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Megagen DPR45

1. This document is printed from SPI Not for Resale 6 SEBU7833 03 Safety Section General Hazard Information 02328435 General Hazard Information 4 WARNING LL Illustration 3 g0 1682820 The ether warning label 2 is located on the cover of the inlet manifold Refer to illustration 4 Illustration 5 g00104545 Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment p R X IA 9 PEL g0 1682833 Illustration 4 g00702020 Illustration 6 Typical example Wear a hard hat protective glasses and other protective equipment as required Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine Make sure that all protective guards and all covers are secured in place on the engine Keep the engine free from foreign material Remove debris oil tools and other items from the deck from walkways and from steps Never put maintenance fluids into glass containers Drain all liquids into a suitable container Obey all local regulations for the disposal of liquids Use all cleaning solutions with care This document is printed from SPI Not for Resale SEBU7833 03 Report all necessary repairs Do not allow unauthorized personnel on the equipment Ensu
2. Fill the cooling system with an approved antifreeze mixture because this gives protection against corrosion The maximum flow rate is 1 L 0 2200 Imp gal per minute in order to fill the system Note Certain corrosion inhibitors could cause damage to some engine components Contact the Service Department of Perkins for advice 8 Operate the engine for a short period in order to circulate the lubricating oil and the coolant in the engine Disconnect the battery Put the battery into safe storage in a fully charged condition Before the battery is put into storage protect the terminals against corrosion 1734115 POWERPART Lay Up 3 can be used on the terminals 10 Clean the crankcase breather if one is installed seal the end of the pipe 11 Remove the fuel injector nozzles and spray 1762811 POWERPART Lay Up 2 for one or two seconds into each cylinder bore with the piston at BDC 12 Slowly rotate the crankshaft for one complete revolution and then replace the fuel injector nozzles Induction System Remove the air filter assembly If necessary remove the pipes that are installed between the air filter assembly and the turbocharger Spray 1762811 POWERPART Lay Up 2 into the turbocharger The duration of the spray is printed on the container Seal the turbocharger with waterproof tape Exhaust System Remove the exhaust pipe Spray 1762811 POWERPART Lay Up 2 into the turbocharger The duration of th
3. RENTAL SERIES GENERATOR SET gt gt aiie DAZ AYA A r wW ATAY 7 epee lees a WV megacgen l RENTAL SERIES ELECTRICAL GENERATOR VEC OIE E A E E EEA A E E A EE S A E EAA E AET 2 1 BASIC SAFETY RULES Q cccccccccccecceccececcecceccececcaccececcecceceesecceccecaeceecuscececcecaeseees 3 2 INSTALLATION OF THE ELECTRICAL GENERATOR 2cceccececceccececceccecececceceass 5 2 1 SOUND INSULATION 0c ccccccececceccecceccccucceccecuccuccececcuucecaucuucuuaecsecausueaecaeeeuaeees 7 2 2 CONTROL UNITS cccccccceccececcecceccecccucceccecuccuccuceesuccuuauceecucaucuucueaecuecuuaureecaeeauaes 7 2 2 1 GPM 2 ANALOG CONTROL MODULE 10000 ccccccccecccccceccecceceececceccsceesecsecesesses 9 2 2 2 DEEP SEA DIGITAL CONTROL MODULE c cccccccccsscccccccccccccteccecnseneeseenes 10 2 2 3 INTELIGEN DIGITAL CONTROL MODULE 0 0 cccecescscceccecccceececceenscesnenereens 11 2 3 TRAILER cccccececcecceccececcecceccececcecaccecceccecsececcuccecsecuccucauceucuccecaucecceceesaccencecansess 12 3 INSTALLATION OF THE ELECTRICAL GENERATOR c ccccceececceccececcecceceeceeees 13 3 1 UNLOADING AND TRANSPORT cccscseceececceccececcececcucceccececcuccuceecacsesseseeseees 13 3 2 INSTALLTION OF PORTABLE UNITS cccccecceccecccecceccececceccececcueeececeeeeeees 15 3 2 1 PLACEMENT eeren ERE EAA EAE AA
4. Before Starting Engine Before the engine is started perform the required daily maintenance and any other periodic maintenance that is due Refer to the Operation and Maintenance Manual Maintenance Interval Schedule for more information e For the maximum service life of the engine make a thorough inspection within the engine compartment before the engine is started Look for the following items oil leaks coolant leaks loose bolts and excessive dirt and or grease Remove any excess dirt and or grease buildup Repair any faults that were identified during the inspection Inspect the cooling system hoses for cracks and for loose clamps Inspect the alternator and accessory drive belts for cracks breaks and other damage Inspect the wiring for loose connections and for worn wires or frayed wires e Check the fuel supply Drain water from the water separator if equipped Open the fuel supply valve if equipped NOTICE All valves in the fuel return line must be open before and during engine operation to help prevent high fuel pressure High fuel pressure may cause filter housing failure or other damage If the engine has not been started for several weeks fuel may have drained from the fuel system Air may have entered the filter housing Also when fuel filters have been changed some air pockets will be trapped in the engine In these instances prime the fuel system Refer to the Operation and Maintenance
5. Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes This document is printed from SPI Not for Resale SEBU7833 03 After cleaning start the engine and accelerate the engine to high idle rom This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary Inspect the fins for damage Bent fins may be opened with a comb Note If parts of the aftercooler system are repaired or replaced a leak test is highly recommended Inspect these items for good condition Welds mounting brackets air lines connections clamps and seals Make repairs if necessary 102322311 Alternator Inspect Perkins recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and correct battery charging Check the ammeter if equipped during engine operation in order to ensure correct battery performance and or correct performance of the electrical system Make repairs as required Check the alternator and the battery charger for correct operation If the batteries are correctly charged the ammeter reading should be very near zero
6. cseeseeeeeeeeeees 52 Aftercooler Core INSD Ct ccceeseeeeeeeeeeeeeeeens 52 Alternator Inspect cccceccecsseeeeesseeeceseeeseaees 53 Alternator and Fan Belts Inspect Adjust ReDlAC Onia a a 53 AdUStMEN rosina a 53 Tals 6 0 9 eee 53 MeEDIACCMON Gricdstal turner terior wilieritinubeaas Veolia 54 B Battery REplaCe cccccsececsseeecseseeceeeeesseeeeees 54 Battery Electrolyte Level Check c seeeeee 54 Battery or Battery Cable Disconnect 55 Before Starting Engine cccccceeeseeeeeeeeeees 10 28 BUM PrEVEnUO enerne ina macau eae tas 7 BatterieS cc ceccceccccsseeceeeeeaeeeeseeeseeeeseeeesegeeseneess 8 COO AN deassue distinc incuetabattnnec E E 8 COINS ERE A PAE FE A T EREE EE 8 C Cold Weather OperatiOn c cccccccsseseeeeeeeeeeeees 33 Hints for Cold Weather Operation 0 33 GUNG the ENGINE sisiane ia pra 34 Recommendations for Coolant Warm Up 34 Recommendations for the Coolant 06 33 Viscosity of the Engine Lubrication Oll 33 Cold Weather Starting ccccccececeesssseeeeeeeeeeees 29 Cooling System Coolant Change cccccee 58 Cooling System Coolant Commercial Heavy Duty CAG sites bg ett e e E T NA 55 DraMa T E 55 Fil loess cesemeannwesanantdaciadanelansscutcidounedasdesiauvedendiuvectasted 56 FIUS I ascseeccens Auth a ie et oh eth 56 Cooling Sy
7. LOCK EARTH LEAKAGE j CIRCUIT BREAKER HOUR METER Onin InteliGen Hiat OLTI a r 1 9 S18 6 l E ENGINE BLOCK HEATER PILOT YELLOW GREEN FUEL BUTTON AUTO FUEL REFILL E Pa SWITCH OPTIONAL EMERGENCY STOP ON GREEN LIGHT gt D i SLAVE MASTER SWITCH OPTIONAL LOAD AMMETER FUEL GAUGE Image 7 CONTROL PANEL FOR THE INTELIGEN CONTROL MODULE USERS MANUAL Page 11 of 62 gt 2 RENTAL SERIES ELECTRICAL GENERATOR i POWER 2 3 TRAILER The generator can be supplied with a trailer for transporting the unit Site Trailer for private use areas only Includes DIN hitch ring safety brake and jockey wheel Note Ask about the possibility of using trailer with drip pan Image 8 TRAILER USERS MANUAL Page 12 of 62 RENTAL SERIES ELECTRICAL GENERATOR 3 INSTALLATION OF THE ELECTRICAL GENERATOR 3 1 UNLOADING AND TRANSPORT The unloading and transport of the unit should only be done by qualified personnel observing certain minimum safety conditions e The ground must be capable of supporting the full weight of the Generator and the forklift e Make sure that the battery is disconnected e Make sure that the fuel tank is empty e Place the open arms of the forklift below the chassis at an equal distance with respect to the lifting frame e With a hoist raise the unit using the lifting frame eyebolt The image below shows a generator unit th
