Perkins 4006 User Handbook Manual
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Perkins 4006 User Handbook Manual

Diesel engine
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TSL4184E
May 1998
User's
Handbook
Perkins 4006 and 4008 Diesel
4006
4008

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  • Page 1 TSL4184E May 1998 User’s Handbook Perkins 4006 and 4008 Diesel 4006 4008...
  • Page 2 INCLUDED IN THE INSTALLATION MANUAL TSL4068 MAY INVALIDATE THE WARRANTY OFFERED WITH THE ENGINE. MAKE QUITE CERTAIN THAT THE ENGINE CANNOT BE STARTED IN ANY WAY BEFORE UNDERTAKING ANY MAINTENANCE, PARTICULARLY IN THE CASE OF AUTOMATICALLY STARTING GENERATING SETS. 4006/8 Diesel, May 1998...
  • Page 3 Tel.: (49) (6027) 5010 Fax: (49) (6027) 501130 In addition to the above companies, there are Perkins Distributors in most countries. Perkins Engies (Peterborough) Limited or one of the above companies can provide distributor handbooks Publication No. 1407/4/97 Publication TSL4184 Published by the Technical Publications Department, Stafford.
  • Page 4 PERKINS ENGINES (STAFFORD) ENGINE DESIGNATIONS 4000 SERIES AND SE SERIES EQUIVALENT TERMS 4000 SERIES SE SERIES 4006TG 6SET 4006TWG 6SETCR 4006TWG3 6SETCR3 4006TAG1 6SETCA1 4006TAG2 6SETCA2 4006TAG3 6SETCA3 4006TEG 6SETCW 4008TWG2 8SETCR2 4008TAG 8SETCA 4008TAG1 8SETCA1 4008TAG2 8SETCA2 4006/8 Diesel, May 1998...

  • Page 5: Table Of Contents

    CONTENTS PAGE INTRODUCTION & LIST OF PERKINS COMPANIES WORLDWIDE ENGINE DESIGNATIONS PHOTOGRAPHS INSERTS BRIEF DESCRIPTION OF THE 4006/8 DIESEL ENGINES GENERAL INFORMATION DIESEL ENGINE DATA 7-11 TORQUE SETTINGS 12-14 LUBRICATING OIL RECOMMENDATIONS 15-16 COOLANT, CORROSION INHIBITORS, ANTI-FREEZE FUEL SPECIFICATION OPERATING INSTRUCTIONS...
  • Page 6 4006TWG3 4006TG...
  • Page 7 4006TAG3 4008TAG2...

  • Page 8: Brief Description Of The 4006/8 Diesel Engines

    BRIEF DESCRIPTION OF THE 4006/8 DIESEL ENGINES 4006TG 6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler in engine cooling circuit. 4006TWG 6 cylinder, inline, water cooled, 4 stroke, turbocharged diesel engine, with jacket water cooled oil cooler and charge air cooler in engine cooling circuit.

  • Page 9: General Information

    12. Where there is the possibility of a risk to result in skin cancer. the eyes, goggles or a face shield Adequate means of skin protection and should be worn. An eye wash facility washing facilities should be readily available. should be readily available. 4006/8 Diesel, May 1998...
  • Page 10 Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling. 4006/8 Diesel, May 1998...

