Perkins 4000 Gas Engine

Perkins 4000 Series
In-line Gas
4006 and 4008 Series engines
USER’S HANDBOOK
6 and 8 cylinder turbocharged gas engines
Publication TSL 4185E.

© Proprietary information of Perkins Engines Company Limited, all rights reserved.
The information is correct at the time of print.
Published in March 2001 by Technical Publications,
Perkins Engines Company Limited, Tixall Road, Stafford, ST16 3UB, England
i
This publication is divided into six chapters:
1 General information
2 Engine views
3 Operation instructions
4 Preventive maintenance
5 Gas and engine fluids
6 Fault diagnosis
The following pages contain a detailed table of contents
ii
4006/4008 In-line Gas
Contents
1 General information
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1
How to care for your engine ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2
Safety precautions .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Practical information for cleaning components ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6
Engine preservation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6
Parts and service ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7
Service tools ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7
Engine identification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8
Engine data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9
Protection equipment .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12
Electrical system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12
Electrical wiring diagrams ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 13
Perkins companies .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 19
2 Engine views
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 21
6 cylinder engines ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 21
8 cylinder engines ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 22
User’s Handbook, TSL 4185E, March 2001 iii

3 Operating instructions
Introduction .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23
Instrument panel .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24
Instrument operation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25
How to fill the engine with oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
How to prime the lubrication system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
How to fill a CHP type cooling system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
How to fill a radiator type cooling system ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29
Final checks and first engine start ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30
Typical engine start sequence . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
Typical engine stop sequence . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32
4 Preventive maintenance
Maintenance procedures . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
Service schedules ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 34
How to check the oil level ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
How to check the coolant level ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
How to check and clean the radiator (if fitted) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
How to check the radiator fan drive belts (if fitted) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39
How to check the battery charging alternator (if fitted) ... ... ... ... ... ... ... ... ... ... ... ... ... 40
How to change the engine oil and filters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41
How to change the change-over filters (if fitted) .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 42
How to clean the open circuit crankcase breather ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 43
How to clean the closed circuit breather system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 44
How to check the air cleaner restriction indicator ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45
How to change the air filter element ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 45
How to remove a spark plug ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 46
How to clean, set and fit a spark plug .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 47
Preparation for equalising bridge pieces and setting valve clearances ... ... ... ... ... ... ... 48
How to equalise bridge pieces . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 50
How to set valve clearances ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51
How to check valve and seat recession .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 52
iv User’s Handbook, TSL 4185E, March 2001

5 Gas and engine fluids specification

Gas specifications ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 53
Approved lubricating oils . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 54
Oil and filter change program .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 54
Coolant specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 55
Maintenance of coolant ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 55
6 Fault diagnosis
Problems and possible causes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 57
List of possible causes ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 58
User’s Handbook, TSL 4185E, March 2001 v

vi User’s Handbook, TSL 4185E, March 2001

1
General information 1
Introduction
The 4006 and 4008 gas engines are a family of 6 and 8 cylinder turbocharged gas engines, designed by
Perkins Engines Company Limited, Stafford, a world leader in the design and manufacture of high-
performance gas engines. They form part of the 4000 Series range of engines.
Perkins approved assembly and quality standards, together with the latest technology, have been applied to
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 8.
The terms ‘left side’ and ‘right side’ apply when the engine is seen from the flywheel end.
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.
User’s Handbook, TSL 4185E, March 2001 1

1 4006/4008 In-line Gas
How to care for your engine

This handbook has been written to assist you to maintain and operate your engine correctly, and to carry out
routine servicing of the engine.
The instructions contained in this handbook will, provided that they are correctly carried out, ensure the safe
operation of the equipment.
Before undertaking any work on the engine the relevant chapter in the Workshop Manual should be read and
fully understood.
The information contained within this handbook is based on such information as was available at the time of
print. In line with Perkins Engines Company Limited, Stafford policy of continual development and
improvement that information may change at any time without notice. The engine user should therefore ensure
that he has the latest information before starting work.
Users are respectfully advised that it is their responsibility to employ competent persons to operate the
equipment in the interest of safety.
Special tools are required to perform certain operations. A list of those required for the operations described
in this handbook is given in "Service tools" on page 7. Reference to the relevant special tools is also made at
the beginning of each operation, along with those which are universally available (UA) and any additional
specialist supplied equipment (SP) required.
Operators who are not equipped to undertake major repairs are urged to consult their Perkins distributor.
When not working on the engine, ensure that all covers, blank flanges, doors, etc., are refitted to openings to
prevent the ingress of dirt, etc.
Please quote the engine type and serial number with all your enquiries. The type and serial number are on a
plate fitted to the crankcase.
If any doubt exists regarding the installation, use or application of the engine, the Installation Manual
(TSL 4068) should be consulted. For further advice contact the Applications Department at Perkins Engines
Company Limited, Stafford.
To obtain the best performance and the longest life from your engine, you must ensure that the maintenance
operations are done at the required intervals. Refer to the “Service schedules” in Chapter 4, Preventive
maintenance. If the engine works in a very dusty environment or other adverse conditions, certain
maintenance intervals will have to be reduced.
Oil change intervals may be changed according to operating experience by agreement with Perkins Engines
Company Limited, Stafford and subject to oil analysis being carried out at regular intervals.
Ensure that all adjustments and repairs are done by personnel who have had the correct training. Perkins
distributors have this type of personnel available. You can also obtain parts and service from your Perkins
distributor. If you do not know the address of your nearest distributor, enquire at one of the Perkins companies
listed on page 19.
Warning! Read and remember the "Safety precautions" on page 3. They are given for your protection and
must be observed at all times.
2 User’s Handbook, TSL 4185E, March 2001

4006/4008 In-line Gas 1
Safety precautions
General
For safe and reliable operation of the engine it is very important that these safety precautions, and those
Warnings and Cautions given throughout this handbook, are observed, and where necessary the special
tools indicated are used.
All safety precautions should be read and understood before operating or servicing the engine.
Improper operation or maintenance procedures are dangerous and could result in accidents, injury or death.
The operator should check before beginning an operation that all the basic safety precautions have been
carried out to prevent accidents occurring.
You must also refer to the local regulations in the country of use.
Note: Some items only apply to specific applications.
Guards
Ensure that guards are fitted over exposed rotating parts, hot surfaces, air intakes, belts or live electrical
terminals (high and low tension).
Protection equipment
Ensure that correct protection equipment is worn at all times.
Always wear protective gloves when using inhibitors or anti-freeze, removing the pressure cap from the
radiator or heat exchanger filler, changing the lubricating oil/filter or changing the electrolyte in the battery.
Always wear ear protection when working in an enclosed engine room.
Always wear suitable eye protection when using an air pressure line.
Always wear protective boots when working on the engine.
Always wear protective headgear when working on or underneath the engine.
Naked flames
Ensure that no smoking or naked flames are lit when checking battery electrolyte, working in the engine
room or when operating or servicing the engine.
Fuel/oil pipes
Ensure that all pipes are regularly checked for leaks.
Ensure that all pipes and the surrounding area are regularly checked for spilt oil (and cleaned up where
necessary).
Always apply suitable barrier cream to hands before any work is carried out.
Gas pipes
Always check for gas/air mixture leaks.
Ensure that the gas line and valves meet local safety standards.
Ensure that the gas line pressure is correct.
Shutdown equipment
Always test that the protection system is working correctly.
When stopping the engine in case of overspeed, high water temperature or low oil pressure should be
provided.
For heat sensors, methane and smoke protectors should be provided (if applicable).
Always be in a position to stop the engine (even remotely).

1 4006/4008 In-line Gas
Start-up
When working on the engine always ensure that the battery has been disconnected, and that any other
means of accidental start-up has been disabled.
Never start the engine with the governor linkage disconnected.
Do not hold the stop lever in the run position when starting the engine.
Always hold the stop lever in the stop position when cranking only.
Electrical equipment
Always check that electrics are earthed to local safety standards.
Always disconnect the electrical supply to the jacket water heater (if fitted) before working on the engine.
Take care to prevent any danger of electric shock.
Never re-adjust the settings of electronic equipment without reference to the Workshop Manual.
Freezing or heating components
Always use heat resistant gloves and use the correct handling equipment.
Exhaust system
Check the system for leaks.
Ensure that the engine room is correctly ventilated.
Check that all the guards are fitted.
Check that the pipework allows the exhaust gas to escape upwards.
Check that the pipework is supported.
Stopping the engine
1 Disengage the engine load.
2 Run the engine on NO LOAD for 5 to 7 minutes before stopping.
Note: This will allow the circulating lubricating oil to dissipate heat from the bearings, pistons, etc. It will also
allow the turbochargers, which run at a very high speed, to slow down while there is still oil flow through the
bearings.
Ensure that the engine is stopped before performing any of the following operations:
Changing the lubricating oil.
Filling or topping up the cooling system.
Beginning any repair work on the engine.
Adjusting belts (where fitted).
Adjusting bridge pieces / valve clearance.
Changing spark plugs.
Changing air or oil filters.
Tightening any fixing bolts.
Flammable fluids
Ensure that these are never stored near the engine.
Ensure that they are never used near a naked light.
Clothing
Do not wear loose clothing, ties, jewellery, etc.
Always wear steel toe cap shoes/boots.
Always wear the correct head, eye and ear protection.
Always wear suitable overalls.
Always replace a spillage contaminated overall immediately.