8. _ RATED RATED kW ne HIGH IDLE rpm MAX ALT cfm g01381316 I U Illustration 19 Typical example The label that is shown in illustration 19 is for engines that operate in underground coal mines in North America The label is installed on engines that comply with the Mine Safety and Health Administration MSHA emissions Approved diesel engines shall be identified by an approved mark that is legible and permanent The approved mark is scribed with the approved MSHA number The label should be securely attached to the diesel engine Label for engines that do not comply with emissions EMISSIONS CONTROL INFORMATION Perkins Seba or NT MODEL YEAR 2005 ENGINE DISPLACEMENT This non road engine may be used as a REPLACEMENT engine within the EU as per the provisions of Directive 97 68 EC INFORMATION APPLICABLE TO USA ONLY This non road engine does not comply with either federal non road or California off road engine emission regulation requirements Sale or installation of this engine is a violation of federal and Californian law subject to civil penalty for any purpose other than as an EXPORT ONLY or REPLACEMENT engine Export only engine is indicated by an additional attached tag Hanger No Position Label No 3181A081 Illustration 20 g01156734 This typical example of a label is installed on engines that do not comply with emissions This document is printed from SPI Not for R
9. All batteries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge 101929797 Alternator and Fan Belts Inspect Adjust Replace Inspection To maximize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged 53 Maintenance Section Alternator Inspect For applications that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched The additional load on the new belt could cause the new belt to break If the belts are too loose vibration causes unnecessary wear on the belts and pulleys Loose belts may slip enough to cause overheating To accurately check the belt tension a suitable gauge should be used Illustration 26 g01003936 Typical example 1 Burroughs Gauge Fit the gauge 1 at the center of the longest free length and check the tension The correct tension is 535 N 120 Ib If the tension of the belt is below 250 N 56 Ib adjust the belt to 535 N 120 Ib If twin belts are installed check and
10. Change cccccsseeeeees 65 Fuel System Primary Filter Water Separator Element Re6plaCe inira Wariner 70 Fuel System Secondary Filter Replace 71 Hoses and Clamps Inspect Replace 74 Radiator Clean cccccccseeeeeceeseeeeeeseeeeeeesaeeeeeeeeas 75 Every 1000 Service Hours Engine Valve Lash Inspect Adjust 008 67 Every 2000 Service Hours Aftercooler Core Inspect cccceseeeeeeeeeeeeeeeees 52 Alternator Inspect cccccccecsseeeeeeseeeceseeesaeees 53 Engine Mounts Inspect cccsseeeeeeeeeeseeeeeees 64 Starting Motor Inspect nnenoennenoennensennnnnennnenne 76 Turbocharger Inspect cccceeeeeeeeeeeeeeeeeeaeeeeees 76 Water Pump Inspect cccccceeeeeeeseeeeeeeeeseeeees 78 51 Maintenance Section Maintenance Interval Schedule Every 2 Years Cooling System Coolant Change 0008 58 Every 3000 Service Hours Fuel Injector Test Change ccceceeeeeeeeeeeeees 68 Every 3000 Service Hours or 2 Years Cooling System Coolant Commercial Heavy Duty CANOE Aocteeilosenciel et eee fone 55 Every 4000 Service Hours Aftercooler Core Clean Test cccccceeeeceeeeeees 52 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 59 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change
11. It is not necessary to use aftermarket additives in order to achieve the engine s maximum service life or rated performance Fully formulated finished oils consist of base oils and of commercial additive packages These additive packages are blended into the base oils at precise percentages in order to help provide finished oils with performance characteristics that meet industry standards There are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in finished oil Aftermarket additives may not be compatible with the finished oil s additive package which could lower the performance of the finished oil The aftermarket additive could fail to mix with the finished oil This could produce sludge in the crankcase Perkins discourages the use of aftermarket additives in finished oils To achieve the best performance from a Perkins engine conform to the following guidelines Select the correct oil or a commercial oil that meets the EMA Recommended Guideline on Diesel Engine Oil or the recommended API classification See the appropriate Lubricant Viscosities table in order to find the correct oil viscosity grade for your engine At the specified interval service the engine Use new oil and install a new oil filter Perform maintenance at the intervals that are specified in the Operation and Maintenance Manual Maintenance Interval Schedule S O S Oil analysi
12. USERS MANUAL Page 35 of 62 RENTAL SERIES ELECTRICAL GENERATOR Stop button Red LED MANUAL mode button Red LED Settings Settings AUTOMATIC mode button Settings ENTER Red LED Button to silence alarms Control module Red LED LED test Button for starting up Electrical generator When lit indicates correct readings for Red LED Electrical Generator Configurable LED indicators Red LED Screen indicating the status of the Electrical Generator Down button on the screen menu Button to scroll to next page of screen menu Electrical Generator is Red LED supplying consumers USERS MANUAL Page 36 of 62 RENTAL SERIES ELECTRICAL GENERATOR STARTUP If the LCD screen is off press fo 1 to connect the control module and the LCD screen will turn on Press the button 2 and the LED in the top part of the button will turn on indicating that the unit is operating Press A 5 to start up the unit Follow the instructions detailed in point 5 STARTING AND STOPPING THE UNIT There will be a maximum of 3 startup attempts after which the information screen will display a startup alarm STOPPING THE UNIT Follow the instructions detailed in point 5 STARTING AND STOPPING THE UNIT Press lo 1 to stop the unit The unit will be stopped immediately USERS MANUAL Page 37 of 62 RENTAL SERIES ELECTRICAL GENERATOR ALARMS 5 to silence the audible
13. country the importer is required to notify the manufacturer thereof prior to carrying out the sale transaction 10 NOISE LEVEL SE POWER Electrical Generators produce different acoustic levels depending on the output and soundproofing of the Electrical Generator The noise output is indicated on a sticker affixed to the unit s base frame Each Electrical Generator is provided with a sticker indicating the level of noise output produced see APPENDIX 1 FIGURES The noise level has been measured according to the European directive 2000 14 EC and in compliance with the maximum levels established by the directive 2005 88 EC Noise levels Sales reference dBA 7m DPR 20 DZR 40 7 o 6 66 o 6 66 66 66 69 69 6O 69 69 6O 69 70 Oo 62 Note Ifyou work near the unit for any extended period of time it is advisable to use hearing protection USERS MANUAL Page 58 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER 11 DECLARATION OF CONFORMITY CE SE POWER shall deliver a CE Declaration of Conformity form along with the unit in compliance with the referenced regulations or standardized documents USERS MANUAL Page 59 of 62 2 RENTAL SERIES ELECTRICAL GENERATOR x POWER 12 APPENDIX 1 FIGURES Detail of the unit s nameplate _ Model DPS 100 l2 Normal Output 8260 kW B Power Factor 0 8 lal Nominal Frequency 50Hz Nominal Volt 400
14. generator When lit indicates correct readings for Electrical Red LED Generator Configurable LED indicators Screen indicating the status of the Electrical Generator Down button on the screen menu Event Log button LED lit Electrical Generator is Red LED supplying consumers USERS MANUAL Page 27 of 62 RENTAL SERIES ELECTRICAL GENERATOR STARTUP If the LCD screen is off press fo 1 to connect the control module and the LCD screen will turn on Press the button 2 and the LED in the top part of the button will turn on indicating that the unit is operating Press A 5 briefly to start up the unit Follow the instructions detailed in point 5 STARTING AND STOPPING THE UNIT There is a maximum of 3 startup attempts after which the flashing stop symbol ee will be displayed along with the startup failure indicator The status screen of the Deep Sea 5210 Control Module will indicate all of the possible events of the Electrical Generator This image shows all of the symbols displayed on the LCD screen 8 The LCD display 8 will normally look similar to this Example of the screen indicating the voltage readings for each phase of the Electrical Generator STOPPING THE UNIT Follow the instructions detailed in point 5 STARTING AND STOPPING THE UNIT Press 6 1 to stop the unit The unit will be stopped immediately USERS MANUAL Page 28 of 62 a RENTAL SERIES ELEC
