DPA 4016 Installation Manual Page 1

TSL4186E, Issue 1 February 1998User’sHandbook4000 Series Diesel4016 TAG14016 TAG2

GENERAL INFORMATION4012/16 Diesel, February 1997 10Environmental protectionThere is legislation to protect theenvironment from the incorrect disposal

DIESEL ENGINE DATA4012/16 Diesel, February 1997 11For full technical data please refer to the Product Information Manual.Type: Water-cooled, turbochar

DIESEL ENGINE DATA12 4012/16 Diesel, February 1997TYPICAL COOLING SYSTEM* Engine only** Engine with heat exchangerFUEL SYSTEMGOVERNORS4006 4008Approve

DIESEL ENGINE DATA4012/16 Diesel, February 1997 13LUBRICATION SYSTEMINDUCTION SYSTEMEXHAUST SYSTEMFLYWHEELFLYWHEEL HOUSING4012 4016Recommended oil Se

DIESEL ENGINE DATA14 4012/16 Diesel, February 1997TYPICAL DRY WEIGHTHOLDING DOWN BOLT HOLESELECTRICAL SYSTEM4012 4016Dry weight (engine) 4360 kg 4012T

DIESEL ENGINE DATA4012/16 Diesel, February 1997 15PROTECTION EQUIPMENTBefore resetting protection equipment, it must be established whether special se

TORQUE SETTINGS16 4012/4016 Diesel, February 1997NOTE: * Bolt heads and threads must be lubricated with clean engine oil.** Cylinder head bolts to be

TORQUE SETTINGS4012/4016 Diesel, February 1997 17LUBRICATING OIL PUMP lbf.ft NmBolts, pump housing to gearcase plate M10 35 50Thin nut, gear to drive

TORQUE SETTINGS18 4012/4016 Diesel, February 1997GENERAL TORQUE LOADINGSThe following torque loadings are general for metric coarse threads and for gr

LUBRICATING OIL RECOMMENDATIONS4012/16 Diesel, February 1997 19QUANTITY OF OILTYPE OF OILThe industrial diesel engine should be lubricated with a good

4012/16 Diesel, February 1997WARNINGREAD AND UNDERSTAND ALL SAFETY PRECAUTIONS ANDWARNINGS MENTIONED IN THIS MANUAL.IMPROPER OPERATION OR MAINTENANCE

LUBRICATING OIL RECOMMENDATIONS20 4012/16 Diesel, February 1997ENGINE OPERATIONExcessive periods of idling or repeated cold starts should be avoided,

COOLANT4012/16 Diesel, February 1997 21ENGINE COOLING SYSTEMThe cooling system of an engine containsmany different materials e.g. cast iron,aluminium,

FUEL SPECIFICATION22 4012/16 Diesel, February 1997Fuel should be wholly hydrocarbon oil derived from petroleum, with which small quantitiesof additive

OPERATING INSTRUCTIONS4012/16 Diesel, February 1997 23PREPARING FOR INITIAL STARTFILLING THE ENGINE WITH OILRemove the drain plug to ensure that thesu

OPERATING INSTRUCTIONS24 4012/16 Diesel, February 1997For earlier engines not fitted with a stoplever, disconnect the battery leads andremove the elec

OPERATING INSTRUCTIONS4012/16 Diesel, February 1997 25BATTERIES (SUPPLIED DRY CHARGED)See Installation ManualCheck the level of electrolyte in each ba

OPERATING INSTRUCTIONS26 4012/16 Diesel, February 1997PRIMING AND VENTING THE FUELSYSTEM AS FITTED ON THE EARLIER 12& 16 CYLINDER ENGINES.Loosen t

OPERATING INSTRUCTIONS4012/16 Diesel, February 1997 27PRIMING AND VENTING THE FUELSYSTEM AS FITTED ON LATER 12 & 16CYLINDER ENGINESLoosen the unio

OPERATING INSTRUCTIONS28 4012/16 Diesel, February 1997INITIAL STARTING OF THE ENGINEWHEN FITTED WITH THE ELECTRONICGOVERNORWith the load disengaged, e

OPERATING INSTRUCTIONS4012/16 Diesel, February 1997 29INITIAL STARTING OF THE ENGINEWHEN FITTED WITH THEREGULATEURS EUROPA 2100HYDRAULIC GOVERNORNOTE:

INTRODUCTION4012/16 Diesel, February 1997 1The purpose of this Operators Handbook is to enable the operator to carry out routine servicing of the engi

OPERATING INSTRUCTIONS30 4012/16 Diesel, February 1997NORMAL STARTING PROCEDUREWHEN FITTED WITH THEREGULATEURS EUROPA 2100GOVERNOR AND A WOODWARD TYPE

OPERATING INSTRUCTIONS4012/16 Diesel, February 1997 31ENGINE SHUTDOWNThe engine is normally stopped by operatingan electric stop control via a key swi

