KENR6944-00

July 2008

Systems Operation
Testing and Adjusting
4012-46A Industrial Engine
S12 (Engine)
KENR6944 21
Testing and Adjusting Section

Testing and Adjusting

Section

Electronic Control System

i02857716

Engine Governing - Adjust

The engine is governed by the Pandaros Digital

Governor. In order to make adjustments to the
Pandaros Digital Governor, refer to Special
Instruction, REHS2806, “Pandoras Digital Governor”
for more information.
22 KENR6944
Testing and Adjusting Section

Fuel System i02990052

Checking Engine Cylinders

i01938966

General Information (Fuel

When the engine is under load, the temperature of
System) an exhaust manifold port can indicate the condition
of a fuel injector. Low temperature at an exhaust
manifold port is an indication of no fuel to the cylinder.
This can possibly indicate an injector with a defect
Either too much fuel or not enough fuel for or a problem with the control system. An extra high
combustion can be the cause of a problem in the temperature at an exhaust manifold port can indicate
fuel system. Work is often done on the fuel system too much fuel to the cylinder. High temperatures may
when the problem is really with some other part of the also be caused by an injector with a defect.
engine. It is difficult to find the cause of the problem,
especially when smoke comes from the exhaust.
Smoke that comes from the exhaust can be caused i03174241
by a faulty fuel injector. Smoke can also be caused
by one or more of the reasons that follow: Fuel Injector Adjustment
• Not enough air for good combustion
• Oil leakage into combustion chamber Adjust the Fuel Injectors
• Air inlet and exhaust leaks Note: When you adjust three or more fuel injectors,
all the fuel injectors on the engine must be adjusted.
• Not enough compression
Table 1

i02953018 Required Tools

Fuel System Inspection Tool Part Number Part Name Qty

A T6253/147 Injector Compressor 12
Calibration Tool for 12
T6253/177 mm injectors on 1800 rpm 1
A problem with the components that supply fuel to engines
the engine can cause low fuel pressure. This can B
decrease engine performance. Calibration Tool for 14
T6253/353 mm injectors on 1500 rpm 1
1. Check the fuel level in the fuel tank. Look at the engines
cap for the fuel tank. Make sure that the vent is C SE253 Crankshaft Turning Tool 1
not filled with debris.
D - 3 mm Allen Wrench 1
2. Check the fuel lines for fuel leakage. Be sure that 21825496 Dial Gauge 1
none of the fuel lines have a restriction or a faulty E
bend. - Magnetic Base 1

3. Install new main fuel filters.

4. Inspect the pressure valve on the fuel return rail.

KENR6944 23
Testing and Adjusting Section

Calibrating the Fuel Injectors

g01241065
Illustration 17
g01236621
Illustration 14
4. In order to calibrate the fuel injector, position
1. Remove the rocker assemblies. Refer to Tooling (B) with the step against the control arm
Disassembly and Assembly, “Rocker Arm and (3). Adjust the length of the link in order to move
Shaft - Remove” for the correct procedure. the control arm (3) so that NO FUEL line (5) on
Tooling (B) is aligned with the line on the injector.
2. Install Tooling (A) to the rocker bases (1). Tighten
the screws on Tooling (A) in order to compress the 5. Repeat step 4 for the remaining fuel injectors.
fuel injector springs (2). Compress the fuel injector
springs until the control arms (3) are free to move. 6. Remove the wedge (4) from the governor.

7. If a new link is installed, follow steps 7.a and 7.b

in order to adjust the length of the link.

g01470285
Illustration 15

3. Use a wedge (4) in order to set the governor to g01236626

the 5% open position (Y). Illustration 18

a. Ensure that dimension (Z) of the link (6) is

80 mm (3.15 inch) .

g01236623
Illustration 16
24 KENR6944
Testing and Adjusting Section

g01618891
Illustration 21

8. Move the governor actuator in order to position

the control arms (3) of injectors A1 and B1 to the
calibration position. Align the edge of the control
arms (3) with the line (11) on injectors A1 and B1.
g01236693
Illustration 19
9. Check the calibration position of the remaining
injectors. Ensure that all control arms (3) are
b. Install the spacer (8), the link (6) and the allen aligned with the line (11) on the injectors.
head bolt (7) to the control arm (3). Install the
link (6) and the bolt (10) to the break-back lever Note: If any control arms (3) are below the line (11)
(9). Tighten the fasteners to a torque of 8 N·m on the injectors, move the governor actuator and use
(71 lb in). the lowest injector as the calibration point.

10. Recheck the calibration position of the remaining

injectors. Ensure that all control arms (3) are
aligned with the line (11) on the injectors. If
necessary, reduce the lengths of the links (6) in
order to achieve the correct position.