15. installation operation and preventive maintenance Additionally you should have received a specific user manual for the Engine and Alternator electrical setup and a set of keys Should you have any problem with the equipment provided please contact the distributor directly SE POWER as a part of its dedication to constant product improvement will revise its manuals and incorporate the improvements made to supplied units Thus the information contained in this document is subject to change without prior notice and without obligation to update USERS MANUAL Page 2 of 62 POWER RENTAL SERIES ELECTRICAL GENERATOR 1 BASIC SAFETY RULES Safety precautions and recommendations for handling the Electrical Generator supplied by SE POWER 1 Do not allow the unit to be used by non authorized personnel or by minors without adult supervision 2 Use the necessary Individual Protection Equipment 3 Ground the machine 4 Make sure there is sufficient lighting on the control panel 5 Do not install the open skid Electrical Generator outdoors risk of electrocution and inoperability 6 The connection should be made by a qualified electrician in accordance with current norms and regulations An improper connection can cause electrical feedback with electrocution hazards for anyone working with the mains power supply 7 The supply line between the Electrical Generator and the consumers should be protected by means o
16. the engine may not start in an emergency situation SEBU7833 03 Check the starting motor for correct operation Check the electrical connections and clean the electrical connections Refer to the Systems Operation Testing and Adjusting Manual Electric Starting System Test for more information on the checking procedure and for specifications or consult your Perkins dealer or your Perkins distributor for assistance 02184788 Turbocharger Inspect If Equipped A regular visual inspection of the turbocharger is recommended Any fumes from the crankcase are filtered through the air inlet system Therefore by products from oil and from combustion can collect in the turbocharger compressor housing Over time this buildup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quanti ties of oil to enter the air intake and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of oil into a turbocharger under extend ed low idle operation should not cause problems as long as a turbocharger bearing failure has not oc cured When a tur
17. 03 102203595 Cooling System Coolant ELC Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Dispose of all fluids according to Local regulations and mandates NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is needed when the ELC is drained and replaced Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to
18. 3 to the filter bowl 2 6 Locate a new filter element 4 into the filter bowl Press on the element and rotate the element clockwise in order to lock the element into the filter bowl 7 Install the filter bowl 4 into the top of the filter head 5 8 Tighten the filter bowl by hand until the filter bowl contacts the filter head Rotate the filter bowl through 90 degrees Note Do not use a tool to tighten the filter bowl 9 Open the valves for the fuel lines if equipped Spin on filter Turn the valves for the fuel lines if equipped to the OFF position before performing this maintenance Place a tray under the fuel filter in order to catch any fuel that might spill Clean up any spilled fuel immediately Illustration 49 SEBU7833 03 g01121396 1 Filter Head 2 Spin on filter 3 Drain i Clean the outside of the fuel filter assembly Open the fuel drain 3 and drain the fuel into a suitable container Use a suitable tool in order to remove the spin on filter 2 from
19. 57 This document is printed from SPI Not for Resale 52 Maintenance Section Aftercooler Core Clean Test 102322260 Aftercooler Core Clean Test 1 Remove the core Refer to the OEM information for the correct procedure 2 Turn the aftercooler core upside down in order to remove debris Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 3 Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes 4 Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 5 Back flush the core with a suitable cleaner 6 Steam clean the core in order
20. Consult the OEM information for the correct procedure to replace the air cleaner 101909507 Engine Air Cleaner Service Indicator Inspect some engines may be equipped with a different service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendations in order to service the air cleaner service indicator The service indicator may be mounted on the air cleaner element or in a remote location Illustration 36 g00103777 Typical service indicator Observe the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments e Check for ease of resetting The service indicator should reset in less than three pushes e Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum
21. Injection DI diesel engines with fuel sulphur levels over 0 5 percent will require shortened oil change intervals in order to help maintain adequate wear protection SEBU7833 03 Table 12 Percentage of Sulfur in Oil change interval the fuel Lower than 0 5 Normal 0 5 to 1 0 0 75 of normal Greater than 1 0 0 50 of normal Lubricant Viscosity Recommendations for Direct Injection DI Diesel Engines The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start up and the maximum ambient temperature during engine operation Refer to Table 13 minimum temperature in order to determine the required oil viscosity for starting a cold engine Refer to Table 13 maximum temperature in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated Generally use the highest oil viscosity that is available to meet the requirement for the temperature at start up Table 13 Engine Oil Viscosity EMA LRG 1 Ambient Temperature API CH 4 Viscosity Grade Minimum Maximum SAE 0W20 40 C 40 F 10 C 50 F SAE O0W30 40 C 40 F 30 C 86 F SAE 0W40 40 C 40 F 40 C 104 F SAE 5W30 30 C 22 F 30 C 86 F SAE 5W40 30 C 22 F 40 104 F SAE 10W30 20 C 4 F 40 104 F SAE 15W40 10 C 14 F 50 C 122 F Sy
22. LED Flashing red light imminent stoppage Continuous red light stop command Flashing blue see maintenance section Button Button MAN STOP AUTO Flashing or Continuous red light user defined Page 22 of 62 _ RENTAL SERIES ELECTRICAL GENERATOR POWER The GPM 2 control module has three positions STOP Automatic AUTO and Manual MAN Key selectable numbers 14 through 16 of the descriptive chart for the control module STARTUP When the key is turned to Manual Mode position LED indicators for low oil level ea 3 battery charge alternator 2 and preheating 9 will be turned on and after 10 seconds the LED indicator 9 will be turned off at which point the START button es 13 can be pressed to start up the unit Follow the instructions detailed in point 5 STARTING AND STOPPING THE UNIT Note While the key is in the MAN position if the button 13 is not pressed within 20 seconds the control module will shut down the system STOPPING THE UNIT Follow the instructions detailed in point 5 STARTING AND STOPPING THE UNIT Turn the key to the central STOP position USERS MANUAL Page 23 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER INDICATOR LIGHTS AUTO TES 8 Indicates Remote Startup continuous green light turns on when unit is operating remotely 9 Indicates Heating of the unit continuous yellow light turns on when unit i
23. Never operate an engine without water temperature regulators in the cooling system Water temperature regulators help to maintain the engine coolant at the proper operating temperature Cooling system prob lems can develop without water temperature regula tors Many engine failures are related to the cooling system The following problems are related to cooling system failures Overheating leakage of the water pump and plugged radiators or heat exchangers These failures can be avoided with correct cooling system maintenance Cooling system maintenance is as Important as maintenance of the fuel system and the lubrication system Quality of the coolant is as important as the quality of the fuel and the lubricating oil Coolant is normally composed of three elements Water additives and glycol Water Water is used in the cooling system in order to transfer heat Distilled water or deionized water is recommended for use in engine cooling systems 45 Maintenance Section Refill Capacities DO NOT use the following types of water in cooling systems Hard water softened water that has been conditioned with salt and sea water If distilled water or deionized water is not available use water with the properties that are listed in Table 16 Table 16 Perkins Minimum Acceptable Water Requirements Property Maximum Limit Chloride Cl 40 mg L Sulfate SO 100 mg L Total Hardness 170 mg L Tot
24. No 1509 Engine oils that bear the API symbol are authorized by API Illustration 24 g00546535 Typical API symbol Diesel engine oils CC CD CD 2 and CE have not been API authorized classifications since 1 January 1996 Table 11 summarizes the status of the classifications Table 11 API Classifications Current Obsolete CF 4 CG 4 CH 4 CE CF CC CD CF 2 1 CD 2 1 1 The classifications CD 2 and American Petroleum Institute CF 2 are for two cycle diesel engines Perkins does not sell engines that utilize CD 2 and API CF 2 oils Terminology Certain abbreviations follow the nomenclature of SAE J754 Some classifications follow SAE J183 abbreviations and some classifications follow the EMA Recommended Guideline on Diesel Engine Oil In addition to Perkins definitions there are other definitions that will be of assistance in purchasing lubricants Recommended oil viscosities can be found in this publication Fluid Recommendations Engine Oil topic Maintenance Section This document is printed from SPI Not for Resale SEBU7833 03 Engine Oil Commercial Oils The performance of commercial diesel engine oils is based on American Petroleum Institute API classifications These API classifications are developed in order to provide commercial lubricants for a broad range of diesel engines that operate at various conditions Only use commercial oils that meet t
