No 38 Gul Drive, Jurong, Singapore 629486.

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

ORIGINAL ISSUE AMENDMENTS

JOB NO DATE COPIES DATE CHANGES

1138-MJ-Z2G 20-10-11 1

REPRINTS

OPERATING & INSTRUCTION MANUAL

FOR

45KVA 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

General Safety Information ……………………………………………………………… 1

Introduction ………………………………………………………………………………. 5

Operating Instructions ……………………………………………………………………. 6

Mechanical Instrumentation ……………………………………………………………… 7

Exhaust System .………………………………………………………………………….. 9

Inlet System ……………………………………………………………………………….. 16

Cooling System ………………………………………………………………………….... 21

Miscellaneous ……………………………………………………………………………... 22

Starting System ………………………………………………………………………….…. 23

Diesel Engine Maintenance ……………………………………………………………… 29

Part List of Protection System …………………………………………………………….. 56

Engine Shutdown Control Function Chart ………………………………………………... 58

Appendix A

Appendix B (OEM Data Sheets)

 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
 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.
 SAFETY

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.
 SAFETY

GENERAL SAFETY
General Safety Information

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.

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

38 Gul Drive
Jurong, Singapore 629486
Tel: (65) 6558 7789
Fax: (65) 6558 7977
 INTRODUCTION

The Pyroban safety kit are fitted to the Perkins Engine 1006.6TG 2A.

The principal items supplied are:

INLET SYSTEM components:

 Chalwyn SVX-520
 Intake flametrap ILS 5‖

EXHAUST SYSTEM components:

 Exhaust Manicooler
 Exhaust flame arrestor
 Dummy exhaust flame arrestor
 Exhaust flexible (flanged)
 Exhaust spark arrestor

CONTROL SYSTEM components:

 Coolant temperature probe

 Exhaust gas temperature probe
 Over speed valve Chalwyn shut down valve SVX-520
 Engine start button
 Engine stop button

MISCELLANEOUS components:

 Exhaust gas temperature gauge

 Coolant temperature gauge
 Lube oil pressure gauge
 Hour meter
 Engine breather flame trap
 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. As the system has a manually operated hydraulic starting system, manual input is
necessary. Once the start button is pressed, move to the hydraulic starting system and wait until
the signal light is on. When the light is on, depress the foot switch to crank the engine. The system
will turn the light on for 10 seconds, then off for 6 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.
 MECHANICAL INSTRUMENTATION

INSTRUMENTATION & CONTROL PANEL ORIENTATION

INSTALLATIONS

The exhaust gas temperature gauge, coolant temperature gauge and oil pressure gauges are supplied
as loose items.
Exhaust gas temperature gauge is mounted on the exhaust pipe by the 1/2‖ NPT fitting after the
exhaust spark arrestor, with the probe protruding into the exhaust gas.
To fit coolant temperature gauge, remove the 3/8‖ adaptor and 5/8‖ UNF thread should be mounted
directly into the thermostat housing.
Oil pressure indicator heads should be panel mounted at a convenient location.
The capillary lines for these gauges must be adequately protected against external damage and free
from twisting and bucking. Excess line length must be accommodated by coiling, not cutting off the
surplus. Do not place the line past hold or cold sources. When installing the probe, ensure that it is not
forced against any obstruction when tightening the nut. This can lead to an increase in pressure within
the probe and cause incorrect readings. If the probe is touching any obstruction, withdraw
approximately 3mm before tightening the nut.

MAINTENANCE
Visually check the capillary line for damage or deterioration. Check that all fixings are secure and
inspect the unit for mechanical damage. The function of the gauge does not require any special
maintenance procedure, but frequent checks must be made to ensure the instrument is working
correctly and accurately.
 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.

ILS INLET FLAME TRAP

EXHAUST OUTLET
BOX

MANICOOLER
FLAME TRAP
 Typical Manicooler Installation

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

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: 700 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.

