases to be
order to relieve pressure. drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
Cooling system conditioner contains alkali. Alkali can property damage, or engine damage could result.
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth. If the application involves the presence of combustible
gases, consult your Perkins dealer and/or your
Perkins distributor for additional information about
suitable protection devices.
8 SEBU8604
Safety Section
Fire Prevention and Explosion Prevention
Remove all flammable combustible materials or Oil filters and fuel filters must be correctly installed.
conductive materials such as fuel, oil, and debris from The filter housings must be tightened to the correct
the engine. Do not allow any flammable combustible torque. Refer to the Disassembly and Assembly
materials or conductive materials to accumulate on manual for more information.
the engine.
• Wires are exposed. Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
• Outer coverings are ballooning. climb on the engine, and do not jump off the engine.
• Flexible part of the hoses are kinked. Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
• Outer covers have embedded armoring. with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
• End fittings are displaced. controls as handholds.
Make sure that all clamps, guards, and heat shields Do not stand on components which cannot support
are installed correctly. During engine operation, this your weight. Use an adequate ladder or use a work
will help to prevent vibration, rubbing against other platform. Secure the climbing equipment so that the
parts, and excessive heat. equipment will not move.
See the Service Manual for repairs and for Use the Emergency Stop Button ONLY in an
adjustments. emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
i02414669 problem that caused the emergency stop has been
corrected.
Engine Starting
Stop the engine if an overspeed condition occurs
during the initial start-up of a new engine or an
engine that has been overhauled. In the event of
an overspeed condition, the air shutoff valves will
operate. After operation, the air shutoff valves must
Do not use aerosol types of starting aids such as be manually reset.
ether. Such use could result in an explosion and
personal injury.
i02414684
Engine Electronics
• Control unit
• Actuator
12 SEBU8604
Product Information Section
General Information
Product Information
Section
General Information
i02640420
NOTICE
Proper welding procedures are necessary in order
to avoid damage to the engine's ECM, sensors, and
associated components. When possible, remove the
component from the unit and then weld the compo-
nent. If removal of the component is not possible, Illustration 9
g01324562
the following procedure must be followed when you Use the example above. The current flow from the welder to
weld with a unit that is equipped with an Electronic the ground clamp of the welder will not cause damage to any
Engine. The following procedure is considered to be associated components.
the safest procedure to weld a component. This pro- (1) Engine
cedure should provide a minimum risk of damage to (2) Welding rod
electronic components. (3) Keyswitch in the OFF position
(4) Battery disconnect switch in the open position
(5) Disconnected battery cables
(6) Battery
NOTICE (7) Electrical/Electronic component
Do not ground the welder to electrical components (8) Maximum distance between the component that is being
such as the ECM or sensors. Improper grounding can welded and any electrical/electronic component
cause damage to the drive train bearings, hydraulic (9) The component that is being welded
(10) Current path of the welder
components, electrical components, and other com- (11) Ground clamp for the welder
ponents.
4. Connect the welding ground cable directly to the
Clamp the ground cable from the welder to the com- part that will be welded. Place the ground cable as
ponent that will be welded. Place the clamp as close close as possible to the weld in order to reduce the
as possible to the weld. This will help reduce the pos- possibility of welding current damage to bearings,
sibility of damage. hydraulic components, electrical components, and
ground straps.
1. Stop the engine. Turn the switched power to the
OFF position. Note: If electrical/electronic components are used
as a ground for the welder, or electrical/electronic
2. Disconnect the negative battery cable from the components are located between the welder ground
battery. If a battery disconnect switch is provided, and the weld, current flow from the welder could
open the switch. severely damage the component.
3. Disconnect the connectors from the ECM. 5. Protect the wiring harness from welding debris
and spatter.
Model Views
i03754000
4016-61TRG
The following model views show typical features of
the engine. Due to individual applications, engines
may appear different from the Illustrations.
g02029553
Illustration 10
Left side view of engine
(1) Engine crankcase breather (A Bank) (5) Engine crankcase breather (B Bank) (9) Oil level gauge (Dipstick)
(2) Thermostat housing (A Bank) (6) Air shutoff valve (B Bank) (10) Oil filler
(3) Electronic governor actuator (7) 3x Oil filters (B Bank) (11) Water pump
(4) Thermostat housing (B Bank) (8) Oil cooler (12) Stop solenoid
SEBU8604 15
Product Information Section
Model Views
g02029554
Illustration 11
Right side view of engine
(13) Air cleaner (18) Fuel filters (23) Starter relay
(14) Restriction indicator for air cleaner (19) Oil drain plug (24) Starting motor
(15) Turbocharger (20) Fuel priming pump (25) Aftercooler
(16) Electronic governor control unit (21) Oil cooler (A Bank)
(17) Alternator (22) 3x Oil filters (A Bank)
Table 1
i03754088
L TAG
g02029586
Illustration 14
g01266904
Illustration 13 Typical example
Serial number plate
The serial number plate (1) on a engine is located on
The engine serial number plate contains the following the left side of the cylinder block (bank B).
information:
• Place of manufacture
• Telephone number of manufacturer
• Fax number of manufacturer
• Type of engine
• Engine serial number
• Rated speed
• Power output
• Engine timing
• Rating
SEBU8604 19
Operation Section
Lifting and Storage
Operation Section
Engine Lifting
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
g02126835
Illustration 15
Typical example
g02131153
Illustration 16
(1) Front lifting eyes (2) Rear lifting eye
To remove the engine ONLY, use the lifting eyes that Lifting eyes are designed and installed for specific
are shown in illustration 16. If necessary, remove engine arrangements. Alterations to the lifting eyes
engine components in order to avoid damage from and/or the engine make the lifting eyes and the lifting
the lifting device. fixtures obsolete. If alterations are made, ensure
that correct lifting devices are provided. Consult
your Perkins dealer or your Perkins distributor for
information regarding fixtures for correct engine
lifting.
g02130795
Illustration 17
i03781209
Engine Storage
Level “A ”
Level “A” will give protection for 12 months for diesel
engines and for gas engines. This level is used for
engines that are transported in a container or by a
truck.
Level “B ”
This level is additional to level “A”. Level “B ” will
give protection under normal conditions of storage
from −15° to +55°C (5° to 99°F) and “90%” relative
humidity, for a maximum of 2 year.
Level “C ”
This level is additional to level “B”. Level “C” will
give protection for five years in tropical or in arctic
climates. Level “C” also meets MOD NES 724
Level “J” for Europe, when engines are stored in an
unheated building or in the open under a waterproof
cover.
