No 13 Kwong Min Road, Singapore 628717.

Tel (65)6558 7789, Fax (65)6558 7977

ORIGINAL ISSUE AMENDMENTS

JOB NO DATE COPIES DATE CHANGES

1149-MJ-Z2G 06-08-12 1

REPRINTS

OPERATING & INSTRUCTION MANUAL

FOR

60KVA 50HZ DIESEL DRIVEN GENERATOR

FOR

ATEX 3G ZONE2 T3 200°C

This manual contains the following:

GENERAL SAFETY INFORMATION  MAINTENANCE & SERVICING 

COMPONENTS LAYOUT  PARTS LIST 

OPERATING INSTRUCTIONS  CERTIFICATE X

 Contents
SAFETY .................................................................................................................................... 1
GENERAL SAFETY ............................................................................................................. 1
General Safety Information................................................................................................ 2
Maintenance of Safety Equipment ..................................................................................... 3
Servicing of Safety Equipment .......................................................................................... 3
Ordering Spares and Replacement Parts ............................................................................ 3
Operating............................................................................................................................ 3
Maintenance Scheme ......................................................................................................... 3
INTRODUCTION ..................................................................................................................... 4
System Overview ............................................................................................................... 4
OPERATING INSTRUCTIONS ............................................................................................... 5
To Start the Engine ............................................................................................................ 5
To Stop the Engine ............................................................................................................. 5
Emergency Stop ................................................................................................................. 5
EXHAUST SYSTEM ................................................................................................................ 6
MANICOOLER AND OUTLET BOX ................................................................................. 6
Description ......................................................................................................................... 6
Temperature Monitoring Upper Case ................................................................................ 7
Installation and Assembly .................................................................................................. 7
Maintenance ....................................................................................................................... 7
DRY EXHAUST FLEXIBLE ............................................................................................... 8
Description ......................................................................................................................... 8
Installation .......................................................................................................................... 8
Maintenance ....................................................................................................................... 8
EXHAUST FLAME ARRESTER (FLAMETRAP) ............................................................. 9
Description ......................................................................................................................... 9
Installation .......................................................................................................................... 9
Maintenance ....................................................................................................................... 9
STAINLESS STEEL EXHAUST SPARK ARRESTER .................................................... 10
Description ....................................................................................................................... 10
Installation ........................................................................................................................ 10
Maintenance ..................................................................................................................... 10
TURBOCHARGER ............................................................................................................. 11
Description ....................................................................................................................... 11
Installation ........................................................................................................................ 11
Maintenance ..................................................................................................................... 11
 Servicing .......................................................................................................................... 12
Operating Instructions ...................................................................................................... 13
INLET SYSTEM ..................................................................................................................... 14
DIESEL ENGINE AIR SHUT DOWN VALVE ................................................................ 14
Description ....................................................................................................................... 14
Dimensions ...................................................................................................................... 15
INSTALLATION ............................................................................................................ 16
ILS INLET FLAMETRAP DESCRIPTION ....................................................................... 17
COOLING SYSTEM ............................................................................................................... 19
COOLING SYSTEM ........................................................................................................... 19
MISCELLANEOUS ................................................................................................................ 20
CRANKCASE BREATHER FLAMETRAP ...................................................................... 20
CONTROL SYSTEM .............................................................................................................. 21
Control Panel Layout & Detail ............................................................................................ 21
STARTING SYSTEM ............................................................................................................. 22
Electrical Starting System and Engine Safety Control ........................................................ 22
Description ....................................................................................................................... 22
Genset Control Buttons .................................................................................................... 23
Genset Operation Indicators............................................................................................. 23
Display and Control Button ............................................................................................. 23
Display Screens and Pages Structure ............................................................................... 24
Alarms .............................................................................................................................. 25
Browsing ECU Alarm ...................................................................................................... 25
Setpoint Change ............................................................................................................... 26
Entering Password ........................................................................................................... 26
Controller Information Screen ......................................................................................... 27
Display Contrast Adjustment ........................................................................................... 27
DIESEL ENGINE .................................................................................................................... 28
PERKINS DIESEL ENGINE .............................................................................................. 28
Perkins Engine ................................................................................................................. 28
Engine Specifications ....................................................................................................... 28
Engine Illustration ............................................................................................................ 29
Preventive Maintenance ....................................................................................................... 30
Preventive Maintenance Period ....................................................................................... 30
How to drain the cooling system ..................................................................................... 32
How to check the specific gravity of coolant ................................................................... 33
Specific Gravity Chart ..................................................................................................... 34
 How to check the drive belt (s) ........................................................................................ 35
How to adjust the belt tension .......................................................................................... 35
How to clean the gauze strainer of the fuel lift pump ...................................................... 36
Fuel pre-filter ................................................................................................................... 36
How to renew the element(s) of the fuel filter ................................................................. 36
How to renew the element (s) of the separate element type ............................................ 37
How to renew the filter canister of the canister fuel filter ............................................... 37
How to renew the filter canister of the canister quick release fuel filter ......................... 38
Atomiser fault .................................................................................................................. 39
How to renew an atomiser ............................................................................................... 39
How to eliminate air from the fuel system ....................................................................... 40
Standard method to eliminate air from the fuel system ................................................... 41
Standard method to eliminate air from the fuel system ................................................... 42
Self –vent method ............................................................................................................ 43
How to renew the lubrication oil of the engine ................................................................ 44
How to renew the canister of the lubricating oil filter ..................................................... 45
How to clean the integral closed breather system ............................................................ 46
To assemble integral closed breather system ................................................................... 46
The open breather system ................................................................................................ 47
Air cleaner ........................................................................................................................ 47
Air filter ........................................................................................................................... 48
Restriction indicator ......................................................................................................... 48
How to check the valve tip clearances ............................................................................. 49
Four cylinder engine ........................................................................................................ 49
Six cylinder engine .......................................................................................................... 50
Lubricating Oil Specification ........................................................................................... 50
Coolant Specification ....................................................................................................... 51
General Safety Precautions .............................................................................................. 52
TORQUE SETTINGS ............................................................................................................. 53
PARTS LIST ............................................................................................................................ 54
Mechanical Component ................................................................................................... 54
Electrical Components ..................................................................................................... 55
ENGINE SHUTDOWN CONTROL FUNCTION CHART ................................................... 56
GENERAL ARRANGEMENT DRAWING ........................................................................... 57
ELECTRICAL WIRING DIAGRAM ..................................................................................... 58
 SAFETY

GENERAL SAFETY

It is essential that this section is read before reading any other

section of this manual.
The preventative and protective measures described in this manual, will not provide the
user, the required level of safety and protection, unless the equipment is operated and
maintained in accordance with the original manufacturers recommendations and is
operated and maintained within its intended use as stated by PYROBAN LIMITED.

Read and understand all warning, Do not operate the equipment until you
caution, prohibition and mandatory have read and understand the
notices and labels on the equipment instruction in the “Operating
before operating or carrying out any Instructions” section of this manual.
maintenance or servicing.

Do not perform any servicing or When washing parts in or with a

maintenance on this equipment until cleaning solvent, provide adequate
you have read and understood the ventilation, safety equipment and
instructions in the “Routine Servicing” protection, as stated in the safety data
section of this manual. sheets supplied by your company.

THIS MANUAL MUST BE READ IN ASSOCIATION WITH THE

ORIGINAL EQUIPMENT MANUFACTURERS INSTRUCTIONS

If the engine

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 SAFETY

General Safety Information

When handling, operating, installing, overhauling and / or performing maintenance or repairs, personnel
are expected to practice safe engineering and to observe all relevant safety requirements and
regulations, relevant to the country or locality the equipment is being used in.
The following safety precaution must be observed, where applicable:
When safety equipment had been installed or services, it must be checked and passed by the person in
authority before returning back to services.
DO NOT ATTEMPT TO RESTART equipment if the engine safety system trips whilst in a hazardous
area. Advice from the person in authority must be obtained and the cause of shutdown found and
corrected before re-starting can permitted.
When using any non- Pyroban supplied product in the operation, installation, servicing or maintenance
of the Pyroban safety system, ensure that the product manufactures warnings/ recommendations are
strictly adhered to. This information should be held by your safety department.
Always fit new gaskets when refitting parts. Do not use any sealant (except where specified).
Ensure that the exhaust spark arrestor is fitted in accordance with the direction of the flow of Gases
indicated on the unit.
Ensure that the coolant in the cooling system is always full and the expansion tank is between 1/3 and ½
full. (Expansion tank is not included).
Ensure safe use of antifreeze and inhibitor (if applicable).
Ensure all fixings are secured tightened to the correct torque, to ensure safety is maintained at all times.
(See Torque Setting).
Do not use probes to clean the element of any flame trap in the safety system.
Ensure that all operators, maintenance and service engineers are properly trained, have the relevant
experience or are under supervision of someone qualified for the job.
Pyroban offer operator training programs.
To avoid injury, lift correctly or use proper lifting gear when lifting heavy components. Be properly trained
to do so.
Use correct tools for the job.
Keep a record of all maintenance, repair work and servicing. The frequency and nature or repairs can
reveal unsafe conditions.
Ensure all instructions regarding the safety system operation and maintenance are strictly followed and
that all components are in good repair and free from abnormal wear.
Maintain all regulating and safety devices with care to ensure they continue to function properly.
Pressure and temperature gauges must be installed, tested and maintained in accordance with HSE
Pressure Systems Regulations, Statutory Instrument No. 2169 and British Standards BS1780 and BS
5235, or the country or locality the equipment is being used in.
Ensure a new electrically conductive fan- belt is fitted to the cooling system every 1000 hours (6
months).
Protection devices must be tested to determine that they are in good operating condition. Pyroban
operates a component service exchange scheme.
Skilled technician is required to fit this equipment.
The component parts supplied must be installed correctly and the complete installation approved by the
person in authority before the equipments is used in a hazardous area.
Most of the components supplied are special manufacture either in duty or specification.

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 SAFETY

GENERAL SAFETY

Maintenance of Safety Equipment

The integrity of the safety equipment supplied, like all safety features, depends entirely on a responsible
attitude towards its maintenance for the total life of the equipment.

Maintenance must be carried out in accordance with the routine maintenance stated in the maintenance
manual.

Running hours, or the period over which the equipment has been in use should be used to indicate what
servicing is required, e.g. as the time interval increases, servicing is additive, i.e. after three months, all
the previous weekly checks are required in addition to the 3 months check, and so on.

