Perkins 2000 Series

Models 2006SI and 2006TSI

USER’S HANDBOOK

6 cylinder spark ignited engines for industrial

applications

This publication is divided into six chapters:

1    General information

2    Engine views

3    Operation instructions

4    Preventive maintenance

5    Engine systems

6    Fault diagnosis

The following pages contain a detailed table of contents

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Contents

1 General information

Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  1

Safety precautions  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  2

How to care for your engine  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  3

Engine preservation  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  3

Parts and service  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  4

Training  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  4

Service Bulletins  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  4

Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  5

General engine data   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  6

Cooling system data   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  6

Fuel system data ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  6

Ignition system data  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  7

Lubrication system data .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  8

Induction system data    ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  8

Electrical equipment . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  8

Engine protection equipment   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  8

2 Engine views

Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  9

Location of engine parts - naturally aspirated engines  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...  9

Location of engine parts - turbocharged engines  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .  11

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3 Operation instructions

Routine procedure with a new or an overhauled engine . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 13

Routine starting  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14

Running the engine   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14

Stopping the engine  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 14

4 Preventive maintenance

Preventive maintenance periods   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15

Schedule for naturally aspirated engines in normal use  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16

Schedule for naturally aspirated engines in intermittent use  . ... ... ... ... ... ... ... ... ... ... ... ... ... 17

Schedule for turbocharged engines in normal use  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18

Schedule for turbocharged engines in intermittent use  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19

Air filter  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 20

Restriction indicator   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21

How to check the drive belts   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22

How to adjust the drive belts   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23

How to check the specific gravity of the coolant   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24

How to check the pH value of the coolant  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25

How to renew the engine lubricating oil   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 26

How to renew the canisters of the oil filter  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28

Lubricating oil by-pass filter  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29

How to change the spark plugs  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30

How to renew the filter of the crankcase breather  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31

How to clean the crankcase breather control valve  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32

How to check the tappet clearances  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33

How to drain the cooling system  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34

5 Engine systems

Ignition system - distributor type  . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35

Ignition system - Fairbanks Morse type   ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 36

Fuel system  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37

Coolant  ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38

Condemnation levels for oil sample analysis  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39

Lubricating oil specification  .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 40

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6 Fault diagnosis

Problems and possible causes . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .  41

Code list of possible causes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .  42

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1

General information

1

Introduction

The new range of Industrial engines is the latest development from Perkins Engines Company Limited, a world

leader in the design and manufacture of high performance engines.

More than fifty years of engine production experience, together with the use of the latest technology, have been

used in the manufacture of your engine to give you reliable and economic power.

To ensure that you use the correct information for your specific engine type, refer to "Engine identification" on

page 5.

Danger is indicated in the text by two methods:

Warning! This indicates that there is a possible danger to the person.

Caution: This indicates that there is a possible danger to the engine.

Note: Is used where the information is important, but there is not a danger.

A

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Safety precautions

These safety precautions are important.

Reference must also be made to the local regulations in the country of operation.

z   Do not use salt water or any other coolant which can cause corrosion in the cooling system.

z   Do not change the specification of the engine. Do not allow sparks or fire near the batteries (especially

when the batteries are on charge) as the gases from the electrolyte are highly flammable. The battery fluid

is dangerous to the skin and especially to the eyes.

z   Keep away from naked flames, hot exhaust pipes and sparks when working with gaseous fuels and when

conducting fuel tests.

z   Do not smoke when you are on or near the gas pipes or system.

z   Do not replenish the gas supply while the engine runs.

z   Disconnect the battery terminals before you make a repair to the electrical system.

z   Beware of electric shocks from the high tension current in the ignition system. Shocks from this system can

propel limbs into moving machinery.

z   Never clean, add lubricating oil to, or adjust the engine while it runs (unless you have had the correct

training, when extreme caution must be used to prevent injury).

z   Lubricating oil (especially used lubricating oil) can damage the skin of certain persons. Protect your hands

with gloves or a special solution to protect the skin.

z   Do not wear clothing which is contaminated by lubricating oil Do not put material which is contaminated

with oil into the pockets.

z   Fuel and oil pipes must be inspected for cracks or damage before they are fitted to the engine.

z   Discard used lubricating oil in a safe place to prevent contamination.

z   Only one person must control the engine. Ensure that the engine is operated only from the control panel or

from the operator's position.

z   Do not make any adjustments that you do not understand.

z   Ensure that the engine is not in a position to cause a concentration of toxic emissions.

z   Other people must be kept at a safe distance while the engine is operated.

z   Do not permit loose clothing or long hair near parts which move.

z   Keep away from parts which move during engine operation.