22 SEBU8604
Operation Section
Features and Controls
Monitoring System
i03781211
Sensor Locations
g02088773
Illustration 18
(1) Electronic control unit (ECU) (5) High turbine inlet temperature shutdown (8) Overspeed sensor
(2) Coolant temperature sensor sensor (A bank) (9) High turbine inlet temperature shutdown
(3) Boost pressure sensor (6) Thermocouple sensor (B bank)
(4) Oil pressure switch (7) Speed sensor (10) Oil pressure switch
SEBU8604 23
Operation Section
Features and Controls
The Illustrations show the typical locations of the The boost pressure sensor (3) measures the
sensors on the engine. Specific engines may appear pressure in the inlet air manifold. A signal is sent to
different from the illustrations due to differences in the ECU (1).
applications.
g02088775
Illustration 19
Coolant temperature switches
g02125658
Illustration 20
Boost pressure sensor
24 SEBU8604
Operation Section
Features and Controls
g02041294
Illustration 21
Engine oil pressure sensor
(4) Oil pressure sensor (A Bank) (9) Oil pressure sensor (B Bank)
g02124274
Illustration 22
(5) High turbine inlet temperature shutdown (8) High turbine inlet temperature shutdown
sensor (A bank) sensor (B bank)
SEBU8604 25
Operation Section
Features and Controls
Overspeed Sensor
g02123434
Illustration 23
Thermocouple
Speed Sensor
g01231518
Illustration 25
Overspeed sensor
g02123433
Illustration 24
Speed sensor
26 SEBU8604
Operation Section
Engine Starting
1. Open the fuel supply valves and open the return The engine is now ready to run.
lines (if equipped).
i02415223
Engine Operation
The efficiency of the engine can affect the fuel
economy. Perkins design and technology in
manufacturing provides maximum fuel efficiency in
Correct operation and maintenance are key factors all applications. Follow the recommended procedures
in obtaining the maximum life and economy of in order to attain optimum performance for the life
the engine. If the directions in the Operation and of the engine.
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized. • Avoid spilling fuel. Fuel expands when the fuel is
warmed up. The fuel may overflow from the fuel
Gauge readings (if equipped) should be observed tank. Inspect fuel lines for leaks. Repair the fuel
and the data should be recorded frequently while lines, as needed.
the engine is operating. Comparing the data over
time will help to determine normal readings for each • Be aware of the properties of the different fuels.
gauge. Comparing data over time will also help Use only the recommended fuels.
detect abnormal operating developments. Significant
changes in the readings should be investigated. • Avoid unnecessary running at a low load. If the
engine is not under load, the engine should be
shut down.
The engine should be equipped with an emergency Pressurized System: Hot coolant can cause seri-
stop button. For more information about the ous burns. To open the cooling system filler cap,
emergency stop button, refer to the OEM information. stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
Ensure that any components for the external system pressure cap slowly in order to relieve the pres-
that support the engine operation are secured after sure.
the engine is stopped.
Lubrication System
i03837413
The refill capacities for the engine crankcase
reflect the approximate capacity of the crankcase Fluid Recommendations
or sump plus standard oil filters. Auxiliary oil filter
systems will require additional oil. Refer to the OEM
(Cooling System
specifications for the capacity of the auxiliary oil filter. Specifications)
Refer to the Operation and Maintenance Manual,
“Maintenance Section” for more information on
Lubricant Specifications.
Table 5
General Coolant Information
Engine NOTICE
Refill Capacities
Never add coolant to an overheated engine. Engine
Compartment or System 4016 TRG damage could result. Allow the engine to cool first.
Crankcase Oil Sump(1) 238 L (52.4 Imp gal)
(1) These values are the total capacities for the crankcase oil NOTICE
sump which includes the standard factory installed oil filters If the engine is to be stored in, or shipped to an area
and oil coolers. Engines with auxiliary oil filters will require with below freezing temperatures, the cooling system
additional oil. Refer to the OEM specifications for the capacity
of the auxiliary oil filter. must be either protected to the lowest outside temper-
ature or drained completely to prevent damage.
Cooling System
NOTICE
Refer to the OEM specifications for the External Frequently check the specific gravity of the coolant for
System capacity. This capacity information will be proper freeze protection or for anti-boil protection.
needed in order to determine the amount of coolant
and antifreeze that is required for the Total Cooling
System. Clean the cooling system for the following reasons:
Many engine failures are related to the cooling • Formation of mineral deposits
system. The following problems are related to cooling
system failures: Overheating, leakage of the water • Rust
pump, and plugged radiators or heat exchangers.
• Scale
These failures can be avoided with correct cooling
system maintenance. Cooling system maintenance is • Foaming of the coolant
as important as maintenance of the fuel system and
the lubrication system. Quality of the coolant is as Many additives are depleted during engine operation.
important as the quality of the fuel and the lubricating These additives must be replaced periodically.
oil.
Additives must be added at the correct concentration.
Coolant is normally composed of three elements: Overconcentration of additives can cause the
Water, additives, and glycol. inhibitors to drop out-of-solution. The deposits can
enable the following problems to occur:
Water
• Formation of gel compounds
Water is used in the cooling system in order to
transfer heat. • Reduction of heat transfer
Ethylene Glycol
Additives
Freeze Boil
Concentration
Additives help to protect the metal surfaces of Protection Protection
the cooling system. A lack of coolant additives or 50 Percent −36 °C (−33 °F) 106 °C (223 °F)
insufficient amounts of additives enable the following
conditions to occur: 60 Percent −51 °C (−60 °F) 111 °C (232 °F)
• Corrosion
32 SEBU8604
Maintenance Section
Refill Capacities
NOTICE
When using Perkins ELC, do not use standard SCA's NOTICE
or SCA filters. Incorrect or incomplete flushing of the cooling system
can result in damage to copper and other metal com-
ponents.
ELC Cooling System Cleaning
To avoid damage to the cooling system, make sure to
Note: If the cooling system is already using ELC, completely flush the cooling system with clear water.
cleaning agents are not required to be used at Continue to flush the system until all the signs of the
the specified coolant change interval. Cleaning cleaning agent are gone.
agents are only required if the system has been
contaminated by the addition of some other type of
7. Shut down the engine by using the normal
coolant or by cooling system damage.
shutdown procedure. Drain the cooling system
into a suitable container and flush the cooling
Clean water is the only cleaning agent that is required
system with clean water.
when ELC is drained from the cooling system.
Note: The cooling system cleaner must be thoroughly
After the cooling system is drained and after the
flushed from the cooling system. Cooling system
cooling system is refilled, install the filler cap. Operate
cleaner that is left in the system will contaminate the
the engine until the coolant level reaches the normal
coolant. The cleaner may also corrode the cooling
operating temperature. Shut the engine down using
system.
the normal shutdown procedure.
