Perkins 400 Series Product Training

Perkins 400 Series Perkins 100 Series

General Information LCP2 panel as standard. Optional; LCP0, LCP1 Access 4000. All panel communication options available. Available in G - Series canopy. Bunded base tank option (integral to canopy) Accepts 100% load within G2 standards Within EPA and EC emission limits for 2004 Bare engine noise reduced by Compact Timing device fuel injection pump. New combustion chamber design. 40% Antifreeze as standard (50% optional) General Information

Release Dates

Genset, Engine & Alternator Model Codes

400 Series Design Features -1- Oil fill point Fuel Filter Fuel Control Solenoid Mechanical Lift Pump Fuel Pump Oil Filter Speed Control Oil Dipstick Sump drain tap 400 Series Design Features -1-

400 Series Design Features -2- Inlet Manifold Closed Circuit Breather (CCB) Exhaust Manifold Charging Alternator Starter Motor Large Sump 400 Series Design Features -2-

Engine Identification Engine build list numbering system Standard engine build list code; Code I - Engine build code Code II - Engine build list Code III - Country of Manufacture The build list increases numerically as changes are made. Code IV - Engine build list Code V - Year of manufacture Individual serial number commencing with 000001 increasing numerically. Engine Identification

Engine Data

Coolant System Antifreeze Thermostat The coolant must consist of equal quantities of anti freeze and soft water. The corrosion inhibitor in the antifreeze will be diluted if a concentration of less than 50% is used. Concentrations of more than 50% of antifreeze may have an adverse effect on the cooling properties of the coolant. Coolant Pump tell tale hole (1) for Coolant Leakage If an antifreeze mixture, other than Perkins Powerpart is used to prevent frost damage, it must have an ethanediol base (ethylene glycol) with a corrosion inhibitor. The specification must be at least as good as BS 6580, ASTMD 3306-89, or AS 2108-1977. Caution: Do not use salt water or any other coolant that can cause corrosion in the closed cooling circuit. Thermostat Thermostat opens 80ºC - 84ºC, and is fully open at 95ºC Coolant System

To get the correct power and performance from the engine, use good quality fuel. The recommended fuel specification for Perkins engines is shown below:- Cetane number: 45 minimum Viscosity: 2.0 / 4.5 centistokes at 40 °C (104 °F) Density: 0,835 / 0,855 kg/litre Sulphur: 0.2% of mass, maximum Distillation: 85% at 350 °C (662 °F) Cetane number; Indicates ignition performance. Fuel with a low cetane number can cause cold start problems and affect combustion. Viscosity; Is the resistance to flow and if this is outside limits, engine performance can be affected. Density; Low density will reduce engine power, higher density will increase engine power and exhaust smoke. Sulphur; High sulphur content (not normally found in Europe, N. America or Australasia) can cause engine wear. Where only high sulphur fuels are available, it will be necessary to use a highly alkaline lubricating oil in the engine or reduce the lubricating oil change interval. Distillation; This is an indication of the mixture of different hydrocarbons in the fuel. A high ratio of light weight hydrocarbons can affect the combustion characteristics. Fuel Specification

High Pressure Pipes Optimised Internal diameter optimised to work more effectively with the injectors. This gives more accurate delivery to the injectors and has a positive impact on fuel consumption, smoke and emissions. High Pressure Pipes Optimised

Fuel Pump Return Vent pipe Fuel pump return/self venting pipe is standard on all 400 Series engines. Vent pipe This pipe allows any air which is trapped in the fuel to escape back to the fuel tank without causing any problems in the fuel pump. Fuel Pump Return

Fuel System To eliminate air from the fuel system 1. Loosen the vent screw on the fuel filter (1). 2. Operate the hand primer until fuel, free of air, flows from the vent screw. Tighten the vent screw (1). 3. Loosen the vent screw on the fuel injection pump (2). Operate the hand primer until fuel, free of air, flows. Tighten the vent screw (2). 4. Attempt to Start the engine using the starter motor for a maximum of 15 seconds (if keystart panel fitted), wait for 30 seconds before trying again. Caution: When using the starter motor, do not exceed continuous rotation of more than 15 seconds periods. If the engine does not run, on initial rotation, wait for 30 seconds and try again. Fuel System

To Remove and fit If the fuel injection pump is renewed, shims of the same thickness as originally fitted should be used. If a new fuel injection pump is fitted, it should be replaced with a fuel pump with the same part number as originally fitted. When the fuel injection pump is replaced it is essential that the fuel adjustment screw is not altered from the original setting. The maximum no load speed should be checked after assembly. Note; There are no service parts available for the 400 series injection pump. Fuel Injection Pump