4006/4008 In-line Gas 1
Lifting heavy components
Always use the correct lifting equipment.
Never work alone.
Always wear a helmet, if the weight is above head height.
De-scaling solution
Always wear both hand and eye protection when handling.
Always wear overalls and correct footwear.
Waste disposal
Do not leave oil covered cloths on or near the engine.
Do not leave loose items on or near the engine.
Always provide a fireproof container for oil contaminated cloths.
Note: Most accidents are caused by failure to observe basic safety precautions and can be prevented by
recognising potentially dangerous situations before an accident occurs. While there are many potential
hazards that can occur during the operation of the engine which cannot be always be anticipated, and thus a
warning cannot be included to cover every possible circumstance that might involve a potential hazard, by
following these basic principles the danger can be minimised.
Dangers from used engine oils

Prolonged and repeated contact with mineral oil will result in the removal of natural oils from the skin, leading
to dryness, irritation and dermatitis. The oil also contains potentially harmful contaminants which may result in
skin cancer.
A suitable means of skin protection and washing facilities should be readily available.
The following is a list of 'Health Protection Precautions', suggested to minimise the danger of contamination.
1 Prevent prolonged and repeated contact with used engine oils.
2 Wear protective clothing, including impervious gloves where applicable.
3 Do not put oily rags into pockets.
4 Prevent contaminating clothes, particularly underwear, with oil.
5 Overalls must be cleaned regularly. Discard unwashable clothing and oil impregnated footwear.
6 First aid treatment should be obtained immediately for open cuts and wounds.
7 Apply barrier creams before each period of work to aid the removal of mineral oil from the skin.
8 Wash with soap and hot water, or alternatively use a skin cleanser and a nail brush, to ensure that all oil is
removed from the skin. Preparations containing lanolin will help replace the natural skin oils which have been
removed.
9 Do NOT use petrol, kerosene, diesel fuel, thinners or solvents for washing the skin.
10 If skin disorder appears, medical advice must be taken.
11 Degrease components before handling if practicable.
12 Where there is the possibility of eye damage, suitable eye protection or a face shield should be worn. An
eye wash facility should be readily available.
Environmental protection
There is legislation to protect the environment from the incorrect disposal of used lubricating oil. To ensure that
the environment is protected, consult your Local Authority who can give advice.

1 4006/4008 In-line Gas
Danger from ‘fluorosilicone’ (Viton) ‘O’ ring seals

All of the engines ‘O’ ring seals are made from fluorosilicone material.
It is a safe material under normal conditions of operation, but if it is burned the extremely dangerous
hydroflouric acid is produced.
If it is necessary to come into contact with components which have been burnt, follow the precautions below:
Allow the components to cool.
Use Neoprene gloves and a face mask.
Wash the contaminated area with a calcium hydroxide solution and then with clean water.
Disposal of gloves and components which are contaminated must be in accordance with local regulations.
Caution: If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean
water. Obtain immediate medical attention.
Practical information for cleaning components

Use suitable gloves for protection when components are degreased.
Keep the work area clean and ensure that components are protected from dirt and debris. Ensure that dirt does
not contaminate the fuel system.
Before a component is removed from the engine, clean around the component and ensure that all openings,
disconnected hoses and pipes are sealed.
Remove, clean and inspect each component carefully. If it useable, put it in a clean dry place until needed. Ball
and roller bearings must be cleaned thoroughly and inspected. If the bearings are usable, they must be flushed
in low viscosity oil and protected with clean paper until needed.
Before the components are assembled, ensure that the area is free from dust and dirt as possible. Inspect each
component immediately before it is fitted, wash all pipes and ports, and pass dry compressed air through them
before connections are made.
Engine preservation
Ex-works preservation treatment
The preservation treatment will give up to 12 months shipping and storage protection under normal enclosed
storage conditions of -15 °C to +55 °C and up to 90% relative humidity.
1 The oil used on engine test will give protection for up to 12 months after despatch from the works.
2 After test the oil is then drained from the sump.
3 The corrosion inhibited anti-freeze at 50% dilution with clean water used on engine test will give protection
for up to 12 months after despatch from the works.
4 After spray painting, all openings in the engine (including points where pipework has been removed and air
cleaner inlets, etc.), are sealed with plastic plugs or covers.
5 The drive face of the flywheel is coated with Valvoline Tectyl 506 preservative.

4006/4008 In-line Gas 1
Parts and service
Service literature
Workshop manuals, installation drawings and other service publications are available from your Perkins
distributor.
Training
Local training for the correct operation, service and overhaul of engines is available at certain Perkins
distributors. If special training is necessary, your Perkins distributor can advise you how to obtain it at the
Perkins Customer Training Department or other main centres.
Service Bulletins
Service procedures and engine design are checked continuously at Perkins Engines. 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.
Service tools
The following tools and equipment are required to carry out the operations described in this handbook.
Part No. Description
699/2 Feeler gauge set
61008 8 mm Allen key (*)
5
348/3 /8 Allen key (*)
483/25 Strap wrench (*)
2710190 Spark plug removal tool (*)
SE253 Engine cranking device
687/1 Tool box (*)
477/1 Screwdriver set (*)
T6253/312 Valve seat recession checking tool
483/28 19 mm Combination spanner (*)
Note: Items marked (*) are supplied as a tool kit under part number SE671E.

1 4006/4008 In-line Gas
Engine identification
The engine number and its build specification details are given on its data plate (A1) which is fitted to the right
side of the crankcase by the oil filters.
A reference code and engine description is given in the table below.
Reference
Description
Code
6 cylinder, in-line, 4 stroke, turbocharged, spark ignition gas engine, with water based engine
4006TESI
coolant and oil cooler, raw water pump and separate cooling system for charge air
200 LC
intercooler. With NOx emission of 200g/GJ or less.
4006TESI
140 LC
intercooler. With NOx emission of less than 140g/GJ.
4006TESI coolant and oil cooler, raw water pump and separate cooling system for charge air
140 HC intercooler. With NOx emission of less than 140g/GJ, and higher thermal efficiency than the
4006TESI 140 LC.
4006TESI
90 HC
4008TESI
200 LC
intercooler. With NOx emission of 200g/GJ or less.
4008TESI
140 LC
4008TESI coolant and oil cooler, raw water pump and separate cooling system for charge air
140 HC intercooler. With NOx emission of less than 140g/GJ, and higher thermal efficiency than the
4006TESI 140 LC.
4008TESI
90 HC
1
A 1665.2

4006/4008 In-line Gas 1
Engine data
Engine specifications
The figures quoted are based on engines set to meet the requirements of ISO8528. For full technical data
please refer to the relevant Technical Data sheet.
General
4006TESI LC 4008TESI LC
Engine model
4006TESI HC 4008TESI HC
Cycle 4 stroke, spark ignition
Configuration In-line
Bore 160 mm
Stroke 190 mm
Total swept volume 22,921 litres 30,561 litres
Compression ratio 9.5:1 (LC), 11.5:1 (HC)
Rotation Anti-clockwise looking on flywheel end
Firing order 1-5-3-6-2-4 1-4-7-6-8-5-2-3
Cylinder numbering Cylinder 1 furthest from flywheel
Valve clearances (engine cold) Exhaust and inlet 0,40 mm (0.016”)
Engine weight
Engine model
Dry weight (engine) 2420 kg 3350 kg
Dry weight (engine including charge cooler and
2574 kg 3558 kg
wet exhaust manifolds)
Typical cooling system