8. Repeat the Steps 6 and repeat the steps 7 until
As needed, add the coolant mixture in order to fill the
the system is completely clean.
system to the specified level. Install the filler cap.
9. Fill the cooling system with the Perkins Premixed
Changing to Perkins ELC ELC.
To change from heavy-duty coolant to the Perkins
ELC, perform the following steps:
ELC Cooling System Contamination
NOTICE
NOTICE
Mixing ELC with other products reduces the effective-
Care must be taken to ensure that all fluids are
ness of the ELC and shortens the ELC service life.
contained during performance of inspection, main-
Use only Perkins Products for premixed or concen-
tenance, testing, adjusting and the repair of the
trate coolants. Use only Perkins ELC extender with
product. Be prepared to collect the fluid with suitable
Perkins ELC. Failure to follow these recommenda-
containers before opening any compartment or dis-
tions can result in shortened cooling system compo-
assembling any component containing fluids.
nent life.
Dispose of all fluids according to local regulations and
mandates. ELC cooling systems can withstand contamination to
a maximum of ten percent of conventional heavy-duty
coolant or SCA. If the contamination exceeds ten
1. Drain the coolant into a suitable container.
percent of the total system capacity, perform ONE of
the following procedures:
2. Dispose of the coolant according to local
regulations.
• Drain the cooling system into a suitable container.
Dispose of the coolant according to local
3. Flush the system with clean water in order to
regulations. Flush the system with clean water. Fill
remove any debris.
the system with the Perkins ELC.
34 SEBU8604
Maintenance Section
Refill Capacities
• Drain a portion of the cooling system into a suitable Use the equation that is in Table 13 to determine the
container according to local regulations. Then, fill amount of Perkins SCA that is required when the
the cooling system with premixed ELC. This should cooling system is initially filled.
lower the contamination to less than 10 percent.
Table 13
• Maintain the system as a conventional Heavy-Duty Equation For Adding The SCA To The Heavy-Duty
Coolant. Treat the system with an SCA. Change Coolant At The Initial Fill
the coolant at the interval that is recommended for
the conventional Heavy-Duty Coolant. V × 0.045 = X
V is the total volume of the cooling system.
Commercial Heavy-Duty Coolant and X is the amount of SCA that is required.
SCA
Table 14 is an example for using the equation that
NOTICE is in Table 13.
Commercial Heavy-Duty Coolant which contains
Amine as part of the corrision protection system must Table 14
not be used.
Example Of The Equation For Adding The SCA To
The Heavy-Duty Coolant At The Initial Fill
NOTICE Total Volume Multiplication Amount of SCA
Never operate an engine without water temperature of the Cooling Factor that is Required
regulators in the cooling system. Water temperature System (V) (X)
regulators help to maintain the engine coolant at the
correct operating temperature. Cooling system prob- 15 L (4 US gal) × 0.045 0.7 L (24 oz)
lems can develop without water temperature regula-
tors. Adding The SCA to The Heavy-Duty
Coolant For Maintenance
Check the coolant (glycol concentration) in order
to ensure adequate protection against boiling Heavy-duty coolant of all types REQUIRE periodic
or freezing. Perkins recommends the use of a additions of an SCA.
refractometer for checking the glycol concentration.
Test the coolant periodically for the concentration
Perkins engine cooling systems should be tested of SCA. For the interval, refer to the Operation
at 500 hour intervals for the concentration of and Maintenance Manual, “Maintenance Interval
Supplemental Coolant Additive (SCA). Schedule” (Maintenance Section). Test the
concentration of SCA.
Additions of SCA are based on the results of the test.
An SCA that is liquid may be needed at 500 hour Additions of SCA are based on the results of the
intervals. test. The size of the cooling system determines the
amount of SCA that is needed.
Refer to Table 12 for part numbers and for quantities
of SCA. Use the equation that is in Table 15 to determine the
amount of Perkins SCA that is required, if necessary:
Table 12
Perkins Liquid SCA Table 15
Part Number Quantity Equation For Adding The SCA To The Heavy-Duty
Coolant For Maintenance
21825735 10
V × 0.014 = X
V is the total volume of the cooling system.
Adding the SCA to Heavy-Duty Coolant
at the Initial Fill X is the amount of SCA that is required.
Commercial heavy-duty coolant that meets “ASTM Table 16 is an example for using the equation that
D4985” specifications MAY require an addition of is in Table 15.
SCA at the initial fill. Read the label or the instructions
that are provided by the OEM of the product.
SEBU8604 35
Maintenance Section
Refill Capacities
Sulfur
i03837412
High sulfur content of the fuel is not normally found
Fluid Recommendations in Europe, North America or Australasia. This can
(Fuel Specifications) cause engine wear. When only high sulfur fuels
are available, it will be necessary that high alkaline
lubricating oil is used in the engine or that the
lubricating oil change interval is reduced.
Fuel Recommendations Distillation
To get the correct power and performance from
This is an indication of the mixture of different
the engine, use a fuel of the correct quality. The
hydrocarbons in the fuel. A high ratio of light weight
recommended fuel specification for Perkins engines
hydrocarbons can affect the characteristics of
is shown below:
combustion.
Class A1 Fuels
Lubricity
• Cetane number_______________________________________50 This is the capability of the fuel to prevent pump wear.
• Viscosity___________ 1.5 to 5.0 cSt at 40 °C (104 °F) Diesel engines have the ability to burn a variety
of fuels. These fuels are divided into two general
• Carbon residue__________________________________0.20% groups:
Ramsbottom on 10% reidue
• Cetane number_______________________________________45
36 SEBU8604
Maintenance Section
Refill Capacities
Note: Only use Arctic fuels when the temperature is Refer to the following fuel specifications for
below 0 °C (32 °F). Do not use Arctic fuels when the North America.
ambient temperature is above 0 °C (32 °F). To ensure
that the time period between cranking the engine and The preferred fuels provide maximum engine service
first fire is kept to a minimum, only use fuel of the life and performance. The preferred fuels are distillate
correct viscosity and at the correct temperature. fuels. These fuels are commonly called diesel fuel
or gas oil.
Gas oil to “BS29 Class A2”
The permissible fuels are crude oils or blended fuels.
Note: If low sulfur or low sulfur aromatic fuels are Use of these fuels can result in higher maintenance
used, then fuel additives can be used to increase costs and in reduced engine service life.
lubricity.