25. Prevention Illustration 7 g00687600 Always use a board or cardboard when you check for a leak Leaking fluid that is under pressure can penetrate body tissue Fluid penetration can cause serious injury and possible death A pin hole leak can cause severe injury If fluid is injected into your skin you must get treatment immediately Seek treatment from a doctor that is familiar with this type of injury Containing Fluid Spillage Care must be taken in order to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the engine Make provision to collect the fluid with a suitable container before any compartment is opened or before any component is disassembled e Only use the tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids e Only use the tools that are suitable for containing fluids and equipment that is suitable for containing fluids Obey all local regulations for the disposal of liquids 02143195 Burn Prevention Do not touch any part of an operating engine Allow the engine to cool before any maintenance is performed on the engine Relieve all pressure in the air system in the hydraulic system in the lubrication system in the fuel system or in the cooling system before any lines fittings or related items are disconnected This document is printed from SPI Not for Resale 8 Safety Section Fire Prev
26. RENTAL SERIES ELECTRICAL GENERATOR POWER 2 2 1 GPM 2 ANALOG CONTROL MODULE If you purchased a generator unit with a GPM 2 control module the electrical panel will look like the following diagram AMMETER VOLTMETER FREQUENCY METER HOUR METER VOLTMETER SWITCH EMERGENCY STOP EARTH LEAKAGE CIRCUIT BREAKER TEMP AND FUEL GAUGE FUEL GAUGE OIL PRESSURE BATTERY GAUGE VOLTMETER OPTIONAL OPTIONAL ENGINE TEMP GAUGE Image 5 CONTROL PANEL FOR THE GPM 2 CONTROL MODULE USERS MANUAL Page 9 of 62 2 RENTAL SERIES ELECTRICAL GENERATOR i POWER 2 2 2 DEEP SEA DIGITAL CONTROL MODULE If you purchased a generator unit with a DEEP SEA control module models 5210 and 5310 the electrical panel will look like the following diagram AMMETER VOLTMETER FREQUENCY METER HOUR METER EMERGENCY STOP DIAGNOSTIC BUTTON EARTH LEAKAGE FUEL GAUGE CIRCUIT BREAKER Image 6 CONTROL PANEL FOR THE DEEP SEA CONTROL MODULE Note The in OFF AUTO mode Button on the control module performs the same function as the Diagnostic Button while USERS MANUAL Page 10 of 62 _ RENTAL SERIES ELECTRICAL GENERATOR POWER 2 2 3 INTELIGEN DIGITAL CONTROL MODULE If you purchased a generator unit with an INTELIGEN control module the electrical panel will look like the following diagram AMMETER VOLTMETER FREQUENCY METER
27. SERIES ELECTRICAL GENERATOR l d 9 d 5 13 Image 2 Detailed view of Image 1 1 Coolant tank hatch 9 Electrical Panel Door 2 Side access door 10 Ventilation grill 3 Fuel tank cap 11 Lifting frame and eyebolt 4 Smoke exhaust 12 Electrical Control Panel 5 Engine 13 Alternator 6 Antivibration feet 14 Electrical power panel 7 Base frame 15 Battery 8 Capot 16 Fuel tank 17 Retention bath USERS MANUAL Page 6 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER 2 1 SOUND INSULATION The supplied unit is soundproofed and includes sound insulating canopy See details on part 11 Image 3 INTERIOR OF A SOUNDPROOFED ELECTRICAL GENERATOR 2 2 CONTROL UNITS The unit provided may be controlled by different modules depending on the type of function it has been designed to perform The following is a generic control panel which contains all of the electrical and mechanical options available USERS MANUAL Page 7 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER AMMETER VOLTMETER FREQUENCY METER LOCK HOUR METER AUTOMATIC CONTROL UNIT fete Ft AN EMERGENCY STOP LOCK LEAKAGE fe EAN p 7N ooo E AUTO FUEL CIRCUIT AA AD AIJ ASI REFILL SWITCH BREAKER OIL BATTERY FUEL GAUGE PRESSURE VOLTMETER B GAUGE OPTIONAL Image 4 GENERIC CONTROL PANEL USERS MANUAL Page 8 of 62 lt
28. System Secondary Filter Replace NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component Element filter Turn the valves for the fuel lines if equipped to the OFF position before performing this maintenance Place a tray under the fuel filter in order to catch any fuel that might spill Clean up any spilled fuel immediately Illustration 47 g01010637 1 Drain 2 Filter bowl 1 Close the valves for the fuel lines if equipped 2 Clean the outside of the fuel filter assembly Open the fuel drain 1 and drain the fuel into a suitable container This document is printed from SPI Not for Resale 72 Maintenance Section Fuel System Secondary Filter Replace g01010595 Illustration 48 3 O ring seal 4 Element 5 Filter head 3 Remove the filter bowl 2 from the filter head 5 Press on the element 4 Rotate the element counterclockwise in order to release the element for the filter bowl and remove the element from the bowl Discard the used element 4 Remove the O ring 8 from the filter bowl and clean the filter bowl Check that the threads of the filter bowl are not damaged 5 Install a new O ring seal
29. Views Illustration 11 9010 12280 1 Valve mechanism cover 4 Fuel injection pump 7 Water pump 2 Crankcase breather 5 Engine oil filter 8 Fan pulley 3 Fuel filter 6 Crankshaft pulley 9 Water temperature regulator housing This document is printed from SPI2 Not for Resale 14 SEBU7833 03 Product Information Section Model Views Illustration 12 g01012281 1 Oil filler cap 4 Turbocharger 7 Flywheel 2 Exhaust manifold 5 Starter motor 8 Air intake 3 Alternator 6 Flywheel housing This document is printed from SPI Not for Resale SEBU7833 03 15 Product Information Section Model Views 1103 Engine Model Views Illustration 13 901011348 1 Alternator 3 Turbocharger oil supply 5 Turbocharger 2 Fan pulley 4 Turbocharger oil drain 6 exhaust manifold This document is printed from SPI Not for Resale 16 SEBU7833 03 Product Information Section Model Views Pi Illustration 14 g01011349 1 Fuel transfer pump 5 Dipstick 9 Water pump 2 Oil filler cap 6 Oil filter 10 Water temperature regulator housing 3 Fuel filter 7 Oil pan 4 Starter motor 8 Crankshaft pulley 02196981 e Naturally aspirated Engine Description Engine Specifications Note The front end of the engine is opposite the Perkins Engines are designed for the following flywheel end of the engi
30. adjust the tension on both belts Adjustment Tr Zl x iT Q 3 E m6 7 f gt oe ea Illustration 27 g01003939 1 Loosen The alternator pivot bolt 2 and the bolt 3 This document is printed from SPI Not for Resale 54 Maintenance Section Battery Replace 2 Move the alternator in order to increase or decrease the belt tension Tighten the alternator pivot bolt and the link bolt to 22 N m 16 lb ft 1 Replacement Refer to the Disassembly and Assembly Manual for the installation procedure and the removal procedure for the belt 102322315 Battery Replace Ay WARNING Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite This can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury a Switch the engine to the OFF position Remove all electrical loads N Turn off any battery chargers Disco
31. at least 40 If the viscosity is below 1 4 cSt at 38 C 100 F use the fuel only in temperatures below 0 C 32 F Do not use any fuels with a viscosity of less than 1 2 cSt at 38 C 100 F Fuel cooling may be required in order to maintain the minimum viscosity of 1 4 cSt at the fuel injection pump There are many other diesel fuel specifications that are published by governments and by technological societies Usually those specifications do not review all the requirements that are addressed in this specification To ensure optimum engine performance a complete fuel analysis should be obtained before engine operation The fuel analysis should include all of the properties that are listed in Table 14 This document is printed from SPI Not for Resale SEBU7833 03 Cooling System Specifications General Coolant Information NOTICE Never add coolant to an overheated engine Engine damage could result Allow the engine to cool first NOTICE If the engine is to be stored in or shipped to an area with below freezing temperatures the cooling system must be either protected to the lowest outside temper ature or drained completely to prevent damage NOTICE Frequently check the specific gravity of the coolant for proper freeze protection or for anti boil protection Clean the cooling system for the following reasons e Contamination of the cooling system e Overheating of the engine e Foaming of the coolant NOTICE