Note: When you tighten the linkage after any

adjustment, ensure that the ball joints stay at 90
degrees to each other. This will allow maximum free
movement.

11. Loosen the screws on Tooling (A). Remove

Tooling (A) from each rocker base (1).

12. Install the rocker assemblies. Refer to

Disassembly and Assembly, “Rocker Arm and
Shaft - Install” for the correct procedure.

Setting the Timing Pins on the Fuel

Illustration 20
g01236628 Injectors
Note: Setting the timing pins on the fuel injectors
should be carried out at the same time as the valve
bridges are equalized and the valve lash is adjusted.
Refer to System Operation, Testing and Adjusting ,
“Valve Lash - Adjust ” for more information.

Note: The timing pin is the reference point for the

start of the fuel injection process.
KENR6944 25
Testing and Adjusting Section

g01236629 g01236632
Illustration 22 Illustration 23
Typical example
Set the timing pins on the fuel injectors and adjust the
valve lash in the sequence that is shown in table 2. Note: The fuel injection timing is shown on the
engine serial number plate. The timing window is
Table 2
located in the flywheel housing of B bank.
4012 Engines
3. Use Tooling (C) in order to rotate the crankshaft
Check and Adjust Valves
Valves on the Rock counterclockwise until the spill timing mark
and the Fuel Injector.
(16) passes the timing pointer (15). Rotate the
A6 A1 crankshaft in the normal direction of rotation until
the spill timing mark (16) is in line with the timing
B1 B6
pointer (15).
A2 A5
B5 B2
A4 A3
B3 B4
A1 A6
B6 B1
A5 A2
B2 B5
A3 A4
B4 B3

1. Set the piston (A1) to top dead center on the

compression stroke. (A6) valves on the rock.

2. Set the engine valve lash (A1). Refer to System

Operation, Testing and Adjusting , “Valve Lash -
Adjust ” g01236630
Illustration 24

4. Loosen the nut (13).

5. Use Tooling (D) in order to rotate the adjuster (12)

in a counterclockwise direction as far as possible.

6. Use a screwdriver in order to apply light pressure

to the timing pin (14). Use Tooling (D) in order to
rotate the adjuster (12) in a clockwise direction
until the timing pin just engages into the injector.
Ensure that the timing pin can move out to the
normal position.
26 KENR6944
Testing and Adjusting Section

Contact with high pressure fuel may cause fluid

penetration and burn hazards. High pressure fu-
el spray may cause a fire hazard. Failure to fol-
low these inspection, maintenance and service in-
structions may cause personal injury or death.

Note: The recommended test oils are Calibration

fluid B or C (Viscosity 38 Redwood at 100º F / 38º
C). Do not use diesel fuel.

1. Ensure that the reservoir of Tooling (C) is filled

to the correct level. Use Calibration fluid B or C
(Viscosity 38 Redwood at 100º F / 38º C). This is
approximately halfway up on the sight tube.

2. Remove the plunger spring assembly from the

injector with a suitable tool. Lift up the spring
plate locating collar over the spring dowel. Then
Illustration 25
g01236631 withdraw the plunger spring assembly from the
element housing.
7. Install Tooling (E) to the rocker base of cylinder.
Position the plunger of Tooling (E) on the top face 3. Install the fuel injector into the clamp. The dowel
of the adjuster (12). Ensure that the dial of Tooling will be at the top.
(E) is set to zero.
4. Grease the oil seal on the adapter for the fuel
Note: Ensure that the plunger of tooling (E) has feed. Push the adapter through the clamp. Push
sufficient travel. the adapter into the housing. Lock into position
with the knurled nut.
8. Use Tooling (D) in order to rotate the adjuster
(12) until the dial on Tooling (E) indicates 3 mm Note: The oil seal on the adapter for the fuel feed
(0.118 inch) of travel. should be renewed after 10 to 15 tests.

9. Tighten the nut (13).

10. Remove tooling (E).

11. Use tooling (C) to rotate the crankshaft in the

normal direction of rotation until the next spill
timing mark (16) is in line with the timing pointer
(15). Set the engine valve lash for the next
cylinder that is shown in table 2. Refer to System
Operation, Testing and Adjusting, “Valve Lash -
Adjust ”. Repeat steps 4 through 10 for the injector
that is in the sequence that is shown in table 2.