Warning! The fan cannot be seen clearly while the engine runs.

z   Do not operate the engine if one or more of the safety guards have been removed.

z   Do not remove the coolant caps while the engine is hot and while the coolant is under pressure, because

dangerous hot coolant can be discharged.

z   The combustible material of some components of the engine (for example certain seals) can become

extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with

the eyes.

z   Fit only genuine Perkins parts.

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2000 Series Gas

How to care for your engine

This handbook has been written to assist you to maintain and operate the engine correctly.

To obtain the best performance and the longest life from your engine, you must ensure that the maintenance

operations are done at the intervals given in Chapter 4, Preventive maintenance.

If the engine is operated in very dusty or other adverse conditions, certain maintenance intervals will have to

be reduced. Change the filter elements and lubricating oil regularly to ensure that the inside of your engine

remains clean.

Ensure that all adjustments and repairs are done by personnel who have had the correct training.

The left and right sides of the engine are as seen from the rear (flywheel) end.

Read and remember the "Safety precautions" on page 2. They are given for your protection and must be

applied at all times.

Engine preservation

All new or reconditioned engines leaving the factory have been treated with corrosion inhibitors to Perkins

standards. Each engine may be stored under cover, in dry conditions, for a period of up to 12 months from the

date of despatch from the factory, without the need for further inhibition.

Should the storage period exceed 12 months, the engine must be thoroughly examined and re- inhibited. For

further details contact Perkins Engines Company Limited.

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Parts and service

If a problem occurs with your engine or with the components fitted to it, contact the Service Department at

Perkins Engines Company Limited.

For information of the supply of replacement parts and arrangements for ordering, contact:

Perkins Parts Limited

Frank Perkins Way

Northbank Industrial Estate

Irlam

Manchester

M44 5PP

Telephone: 0161 776 5000

Fax: 0161 776 5200

Training

Courses on the service and overhaul of the 2000 Series range of engines are available at the factory. For

details, apply to:

The Customer Training Centre

Perkins Engines Company Limited

Shrewsbury

SY1 3NX

England.

Service Bulletins

Service procedures and engine design are checked continuously at Perkins. As a result of this development

work, it may become necessary to alter the information in manuals and other service publications. Between

revisions of the literature, all relevant personnel are provided with full details of changes as they occur. The

information is produced as a Service Bulletin; these are supplied to distributors for distribution as necessary.

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Engine identification

The 2000 Series engine is a six cylinder, in-line unit, which can be normally aspirated or turbocharged. It is

supplied in various power ratings, depending on the application and the calorific value of the gas supply.

The engine number is stamped on the data plate which is fastened to the right side of the crankcase (A1).

For early engines, a typical engine number is: 8E28013U 59426T, which consists of these codes:

8E

Engine family

28013

U

59426

T

Engine number

Country of manufacture

Build line number

Year of manufacture

Engines produced after August 1994, have a new engine number system. For these engines, a typical engine

number is SIC060057U951234A which consists of these codes:

SI

Engine application

C

Engine type

06

0057

U

951234

A

Number of engine cylinders

Engine specification number

Country of manufacture

Build line number

Year of manufacture

If you need parts, service or information for your engine, you must give the complete engine number to the

Perkins Distributor.

