Starting the Engine
Under warm conditions, it is only necessary to engage the starter motor by turning the starter switch to the "HS" position (see Fig. C.1) or to the "S" position for earlier switches (see Fig. C.2), at the same time adjusting the engine speed control. Always ensure that the stop control is in the "run" position.
As soon as the engine starts, release the starter switch. Always ensure that the flywheel and starter pinion have stopped rotating before attempting to re-engage the starter motor, otherwise the starter ring or pinion, or both, may be damaged.
To Stop the Engine
A spring loaded stop control is usually situated near the normal engine controls and it is only necessary to pull out the stop control until the engine ceases to rotate. Ensure the engine movement has completely stopped before returning the control to the normal running condition. Turn the starter switch to the "O" position.
Some engines may have an electric solenoid stop control on the fuel injection pump operated by a switch on the control panel.
Cold Starting Aid; Using the Starting Aid
1. Off Position
2. Run Position
3. Heat Position
4. Heat and Start Position
C1
To start the engine, proceed as follows:-
Ensure engine stop control is pushed fully home.
Turn starter switch (Fig. C.1) to the "H" position and hold it there for fifteen to twenty seconds.
With the accelerator in the fully open position, turn the starter switch to the "HS" position thereby engaging the starter motor.
If the engine does not start within fifteen seconds, return the switch to the "H" position for ten seconds and then re-engage the starter motor by switching to the "HS" position.
As soon as the engine starts, the switch should be returned to the "R" position.
Earlier Heat Start Switch
1. Off
2. Start
3. Heat
4. Heat and Start
C2
The cold start switch fitted to earlier engines is shown in Fig. C.2.
Where this type of switch is used, it is customary to have a separate switch for the electrical circuits and this should be turned on before starting the engine and turned off after stopping the engine.
Things to Note
Ensure that the electrical connection to the cold starting aid is correctly made.
In the event of difficult starting, check that fuel is reaching the cold starting aid in the induction manifold by unscrewing the inlet fuel connection. If fuel is reaching it satisfactorily, then it may be that the cold starting aid itself is not working correctly. This can be checked by removing the air cleaner and watching the cold starting aid whilst the equipment is used. When the starting switch is turned to the "heat" position, the element should become red hot, and on engagement of the starter motor, ignition of the fuel should take place. The engines are fitted with efficient cold starting equipment and no responsibility can be accepted for any damage caused by unauthorised starting aids.
Running In
It is not necessary to gradually run-in a new or factory rebuilt engine and any prolonged light load running during the early life of the engine can in fact prove harmful to the bedding in of piston rings and liners.
Full load can be applied on a new or factory rebuilt engine as soon as the engine is used, provided that the engine is first allowed to reach a temperature of at least 140°F (60°C).
Preventive Maintenance
Whilst we have given specific periods for preventive maintenance, you should have due regard for the local regulations concerning your vehicle or machine and ensure that the engine is operating within those regulations.
The time period for cleaning the oil bath type air cleaner or the renewing of the element in the dry type air cleaner depends on operating conditions. Therefore, under extremely dusty conditions, the limit recommended should be decreased considerably.
Operators of engines are reminded that preventive maintenance periods are general in application. They should be compared with the schedules specified by the manufacturer of the application to which the engine is fitted and where necessary, the shorter periods should be adopted. Whilst we have given specific periods for preventive maintenance, you should have due regard for the local regulations concerning your vehicle or machine and ensure that the engine is operating within those regulations.
He should reduce the routine maintenance periods to suit any exceptional operating conditions, e.g., for stop-start low mileage work, the hours run apply more than the mileage run.
It is good maintenance practice that the checking of coolant, fuel or oil leaks and the tightness of nuts, setscrews and hose clips be carried out at each servicing period.
It should be noted that the periods given are on the assumption that the fuels and lubricating oils are to the specifications given in this manual.
4.248, T4.236, 4.236 and 4.212 Engines
Daily or every 8 Hours (whichever occurs first)
Check coolant level.
Check oil level in sump (make sure the vehicle or machine is standing level).
Check oil pressures (where gauge is fitted).
In extreme dust conditions, clean oil bath air cleaner and empty the dust bowl on dry type air cleaners.
Every 5,000 Miles (7,500 km), 250 Hours or Four Months (whichever occurs first)
Drain and renew engine lubricating oil. (See list of Approved Lubricating Oils in Appendix).
Renew lubricating oil filter element or canister.
