Perkins 4006-23TAG1A Instruction Manual

TPD1508E, Issue 1
December 2003
User’s
Handbook
Perkins 4000 Series Inline diesel engine
4006-23TAG1A
4006-23TAG2A
4006-23TAG3A

ii
This publication is written in
Perkins Approved Clear English
This publication is divided into six chapters:
1 General information
2 Engine views
3 Operation instructions
4 Maintenance schedule
5 Engine fluids
6 Fault diagnosis
The following pages contain a detailed table of contents

User’s Handbook, TPD 1508E, issue 1 iii
4000 Series
Contents
1 General information
Introduction . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1
General safety precautions ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3
Viton seals .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4
How to care for your engine .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4
Engine preservation . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5
POWERPART recommended consumable products . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7
Engine identification . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 9
Engine data ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 10
Coolant system data ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 10
Fuel system data ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 10
Governors data .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 10
Lubrication system data .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
Induction system data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
Exhaust system data ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
Flywheel data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
Flywheel housing data ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
Crankshaft data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
Dry weight data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
Engine mounting bolts . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 11
Electrical system data . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12
Protection data .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12

iv User’s Handbook, TPD 1508E, issue 1
4000 Series
2 Engine views
Location of engine parts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 13
3 Operation instructions
How to start the engine . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 15
Normal engine start ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 17
How to stop the engine .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18
Light load operation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 19
4 Maintenance
Maintenance periods .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 21
Maintenance and overhaul schedule ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22
How to drain the cooling system . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 24
How to fill the cooling system .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25
How to drain the water sediment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 27
How to check the tension of the alternator belt . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 28
How to check the tension of the fan belts ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29
How to renew the engine lubricating oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 30
How to renew the lubricating oil filters .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31
How to change the main fuel filter canisters ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 32
How to adjust the bridge piece and set valve clearance . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33
How to clean the crankcase breather element ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 35
5 Engine fluids
Fuel specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
Lubricating oil specification .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 37
Coolant specification .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
Warranty ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 38
6 Engine fault diagnosis
Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 39
Problems and possible causes .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 40
List of possible causes . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 41

User’s Handbook, TPD 1508E, issue 1 1
1
4000 Series
General information 1
Introduction
The Perkins 4006-23 TAG1A, TAG2A and TAG3A engines for electric applications arethe latest developments
from Perkins Engines Company Limited, a world leader in the design and manufacture of high performance
diesel and gas engines.
The purpose of this User’s Handbook is to enable the operator to carry out preventive maintenance on the
engine.
The appropriate section in the User’s Handbook should be read fully and completely understood prior to the
start of the work.
The information contained within the User’s Handbook is based on such information as was available at the
time of going to print. In line with Perkins Engines Company Limited policy of continual development and
improvement that information may change at any time without notice. The engine user should therefore
ensure that they have the latest information before the work is started.
Certain overhaul operations are not advised without the use of special tools, and those operators who are not
equipped to undertake major repairs are urged to consult their Perkins distributor.
When the engine is not in operation, ensure that all covers, blank flanges, doors, etc., are fitted to prevent the
ingress of dirt, etc.
Please quote the engine type and serial number with all your enquiries. This will help us to help you. The type
and serial number are on a plate fitted to the crankcase, see "Engine identification" on page 9.
If any doubt exists in regard to the installation, or application of the engine, the Installation Manual should
be consulted. For further advice contact the Applications Department at Perkins EnginesCompany Ltd.
Oil change intervals may be changed due to operational experience and by agreement with Perkins Engines
company and are subject to oil analysis being carried out at regular intervals.
To ensure that you use the relevant information for your specific engine type, see "Engine data" on page 10.
The "left side" and "right side" of the engine are as seen from the flywheel end.
Danger is indicated in the text by two methods:
Warning! This indicates that there is a possible danger to the person.
Caution: This indicates that there is a possible danger to the engine.
Note: Is used where the information is important, but there is not a danger.