Test and Set the Fuel Injectors

Table 3
Required Tools
Tool Part Number Part Name Qty
Fuel Injector Clamp for
A T6253/356 1
14 mm 1500 rpm engine
Fuel Injector Clamp for
B T6253/146 1
12 mm 1800 rpm engine
C T6253/208 Nozzle Testmaster 1
KENR6944 33
Testing and Adjusting Section

i02990055

Measuring Inlet Manifold

Pressure

Table 5
Required Tools
Part
Tool Number Part Description Qty
- Pressure Gauge 1
A Connector
- 3/8 inch BSP 1

The inlet manifold air pressure is a good indication

of the engine load.

g01515162
Illustration 31
Typical example

On 4012-46A TAG engines, in order to measure the

inlet manifold air pressure, connect Tooling (A) to the
position (X). Operate the engine on load.

i02858294

Valve Lash - Adjust

Table 6
Required Tools
Part
Tool Part Name Qty
Number
A SE253 Crankshaft Turning Tool 1
g01376057
Illustration 30
B - Feeler Gauges 1
Typical example

On 4012-46A TWG engines, in order to measure NOTICE

the inlet manifold air pressure, remove the plug from Only qualified service personel should perform this
position (2) from inlet manifold (1). Connect a line maintenance. Refer to the Service Manual or your au-
from the opening to Tooling (A). Operate the engine thorized Perkins dealer or your Perkins distributor for
on load. the complete valve lash adjustment procedure.

Operation of Perkins engines with incorrect valve lash

can reduce engine efficiency, and also reduce engine
component life.
34 KENR6944
Testing and Adjusting Section

Table 7
4012 Engines
Ensure that the engine can not be started while Valves on the Check and
this maintenance is being performed. To help pre- Piston at T.D.C.
Rock Adjust Valves.
vent possible injury, do not use the starting motor
to turn the flywheel. A1 & A6 A6 A1
B1 & B6 B1 B6
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea- A2 & A5 A2 A5
suring/adjusting valve lash clearance. B2 & B5 B5 B2
A3 & A4 A4 A3
Note: The valve bridges must be set before the
valve lash is adjusted. B3 & B4 B3 B4
A1 & A6 A1 A6
B1 & B6 B6 B1
A2 & A5 A5 A2
B2 & B5 B2 B5
A3 & A4 A3 A4
B3 & B4 B4 B3

g01241573
Illustration 32

1. Remove the setscrews (1).

2. Remove the rocker cover (2).

3. Remove the joint (not shown).

4. Repeat Steps1 through 3 for the remaining rocker

covers. Illustration 33
g01236629

4012 Engine
For 4012 engines, set the valve lash in the
sequence that is shown in the Table 7.

g01241570
Illustration 34
Typical example
KENR6944 35
Testing and Adjusting Section

5. Use Tooling (A) in order to rotate the crankshaft

until the appropriate mark (4) on the flywheel is
in alignment with the pointers (3). Ensure that
there is clearance between the rocker arm and
the bridgepiece.

Note: The timing window is located in the flywheel

housing of B bank.

g01241598
Illustration 36

10. Use Tooling (B) in order to check the valve lash.

If necessary, follow Steps 10.a through 10.f in
order to adjust the valve lash. Set the valve lash
to 0.4 mm (0.016 inch).

a. Loosen the locknut (9) on the rocker arm of the

Illustration 35
g01241584 inlet valve.

6. Loosen the locknut (7) on the inlet valve bridge. b. Use Tooling (B) in order to set the valve lash.

7. Turn the adjuster (6) until the fixed pad on the c. Turn the adjuster (8) until the pad on the rocker
valve bridge (5) and the adjuster are in contact arm is in contact with Tooling (B).
with the valve.
d. Tighten the locknut (7) to a torque of 50 N·m
8. Tighten the locknut (7) to a torque of 50 N·m (37 lb ft).
(37 lb ft).
e. Ensure that the valve lash is correct.
9. Repeat Steps 6 through 8 for the exhaust valve
bridge. f. Repeat Step 10 for the rocker arm of the
exhaust valve.

11. Repeat Steps 5 through 10 for the remaining

rockers.

g01241917
Illustration 37
36 KENR6944
Testing and Adjusting Section

12. Ensure that the rocker cover (2) is clean and free Before you begin inspection of the turbocharger,
from damage. Ensure that the joint face of the be sure that the inlet air restriction is within the
rocker base (10) is clean and free from damage. specifications for your engine. Be sure that the
exhaust system restriction is within the specifications
13. Install a new joint (not shown). for your engine. Refer to Systems Operation, Testing
and Adjusting, “Air Inlet and Exhaust System -
14. Install the rocker cover (2). Inspect”.