Engine model
Approved coolants Refer to "Coolant specification" on page 55
Total capacity engine including charge cooler
40 litres (10.57 gal) 61 litres (13.43 gal)
and wet exhaust manifold
Total capacity engine and radiator
150 litres (33 gal) 175 litres (38.5 gal)
(if Perkins Engines approved radiator fitted)
Total capacity engine and heat exchanger 80 litres (17.5 gal) 94 litres (20.7 gal)
Engine shut down temperature 93 °C (200 °F)
To be determined from heat dissipated and water flow
Max. temperature into engine
through each particular engine model
71 °C (natural gas) 85 °C (landfill or biogas)
Thermostat opening temperature
92 °C (HC engines)
System pressure 0,5 - 0,7 bar
Maximum pressure at jacket coolant pump
2,5 bar max
outlet

1 4006/4008 In-line Gas
Coolant jacket
Engine model
Heater (when fitted) 1 x 2 kw 1 x 4 kw
Gas system
Engine model
Approved gas British Natural Gas
Lower calorific value (at 15 °C and 1,013 bar) 34,71 MJ/Nm3
Carburettor type mixing unit Check fuel specification
Main adjusting screw Deltec (2”) VM5394
Gas pressure min. 1,5 kPa (15 mb)
Gas pressure max. 5 kPa (50 mb)
Regulator type (zero pressure) Dungs FRS520 or KROM SCHRODER
Supply pressure 50 mbar (5 kPa) maximum
Additional items to meet the Institution of Gas Engineers Procedures IGE UP3
Low pressure detector To engines specification
Gas solenoid valves Not Perkins supply
Ignition system
Engine model
Ignition unit type Altronic DISN 800
Altronic 501061 LC
Ignition coil type
Altronic 591010 HC
Spark plug type (18 mm) Champion RB77WPC
Spark plug gap 0,4 mm (0.015 in)
Governor
Engine model
Type Electronic
Make Heinzmann E6 (6 cyl) Heinzmann E10 (8 cyl)
Note: The governor specification may alter due to application and speed.
Induction system
Engine model
Air cleaner Single (paper element)
Type S551A
Max. Air intake depression Refer to relevant Technical Data sheet
Air restriction indicator setting 380 mm H2O
SCHWITZER HC GARRETT HC
Turbocharger make and type S4T-114.58 AE-1.3N5 TV94/44/T18A/1.32G
SCHWITZER LC SCHWITZER LC

4006/4008 In-line Gas 1
Lubrication system
Engine model
Recommended oil Refer to "Approved lubricating oils" on page 54
Type of system Wet sump, external mounted oil pump
Total oil capacity (oil cooler and filter) 122,7 litres (27 gal) 165,6 litres (36.5 gal)
Sump capacity (dipstick) min. 90,9 litres (20 gal) 127 litres (27.9)
Sump capacity (dipstick) max. 113,4 litres (25 gal) 154 litres (33.9 gal)
Min oil pressure (rated speed) to bearings 240 kPa (35 lb/in2)
Crankcase pressure open circuit breather system 25 mm water gauge pressure
Crankcase pressure closed circuit breather
Negative pressure
system
Max. oil temperature to bearings 105 °C
Lubricating oil filter Disposable canister type
Crankcase breather Closed circuit
Exhaust system
Engine model
Manifold type Wet
Exhaust outlet flange Vertical (single)
Mating flange 1 x 6” Table D
Max. exhaust back pressure Refer to relevant Technical Data sheet
Flywheel and flywheel housing

Engine model
SAE size 14” 14”
Flywheel housing
“00” Early engines
SAE size “0”
“0” Later engines
Crankshaft
Engine model
End float 0,13 - 0,48 mm
Max additional load applied to flywheel due to all rotating
Maximum overhung weight on rear bearing
components 650 kg
T.V. Damper 1 x 14” 1 x 20”
Tuning Disc 1 x 18”
Note: Subject to a satisfactory torsional vibration investigation different T.V. dampers may be fitted.
Engine fixing bolt
Engine model
Bolt size (engine feet) 20 mm
No. off 6

1 4006/4008 In-line Gas
Protection equipment
Before resetting protection equipment, it must be established whether special settings (for that individual
engine) have been specified in the engine sales contract. This is particularly important with ALL high water
temperature settings, and ALL Cogen applications.
Standard settings for protection equipment are as follows:.
Shutdown switches Alarm Shutdown
2
High air manifold pressure switch 172 kPa (25.1 lb/in )
High Oil temperature 115 °C 120 °C
2
Low oil pressure 2,06 bar (30 lb/in ) 1,93 bar (28 lb/in2)
High water temperature
71 °C Thermostat 91 °C 96 °C
Overspeed 15% (on 1500 rev/min only)
Caution: The above standard settings do not supersede any settings specified in the engine sales contract.
Electrical system
Engine model
Voltage 24V
Alternator type (when fitted) PRESTOLITE (BUTEC) with internal regulator
Alternator output (amps) 30 at a stabilised output of 28 volts
PRESTOLITE/
Starter motor type MS7/3A
BUTEC MS1/105
No. of teeth (gear ring) 190
No. of teeth (starter motor) 12
Battery capacity cold cranking amps to IEC
540 (each battery) 600 (each battery)
Standard at 0 °C (32 °F)
24 V (2 x 12 V) a 0 °C (32 °F)
Battery (lead acid)
143 Ah 178 Ah

4006/4008 In-line Gas 1
Electrical wiring diagrams
4006/8 engine starting circuit without repeater relay
Item Description
A1 Battery charging alternator
A2 Signal for tacho
A3 Oil pressure switch
A4 Resistor
A5 24 Volt starting batteries
A6 Ammeter
A7 Start relay
A8 Fuel solenoid relay
A9 Fuel stop solenoid (energised to stop)
A10 Starter motor (Prestolite)
A11 Start button
A12 Energise +ve for engine to run, remove to stop
2
W
D+
1 +
-
220W 5w
3 4
6
9
45.0 AMPS INRUSH
0.75 HOLDING
Aux -
5 7 8
10
+
B+ FPS
11 +VE
12
A 323.4

1 4006/4008 In-line Gas
4006/8 engine starting circuit with repeater relay

Item Description
A1 Battery charging alternator
A2 Signal for tacho
A3 Oil pressure switch
A4 Resistor
A5 24 Volt starting batteries
A6 Ammeter
A7 Start relay
A8 Fuel solenoid
A9 Repeat start unit
A10 Fuel stop solenoid (energised to run)
A11 Starter motor (Prestolite)
A12 Start button
A13 Energise +ve for engine to run, remove to stop
2
W
D+
1 +
-
220W 5w
3 4
6
+ 10
45.0 AMPS INRUSH
5 7 8 9 0.75 HOLDING
-
-
6 5 4 3 2 1
11
FPS
+VE
13
SMC
B+
12
A 324.4

4006/4008 In-line Gas 1
4006TESI engine wiring diagram
Item Description Item Description
A1 Ignition coils A10 Magnetic disc on camshaft
A2 High tension leads A11 Emergency stop button
A3 Spark plugs A12 Heinzmann control box
A4 Engine fitted terminal box A13 10 pin plug
A5 Altronic DISN 800 unit A14 2 pin plug
A6 10 pin plug A15 14 pin plug
A7 6 pin plug A16 Heinzmann actuator
A8 5 pin plug A17 Engine flywheel ring gear
A9 Ignition pick-up A18 Magnetic pick-ups
Note: GET knock sensing protection equipment can be wired into this system. Refer to the wiring diagram on
page 16.
8 5 16 12
17
1
3 2
6
13 18
7
14
15
10
11
9
4
A 1800.1

1 4006/4008 In-line Gas
4006TESI engine GET knock sensing system wiring diagram

Item Description
A1 Wiring rail
A2 Knock sensors
A3 Plug in cable (2,5 metres long)
A4 AKR Controller
A5 Grounding screw
A6 Engine fitted terminal box
Warning! When GET knock sensing system is fitted, remove the engine terminal box links A2 - A1, C2 - C1,
add links C5 - E5, B5 - D5.
3
2
J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J
8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 13 13 13 13 13 13 13 13 13 13
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10
GOV
A5 B5 C5 D5 E5 G C2 B2 A2 A1 B1 C1 D S0 S0 Ign
+ -
Ign
A3 B3 E3SC3 B- +
1 2 3 4 PU+ PU- SC1 SW1 SW2 SCR
6
A 1802.1