Diesel fuels that meet the specifications in Table
Group 2 (permissible fuels): Specification 17 will help to provide maximum engine service life
and performance. In North America, diesel fuel that
These fuel specifications are considered acceptable is identified as No. 2-D in “ASTM D975” generally
for issues of warranty. However,these fuels may meets the specifications. Table 17 is for diesel fuels
reduce the life of the engine, the engine's maximum that are distilled from crude oil. Diesel fuels from
power and the engine's fuel efficiency. other sources could exhibit detrimental properties
that are not defined or controlled by this specification.
“ASTM D975 - 91 Class 1D”
Table 17
“JP7, Mil T38219” Perkins Specifications for Distillate Diesel Fuel
• White smoke
• Deterioration of emissions and misfire at certain
operating conditions
Biofuel: Specification
NOTICE
Water emulsion fuels: These fuels are not permitted
SEBU8604 37
Maintenance Section
Refill Capacities
Table 20
g00799818
Illustration 27 Engine Oil Viscosity
(Y) TBN by “ASTM D2896”
(X) Percentage of fuel sulfur by weight EMA LRG-1
Ambient Starting
(1) TBN of new oil API CH-4
Temperature
(2) Change the oil when the TBN deteriorates to 50 percent of Viscosity Grade
the original TBN.
Temperatures below
SAE 10W30
−15 °C (5 °F)
Use the following guidelines for fuel sulfur levels that
exceed 1.5 percent: −15 °C (5 °F) to
SAE 15W40
0 °C (32. °F)
• Choose an oil with the highest TBN that meets one 0 °C (32. °F) to
of these classifications: EMA DHD-1 and API CH-4. SAE 15W40
32 °C (89.5 °F)
• Reduce the oil change interval. Base the oil Temperatures above
SAE 15W40
change interval on the oil analysis. Ensure that the 32 °C (89.5 °F)
oil analysis includes the condition of the oil and a
wear metal analysis.
Synthetic Base Stock Oils
Excessive piston deposits can be produced by an oil
Synthetic base oils are acceptable for use in
with a high TBN. These deposits can lead to a loss
these engines if these oils meet the performance
of control of the oil consumption and to the polishing
requirements that are specified for the engine.
of the cylinder bore.
40 SEBU8604
Maintenance Section
Refill Capacities
Synthetic base oils generally perform better than Second Choice – Use an oil that has a CH-4
conventional oils in the following two areas: additive package. Although the oil has not been
tested for the requirements of the API license, the oil
• Synthetic base oils have improved flow at low must be either SAE 0W20, SAE 0W30, SAE 0W40,
temperatures especially in arctic conditions. SAE 5W30, or SAE 5W40.
Lubricants for Cold Weather • Select the correct oil, or a commercial oil that meets
the “EMA Recommended Guideline on Diesel
Engine Oil” or the recommended API classification.
When an engine is started and an engine is operated
in ambient temperatures below −20 °C (−4 °F), use
multigrade oils that are capable of flowing in low • See the appropriate “Lubricant Viscosities” table in
order to find the correct oil viscosity grade for your
temperatures.
engine.
These oils have lubricant viscosity grades of SAE
10W or SAE 15W. • At the specified interval, service the engine. Use
new oil and install a new oil filter.
When an engine is started and operated in ambient
temperatures below −30 °C (−22 °F), use a synthetic • Perform maintenance at the intervals that are
specified in the Operation and Maintenance
base stock multigrade oil with an 0W viscosity grade
Manual, “Maintenance Interval Schedule”.
or with a 5W viscosity grade. Use an oil with a pour
point that is lower than −50 °C (−58 °F).
Oil analysis
The number of acceptable lubricants is limited in
cold weather conditions. Perkins recommends the Oil samples should be taken on a regular basis for the
following lubricants for use in cold weather conditions: purpose of oil analysis. Oil analysis will complement
the preventive maintenance program.
First Choice – Use oil with an EMA DHD-1
Recommended Guideline. Use a CH-4 oil that has
an API license. The oil should be either SAE 0W20,
SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40
lubricant viscosity grade.
SEBU8604 41
Maintenance Section
Refill Capacities
Daily
Cooling System Coolant Level - Check ................ 53
Driven Equipment - Check .................................... 54
Engine Air Cleaner Service Indicator - Inspect ..... 55
Engine Oil Level - Check ...................................... 57
Fuel System Primary Filter/Water Separator -
Drain ................................................................... 66
Walk-Around Inspection ........................................ 74
Every Year
Cooling System Coolant - Change ....................... 51
Engine Mounts - Inspect ....................................... 56
SEBU8604 43
Maintenance Section
Actuator Control Linkage - Lubricate
i02471679 i03895079
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
cleaner.
i02322311
Alternator - Inspect
Personal injury can result from air pressure.
i03896155
Note: Adjust the frequency of cleaning according to
the effects of the operating environment. Alternator Pulley - Check
Inspect the aftercooler for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the aftercooler, if necessary. 1. Isolate the electrical supply to the engine.
g02139698
Illustration 30
Typical example
4. Install the guard (3). Note: Before the cables are connected, ensure that
the engine start switch is OFF.
5. Restore the electrical supply to the engine.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
i02322315
i02747977
The battery cables or the batteries should not be All lead-acid batteries contain sulfuric acid which
removed with the battery cover in place. The bat- can burn the skin and clothing. Always wear a face
tery cover should be removed before any servic- shield and protective clothing when working on or
ing is attempted. near batteries.
Removing the battery cables or the batteries with 1. Remove the filler caps. Maintain the electrolyte
the cover in place may cause a battery explosion
level to the “FULL” mark on the battery.
resulting in personal injury.
If the addition of water is necessary, use distilled
1. Switch the engine to the OFF position. Remove water. If distilled water is not available use clean
all electrical loads. water that is low in minerals. Do not use artificially
softened water.
46 SEBU8604
Maintenance Section
Battery or Battery Cable - Disconnect
2. Check the condition of the electrolyte with a 7. Proceed with necessary system repairs.
suitable battery tester.
8. In order to connect the battery, connect the
3. Install the caps. positive connection before the negative connector.
i02323088
2. Disconnect the negative battery terminal. Ensure 2. Remove the guard (3).
that the cable cannot contact the terminal. When
four 12 volt batteries are involved, two negative Note: The bolts (2) are captive.
connection must be disconnected.
3. Inspect the belt (1) for cracks. Inspect the belt
3. Remove the positive connection. for contamination. If necessary, replace the belt.
Refer to “Replacement” for more information.
4. Clean all disconnected connection and battery
terminals.
g01239310
Illustration 33
Replacement 2. Pull the alternator (6) away from the engine. Install
bolt (4) and nut (5).