Continue to observe the original equipment manufacturers instructions except where otherwise stated.

Servicing of Safety Equipment

When this safety equipment or any other equipment affecting its operation has been serviced, the
equipment must be checked by the person in authority before returning it to service.

Ordering Spares and Replacement Parts

Spare parts should be ordered directly from Adex Zonex Pte Ltd quoting the part number and the item
description. Parts not listed should be ordered in the normal manner from the original equipment
manufacturer.

Operating
If the engine safety system trips whilst being used in a hazardous area DO NOT ATTEMPT TO
RESTART until advice from the person in authority has been obtained from the original equipment
manufacturer.

Maintenance Scheme
It is strongly recommended that use is made of the Pyroban ‘Safesure Maintenance Scheme’. For
further information, contact Adex Zonex at the address shown below:

Adex Zonex Pte Ltd

13 Kwong Min Road
Singapore 628717
Tel: (65) 6558 7789
Fax: (65) 6558 7977

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 INTRODUCTION
System Overview

This Diesel Engine Driven Power Generator is designed to use for Category 3G, Temperature Class T3,
Gas Group IIA.

The principle of operation is to limit all surfaces and exhaust gas temperature to below 200°C and offer
automatic shutdown of the engine on engine malfunction.

The generator set is started by the electrical starting system mounted on the Genset Control Enclosure
Box.

The Pyroban safety kit are fitted to the Perkins Engine 1006.6TG2A.

The principal items supplied are:

INLET SYSTEM components:

 Chalwyn SVX-520

 Intake flametrap ILS 5”

EXHAUST SYSTEM components:

 Exhaust Manicooler

 Exhaust flame arrester

 Dummy exhaust flame arrester (for use in non-hazardous areas only)

 Exhaust flexible

 Exhaust spark arrestor

CONTROL SYSTEM components:

 Coolant temperature probe

 Exhaust gas temperature probe

 Over speed valve (integral to Chalwyn shut down valve SVX-520)

 Engine start button

 Engine stop button

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 OPERATING INSTRUCTIONS
To Start the Engine
1. Ensure that the machine is on the level ground, securely mounted to sub-frame assembly and no
missing bolts are observed.

2. Lubrication oil & fuel shall be filled to sufficient level.

3. Non metallic fan, anti-static fan belt & protective guard have been securely fastened.

4. Engine coolant radiator & connection piping has been securely fastened & no water seepage is
observed.

5. Exhaust system has been securely fixed exhaust flame trap, spark arrestor and exhaust piping joints
are not defective or having loose connection.

6. Ensure the electric supply to the controller & no fault indicates on the local control panel.

7. Press “Start” button from the local control panel to initiate the start sequence of the engine. The
system will open the butterfly valve then begin the cranking and fuel priming sequence after 3
seconds. It will repeat this 3 times. If the engine is not started during these 3 x 10 second intervals,
return to the control panel and press the reset button followed by the start button to try again.

To Stop the Engine

1. Press the “Stop” button from the enclosure 2/ Local control panel.

Emergency Stop
By pushing the “EMERGENCY STOP” button located on the enclosure 3/ external emergency stop
button.

WARNING

If the engine safety system trips whilst the engine being used in an hazardous area,
DO NOT ATTEMPT TO RESTART
until advice has been obtain from the person in authority and the cause of the shutdown
found and correct.

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 EXHAUST SYSTEM

MANICOOLER AND OUTLET BOX

Description
Gases to liquid heat exchangers are fabricated structures utilizing radial, serrated finned tubes for
maximum heat transfer rate. Their primary purpose is to reduce engine exhaust gas temperature and
surface temperature to below the specified ‘T’ class limit. Manicoolers also function as explosion proof
enclosures intended to contain an exhaust system detonation and, as such are designed and tested to
withstand a 10 bar routine pressure test. They are designed to suit individual installations/duty and
incorporate a water cooled manifold and are fixed directly to the engine cylinder head. The cooler is
connected in series with the engine coolant system.

Additional Technical Data -

Materials:

a) Industrial duty: Mild steel FE430A casing and finned tube.

b) Arduous duty: Stainless steel for IC engines exhaust systems with the following limitations to
use:

Maximum exhaust gas temperature: 200°C

Maximum operating pressure: 5 bar

Maximum coolant temperature: 100°C

The outlet box in the other hand acts as an interface between the flametraps and remaining exhaust
system.

Typical Manicooler Installation

EXHAUST
OUTLET BOX

EXHAUST
FLAME
ARRESTER

MANICOOLER

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 EXHAUST SYSTEM

Temperature Monitoring Upper Case

Exhaust gas temperature monitoring is a mandatory element of the protection system. There are 2 forms
of exhaust gas temperature sensor – mechanical and electrical. Both sensor types require periodic
inspection to ensure the protection system is maintained. Refer to the control system section of this
manual for specific installation, maintenance and operation information.

Installation and Assembly

The manicooler and outlet box are heavy items and appropriate lifting equipment should be used to
handle them. Before installation, ensure all packing material is removed. During installation, refer to the
application specific layout drawing and parts list at the rear of this manual.

Drain the engine of coolant and remove the existing manifold, studs and gaskets. Clean the exposed
cylinder head face thoroughly. Fit the cylinder head plugs into the unused central stud holes in the
cylinder head using thread sealant to block off the coolant passage. Fit the studs into the remaining stud
fixing holes with the ½” thread length end of each stud located into the cylinder head. Slide the gasket
supplied and the Pyroban manicooler over the studs into position.

Using the washers and hex nuts supplied tighten the manicooler to the cylinder head. The customer
must supply suitable support brackets from the side of the engine block to the manicooler gusset. Drill
the manicooler gussets as required but do not drill or weld any other part of the manicooler body. Fit the
exhaust flametrap (or DUMMY exhaust flametrap) and the exhaust outlet box on to the top flange face of
the manicooler using the fixing kit supplied. The system must not be used in a hazardous area without a
standard exhaust flametrap fitted.

Maintenance
On major overhauls or in the event of shutdown due to excessive exhaust temperature not reconciled by
other checks, clean the manicooler interior with a carbon removing solvent. Clean the manicooler
whenever the carbon built-up inside exceeds a thin layering of surfaces in the exhaust gas flow. The
frequency of cleaning is dependent on local operating conditions, but where regular idling occurs
cleaning may be needed more frequently. When washing parts in or with a cleaning solvent, provide
adequate ventilation, safety equipment and protection, as stated in the product safety data sheets.

Remove the manicooler from the engine, discard the existing gasket and blank off the exhaust outlet of
the engine. With the outlet uppermost, fill the casing with the solvent and allow to soak for 4-5 hours.
Empty and thoroughly hose out the interior. Remove all fluid from the manicooler and repeat the
cleaning process if necessary with clean solvent, empty again and thoroughly hose out.

Blow out the manicooler gas away with an air line and then refit the manicooler to the engine using a new
gasket. Run the engine until warm, top up the coolant system and check the coolant and gas connection
for leaks.

After cleaning, subject to the method and thoroughness of cleaning, loose carbon particles will be
released during the initial period of operation. These particles may cause additional failing of the
flametrap which will require more frequent cleaning until the deposits have stabilized. Normal exhaust
flametrap service life will be resumed.

Approved Cleaning Fluids:

Jumbo Unicorn Chemicals Limited. (01253) 395000
Combat Servo-Chem Limited. (01934) 625421
Powerwash DEB Group Limited. (01773) 822712

-7-
 EXHAUST SYSTEM
DRY EXHAUST FLEXIBLE

Description
Dry exhaust flexible assemblies are constructed from braided or unbraided steel corrugated hose to BS
6501:1991 part 1 and mild steel collars and flanges to suit application.

Suitable for use on IC engine exhaust systems with the following parameters:

Maximum exhaust gas temperature: 200C

Maximum operating pressure: 5 bar

Installation
The dry exhaust flexible should be fitted as close as possible to the outlet from the exhaust gas
cooler/manicooler. Fit the dry exhaust flexible to the outlet flange on the exhaust outlet box using the
gasket and fixings supplied. Ensure that no undue strain or torque loading is imposed on the dry exhaust
flexible assembly during assembly or when tightening fixings.

When refitting, ensure that all fixings are secure and new gaskets are used on all flange connections.

Dry Exhaust Flexible

Maintenance
Before commencing any maintenance operations make sure that the correct procedure has been
obtained from the person in authority. A record must be kept of all maintenance and repair in line with BS
EN60079-14. After maintenance and before use, the dry exhaust flexible assembly must be checked
and approved by the person in authority.

Ensure new gaskets are fitted (where applicable) and that fixings are secure when re-fitting the dry
exhaust flexible assembly.

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 EXHAUST SYSTEM

EXHAUST FLAME ARRESTER (FLAMETRAP)

Description
Exhaust flametraps are designed and tested to extinguish explosions created in the exhaust system.
The flametrap is sized to operate within the backpressure limit of the engine. All Pyroban plate type
exhaust flame arresters are constructed from stainless steel. Exhaust flametraps supplied can be CT
type or standard. The CT designates that the thickness is machined to a close tolerance limit. CT
flametraps are used where more than 1 flametrap is fitted on the exhaust system by a common outlet
box, not individual outlet boxes. CT exhaust flametraps are identified by handles of flat rather than round
section. CT exhaust flametraps must not be interchanged with standard (i.e. round handled) exhaust
flametraps used elsewhere
The engine must not be used in a hazardous area without exhaust flametraps fitted. The Person in
Authority must be consulted before fitting a dummy exhaust flametrap to the system. Dummy exhaust
flametraps may only be used if the system is being used in a safe area.

FLAME ARRESTER
DUMMY
Installation
Exhaust flametraps are heavy items and appropriate lifting equipment should be used to handle them.
Ensure cooler, flametrap and outlet box flanges are clean and free from damage or rust. Slide the
exhaust flametraps (or DUMMY flametraps) between the exhaust gas cooler and the outlet box. Do not
use sealant between joints. The exhaust flametraps fixing kit include heavy duty springs. These are
designed to push the outlet box away from the exhaust gas cooler when the bolts are released allowing
the exhaust flametraps to be removed for cleaning. Tighten the fixings to correct torque.