15. Install the setscrews (1). Tighten the setscrews to The condition of the turbocharger will have definite
a torque of 4 N·m (35 lb in). effects on engine performance. Use the following
inspections and procedures to determine the
16. Repeat Steps 12 through 15 for the remaining condition of the turbocharger.
rocker covers.
• Inspection of the Compressor and the Compressor
Housing
i02863396

Turbocharger • Inspection of the Turbine Wheel and the Turbine

Housing

Inspection of the Compressor and

the Compressor Housing
Hot engine components can cause injury from Remove air piping from the compressor inlet.
burns. Before performing maintenance on the
engine, allow the engine and the components to 1. Inspect the compressor wheel for damage from a
cool. foreign object. If there is damage, determine the
source of the foreign object. As required, clean
the inlet system and repair the intake system.
Replace the turbocharger. If there is no damage,
go to Step 3.
Personal injury can result from rotating and mov-
ing parts. 2. Clean the compressor wheel and clean the
compressor housing if you find buildup of foreign
Stay clear of all rotating and moving parts. material. If there is no buildup of foreign material,
go to Step 3.
Never attempt adjustments while the machine is
moving or the engine is running unless otherwise 3. Turn the rotating assembly by hand. While you
specified. turn the assembly, push the assembly sideways .
The assembly should turn freely. The compressor
The machine must be parked on a level surface wheel should not rub the compressor housing.
and the engine stopped. Replace the turbocharger if the compressor wheel
rubs the compressor wheel housing. If there is no
rubbing or scraping, go to Step 4.
NOTICE
Keep all parts clean from contaminants. 4. Inspect the compressor and the compressor
wheel housing for oil leakage. An oil leak from
Contaminants may cause rapid wear and shortened the compressor may deposit oil in the aftercooler.
component life. Drain and clean the aftercooler if you find oil in
the aftercooler.
NOTICE
Care must be taken to ensure that fluids are contained a. Check the oil level in the crankcase. If the oil
during performance of inspection, maintenance, test- level is too high, adjust the oil level.
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- b. Inspect the air cleaner element for restriction. If
ing any compartment or disassembling any compo- restriction is found, correct the problem.
nent containing fluids.
c. Inspect the engine crankcase breather. Clean
Dispose of all fluids according to local regulations and the engine crankcase breather or replace
mandates. the engine crankcase breather if the engine
crankcase breather is plugged.
KENR6944 37
Testing and Adjusting Section

d. Remove the oil drain line for the turbocharger. 3. Turn the rotating assembly by hand. While you
Inspect the drain opening. Inspect the oil drain turn the assembly, push the assembly sideways.
line. Inspect the area between the bearings of The assembly should turn freely. Turbine wheel (2)
the rotating assembly shaft. Look for oil sludge. should not rub turbine wheel housing (1). Replace
Inspect the oil drain hole for oil sludge. Inspect turbocharger (3) if turbine wheel (2) rubs turbine
the oil drain line for oil sludge in the drain housing (1). If there is no rubbing or scraping, go
line. If necessary, clean the rotating assembly to Step 4.
shaft. If necessary, clean the oil drain hole. If
necessary, clean the oil drain line. 4. Inspect the turbine and turbine housing (1) for oil
leakage. Inspect the turbine and turbine housing
e. If Steps 4.a through 4.d did not reveal the (1)for oil coking. Some oil coking may be cleaned.
source of the oil leakage, the turbocharger has Heavy oil coking may require replacement of
internal damage. Replace the turbocharger. the turbocharger. If the oil is coming from the
turbocharger center housing go to Step 4.a.
Inspection of the Turbine Wheel a. Remove the oil drain line for the turbocharger.
and the Turbine Housing Inspect the drain opening. Inspect the area
between the bearings of the rotating assembly
Remove the air piping from the turbine housing. shaft. Look for oil sludge. Inspect the oil drain
hole for oil sludge. Inspect the oil drain line
for oil sludge. If necessary, clean the rotating
assembly shaft. If necessary, clean the drain
opening. If necessary, clean the drain line.

b. If crankcase pressure is high, or if the oil drain

is restricted, pressure in the center housing
may be greater than the pressure of turbine
housing (1). Oil flow may be forced in the wrong
direction and the oil may not drain. Check the
crankcase pressure and correct any problems.

c. If the oil drain line is damaged, replace the oil

drain line.

d. Check the routing of the oil drain line. Eliminate

any sharp restrictive bends. Make sure that
the oil drain line is not too close to the engine
exhaust manifold.

e. If Steps 4.a through 4.d did not reveal the

Illustration 38
g00763164 source of the oil leakage, turbocharger (3) has
internal damage. Replace turbocharger (3).
Typical example
(1) Turbine Housing
(2) Turbine Wheel
(3) Turbocharger

1. Inspect the turbine for damage by a foreign object.

If there is damage, determine the source of the
foreign object. Replace turbocharger (3). If there
is no damage, go to Step 2.

2. Inspect turbine wheel (2) for buildup of carbon and

other foreign material. Inspect turbine housing (1)
for buildup of carbon and foreign material. Clean
turbine wheel (2) and clean turbine housing (1) if
you find buildup of carbon or foreign material. If
there is no buildup of carbon or foreign material,
go to Step 3.