LIGHT LOAD OPERATION & STANDBY GENERATING SETS32 4012/16 Diesel, February 1997If an engine is operated on a load less than25-30% of its rated outp

INSTRUMENT PANEL (ENGINE MOUNTED)4012/16 Diesel, February 1997 33DESCRIPTIONThe instrument panel is flexibly mounted on the engine (see Fig. 15). The

INSTRUMENT PANEL34 4012/16 Diesel, February 19971 Engine water temperature gauge(Fahrenheit/Centigrade) Fig. 16The coolant temperature during normalop

INSTRUMENT PANEL4012/16 Diesel, February 1997 355 Engine tachometer and hour counter(revolutions per minute x 1000 andhours) Fig. 20The electrically o

EXHAUST TEMPERATURE GAUGE (OPTIONAL)36 4012/16 Diesel, February 1997DESCRIPTIONAll exhaust temperature gauges are of thehigh accuracy type with digita

EXHAUST TEMPERATURE GAUGE (OPTIONAL)4012/16 Diesel, February 1997 37SPECIFICATIONTemperature range -20/+800°CResolution 1°CAccuracy + 0.5% F.S.D.Probe

EXHAUST TEMPERATURE GAUGE (OPTIONAL)38 4012/16 Diesel, February 1997A four point gauge may also be fitted whichmeasures the exhaust temperature of bot

MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 39Towards the rear of this section are twocheck sheets, one for continuous duty set

ENGINE DESIGNATIONS2 4012/16 Diesel, February 1997PERKINS ENGINES (STAFFORD)ENGINE DESIGNATIONS4000 SERIES AND SE SERIESEQUIVALENT TERMS4000 SERIES SE

MAINTENANCE SCHEDULE & CHECKLISTS40 4012/16 Diesel, February 1997AIR FILTER MAINTENANCEGENERAL SERVICING INSTRUCTIONSServicing procedures include

MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 41DAILY INSPECTIONDRAINING THE WATER TRAP/SEDIMENTER (WHERE FITTED)There are no mov

MAINTENANCE SCHEDULE & CHECKLISTS42 4012/16 Diesel, February 1997EVERY 250 HOURS OR 6 MONTHSCENTRIFUGAL OIL FILTER (IF FITTED)Stop the engine, and

MAINTENANCE SCHEDULE & CHECKLISTS43 4012/16 Diesel, February 1997EVERY 250 HOURS OR EVERY 6MONTHSALTERNATOR DRIVE BELTRemove the small mesh guard

MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 44EVERY 250 HOURS OR EVERY 6 MONTHSBEARINGS AND BELTS (COVRADRADIATOR)Remove the me

MAINTENANCE SCHEDULE & CHECKLISTS45 4012/16 Diesel, February 1997EVERY 250 HOURS OR EVERY 6 MONTHSCRANKCASE BREATHER, EARLIERENGINES (RADIATOR COO

MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 46EVERY 250 HOURS OR EVERY 6 MONTHSCRANKCASE BREATHER (HEATEXCHANGER COOLED ENGINES

MAINTENANCE SCHEDULE & CHECKLISTS47 4012/16 Diesel, February 1997EARLY 250 HOURS OR 6 MONTHSCRANKCASE BREATHER (RADIATOROR HEAT LATEST EXCHANGERCO

MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 48EVERY 250 HOURS OR EVERY 6 MONTHSCLOSED CIRCUIT BREATHER SYSTEM(IF FITTED)The clo

MAINTENANCE SCHEDULE & CHECKLISTS49 4012/16 Diesel, February 1997EVERY 250 HOURS OR EVERY 6 MONTHSTwo breather valves are mounted in thecircuit. T

CONTENTS4012/16 Diesel, February 1997 3PAGEINTRODUCTION 1-2CONTENTS 3SAFETY PRECAUTIONS INSERTPHOTOGRAPHS 6-7BRIEF DESCRIPTION OF THE 4012 & 4016

MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 50EVERY 250 HOURS OR EVERY 6 MONTHSCHANGING ENGINE OIL AND OIL FILTERS(STANDARD HOR

MAINTENANCE SCHEDULE & CHECKLISTS51 4012/16 Diesel, February 1997EVERY 250 HOURS OR 6 MONTHSCHANGING THE FILTER ELEMENTSWHEN THE ENGINE IS STOPPED

MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 52EVERY 250 HOURS OR 6 MONTHSCHANGING THE CHANGE OVER FILTERELEMENTS WITHOUT STOPPI

MAINTENANCE SCHEDULE & CHECKLISTS53 4012/16 Diesel, February 1997EVERY 250 HOURS OR EVERY 6 MONTHSCHANGING FUEL FILTER ELEMENTSNOTE: Ensure comple

MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 54EVERY 250 HOURS OR EVERY 6 MONTHSCHANGING THE CHANGE OVER FUELFILTER ELEMENTS WHE