Removal of the Alternator Belt
3. Tighten nuts (5) and (7).
1. If necessary, Isolate the electrical supply to the
engine and remove the guards. 4. Check the tension of the belt. Refer to “Inspection”
for the correct procedure.
i03754170
Belts - Inspect/Adjust/Replace
(Fan Drive Belts)
Inspection
1. Isolate the electrical supply to the engine.
48 SEBU8604
Maintenance Section
Belts - Inspect/Adjust/Replace
g01239588
Illustration 36
Adjustment 3. Rotate the rod (3) until the pulley (2) is toward the
center of the engine.
1. If necessary, isolate the electrical supply to the
engine. Loosen the fasteners for the air pipes and 4. Remove the belts (1).
remove the guards.
Installation of the Fan Drive Belts
1. Install the belts (1) over the pulleys.
SEBU8604 49
Maintenance Section
Cooling System Coolant (ELC) - Change
3. Tighten the locknut (4) to a torque of 120 N·m Pressurized System: Hot coolant can cause seri-
(88.5 lb ft). ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
4. If necessary, restore the electrical supply to the components are cool. Loosen the cooling system
engine. Tighten the fasteners for the air pipes and pressure cap slowly in order to relieve the pres-
install the guards. sure.
i03837530
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. Illustration 37
g01211179
Typical example
Dispose of all fluids according to Local regulations and
mandates.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap (1) slowly in
NOTICE order to relieve any pressure. Remove the cooling
Keep all parts clean from contaminants. system filler cap.
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
NOTICE
Keep all parts clean from contaminants.
4. Remove the filler cap. Check that the coolant level Clean the cooling system and flush the cooling
is within 25 mm (1.0 inch) of the bottom of the system before the recommended maintenance
filler pipe. Clean the cooling system filler cap (1) interval if the following conditions exist:
and inspect the seal (2). If the seal is damaged,
discard the old filler cap and install a new filler • The engine overheats frequently.
cap. If the seal is not damaged, use a suitable
pressurizing pump in order to pressure test the • Foaming of the coolant is observed.
filler cap. The correct pressure is stamped on the
face of the filler cap. If the filler cap does not retain • The oil has entered the cooling system and the
the correct pressure, replace the filler cap. coolant is contaminated.
5. Install the cooling system filler cap. • The fuel has entered the cooling system and the
coolant is contaminated.
6. Start the engine and operate the engine.
Inspect the cooling system for leaks. Ensure Note: When the cooling system is cleaned, only
that the cooling system operates at the correct clean water is needed when the inhibitor is drained
temperature. and replaced.
Drain
g01211161
Illustration 44
Typical example
g01211179
Illustration 42
Typical example
g02126488
Illustration 45
Typical example
Illustration 43
g01211160 5. Remove both the drain plugs (5) in the
Typical example
aftercoolers.
Flush Note: Open the air vent (4) in order to allow air to
be removed from the system. Fill the cooling system
1. Flush the cooling system with clean water in order until coolant free of air flows from the vent . Tighten
to remove any debris. the air vent securely. Ensure that the filler cap is
installed before operating the engine.
2. Close the drain cock or install the drain plug (2) in
the cylinder block. Close the drain cock or install 3. Start the engine. Operate the engine in order to
the drain plug on the radiator. Close the drain purge the air from the cavities of the engine block.
cocks or install the drain plugs (3) in the oil coolers. Use the normal shutdown procedure in order to
Close the drain cocks or install the drain plugs (5) stop the engine.
in the aftercoolers. Tighten the plugs securely.
4. Check that the coolant level is within 25 mm
NOTICE (1.0 inch) of the bottom of the filler pipe.
Do not fill the cooling system faster than 5 L
(1.3 US gal) per minute to avoid air locks.
Loosen the air vent (4) in the aftercoolers. Fill the Illustration 46
g01239656
cooling system until coolant free of air flows from
the vent . Tighten the air vent securely. 5. Clean the cooling system filler cap (1) and inspect
the seal (2). If the seal is damaged, discard the
Install the cooling system filler cap (1). old filler cap and install a new filler cap. If the seal
is not damaged, use a suitable pressurizing pump
4. Start the engine. Operate the engine until the in order to pressure test the filler cap. The correct
temperature reaches 49 to 66 °C (120 to 150 °F). pressure is stamped on the face of the filler cap. If
the filler cap does not retain the correct pressure,
5. Stop the engine and allow the engine to cool. replace the filler cap.
Loosen the cooling system filler cap (1) slowly
in order to relieve any pressure. Remove the Install the cooling system filler cap.
cooling system filler cap. Open the drain cock or
remove the drain plug (2) in the cylinder block. 6. Start the engine and operate the engine.
Open the drain cock or remove the drain plug on Inspect the cooling system for leaks. Ensure
the radiator. Open the drain cocks or remove the that the cooling system operates at the correct
drain plugs (3) in the oil coolers. Remove the drain temperature.
plugs (5) in the aftercoolers. Allow the water to
drain. Flush the cooling system with clean water.
i02415245
i02415247
Engine - Clean
1. Remove the cooling system filler cap (1) slowly in Moisture can create paths of electrical conductiv-
order to relieve pressure. ity.
2. Maintain the coolant level within 25 mm (1.0 inch) Make sure that the electrical system is OFF. Lock
of the bottom of the filler pipe. out the starting controls and tag the controls “DO
NOT OPERATE”.
NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.
g01239656
Illustration 48
NOTICE
3. Clean the cooling system filler cap (1) and inspect Water or condensation can cause damage to gen-
the seal (2). If the seal is damaged, discard the erator components. Protect all electrical components
old filler cap and install a new filler cap. If the seal from exposure to water.
is not damaged, use a suitable pressurizing pump
in order to pressure test the filler cap. The correct
pressure is stamped on the face of the filler cap. If NOTICE
the filler cap does not retain the correct pressure, Failure to protect some engine components from
replace the filler cap. washing may make your engine warranty invalid.
Allow the engine to cool for one hour before washing
Install the cooling system filler cap. the engine.
g01242320
Illustration 50
g01242332
Illustration 49
g02041313 Illustration 51
1. Release the clips (3) and remove cover (4). When the air filter element requires replacement, the
center section of the service indicator (1) is red.
2. Remove the old element (2) from the housing (1).
Discard the old element.
g01242328
Illustration 52
If the service indicator does not reset easily, the Typical example
service indicator should be replaced.