1

A

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General engine data

Type

Bore

Liquid cooled, four stroke, six cylinder in-line, spark ignited engine

130,17 mm (5.125 in)

Stroke

Capacity

Compression ratio

152,4 mm (6.00 in)

12,17 litres (742.64 in3)

12:1 Naturally aspirated (Natural gas)

10:1 Turbocharged (Natural gas)

Rotation

Cylinder firing order

Cylinder numbering

Anti-clockwise, viewed on flywheel

1, 4, 2, 6, 3, 5

From front (fan end) to rear (flywheel end)

Valve tappet clearance - Naturally aspirated and turbocharged

Inlet

0,254 mm (0.010 in) hot or cold

Exhaust

0,508 mm (0.020 in) hot or cold

Engine weight

Naturally aspirated

Turbocharged

With air cooled exhaust manifold

Dry - 1082 kg (2385 lb)

Wet - 1125 kg (2480 lb)

With water cooled exhaust manifold

Dry - 1090 kg (2403 lb)

Wet - 1350 kg (2976 lb)

Dry - 1100 kg (2425 lb)

Wet - 1360kg (2998 lb)

Cooling system data

Total coolant capacity (engine only)

With air cooled exhaust manifold

With water cooled exhaust manifold

System pressure cap setting

Operating temperature (at sea level)

Maximum operating temperature

Thermostat (where fitted)

Naturally aspirated

20,4 litres (4.5 UK gallons)

Turbocharged

28,0 litres (6.16 UK gallons)

29,0 litres (6.38 UK gallons)

2

2

Maximum 70 kN/m  (10 lbf/in  ) to suit installation

Normal running 78 to 95 °C (172 to 203 °F)

103 °C (217.4 °F)

Triple-element wax capsule type with radiator by-pass

Single unit, baffled and finned tube pack, with part coolant by-pass

Belt driven centrifugal type

Heat exchanger (oil-to-coolant)

Coolant pump

Protection switch settings

Warning - 100 °C (212 °F)

Shutdown - 106 °C (222.8 °F)

Fuel system data

2

Gas supply pressure

1,96 to 4,90 kN/m  (200 to 500 mm H O at full rated flow). An engine

2

can be modified to operate on a gas pressure different from that

quoted above; for details please contact Perkins Engines Company

Limited.

Gas carburettor

Naturally aspirated

Turbocharged

Deltec 100 - II

Deltec 140 - II

Zero pressure regulator

Diaphragm type Krom Schreoder GI 40

(GI 25 on early engines)

Governor (optional)

Electronic type

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Ignition system data

Naturally aspirated

Type

Primary voltage

Polarity

Electronic contactless distributor

12 volts

Negative earth

Distributor

Amplifier

Ignition coil

Spark plugs

Spark plug gap

Spark plug leads

‘Hall effect', Lucas 42638 43D4 1291

Sealed unit, Lucas 60041013 DAB 100

Lucas DLB105B - 12V, inductive type

Champion RC 78 PYP 16 mm AF hexagon, long reach type

0,30 mm (0.012 in)

7 or 8 mm suppressed carbon ignition wire

(Later engines: spark plug leads with core of copper and suppression

in the spark plug connectors)

Ignition harness

Ignition timing

Supplied complete with 6-way connectors

As stamped on the data plate

Later ignition system which replaces that shown above

Notes:

z   Must only be used in sets shown and not interchanged with any other.

z   Engines equipped with these items are identified by the engine specification number 8E28421

Distributor

Ignition module

Ignition coil

Contactless, Hall effect, Lucas 42590A

Lucas sealed unit DAB 111

Lucas inductive type DLB 198

Turbocharged and later naturally aspirated engines

Type

Fairbanks Morse IQ 250

Primary voltage

Polarity

24 volts

Negative earth

Amplifier

Separate

Ignition coil

Timing method

Spark plug type

Spark plug gap

Spark plug leads

One per cylinder

Sensors at starter ring and camshaft disc

Champion RC 78 PYP 16mm AF hexagon

0,30 mm (0.012 in)

8 mm spark plug leads with core of copper and suppression in the

spark plug connectors

Ignition harness

Ignition timing

Supplied complete with 6 way connectors

As stamped on the data plate

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2000 Series Gas

Lubrication system data

Type

Wet sump

Oil capacity

Naturally aspirated (standard sump)

Sump capacity 25 litres (5.5 UK gallons)

Total engine capacity 29,5 litres (6.5 UK gallons)

Sump minimum 18,2 litres (4.0 UK gallons)

Turbocharged and later naturally aspirated

engines

Sump capacity 82 litres (18.0 UK gallons)

Total engine capacity 86.5 litres (18.6 UK gallons)

Sump minimum 73 litres (16.0 UK gallons)