32. be connected to terminals U V W and N or L1 L2 L3 and N or to the socket panels The four pole circuit breakers have copper bus bars to facilitate the connection with conductors and prevent deterioration produced by repeated connecting Depending on the options selected sockets may or may not have individual protection which is distinguished from the general unit protection by the use of an individual circuit breaker for each socket USERS MANUAL Page 16 of 62 RENTAL SERIES ELECTRICAL GENERATOR 3 3 STORAGE If you think your generator will be inactive for a long period of time follow these instructions 1 Press STOP on the control module 2 Press the emergency stop button to avoid future involuntary startups when connecting 3 Empty the fuel tank Make sure the internal protection valve is in the correct position 4 Leave the battery disconnected 5 Avoid storing the unit in areas with high dust accumulation or excessive moisture 6 Do not use pressurized water when cleaning the unit 7 Check your Engine manual for care instructions the manual has been provided along with this booklet 8 For Alternator care instructions please check your Alternator s manual which has been provided along with the document you are now reading USERS MANUAL Page 17 of 62 POWER RENTAL SERIES ELECTRICAL GENERATOR 4 STARTING AND STOPPING THE UNIT To start up the Electrical Generator follow
33. copy of this list for a record Keep the information for future reference Record for Reference Engine Model Engine Serial number Engine Low Idle rom This document is printed from SPI Not for Resale 20 SEBU7833 03 Product Information Section Product Identification Information Engine Full Load rom Primary Fuel Filter Water Separator Element Secondary Fuel Filter Element Lubrication Oil Filter Element Auxiliary Oil Filter Element Total Lubrication System Capacity Total Cooling System Capacity Air Cleaner Element Fan Drive Belt Alternator Belt 02758852 Emissions Certification Film Label for compliant engines Typical examples of emissions labels This document is printed from SPI Not for Resale SEBU7833 03 21 Product Information Section Product Identification Information IMPORTANT ENGINE INFORMATION Engine Family 5PKXL04 4RH2 List Displacement 4 4 ED List RH37881 EPA Advertised kw 86 O 2372 2500 OO Family Max Fuel Rate 0 mm3 stk SN eer Values Init Timing DEG ATDC idle RPM 2001 63 0247 00 9372 2500 O Engine Type Factory Reset if Refer to setting Applicable Manufacturer Settings are to be made with engine at normal operating temperature with transmission in neutral This engine conforms to 2004 U S EPA non road and California off road Regulations for large C I engines and is certified to operate on commercially available diesel fuel Emiss
34. due to faulty Contact Technical Svcs A LED indicator lt Does not stop when Defective Shutdown Press Emergency Stop Button emergency occurs System Contact Technical Svcs w Generator does not Faulty Control Unit Press Emergency Stop Button stop when in Stop Defective Shutdown Contact Technical Sues position System High voltage at no Excessive Speed Contact Technical Svcs load Alternator failure Low voltage at no load peouced sped Contact Technical Svcs Alternator failure Correct voltage but High load Adjust the unit s loads low when on load Underspeed on load Alternator failure Contact Technical Services Voltage meter Voltage unstable damaged Contact Technical Svcs Engine unsteady Make sure nothing is preventing the Various causes unit from functioning properly Unit in operation Strange noise inside Originating in engine s interior meat Contact Technical Svcs Ventilation openings Remove obstructions from internal High Alternator b d d l ilati temperature O structe and external ventilation openings Possible overload Check loads USERS MANUAL Page 55 of 62 POWER RENTAL SERIES ELECTRICAL GENERATOR 8 PROTECTION FROM THE ENVIRONMENT Once the Electrical Generator has been installed it is necessary to clean the packaging accessories electrical tools etc that were used during the installation process When it is time to dispose of the batteries in keeping with Environmen
35. engine is equipped with a sight glass maintain the coolant level in the sight glass Observe the air cleaner service indicator if equipped Service the air cleaner when the yellow diaphragm enters the red zone or when the red piston locks in the visible position Ensure that any equipment that is driven by the engine has been disengaged from the engine Minimize electrical loads or remove any electrical loads This document is printed from SPI Not for Resale SEBU7833 03 102198348 Starting the Engine Ay WARNING Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury Refer to the OMM for your type of controls Use the following procedure to start the engine 1 If equipped move the throttle lever to the full throttle position before you start the engine NOTICE Do not crank the engine for more than 30 seconds Allow the electric starting motor to cool for two minutes before cranking the engine again 2 Turn the engine start switch to the START position Hold the engine start switch in the START position and crank the engine 3 When the engine starts release the engine start switch 4 If equipped slowly move the throttle lever to the low idle position and allow the engine to idle Refer to the Operation and Maintenance Manual After Starting Engine topic 5 If the engine does not start release the engine start switch and allow th
36. finished commercial oil The use of API Base Oil Interchange Guidelines are not appropriate for DHD 1 oils This feature reduces the variation in performance that can occur when base stocks are changed in commercial oil formulations 39 Maintenance Section Refill Capacities DHD 1 oils are recommended for use in extended oil change interval programs that optimize the life of the oil These oil change interval programs are based on oil analysis DHD 1 oils are recommended for conditions that demand a premium oil Your Perkins dealer or your Perkins distributor has the specific guidelines for optimizing oil change intervals API CH 4 API CH 4 oils were developed in order to meet the requirements of the new high performance diesel engines Also the oil was designed to meet the requirements of the low emissions diesel engines API CH 4 oils are also acceptable for use in older diesel engines and in diesel engines that use high sulfur diesel fuel API CH 4 oils may be used in Perkins engines that use API CG 4 and API CF 4 oils API CH 4 oils will generally exceed the performance of API CG 4 oils in the following criteria deposits on pistons control of oil consumption wear of piston rings valve train wear viscosity control and corrosion Three new engine tests were developed for the API CH 4 oil The first test specifically evaluates deposits on pistons for engines with the two piece steel piston This test piston deposit a
37. fuel obtain medical assistence immediately Operate the engine at a fast idle speed in order to identify the faulty fuel injector Individually loosen and tighten the union nut for the high pressure pipe to each fuel injector Do not loosen the union nut more than half a turn There will be little effect on the engine speed when the union nut to the faulty fuel injection nozzle is loosened Refer to the Disassembly and Assembly Manual for more information Consult your authorized Perkins dealer or your Perkins distributor for assistance 102890360 Fuel System Prime If air enters the fuel system the air must be purged from the fuel system before the engine can be started Air can enter the fuel system when the following events occur e The fuel tank is empty or the fuel tank has been partially drained e The low pressure fuel lines are disconnected e A leak exists in the low pressure fuel system e The fuel filter is replaced e A new injection pump is installed 69 Maintenance Section Fuel System Prime Use the following procedure in order to remove air from the fuel system 1 Ensure that all low pressure fuel connections and high pressure fuel lines are installed correctly 2 Turn the ignition key to the RUN position Leave the ignition key in the RUN position for three minutes If a manual purging screw is installed the purging screw should be slackened during priming the fuel system g01003929 Illu
38. help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component Illustration 45 g01118416 1 Screw 2 Element 3 Glass bowl 4 Sensor connection 5 Drain 6 Bottom cover 1 Turn the fuel supply valve if equipped to the OFF position 2 Place a suitable container under the water separator Clean the outside of the water separator 3 Open the drain 5 Allow the fluid to drain into the container 4 Tighten the drain 5 by hand pressure only 5 Hold the element 2 and remove the screw 1 Remove the element and the glass bowl 3 from the base Discard the old element 6 Clean the glass bowl 4 Clean the bottom cover 6 7 Install the new O ring seal Install the bottom cover onto the new element Install the assembly onto the base 8 Install the screw 1 and tighten the screw to a torque of 8 N m 6 lb ft 9 Remove the container and dispose of the fuel Safely 10 Open the fuel supply valve 11 Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime for more information 102211066 Fuel System Primary Filter Water Separator Drain Fuel