MAINTENANCE SCHEDULE & CHECKLISTS55 4012/16 Diesel, February 1997EVERY 250 HOURS OR 6 MONTHSEQUALISE ROCKER BRIDGES ANDSETTING VALVE CLEARANCESNOT

MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 56Engine 4012T.D.C.Valves Rocking onCylinder No.Set Bridge Piecesand Valve Clearanc

MAINTENANCE SCHEDULE & CHECKLISTS57 4012/16 Diesel, February 1997EVERY 250 HOURS OR EVERY 6 MONTHSIf the valves required to be rocking areclosed,

MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 58EVERY 250 HOURS OR EVERY 6 MONTHSE.g. to adjust valves and bridge pieces onNo. A1

MAINTENANCE SCHEDULE & CHECKLISTS59 4012/16 Diesel, February 1997OVERHAUL PERIODSThe intervals at which routine overhauls arerequired, to keep an

PHOTOGRAPHS6 4012/16 Diesel, February 19974012 TAG4012 TAG

MAINTENANCE SCHEDULE & CHECKLISTS4012/16 Diesel, February 1997 60EVERY 2500 HOURS OR 12 MONTHS IFNECESSARYVALVE SEAT INSERTSExamine the valve seat

PREVENTIVE MAINTENANCE4012/16 Diesel, February 1997 61SCHEDULE FOR ENGINES IN STAND-BY DUTYFor engines which are in use for a total of less than 400 h

PREVENTIVE MAINTENANCE62 4012/16 Diesel, February 1997SCHEDULE FOR ENGINES IN CONTINUOUS DUTYFor preventive maintenance operations must be applied at

4012/4016 ENGINE FAULT TRACING4012/16 Diesel, February 1997 63Fig. 54

4012 STARTING CIRCUIT, SINGLE STARTER WITH REPEATER RELAY (EARLY ENGINES)64 4012/16 Diesel, February 1997Starting circuit for 4012 engine range, readi

4012/16 STARTING CIRCUIT, STARTERS AND TWIN START RELAYS(EARLY ENGINES)4012/16 Diesel, February 1997 65Starting circuit for 4012 engine range, readin

4012/16 WIRING DIAGRAM, STARTER, ELECTRONIC GOVERNOR (EARLY ENGINES)66 4012/16 Diesel, February 1997NOTES:1 To enable to run immediately ondepressing

4012/16 WIRING DIAGRAM, TWIN STARTERS & RELAYS, ELECTRONIC GOVERNOR(EARLY ENGINES)4012/16 Diesel, February 1997 67NOTE: To enable engine to run im

4012/16 WIRING DIAGRAM, SINGLE STARTER AND HYDRAULIC GOVERNOR(EARLY ENGINES)68 4012/16 Diesel, February 1997Engine fitted with regulators Europahydrau

4012/16 WIRING DIAGRAM, TWIN STARTERS, SINGLE START RELAY, ORIGINAL AIRSHUT OFF VALVES4012/16 Diesel, February 1997 69Key(Fig. 60)1 Terminal box2 Star

PHOTOGRAPHS4012/16 Diesel, February 1997 74016 TAG4016 TAG

4012/16 WIRING DIAGRAM, TWIN STARTERS, SINGLE START RELAY, ELECTRONICGOVERNOR (LATER ENGINES)70 4012/16 Diesel, February 1997Engine engine wiring to e

4012/16 WIRING DIAGRAM, TWIN STARTERS, ELECTRONIC GOVERNOR(INTERMEDIATE ENGINES)4012/16 Diesel, February 1997 71Key(Fig. 62)1 Engine fitted terminal b

4016 WIRING DIAGRAM, TWIN STARTERS, ELECTRONIC GOVERNOR(INTERMEDIATE ENGINES)72 4012/16 Diesel, February 1997Key(Fig. 63)1 Engine fitted terminal box2

4012 WIRING DIAGRAM TWIN STARTERS AND ELECTRONIC GOVERNOR(CURRENT ENGINES)4012/16 Diesel, February 1997 73Key(Fig. 64)1 Engine fitted terminal box2 Oi

4016 WIRING DIAGRAM, TWIN STARTERS, ELECTRONIC GOVERNOR(CURRENT ENGINES)74 4012/16 Diesel, February 1997Key(Fig. 65)1 Engine fitted terminal box2 Oil

© 1998 Perkins Engines Company Limited All Rights Reserved California Proposition 65 Warning Diesel engine exhaust and some of its constituents are kn

BRIEF DESCRIPTION OF THE 4012/16 SERIES DIESEL ENGINES8 4012/16 Diesel, February 19974012TWG 12 cylinder "V" form diesel engine, water coole

GENERAL INFORMATION4012/16 Diesel, February 1997 9SAFETYEngine lift equipmentUse only the lift equipment which is designedfor the engine.Use lift equi