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

EXHAUST SYSTEM
STAINLESS STEEL EXHAUST SPARK ARRESTOR
DESCRIPTION

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 arrestor 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.

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 a 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.

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 marked X are not required.

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 8- Weekly 1 Month 3 Months 6 months 2 Years

requirements 12 hrs 50 hrs 200 hrs 500 hrs 1000 hrs 4000 hrs
Exhaust Flametrap: clean
element. o x x x x x
Exhaust Flexible (Water-
Cooled): check exterior for
damages or distress, check x x o x x x
pipework and joints for leaks.
Exhaust System: check the
mechanical integrity of all
pipework/components and x x o x x x
joints.
Exhaust Gas Cooler: remove
carbon. Depending on x x x o x x
application.
Exhaust Manicooler: remove
carbon. x x x o x x
Exhaust Flexible (Dry): check
exterior for damages or
distress, check pipework and x x o x x x
joints for leaks.
Temperature Monitoring
Device: check exterior for x x o x x x
damage.
Spark Arrestor: check exterior
for damages or distress,
check pipework and joints for
leaks, clean interior, perform x x x o x x
visual 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

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.

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

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

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 form 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 fail safe (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.

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 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.
 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 marked X are not required.

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 8- Weekly 1 Month 3 Months 6 months 2 Years

requirements 12 hrs 50 hrs 200 hrs 500 hrs 1000 hrs 4000 hrs
Inlet Flametrap: check
exterior for damages or
distress, check pipework
O X X X X X
and joints for leaks.
Inlet Manifold: inspect
exterior surface for damage
or cracks, check that all
X X O X X X
fixings are secure.
Inlet Shut-Off Valve: check
for correct operation.
X X O X X X
Inlet Air Shut-Off Valve:
visual inspection. Engine X X X O X X
shut-down 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
 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 blanking cap on the radiator neck.

Fit a 13 psi pressure cap on the expansion bottle, unless engine manufacturer specifies otherwise
follow engine manufacturers 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 manufacturers instructions.

Fan Belt Maintenance

1000 hours (6months) 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
 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.

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

13 5 6

9 3

10 4
11
7

12

Intellite MRS15 Genset Controller

 STARTING SYSTEM
Genset Control Buttons

Position Button Description

1 START button. Work in MAN mode only. Press this button to initiate
the start sequence of the engine.

2 STOP button. Works in MAN mode only. Press this button to initiate
the stop sequence of the gen-set. Repeated pressing or holding the
button for more than 2s will cancel current phase of stop sequence
(like ramping the power down or cooling) and next phase will
continue.
3 FAULT RESET button. Use this button to acknowledge alarms and
deactivate the horn output. Inactive alarms will disappear
immediately and status of active alarms will be changed to
―confirmed‖ so they will disappear as soon as their reasons dismiss.
4 HORN RESET button. Use this button to deactivate the horn output
without acknowledging the alarms.

5 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.
NOTE:
This button will not work if the controller mode is forced by one of
binary inputs Remote OFF, Remote MAN, Remote AUT.
6 MODE RIGHT button. Use this button to change the mode. The
button works only if the main screen with the indicator of currently
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

7 Gen-set failure. Red LED starts flashing when gen-set failure occurs. After FAULT
RESET button is pressed, goes to steady light (if an alarm is still active) or is off (if no
alarm is active).
8 Gen-set voltage OKI. Green LED is on if the generator voltage is present and within
limits.
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

9 PAGE button. Use this button to switch over display pages. See
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.

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

right in the history page.

13 Graphic B/W display, 128x64 pixels

 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.
 STARTING SYSTEM

Electrical Starting System and Engine Safety Control

Alarms

Browsing ECU Alarm

 STARTING SYSTEM

Setpoint Change

Entering Password
 STARTING SYSTEM

Controller Information Screen

Display Contrast Adjustment

 DIESEL ENGINE

PERKINS DIESEL ENGINE

Perkins Engine

The 1104C-44TAG2 is a turbocharged, but with an air to water intercooler to cool the induction air
between the turbocharger and the cylinders, 4 cylinder, 4.41 litre engine.