Fuel Injection Pump To Check the timing of the Fuel Injection Pump 1. Set the piston for number one cylinder to TDC on the compression stroke. Turn the crankshaft counterclockwise a quarter of a revolution. 2. Remove the Fuel Control Solenoid, high pressure fuel pipes and low pressure fuel from the fuel injection pump. 3. Ensure that the throttle lever is held in the maximum fuel position. 4. Remove the delivery valve holder for number 1 cylinder and remove the delivery valve (store the delivery valve in clean fuel until reassembly). Note. The Fuel Pump may have to be moved to an upright position to remove and fit the delivery valves. 5. Connect the fuel pump spill pipe (1) to the delivery valve holder for number 1 cylinder. Fuel Injection Pump

Fuel Injection Pump To Check the timing of the Fuel Injection Pump 6. Connect a suitable clean fuel reservoir (1), which has a tap and contains approximately 0.2 litres (1/4 pint) of clean fuel, to the fuel injection pump inlet. 7. Put a waste fuel container below the pipe neck and open the tap, if set correctly the fuel should flow. Note; The fuel reservoir should be approximately 152mm (6in) above the fuel injection pump. 8. Turn the crankshaft slowly until the fuel flow reduces to a drop which falls every 7 - 10 seconds. This is then the timing point. 9. Use the value shown by the timing mark (2) with the injection timing table below. Fuel Injection Pump

Fuel Injection Pump To Check the timing of the Fuel Injection Pump 10. If the engine timing is incorrect adjust the thickness of the fuel injection pump shim. Note; Changing the fuel injection pump shim by 0.1mm will change the timing by approximately one degree. Thicker shims will retard the timing and thinner shims will advance the timing. 11. Fit the delivery valve (1) and tighten the delivery valve holder. 12. The engine must be tested on an available load to check the maximum no load speed and engine settings after assembly. Fuel Injection Pump

Compact Timing Device Benefits; Allows Fuel Injection pump to alter it’s timing depending on throttle position. By reducing initial injection volume it improves timing control. Benefits; Reduction in noise/diesel knock. Reduction in Nox emissions. Reduction in smoke at low speed. Compact Timing Device

CTD sub port CTD Cut Compact Timing Device

Compact Timing Device Operation How does the CTD work? The very small sub port drilling in the plunger barrel will only allow a finite volume of fuel to pass through it, therefore when the plunger rises at a slower rate because the engine is rotating slowly, the volume of fuel allowed to pass through the sub port causes the fuel delivery to the injectors to be delayed until the lower edge of the CTD Cut covers the sub port. However as the rotational speed of the engine increases, the rise rate of the plunger also increases but the fuel attempting to exit the sub port is in excess of the capacity of the port, thus some of the fuel is forced to exit via the injector thus advancing the injection timing from its original static setting. This brings about the improvements in emissions, smoke, power and noise. Compact Timing Device Operation

Angleich Governing System Angleich unit. Gives tailored torque curves and increased Torque Back Up Improved control of low speed ratings More robust design gives longer life Angleich Governing System

Angleich Governing System Angleich unit Angleich Governing System

Angleich Governing System Angleich Operation; The angleich unit works by trimming down the fuel delivery as the governor weights and spring come into equilibrium. A change in this state caused by the slowing of the engine as load increases allows the unit to quickly increase the fuel giving a rapid increase in torque. This torque back-up gives increased power as engine load is increased at any governed speed. Angliech is an obscure German word for adjuster however this does not mean that the unit can be adjusted to the customers requirements or by the customer. The units are set up in Japan, by ISM, for compressive resistance and for movement. They are then checked by PSEL on a £10,000 checking machine. Each unit is set for a particular engine type which means that a unit set up for a 404C.22 will not suit a 403C.15 and vice versa. Angleich Governing System

Pre-combustion chamber Swirl Chamber Throat area (Throat angle of 45 degrees) Pre-combustion chamber

Tamper Evident Caps New style nut Tamper evident cap The tamper evident cap, is fitted to the max. speed screw and is used in conjunction with the tamper evident cap fitted to the max. speed adjustment screw. Tamper Evident Caps

Tamper Evident Caps Maximum fuel screw and maximum speed screw The maximum fuel setscrew (1) and the maximum speed setscrew (2) should not be adjusted by the operator. Tamper evident caps (3), are fitted to the max. speed screw and used to reduce the incidence of unnecessary adjustment. Tamper Evident Caps