Maintenance
No gaskets are required on the mating faces with the exhaust gas cooler body or outlet box. No
maintenance is required on a DUMMY exhaust flametraps (if fitted/supplied). Exhaust flametraps must
be cleaned every 12 hours or more frequently if required. To remove the exhaust flametraps, slacken the
retaining bolts (fixing kit) then carefully slide the exhaust flametraps out using the handle. Clean the
exhaust flametraps by soaking in carbon removing solvent. Never clean the exhaust flametraps by
inserting probes as the fine passages could be enlarged thereby impairing the flametraps performance.
Check mating surfaces, they should be free from damage, and rust. Refit in reverse order. No gaskets
are fitted. When washing parts in or with a cleaning solvent, provide adequate ventilation, safety
equipment and protection, as stated in the product safety data sheets.
Approved Cleaning Fluids:
Jumbo Unicorn Chemicals Limited. +44 (0)1253 395000
Combat Servo-Chem Limited. +44 (0)1934 625421
Powerwash DEB Group Limited. +44 (0)1773 822712
Unitor www.unitor.com

-9-
 EXHAUST SYSTEM
STAINLESS STEEL EXHAUST SPARK ARRESTER

Description
Exhaust Spark Arrester is designed for fitting into and suppressing sparks emitted by a diesel engine
exhaust system (engine configurations with a nominal inlet velocity of 55-75m/s). Made from stainless
steel, it is designed as a cylindrical ‘can’ with inlet and outlet pipe studs containing serrated and louvered
inner tube welded to it.

Installation
The direction of the flow of gases is indicated on the exhaust spark arrester and must be strictly adhered
to. Fit the exhaust spark arrestor to the outlet flange on the dry exhaust flexible using gasket and fixings
supplied. Tighten to the correct torque. Ensure that the gas enters the exhaust spark arrestor via the port
marked 'inlet'.

Typical Example of a Spark Arrestor

Although the item is of stainless steel construction for long life, the following points should be observed:
When an exhaust gas cooler is fitted, operation at low power can cause exhaust gas temperatures to fall
below the dew point. This will lead to warm acid condensate collecting, particularly in the exhaust spark
arrestor, leading eventually to corrosion. To alleviate this problem, it is advisable to remove the exhaust
spark arrestor if mounted in the horizontal position and empty the condensate which has collected. After
long periods of idling, run on load before shutting down the engine, even if the engine is warm. If the
exhaust appears ‘steamy’, continue running on load until the exhaust clears before shutting down the
engine.
In an offshore environment, condensates may contain chlorides, increasing the risk of corrosion. To
minimize this risk:
a) The induction air intake should be positioned and/or protected so as to reduce the ingestion of
marine spray or mist when the engine is running.
b) The exhaust outlet should be positioned and/or protected so as to reduce the ingress of marine
spray or mist when the engine is not running. Raincaps should always be fitted to the exhaust
outlet if there is a danger of this occurring.

Maintenance
Check the exterior of the exhaust spark arrestor for damage or distress and check the pipework and
joints for leaks. Remove the exhaust spark arrestor and lightly tap with a soft mallet to loosen deposits,
then shake out all loose particles. Visually examine the interior of the exhaust spark arrestor via the inlet
and outlet ports.

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 EXHAUST SYSTEM

TURBOCHARGER

Description
The turbocharger is a device composed of two sealed chambers containing fan blades, also known as
turbines, which are connected by a shaft.
The greater the load on the engine, the higher the volume of exhaust and thus the more fresh air and by
extension, fuel—that is pumped into the engine, increasing output.
The unit supplied for hazardous area use, includes water-cooled exhaust housing. To maintain surface
temperature limit. The oil bearing housing may also be water-cooled.

TURBOCHARGER WITH WATER COOLED EXHAUST HOUSING

Installation
Ensure the turbocharger is clean and free from any packing material. Fit gaskets (not supplied) to the
turbocharger.
Align the water cooled exhaust flexible with the turbocharger. Mark out the position of the required fixing
holes on the flange of the water cooled exhaust flexible with the fixings on the turbocharger (if required).
Drill the required number of holes in the flange of the water cooled exhaust flexible (if required).
Secure the water cooled exhaust pipe work flexible to the turbocharger using suitable fixings (not
supplied) in accordance with standard torque values. Once the water cooled exhaust flexible has been
secured to the turbocharger, firmly secure the exhaust gas cooler/exhaust plenum assembly to the
mounting frame ensuring that no undue strain is placed on the water cooled exhaust flexible or the
turbocharger when the fixings are tightened.

Maintenance
Routinely check seals and gaskets.
Ensure air cleaner is maintained and not damaged. Once a month check blades on both sides for
damage or scoring.
Strip down and rebuild with new bearings and seals every 50000 hours.
It is important to remember that the turbocharger uses the same oil as the engine and therefore regular
oil and filter changes will enhance turbo life. Only have the turbo removed and attended to when the
cause of a problem has been isolated to the turbocharger by someone competent to do so. The
occasional dynamometer test to check that all settings are correct can be worthwhile.

- 11 -
 EXHAUST SYSTEM

Servicing
The following table defines the servicing requirements for the Pyroban system (where applicable). Only
competent and suitably trained staff may operate service and maintain the equipment. The Person in
Authority is responsible to authorize personnel to undertake service work.

 Items marked O are to be carried out by the Service provider.

Items listed in this schedule may not be supplied or fitted. Refer to parts list to identify installed parts. A
record of servicing and maintenance should be maintained.

Task-In addition to original Daily Weekly 1 Month 3 Months 6 months 2 Years

requirements 8-12 hrs 50 hrs 200 hrs 500 hrs 1000 hrs 4000 hrs

Exhaust Flametrap: clean

element. o

Exhaust Flexible (Water-Cooled):

check exterior for damages or
distress, check pipework and o
joints for leaks.

Exhaust System: check the

mechanical integrity of all o
pipework/components and joints.

Exhaust Gas Cooler: remove

carbon. Depending on o
application.

Exhaust Manicooler: remove

carbon. o

Exhaust Flexible (Dry): check

exterior for damages or distress,
check pipework and joints for o
leaks.

Temperature Monitoring Device:

check exterior for damage. o

Spark Arrester: check exterior for

damages or distress, check
pipework and joints for leaks,
clean interior, perform visual o
check of interior via inlet and
outlet ports.

Copyright 2003 Issue 1 Pyroban Ltd, Endeavour Works, Dolphin Rd, Shoreham-by-Sea West Sussex. BN43 6QG. United
Kingdom. Tel: +44(0) 1273 466200

- 12 -
 EXHAUST SYSTEM

Operating Instructions
Ensure all water cooled components are full of coolant with appropriate bleeds attached. It is not advised
to run the water cooled system without coolant.

Ensure all exhaust system temperature monitoring devices are installed and connected to control
system. Carry out pre-start checks as defined by the engine manufacturer.

A consequence of exhaust gas cooling is the formation of exhaust condensate.

When the engine is run up from cold, the system sees a transition period where exhaust gas
temperature difference between the gas and the exhaust system steel work will precipitate
condensation. This precipitation period is at its longest when the engine is run up from cold and at its
shortest when the engine is directly put on to full load -full speed.

When the engine and exhaust system have heated up beyond the dew point of the gas, the precipitation
of condensate will stop and any residue in the system will be cleared by the hot exhaust gas.

If what appears to be condensate continue to form, check the coolant system for leaks.

Operation at low power can cause exhaust gas temperatures to fall below the dew point. This will lead to
warm acidic condensate collecting in the exhaust system, with possible failure due to corrosion.

To reduce this problem, it is important to avoid shutting an engine down before it is fully warmed, and to
minimize long periods of idling.

If extended idling is unavoidable, it is particularly important to operate on a low sulphur fuel.

After long periods of idling, run the engine on load before shutting down the engine, even if the engine is
warm.

In an offshore environment, condensates may contain chlorides, increasing the rate of corrosion.

To minimize the risk:

a) The induction air intake should be positioned and/or protected so as to reduce the ingestion of
marine spray or mist when the engine is running.

b) The exhaust outlet should be positioned and/or protected so as to reduce the ingress of
marine spray or mist when the engine is not running. Raincaps should always be fitted to the
exhaust outlet if there is a danger of this occurring.

- 13 -
 INLET SYSTEM

DIESEL ENGINE AIR SHUT DOWN VALVE

Description
A range of 12 AND 24 volt EExe solenoid operated diesel engine air intake closure valves based on the
standard Chalwyn slimifit 3”, 5” and 8” butterfly valves. These products are available in basic flange
mounted form, but can also be supplied fitted with hose adaptors.

These valves are designed to “fail safe” in that if electrical power is lost for any reason the valve will
revert to the closed condition.

Valve bodies and discs are all manufactured from corrosion resistant hard anodized aluminium with a
PTFE coating. Spindles and mechanisms are manufactured from 316 stainless steel.

AIR INLET/ OVERSPEED

SHUT DOWN VALVE
ILS INLET
FLAME TRAP

SVX-520 AIR INLET/ OVERSPEED SHUT DOWN VALVE

- 14 -
 INLET SYSTEM

Dimensions

DIMENSION AND TYPICAL ARRANGEMENT

Nominal
VALVE TYPE A B C1 C2 D
Bore Dia.
102.0 to
SVX-520 127 (5”) 217.0 167.5 45.5 125.5
157.5

- 15 -
 INLET SYSTEM

INSTALLATION
1. In the case of a naturally aspirated engine, the Chalwyn SVX shut down valve should generally be
fitted as close to the engine air intake manifold as possible. If an air intake flame trap is also fitted,
the SVX valve must be installed upstream (air cleaner side) of the flame trap.
2. If the engine is turbocharged, it may be necessary to fit the valve upstream of the turbocharger in
order to avoid temperatures in excess of the maximum permitted for the solenoid. Again if an air
intake flametrap is also fitted the valve must be installed upstream of the flame trap.
3. Where more than one SVX valve is installed on an engine, as in the case of an engine with multiple
intake pipes, the shut down valve control system must be arranged to ensure all valves close
simultaneously.
4. This valve may be installed either horizontally or vertically.
5. If hose adaptors are used, the mating hose should be of a reinforced type, provide adequate support
for the valve and prevent excessive vibration. If necessary, additional support brackets mounted
from the engine should be considered.
6. Particular care must be taken to ensure the integrity of the intake pipework between the Chalwyn
valve and intake manifold. Ideally metal pipework should be used and any gaps kept as short as
possible, (taking into account any relative movement) and closed by reinforced hose.
7. Any engine crankcase breather connections into the intake system between the SVX valve and
engine, or any internal crankcase breather arrangement venting directly into the engine intake ports
must be sealed and replaced by an external breather system venting either to atmosphere or to the
intake system upstream of the shutdown valve. External breather system kits for various engine
types are available from Chalwyn.