39. in this publication are on the basis of information that was available at the time that the publication was written The specifications torques pressures measurements adjustments illustrations and other items can change at any time These changes can affect the service that is given to the product Obtain the complete and most current information before you start any job Perkins dealers or Perkins distributors have the most current information available When replacement parts are required for this product Perkins recommends using Perkins replacement parts Failure to heed this warning can lead to prema ture failures product damage personal injury or death This document is printed from SPI Not for Resale SEBU7833 03 3 Table of Contents Table of Contents ORC WOM Gt hase tis Oi et oiled ca eee 4 Safety Section Safety Messages ccccccccsseeeeeeeseeeesseeeeeeeseaeeeeeeas 5 General Hazard Information cccccsseeeeeeeeeeeeees 6 BUN Proventi sibsctiteatncn tegen iiisrestaneniuivaiwvases 7 Fire Prevention and Explosion Prevention 8 Crushing Prevention and Cutting Prevention 10 Mounting and DISMOUNTING c csesceeseeeeeeeeeeeees 10 Before Starting Engine ccccccccseceeeeseeeeeeseeees 10 Engine
40. instructions that follow SEBU7833 03 Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule The actual operating environment of the engine also governs the Maintenance Interval Schedule Therefore under extremely severe dusty wet or freezing cold operating conditions more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary The maintenance schedule items are organized for a preventive maintenance management program If the preventive maintenance program is followed a periodic tune up is not required The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures Maintenance Intervals Perform maintenance on items at multiples of the original requirement We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder We also recommend that a maintenance record be maintained as part of the engine s permanent record Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment Overhaul Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that int
41. is needed Use the equation that is in Table 25 to determine the amount of Perkins SCA that is required if necessary Table 25 Equation For Adding The SCA To The Heavy Duty Coolant For Maintenance V x 0 014 X V is the total volume of the cooling system X is the amount of SCA that is required Table 26 is an example for using the equation that is in Table 25 Table 26 Example Of The Equation For Adding The SCA To The Heavy Duty Coolant For Maintenance Total Volume Multiplication Amount of SCA of the Cooling Factor that is Required System V X 15 L 4 US gal x 0 014 0 2 L 7 oz This document is printed from SPI Not for Resale 50 SEBU7833 03 Maintenance Section Refill Capacities Cleaning the System of Heavy Duty Coolant Antifreeze Perkins cooling system cleaners are designed to clean the cooling system of harmful scale and corrosion Perkins cooling system cleaners dissolve mineral scale corrosion products light oil contamination and sludge e Clean the cooling system after used coolant is drained or before the cooling system is filled with new coolant e Clean the cooling system whenever the coolant is contaminated or whenever the coolant is foaming This document is printed from SPI Not for Resale SEBU7833 03 103302982 Maintenance Interval Schedule When Required Battery Replace nenna lone itaass 54 Battery or Battery Cable Disco
42. leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE The water separator is not a filter The water separa tor separates water from the fuel The engine should never be allowed to run with the water separator more than half full Engine damage may result NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system This document is printed from SPI Not for Resale SEBU7833 03 Illustration 46 g01118416 1 Screw 2 Element 3 Glass bowl 4 Sensor connection 5 Drain 6 Bottom cover 1 Place a suitable container below the water separator 2 Open the drain 5 Allow the fluid to drain into the container 3 When clean fuel drains from the water separator close the drain 5 Tighten the drain by hand pressure only Dispose of the drained fluid correctly 102469473 Fuel System Secondary Filter Replace Ay WARNING Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To help pre vent possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately 71 Maintenance Section Fuel
43. or 2 again to adjust to the desired setting Press the 10 button to confirm the selection made and select the month The value will start to flash Press 3 or 2 again to adjust the month Lastly set the correct year by pressing the 10 button The year will start to flash Press 3 or 2 again to adjust to the desired setting Press 4 to save the changes made to Date and Time The screen will display the date and time Date and time entered gt RaR ER AEA USERS MANUAL Page 45 of 62 RENTAL SERIES ELECTRICAL GENERATOR 5 5 INTELIGEN DIGITAL CONTROL MODULE Image 14 INTELIGEN CONTROL MODULE USERS MANUAL Page 46 of 62 _ RENTAL SERIES ELECTRICAL GENERATOR POWER RH 1 2 3 4 5 6 7 8 9 7 af amp bee Start l oft fea 10 o B 12 13 14 i a5 p 9 Be 18 audible Deactivates alarm Scrolls different modes through operating Fault reset Start button Stop button Generator present voltage Electrical Generator Failure State of GCB GCB ON OFF State of MCB MCB ON OFF State of Mains Power State of Voltage supplied to consumers Enter Button Selects on screen value Button to cycle through the menus USERS MANUAL OFF MAN lt AUT lt TEST OFF MAN AUT TEST Acknowledges faults and alarms In Manual Mode In Manual Mode Green
44. or perform any lubrication maintenance or repair on this product until you have read and understood the operation lubrication maintenance and repair information Safety precautions and warnings are provided in this manual and on the product If these hazard warnings are not heeded bodily injury or death could occur to you or to other persons The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such as DANGER WARNING or CAUTION The Safety Alert WARNING label is shown below The meaning of this safety alert symbol is as follows Attention Become Alert Your Safety is Involved The message that appears under the warning explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this publication Perkins cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this publication and on the product are therefore not all inclusive If a tool procedure work method or operating technique that is not specifically recommended by Perkins is used you must satisfy yourself that it is safe for you and for others You should also ensure that the product will not be damaged or be made unsafe by the operation lubrication maintenance or repair procedures that you choose The information specifications and illustrations
45. or spilled onto hot surfaces or onto electrical components can cause a fire Fire may cause personal injury and property damage A flash fire may result if the covers for the engine crankcase are removed within fifteen minutes after an emergency shutdown Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system These gases could cause the engine to overspeed Personal injury property damage or engine damage could result lf the application involves the presence of combustible gases consult your Perkins dealer and or your Perkins distributor for additional information about Suitable protection devices Remove all flammable combustible materials or conductive materials such as fuel oil and debris from the engine Do not allow any flammable combustible materials or conductive materials to accumulate on the engine Store fuels and lubricants in correctly marked containers away from unauthorized persons Store oily rags and any flammable materials in protective containers Do not smoke in areas that are used for storing flammable materials Do not expose the engine to any flame Exhaust shields if equipped protect hot exhaust components from oil or fuel spray in case of a line a tube or a seal failure Exhaust shields must be installed correctly Do not weld on lines or tanks that contain flammable fluids Do not flame cut lines or tanks that contai
46. point e A higher energy per unit volume of fuel Note Group 3 fuels reduce the life of the engine The use of Group 3 fuels is not covered by the Perkins warranty Group 3 fuels include Low Temperature Fuels and Aviation Kerosene Fuels Special fuels include Biofuel The cloud point is a temperature that allows wax crystals to form in the fuel These crystals can cause the fuel filters to plug The pour point is the temperature when diesel fuel will thicken The diesel fuel becomes more resistant to flow through fuel lines fuel filters and fuel pumps Be aware of these facts when diesel fuel is purchased Consider the average ambient air temperature for the engine s application Engines that are fueled in one climate may not operate well if the engines are moved to another climate Problems can result due to changes in temperature Before troubleshooting for low power or for poor performance in the winter check the fuel for waxing Low temperature fuels may be available for engine operation at temperatures below 0 C 32 F These fuels limit the formation of wax in the fuel at low temperatures For more information on cold weather operation refer to the Operation and Maintenance Manual Cold Weather Operation and Fuel Related Components in Cold Weather This document is printed from SPI Not for Resale 36 SEBU7833 03 Operation Section Cold Weather Operation 01903588 Fuel Related Components in Col