Clean oil bath air cleaner.
Empty dust bowl on dry type air cleaner.
Check fan belt tension.
Clean water trap.
Lubricate dynamo rear bush (where fitted).
Clean compressor air cleaner (where fitted).
Every 10,000 Miles (15,000 km), 500 Hours or 12 Months (whichever occurs first)
Renew final fuel filter element (Industrial and Agricultural applications).
Clean lift pump sediment chamber.
Clean element of dry type air cleaner or renew, if not indicated earlier.
Every 20,000 Miles (30,000 km) or 1,000 hours
Renew final fuel filter element (vehicle).
T4.236 - Check turbocharger impeller. Clean if necessary.
Every 60,000 Miles (90,000 km) or 2,500 Hours
Arrange for examination and service of proprietary equipment, i.e. compressor/exhauster, starter motor, alternator etc.
Service atomisers.
Check and adjust valve tip clearances.
4.2482 Engines
Daily or every 8 Hours (whichever occurs first)
Check coolant level.
Check oil level in sump (make sure machine is standing level).
Check oil pressure (where a gauge is fitted).
In extreme dust conditions, clean oil bath air cleaner or empty dust bowl on dry type air cleaner.
Every 200 Hours or 4 Months (whichever occurs first)
Clean oil bath air cleaner or empty dust bowl on dry type cleaner.
Check drive belt tension.
Clean fuel water trap (where fitted).
Every 400 Hours or 12 Months (whichever occurs first)
Drain and renew engine lubricating oil.
Renew lubricating oil filter canister.
Renew final fuel filter element.
Clean lift pump sediment chamber.
Every 800 Hours
Renew dry type air filter element.
Every 2,400 Hours
Arrange for examination and service of proprietary equipment, i.e. starter motor, alternator, etc.
Service atomisers.
Check and adjust valve clearance.
Post-Delivery Checkover
After a customer has taken delivery of his Perkins Diesel engine, a general checkover of the engine must be carried out by an experienced fitter after the first 500/1,000 miles (800/1600 km) or 25/50 hours in service with the engine warm.
The checkover should comprise the following points:-
1. Drain lubricating oil sump and refill to full mark on dipstick with new oil. See list of Approved Lubricating Oils in Appendix. When the sump is drained and it is possible to gain access to the sump strainer, it is recommended that this be cleaned.
2. Renew the lubricating oil filter element.
3. Remove the rocker assembly; tighten the cylinder head nuts/setscrews in the correct sequence (see Fig. E.12) and to the correct torque (see Page B.2). (Not necessary for 4.2482 The correct procedure for retightening of cylinder head nuts/setscrews is given on Page E.7. Reset valve tip clearances.
4. Check coolant level and check for leaks.
5. Check external nuts, setscrews, hose clips, mountings etc. for tightness.
6. Check fan belt tension.
7. Check electrical equipment and connections.
8. Check for lubricating oil leaks.
9. Check slow running speed (see Page N.9).
10. Check general performance of engine.
Routine maintenance should follow as detailed under Preventive Maintenance.
Protection of an engine not in service
The recommendations given below are to ensure that damage is prevented when an engine is removed from service for an extended period. Use these procedures immediately the engine is removed from service. The instructions for the use of POWERPART products are given on the outside of each container.
1. Thoroughly clean the outside of the engine.
2. Where a preservative fuel is to be used, drain the fuel system and fill with the preservative fuel. POWERPART Lay-Up 1 can be added to the normal fuel to change it to a preservative fuel. If preservative fuel is not used, the system can be kept charged with normal fuel but this will have to be drained and discarded at the end of the storage period together with the fuel filter.
3. Run the engine until it is warm. Correct any fuel, lubricating oil or air leakage. Stop the engine and drain the lubricating oil sump.
4. Renew the lubricating oil filter canister.
5. Fill the sump to the full mark on the dipstick with clean new lubricating oil or with a correct preservative fluid. POWERPART Lay-Up 2 can be added to the lubricating oil to give protection against corrosion during the period in storage. If a preservative fluid is used, this must be drained and normal lubricating oil used when the engine is returned to service.
6. Drain the cooling system, see Page C.4. To give protection against corrosion, it is better to fill the cooling system with a coolant that has a corrosion inhibitor. If frost protection is needed, use water with an approved corrosion inhibitor mixture.