Oil pump

Oil pressure

Spur gear driven, gear type single unit pump

2                               2

345 to 483 kN/m   (50 to 70 lbf/in ) at rated speed

2                   2

Minimum at rated speed 207 kN/m  (30 lbf/in  )

Oil filters

Two spin-on expendable canisters with integral by-pass valves

operating in parallel

Pressure relief valve

Spring and plunger type housed in oil pump body

Induction system data

Air filter

12 inch, 2 stage, dry type

Maximum air intake restriction

Clean filter - 255 mm (10 in H O)

2

2

Dirty filter - 635 mm (25 in H  O)

Turbocharger

Holset H2D water cooled bearing housing

Electrical equipment

Type

Insulated return

Alternator

Starter motor

Prestolite (Butec) belt driven, 32 amps and 28 volts

Prestolite (Butec) flange mounted MS1A 24 volt

Engine protection equipment

Depends on specification. Certain protection devices may be incorporated in the system which will stop the

engine or prevent it from starting if a fault occurs or is present. Often an "Annunciator" is incorporated in the

switch panel which will indicate the fault.

It is usual for low oil level, low oil pressure, high coolant temperature, low coolant level and low coolant

pressure to be covered. The specification of your engine may have all or some of these devices.

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Engine views

2

Introduction

Perkins engines are made for specific applications and the views which follow do not necessarily match your

engine specification.

Location of engine parts - naturally aspirated engines

Front and left side view of engine (A)

1 Exhaust manifold

2 Spark plug leads

3 Distributor

6 Oil filler tube

7 Coolant rail

8 Mixture adjusting screw (MAS)

9 Carburettor

4 Oil filler cap

5 Dipstick and tube

10 Air cleaner

7

8

9

10

1

2

3

4

5

6

A

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Front and right side view of engine (B)

11 Thermostat

12 Alternator

17 Coolant drain plug

18 Breather pipe

13 Belt tensioner

14 Coolant by-pass

15 Oil cooler

19 Lubricating oil feed to main gallery

20 Starter motor

21 Inlet manifold

16 Oil filter canister (2)

11

21

12

20

19

13

14

18

15

17

16

B

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Location of engine parts - turbocharged engines

Front and left side view of engine (A)

1 Mixture adjusting screw (MAS)

2 Spark plug leads

6 Oil drain plug

7 Dipstick and tube

3 Ignition coils

4 Crankcase air inlet filter

5 Oil filler tube and cap

8 Ancillary equipment tapping

9 Turbocharger and insulating cover

10 Exhaust outlet

1

10

9

2

3

4

5

8

7

6

A

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Front and right side view of engine (B)

11 Inlet manifold

12 Oil filter canister

13 Oil cooler

14 Starter motor

15 Crankcase ventilator valve

16 Air/fuel mixer, main adjusting screw and throttle (butterfly)

16

15

11

14

13

12

B

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3

Operation instructions

3

Routine procedure with a new or an overhauled engine

Gas quality and type will have a major effect on the performance and reliability of the engine. It is imperative

that all Perkins spark ignited engines are commissioned by Perkins approved installers, to ensure correct and

safe operation of the equipment.

Refer to Chapter 5, Engine systems which outlines the safeguards required for the fuel and lubricating oil

systems.

1  Check that all wrappings and sealing blanks have been removed.

2  Refit any components removed for storage or transportation.

3  Ensure that all coolant and lubricating oil drain plugs are securely fitted.

4  Dependent on installation, connect the remote control linkages, pressure gauge pipework, air intake duct

and electrical wiring.

5  Connect the gas supply and exhaust pipework ensuring that all valves and filters are correctly positioned

and operating.

6  Fill the coolant system with the approved coolant mixture, see "Coolant" on page 38.

7  Fill the sump to the upper mark on the dipstick with the correct grade of lubricating oil, see "Lubricating oil

specification" on page 40.

8  Lubricate all control linkages and check for freedom of movement.

9  Prime the turbocharger, see "To prime the turbocharger" on page 14.

Note: Every new or reconditioned engine supplied by Perkins Engines Company Limited, Shrewsbury, is run

in before delivery to the customer.

