Maintenance Procedures of Perkins Engines

This article will introduce maintenance procedures of Perkins generator 4000 Series engines. Make quite certian that the engine cannot be started in any way before undertaking any maintenance, particularly in the case of automatically starting generating sets.

Towards the rear of this section there is a check list sheet for continuous duty generator sets which is to be used as a guide for operators and maintenance personnel.

The following schedule details some of the maintenance to be carried out as in the maintenance check fists, however not all are detailed. In these cases please refer to the Workshop Manual.

The schedule within this section will be perfectly suitable for an engine working under average conditions. If your engine is working under particularly dirty or dusty conditions, more frequent servicing will be necessary particularly in respect of the lubricating oil and air cleaners. Correct and regular maintenance will help prolong engine life.

WARNING!! Make quite certain the engine cannot be started before undertaking any maintenance, particularly starting generating sets or remote starting engines.

Daily Inspection

Lubricating Oil Level

With the engine stopped for at least 5 minutes:

i) Withdraw the dipstick and wipe clean.

ii) Re-insert the dipstick fully into the sump.

iii) Wait for at least 5 seconds, withdraw and check the oil level in relation to the two marks on the dipstick.

iv) Repeat operation (i)(ii) (iii) at least twice, until identical recordings are observed. If the oil level is below the top mark, add sufficient of the same grade as that already in the engine to bring the oil level up to the top mark. Always replace the filler plug immediately replenishment is completed.

Coolant Level

WARNING!! The cooling system is pressurized - do not remove the filler cap when the engine is hot. Hand protection must be worn.

With the engine stopped remove the radiator cap; the coolant should be 25 mm (1") below the top of the filler neck. If the level is low top up with a solution of water and inhibitor or water and anti-freeze similar to that already in the engine. 

Leaks

Visually check the engine for fuel, oil, coolant and exhaust leaks, repairing where necessary.

Weekly

Deal with items under Daily Inspection.

Air Cleaner Restriction Indicator

The middle section of the restriction indicator 'A' will remain clear while the air cleaner is in a serviceable condition. When the filter reaches its contamination limit the restriction indicator will sense the change in manifold pressure and middle section 'A' will change to red, At this point the air filter must be changed. When the air filters have been changed reset the indicator by pressing button 'B'.

Battery

WARNING!! Hand protection must be worn when checking electrolyte level in the battery. Inflammable gas giving off by the battery. Do not check with a naked flame.

Remove the plugs or 'quick fill' covers and check the level of electrolyte. It should be approximately 3 mm above the top of the plates. If it is low, top up with pure distilled water. Replace the plugs and wipe the top of the battery clean and dry.

Radiator

If the engine is working in dirty or dusty conditions check that the air passages in the radiator are not becoming choked, They can be cleaned out by blowing compressed air in the direction opposite to that of the normal air flow.

Fenner Taper Lock Bushes Maintenance Instructions

Experience has shown that taper lock bushes as fitted in the fan pulleys and battery alternator driven pulleys can work loose shortly after being put into service. Check using a hexagon wrench to tighten screws (1) gradually and alternately until all are tightened to the required torque full details of taper lock pulley. 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.

Flanges And Fasteners

Check the torque on all external fasteners including the exhaust manifold and turbocharger flanges. Tighten all hose clips and pipe union  s.

Turbochargers

If the engine has been overhauled and a filter joint fitted to the turbocharger oil feed, this should now be removed and replaced with the standard joint.

Engine Oil And Spin-on Filters, Also Centrifugal Oil Filter (Where Fitted)

Change engine oil and disposable filters clean centrifugal filter.

Draining the Water Trap/Sedimenter (Where Fitted)

There are no moving parts or elements to service, however daily open the drain plug to remove collected water and sediment. The plug is self retaining, unscrew until loose. Leave open until clean fuel is seen. Screw back in (see Fig. 21).

Engine Alternator Drive Belt

WARNING!! Disconnecting batteries or any other means of starting.

Remove the small mesh guard (1) around the alternator. The toothed belt used to drive the alternator replies on tooth engagement to transmit to load. It does not require preloading, however a slight initial tension to ensure that the belt fits snugly round the pulleys is desirable. Using light pressure midway between the two pulleys a total deflection of 1.5 mm is satisfactory (see Fig. 22). Refit the guard.

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