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2User’s Handbook, TPD 1508E, issue 1
4000 Series
Model engine 4006-23 right hand side
Model engine 4006-23 left hand side
A
D1001
JC
B
D1002

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User’s Handbook, TPD 1508E, issue 1 3
4000 Series
General safety precautions
These safety precautions are important. You must refer also 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 spilt. 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 allow sparks or fire near the batteries (especially when the batteries are on charge) because the
gases from the electrolyte are highly flammable. The battery fluid is dangerous to the skin and especially
to the eyes.
!Do not smoke when you are in the working area of the engine.
!Disconnect the battery terminals before a repair is made to the electrical system.
!Do not clean, add lubricating oil, or adjust the engine while it runs (unless you have had the correct training,
even then 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.
!Ensure that the exhaust system from the engine is supported.
!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 the engine runs.
!Do not operate the engine if a safety guard has been removed.
!Do not remove the 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 operator’s 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.
!Ensure that all personal protection equipment for your head, ears, eyes and feet etc, are used when you
are in the working area of the engine.
!Do not wear clothing which is contaminated by lubricating oil. Do not put material which is contaminated
with oil into the pockets of clothing.
!Discard used lubricating oil in accordance with local regulations to prevent contamination.
!Ensure that the control lever of the transmission drive is in the "out-of-drive" position before the engine is
started.
!Use extreme care if emergency repairs must be made in adverse conditions.
!The combustible material of some components of the engine (for example certain seals) can become
extremely dangerous if it is burned. Never allow this burnt material to come into contact with the skin or with
the eyes.
!Always use a safety cage to protect the operator when a component is to be pressure tested in a container
of water. Fit safety wires to secure the plugs which seal the hose connections of a component which is to
be pressure tested. Continued

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4User’s Handbook, TPD 1508E, issue 1
4000 Series
!Do not allow compressed air to contact your skin. If compressed air enters your skin, obtain medical help
immediately.
!Turbochargers operate at high speed and at high temperatures. Keep fingers, tools and debris away from
the inlet and outlet ports of the turbocharger and prevent contact with hot surfaces.
!Fit only genuine Perkins parts, failure to do so can damage the engine and may effect the warranty.
!Do not wash an engine while it runs or while it is hot. If cold cleaning fluids are applied to a hot engine,
certain components on the engine could be damaged.
!Always use lift equipment of the approved type and of the correct capacity to lift heavy engine components.
Never work alone when you operate lift equipment.
Viton seals
Viton is used by many manufacturers and is a safe material under normal conditions of operation.
Some seals used in engines and in components fitted to these engines are made of Viton.
If Viton is burned, a product of this burnt material is an acid which is extremely dangerous. Never allow this
burnt material to come into contact with the skin or with the eyes.
If it is necessary to come into contact with components which have been burnt, ensure that the precautions
which follow are used:
!Ensure that the components have cooled.
!Use neoprene gloves and discard the gloves safely after use.
!Wash the area with calcium hydroxide solution and then with clean water.
!Disposal of components and gloves which are contaminated must be in accordance with local regulations.
If there is contamination of the skin or eyes, wash the affected area with a continuous supply of clean water or
with calcium hydroxide solution for 15 to 60 minutes. Obtain immediate medical attention.
How to care for your engine
Warning! Read the "Safety precautions" and remember them. They are given for your protection and must be
applied at all times.
Caution: Do not wash an engine while it runs or while it is hot. If cold cleaning fluids are applied to a hot engine,
certain components on the engine could be damaged.
This handbook has been written to assist you to maintain and operate your engine correctly.
To obtain the best performance and the longest life from your engine, you must ensure that the maintenance
operations are done at the intervals indicated in the "Maintenance schedule". If the engine is operated in a very
dusty environment or other adverse conditions, certain maintenance intervals will have to be reduced.
Ensure that all adjustments and repairs are done by personnel who have had the correct training.