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Routine starting

Daily checks before initial start

1  Where a radiator is fitted check that the coolant level is about 76 mm (3 in) below the filler neck, or as

otherwise specified in the equipment manufacturer’s manual. Top up, if necessary, with the correct coolant.

Investigate any marked loss of coolant.

2  Check the oil level in the engine sump. Replenish, as necessary, to the H mark on the dipstick. Use the

correct grade of oil.

Caution: Do not overfill.

3  For a turbocharged engine which has not run for a long period the turbocharger must be primed.

To prime the turbocharger

Clean the area around the connection for the oil feed on top of the bearing housing. Remove the pipe

connection from the turbocharger or the plug if fitted. The clip which supports the pipe and the lower connection

may have to be loosened to allow the top of the pipe to be moved.

1

Add 0,2 litre (  /  pint) of clean engine oil to the turbocharger. Fit the connection or plug. Tighten the plug or

3

connections and the clip securely.

Starting procedure

Perform daily service checks detailed above, then proceed as follows:

1  Move the gas tap (if fitted) to the ON or OPEN position.

2  Turn the ignition switch to ON, this will open the gas solenoids and energise the ignition electrical circuit.

3  Press the starter button, or turn the key further to the START position to activate the starter motor. Hold in

the START position for a period of 3 to 5 seconds when the engine will start.

Running the engine

The following precautions will help to ensure a long and trouble-free life for the engine.

1  Do not subject the engine to high speeds and loads until working temperature is reached.

2  Avoid long periods of idling or "OFF LOAD" running.

3  Do not allow engine speeds to exceed the rated maximum. Over-speeding will shorten engine life and can

result in component failure.

Stopping the engine

Run the engine "OFF LOAD" for a short period. Move the ignition key to the OFF position.

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4

Preventive maintenance

4

Preventive maintenance periods

These preventive maintenance periods are general in application. Check the periods given by the

manufacturer of the equipment in which the engine is installed.

The servicing intervals may be reduced at the discretion of operators to suit local conditions but must NOT be

extended without the written consent of Perkins Engines Company Limited as required by the Perkins

Guarantee.

It is good maintenance to check for leakage and loose fasteners at each service.

These maintenance periods are only for engines that are operated with coolant, gas and lubricating oil to the

specifications given in this handbook.

Schedules

The schedules which follow must be applied at the recommended interval as shown.

Engines in normal use

Engines in this category are those which are in use for an aggregate of more than 400 hours in twelve months.

Refer to the appropriate schedules on page 16 and page 18.

Engine in intermittent use

Engines in this category are those which are in use for an aggregate of less than 400 hours in twelve months.

Refer to the appropriate schedules on page 17 and page 19.

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Schedule for naturally aspirated engines in normal use

The preventive maintenance operations must be applied at the interval (hours or months) which occurs first.

A - Every 10 hours or daily

B - Every 500 hours or 12 months

C - Every 1000 hours

A

z

z

z

z

z

B

C

Operation

Check the amount of coolant in the radiator

Check the level of the lubricating oil in the sump

Check the gas supply pressure

Check the lubricating oil pressure at the gauge  (2)

Check the restriction indicator for the air filter. Renew the filter element if the indicator shows red

Check the condition and tension of all drive belts  (2)

Check the specific gravity and the pH value of the coolant

Renew the lubricating oil  (3)

Renew the canisters of the lubricating oil filter and the rotor of the by-pass filter  (2)

z

z

z

z

z

z

z

Check that the radiator is clean and free from debris

Check and reset or change the spark plugs

Renew crankcase breather filter and clean the crankcase breather  (2)

Ensure that the tappet setting clearances are checked and adjusted if it is necessary (1) (4)

z

(1) By a person who has had the correct training.

(2) If fitted.

(3) The selection of suitable lubricants should be made in co-operation with a reputable oil company, who can offer the necessary oil

sample analysis support to ensure successful lubrication of spark ignited engines. Analysis results will determine the service period

which could be less than the 500 hour service period. Refer to Chapter 5, Engine systems for details.

(4) After the first 500 hours on a new and overhauled engine.

