@ Perkins Proprietary Information of Perkins Engines Company Ltd., © 2000

@ PerkinsProprietary Information of Perkins Engines Company Ltd., © 2000.


4000 Series Features & Benefits

ServiceReliability

Components

Durability


4000 Series Common Components

Crankshafts

• One spec per engine

• All cranks heat treated

• Balanced on site

Benefits

• Only one component to buy

• Journals and pins can be re-ground for engine overhauls



Big End & Main Bearings

• All Aluminium Alloy

(Diesel and Gas)

Benefits

• Only one specification

• Resistant to Nitrous Oxides.

• Better part Pricing.

• Reduced Inventory



Con Rods

• Two types; Low and High Power

• Graded by Weight

Benefits

• Each Rod can be serviced separately

• Can accommodate oversize bearings



Cylinder Heads

• Single Head per Cylinder

• 4 valves per head

• Two types; In-line and Vee

Benefits

• All Fully assembled

• Easily serviceable

• Re-manufactured versions available

• Efficient Combustion



Cylinder Heads

The difference between an in-line and Vee cylinder headlies in the oil drain. The in-line engine drains through the ‘push rod’ hole whereas on the Vee engine the oil drains through a special drain hole.

Oil Drain Hole (Vee Engines).



Pistons

• Valve cut-outs on crown for diesel

• Internal oil cooling Gallery

• High Power density - Heavier

Benefits

• Gallery Cooling increases durability

• Common on all engines




Cylinder Liners

• Wet liners only

• All engines, same bore and stroke

• Two grooves and two ‘O’ rings per liner

Benefits

• Allows one change of Piston rings before replacement

• Easily replaced




Inlet & Exhaust Valves

• 4 valves per head

• one piece valves

• Stellite tipped for durability

• Valve seat inserts cryogenically fitted

• 2 rockers per cylinder

• Stellite tipped rocker arms for durability

Benefits

• Durable and easily serviceable

• Common Component

• Reduced inventory



Turbochargers

• Usually one per In-line engine

• 2 per vee engine

• 4 for vee-16

Benefits

• Easily accessible

• Repair kits available (bearings and seals)

• Re-manufactured units available



Oil Pumps

• Replacement Pumps only

• Re-manufactured units may be available

Benefits

• Easily accessed

• Volume part, lower cost




Oil Filters

• 3 per in-line engine

• 6 for Vee engines

Benefits

• Easily accessible

• Bypass system available for base load engines



Fuel Injection Equipment

• Lucas Unit Injectors

• One injector type for 90% of engines

• Operated by rocker arm

Benefits

• No high pressure fuel pipes

• Volume part, lower cost




Water Pumps

• 2 pumps per vee engine

• 1 per in-line engine

Benefits

• Service options include;

# Replacement Pump

# Repair kit (excl. housing)

# Re-manufactured units


4000 Series Durability

Engineering Programme;

• Connecting Rod Bearings Analysis

• Connecting Rod Bolts Analysis

• Main Bearing Failures

• Crankshaft Dynamics and Stressing

• Cylinder Block Dynamics

• Piston Geometry and Bore Shape

• Oil and Coolant Circuit Analysis

Predictive Engineering used Extensively

(CAE and FEA )


4000 Series Durability

• Spheroidal Graphite Iron (sgi) crankcase for better strength and stiffness.

• Heat treated Crank fillets

• Improved bearings specification

• Stellite tipped valves reduce wear

• Stellite tipped rocker arms

• Oil gallery cooling on pistons


4000 Series Ease of Service

• Crankcase doors at side of block enable change of conrod bearings without removing sump

• Single side servicing for in-line engines.

• Easily removed cylinder heads.


4000 Series ReliabilitySignificant Reduction in Warranty Costs achieved by:

• Improvements to Main and Con-Rod Bearings

• Con-Rod Bolts

• Increased Monitoring on Con-Rods, Crankcase and Crankshaft

• Improvements in Lubrication Circuit

• Improvements in Factory Environment

• Introduction of Full Strip Investigation Process

• Use of Predictive Tools at Design Stage

• Re-Definition of Prime Ratings


4000 Series FAB’s summary

• Range of common parts - Reduced Inventory costs

• Improved Durability - Longer Component Life

• Improved Reliability - Less Down Time

• Ease of service - Contributes to overall Cost of Ownership

Documents

@ Perkins Proprietary Information of Perkins Engines Company Ltd., © 2000