47. reduce engine efficiency and also reduce engine component life This document is printed from SPI Not for Resale 68 Maintenance Section Fuel Injector Test Change Ay WARNING Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance Ensure that the engine is stopped before measuring the valve lash The engine valve lash can be inspected and adjusted when the temperature of the engine is hot or cold Refer to Systems Operation Testing and Adjusting Engine Valve Lash Inspect Adjust for more information 102198352 Fuel Injector Test Change Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component NOTICE If a fuel injector is suspected of operating outside of normal parameters it should be removed by a qualified technician The suspect fuel injector should be taken to an authorised agent for inspection The fuel injector 1 in illustration 43 has no fuel return The fuel injector 2 has a fuel return SEBU7833 03 Illustr
48. remove a component at an angle only use a link bracket that is properly rated for the weight Use a hoist to remove heavy components Use an adjustable lifting beam to lift the engine All supporting members chains and cables should be parallel to each other The chains and cables should be perpendicular to the top of the object that is being lifted SEBU7833 03 Some removals require lifting the fixtures in order to obtain correct balance and safety To remove the engine ONLY use the lifting eyes that are on the engine Lifting eyes are designed and installed for specific engine arrangements Alterations to the lifting eyes and or the engine make the lifting eyes and the lifting fixtures obsolete If alterations are made ensure that correct lifting devices are provided Consult your Perkins dealer or your Perkins distributor for information regarding fixtures for correct engine lifting i01930351 Engine Storage If the engine will not be started for several weeks the lubricating oil will drain from the cylinder walls and from the piston rings Rust can form on the cylinder walls Rust on the cylinder walls will cause increased engine wear and a reduction in engine service life Lubrication System To help prevent excessive engine wear use the following guidelines Complete all of the lubrication recommendations that are listed in this Operation and Maintenance Manual Maintenance Interval Schedule Maintenan
49. restricted 4 Open the radiator drain tap or remove the drain plug at the bottom of the radiator in order to drain the radiator If the radiator does not have a radiator drain tap or a drain plug disconnect the hose at the bottom of the radiator 5 Flush the coolant system with clean water 6 Install the drain plugs and close the radiator drain tap Install the radiator hose if the radiator hose was previously removed 7 Fill the system with an approved antifreeze mixture The maximum flow rate is 1 L 0 2200 Imp gal per minute in order to fill the system Install the filler cap 8 Run the engine and check for coolant leaks This document is printed from SPI Not for Resale SEBU7833 03 02335364 Cooling System Coolant Extender ELC Add The Perkins Extended Life Coolant ELC does not need the frequent addition of Supplemental Coolant Additives SCA that are associated with conventional coolants The Extender only needs to be added once Check the cooling system only when the engine is stopped and cool 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Extender 3 Add Extender according to the requirements for your engine s cooling system capacity Refer to this Operation and Maintenance Manual Refill Capacities in the Maintenance Section fo
50. several sizes are available Consult your Perkins dealer or your Perkins distributor for the part numbers Use the formula in Table 20 to determine the correct amount of ELC Extender for your cooling system Refer to Operation and Maintenance Manual Refill Capacities in order to determine the capacity of the cooling system Table 20 Formula For Adding ELC Extender To ELC V x 0 02 X V is the total capacity of the cooling system X is the amount of ELC Extender that is required Table 21 is an example for using the formula that is in Table 20 Table 21 Example Of The Equation For Adding ELC Extender To ELC Total Volume Multiplication Amount of ELC of the Cooling Factor Extender that is System V Required X 0 18 L 9 L 2 4 US gal x 0 02 0 05 US gal or 6 fl oz NOTICE When using Perkins ELC do not use standard SCA s or SCA filters Not for Resale 48 Maintenance Section Refill Capacities ELC Cooling System Cleaning Note If the cooling system is already using ELC cleaning agents are not required to be used at the specified coolant change interval Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage Clean water is the only cleaning agent that is required when ELC is drained from the cooling system After the cooling system is drained and after the cooling
51. that is attained lf the service indicator does not reset easily or if the yellow core does not latch at the greatest vacuum the service indicator should be replaced If the new service indicator will not reset the hole for the service indicator may be restricted The service indicator may need to be replaced frequently in environments that are severely dusty This document is printed from SPI Not for Resale 64 Maintenance Section Engine Ground Inspect Clean 101941505 Engine Ground Inspect Clean Inspect the wiring harness for good connections Perkins use the starter motor in order to ground the engine Check the connection on the starter motor at every oil change Ground wires and straps should be combined at engine grounds All grounds should be tight and free of corrosion e Clean the grounding stud on the starter motor and the terminals with a clean cloth e f the connections are corroded clean the connections with a solution of baking soda and water e Keep the grounding stud and the strap clean and coated with suitable grease or petroleum jelly 102323089 Engine Mounts Inspect Note The engine mounts may not have been supplied by Perkins Refer to the OEM information for further information on the engine mounts and the correct bolt torque Inspect the engine mounts for deterioration and for correct bolt torque Engine vibration can be caused by the following conditions e Incorrect mountin
52. turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the intake air clogged air filters which causes the turbocharger to slobber 3 Inspect the bore of the housing of the turbine outlet for corrosion 4 Fasten the air intake pipe and the exhaust outlet pipe to the turbocharger housing 102177973 Walk Around Inspection Inspect the Engine for Leaks and for Loose Connections A walk around inspection should only take a few minutes When the time is taken to perform these checks costly repairs and accidents can be avoided For maximum engine service life make a thorough inspection of the engine compartment before starting the engine Look for items such as oil leaks or coolant leaks loose bolts worn belts loose connections and trash buildup Make repairs as needed 77 Maintenance Section Walk Around Inspection e The guards must be in the correct place Repair damaged guards or replace missing guards e Wipe all caps and plugs before the engine is serviced in order to reduce the chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is pr
53. used If the engine is operating above the normal range and steam becomes apparent perform the following procedure This document is printed from SPI 27 Operation Section Gauges and Indicators 1 Reduce the load and the engine rpm 2 Inspect the cooling system for leaks 3 Determine if the engine must be shut down immediately or if the engine can be cooled by reducing the load Tachometer This gauge indicates engine speed rom When the throttle control lever lt is moved to the full throttle position without load the engine is running at high idle The engine is running at the full load rom when the throttle control lever is at the full throttle position with maximum rated load NOTICE To help prevent engine damage never exceed the high idle rom Overspeeding can result in serious damage to the engine The engine can be operated at high idle without damage but should never be allowed to exceed high idle rpm amount of charge or discharge in the battery charging circuit Operation of the indicator should be to the right side of O zero Fuel Level This gauge indicates the fuel level in the fuel tank The fuel level gauge operates when the START STOP switch is in the ON position Service Hour Meter The gauge indicates operating time of the engine 4 Ammeter This gauge indicates the Not for Resale 28 Operation Section Engine Starting Engine Starting 102194223