In addition to the above, the operations shown below must be applied at 12 month intervals:

z   Drain and flush the coolant system and renew the coolant mixture.

z   Check the distributor cap for cracks or ‘tracking’ and the condition of the high tension leads.

z   Change the air filter element.

z   Ensure that the alternator, starter motor etc and protection switches are checked or serviced as

(1)

.

necessary

16

User’s Handbook, TSD 3409, Issue 4

This document has been printed from SPI². Not for Resale

4

2000 Series Gas

Schedule for naturally aspirated engines in intermittent use

The preventive maintenance operations must be applied at the interval (hours or months) which occurs first.

A - Monthly

B - Every 200 hours or 12 months

A

z

z

z

z

z

z

B

Operation

Check the amount of coolant in the radiator

Check the level of the lubricating oil in the sump

Check the gas supply pressure

Start and run the engine until normal operating temperature is attained

Check the lubricating oil pressure at the gauge  (2)

Check the restriction indicator for the air filter. Renew the filter element if the indicator shows red

Check the condition and tension of all drive belts  (2)

Check the specific gravity and the pH value of the coolant

Renew the lubricating oil  (3)

Renew the canisters of the lubricating oil filter and the rotor of the by-pass filter  (2)

z

z

z

z

z

z

z

Check that the radiator is clean and free from debris

Check and reset or change the spark plugs

Ensure that the tappet setting clearances are checked and adjusted if it is necessary  (1)(4)

(1) By a person who has had the correct training.

(2) If fitted.

(3) The selection of suitable lubricants should be made in co-operation with a reputable oil company, who can offer the necessary oil

sample analysis support to ensure successful lubrication of spark ignited engines. Analysis results will determine the service period

which could be less than the 500 hour service period. Refer to Chapter 5, Engine systems for details.

(4) After the first 500 hours on a new and overhauled engine.

In addition to the above, the operations shown below must be applied at 12 month intervals:

z   Drain and flush the coolant system and renew the coolant mixture.

z   Check the distributor cap for cracks or ‘tracking’ and the condition of the high tension leads.

z   Change the air filter element.

z   Ensure that the alternator, starter motor etc and protection switches are checked or serviced as

(1)

.

necessary

z   Renew crankcase ventilator filter and clean crankcase breather (1)(2).

User’s Handbook, TSD 3409, Issue 4

17

This document has been printed from SPI². Not for Resale

4

2000 Series Gas

Schedule for turbocharged engines in normal use

The preventive maintenance operations must be applied at the interval (hours or months) which occurs first.

A - Every 10 hours or daily

B - Every 750 hours or 12 months

C - Every 1500 hours

A

z

z

z

z

z

B

C

Operation

Check the amount of coolant in the radiator

Check the level of the lubricating oil in the sump

Check the gas supply pressure

Check the lubricating oil pressure at the gauge  (2)

Check the restriction indicator for the air filter. Renew the filter element if the indicator shows red

z

z

z

z

z

z

z

z

z

Check the condition of the high tension leads

Check the condition and tension of all drive belts  (2)

Check the specific gravity and the pH value of the coolant

Renew the lubricating oil  (3)

Renew the canisters of the lubricating oil filter and the rotor of the by-pass filter  (2)

Check that the radiator is clean and free from debris

Check and reset or change the spark plugs

Renew the crankcase ventilator filter and clean crankcase breather  (1)

Ensure that the mounting nuts for the turbocharger are tightened securely

Ensure that the tappet setting clearances are checked and adjusted if it is necessary  (1)(4)

z

(1) By a person who has had the correct training.

(2) If fitted.

(3) The selection of suitable lubricants should be made in co-operation with a reputable oil company, who can offer the necessary oil

sample analysis support to ensure successful lubrication of spark ignited engines. Analysis results will determine the service period

which could be less than the 750 hour service period. Refer to Chapter 5, Engine systems for details.

(4) After the first 750 hours on a new and overhauled engine.

In addition to the above, the operations shown below must be applied at 12 month intervals:

z   Drain and flush the coolant system and renew the coolant mixture.

z   Ensure the control linkages for the carburettor are free to move and are lubricated.

z   Change the air filter element.

z   Ensure that the alternator, starter motor, turbocharger and protection switches are checked or serviced as

(1)

.

necessary

18

User’s Handbook, TSD 3409, Issue 4

This document has been printed from SPI². Not for Resale