4006/4008 In-line Gas 1
4008TESI engine wiring diagram
Item Description Item Description
A1 Ignition coils A10 Magnetic disc on camshaft
A2 High tension leads A11 Emergency stop button
A3 Spark plugs A12 Heinzmann control box
A4 Engine fitted terminal box A13 10 pin plug
A5 Altronic DISN 800 unit A14 2 pin plug
A6 10 pin plug A15 14 pin plug
A7 6 pin plug A16 Heinzmann actuator
A8 5 pin plug A17 Engine flywheel ring gear
A9 Ignition pick-up A18 Magnetic pick-ups
Note: GET knock sensing protection equipment can be wired into this system. Refer to the wiring diagram on
page 18.
8 5 16 12
17
1
3 2 6
13 18
7
15 14
10
11
9
4
A 1801.1

1 4006/4008 In-line Gas
4008TESI engine GET knock sensing system wiring diagram

Item Description
A1 Wiring rail
A2 Knock sensors
A3 Plug in cable (2,5 metres long)
A4 AKR Controller
A5 Grounding screw
A6 Engine fitted terminal box
Warning! When GET knock sensing system is fitted, remove the engine terminal box links A2 - A1, C2 - C1,
add links C5 - E5, B5 - D5.
3
2
J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J J
8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 13 13 13 13 13 13 13 13 13 13
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10
A5 B5 C5 D5 E5 G C2 B2 A2 A1 B1 C1 D S0 S0 Ign Ign GOV

+ -
A3 B3 E3 SC3 B- + 1 2 3 4 PU+ PU- SC1 SW1 SW2 SCR
6
A 1803.1

4006/4008 In-line Gas 1
Perkins companies
Australia Singapore
Perkins Engines Australia Pty. Ltd, Perkins Engines Asia Pacific Ltd,
Suite 4, 13A Main Street, 20 Harbour Drive, 07-06A PSA Vista,
Mornington, Victoria 3931, Australia. Singapore 117612.
Telephone: 0061 (0) 597 51877 Telephone: [65] (874) 77 12
Telex: Perkoil AA30816 Fax: [65] (874) 77 22
Fax: 0061 (0) 597 1305
United Kingdom
China Perkins Engines Company Limited,
Perkins Engines (Tianjin) Ltd, Eastfield, Peterborough, PE1 5NA, England.
Jin Wei Road, Beichen District, Telephone: 0044 (0) 1733 583000
Tianjin, 300402, PR China. Telex: 32501 Perken G
Telephone: (86) (22) 2699 2288 Fax: 0044 (0) 1733 582240
Fax: (86) (22) 2699 3784
Perkins Engines Company Limited,
France Tixall Road, Stafford, ST16 3UB, England.
Moteurs Perkins S.A., Telephone: 0044 (0) 1785 223141
Paris Nord II - Parc des reflets, Fax: 0044 (0) 1785 215110
165 Avenue du Bois de la Pie, BP 40064,
F-95913 Roissy - CDG Cedex, France. Perkins Engines Company Limited,
Telephone: 0033 (01) 49-90-7168 Lancaster Road, Shrewsbury, SY1 3NX, England.
Fax: 0033 (01) 49-90-7190 Telephone: 0044 (0) 1743 212000
Fax: 0044 (0) 1743 212700
Germany
Perkins Motoren GmbH, United States of America
Saalaeckerstrasse 4, Perkins Engines Inc,
D-63801 Kleinostheim, Germany. 26200 Town Centre Drive, Suite 280, Novi,
Telephone: 0049 6027 5010 Michigan 48375, USA
Fax: 0049 6027 501130 Telephone: 001 248 374 3100
Fax: 001 248 374 3100
India
Perkins Engines Company Limited Perkins Engines Latin America Inc,
17, S-1 International Trade Tower, Nehru Place, 701 Waterford Way (NW 62nd Avenue), Suite 200,
New Delhi - 19 India. Miami, FL 33126, U.S.A.
Telephone: [91](11) 644 2595 Telephone: 001 305 442 7413
Fax: [91](11) 623 1598 Telex: 32501 Perken G
Fax: 001 305 442 7419
Italy
Motori Perkins S.p.A.,
Via Socrate 8,
22070 Casnate con Bernate (Como), Italy.
Telephone: 0039 (0) 31 564633/564625
Fax: 0039 (0) 31 565480/564145/396001
Japan
Perkins Engines Inc (Japan Branch)
Address Building 8th Floor, 2-2-19 Akasaka,
Minato-ku, Tokyo, 107-0052 Japan.
Telephone: [81](3) 3560 3877
Fax: [81](3) 3560 3878
Note: In addition to the above companies, there are Perkins distributors in most countries. Perkins Engines
Company Limited, Stafford or one of the above companies can provide details.

1 4006/4008 In-line Gas
This page is intentionally blank

2
Engine views 2
Introduction
Perkins engines are built for specific applications and the views which follow do not necessarily match your
engine specification.
6 cylinder engines
Left side of engine (gearcase end)
A
Right side of engine (flywheel end)

2 4006/4008 In-line Gas
8 cylinder engines
Left side of engine (gearcase end)
A
Right side of engine (flywheel end)

3
Operating instructions 3
Introduction
Information for the mechanical maintenance of the 4006/8 gas engines is given in this User’s Handbook
(Publication TSL 4185E) , the Workshop Manual (Publication TSL 4078E) and also the manual for the anti-
knock control system (supplied by Gas Engine Technology Bv) when fitted.
These publications should be understood and used together for the safe operation of the engine.
Note: For oil and coolant details refer to Chapter 5, Gas and engine fluids specification.

3 4006/4008 In-line Gas
Instrument panel
CHP engines
The siting of instruments on CHP engines will vary with each individual installation.
The instruments are normally the same as on a radiator cooled engine, refer to "Instrument operation" on page
25, with the exception of an ammeter, as a battery charging alternator is not usually fitted to CHP engines.
Radiator cooled engines
The instrument panel is mounted on the air inlet manifold.
The individual components of the instrument panel are shown in (A), and listed below:
A1 Exhaust temperature gauge (if fitted)
A2 Coolant temperature gauge
A3 Lubricating oil temperature gauge
A4 Lubricating oil pressure gauge
A5 Battery charging rate gauge
A6 RPM and hours run indicator
A7 Fuse holder
1 2 3 4 5 6 7
A 299.5

4006/4008 In-line Gas 3
Instrument operation
Coolant temperature (A)
1 With the engine running on natural gas the coolant temperature during normal operation should be between
65 °C - 85 °C (149 °F - 185 °F).
2 With the engine running on landfill gas the coolant temperature during normal operation should be between
85 °C - 90 °C (185 °F - 194 °F).
3 If the temperature should rise above 93 °C (200 °F) the engine protection switch will automatically stop the
engine.
4 Investigate the cause.
Engine oil temperature (B)
The lubricating oil temperature should be between 80 °C - 90 °C (176 °F - 194 °F) when the engine is hot.
A 300.3 B 301.3
Engine oil pressure (C)

1 The lubricating oil pressure should be between 300 - 350 kPa (45 - 50 lb/in2) when the engine is hot.
2 If the pressure should drop below 200 kPa (30 lb/in2) at engine operating speed the engine protection switch
will automatically stop the engine.
3 Investigate the cause.
Ammeter - if fitted (D)
The ammeter indicates the charge rate to the batteries from the alternator.
C 302.3 D 303.3

3 4006/4008 In-line Gas
Tachometer and hour counter (A)

The electrically operated tachometer/hour counter shows the speed of the engine and the actual operating
hours the engine has run.
Exhaust temperature gauge - if fitted (B)
The gauge shows readings of turbine outlet temperature between -20 °C and + 800 °C.
A 304.3 B 307.3
Fuse holder (C)

To protect the instrument panel a 2 amp fuse is fitted. To remove the fuse unscrew the holder (C1) and
withdraw the fuse (C2).
1 2
C 1066.4

4006/4008 In-line Gas 3
How to fill the engine with oil
1 Remove the drain plug and check the sump is clean and empty. Refit and tighten the plug.
2 Remove the oil filler plug situated on the right hand side of the gearcase by rotating the T-bar anti-clockwise
and pulling (A).
3 Fill the sump to the maximum mark on the dipstick (B1) with the correct grade of oil as specified in Chapter 5,
Gas and engine fluids specification.
4 Refit the oil filler plug.
Quantity of oil
Sump capacity Dipstick
Engine model
maximum minimum
4006TESI 127,4 litres (25 gal) 90,7 litres (20 gal)
4008TESI 154,0 litres (30 gal) 127,4 litres (25 gal)
A 2.3 B 312.3
How to prime the lubrication system

Caution: Before starting the engine for the first time, or after it has stood idle for more than three months, the
engine lubrication system must be primed.
1 Operate the oil priming pump (C) until 35 kPa (5 lb/in2) is indicated on the oil pressure gauge (D).
2 Continue pumping for 20 seconds to ensure oil has reached the turbocharger.
C 903.3 D 302.3