  • Page 11: Diesel Engine Data

    Engine with heat exchanger Engine shut down temperature 96°C To be determined from heat dissipated & water flow Max water temperature into engine through each particular engine model Thermostat opening temperature 71°C System pressure 0.5 to 0.7 bar 4006/8 Diesel, May 1998...
  • Page 12 Twin air cleaners Twin air cleaners (Uprate) Type (paper element) S551A Max. Air intake depression 381 mm H O (28 mm Hg) Air restriction Indicator setting 380 mm H Turbocharger (x2) Garrett (x1) (x2 uprate only) 4006/8 Diesel, May 1998...
  • Page 13 Max. overhung weight on rear bearing 1000 kg Tuning plate 1 x 14.6" T.V. damper (non uprate) 1 x 14" 2 x 20" (uprate) 1 x 18" NOTE: Subject to a torsional vibration investigation different T.V. dampers may be fitted 4006/8 Diesel, May 1998...
  • Page 14 No. of teeth (starter motor) Battery capacity cold cranking amps 540 (each battery) 600 (each battery) to IEC Standard at 0°C (32°F) Battery (lead acid) 24 V (2 x 12V) Total 143 Ah (2 x 12V) Total 178 Ah 4006/8 Diesel, May 1998...
  • Page 15 Between 300-560 kPa (42.6-80 lb/in²) Oil temperature Between 80-90°C (176-194°F) Water temperature Between 65-85°C (149-185 °F) Exhaust temperature Product Information Manual Boost pressure See Test Certificate COOLANT JACKET HEATING Heater 1 x 2 kW 1 x 4 kW 4006/8 Diesel, May 1998...

  • Page 16: Torque Settings

    CRANKCASE AND CRANKSHAFT GROUPS * Main bearing bolt Side bolts (main bearing caps) Bolts sump to crankcase * Connecting rod bolt Viscous damper botls (4006/8 series) Flywheel bolts Front drive adaptor bolts Balance weight bolt Front crankshaft pulley bolt Piston cooling jet bolt...
  • Page 17 Injector nozzle nut to holder Fuel pump control linkage screw Unit injector control lever capscrews FLEXIBLE COUPLING (HOLSET) Flexible coupling cover screw M12 or " UNC Coupling driving flange screws (coupling size 2.15) M12 or " UNC 4006/8 Diesel, May 1998...
  • Page 18 The following torque loadings are general for metric coarse threads for grade 8.8 steel and do not supersede the figures quotes above. Thread size (mm) lbf.ft General Note: M10-12.9 steel These are based to BS 3692. 4006/8 Diesel, May 1998...

  • Page 19: Lubricating Oil Recommendations

    The flash point of the oil should exceed 180°C. The water content of the oil must not exceed 1%. The fuel content of the oil must not exceed 1%. Oil samples should be taken from the mean sump oil level of the engine. 4006/8 Diesel, May 1998...
  • Page 20 The following list gives details of some of the oils that meet the required specifications. Note that the brand names may change as oils are upgraded or reformulated. An up-to-date list is maintained by Perkins Engines (Stafford) Limited of major oil companies products and information, which can be obtained from Perkins Engines (Stafford) Service Department.
  • Page 21 Perkins Engines (Stafford) Ltd for advice. Under no circumstances should an additive containing nitrites, borates, phosphates, chromates, nitrates or silicates be used, as these materials are not compatible with the materials used in the cooling system. 4006/8 Diesel, May 1998...

  • Page 22: Fuel Specification

    British Standard Specification 2869. Class A1 or A2. If fuels other than the above classes are considered, the operator must consult Perkins Engines (Stafford) Limited, and ensure that a suitable grade of lubricating oil is used.

  • Page 23: Operating Instructions

    Fig. 2. Fill the sump to maximum mark on the dipstick see Fig. 3 with the appropriate grade and quality of oil specified, see Pages 15 - 16 replace the plug, rotating the T-bar to tighten and seal it. 4006/8 Diesel, May 1998...

  • Page 24: Priming The Lubrication System

    25 mm (1") below the top of the filter neck then replace the cap. 4006/8 Diesel, May 1998...

  • Page 25: Priming The Fuel System

    On engines fitted with a change over filter system prime the system as described above but prime the filter on the engine feed side union (6) Fig. 8 before priming the fuel rail. Fig. 7 Fig. 8 4006/8 Diesel, May 1998...

  • Page 26: Instrument Panel (Engine Mounted)

    Cooling water temperature Battery charging rate Fuse holder Lubricating oil temperature Speed and hours run Exhaust temperature Lubricating oil pressure Keyswitch gauge (when fitted) Fig. 9 4006/8 Diesel, May 1998...
  • Page 27 Ammeter (Ampere) Fig. 13 The ammeter indicates at what charging current the battery is being charged by the alternator, or to what extent current is taken from the battery without the battery being recharged. Fig. 12 Fig. 13 4006/8 Diesel, May 1998...