7. Run the engine for a short period to send the lubricating oil and coolant around the engine.
8. Clean out the engine breather pipe (where fitted) and seal the end of the pipe.
9. Remove the atomisers and spray POWERPART Lay-Up 2 into each cylinder bore. If this is not available, clean engine lubricating oil will give a degree of protection. Spray into the cylinder bores 140 ml (1/4 pint) of lubricating oil divided evenly between the four cylinders.
10. Slowly turn the crankshaft one revolution and then install the atomisers complete with new seat washers.
11. Remove the air filter and any pipe installed between the air filter and induction manifold or turbocharger. It is recommended that the spray time for the turbocharger is 50% longer than the manifold spray time. Spray POWERPART Lay-Up 2 into the induction manifold or turblcharger. Seal the manifold with waterproof tape.
12. Remove the exhaust pipe. Spray POWERPART Lay-Up 2 into the exhaust manifold or turbocharger. It is recommended that the spray time for the turbocharger is 50% longer than the manifold spray time. Seal the manifold or turbocharger with waterproof tape.
13. Remove the lubricating oil filler cap. Spray POWERPART Lay-Up 2 around the rocker shaft assembly. Fit the filler cap.
14. Disconnect the battery and put it into safe storage in a fully charged condition. Before the battery is put into storage, give the battery terminals a protection against corrosion. POWERPART Lay-Up 3 can be used on the terminals.
15. Seal the vent pipe of the fuel tank or the fuel filler cap with waterproof tape.
16. Remove the fan belt and put it into storage.
17. To prevent corrosion, spray the engine with POWERPART Lay-Up 3. Do not spray inside the alternator cooling fan area.
NOTE: Before the engine is started after a period in storage, operate the starter motor with the engine stop control in the 'off position until oil pressure shows on the oil pressure gauge or the oil warning light goes out. If a solenoid stop control is used, this will have to be disconnected for this operation.
If the engine protection is done correctly according to the above recommendations, no corrosion damage will normally occur. Perkins Engines Ltd. are not responsible for any damage that occurs in relation to a service storage period.
Engine Coolant
The quality of the coolant used can have a large effect on the efficiency and life of the cooling system. The recommendations given below can be of assistance in the maintenance of a good cooling system with frost and/or corrosion protection.
1. Where possible, use clean soft water.
2. If an antifreeze mixture is used to prevent frost damage, it must have an ethylene glycol (ethanediol) base. An antifreeze that is to one of the standards given below or to an equal standard is acceptable if the pH value is kept within the range of 7.0-8.5 when diluted.
- U.K. BS 3151:1959
'Ethanediol Antifreeze Type B with Sodium Benzoate and Sodium Nitrite Inhibitors.' U.S.A. ASTM D3306-74
'Ethylene Glycol Base Engine Coolant'. Australia AS 2108-1977
'Antifreeze Compounds and Corrosion Inhibitors for Engine Cooling Systems.
When Perkins POWERPART antifreeze is used, the correct mixtures of antifreeze and water are as given below. Perkins POWERPART Antifreeze fully passes the above standards.
The quality of the antifreeze coolant must be checked at least once a year, for example, at the start of the cold period.
3. When frost protection is not necessary, it is still an advantage to use an approved antifreeze mixture as this gives protection against corrosion and also raises the boiling point of the coolant. A minimum concentration of 25% by volume of antifreeze is necessary, but it is our recommendation that 33% concentration by volume is used.
If an antifreeze is not used, add a correct corrosion inhibitor mixture to the water.
Change the water/corrosion inhibitor mixture every six months or check according to the inhibitors manufacturer's recommendations.
NOTE: Some corrosion inhibitor mixtures contain soluble oil which can have an adverse effect on some types of water hose.
If the correct procedures are not used, Perkins Engines Ltd., can not be held responsible for any frost or corrosion damage.
To Drain the Cooling System
1. Ensure that the vehicle or machine is on level ground.
2. Remove the radiator filler cap.
3. Remove the drain plug from the side of the cylinder block (see engine views) to drain the engine. Ensure that the drain hole does not have any restriction.
4. Open the tap or remove the drain plug at the bottom of the radiator to drain the radiator. If a tap or plug is not fitted to the radiator, disconnect the bottom radiator hose.
With T4.236 engines, the oil cooler in the lubricating oil filter assembly must be drained. To do this, remove either the inlet or outlet water connection at the cooler.
5. Where necessary, flush the system with clean water.
6. Fit the drain plugs and radiator tap or connect the radiator hose.