3 4006/4008 In-line Gas
How to fill a CHP type cooling system

Note: The siting of the cooling system filler cap is dictated by each OEM’s individual installation. The operator
must be aware of their position.
1 A solution of clean water and anti-freeze, or clean water and corrosion preventative, must be used in the
cooling system, refer to "Coolant specification" on page 55.
2 Remove the cooling system filler cap (A1).
3 Loosen the vent plug (B1) in the charge cooler.
4 Fill the cooling system until air free coolant flows from the vent plug.
5 Stop filling and tighten the vent plug.
6 Loosen the vent plug (C1) on the exhaust manifold.
7 Fill the cooling system until air free coolant flows from the vent plugs.
8 Stop filling and tighten the vent plug.
9 Fill the cooling system to 25 mm (1” inch) (A2) below the filler neck.
10 Replace the filler cap.
Caution: All trapped air must be vented from the engines cooling system. If an airlock is present on engine
start up localised overheating will occur, possibly causing engine damage.
2
1
A 1486.1 B 1300.1
C 1301.2

4006/4008 In-line Gas 3
How to fill a radiator type cooling system
1 A solution of clean water and anti-freeze, or clean water and corrosion preventative must be used in the
cooling system, refer to "Coolant specification" on page 55.
2 Remove the radiator filler cap (A1).
3 Loosen the vent plug (B1) in the charge cooler.
4 Fill the radiator until air free coolant flows from the vent plug.
5 Stop filling the radiator and tighten the vent plug.
6 Loosen the vent plug (C1) on the exhaust manifold.
7 Fill the radiator until air free coolant flows from the vent plug.
8 Stop filling the radiator and tighten the vent plug.
9 Fill the radiator to 25 mm (1” inch) (A2) below the filler neck.
10 Replace the filler cap.
Caution: All trapped air must be vented from the engines cooling system. If an airlock is present on engine
start up localised overheating will occur, possibly causing engine damage.
A 11.4 B 1300.1
C 1301.2

3 4006/4008 In-line Gas
Final checks and first engine start

Note: The gas supply pipework, solenoid valves etc. must comply with the Institution of Gas Engineers
Procedures IGE UP3.
1 Starting and stopping must be on NO LOAD.
2 The procedure for starting and stopping radiator cooled and CHP gas engines will be determined by the
OEM relative to each individual engine installation.
A typical engine start sequence is given on page 31 and a typical engine stop sequence on page 32.
3 Run the engine at rated speed for 10 minutes.
4 Check for oil and coolant leaks.
5 Stop the engine and check oil and coolant levels.
6 When the engine is in service and on load check its condition using the instrument readings.
Warning! Experience has shown that taper lock bushes, as fitted in the fan pulleys and battery alternator
driven pulley, can work loose shortly after being put into service. Refer to Chapter 14 in the Workshop Manual.
Radiator pulley (if fitted)
Fan driven pulley taper lock bush screws
5/
8” BSW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Nm (65 lbf ft)
1
/2” BSW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Nm (35 lbf ft)
Battery charging alternator (if fitted)

Drive pulley taper lock bush screws
3
/8” BSW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Nm (15 lbf ft)
Warnings!
If the engine fails to start after two attempts, turn off the gas supply and investigate the cause. Before
attempting to restart the engine it must be purged of gas. Disconnect the ignition system and gas supply
and crank the engine over for six seconds maximum.
The cooling system is pressurised - DO NOT remove the filler cap from the radiator while the engine is hot.
Personal protective equipment must be worn.

4006/4008 In-line Gas 3
Typical engine start sequence
Start signal
received
Is gas
pressure NO Low gas pressure
within alarm & lockout
limits?
YES
Energise
governor
Energise starter
motor & crank
timer
Crank for 3
seconds
(Purge system)
Energise gas
valves & ignition
continue cranking
NO
Has Max
engine NO cranking YES Fail to start
time lockout
started ? reached?
YES
De-energise
starter
motor
Engine
running
A 623.4

3 4006/4008 In-line Gas
Typical engine stop sequence
Engine
running
Over Switch off ignition

YES
speed system & de-energise
gas valves
fault?
NO
Other
YES De-energise
engine
gas valves
fault?
NO Stop YES De-energise

engine? gas valves
A 623.5

4
Preventive maintenance 4
Maintenance procedures
These maintenance procedures are 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.
Warnings!
Make quite certain that the engine cannot be started before undertaking any maintenance.
This is particularly important in the case of automatically starting generating sets or remote starting
engines.
Personal protective equipment must always be worn.

4 4006/4008 In-line Gas
Service schedules
The following service schedules are applicable to engines running on both natural and biogas. Extra work
required for biogas engines only is indicated (*).
Oil and filter change intervals
For engines running on gas to the specification given in "Gas specifications" on page 53 and using approved
lubricating oils as specified in "Approved lubricating oils" on page 54, the oil and filters must be changed after
the first 500 hours of operation.
Subsequent oil and filter changes must be determined using an oil analysis program. For further details refer
to "Oil and filter change program" on page 54.
Warning! If oil analysis is not used to establish the oil change intervals, it is essential that Perkins Engines
Company Limited, Stafford are consulted. Failure to do so could affect engine warranty.
Using Manuals
Users Handbook (Publication TSL 4185E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UH
Workshop Manual (Publication TSL 4078E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WM
A service - First 500 hours
Description Manual
Oil and filters - change UH
Equalise bridge pieces and set valve clearance UH
Spark plugs - clean and re-gap UH
Fan and battery charging alternator drive belts - check WM
Fan and battery charging alternator taperlock drive pulleys - check UH
B service - 1,000, 2,000, 4,000, 5,000, 7,000, 8,000, 10,000, 11,000, 13,000, 14,000, 16,000, 17,000, 19,000,
20,000, 22,000 and 23,000 hours
Description Manual
Equalise bridge pieces, set valve clearance and check valve seat recession UH
Spark plugs - check, clean and re-gap UH
Breather systems - clean or replace element UH
Air filter - replace (subject to environmental conditions) UH
Governor actuator - lubricate ball joints WM
C service - 3,000, 9,000, 15,000 and 21,000 hours

Description Manual
Spark plugs - check, clean and re-gap UH
Breather systems - clean or replace element. Replace valves on closed circuit system UH
Check emissions To be done by
or every 12 months specialist
Check exhaust back pressure personnel
Clean and lubricate gas control valve (stepper motor) WM
Check coolant mixture or every 6 months WM

4006/4008 In-line Gas 4
D service - 6,000 and 18,000 hours
Description Manual
Spark plugs - replace UH
Governor actuator - lubricate ball joints WM
Check coolant concentration UH
Magnetic pick-ups - clean and set UH
High tension leads - replace UH
Charge cooler - remove and clean (closed circuit breather system only) WM
Check emissions To be done by
or every 12 months specialist
Check exhaust back pressure personnel
Clean venturi (in gas mixer) WM
E service - 12,000 hours

Description Manual
Charge cooler - remove and clean (open and closed circuit systems) WM
Magnetic pick-ups - clean and set WM
Oil cooler (8 cylinder only) - remove and clean WM
Turbocharger - replace WM
Cylinder heads - replace WM
Governor actuator - replace ball joints WM
Piston rings - replace (*) WM
De-glaze liners (*) WM
Piston cooling jets - replace WM
Change coolant and inspect the system UH
(*) Biogas engines only

4 4006/4008 In-line Gas
F service - 24,000 hours

Description Manual
Charge cooler - remove and clean (open and closed circuit systems) WM
Magnetic pick-ups - clean and set WM
Oil cooler - remove and clean WM
Turbocharger - replace WM
Cylinder heads - replace WM
Governor actuator unit and ball joints - replace WM
Piston rings and liners - replace, clean pistons WM
Big end bolts and bearings - replace WM
To be done by
Low pressure gas regulator - replace and reset specialist
personnel
Cam and followers - inspect WM
Oil pump - inspect WM
Coolant pump - inspect WM
Notes:
Maintenance schedule from 24,000 hrs to 48,000 hrs is the same as 1,000 to 24,000 hrs.
At 48,000 hrs operation consult Perkins Engines Company Limited, Stafford reference major overhaul and
service exchange engine components.