  • Page 28: Exhaust Temperature Gauge (Engine Mounted)

    (see Fig. 16) viewed from front of switch. Fuse holder To protect the instrument panel a 2 amp fuse Fig. 15 is fitted to remove the fuse (1) unscrew its holder (2) (see Fig. 17). Fig. 16 Fig. 17 4006/8 Diesel, May 1998...

  • Page 29: Normal Starting Procedure

    Manual stopping can be used override electrical system necessary. Should the engine stop due to the air shut-off valves being operated, it is imperative that the cause of the fault be investigated immediately. 4006/8 Diesel, February 1998...

  • Page 30: Light Load Operation And Standby Generating Sets

    1) Running on light load should be avoided or reduced to the minimum period. If weekly exercising on no load is carried out, the running period should be kept down to say, 10 minutes, or until the battery charging rate returns to normal 4006/8 Diesel, May 1998...

  • Page 31: Maintenance Procedures

    At this point the air filter must be Always replace the filler plug immediately changed (see page 40). When the air filters replenishment is completed. have been changed reset the indicator by pressing button 'B'. (See Fig. 19). 4006/8 Diesel, May 1998...
  • Page 32 D1 of the Workshop Manual. Replace any guards removed before running the engine (see Fig. 20). NEW OR REBUILT ENGINES It is essential to carry out the following maintenance procedure after the initial 100 hours. 4006/8 Diesel, May 1998...
  • Page 33 Using light pressure midway between the two pulleys a total Fig. 22 deflection of 1.5 mm ( ") is satisfactory (see Fig. 22). Refit the guard. 4006/8 Diesel, May 1998...
  • Page 34 Force lb Force 3 - 4.3 6.67 - 9.47 11 mm Fan belts if worn, should be replaced as a complete, matching set. Individual belts should NOT be replaced. deflection 11 mm force Fig. 23 4006/8 Diesel, May 1998...

  • Page 35: Fault Tracing Chart

    (2 belts banded together to make a The crankcase breather is mounted on the W belt). side of the radiator Fig. 24 and is connected to an elbow mounted on the gearcase by a flexible pipe Fig. 4006/8 Diesel, May 1998...
  • Page 36 (Fig. 26) 1. Position of breather when engine is fitted with a radiator 2. Position of breather when engine is fitted with heat exchanger 3. Flexible pipe 4. Elbow Fig. 25 Fig. 26 4006/8 Diesel, May 1998...
  • Page 37 (See Fig. 26). NOTE: When replacing the cover check the sealing gasket is in good condition and the cover has located on its dowel. Fig. 28 4006/8 Diesel, May 1998...
  • Page 38 Check that the spring and shuttle are undamaged and free to move. Examine gasket for damage. Renew if necessary. Re-assemble cut-off valve assembly. 4006/8 Diesel, May 1998...
  • Page 39 Use only genuine Perkins oil filters. The use of other filters may cause serious damage to the engine.
  • Page 40 Check the filter for leaks after the engine is restarted. Fig. 31 4006/8 Diesel, May 1998...
  • Page 41 The valve is then returned to its original position, so that both elements of the filter are back in service. Check for oil leaks. Fig. 32 4006/8 Diesel, May 1998...
  • Page 42 Check for leaks when the engine is restarted. Fig. 34 NOTE: Prepare for some spillage of fuel by placing a bowl of about 5 litres or 1 gallon capacity under the filter when changing the capacities. 4006/8 Diesel, May 1998...
  • Page 43 5 litres or 1 gallon capacity under the filter when changing the capacities. (Fig. 35) 1. Both filters in use (Normal Running Position) 2. Change right hand filter 3. Change left hand filter 4006/8 Diesel, May 1998...
  • Page 44 "clean air side" of the element and the outlet side of the filter housing for any unusual dust accumulations. (a) Dust accumulations on the clean air side of the element usually indicates a rupture in the filter medium. Immediate replacement element necessary. 4006/8 Diesel, May 1998...
  • Page 45 Before refitting ensure that the cup at the base of the two breather valves are full of clean engine oil and the 'O' ring at the base Fig. 38 of the breather valve is in tact. (See Fig. 39). Fig. 39 1005.3 4006/8 Diesel, May 1998...
  • Page 46 Clean any oil sludge deposits from the filter body re- assemble and fit to engine. NOTE: Cleaning agents must not enter the Fig. 40 engine via the breather system as oil dilution may occur causing engine damage. 4006/8 Diesel, May 1998...
  • Page 47 Fig. 43. 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. Fig. 43 4006/8 Diesel, May 1998...
  • Page 48 Set Bridge Piece and Valve T.D.C. Cylinder No. Clearance on Cylinder No. 1 and 8 4 and 5 2 and 7 3 and 6 1 and 8 4 and 5 2 and 7 3 and 6 4006/8 Diesel, May 1998...
  • Page 49 Equalise bridge pieces and check valve clearances NOTE: All bolts, hose clips, terminal connections, pipes and joints must be checked for tightness and leaks every 3 months unless stated otherwise. * By a person who has had the correct training. 4006/8 Diesel, May 1998...
  • Page 50 Drain and flush the coolant system and renew coolant mixture Ensure that the fuel injectors are checked and corrected or renewed, if necessary * * By a person who has had the correct training. 4006/8 Diesel, May 1998...
  • Page 51 4006/4008 ENGINE FAULT TRACING Fig. 46 4006/8 Diesel, May 1998...