OPERATION
When powered the solenoid holds the air intake shut down valve in the open (engine run) condition. On
loss of power the spring within the shut down valve assembly moves the valve to the closed (engine
stop) position, i.e. failure of power supply gives a failsafe (engine stopped) condition.

MAINTENANCE
WEEKLY: Visually check the valve, solenoid, cable and cable gland for damage or deterioration.
Withdraw from service if significant damage or deterioration is observed.
NOTE: Chalwyn hazardous area solenoids are sealed units. The cable gland must not be
loosened or removed. If a service problem occurs, the valve should be returned to
Chalwyn for repair.
MONTHLY: Check that the fasteners locating the shut down valve and any associated intake
system or support bracket fasteners are securely tightened.
Check that any flexible hoses in the engine intake between the SVX valve and engine
are free from damage and suitable for further service.
Run engine, preferably at low idle. Use shut down control system emergency stop to
close the intake shut down valve. The engine should stop within a few seconds. If not
check there are no leaks in the engine air intake system between the SVX valve and
engine. If this does not resolve the problem remove the SVX valve to return to Chalwyn
for investigation.

- 16 -
 INLET SYSTEM

ILS INLET FLAMETRAP DESCRIPTION

The ILS Flametrap is mounted in the engine air intake system.The flametrap is an in line flame arrester,
which offers protection against high flame velocity propagations in the engine inlet system.

ILS INLET FLAMETRAP

INSTALLATION
Before installation, ensure that any packing material is blown well clear of all components. The air flow
direction is marked on the ILS inlet flametrap and must be strictly adhered to. Remove the air shutdown
flap assembly, if fitted. Position the ILS unit in correct location for application, if in doubt contact Pyroban.
Complete seal with fixings and gasket for flanges, or hose and clamps for pipe end and adapters.

Re-site the air shutdown flap directly on top of the ILS unit and secure using a suitable gasket
and fixings.
Make good all pipework connections from the ILS unit to the inlet air cleaner.

MAINTENANCE
Do not clean the ILS inlet flametrap by inserting probes as the fine passages could be enlarged thereby
impairing the flametrap performance.

If necessary, the ILS inlet flametrap should be washed in a suitable solvent. The flametrap should then
be blown through using compressed air. Ensure eye protection is worn during this operation.

Visually examine inside the ILS inlet flametrap via the inlet and outlet ports by holding up to a light,
ensuring that the passages are clear.

Before refitting, ensure that the ILS inlet flametrap casing and flanges are not damaged or corroded.

When assemblies with flanged connections are dismantled, new gaskets must always be used when
refitting. Do not use sealer.

- 17 -
 INLET SYSTEM

Servicing
The following table defines the servicing requirements for the Pyroban system (where applicable). Only
competent and suitably trained staff may operate, service and maintain the equipment. The Person in
Authority is responsible to authorize personnel to undertake service work.

Items marked O are to be carried out by the Service provider.

Items listed in this schedule may not be supplied or fitted. Refer to parts list to identify installed parts. A
record of servicing and maintenance should be maintained.

Task-In addition to original Daily Weekly 1 Month 3 Months 6 months 2 Years

requirements 8-12 hrs 50 hrs 200 hrs 500 hrs 1000 hrs 4000 hrs

Inlet Flametrap: check exterior

for damages or distress, check O
pipework and joints for leaks.

Inlet Manifold: inspect exterior

surface for damage or cracks,
check that all fixings are O
secure.

Inlet Shut-Off Valve: check for

correct operation.
O

Inlet Air Shut-Off Valve: visual

inspection. Engine shut-down O
test.

©Copyright 2003 Issue 1 Pyroban Ltd, Endeavour Works, Dolphin Rd, Shoreham-by-Sea West Sussex. BN43 6QG. United
Kingdom. Tel: +44(0) 1273 466200

- 18 -
 COOLING SYSTEM
COOLING SYSTEM

INSTALLATION
The cooling system must be sized to the specified amount of heat rejection from the Pyroban exhaust
equipment. This is additional to the normal heat rejection from the engine and any other water cooled
items such as transmission oil coolers. The exhaust gas cooler is designed to accept the full flow of the
coolant circuit before the coolant enters the engine.

A permanent vent line approximately 1/4" bore should be connected to the vent socket provided on the
exhaust gas cooler, sloping continually upward to a high point in the cooling system, e.g. the expansion
tank. These circuits should be connected to suitable tappings on the engine with sufficient pressure
differential between them to ensure adequate flow.

Permanent vent lines should be connected to the highest point in the cooling system. Air vent lines must
be taken back to the radiator top tank or expansion tank, from any point on components or pipes in the
coolant system likely to trap air (use 3/16” or 1/4" i/d max.).

Ensure that the radiator top tank volume is suitably sized to accommodate the extra cooling system
volume and operate normally right up to the maximum coolant temperature.

Keep all pipe runs to a minimum and use long radius bends where possible.

Coolant Fill Procedure.

Fit a 13 psi pressure cap on the radiator neck.

Unless engine manufacturer specifies otherwise follow engine manufacturer’s guideline on system fill.

MAINTENANCE
Thermostat Replacement

When fitting a new thermostat, ensure that the replacement is of the correct temperature rating.

Fan Belt Tension

Adjust the fan belt tension in accordance with the engine manufacturer’s instructions.

Fan Belt Maintenance

1000 hours (6 months) replace the electrically conductive fan belt and check tension.

©Copyright 2003 Issue 1 Pyroban Ltd, Endeavour Works, Dolphin Rd, Shoreham-by-Sea West Sussex. BN43 6QG.
United Kingdom. Tel: +44(0) 1273 466200

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 MISCELLANEOUS
CRANKCASE BREATHER FLAMETRAP

DESCRIPTION
End-of-line vent application flame arresters which comprise a housing with threaded or flanged end
connection and integral element are designed to prevent the travel of flame caused by an external
source of ignition, from entering as system and also sometimes to prevent flashback of a flame which
has been stabilized on the arrester. Made out of stainless steel weather cowl to protect against the
ingress of rain, snow and foreign bodies. Please refer to parts list for the end of line breather technical
data.

INSTALLATION
Fit engine breather pipe with small flametrap element to gear train cover. Bracket pipe to engine. Ensure
all joints are satisfactory sealed.

End of Line Arresters

MAINTENANCE
It is recommended that the flame arrester element is inspected at 6 monthly intervals, or if excessive
pressure drop is experienced. In the event of a flashback occurring immediate inspection should be
made. If the element is found to be damaged or distorted a new replacement unit should be fitted.
Elements are sealed into the housing and cannot be removed for cleaning. In order to clean the
element, remove the unit from the line, wash the complete flame arrester in a suitable solvent, then blow
thoroughly with compressed air.
Never attempt to clean the engine breather flametrap by inserting probes as the fine passages could be
enlarged, thereby impairing the engine breather flametrap performance.
When refitting onto the line, always use a new gasket of the correct size and of the type suitable for that
application.

- 20 -
 CONTROL SYSTEM
Control Panel Layout & Detail

1
2

3
5
2

No Description

1 EJB 51 Exd Control Panel

2 Emergency Stop

3 MCCB On Indicator

4 Earth Leakage Indicator

5 Earth Leakage Reset

6 MCCB Handle

- 21 -
 STARTING SYSTEM
Electrical Starting System and Engine Safety Control

Description
NT
Intellite -MRS is a comprehensive controller for single generating sets. IL-NT MRS 15 features
NT
extended support of electronic engines and extension modules. Intellite controllers are equipped with
a powerful graphic display showing icons, symbols and bar-graphs for intuitive operation, which sets,
together with high functionality, new standards in Gen-set controls.
InteliLite automatically starts the Gen-set, closes the Gen-set C.B. when all conditions are met, then
stop the engine on external signal or by pressing push buttons.
The key feature of InteliLiteNT is its easy-to-use operation and installation. Predefined configurations for
typical applications are available as well as user-defined configurations for special applications.

Genset Control Enclosure Box

5 6

1
13
2
9

7
10

11
8

12 4
Intellite MRS15 Genset Controller

- 22 -
 STARTING SYSTEM
Genset Control Buttons

Position Button Description

START button. Work in MAN mode only. Press this button to initiate
1
the start sequence of the engine.
STOP button. Works in MAN mode only. Press this button to initiate
the stop sequence of the gen-set. Repeated pressing or holding the
2 button for more than 2s will cancel current phase of stop sequence
(like ramping the power down or cooling) and next phase will
continue.
FAULT RESET button. Use this button to acknowledge alarms and
deactivate the horn output. Inactive alarms will disappear
3
immediately and status of active alarms will be changed to
“confirmed” so they will disappear as soon as their reasons dismiss.
HORN RESET button. Use this button to deactivate the horn output
4
without acknowledging the alarms.
MODE LEFT button. Use this button to change the mode. The button
works only if the main screen with the indicator of currently selected
mode is display.
5
NOTE:
This button will not work if the controller mode is forced by one of
binary inputs Remote OFF, Remote MAN, Remote AUT.
MODE RIGHT button. Use this button to change the mode. The
button works only if the main screen with the indicator of currently
6 selected mode is displayed.
NOTE: This button will not work if the controller mode is forced by
one of binary inputs Remote OFF, Remote MAN, Remote AUT.

Genset Operation Indicators

Position Indicator Description

Gen-set failure. Red LED starts flashing when gen-set failure occurs. After FAULT
7 RESET button is pressed, goes to steady light (if an alarm is still active) or is off (if no
alarm is active).
Gen-set voltage OKI. Green LED is on if the generator voltage is present and within
limits.
8
NOTE: The limits for the generator voltage and frequency are given by setpoints in the
Gener Protect group.

Display and Control Button

Position Button Description

PAGE button. Use this button to switch over display pages. See
9 Display Screens and Pages Structure chapter below this table for
more details.

10 UP button. Use this button to move up or increase a value.

11 DOWN button. Use this button to move down or decrease a value.

ENTER button. Use this button to finish editing a setpoint or moving

12
right in the history page.

13 Graphic B/W display, 128x64 pixels

- 23 -
 STARTING SYSTEM
Display Screens and Pages Structure

The displayed information is structured into “pages” and “screens”. Use PAGE button to switch over the
pages.
1. The page Measurement consists of screens which display measured values like voltages, current,
oil pressure etc., computed values like i.e. gen-set power, statistic data and the alarm list on the last
screen.
2. The page Setpoints contains all setpoints organized to groups and also a special group for entering
password.
3. The page History log shows the history log in the order that the last record is displayed first.