Engine Description

Model 1104C-44TAG2
No. of Cylinder 4 in
Power Output 99.5kWm@1500 rev/min,112.4kWm@1800rev/min
Cylinder Arrangement Vertical, in –line
Cycle 4-stroke
Induction System Turbocharged
Combustion System Direct Injection
Cooling System Water –Cooled
Displacement 4.41 Liters
Bore and Stoke 105mm x 127 mm
Compression Ratio 18.2:1
Direction of Rotation Anti-Clockwise, Viewed on flywheel
Firing Order 1,5,3,6,2,4
Total Lubrication System 8.0 Liters
Capacity
Coolant Capacity 12.6 Liters
(inc radiator)
 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
 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
 DIESEL ENGINE

Schedules
A B C D E Operation
● ● Check the amount of coolant
●
Check the concentration of the coolant (2)
●
● 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

(3)
Ensure that the idle speed is checked and adjusted, if it is necessary.
●
Check the Stanadyne fuel injection pump for governor operation(3)
● ●
● Check the amount of lubricating oil pressure at the gauge(1)
Check the lubricating oil pressure at the gauge(1)
●

●
Renew the engine lubricating oil(4)(5)

● Renew the canisters(s) of the lubricating oil filter(4)

●

●
Renew the canister of the lubricating oil filter ( six cylinder naturally
aspirated engines with a single filter canister)
●

(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.
 DIESEL ENGINE
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 compressor

(2)
casing are cleaned

●
● Clean the compressor air filter(1)
(1) (2)
Ensure that the exhauster or compressor is checked
●
●
Ensure that the valve tip clearances of the engine are checked and if
(2)
● necessary, adjusted

Ensure that the alternator and starter motor are checked(2)

(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.
 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.
 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.

DIESEL ENGINE
 Specific gravity chart

Preventive
A = Percentage antifreeze by volume Maintenance
B = Mixture temperature in Fahrenheit
C = Specific Gravity
D = Mixture temperature in Celsius

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

with
the 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.
 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).
 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.
 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.
 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 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 fro 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.
 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 instructions.
 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.
 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.
 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.
 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.
 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
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

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.
 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.
 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.
 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 cylinder.
 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.
 DIESEL ENGINE
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
ACEA E 2 or E3(1)
API CE, CF4 or CG4(1)
For use in heavy duty applications with a lubricating oil change period of 250 hours.
 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, fro 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.
 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.
 PARTS LIST OF PROTECTION SYSTEM
COMPONENT PART DESCRIPTION
460992 AIR FILTER RAIN CAP 1006Y
440062 FTRAP ILS .024‖7.30 3‖ B B
806466 FTRAP ILS 5‖ CHALFLANGE B
201765 GSKT 3‖ BS10 TABLEE FLNG Y
471117 BOLT HEX HD M16x55 Y
616014 WASHER PLAIN M16 Y
618013 WASHER SPRING M16 Y
611025 NUT M16
806612 BRKT INLET F‘TRAP Y
201675 GASKET
814489 INLET PIPE PERKINS 1006 B
806224 EXCOOLER PERKINS 1006.6 B
806657 SUPPORT BRACKET COOLER Y
806242 GASKET MANICOOLER Y
806352/3 STUD M10 325 LONG Y
616011 WASHER PLAIN M10
618010 WASHER SPRING M10
611019 NUT M10 Y
806305 GASKET
814482 WATER COOLED SPACER BLOCK
460741 TURBO CHARGER W/COOLED
812743 ADAPTOR BLOCK TURBO Y
802939 GASKET TURBO ADAPTOR Y
802938 GASKET TURBO
813674 V BAND CLAMP ADAPTOR
501004 V BAND CLAMP
813975 GASKET TURBO DRAIN
813974 FLANGE TURBO DRAIN
813979 GASKET TURBO FEED
813978 FLANGE TURBO FEED
806304 GASKET
814485 CROSSOVER PIPE
813676 GASKET
806352/2 STUD M10 56 LONG Y
616011 WASHER PLAIN M10 Y
618010 WASHER SPRING M10 Y
611019 NUT M10 Y
806312 GASKET OUTLET BOX TURBO Y
806298 OUTLET BOX TURBO ADA Y
609216 BOLT HEX HD M10x115mm Y
616011 WASHER PLAIN M10 Y
618010 WASHER SPRING M10 Y
806304 GASKET OUTLET BOX Y
601199 SCREW HEX HD M10x35mm Y
616011 WASHER PLAIN M10 Y
618010 WASHER SPRING M10 Y
806429 HOSE TURBO PERKINS Y
806516 WATER PIPE PERKINS1006.6 B
420213 SILICON HOSE 2‖ID Y
470273 CLIPJUB 2x45mm-60mm Y
802507/53 FTRAP 210/5/50/L C
39935 FTRAP DMY 210HP HD L/S Y
 PARTS LIST OF PROTECTION SYSTEM