2. Remove the wing nut (1) and the cover (2).
Note: The service indicator may need to be replaced
frequently in environments that are severely dusty. 3. Remove the filter elements (3) from the breather
body (5).
i03874496 4. Clean the filter elements (3) and dry the filter
elements. Inspect the filter elements for damage
Engine Crankcase Breather - or deterioration. If necessary, replace the filter
Clean elements.
i02415257
• Improper mounting
SEBU8604 57
Maintenance Section
Engine Oil Filter (Auxiliary) - Change
• Deterioration of the isolators • (A) The oil flow is to both oil filters.
Ensure that the mounting bolts are tightened to the • (B) The oil flow is to the left hand oil filter.
correct torque.
• (C) The oil flow is to the right hand oil filter.
Ensure that the isolators are free of oil and
contamination. Inspect the isolators for deterioration. 1. Rotate the changeover valve to position B. By
Ensure that the bolts for the isolators are tightened to using a suitable tool (2), remove the right hand
the correct torque. oil filter.
Replace any isolator that shows deterioration. For Note: Oil flow direction (D and E ).
more information, see the literature that is provided
by the OEM of the isolators. 2. Ensure that the sealing face on the housing is
clean. Fill the new oil filter with clean engine oil.
Install the new oil filter. Rotate the changeover
i02472513
valve to position A. Check for oil leaks.
Engine Oil Filter (Auxiliary) - 3. Rotate the changeover valve to position C. By
Change using a suitable tool, remove the left hand oil filter.
NOTICE
Perform this maintenance with the engine stopped.
NOTICE
Operating your engine when the oil level is above the
“Max” mark could cause your crankshaft to dip into
the oil. The air bubbles created from the crankshaft
dipping into the oil reduces the oil's lubricating char-
acteristics and could result in the loss of power.
g01233078
Illustration 54
Typical example
58 SEBU8604
Maintenance Section
Engine Oil Pump - Inspect
i02415262
g01165836
Note: Perkins Engines Stafford must agree to the
Illustration 56 maintenance schedule.
(Y) “Min” mark. (X) “Max” mark.
1. Maintain the oil level between the “Min” mark (Y) Obtain the Sample and the Analysis
and the “Max” mark (X) on the engine oil level
gauge (2). Do not fill the oil pan above the “Max”
mark (X).
Hot oil and hot components can cause personal
2. If necessary, remove the oil filler cap (1) and add injury. Do not allow hot oil or hot components to
oil. Clean the oil filler cap. Install the oil filler cap. contact the skin.
i03883009 The oil sample must be taken from the mean level in
the engine oil pan. Do not take an oil sample from
Engine Oil Pump - Inspect the drain plug.
• The amount of oil that has been added since the Failure to follow this recommended procedure will
last oil change cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
Ensure that the container for the sample is clean and
dry. Also ensure that the container for the sample is
clearly labelled.
Drain the Engine Lubricating Oil
Engine Oil and Filter - Change 1. Place a suitable container below the engine oil
pan. Remove the drain plug (3). Allow the engine
oil to drain.
g01237432
Illustration 58 g01165836
Illustration 59
Typical example
(Y) “Min” mark. (X) “Max” mark.
1. Use Tooling (A) in order to remove the oil filters (4).
5. Remove the engine oil level gauge (2) in order to
2. Ensure that the sealing face of the filter base (6) check the oil level. Maintain the oil level between
is clean. the “MIN” and “MAX” marks on the engine oil level
gauge.
3. Lubricate the sealing rings (5) with clean engine
oil. Fill the oil filters with clean engine oil. Ensure i02461963
that the engine oil that is added to the oil filters
has not been contaminated. Install the new oil Engine Protective Devices -
filters (4).
Check
Note: Apply hand pressure only in order to tighten
the oil filters.
Alarms and shutoffs must function properly. Alarms
Fill the Oil Pan provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
Refer to Operation and Maintenance Manual, “Fluid to determine if the engine protective devices are
Recommendations” for information on suitable oils. in good working order during normal operation.
Malfunctions must be simulated in order to test the
1. Remove the oil filler cap. engine protective devices.
2. Fill the oil pan with the correct amount of new A calibration check of the engine protective devices
engine lubricating oil. Refer to Operation and will ensure that the alarms and shutoffs activate
Maintenance Manual, “Refill Capacities” for more at the setpoints. Ensure that the engine protective
information. devices are functioning properly.
NOTICE NOTICE
If equipped with an auxilliary oil filter system or a re- During testing, abnormal operating conditions must be
mote filter system, follow the OEM or the filter manu- simulated.
facture's remonmendations. Under filling or over filling
the crankcase with oil can cause engine damage. The tests must be performed correctly in order to pre-
vent possible damage to the engine.
Note: Before starting the engine, crank the engine on
the starter in order to obtain oil pressure.
SEBU8604 61
Maintenance Section
Engine Valve Lash - Inspect/Adjust
Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
immediately.
i03783810
g01241941
Illustration 61
4016 Engine
g01241584
Illustration 63
g01241598
Illustration 64
g01238304
Illustration 66
Typical example
g01241917
Illustration 65
12. Ensure that the rocker cover (2) is clean and free
from damage. Ensure that the joint face of the
rocker base (10) is clean and free from damage.
i03784609
i02415266
• A leak exists in the low pressure fuel system. Note: Clean up any spillage of fuel immediately.
• The fuel filter has been replaced. 3. Loosen the connection (1) at the tee piece (2).
Use the following procedures in order to remove air 4. Unscrew the handle (4) in order to operate the fuel
from the fuel system. priming pump (3). Pump the handle until fuel that
is free of air flows from the tee piece (2).
Note: Do not bleed the fuel system from the water
separator (if equipped). 5. Tighten the connection (1) on the tee piece (2).
g01237503
Illustration 69
Typical example
8. Operate the handle (4) until fuel that is free of air 2. Place a suitable container under the fuel filter in
flows from the connection (5). order to catch any fuel that might spill.
9. Tighten the connection (5). Note: Clean up any spilled fuel immediately.
11. Operate the handle (4) until fuel that is free of air
flows from the connection (6) and (8).
g02126034
i03837989 Illustration 70
Fuel System Filter - Replace 3. Loosen the drain plug (2). Allow the fluid to drain
into the container.
Fuel Filter with Water Separator 9. Prime the fuel system. Refer to the Operation and
Maintenance Manual, “Fuel System - Prime” for
Table 24 more information.
Required Tools
10. Start the engine and run the engine. Check the
Part fuel system for leaks.