NOTE: History and Setpoints pages are available only when you choose Engineer interface (not
User). See Controller Information Screen subchapter below.

- 24 -
 STARTING SYSTEM

Electrical Starting System and Engine Safety Control

Alarms

Browsing ECU Alarm

- 25 -
 STARTING SYSTEM

Setpoint Change

Entering Password

- 26 -
 STARTING SYSTEM

Controller Information Screen

Display Contrast Adjustment

- 27 -
 DIESEL ENGINE

PERKINS DIESEL ENGINE

Perkins Engine
The 1006.6TG2A is a turbocharged, but with an air to water intercooler to cool the induction air between
the turbocharger and the cylinders, 6 cylinder, 6 litres engine.

Engine Specifications
Model 1006.6TG2A
No. of Cylinder 6 In-Line
Power Output 100kWm@1500rev/min,118kWm@1800rev/min
Cylinder Arrangement Vertical, in –line
Cycle 4-stroke
Induction System Turbocharged
Combustion System Direct Injection
Cooling System Water –Cooled
Displacement 6 Liters
Bore and Stoke 100mm x 127 mm
Compression Ratio 16.0:1
Firing Order 1, 5, 3, 6, 2, 4
Direction of Rotation Anti-Clockwise, Viewed on flywheel
Total Lubrication System Capacity 16.1 Liters
Coolant Capacity 27.7 Liters (inc radiator)

- 28 -
 DIESEL ENGINE
Engine Illustration

1. Filler Cap for Lubricating Oil

2. Fuel Filter
3. Lubricating Oil Cooler
4. Fuel Injection Pump
5. Lubricating Oil Dipstick
6. Drain Plug for Lubricating
Oil
7. Crankshaft Pulley
8. Drive Belt
9. Coolant Pump
10. Fan
11. Coolant Outlet
12. Front Lift Bracket
13. Atomiser

Engine Illustration

14. Induction Manifold

15. Alternator
16. Lubricating Oil Filter
17. Fuel Lift Pump
18. Lubricating Oil Sump
19. Starter Motor
20. Flywheel Housing
21. Flywheel
22. Turbocharger
23. Exhaust Manifold
24. Rear Lift Bracket

- 29 -
 DIESEL ENGINE

Preventive Maintenance

Preventive Maintenance Period

These preventive maintenance periods apply to average conditions of operation. Check the periods
given by the manufacturer of the equipment in which the engine is installed. Use the periods which are
shortest. When the operation of the engine must conform to the local regulations these periods and
procedures may need to be adapted to ensure correct operation of the engine.
It is good preventive maintenance to check for leakage and loose fasteners at each service.
These maintenance periods apply only to engines that are operated with fuel and lubricating oil which
conform to the specifications given in Manual.

Schedules

The schedules which follow must be applied at the interval (hours or months) which occurs first.
A First service at 20/40 hours
B Every day or every 8 hours
C Every 200 hours or 6 months
D Every 400 hours or 12 months
E Every 2000 hours

Schedules

A B C D E Operation
● ● Check the amount of coolant
(2)
● Check the concentration of the coolant
● ● Check the tension and the condition of the drive belt
● Clean the sediment chamber and the strainer of the fuel lift pump
(1)
Check for water in the pre-filter , (or earlier if your fuel supply is
●
contaminated)
● Renew the elements of fuel filter(s)
● Ensure that the atomisers are checked
Ensure that the idle speed is checked and adjusted, if it is
● (3)
necessary.
(3)
● Check the Stanadyne fuel injection pump for governor operation
(1)
● Check the amount of lubricating oil pressure at the gauge
(1)
● ● Check the lubricating oil pressure at the gauge
(4)(5)
● ● Renew the engine lubricating oil
(4)
● ● Renew the canisters(s) of the lubricating oil filter
● ● Renew the elements of fuel filter(s)

- 30 -
 DIESEL ENGINE
(1) If one is fitted.
(2) Renew the antifreeze every 2 years. If a coolant inhibitor is used instead of antifreeze, it should
be renewed every 6 months.
(3) By a person who has had the correct training.
(4) The lubricating oil and the filter canister(s) must be renewed every 250 hours or 12 months for
applications where the engine normally runs at full load for periods of more than 20 minutes, for
example (see the table in fuel specification) The interval to change the canister of the lubricating
oil filter is not affected

Schedules

A B C D E Operation
(3)
● Clean the engine breather system
Clean the air cleaner or empty the dust bowl of the air filter
● ● - extremely dusty conditions
● - normal conditions
Clean or renew the air filter element, if it has not been indicated
●
earlier
Ensure that the turbocharger impeller and turbocharger
● (2)
compressor casing are cleaned
(1)
● Clean the compressor air filter
(1) (2)
● Ensure that the exhauster or compressor is checked
Ensure that the valve tip clearances of the engine are checked and
● ● (2)
if necessary, adjusted
(2)
● Ensure that the alternator and starter motor are checked

(1) If one is fitted

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

(3) The oil separator of the open breather assembly should not be dismantle or cleaned, but must be
renewed at every overhaul of the engine or 8000 hours.

- 31 -
 DIESEL ENGINE

How to drain the cooling system

Warnings!

 Discard the used coolant in a safe place and in accordance with local regulations.

 Do not drain the coolant while the engine is still hot and the system is under pressure
because dangerous hot coolant can be discharged.

1. Ensure that the machine is on level

ground.

2. Remove the filler cap of the coolant

system.

3. Remove the brass drain plug from the

side of the cylinder block (A) in order to
drain the coolant.

Ensure that the drain hole is not

restricted.

4. Open the tap or remove the drain plug at

the bottom of the radiator in order to
drain the radiator.

The radiator does not have a cap or

drain plug, disconnect the hose at the
bottom of the radiator.

If a lubricating oil cooler/ filter assembly

(B) is fitted, this must also be drained
and flashed.

To do this disconnect the hoses (B1 and

B2) at the top of the cooler and flush the oil cooler through the outlet connection (B1) until clean water
runs from the inlet (B2).

5. Flush the coolant system is to remain empty temporarily after it is flushed, drain the oil cooler and fit it
with 165ml (1/3 pint) of antifreeze. This will protect the oil cooler against frost if any clean water
drains down from the water jacket when the machine is moved.

6. Fit the hoses to the top of the filler cap. Close the radiator tap or connect the radiator hose.

- 32 -
 DIESEL ENGINE

How to check the specific gravity of coolant

Warning!

Do not drain the coolant while the engine is still hot and the system is under pressure because
dangerous hot coolant can be discharged.

For mixtures which contain inhibited ethylene glycol:

1. Ensure that the machine is on level ground

2. Operate the engine until it is warm enough to open the thermostat. Continue to run the engine until
the coolant has circulated the cooling system.

3. Stop the engine.

▫
4. Allow the engine to cool until the temperature of the coolant is below 60 C

5. Remove the filler cap of the cooling system.

6. Drain some coolant from the cooling system into a suitable container.

7. Use a special coolant hydrometer that will check the temperature and the specific gravity of the
coolant follow the manufacturer’s instructions.

Note: If a special coolant hydrometer is not available, put a hydrometer and a separate the
thermometer into the antifreeze mixture and check the readings on both instruments.
Compare the readings with the chart A.

8. Adjust the strength of the mixture as necessary.

Note: If it is necessary to fill or replenish the coolant system in service, mix the coolant to the
correct strength before it is added to the coolant system. Perkins POWERPART antifreeze
with a concentration of 50% will give protection against frost to a temperature of –35 °C (-31
°F). It will also give protection against corrosion.

This is especially important when there are aluminium components in the coolant system.

- 33 -
 DIESEL ENGINE

Specific Gravity Chart

Specific Gravity Chart

A = Percentage antifreeze by volume

B = Mixture temperature in Fahrenheit
C = Specific Gravity
D = Mixture temperature in Celsius

- 34 -
 DIESEL ENGINE

How to check the drive belt (s)

Renew a belt if it is worn or damaged.

If twin belts are fitted, they must be renewed

together.

To ensure maximum belt life, it is

recommended that a belt tensioner gauge is
used to check the belt tension. Fit the gauge
(A1) at the centre of the longest free length and
check the tension. If a “Burroughs” gauge is
used, the correct tension is 355N (80 lbf) 36
kgf. If the tension is 220 N (50lbf) 22 kgf or
below adjust it to 355N (80lbf) 36 kgf as
indicated below

If the gauge is not available, press down the

belt withthe thumb at the centre of the longest
free length and check the deflection (B).

With moderate thumb pressure –45N (10lbf)

4.5 kgf- the correct deflection of the belt is 10
mm( 3/8”)

If the twin belts are fitted, check/adjust the

tension on the tighter belt.

How to adjust the belt tension

Loosen the pivot fasteners (B1) of the
alternator and the adjustment link fasteners
(B2).

Change the position of the alternator to give

the correct tension.

Tighten the pivot fasteners of the alternator

and the adjustment link fasteners.

Check the belt tension again to ensure that it is

still correct. If a new belt is fitted, the belt
tension must be checked again after the first 20
hours of operation.

- 35 -
 DIESEL ENGINE
How to clean the gauze strainer of the fuel lift pump
1. Release the fastener (A2) and remove the cover
and the joint (A3) from the top of the fuel lift
pump(A4).
 Remove the gauze strainer (A1).
 On the some turbocharged engines, it
will be necessary to remove the small
heat shield which is fitted above the
pump.
2. Wash carefully all of the sediment from the lift
pump body.
3. Clean the gauze strainer, the joint and the cover.
4. Assemble the lift pump. Use a good joint and ensure that the lift pump body and the cover are
fitted together correctly because leakage at this point will let air into the fuel system. Fit the heat
shield, if one is fitted.
5. Eliminate the air from the fuel system through the filter vent plug.

Fuel pre-filter
If a pre-filter is fix between the fuel tank and the engine.
Check the filter bowl for water at regular intervals and drain
as necessary.

How to renew the element(s) of the fuel filter

There are three types of fuel filter in use:
Warning! Discard the used element or canister and fuel oil
in a safe place and in accordance with local regulations.
Cautions:
 It is important that only the genuine Perkins
parts are used. The use of a wrong canister or
element can damage the fuel injection pump.
 Do not allow dirt to enter the fuel system.
Before a connection is disconnected, clean
thoroughly the area around the connection.
After a component has been disconnected, fit
a suitable cover to all open connections.
 The pre-filter and main filter canisters must be
renewed at the same time.
The separate element type where element the filter
element is held between the filter head and the bottom
cover (A).
The canister type where the filter element has an internal
thread (B2) at the top and is fastened to a threaded adaptor (B1) in the filter head (B).