Allows for commonality of parts across Peterborough range. Lucas Fuel Filter

Oil type API-CH4 or ACEA E5 will be the standard service oil recommendation. Use of too high a spec of oil too early in an engines life can cause the cylinder bores to become glazed. Ensure the lubricating oil is filled slowly and check the correct levels with the dipstick after warm up. Change the oil and filter in accordance with the service instruction. Deep sump for greater oil capacity. Drain tap fitted as standard. Oil Specification

Always ensure that the correct viscosity grade of lubricating oil is used for the ambient temperature range in which the engine will run, as shown in the above chart. Oil Viscosity

Large oil gallery drillings To reduce the higher oil temperatures when running at 3000rpm. Increased Oil Flow

Oil Dipstick Redesign Easier to read oil level New style dipstick Old style Oil Dipstick Redesign

New Piston & Oil Control Ring Designed to work in conjunction with the improved cylinder bore honing to reduce oil consumption. This ring when used on other product range has been known as Conformable. This because of its ability to alter its shape slightly to conform to the varying dimensions of the bore. New Piston & Oil Control Ring

Closed Circuit Breather (CCB) Environmental benefit Fitted to top cover Gradeability to 35 degrees Used on all 400 range Crankcase gases redirected via diaphragm control valve and inlet manifold back into the combustion chamber. Eliminates external crankcase/engine breathing improving genset environment. Closed Circuit Breather (CCB)

Closed Circuit Breather Renewing the Engine Breather Assembly The breather assembly (A1, A3 and A4) should be renewed every 2000 hours by a person who has had the correct training. Caution: Ensure that the components of the breather assembly are fitted in their correct position (A). If they are incorrectly fitted, the engine may be damaged. 1. Release the four setscrews (A2) and remove the breather cover (A1), the spring (A4) and the diaphragm assembly (A3). Caution: It is important that the area around the vent hole (A6) is clean. 2. Clean the breather cavity (A5) in the rocker cover. 3. Fit a new breather assembly into the cavity in the rocker cover, ensuring that the breather cover, diaphragm and spring are assembled correctly. 4. Tighten the four setscrews. Closed Circuit Breather

Top Cover Redesign Top cover designed for easier servicing. One piece, preformed, ribbon oil seal used to make refitting of cover more simple. Access to valve clearance adjustment improved. Top Cover Redesign

Valve Tip Clearance To Check and Adjust Note; The valve adjustment sequence is viewed from the front of the engine. Rotate the crankshaft clockwise when viewed from the front. Caution; Only adjust the valve clearances when the engine is cold. Valve Tip Clearance

Crankshaft Bearings Removal and Fitting Note; Remove the bearing holder setscrews (1) and lift the crankshaft assembly out vertically. Note; If the crankshaft or crankshaft bearings are replaced the fuel adjustment screw must not be altered from the original setting. Caution; Remove the Oil Pressure Relief Valve before removing or fitting the Crankshaft. Make sure that the oil ways in the bearings align with the oil ways in the cylinder block. Crankshaft Bearings

Service Intervals Service Intervals Increased from 100 hrs to 500 hrs Oil change every 500 hrs (against 100 hrs) Bigger oil sump (10.0l on 404C-22 / 6.0l on 403C-15 ) Reduced sooting Fuel filters 500 hrs (against 200 hrs) Valve clearance 1000 hrs (against 600 hrs) Better SFC than 100 Series throughout the model range (7.5 l/h for 404C-22 against 8.55 l/h for 104-22 and 5.38 l/h for 403C-15 against 5.60 l/h for 103-15 at peak torque ) with increased performance Service Intervals

A. Every day or every 8 hours B. Every 250 hours or 6 months C. Every 500 hours or 12 months D. Every 1000 hours E. Every 2000 hours F. Every 3000 hours Service Intervals

Service Intervals Maintenance Schedule notes The schedule, must be applied at the interval (hours or months) that occur first. These are; A. Every day or every 8 hours B. Every 250 hours or 6 months C. Every 500 hours or 12 months D. Every 1000 hours E. Every 2000 hours F. Every 3000 hours (1) Renew the antifreeze every 2 years. If a corrosion inhibitor is used instead of antifreeze, it should be renewed every 6 months. Ensure the correct quantity is used. (2) By a person who has had the correct training. (3) The oil change interval will be affected if the load factor is greater than 40% or the incorrect specification oil is used. If you are unsure of how to calculate the load factor for the application contact your nearest Perkins distributor. Refer to the correct oil specification. Note; It is good preventive maintenance to check for leakage and loose fasteners at each service. These maintenance periods only apply to engines that are operated with fuels and lubricating oils that conform to the specifications given. Service Intervals