Tool Part Name Qty
Number
A - Strap Wrench 1
i03880440 i02335436
NOTICE
Care must be taken to ensure that fluids are contained
Fuel leaked or spilled onto hot surfaces or elec- during performance of inspection, maintenance, test-
trical components can cause a fire. To help pre- ing, adjusting, and repair of the product. Be prepared
vent possible injury, turn the start switch off when to collect the fluid with suitable containers before
changing fuel filters or water separator elements. opening any compartment or disassembling any com-
Clean up fuel spills immediately. ponent containing fluids.
• Weekly
• Service intervals
• Refill of the tank
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank. g01280509
Illustration 72
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to 3. Remove the fuel priming pump (5).
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap 4. Disconnect fuel line (3) and the connection (1).
sediment. Filtering fuel that is pumped from the Cap the fuel line with a suitable cap.
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used. 5. Remove the two nuts (4).
Replacement of the Lift Pump Note: Ensure that the oil seal is not damaged as the
lift pump is installed.
Removal of the Lift Pump 3. Install the nuts (4). Tighten the nuts to a torque of
25 N·m (18 lb ft).
1. Isolate the fuel supply to the lift pump.
4. Remove the cap from the fuel line (3). Connect
2. Place a suitable container below the lift pump in the fuel line and the connection (1). Tighten the
order to catch any fuel that might be spilled. fuel line and the connection to a torque of 50 N·m
(37 lb ft).
Note: Clean up any spillage of fuel immediately.
5. Fit the fuel priming pump (5) to the lift pump (2).
Check for the following conditions: 2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
• End fittings that are damaged or leaking system filler cap.
• Outer covering that is chafed or cut Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
• Exposed wire that is used for reinforcement
3. Drain the coolant from the cooling system to a
• Outer covering that is ballooning locally level that is below the hose that is being replaced.
• Flexible part of the hose that is kinked or crushed 4. Remove the hose clamps.
• Armoring that is embedded in the outer covering 5. Disconnect the old hose.
SEBU8604 69
Maintenance Section
Overhaul (Major)
6. Replace the old hose with a new hose. Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
7. Install the hose clamps with a torque wrench. that is provided by the OEM of the driven equipment.
10. Start the engine. Inspect the cooling system for Inspecting Components
leaks.
Inspect the following components during a major
overhaul.
i02461950
Note: Generally, cylinder heads wear out at different After 4000 hours running, the valve seat wear on
rates. In some cases, servicing the cylinder heads at the inlet is 0.65 mm (0.026 inch) and the exhaust is
different times may be the most economic decision. 0.45 mm (0.018 inch).
This depends on the valve stem projection of the
individual cylinders. However, this decision must Note: Maximum permitted valve seat wear is
include the costs of additional downtime that is 1.00 mm (0.040 inch).
caused by this procedure. Perform an economic
analysis in order to determine if cylinder heads should In this example, the valves are still serviceable after
be serviced as a group or divided into smaller groups. 4000 hours running.
Every 500 service hours record the valve lash. The Radiator - Clean
monitoring of the valve seat wear should be carried
out before any adjustment of the valve lash.
1. Remove the rocker covers. Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
2. Refer to Operation and Maintenance Manual,
“Valve Lash - Inspect Adjust”. Inspect the radiator for these items: Damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
3. On all engine cylinders, record the clearance debris. Clean the radiator, if necessary.
before any adjustments are made.
After cleaning the radiator, start the engine. Run the The operating environment, incorrect operating
engine. This will help in the removal of debris and procedures and incorrect maintenance procedures
the drying of the core. Stop the engine. Use a light can be factors which contribute to a severe service
bulb behind the core in order to inspect the core for application.
cleanliness. Repeat the cleaning, if necessary.
Severe service operation can accelerate component • Failure to use recommended fuel, lubricants and
coolant/antifreeze
wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention of
full service life.
Overspeed Sensor
The overspeed sensor is located in the left hand side
of the flywheel housing.
g01237852
Illustration 73
Typical example
i03882553
4. Use a soft, dry cloth in order to clean any debris • Loose connections
from the sensor (2).
• Corrosion
Note: Do not use a wire brush in order to clean the
sensor. Do not use abrasive material in order to clean • Wires that are worn or frayed
the sensor.
• Cleanliness
5. Install Tooling (A). Use Tooling (A) in order to
rotate the engine. Rotate the engine in order to Make repairs, if necessary.
align a tooth on the ring gear with the center of
the tapped hole. The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine
6. By hand, carefully install the sensor (2) until light to start properly. The engine will not start if the
contact is made with the ring gear. starting motor pinion does not engage the flywheel
ring gear. The teeth of the starting motor pinion and
Note: Do not tighten the sensor. the flywheel ring gear can be damaged because of
irregular engagement.
g01237854
Illustration 76
74 SEBU8604
Maintenance Section
Turbocharger - Inspect
For maximum engine service life, make a thorough • Inspect the wiring harness for damage.
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant Belts for multiple groove pulleys must be replaced as
leaks, loose bolts, worn belts, loose connections and matched sets. If only one belt is replaced, the belt will
trash buildup. Make repairs, as needed: carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
• The guards must be in the correct place. Repair the new belt could cause the belt to break.
damaged guards or replace missing guards.
i03882689
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
Water Pump - Inspect
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the A failed water pump may cause severe engine
fluid. If leaking is observed, find the source and correct overheating problems that could result in the following
the leak. If leaking is suspected, check the fluid levels conditions:
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be • Cracks in the cylinder head
unwarranted.
• A piston seizure
NOTICE
Accumulated grease and/or oil on an engine is a fire • Other potential damage to the engine
hazard. Remove the accumulated grease and oil. Re-
Note: The water pump seal is lubricated by the
fer to Operation and Maintenance Manual, “Engine -
coolant in the cooling system. It is normal for a small
Clean” for more information.
amount of leakage to occur as the engine cools down
and parts contract.
• Ensure that the cooling system hoses are correctly
clamped and that the cooling system hoses are Visually inspect the water pumps for leaks. The water
tight. Check for leaks. Check the condition of all pumps are not serviceable items. Replace a leaking
pipes. water pump.
• Inspect the piping for the air intake system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.