- 36 -
 DIESEL ENGINE

A fuel filter with a quick release canister (C) has been

introduced on a certain engines. Some engines are fitted
with a pre-filter of the same type.This filter is fitted next to a
pre-filter, but connected in the fuel system before the fuel lift
pump; both of the filter elements must be renewed at the
same time.
The filter can have one or two elements. When twin
elements are fitted, both of the elements must be renewed
at the same time.

How to renew the element (s) of the separate element type

Caution: It is important that only the genuine Perkins
fuel filter element is used. The use of a wrong element
can cause damage to the fuel injection pump.
1. Clean the outside surfaces of the fuel filter assembly. If
a drain tap (A4) is fitted to the bottom of the filter bowl,
drain the fuel from the filter.
2. Hold the bottom cover of the filter element and release
the setscrew (A3) which is fitted through the filter head
(A3) which is fitted through the filter head (A1) above
the centre of the filter.
3. Lower the bottom cover of the filter.
4. Remove the element (A5) and discard it.
5. Clean the inside surfaces of the filter head and of the cover.
6. Renew the seals (A2) and (A6) and lightly lubricate them with clean fuel.
7. Put the bottom cover under the new element and hold the element squarely to the filter head.
Ensure that the element is fitted in the centre against the joint in the filter head. With the assembly in
this position, engage and tighten the setscrew.
8. Eliminate the air from the fuel system.

How to renew the filter canister of the canister fuel filter

1. Thoroughly clean the outside surfaces of the fuel filter
assembly.
2. Loosen the drain device at the bottom of the filter (A1)
and allow the water /fuel to drain into a suitable
container.
3. Use a strap wrench or similar tool to loosen the filter
canister and remove the canister.
4. Ensure that the threaded adaptor (A2) is secure in the
filter head and that the inside of the head is clean.
5. Lubricate lightly the top seals (A3) of the new canister
with clean canister with clean fuel. Fit the canister to the filter head and tighten, by hand only.
6. Eliminate the air from the fuel system.

- 37 -
 DIESEL ENGINE

How to renew the filter canister of the canister quick release fuel filter

1. Thorough clean the outside surfaces of the filter assembly.

2. Loosen the drain device (A4), if one is fitted, at the bottom of the canister and allow the water/fuel to
drain into a suitable container.

Note: If the filter does not have a drain device fitted release the cap (A1) on top of the filter head.
Remove the nylon insert to the lower the level of the fuel in the filter canister. This will prevent
fuel spill when the clamp ring is released.

3. Unscrew the sediment bowl at the bottom of the canister, if one is fitted.

4. Support the filter canister and rotate the clamp ring (A2) to the left, see the direction arrow, and
remove the clamp ring.

5. Remove the canister from the filter head by a direct pull downwards, and discard the old canister
(A3). Retain the clamp ring.

6. Ensure the filter head is clean and that the seals (A5) and (A6) are in good condition or renew
them. Align the spline (A8) with groove in the filter head and push the new canister fully into the
filter head.

7. Support the canister, if the clamp rings (A7) and rotate it to the right, see the direction arrow,
to fasten the canister to the filter head.

8. If a sediment bowl is fitted, remove the bowl and thoroughly clean the cover of the bowl.

9. Check the “O” ring seals of the sediment bowl for damage and renew if necessary.

10. Clean the threads of the sediment bowl and fit the bowl to the canister and tighten by hand
only.

11. If it was removed, fit the nylon insert used to lower the level of the fuel in the filter canister and
fasten the cap.

12. Eliminate the air from the fuel system.

- 38 -
 DIESEL ENGINE

Atomiser fault
Warning!
If your skin comes to contact with high-pressure
fuel, obtain medical assistance immediately.
Keep away from moving parts during engine
operation. Some moving parts cannot be seen
clearly while engine runs.
An atomiser fault can cause an engine misfire.
In order to find which atomiser is detective, operate the
engine at a fast idle speed. Loosen and tighten the union
nut of the high –pressure fuel pipe at each atomiser.
When the union nut of the defective atomiser is loosened,
there is little or no effect on the engine speed.

How to renew an atomiser

Cautions:
 Atomiser must be removed and fitted by a
person with the correct training.
 Do not allow dirt to enter the fuel system.
Before a connection is disconnected, clean
thoroughly the area around the connection.
After the component has been disconnected,
fit a suitable cover to all open connection.
1. Remove the fuel leak –off pipe.
2. Remove the union nuts (A1) of the high –pressure pipe from the atomiser and from the fuel injection
pump. Don not band the pipe. If necessary, remove the pipe clamps.
3. Remove the atomiser setscrews and remove the clamps (A2), the atomiser (A6) and its seat washer
(A7). Remove the dust seal (A5) and spacer (A4) and fit the spacer and a new dust seal onto the
new atomiser.
Caution: Remove and discard the seat washer (A6). If the original seat washer remains in the
recess for the atomiser, the nozzle protrusion will be incorrect when a new seat washer is
added.
4. Put the new atomiser in position with its spacer, new dust seal and a new seat washer, ensure that
the fuel leak–off connection (A3) is not toward the engine. Position the clamp and engage the
atomiser is not fitted and tighten the set screws from the clamp evenly and gradually to 12 Nm (9
lbft) 1.2 kgf m.
Caution: Do not tighten the union nuts of the high pressure pipes more than the recommended torque
tension. If there is a leakage from the union nut, ensure that the pipe is correctly aligned with the
atomiser inlet. Don not tighten the atomiser union nut more, as this cause a restriction at the end of the
pipe. This can affect the fuel delivery.
5. Fit the high-pressure fuel pipe and tighten the union nuts to 27 Nm (lb ft) 2.8 kgfm. If necessary, fit
the pipe clamps.
6. Renew the sealing washers and fit the leak-off pipe. Tighten the banjo bolt to 9.5Nm (7.0 lbf ft) 1.0
kgfm.
7. Operate the engine and check for leakage of fuel and air.

- 39 -
 DIESEL ENGINE

How to eliminate air from the fuel system

There are two methods to eliminate air from the fuel

system according to the type of fuel injection pump fitted;

The standard method is used where the fuel injection

pump has vent screws (A1/2) and (B1).

The self –vent method is used where the fuel injection

pump has a self –vent feature. These pumps have a vent
pipe (C1) fitted between the connection in the top of the
pump and atomiser leak-off pipe. Vent screws are not
fitted to these pumps.

If air enter the system if;

The fuel tank is drained during normal operation.
The low- pressure fuel pipes are disconnected.
A part of the low –pressure fuel system leaks during the
engine operation.

If air enters the fuel system, it must be eliminated before

the engine can be started.

In order to eliminate air from the fuel system, proceed as

follow;

Cautions: Do not allow the fuel from the engine to

contaminate the engine compartment. Put a drip tray
under the engine and discard old fuel in accordance
with local instruction

- 40 -
 DIESEL ENGINE

Standard method to eliminate air from the fuel system

1. Loosen the vent plug on the top of the twin element

fuel filter (A1).If a single element filter is used,
loosen the banjo connection bolt Which is fitted
on the top of the filter (B1)

2. Operate the priming lever on the fuel lift pump (C )

until fuel, free from air, comes from the filter vent
point. Tighten the vent plug or banjo connection bolt.

Note: If the can for fuel lift pump is at the top of maximum
lift, it will not be possible to operate the priming lever. In
this situation, the crankshaft must be rotated one turn.

3. Ensure that the manual stop control is in the “run”

position. If an electrical stop control is used, turn the
start key to the “R” position.

4. Loosen the vent screw in the lock screw (D2) for the
hydraulic head. Operate the priming lever of the fuel
lift pump until fuel, free from the air, comes from the
vent screw. Tighten the vent screw. Loosen the vent
screw (B1) on the governor cover. Operate the
priming lever of the fuel lift pump until fuel, free from
the air, comes from the vent screw. Tighten the vent
screw.

- 41 -
 DIESEL ENGINE
Standard method to eliminate air from the fuel system
Caution: Use a spanner on the flats (A1) of fuelled
starting aid to prevent its movement when the union nut
(A2) is loosened and tightened.

5. If the pipe to the fuelled starting aid has been drained,

loosen the union nut (A2) at the fuelled starting aid and
operate the lift pump (C) until fuel, free from the air,
comes from the connection. Tighten the union nut at the
starting aid. Use a spanner on the hexagon of the fuelled
starting aid to prevent its movement when the union nut
is loosened and tightened.

6. Loosen the union nuts (B1) of the high- pressure pipes at

two of the atomisers. Operate the starter motor until fuel
from air, comes from the pipe connections. Tighten the
high-pressure connections to 27 Nm( 20lbf ft) 2.8 kgf m.

7. The engine is now ready to start. If the engine runs

correctly for a short time and then stops or runs roughly,
check for air in the fuel system. If there is air in the fuel
system, there is probably a leakage in the low pressure
system.

- 42 -
 DIESEL ENGINE

Self –vent method

Fuel injection pumps used on some Lucas and all
standard fuel injection pumps will automatically
remove air from the fuel system. Vent screws are not
fitted to these pumps.

Caution:

 Although the fuel injection pumps will

eliminate air automatically, use the
procedure that follows to remove air from
the fuel system if the system is drained or a
major component is removed.

 Ensure that fuel has been added to the tank

or that the leakage has been corrected.

1. Loosen the vent plug (A1) on the top of the filter

head.

2. Operate the priming lever lift pump (B) until fuel,

free from air, comes from the filter vent point.
Tighten the vent plug.

Note: If the cam for the fuel lift pump is at the point of
the maximum cam lift, it will not be possible to
operate the priming lever. In the situation, the
crankshaft must be rotated one turn.

Caution: Use a spanner on the flats (A1) of the

fuelled starting aid to prevent its movement
when the union nut (A2) is loosened and
tightened.

3. If the pipe to fuelled starting has been drained,

loosen the union nut (C2) at the fuelled starting
aid and operate the lift pump (C) until fuel, free
from air, comes from the connection. Tighten
the union nut at the starting aid. Use a spanner aid to prevent its movement when the union nut is
loosened and tightened.