4006/4008 In-line Gas 4
How to check the oil level
1 Stop the engine and wait 5 minutes to allow the oil to drain into the sump.
2 Withdraw the dipstick and wipe clean.
3 Re-insert the dipstick and wait 2 seconds.
4 Withdraw the dipstick and check the level against the high and low marks.
5 Top up as required, ensuring that the added oil is the same grade and specification as the oil already in the
system.
How to check the coolant level

Warning! Always stop the engine and allow the pressurised system to cool before removing the filler cap.
Prevent skin contact with the coolant mixture.
1 Remove the filler cap.
2 The coolant level should be 25 mm (1”) below the top of the filler neck.
Caution: If coolant is added to the system during the service, it must consist of the same original mixture as
used to fill the system.
3 Refit the filler cap.

4 4006/4008 In-line Gas
How to check and clean the radiator (if fitted)

Special requirements
Special tools
Description Part number
Air compressor UA
Steam cleaner UA
Under normal operating conditions the radiator cooling fins should be inspected for a build up of dust and oil
contamination every 3 months.
Caution: If adverse site conditions exist inspections must be increased.
Cleaning the radiator cooling fins
Note: To clean the cooling fins on the fan side of the radiator, the fan, its supports and the cowling must first
be removed.
1 Dry dust and general contamination can be blown from the cooling fins using compressed air at a maximum
pressure of 100 - 300 kPa.
2 To clean oil / dirt contamination, brush an industrial liquid detergent onto the fins.
Warning! The detergent manufacturers instructions must be followed.
3 Use a steam jet at a maximum pressure of 500 - 700 kPa to remove the contamination.

4006/4008 In-line Gas 4
How to check the radiator fan drive belts (if fitted)
1 Remove the mesh guard from around the fan belts.
2 Lubricate with grease the fan bearings and jockey pulley bearings.
3 Check the tension and wear of the fan belts using hand pressure midway between the crankshaft and the
pulley. A total deflection of 12,5 mm (0.5”) is acceptable (A1).
4 If the fan belts are worn the complete set should be replaced and the fan pulley to crankshaft pulley
alignment checked.
5 If adjustment is necessary loosen the adjusting screws (A2). Using a tube extension (A3) on the jockey
pulley, move outwards to tension the belts and inwards to loosen.
6 With the tension set, tighten the adjusting screws (A2).
7 Fit the mesh guard.
1
3
A 476.4

4 4006/4008 In-line Gas
How to check the battery charging alternator (if fitted)

1 Remove the guard (A1) around the alternator (this is a three piece item). Start by removing the three bolts
(A4) retaining a small square plate (A3) to the guard. This is located on the underside of the alternator.
2 Remove the single bolt (A5) holding the guard together.
3 Remove the top and bottom retaining bolts (A2) and lift off the guard.
4 Visually inspect the drive belt, checking the drive teeth and the smooth outer face are undamaged.
Caution: The toothed belt used to drive the alternator relies on tooth engagement to transmit the load. It does
not require pre-loading.
5 Check belt tension using light finger pressure midway between the pulleys (A6). A deflection of 1,5 mm
(1/16”) is correct.
6 To adjust the belt tension loosen the pivot bolt (A7) and the tensioning arm bolts (A8). Set the belt tension,
then retighten all the bolts.
7 Fit the guard.
Note: To replace the drive belt refer to Chapter 14 in the Workshop Manual.
2 1
3
6
4
2
A 1026.4

4006/4008 In-line Gas 4
How to change the engine oil and filters
1 Place a container with a capacity of 148 litres (32.5 gal) under the sump drain plug.
2 Remove the sump drain plug and allow the oil to drain into the container.
3 Place a container with a capacity of 5 litres (1 gal) to catch the oil which will be released as the oil filters are
removed.
4 Remove the oil filters using a strap wrench, turning the filter anti-clockwise (A).
5 Clean the sealing faces and the threaded bosses of the oil filter header.
6 Lightly lubricate the sealing ring of the new filters with engine oil.
7 Screw each filter up to the header using firm hand pressure.
8 Refit the sump drain plug and refill the engine with oil.
Warning! Prime the lubrication system as described in "How to prime the lubrication system" on page 27
before starting the engine.
A 1026.4

4 4006/4008 In-line Gas
How to change the change-over filters (if fitted)

With engine running
1 With both filters on line, the marking on the change-over valve will be as (A1).
2 Using a spanner turn the change-over valve to position (A2), directing the oil away from the right hand filter.
3 Remove the filter using a strap wrench, turning the filter anti-clockwise.
Caution: Prepare for a small oil spillage as the filter is removed.
4 Clean the sealing face and threaded boss of the filter header.
5 Fill the new filter with oil and lightly lubricate the sealing ring.
6 Screw the filter up to the header using firm hand pressure.
7 Turn the change-over valve back to position (A1).
8 Turn the change-over valve to position (A3) and change the left hand filter.
Note: View (A4) shows oil flow from engine to filters. View (A5) shows oil flow from filters to engine.
With engine stopped
Follow the procedure for standard filters given in "How to change the engine oil and filters" on page 41.
5
4
A 2 1 3 4 5 80.6

4006/4008 In-line Gas 4
How to clean the open circuit crankcase breather
Warning! Disconnect batteries or any other means of starting. Personal protective equipment must be worn.
The crankcase breather is mounted on the thermostat housing.
1 Unscrew the wing nut (A1).
2 Remove top cover (A2).
3 Lift out the two wire mesh elements (A4) from the filter body.
4 Clean any oil sludge deposits from the breather body, cover and pipework.
Caution: If there is an excessive amount of oil sludge, remove the unit for cleaning.
5 Wash the mesh elements in a suitable cleaning agent and shake dry. If compressed air is available blow dry.
Warning! If the mesh elements still retain a heavy deposit of oil sludge after cleaning, new elements must be
fitted to ensure breather efficiency.
6 Refit the mesh elements into the filter body.
7 Check the sealing joint is in good condition and replace if required. Replace the cover making sure it is in
the correct position on its dowel (A3).
8 Tighten the wing nut (A1).
A 974.4

4 4006/4008 In-line Gas
How to clean the closed circuit breather system

Warning! Disconnect batteries or any other means of starting. Personal protective equipment must be worn.
The closed circuit breather / separator is mounted on the right hand side of the crankcase and is connected to
the carburettor through two breather valves.
1 Release the pipe clips and remove the breather valves (A1) from their pipework.
2 Clean the breather valves in a suitable solvent, removing all oil sludge deposits, and shake dry. If
compressed air is available blow dry.
3 Release the retaining clips (A2) on the breather / separator. Lift off the cover (A3) and pipework.
4 Remove the foam element (B1).
5 Clean any oil sludge deposits from the separator body, cover and pipework.
Note: If there is an excessive amount of oil sludge remove the unit for cleaning.
6 Wash the foam element in a suitable cleaning agent and shake dry. If compressed air is available blow dry.
Caution: If the foam element still retains a heavy deposit of oil sludge after cleaning a new element must be
fitted to ensure breather efficiency.
7 Refit the foam element into the separator body.
8 Refit the cover and pipework. Lock down the retaining clips.
9 Check condition of the ‘O’ ring (C1) in the body of the breather valves.
10 Before refitting the breather valves fill the valve seat (C2) with clean engine oil.
11 Refit the breather valves and align the pipework. Tighten the pipe clips.
3
B 1304.1
A 966.4 C 1005.3

4006/4008 In-line Gas 4
How to check the air cleaner restriction indicator
1 The middle section of the restriction indicator (A1) will remain clear while the air cleaner is in a serviceable
condition.
2 When the filter reaches its contamination limit the restriction indicator will sense the change in manifold
pressure and the middle section (A1) will change to red. At this point the air filter must be changed.
3 When the air filters have been changed reset the indicator by pressing the button (A2).
A 948.4
How to change the air filter element

1 Unscrew the wing nut (B1) and pull the end cover (B2) from the filter body.
2 Lift out the paper element (B3).
3 Clean any dust accumulation from inside the air filter body using a clean cloth.
Caution: Do not use compressed air as dust particles will be blown into the turbo and inlet manifolds.
4 Fit the new air filter into the filter body.
5 When fitting the end cover check it is fully seated before tightening the wing nut.
Cleaning the cyclone unit
For heavy duty air filtration a cyclone unit (B4) is fitted to the filter intake replacing the mesh guard.
1 To clean the cyclone unit remove it from the air filter intake.
2 Using compressed air remove any accumulated dust from the body of the unit.
3 Refit to the air filter intake.
Warning! When using compressed air personal protective equipment must be worn.
3 2 1
4
B 27.4

4 4006/4008 In-line Gas
How to remove a spark plug

Special tools
Spark plug removal tool 484/45
1 Disconnect the spark plug lead (A1).