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User’s Handbook, TPD 1508E, issue 1 5
4000 Series
Engine preservation
N
otes:
!There are three grades of preservation listed below, (together with their applications) for complete engines
and associated equipment, such as radiators, silencers, spares etc.
!For all recommended preservatives contact the Applications Department at Perkins Engines company.
Preservation level ‘A’
Commercial specification for UK/European shipment giving up to 6 months for diesel and 12 months for gas
engines shipping and storage protection when transported by container or lorry.
Preservation level ‘B’
Additional to Level ‘A’ for overseas shipment giving 12 months shipping and storage protection. This treatment
should be adequate under normal enclosed storage conditions of -15 °C to +55 °C and up to 90% relative
humidity for up to 12 months.
Preservation level ‘C’
Additional to Level ‘B’ for UK or overseas shipment when prolonged storage and protection is required for up
to 5 years in tropical temperate, or arctic climates. Also meets preservation to MOD NES 724 Level ‘J’ for UK/
Europe when stored in unheated buildings, or in the open under waterproof covers.
Preservation level ‘A’
Commercial specification for UK/European shipment giving up to 6 months for diesel and 12 months for gas
engines shipping and storage protection when transported by container or lorry.
1 The oil and fuel used on engine test give satisfactory protection for six months after despatch from the
factory
2 The coolant systems shall be flushed through with corrosion inhibited anti-freeze at 50% dilution, see
"Coolant specification" on page 38.
3 After the engine is painted to the appropriate standard, all bright surfaces and unpainted metal shall be
treated with the recommended preservative, brushing quality. (This includes control linkages etc).
4 All openings in the engine, (including points where pipework has been removed and air cleaner inlets etc)
shall be sealed with plugs or blank flanges.
Preservation level ‘B’
Additional to Level ‘A’ for overseas shipment giving 12 months shipping and storage production (for diesel
engines).
1 The oil used on engine test gives satisfactory protection for 12 months after despatch from the factory.
2 The complete fuel system shall be drained including filters, unit injector circuit and fuel tank. This fuel shall
then be replaced by the recommended preservative fluid.
3 The engine shall then be run on the recommended preservative fluid for 5 minutes at idling speed, ensure
the preserving fluid is circulated via the fuel return connection.
4 The engine must be accelerator 2 times briefly to a high idle speed to ensure complete circulation of the
preserving fluid, which then remains in the system after the engine has stopped. Further rotation of the
engine components is to be avoided.
5 The engine oil is then to be drained from the sump.
6 The cooling system shall be drained and flushed through with corrosion inhibited anti-freeze at 50% dilution
with water, see "Coolant specification" on page 38.
7 After the engine is painted to the appropriate standard, all bright surfaces and unpainted metal are to be
treated with the recommended preservative, brushing quality. (This includes control linkages etc).
8 All openings in the engine (including points where pipework has been removed and air cleaner inlets etc)
shall be sealed with plugs or blank flanges.
9 Generator or pump sets etc should have their additional apertures sealed in similar ways. Continued

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6User’s Handbook, TPD 1508E, issue 1
4000 Series
Preservation level ‘C’
Additional to Level ‘B’ for UK or overseas shipment when prolonged storage and protection is required for up
to 5 years in tropical temperate, or arctic climates. Also meets preservation to MOD NES 724 Level ‘J’ for UK/
Europe when stored in unheated buildings or in the open under waterproof covers.
Note: Item numbers: 3,4,5 and 6 do not apply to gas engines.
1 After engine test the oil shall be drained from the sump, filter and oil cooler.
2 Refill with the recommended preservative oil.
3 The complete fuel system shall be drained including filters, unit injector circuit and fuel tank. This fuel shall
be replaced with the recommended preservative fluids.
4 The engine shall then be run on the recommended preservative fluid for 5 minutes at idling speed, ensure
the preserving fluid is circulated via the fuel return connection.
5 During this period, 2 brief accelerations to a high idle speed must be made to ensure complete circulation
of the preserving fluid.
6 The preserving fluid is to remain in the fuel system and further rotation of the engine components is to be
avoided.
7 The engine oil is then to be drained.
8 The cooling system shall be flushed through with corrosion inhibited anti-freeze at 50% dilution, see
"Coolant specification" on page 38.
9 The coolant pump impellor shall be sprayed with the recommended preservative oil film rust preventative.
10 After the engine is painted to the appropriate standard all bright surfaces and unpainted metal are to be
treated with the recommended preservative, brushing quality (this includes control linkages etc).
11 Inlet and exhaust manifolds shall have the recommended preservative vapour phase inhibitor placed in
them before they are sealed normally.
12 Air filters to be sprayed inside with the recommended preservative oil.
13 Plastic plugs are to be fitted to fuel entry points, coolant connections, spare instrument holes in panels and
air filter inlets.
14 Exhaust outlet is to be fitted with steel blanking plate.
15 Coolant hoses are to be treated with silicone grease and wrapped or sleeved with black polythene (silicone
rubber hoses need not be treated).
16 Drive belts are to be removed, wrapped in wax paper and packed in black polythene with silica gel as
desiccant.
17 Starter, alternator, switches, instruments, sensors and wiring are to be sprayed with the recommended
preservative silicone grease.
18 Pulleys, flywheel, starter ring, pinion etc shall be protected by dipped or painted with the recommended
preservative oil film rust preventative.
19 The flywheel housing shall be fitted with a steel blanking plate.
20 Control panels are to have desiccants placed inside.
21 The complete engine assembly shall then be sprayed with the recommended preservative wax film rust
preventative.
The degree of preservation is to be recorded on the Engine Specification and Test Certificate attached to each
engine on despatch.