Warranty Section
Warranty Information
i01903596
Emissions Warranty
Information
Index
A Engine Air Cleaner Service Indicator - Inspect...... 55
Service Indicator Check ..................................... 55
Actuator Control Linkage - Lubricate ..................... 43 Service Indicator Reset...................................... 56
After Stopping Engine............................................ 29 Engine Crankcase Breather - Clean...................... 56
Aftercooler Core - Clean/Test ................................ 43 Engine Description ................................................ 15
Aftercooler Core - Inspect...................................... 44 Engine Cooling and Lubrication ......................... 16
Alternator - Inspect ................................................ 44 Engine Specifications......................................... 15
Alternator Pulley - Check....................................... 44 Engine Electronics.................................................. 11
System Description ............................................. 11
Engine Lifting......................................................... 19
B Engine Mounts - Inspect........................................ 56
Engine Oil and Filter - Change .............................. 59
Battery - Replace................................................... 45 Drain the Engine Lubricating Oil ........................ 59
Battery Electrolyte Level - Check .......................... 45 Fill the Oil Pan.................................................... 60
Battery or Battery Cable - Disconnect ................... 46 Replace the Oil Filter ......................................... 59
Before Starting Engine .................................... 10, 26 Engine Oil Filter (Auxiliary) - Change .................... 57
Belts - Inspect/Adjust/Replace (Alternator Belt) .... 46 Change the Filter with the Engine in Operation.. 57
Adjustment ......................................................... 47 Engine Oil Level - Check ....................................... 57
Inspection........................................................... 46 Engine Oil Pump - Inspect..................................... 58
Replacement...................................................... 47 Engine Oil Sample - Obtain ................................... 58
Belts - Inspect/Adjust/Replace (Fan Drive Belts)... 47 Initiating an Oil analysis Program ...................... 58
Adjustment ......................................................... 48 Obtain the Sample and the Analysis.................. 58
Inspection........................................................... 47 Engine Operation................................................... 28
Replacement...................................................... 48 Engine Protective Devices - Check ....................... 60
Burn Prevention....................................................... 7 Visual Inspection................................................ 61
Batteries............................................................... 7 Engine Starting ................................................ 10, 26
Coolant................................................................. 7 Engine Stopping .............................................. 10, 29
Oils....................................................................... 7 Engine Storage...................................................... 21
Level “A ” ........................................................... 21
Level “B ” ........................................................... 21
C Level “C ” .......................................................... 21
Engine Valve Lash - Inspect/Adjust (Valves and Valve
Cold Weather Starting ........................................... 27 Bridges) ............................................................... 61
Cooling System Coolant - Change (Inhibitor) ........ 51
Drain .................................................................. 52
Fill ...................................................................... 53 F
Flush .................................................................. 53
Cooling System Coolant (ELC) - Change.............. 49 Fan Drive Pulley - Check....................................... 63
Drain .................................................................. 49 Features and Controls ........................................... 22
Fill ...................................................................... 50 Fire Prevention and Explosion Prevention .............. 7
Flush .................................................................. 50 Fire Extinguisher .................................................. 9
Cooling System Coolant Level - Check ................. 53 Lines, Tubes and Hoses ...................................... 9
Crushing Prevention and Cutting Prevention .......... 9 Fluid Recommendations (Cooling System
Specifications) ..................................................... 30
ELC Cooling System Maintenance .................... 32
D General Coolant Information.............................. 30
Fluid Recommendations (Fuel Specifications) ...... 35
Driven Equipment - Check..................................... 54 Fuel Recommendations ..................................... 35
Fluid Recommendations (General Lubricant
Information).......................................................... 38
E Engine Oil .......................................................... 38
Foreword ................................................................. 4 O
California Proposition 65 Warning ....................... 4
Literature Information........................................... 4 Operation Section.................................................. 19
Maintenance ........................................................ 4 Overhaul (Major).................................................... 69
Maintenance Intervals.......................................... 4 Major Overhaul Information ............................... 69
Operation ............................................................. 4 Scheduling a Major Overhaul............................. 69
Overhaul .............................................................. 4 Overhaul (Top End) ............................................... 69
Safety................................................................... 4 Scheduling a Top End Overhaul ........................ 69
Fuel Conservation Practices.................................. 28 Top End Overhaul Information ........................... 70
Fuel Injector - Inspect/Adjust ................................. 64
Inspect the Fuel Injectors................................... 64
Fuel System - Prime .............................................. 64 P
Fuel System Filter - Replace ................................. 65
Fuel Filter with Water Separator ........................ 65 Plate Locations and Film Locations....................... 17
Fuel System Primary Filter/Water Separator - Engine Identification........................................... 17
Drain .................................................................... 66 Serial Number Plate........................................... 18
Fuel Tank Water and Sediment - Drain ................. 66 Product Identification Information .......................... 17
Drain the Water and the Sediment..................... 66 Product Information Section .................................. 12
Fuel Storage Tanks ............................................ 67
Fuel Tank ........................................................... 66
Fuel Transfer Pump (Lift Pump) - Inspect ............. 67 R
Replacement of the Lift Pump............................ 67
Radiator - Clean .................................................... 70
Refill Capacities..................................................... 30
G Cooling System.................................................. 30
Fuel System ....................................................... 30
General Hazard Information .................................... 5 Lubrication System ............................................ 30
Containing Fluid Spillage ..................................... 6
Fluid Penetration.................................................. 6
Pressure Air and Water........................................ 6 S
General Information............................................... 12
Governor Actuator - Check.................................... 68 Safety Messages ..................................................... 5
(1) Universal Warning .......................................... 5
(2) Hot Coolant..................................................... 5
H Safety Section ......................................................... 5
Sensors and Electrical Components ..................... 22
Hoses and Clamps - Inspect/Replace ................... 68 Boost Pressure Sensors .................................... 23
Replace the Hoses and the Clamps .................. 68 Coolant Temperature Sensor ............................. 23
Engine Oil Pressure Switch ............................... 24
High Turbine Inlet Temperature Shutdown
I Sensor.............................................................. 24
Overspeed Sensor ............................................. 25
Important Safety Information ................................... 2 Sensor Locations ............................................... 22
Speed Sensor .................................................... 25
Severe Service Application - Check ...................... 71
L Environmental Factors ....................................... 71
Incorrect Maintenance Procedures .................... 71
Lifting and Storage ................................................ 19 Incorrect Operating Procedures......................... 71
Speed Sensor - Clean/Inspect (Engine Speed Sensor
and Overspeed Sensor)....................................... 72
M Engine Speed Sensor ........................................ 72
Overspeed Sensor ............................................. 72
Maintenance Interval Schedule ............................. 42 Starting Motor - Inspect ......................................... 73
Maintenance Section ............................................. 30 Starting the Engine ................................................ 26
Model View Illustrations......................................... 13 Normal Engine Starting Procedure .................... 26
4016-61TRG ...................................................... 13 Stopping the Engine .............................................. 29
Model Views .......................................................... 13
Monitoring System................................................. 22
Mounting and Dismounting...................................... 9 T
Table of Contents..................................................... 3
SEBU8604 79
Index Section
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
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