2 Remove the spark plug using tool 484/45 (B1).
Note: Store the spark plugs in their cylinder order as the combustion deposits on the plugs will give a guide
to the conditions in each cylinder.
A 1020.3 B 1663.1

4006/4008 In-line Gas 4
How to clean, set and fit a spark plug
Special tools
Cylinder head spark plug thread
27610178
cleaning tool (thread chaser)
1 Clean any carbon / ash deposits from the spark plug thread and ceramic insulator using a suitable solvent
and a dry cloth.
2 A light coating of ash evenly deposited on the electrodes indicates the plug is in good condition with a clean
burning mixture.
3 Clean any loose ash deposit from the end of the spark plug (A1) using a nylon brush.
Caution: Do not use a metal brush to clean a spark plug as the porcelain around the centre electrode will be
scratched, allowing ash deposits to build rapidly on the roughened surface, causing plug failure.
4 Set the spark plug gap to 0,4 mm (0.0015”) (A2).
Caution: The centre and ground electrodes of the spark plug are tipped with a hard surface which must not
be filed or cleaned using abrasive paper.
5 Every time a spark plug is refitted the sealing washer (A3) must be replaced. Use sealing washer part
number Y98/00038.
Warning! The spark plug should be finger tightened into the cylinder head, if resistance is felt clean the plug
thread in the cylinder head using a thread chaser. NEVER use a thread tap.
6 Apply a very small amount of Poly Butyl Cuprysil grease to the thread of the spark plug (A4).
7 Fit the spark plug carefully locating it in the cylinder head. Tighten down finger tight, then torque to 50 Nm
(35 lbf ft).
8 Refit the spark plug lead (B1).
1 2
1
4
A 1332.1 B 1020.3

4 4006/4008 In-line Gas
Preparation for equalising bridge pieces and setting valve clearances

Special tools
Engine cranking device SE253
Warning! Make sure the engine cannot be started before any maintenance is carried out.
1 Remove the spark plug lead from the cylinder head.
2 Take out the four capscrews (A1) holding the rocker box cover (A2).
3 Lift off the rocker box cover (A2).
4 Pull the plug lead tube (A3) out of the cylinder head.
5 To rotate the engine to the positions required for this procedure fit the engine cranking device to the spare
starter motor mounting in the flywheel housing (B).
6 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. Refer to the relevant table for 6 or 8 cylinder
engines on page 49.
7 The flywheel markings are viewed through an inspection hole in the flywheel housing. To get an accurate
reading align by eye the tip of both pointers with the marks on the flywheel (C).
2 1
A 316.3 B 1096.4
C 1224.2

4006/4008 In-line Gas 4
6 cylinder engines
T.D.C. Valves rocking on Set bridge piece and valve
(top dead centre) cylinder No. clearance on cylinder No.
1&6 6 1
2&5 2 5
3&4 4 3
1&6 1 6
2&5 5 2
3&4 3 4
8 cylinder engines
T.D.C. Valves rocking on Set bridge piece and valve
(top dead centre) cylinder No. clearance on cylinder No.
1&8 8 1
4&5 5 4
2&7 2 7
3&6 3 6
1&8 1 8
4&5 4 5
2&7 7 2
3&6 6 3

4 4006/4008 In-line Gas
How to equalise bridge pieces

1 Rotate the engine to the position shown in the relevant table on page 49.
2 Check the inlet and exhaust rockers have clearance on the bridge piece.
3 Loosen the locknut (A1) on the bridge piece.
4 Screw the adjuster (A2) out until the fixed side of the bridge piece rests on its valve.
5 Hold down the top edge of the bridge piece. Screw the adjuster down until it touches the valve.
6 Tighten the locknut without moving the adjuster.
2
1
A 317.5

4006/4008 In-line Gas 4
How to set valve clearances
Special tools
Feeler gauges UA
1 Check the clearance using a feeler gauge.

Note: The correct inlet and exhaust valve clearance is 0,4 mm (0.016”).
2 To set the valve clearance loosen the locknut (A2).
3 Place the feeler gauge (A1) between the rocker and bridge piece.
4 Screw the adjuster (A3) up or down making the feeler gauge a slide fit.
5 Tighten the locknut without moving the adjuster.
6 Refit the plug lead tube and rocker cover.
Caution: An undamaged rocker box sealing joint can only be re-used once.
3 2
A 318.5

4 4006/4008 In-line Gas
How to check valve and seat recession

Special tools
Valve seat recession checking tool T6253/312
Using tool T6253/312, an indication of valve and seat wear (recession) can be obtained without removing a
cylinder head. The tool is to be used as part of the bridge piece and valve clearance setting sequence.
Warning! This check should be done at 3,000 hours and every service when setting bridge pieces and valve
clearances, up to the cylinder heads being replaced.
The inlet valves are easily checked but insufficient clearance means only one exhaust valve can be checked.
1 Place the tool on the rocker box face around the bolt (A1).
2 Position the legs of the tool above the inlet valve spring retainers. The clearance between the legs and valve
spring retainers indicates the valve life left.
3 A leg touching a valve spring retainer indicates the need for a cylinder head overhaul.
4 To check the exhaust valve, place the tool around bolt (A2).
From engine serial number DGB061220U0678F (6 cylinder engines) and DGB080702U0680F (8 cylinder
engines) the following improvements have been introduced:
The rocker box to cylinder head joint has been improved using a graphite material which is 0,7 mm thicker
than the joint it has replaced.
Capscrews have replaced the retaining bolts (A1) and (A2).
To check valve seat recession on these engines use a 0,7 mm feeler gauge (A3) in conjunction with the
recession tool (A4).
2
1 3
A 1199.6

5
Gas and engine fluids specification 5
Gas specifications
A new engine will be set to operate on clean natural gas conforming to the British natural gas specifications
having a lower calorific value of 34,71 MJ/Sm3 (930 BTU/Sft3).
The difference between high calorific value (HCV) and low calorific (LCV) is that (HCV) is the total amount of
heat given off by the gas during combustion and the (LCV) is the high calorific value less the amount of heat
used to vaporize the water content of the gas. Since the amount of heat lost in vaporizing the water is different
for different gases, the lower calorific value of the gas is chosen as the basis for fuel consumption data. There
must be no liquid hydrocarbon fractions in the gas.
Warning! If the engine is not set to suit the site gas, uneconomical running, loss of power or damage may
occur, which could result in injury.
Where gases other than British Natural Gas are to be used, such as wellhead gas, digester gas and landfill
gas, a detailed analysis of the gas must be submitted to Perkins Engines Company Limited, Stafford as
resetting or changing the standard gas equipment may be necessary.
4006/8TESI 4006/8TESI
Limiting values for British Gas
200 & 140 LC 140 & 90 HC
Methane number must exceed 65 80
Combustible constituents must exceed 85% 95%
31,7 MJ/Nm3 34 MJ/Nm3
Calorific value (LCV) to exceed
(850 BTU/Sft ) (912 BTU/Sft3)
3
Ethane 6% 4.5%
Hydrogen content not to exceed 0.2% 0.1%
Propane must not exceed 2.0% 1.0%
Isobutane content not to exceed 0.2% 0.2%
Normal butane not to exceed 0.2% 0.2%
Normal pentane and higher fractions (hexane, heptane, etc).
0.02% 0.02%
The summation must not exceed
15 mbar 15 mbar
Minimum gas pressure at inlet to regulators
(1.5 kPa) (1.5 kPa)
50 mbar 50 mbar
Gas pressure not to exceed without additional pressure regulators
(5 kPa) (5 kPa)
0.01% 0.01%
Hydrogen sulphide not to exceed
or 100 ppm or 100 ppm
Note: The rating may be reduced if lower calorific value of the fuel is lower than 34,71 MJ/Nm3 (930 BTU/Sft3).
Also pressure must be constant to maintain emissions and stability. If any of the above parameters are not
met, Perkins Engines Company Limited, Stafford should be consulted for advice.
Gas safety regulations
There are legal requirements that within the U.K. gas fittings and equipment must be installed only by
competent persons and in accordance with the Institution of Gas Engineers Procedures IGE UP3. Outside the
U.K. anyone undertaking work on the engine or associated with the engine and its gas equipment in particular
should check with local and national regulations to ensure compliance.