39818 KIT FIXING 210HP

806344 BOX OUTLET 210HP 4‖ ANSI Y
807799 EXHFLX 4‖ BORE FLANGE B
440413 SPKAR 4‖ ANSI S/S 316 B
500942 GSKT 4‖ ANSI R/F/ RING Y
609220 BOLT HEX HD M14x50mm Y
616013 WASHER PLAIN M14 Y
618012 WASHER SPRING M14 Y
614066 NUT M14 Y
304381 FTRAP EXH BACK PRESS ASSY
440236 FTRAP EOL ¾‖NPT C
460346 DIPSTICK GAUGE Y
201450 DIPSTICK GLAND MODIFCATN
460347 DIPSTICK TUBE ADAPTOR Y
460997 HOUSING FLYWHEEL SAE2 Y
491039 RAD & FAN ASSY 1006.6 B
420213 SILICON HOSE 2‖ID
460796 W/COOLED TURBO Y
510039 GAUGE VIBR HOUR VER PAN Y
510129 GAUGE OIL PRES 0-100 PSI E
480293 GAUGE COOL. TEMP 0-120C SS
480254 GAUGE EXH TEMP 0-250C SS E
805213 LABEL ZONE 2. CAT.3G Y
814278 SKID FRAME Y
814311 LIFTING EYES Y
814308 ENGINE MOUNT REAR Y
814309 ENGINE MOUNT FRONT Y
814313 ALTERNATOR SPACER
814312 ENCLOSURE BRACKET Y
814310 ENGINE MOUNT SPACER Y
70774/K11344P START ENCL ASSY Y
810974 BATTERY ASSEMBLY ESB75 Y
60412 ESB75 OFFSHORE KIT ASSY Y
936247 CABLE NEK6069 1x50mm2 B
804129 SMOTR FLAMEPROOF FPS23 A
480474 VALVE AIR SHUTOFF 5‖ A
450582 HOSE ADAPTOR 5‖-4‖
990419 CABLE TRAY SS 75MM Y
990432 CABLE TRAY FIXINGS SS Y
990424 CABLE TIE SS 201x4.6 Y
811697 ENCLOSURE ZONE 1 + GLASS C
EP30475 COOLANT TEMPERATURE SENSOR (PT1000)
EP30477 EXHAUST TEMPERATURE SENSOR (PT1000)
360-081-032-014C VDO PRESSURE SENDER
ESD5120CE SPEED CONTROLLER
M319 MAGNETIC SPEED SENSOR
IL-NT-MRS15 MANUAL REMOTE START CONTROL
 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
Oil Pressure 0.8bar x
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
Electrical Wiring Diagram