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User’s Handbook, TPD 1508E, issue 1 7
4000 Series
POWERPART recommended consumable products
Perkins have made available the products recommended below in order to assist in the correct operation,
service and maintenance of your engine and your machine. The instructions for the use of each product are
given on the outside of each container. These products are available from your Perkins distributor.
POWERPART ELC (Extended Life Coolant).
ELC is pre-mixed and protects the cooling system against frost and corrosion. Part number 21820181.(1)
POWERPART Easy flush
Cleans the cooling system. Part number 21825001.
POWERPART Gasket and flange sealant
To seal flat faces of components where no joint is used. Especially suitable for aluminium components.
Part number 21820518.
POWERPART Gasket remover
An aerosol for the removal of sealants and adhesives. Part number 21820116.
POWERPART Griptite
To improve the grip of worn tools and fasteners. Part number 21820129.
POWERPART Hydraulic threadseal
To retain and seal pipe connections with fine threads. Especially suitable for hydraulic and pneumatic systems.
Part number 21820121.
POWERPART Industrial grade super glue
Instant adhesive designed for metals, plastics and rubbers. Part number 21820125.
POWERPART Lay-Up 1
A diesel fuel additive for protection against corrosion. Part number 1772204.
POWERPART Lay-Up 2
Protects the inside of the engine and of other closed systems. Part number 1762811.
POWERPART Lay-Up 3
Protects outside metal parts. Part number 1734115.
POWERPART Metal repair putty
Designed for external repair of metal and plastic. Part number 21820126.
POWERPART Pipe sealant and sealant primer
To retain and seal pipe connections with coarse threads. Pressure systems can be used immediately.
Part number 21820122.
Continued

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8User’s Handbook, TPD 1508E, issue 1
4000 Series
POWERPART Radiator stop leak
For the repair of radiator leaks. Part number 21820127.
POWERPART Retainer (high strength)
To retain components which have an interference fit. Part number 21820638.
POWERPART Retainer (oil tolerant)
To retain components which have an interference fit, but are in contact with oil. Part number 21820608.
POWERPART Safety cleaner
General cleaner in an aerosol container. Part number 21820128.
POWERPART Silicone adhesive
An RTV silicone adhesive for application where low pressure tests occur before the adhesive sets. Used for
sealing flange where oil resistance is needed and movement of the joint occurs. Part number 21826038. (2)
POWERPART Silicone RTV sealing and jointing compound
Silicone rubber sealant which prevents leakage through gaps. Part number 1861108. (2)
POWERPART Stud and bearing lock
To provide a heavy duty seal to components that have a light interference fit. Part number 21820119 or
21820120.
POWERPART Threadlock and nutlock
To retain small fasteners where easy removal is necessary. Part number 21820117 or 21820118.
POWERPART Universal jointing compound
Universal jointing compound which seals joints. Part number 1861117.(2)
(1) Powerpart (ELC) is not recommended for the 4006-23 engine or the 1300 Series.
(2) These product are not recommended for the 4006-23 engine.