5 4006/4008 In-line Gas
Approved lubricating oils

High and low compression engines - ash content < 0.5%
Mobil 705
Esso Estor PC 40
Esso Estor HPC 40
Texaco Geotec L.A.
Q8 Mahler MA
Castrol Duratec L
Shell Mysella LA 40
Low compression engines - ash content < 1%
Mobil 710
Esso Estor P 40
Castrol Duratec M
Shell Mysella MA 40
Landfill, Biogas and low compression engines
Mobil Pegasus 610
Oil and filter change program

Natural and Biogas engines
Lubricating oil and filter life is governed by engine load, gas quality and the type of oil used. To determine the
optimum oil and filter change period after engine commissioning the following program of oil analysis should
be followed.
Initiating an oil analysis program
Caution: The oil sample must be taken from the mean level in the engines sump, NEVER from the sump drain
plug.
Note: During an engines initial 500 hour running period oil analysis will show levels of iron and copper above
the acceptable contamination parameters, as indicated below (*). As the engine continues to run the levels will
drop within the specified parameters.
Every 250 hours after the first 500 hour oil and filter change the oil should be analysed.
At 750 hours by comparing the oil analysis results a contamination trend can be established, allowing each
individual operator to develop an oil and filter change policy for the operating conditions of their engine.
Caution: Irrespective of their condition the lubricating oil and filters MUST be changed at 1500 hours.
Critical lubricating oil contamination parameters
Viscosity at 100 °C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cSt max 20% above original value
Insolubles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5% wt. max
Total Base Number (TBN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60% less than new oil value
Nitration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 abs/cm max
Oxidation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 abs/cm max
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2% volume max
Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 20 ppm*
Copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Less than 40 ppm*

4006/4008 In-line Gas 5
Coolant specification
50% inhibited ethylene glycol or 50% inhibited propylene glycol and 50% clean fresh water should be used.
For combined heat and power systems and where there is no likelihood of ambient temperature below 10 °C,
then clean ‘soft’ water may be used, treated with 1% by volume of Perkins inhibitor in the cooling system.
The inhibitor is available in under Perkins part number OE 45350.
Maintenance of coolant
Warning! Always stop the engine and allow the pressurised system to cool before removing the filler cap.
Prevent skin contact with the coolant mixture.
The coolant mixture should be changed at 12,000 hours or 18 months and checked at 3,000 hours or 6 month
intervals for the correct alkalinity level. The pH should not be above 7.5.
Note: A hydrometer only shows the proportion of ethylene glycol. This is not a measure of protection against
corrosion.
Warning! Failure to follow the above recommendations may result in engine damage and will invalidate the
engine warranty.

5 4006/4008 In-line Gas

6
Fault diagnosis 6
Problems and possible causes
Problem Possible causes

The starter motor turns the engine too slowly 1, 2, 3, 4
The engine does not start 5, 6, 7, 8, 10, 11, 12,
The engine is difficult to start 5, 7, 8, 9, 10, 11, 12, 26, 27, 28, 29, 46, 47
The engine is loosing power 8, 9, 10, 11, 12, 13, 15, 26, 27, 28, 29, 30, 44, 46
Misfire 7, 8, 9, 13, 15, 26, 27, 28, 29, 30
High gas consumption 7, 9, 12, 26, 27, 28, 29, 44, 46
The engine knocks 13, 20, 26, 27, 29, 30, 32, 33, 38
The engine runs erratically 7, 8, 9, 12, 26, 27, 28, 29, 30, 44, 46
Vibration 32, 33, 38, 39, 42
Low oil pressure 16, 17, 18, 32, 33, 34, 37, 43, 48
High oil pressure 4, 17, 35
High oil temperature 4, 13, 16, 48
Crankcase pressure 24, 29, 38
High coolant temperature 22, 23, 25, 26, 40, 41, 42
Blue exhaust smoke 21, 24, 29, 38, 45

6 4006/4008 In-line Gas
List of possible causes

1 Battery capacity low.
2 Bad electrical connections.
3 Fault in starter motor.
4 Wrong grade of lubricating oil.
5 Starter motor turns engine too slowly.
6 Ignition failed (no spark at plugs).
7 Dirty or worn spark plugs.
8 Fault in gas supply.
9 Drop in gas quality.
10 Restriction in air induction system.
11 Restricted movement of engine speed control.
12 Restriction in exhaust system.
13 Engine temperature is too high.
14 Engine temperature is too low.
15 Incorrect valve clearances.
16 Not enough lubricating oil in sump.
17 Defective gauge.
18 Dirty lubricating oil filter element.
19 Fan damaged.
20 Fault in engine mounting or flywheel housing.
21 Too much lubricating oil in sump.
22 Restriction in air or coolant passages of radiator.
23 Electric coolant pump failure.
24 Restriction in breather.
25 Insufficient coolant in system.
26 Cylinder head flame rings leaking.
27 Worn cylinder bores.
28 Leakage between valves and seats.
29 Piston rings are seized in piston (rings worn or broken).
30 Broken valve spring.
31 Valve stems and/or guides are worn.
32 Crankshaft bearings are worn or damaged.
33 Lubricating oil pump is worn.
34 Relief valve does not close.
35 Relief valve does not open.
36 Relief valve spring is broken.
37 Fault in suction pipe of lubricating oil pump.
38 Piston is damaged.
39 Flywheel housing or flywheel is not aligned correctly.
40 Fault in thermostat or thermostat is of an incorrect type.
41 Restriction in coolant passages.
42 Fault in mechanical coolant pump (radiator system).
43 Restriction in sump strainer.
44 Turbocharger impeller is damaged or dirty.

4006/4008 In-line Gas 6
45 Turbocharger lubricating oil seal leaking.
46 Faulty engine governor.
47 Faulty sensor.
48 Oil cooler tubestack blocked.

6 4006/4008 In-line Gas

Perkins 4000 Gas Engine

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Perkins 4000 Gas Engine

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Perkins 4000 Series

6 and 8 cylinder turbocharged gas engines

Publication TSL 4185E.

5 Gas and engine fluids

The following pages contain a detailed table of contents

User’s Handbook, TSL 4185E, March 2001 iii

iv User’s Handbook, TSL 4185E, March 2001

5 Gas and engine fluids specification

User’s Handbook, TSL 4185E, March 2001 v

vi User’s Handbook, TSL 4185E, March 2001

User’s Handbook, TSL 4185E, March 2001 1

How to care for your engine

2 User’s Handbook, TSL 4185E, March 2001

User’s Handbook, TSL 4185E, March 2001 3

4 User’s Handbook, TSL 4185E, March 2001

Dangers from used engine oils

User’s Handbook, TSL 4185E, March 2001 5

Danger from ‘fluorosilicone’ (Viton) ‘O’ ring seals

Practical information for cleaning components

6 User’s Handbook, TSL 4185E, March 2001

User’s Handbook, TSL 4185E, March 2001 7

8 User’s Handbook, TSL 4185E, March 2001

Typical cooling system

User’s Handbook, TSL 4185E, March 2001 9

10 User’s Handbook, TSL 4185E, March 2001

Flywheel and flywheel housing

User’s Handbook, TSL 4185E, March 2001 11

12 User’s Handbook, TSL 4185E, March 2001

User’s Handbook, TSL 4185E, March 2001 13

4006/8 engine starting circuit with repeater relay

14 User’s Handbook, TSL 4185E, March 2001

User’s Handbook, TSL 4185E, March 2001 15

4006TESI engine GET knock sensing system wiring diagram

16 User’s Handbook, TSL 4185E, March 2001

User’s Handbook, TSL 4185E, March 2001 17

4008TESI engine GET knock sensing system wiring diagram

A5 B5 C5 D5 E5 G C2 B2 A2 A1 B1 C1 D S0 S0 Ign Ign GOV

18 User’s Handbook, TSL 4185E, March 2001

User’s Handbook, TSL 4185E, March 2001 19

This page is intentionally blank

20 User’s Handbook, TSL 4185E, March 2001

User’s Handbook, TSL 4185E, March 2001 21

22 User’s Handbook, TSL 4185E, March 2001

User’s Handbook, TSL 4185E, March 2001 23

24 User’s Handbook, TSL 4185E, March 2001

Engine oil pressure (C)

User’s Handbook, TSL 4185E, March 2001 25

Tachometer and hour counter (A)

Fuse holder (C)

26 User’s Handbook, TSL 4185E, March 2001

How to prime the lubrication system

User’s Handbook, TSL 4185E, March 2001 27

How to fill a CHP type cooling system

28 User’s Handbook, TSL 4185E, March 2001

User’s Handbook, TSL 4185E, March 2001 29

Final checks and first engine start

Battery charging alternator (if fitted)

30 User’s Handbook, TSL 4185E, March 2001

User’s Handbook, TSL 4185E, March 2001 31

Typical engine stop sequence

Over Switch off ignition

NO Stop YES De-energise

32 User’s Handbook, TSL 4185E, March 2001