- 43 -
 DIESEL ENGINE

Self –vent method

Cautions: Do not tighten the union nuts of the

high-pressure pipes more than the
recommended torque tension. If there is a
leakage from the union nut, ensure that the pipe
is correctly aligned with the atomiser inlet. Do
not tighten the atomiser union nut more, as this
cause a restriction at the end of the pipe. This
can affect the fuel delivery.

4. Loosen the union nuts (A1) of high –pressure

pipes at two of the atomisers.

5. Put the electrical system switch (page 14/A) to the “ON” position. Ensure that the manual stop
control, if one is fitted, is in the “run” position. Operate starter motor until fuel, free from air, comes
from the pipe connections. Tighten the high-pressure pipe connections to 27 Nm (20 lbft) 2.8 kgf m.
Return the switch to the “OFF” position.

6. The engine is now ready to start. If the engine runs correctly for a short time and then stops or runs
roughly, check for air in the fuel system. If there is air in the fuel system, there is probably a leakage
in the low –pressure system.

How to renew the lubrication oil of the engine

Warning! Discard the used lubricating oil in a
safe place and in accordance with local
regulations.

Caution: Ensure that the application is on level

surface to ensure an accurate reading on the
dipstick.

1. Operate the engine until it is warm.

2. Stop the engine, remove the sump drain plug (

A1) and its “O” ring and drain the lubricating oil
from the sump. Ensure that the “O” ring is not damaged. Fit the drain plug and its “O” ring and
tighten the plug to 34 Nm (25 lbft) 3.5 kgf m.

3. Fill the sump to the mark (A2) on the dipstick with new and clean lubricating oil of an approved
grade.

- 44 -
 DIESEL ENGINE

How to renew the canister of the lubricating oil filter

Warning! Discard the used canister and

lubricating oil in a safe place and in
accordance with local regulations.

Cautions:

 The canister contains a valve and

special tube to ensure that
lubricating oil does not drain
from the filter. Therefore, ensure
that the correct Perkins
POWERPART canister is used.

 Ensure that the application is on a level surface to ensure an accurate reading on the
dipstick.

The filter can have one or two canisters. When two canisters are fitted, both must be renewed at the
same time.

1. Put a tray under the filter to retain split lubricating oil.

2. Remove the filter canister with a strap wrench or similar tool. Ensure that the adaptor (A1) is
secure in the filter head. Discard the canister.

3. Clean the filter head.

4. And clean the engine lubricating oil to the new canister. Allow the oil enough time to pass
through the filter element.

5. Lubricate the top of the canister seal (A2) with clean engine lubricating oil.

6. Fit the new canister and tighten by hand until the seal contacts the filter head. Tighten the
canister a further ½ to ¾ of turn by hand. Do not use a strap wrench.

7. Ensure that there is lubricating oil in the sump. On turbocharged engine ensure that the engine
will not start and operate the starter motor until oil pressure is obtained. To ensure that the
engine will not start., either put the manual stop control in the “Stop” position or disconnect the
electrical stop control of the fuel injection pump. Oil pressure is indicated when the warning light
is extinguished or by a reading on the gauge.

8. Operate the engine and check for leakage from the filter. When the engine has cooled, check
the oil level on the dipstick and put more oil into the sump, if necessary.

Warning! Do not direct compressed air at your skin.

- 45 -
 DIESEL ENGINE
How to clean the integral closed breather system
Caution: Do not use excessive force to remove the
hose (A4) from the lubricator outlet pipe.
Note: The procedure below refers only to the closed
breather shown in (A).
1. Release the hose clip and carefully remove the
hose from the breather outlet.
2. Remove the rocker cover.
Caution: Ensure that the lever does not damage the
cover.
3. Release the fasteners and carefully remove the
breather body. A suitable lever may be necessary
to release the cover from the body of the breather.
Ensure that the lever does not damage the cover.
Discard the joint (A5).
Caution: Do not clean the breather valve or the gauze
filter. The breather valve (A1) and gauze (A3)
must be renewed every 4000 hours.
4. Release the clips ( A2) from the clip fasteners
( A7) and push the breather valve out of the breather cover. Discard the breather valve.
5. Remove and discard the gauze.
Warning! Do not allow compressed air to contact your skin. If compressed air enters your skin,
obtain medical help immediately.
6. Wash the body of the breather, the cover, the baffle plates (A6) and the breather pipe, every
2000 hours of operation. Use an approved kerosene cleaning fluid and dry them with
compressed air at low pressure.
7. Ensure that the holes at the bottom of the baffle plates in the breather body are not restricted. If
necessary, clean the holes.

To assemble integral closed breather system

1. Fit the baffle plates into the grooves in the breather body.
2. Renew and fit the gauze filter into the breather body.
3. Renew and fit the new valve into breather cover. Ensure that the clips are engaged correctly.
Note: The breather valve is renewed every 4000 hours.
4. Renew the joint, which is fitted dry. Put the cover and valve assembly into position on the
breather body. Loosely fit the fasteners. Tighten the fasteners gradually and evenly to 3 Nm
(2.2lbft) 0.3 kgfm.
Caution: Do not use excessive force to fit the hose to the breather outlet pipe.
5. Check that there is no restriction in the breather hose. Fit the breather hose to the over and
tighten the clip.

- 46 -
 DIESEL ENGINE

The open breather system

Some engines have an open breather system that

has an oil separator (A1) fitted to the rocker cover.

The oil separator should not be dismantled or

cleaned, but must be renewed at every engine
overhaul or 8000 hours. Refer to your distributor.

Air cleaner

Caution: Do not us gasoline to clean the air

cleaner.

A typical wet type air cleaner is shown at (A). The

wet type air cleaner must be drained at a suitable
interval. The container and element (A1) must be
cleaned with kerosene or with another suitable
fluid. Do not use gasoline. Check that the seal (A3)
is not damaged and renew it, if necessary. Fill to
the indicated level (A2) with clean engine
lubricating oil.

- 47 -
 DIESEL ENGINE

Air filter

Environmental conditions have an important effect

on the frequency at which the air filter needs service.
Certain air filters a separate dust (A1) which must be
cleaned at intervals. The amount of dust in the bowl
shows if it has been removed at the correct time for
the conditions of operation. Do not let dust
completely fill the bowl, because this will reduce the
life of the filter element (A2).

Certain air filters have automatic dust valves (B1)

through which dust is expelled from the filter. The
rubber dust valve must be kept clean. Ensure that
the sides of the valves close completely together and
that they can separate freely.

If a restriction indicator (C) is fitted, it will indicate

precisely when the air filter element needs service.
This prevents the premature removal of the filter
element which causes extra cost or late removal of
the element which can cause loss of engine power.

Restriction indicator

The restriction indicator for these engines must work

at a pressure difference of 508/558 ( 20/22in 0 of
water gauge. It is fitted on the air filter outlet or
between the air filter and the indication manifold.

When the red warning indicator (C1) is seen through

the clear panel (C2) after the engine has stopped,
the air filter element must be removed for service.

After a clean element has been fitted, press the

rubber bottom (C3) or the button (C4) of the
restriction indicator to reset the red warning indicator.

- 48 -
 DIESEL ENGINE

How to check the valve tip clearances

These are checked between the top of the

valve stem and the rocker lever(A), with the
engine hot or cold. The correct clearance for
inlet valves is 0.02 mm (0.008in) and 0.45 mm
(0.018 in) for exhaust valves. The valve
positions are shown at (B).

The sequence of valves from number 1

cylinder is shown in the table below.

Note: Number 1 cylinder is at the front of the

engine.

Four cylinder engine

1. Rotate the crankshaft in the normal direction

of rotation until the inlet valve (B8) of
number 4 cylinder has just opened and the
exhaust valve (B7) of the same cylinder has
not closed completely. Check the
clearances of the valves (B1 and B2) of
number 1 cylinder and adjust them, if necessary.

2. Set the valve (B3 and B4) of number 2 cylinder as indicated above the number 4 cylinder. Then
check/adjust the clearances of the valves (B5 and B6) of number 3 cylinder.

3. Set the valves (B1 and B2) of number 1 cylinder. Then check/ adjust the clearances of the valves (B7
and B8) of number 4 cylinder.

4. Set the valves (B5 and B6) of number 3 cylinder.Then check/ adjust the clearances of the valves (B3
and B4) of number 2 cylinders.

- 49 -
 DIESEL ENGINE

Six cylinder engine

1. Rotate the crankshaft in the normal
direction of rotation until the inlet valve
(A12) of number 6 cylinder has adjust
opened and the exhaust valve (A11 of
the same cylinder has not closed
completely. Check the clearances of
the valves (A1 and A2) of number 1
cylinder and adjust them, if necessary.

2. Set the valve (A4 and A3) of number 2

cylinder as indicated above for number
6 cylinder. Then check/adjust the
clearance of the valves (A9 and A10) of
number 5 cylinder.

3. Set the valves (A8 and A7) of number 4

cylinder. Then check/ adjust the clearances of the valves (A5 and A6) of number 3 cylinder.

4. Set the valve (A1 and A2) OF NUMBER 1 CYLINDER. Then check/adjust the clearances of the
valves (A11 and A 12) of number 6 cylinder.

5. Set the valves (A9 and A 10) of number 5 cylinder. Then check/ adjust the clearances of valves (A3
and A4) of number 2 cylinder.

6. Set the valves (A5 and A6) of number 3 cylinder. Then check/ adjust the clearances of the valves (A7
and A8) of number 4 cylinder.

Lubricating Oil Specification

If you need advise on adjustments to an engine setting to the lubricating oil change periods which may
be necessary because of the standard of available fuel, consult your nearest Perkins distributor.

Use only good quality oil to the relevant specification as shown in table below.

Caution: The type of lubricating oil to be used may be affected by the quality of the fuel which is
available. For further details see “Fuel specification” and the preventive maintenance schedules.

Always ensure that the correct viscosity grade of lubricating oil is used fro the ambient temperature
range in which the engine will run as shown in the chart (A) and in the table below.

Lubricating Oil specification

Naturally oil specification

Naturally aspirated engines:

ACEA E1 or E2
API CC,CD or CF

Turbocharged Engines
(1)
ACEA E 2 or E3
(1)
API CE, CF4 or CG4

For used in heavy duty applications with a lubricating oil change period of 250 hours.

- 50 -
 DIESEL ENGINE

Coolant Specification

The quality of the coolant which is used can have a great effect on the efficiency and life of the cooling
system. The recommendations indicated below can help to maintain a good cooling system and to
protect it against frost and /or corrosion.