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User’s Handbook, TPD 1508E, issue 1 9
4000 Series
Engine identification
The 4006-23 engine consists of a range of six cylinder engines. This range has three basic engine types,
TAG1A, TAG2A and TAG3A.
In this User’s Handbook, the different engines are identified by their engine number and their type as shown
below:
A typical example of an engine number: DGB 060081 U0017 B
The position of the plate for the engine number (A1).
Engine number identification
D Made in Stafford
G Application code
B Engine type
06 Number of cylinders
0081 Fixed build number
U United Kingdom
0017 Number of engines built
B Year that the engine was built
Engine type
A 4006-23TAG1A
B 4006-23TAG2A
D 4006-23TAG3A
A
D1104
1

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10 User’s Handbook, TPD 1508E, issue 1
4000 Series
Engine data
Number of cylinders... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..6
Cylinder arrangement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Vertical, In line
Cycle.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Four stroke compression ignition
Direction of rotation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Clockwise from the front
Nominal bore.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...160 mm (6.299 in)
Stroke. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .190 mm (7.48 in)
Compression ratio.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .13:1
Cubic capacity ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22,92 litres (1398.66 in3)
Firing order. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..1, 5, 3, 6, 4, 2
Cylinder number 1.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Furthest from flywheel
Valve tip clearances cold:
- Inlet.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,40 mm (0.016 in)
- Exhaust ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..0,40 mm (0.016 in)
Coolant system data
Recommended coolants to conform to.. ... ... ... ... ... ... ... ... ... ... ... ... ... ."Coolant specification" on page 38
Total coolant capacity ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 105 litres (23 gal)
Engine shut down temperature.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...105 °C (221 °F)
Thermostat opening temperature... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...71 °C (159.8°F)
System pressure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .50 kpa to 70 kpa (0,5 to 0,7 bar)
Coolant jacket heater:
Heater ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...1 x 2 kw
Fuel system data
Recommended fuel to conform to.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Class A2
Relief valve setting. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...276 kpa (40 lb/in²)
Injector nozzle pressure. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...230 atm
Injection equipment ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... Combined unit injector
Filter/water separator. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Canister type
Fuel lift pump ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Maximum suction head 2,5 metres
1500 RPM flow rate ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...660 litres per hour
1800 RPM flow rate ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...810 litres per hour
Governors data
Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . Digitalelectronic

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User’s Handbook, TPD 1508E, issue 1 11
4000 Series
Lubrication system data
Recommended oil ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... APICG4 15W/40
Wet sump, external engine mounted oil pump.
Total oil capacity with oil cooler and filter ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 122,7 litres (27 gal)
Sump capacity dipstick minimum ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 90,9 litres (20 gal)
Sump capacity dipstick maximum ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 113,6 litres (25 gal)
Minimum oil pressure to the bearings, at rated speed. ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 200 kpa (28 lb/in²)
Crankcase pressure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 25 mm watergauge
Maximum oil temperature to the bearings... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..105 °C (221°F)
Normal oil temperature to the bearings... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...80 °C (176 °F)
Lubricating oil filters. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..canister type
Induction system data
Twin air filters (element type) . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... std filters
Maximum air intake depression... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 381 mm H 2 O (28 mm Hg)
Air restriction indicator setting . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 380 mm H 2 O
Turbocharger... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..MHI x 2
Exhaust system data
Manifold type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .Dry
Exhaust outlet size (internal) ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 152,4 mm 5.999 in
Mating flange Tag1A, Tag2A and Tag3A . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... BS4 1 x 10" Table "D"
Mating flangeTag1A, Tag2A and Tag3A .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2 x 6" Table "D
Exhaust back pressure TAG1A ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .7 kpa (0,07 bar)
Exhaust back pressure TAG2A ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .6 kpa (0,06 bar)
Exhaust back pressure TAG3A ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .6 kpa (0,06 bar)
Flywheel data
SAE size.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 18 in
Number of teeth on the gear ring. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 190
Flywheel housing data
SAE size.. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 0
Crankshaft data
Maximum overhung weight on rear bearing ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 1000 kg
Damper Tag1A,Tag2A and Tag3A... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1 x 18 in
Note: A different type of damper may be fitted, for more information contact your Perkins Dealer/Distributor.
Dry weight data
Engine dry weight ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 2524 kg
Engine wet weight .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 2663 kg
Engine mounting bolts
Bolt size... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...20 mm
Bolt number. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6