  • Page 52: Wiring Diagram Cav Starter, With Repeater Relay

    6. NOTE: Aux terminal gives a battery negative signal when solenoid is fully energised. enable engine immediately on depressing start button F.P.S. must be fed positive +ve 7. Fuel stop solenoid relay 8. Start button Fig. 47 4006/8 Diesel, May 1998...

  • Page 53: Wiring Diagram Cav Starter, Without Repeater Relay

    5. Fuel stop solenoid relays 6. NOTE: Aux terminal gives a battery negative signal when solenoid is fully energised. enable engine immediately on depressing start button F.P.S. must be fed positive +ve 7. Start button Fig. 48 4006/8 Diesel, May 1998...

  • Page 54: Wiring Diagram Cav Starter With Repeater Relay

    +ve supply 15.Oil pressure sender 33.Speed trim pot 16.Oil pressure sender 34.If speed trim pot is not required remove 17.Key switch if required and connect thus 18.Starter motor 35.Wire sizes 19.Start relay 20.Fuel solenoid relay Fig. 49 4006/8 Diesel, May 1998...

  • Page 55: Wiring Diagram Engine Without Repeater (Manual Start)

    45.0 Amps inrush and connect thus 0.75 Amps holding 13. Combined engine fault switch 14. Water temperature 15. Oil pressure 16. Key switch if required 17. Governor control box 18. Magnetic pick-ups 19. Engine flywheel Fig. 50 4006/8 Diesel, May 1998...

  • Page 56: Wiring Diagram Prestolite Starter With Repeater Relay

    6. 24 volt starting batteries 7. Starter motor 8. Starter relay 9. Fuel solenoid relay 10. Repeat start unit 11. Fuel stop solenoid energised to stop 45.0 Amps inrush 0.75 Amps holding 12. Start button 13. To stop Fig. 51 4006/8 Diesel, May 1998...

  • Page 57: Wiring Diagram Prestolite Starter Without Repeater Relay

    7. Starter motor 8. Starter relay 9. Relay to allow fuel solenoid to energise before crank 10.Fuel stop solenoid energised to stop 45 Amps inrush 11. Start button 12. Must be +ve immediately on start Fig. 52 4006/8 Diesel, May 1998...

  • Page 58: 4006/8 Diesel, May 1998

    14. Sender oil pressure 15. Governor control box 16. Fuel solenoid energised to run 17. Magnetic pick-up 18. Engine flywheel 19. 24 volt starting batteries 20. Starter motor 21. Start relay Fig. 53 4006/8 Diesel, May 1998...
  • Page 59 © 1998 Perkins Engines Company Limited All Rights Reserved...

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