If the correct procedures are not used, Perkins cannot be held responsible for damage caused by frost
or corrosion.

Caution: An antifreeze which contains the correct inhibitor must be used at all times to prevent
damage to the engine by corrosion in the coolant circuit,

If frost protection is not necessary, it is still extremely important to use an approved antifreeze mixture
because this gives a protection against corrosion and also raises the boiling point of the coolant.

If the approved antifreeze mixture is not available, add a correct mixture of corrosion is not used, the
engine will be damaged by corrosion. If there is doubt the corrosion inhibitor to be used, it is
recommended that you consult the Perkins Service Department.

Note: If combustion gases are release into the coolant circuit, the coolant must be renewed after repair
of the fault.

The antifreeze which is recommended for this engine is the latest POWERPLANT Antifreeze. This
antifreeze contains the correct corrosion inhibitor which is especially suitable for this engine.

If it is possible, use clean soft water in the coolant.

The quality of the antifreeze coolant must be checked at least once year, for example, at the beginning
of the cold period. The coolant must be renewed every two years.

Caution: The antifreeze mixture must consist of equal quality of antifreeze and water. The
corrosion inhibitor in the antifreeze will be diluted if a concentration of less than 50% of
antifreeze is used. Concentrations of more than 50% of antifreeze may have an adverse effect
on the performance of the coolant.

- 51 -
 DIESEL ENGINE
General Safety Precautions
These safety precautions are important. You must refer to the local regulations in the country of use.
Some items only refer to specific applications.

Only use these engines in the type of application for which they have been designed.

Do not change the specification of the engine.

Do not smoke when you put fuel in the tank.

Clean away fuel which has been split. Material which has been contaminated by fuel must be moved to
a safe place.

Do not put fuel in the tank while the engine runs (unless it is absolutely necessary)

Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct
training; even the extreme care must be used to prevent injury).

Do not make adjustments that you do not understand

Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions.

Other persons must be kept at a safe distance while the engine or auxiliary equipment is in operation

Do not permit loose clothing or long hair near moving parts.

Keep away from moving parts during engine operation. Warning! Some moving parts cannot be seen
clearly while engine runs.

Do not operate the engine if a safety guard has been removed.

Do not remove filler cap or any component of the cooling system while the engine is hot and while the
coolant is under pressure, because dangerous hot coolant can be discharged.

Only one person must control the engine.

Ensure that the engine is operated only from the control panel or from the operators position.

If your skin comes into contact with high –pressure fuel, obtain medical assistance immediately.

Diesel fuel and lubricating oil (especially used lubricating oil) can damage the skin of certain persons.
Protect your hands with gloves or a special solution to protect the skin.

Do not wear clothing contaminated by lubricating oil.

- 52 -
 TORQUE SETTINGS
Because of variations in frictional conditions, torque figures can give wide variance in bolt tension. The
main precaution that can be taken is to calibrate the torque wrench for each batch of bolts. As this is
usually impracticable, the figures in the following tables may be taken as a guide. They are for
un-lubricated threads and do not take account of the effect of hard or smooth mating surfaces or
hardened washers, etc. in case of doubt, lower values should be used.

IMPERIAL SIZES-STEEL GRADES R, S & T

THREAD FORM: BSW BSF UNF UNF
MATERIAL GRADE: R T R T S T S T
Lb.ft. 8.2 10 9.1 12 11 12 9.8 10
1 / 4” Nm 11 14 12 16 15 16 13 14
Lb.ft. 17 21 18 23 22 24 20 22
5 /16 “ Nm 23 29 24 31 30 33 27 30
Lb.ft. 30 38 32 41 40 43 36 38
3 / 8” Nm 41 52 44 56 54 59 49 52
Lb.ft. 48 60 50 65 65 70 55 60
7 / 16” Nm 65 82 68 88 88 95 75 82
Lb.ft. 70 90 80 100 95 105 90 95
1 / 2” Nm 95 122 109 136 129 143 122 129
Lb.ft. 145 185 155 200 195 200 175 185
5 / 8” Nm 197 252 211 272 265 272 238 252
Lb.ft. 260 320 270 340 340 360 310 320
3 / 4” Nm 354 435 367 463 463 490 422 435
Lb.ft. 415 520 435 560 540 580 490 540
7 / 8” Nm 565 707 592 762 735 789 667 735
Lb.ft. 620 800 660 840 800 860 740 800
1” Nm 844 1088 898 1143 1088 1170 1007 1088

The minimum ultimate tensile strengths of the grades of steel referred to are:
Grade R 45 tons / sq. in. (70.9 kg/mm 2, 695 N/mm2) Grade T 55 tons / sq. in. (86.6 kg/mm2, 849 N/mm2)

Grade S 50 tons / sq. in. (78.7 kg/mm 2, 772 N/mm2) Grade 8.8 50 tons / sq. in. (80.0 kg/mm2, 785 N/mm2)

METRIC SIZES-STEEL GRADE 8.8 METRIC SIZES-STAINLESS STEEL

COARSE FINE COARSE FINE
SIZE
PITCH PITCH PITCH PITCH
TORQUE TORQUE TORQUE TORQUE
(mm) (mm) (mm) (mm)
5.1 lb.ft 5.7 lb.ft 3.6 lb.ft 4.0 lb.ft
M5 0.8 0.50 0.8 0.50
6.9 Nm 7.8 Nm 4.8 Nm 5.5 Nm
8.6 lb.ft 9.5 lb.ft 6.0 lb.ft 6.7 lb.ft
M6 1.00 0.75 1.00 0.75
12 Nm 13 Nm 8.4 Nm 9 Nm
21 lb.ft 22 lb.ft 14.7lb.ft 15.4lb.ft
M8 1.25 1.00 1.25 1.00
28 Nm 30 Nm 19.6 Nm 21 Nm
42 lb.ft 44 lb.ft 29.4 lb.ft 31 lb.ft
M10 1.50 1.25 1.50 1.25
56 Nm 59 Nm 39.2 Nm 41 Nm
72 lb.ft 79 lb.ft 50 lb.ft 55 lb.ft
M12 1.75 1.25 1.75 1.25
98 Nm 107 Nm 69 Nm 75 Nm
180 lb.ft 190 lb.ft 126 lb.ft 133 lb.ft
M16 2.00 1.50 2.00 1.50
244 Nm 259 Nm 171 Nm 181 Nm
350 lb.ft 390 lb.ft 245 lb.ft 273 lb.ft
M20 2.50 1.50 2.50 1.50
476 Nm 528 Nm 333 Nm 370 Nm
610 lb.ft 660 lb.ft 427 lb.ft 462 lb.ft
M24 3.00 2.00 3.00 2.00
822 Nm 894 Nm 575 Nm 626 Nm
Note – The stainless steel torque figures given in the table above are based on 70% of the equivelent
Grade 8.8 values.

- 53 -
 PARTS LIST

Mechanical Component

COMPONENT PART DESCRIPTION

Perkins Engine Model -1006.6TG2A 1500rpm, SAE3 and Fly
65100079
wheel 11.5" & flywheel housing SAE 3 with single starter pocket
Alternator Model RF280L/Z2/TEAB 60kVA 48KW 400V 3PH
50/60HZ 1500/1800RPM Total Enclosed,Air cooled Non
65500079
Sparking,T3,ATEX 3G, Class H insulation, Class B temp Rise,
Twin Braring,
Coupling CF-D-220-75-11-147, 2500 Nm, SAE11 claw flange,
65100062 hub with 85 H7 bore and 22 P9 keyway, 12 x plug in 75SH
elements
Coupling Bellhousing SAE3 (engine) to SAE2 (alternator) -
115mm length
491095 RAD & FAN ASSY 1006TG2A
65100063 Chalwyn Air Shutdown Valve -SVX 520
806466 FTRAP ILS 5" CHALFLANGE
806224 EXCOOLER PERKINS 1006.6
815829 TURBOCHARGER K24 PERKINS 1006 TURBO WITH HCTB
802507/53 FTRAP 210/5/50/L
39935 FTRAP DMY 210HP HD L/S
815976 BOX OUTLET 210HP 4"ANSI
807799 EXHFLX 4"BORE FLANGED
440413 SPKAR 4" ANSI S/S 316
304381 FTRAP EXH BACK PRES ASSY
440236 FTRAP EOL 3/4"NPT
814347 BRACKET VIB HOUR METER
510039 GAUGE VIBR HOUR VER PAN
491044 FANBELT AX58 NOTCHED
807142 FUEL STOP SOLENOID
814627 Main skid Base
65100232 Anti Vibration Mount Vibratec DMS144-60NBR

- 54 -
 PARTS LIST
Electrical Components

COMPONENT PART DESCRIPTION

65500078 IL-NT-MRS 15 ComAp Controller
65500075 Controller PCI 105 (50-60Hz)
MCCB Enclosure c/w push button, Indicator, cable gland.
65500101
(EJB51 Enclosure)
811697 Engine controller display box (ComAp controller box)
65500022 Junction box, EExd, IME 1080WT-02 + ceramic terminal
65500023 Magnetic Speed Sensor
65500059 VDO Pressure Sensor (1-10bar)
65500104 Dual Port Interface Module
65500077 ESD5120CE ESD speed Controller
810374 BATTERY ASSEMBLY ESB75
804129 STARTER MOTOR FLAMEPROOF FPS23
800151/2 PINION HEX PERK 4203.2
70774/15560 Starter Enclosure Assembly
805224/45OL Alternator FPA45 12V/45A
65500098 Enclosure with hinged door IP66 SS316 300x380x210
65100064 Actuator for delphi fuel pump 12V

- 55 -
 ENGINE SHUTDOWN CONTROL FUNCTION CHART

Engine Shutdown Control Function Chart

Fuel Stop Battery

Air Valve Warning Only
Solenoid Disconnect

Emergency Stop x x
Normal Stop x
0.8bar x
Oil Pressure
0.2bar x

Coolant 100°C x
Temperature 95°C x

Exhaust 200°C x
Temperature 195°C x
RPM 1650 RPM x x
Battery Isolation ( Manual) x

PT100 in 95°C x
Alternator 145°C x

- 56 -
 GENERAL ARRANGEMENT DRAWING

57
 ELECTRICAL WIRING DIAGRAM

58
 ELECTRICAL WIRING DIAGRAM

59
 ELECTRICAL WIRING DIAGRAM

60
 ELECTRICAL WIRING DIAGRAM

61