Electrical system data
Type... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...Insulated return
Alternator output ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...40 amps at a stabilized output of 28 volts
Starter motor power ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .7,5 kW
Number of teeth on the starter motor pinion .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12
Battery capacity cold cranking .. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 540 amps
Number of batteries ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2 x 12 volt
Protection data
Caution: Before resetting protection equipment, it must be established whether special settings (for that indi-
vidual engine) have been specified in the engine sales contract. This is particularly important with all high
water temperature settings.
Shutdown switches
High Oil temperature alarm ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...110 °C (230 °F)
High Oil temperature shutdown . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...115 °C (239 °F)
Low oil pressure alarm... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 2.06 bar (30 lb/in²)
Low oil pressure shutdown ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 1.93 bar (28 lb/in²)
High water temperature 71°C Thermostat alarm... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 103 °C (217.4 °F)
High water temperature 71°C Thermostat shutdown. ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ...105 °C (221 °F)
Caution: The above standard settings do not supersede any settings specified in the engine sales contract.
Overspeed . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..15% on 1500 rev/min
Overspeed . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7% on 1800 rev/min

User’s Handbook, TPD 1508E, issue 1 13
2
4000 Series
Engine views 2
Location of engine parts
Right hand side of the 4006-23 engine
1 Twin air filters
2 Governor lever
3 Filler cap for the lubricating oil
4 24 Volt alternator
5 Fuel lift pump
6 Radiator drain plugs
7 Fuel filter/water separator
8 Engine oil pump
9 Fuel hand prime pump
10 Drain plug for the lubricating oil
11 Lubricating oil dipstick
12 Lubricating oil filters
13 Starter relay
14 24 Volt Starter motor
15 Lubricating oil cooler
A
D1001/1
1
14
13
5
12 11 7
3
4
10 9 6
15
8
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14 User’s Handbook, TPD 1508E, issue 1
4000 Series
Left hand side of the 4006-23 engine
1 Twin turbochargers
2 View hole for timing mark
3 Crankshaft inspection cover
4 Sump drain plug
5Drive belt tension screw
6 Engine breather
7 Engine protection switch
8 Air to air charge cooler
9Radiator
B
D1002
7
4
2
6
5
1
3
JC
89
JC

User’s Handbook, TPD 1508E, issue 1 15
3
4000 Series
Operation instructions 3
How to start the engine
Several factors affect engine start, for example:
!The power of the batteries
!The performance of the starter motor
!The viscosity of the lubricating oil
!The type of engine start switch
!The type of engine stop arrangement.
Note: The type of start switch and stop arrangement shown in this chapter are a Perkins option.
Initial start
C
autions:
!Before the engine is started for the first time, or if the engine has stood idle for more than three months, the
crankshaft and turbocharger bearings must be primed.
!Do not start the engine under load.
!The air shut off valves (if fitted) must be in the open position (A2) to start the engine.
Note: Each air shut off valve has two positions. (A1) closed and (A2) open.
!Prime the fuel system
!Check that the air shut off valves are in the open position
!Prime the oil system
!Start the engine with no load.
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16 User’s Handbook, TPD 1508E, issue 1
4000 Series
How to prime the fuel system
Caution: Clean away all fluid before the engine is started.
1 Turn on the fuel feed from the day tank and loosen the union on the tee-piece (A1).
2 Operate the priming pump (A2) until fuel free from air flows from the union, tighten the union (A1) securely.
3 Loosen the union on the fuel feed pipe (B1) at the flywheel end of the fuel rail (B3). Operate the priming
pump (A2), until fuel free from air flows from the union, tighten the union (B1) securely.
4 Loosen the union (B2) and the fuel return union (B4). Operate the priming pump (A2) until fuel free from air
flows from the unions, tighten the unions securely.
Note: One cylinder will be primed and a amount of fuel will have reached other cylinders. After the oil system
is primed, the engine will run in this condition if a little unevenly until air is fully vented from the system.
D1046
2
1
A
D104
7
B
2
4
13