54. with normal lubricating oil Cooling System To help prevent excessive engine wear use the following guidelines NOTICE Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged If freezing temperatures are expected check the cooling system for adequate protection against freezing See this Operation and Maintenance Manual General Coolant Information Maintenance section NOTICE To prevent frost damage ensure that all the coolant is removed from the engine This is important if the sys tem is drained after it has been flushed with water or if an antifreeze solution too weak to protect the system from frost has been used VY Illustration 23 g01003928 1 Ensure that the vehicle is on level ground 2 Remove the filler cap of the cooling system 3 Remove the drain plug 1 from the side of the cylinder block in order to drain the engine Ensure that the drain hole is not restricted 25 Operation Section Lifting and Storage Open the tap or remove the drain plug at the bottom of the radiator in order to drain the radiator If the radiator does not have a tap or a drain plug disconnect the hose at the bottom of the radiator Flush the cooling system with clean water Fit the drain plugs and the filler cap Close the tap or connect the radiator hose
55. 03662 1 Drain plug 2 Square hole 3 Filter bowl 1 Place a suitable container under the oil filter Remove the drain plug 1 and the seal from the oil filter This document is printed from SPI Not for Resale SEBU7833 03 2 Locate a suitable wrench into the square hole 2 in order to remove the filter bowl 3 3 Remove the filter bowl 3 and remove the element from the filter bowl Clean the filter bowl Illustration 41 g01003675 4 O ring seal 5 Element 6 Filter head 4 Install a new O ring 4 onto the filter bowl and lubricate the O ring with clean engine oil Install the filter element 5 into the filter bowl 5 Install the filter bowl into the oil filter head 6 Tighten the filter bowl to the following torque 25 N m 18 lb ft 6 Install a new seal onto the drain plug 1 and install the drain plug into the oil filter Tighten the drain plug to the following torque 12 N m 8 lb ft Note Some engines may have a horizontally mounted oil filter This oil filter has a drain plug that is located in the oil filter head Fill the Engine Crankcase 1 Remove the oil filler cap Refer to the Operation and Maintenance Manual for more information on lubricant specifications Fill the crankcase with the proper amount of oil Refer to the Operation and Maintenance Manual for more information on refill Capacities NOTICE If equipped with an auxiliary oil filter system or a re mote oil filte
56. 150 F This document is printed from SPI Not for Resale 58 Maintenance Section Cooling System Coolant Change 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain cock or remove the drain plug on the engine Open the drain cock or remove the drain plug on the radiator Allow the water to drain Flush the cooling system with clean water Fill 1 Close the drain cock or install the drain plug on the engine Close the drain cock or install the drain plug on the radiator NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 2 Fill the cooling system with Extended Life Coolant ELC Refer to the Operation and Maintenance Manual Fluid Recommendations topic Maintenance Section for more information on cooling system specifications Do not install the cooling system filler cap 3 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 4 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level in the expansion bottle if equipped at the correct level 5 Clea
57. 2 r Sediment DAES Water 0 1 maximum D1744 l 0 05 maximum i Sediment weight D473 Gum and Resins 10 mg per 100 D381 3 mL maximum 0 38 mm ane 0 015 inch i H Lubricity 4 ite D6079 25 C 77 F 1 Perkins fuel systems and engine components can operate on high sulfur fuels Fuel sulfur levels affect exhaust emissions High sulfur fuels also increase the potential for corrosion of internal components Fuel sulfur levels above 0 5 percent may significantly shorten the oil change interval For additional information see this publication Fluid Recommendations Engine Oil topic Maintenance Section 2 The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps If a fuel with a low viscosity is used cooling of the fuel may be required to maintain a 1 4 cSt viscosity at the fuel injection pump Fuels with a high viscosity might require fuel heaters in order to bring down the viscosity to a 20 cSt viscosity 3 Follow the test conditions and procedures for gasoline motor 4 The lubricity of a fuel is a concern with low sulfur fuel To determine the lubricity of the fuel use either the ASTM D6078 Scuffing Load Wear Test SBOCLE or the ASTM D6079 High Frequency Reciprocating Rig HFRR test If the lubricity of a fuel does not meet the minimum requirements consult your fuel supplier Do not treat the fuel without consulting the fuel supplier Some additi
58. 230V eee Nominal figures reduce in le Product Class G1 altitudes above 1 000m and See ees surrounding temperatures above 40 C 1 640 Kg Serial No 1692716 Manufacturers Data S0 03 06 D gt Engine uses Diesel fuel at 1 500 rpm P gt Engine manufacturer is P erkins V olvo C ummins or Deut Z R gt The Electrical Generator is Soundproofed Rental Series 100 gt Commercial name 2 Nominal Power 80 kW Nominal Output of Engine expressed in kW 3 Power Factor 0 8 Indicates Power Factor of Alternator 4 Nominal e RGY 50 Nominal Frequency of Electrical Generator Hertz 1 DPR 100 5 Nominal Voltage 400 230 V Nominal Frequency of Electrical Generator Volts When withstanding an overload engine will perform 6 PTOOUCI Crass Gi according to catalogued response times per ISO 8528 7 Weight 1 640 kg Total weight of Electrical Generator 8 Serial no 169216 Serial Number of Generator Manufacture 9 sill hee V Manufacture Date of Electrical Generator CE Marking indicates that Electrical Generator complies with the Relevant Standards USERS MANUAL Page 60 of 62 RENTAL SERIES ELECTRICAL GENERATOR PLACING IN OPERATION Make sure Baay Shei switch is CLOSED l THIS GENERATOR j o oaemessmermarees N SET COULD START muumuu h J ur witnout A PRIOR WARNING M E Biat up ELECTRICAL GENERATOR i To patorm MAINKNTENAHCE turn ihs i BATTERY 2HUTOFF 2V4ITCH to the OFEN T_ Make cure
59. 5 mm 0 018 inch 0 45 mm 0 018 inch Table 3 1104 Genset Specifications Number of Cylinders 4 In Line Bore 105 mm 4 134 inch Stroke 127 mm 5 0 inch Aspiration Turbocharged aftercooled Turbocharged Naturally aspirated Compression Ratios NA 19 25 1 T 17 25 1 T 18 23 1 TA 18 23 1 Displacement 4 4 L 268 in Firing Order 1342 Rotation flywheel end Counterclockwise Valve Lash Setting Inlet 0 20 mm 0 008 inch Valve Lash Setting Exhaust 0 45 mm 0 018 inch This document is printed from SPI Not for Resale 18 Product Information Section Model Views Table 4 1103 Genset Specifications Number of Cylinders 3 In Line Bore 105 mm 4 134 inch Stroke 127 mm 5 0 inch Aspiration Turbocharged Naturally aspirated Compression Ratio NA 19 25 1 T 17 25 1 Displacement 3 3 L 201 in Firing Order 123 Rotation flywheel end Counterclockwise Valve Lash Setting Inlet 0 20 mm 0 008 inch Valve Lash Setting 0 45 mm 0 018 inch SEBU7833 03 Engine Service Life Engine efficiency and maximum utilization of engine performance depend on the adherence to proper operation and maintenance recommendations In addition use recommended fuels coolants and lubricants Use the Operation and Maintenance Manual as a guide for required engine maintenance Expected engine life is generall
60. ART ccceccececcecceccececcecceccccuccuccececcucecuccueaeceecuuaeseecaceeeaes 53 7 TROUBLESHOOTING eaaa a a a E EA EA 55 8 PROTECTION FROM THE ENVIRONMENT 2 c2cceccececceccececceccececcecceceececeueaeceeees 56 9 WARRANTY 2 2ccecceccececcecceccececceccecuucuccucuecuecucuecuccuuaucaueuecuucecesuutececuuaeceeceecutaeseesaeseees 57 CS eat cans capatecae oot ne ein ntsc ard chon einen aaa asian tans doa neon tua enaeetasuaeduabaheienaetaoent 58 11 DECLARATION OF CONFORMITY ccccccccceccecceccececcecceccceccucceccccucaececcueueceecaceauaes 59 12 APPENDIX 1 FIGURES 2 00 0 cece ccc ees cccccecceccececcecceccecuccuccuccecuccuuceceucueaecueeuuaecseceueaeaes 60 13 APPENDIX 2 IMAGE INDEX ccc ccc ccc ccecceccececcecceccececceccuccecuccucuccuccucaecaecuuaeceeseueauaes 62 USERS MANUAL Page 1 of 62 2 RENTAL SERIES ELECTRICAL GENERATOR x POWER WELCOME Thank you for purchasing a SE POWER Electrical Generator The purpose of this manual is to familiarize the user on how to use and work with the Electrical Generator its components and maintenance We recommend carefully reading the manual prior to working with the equipment in order to ensure proper use Save this manual for future reference and if you ever decide to sell the Electrical Generator be sure to include the manual along with the unit The following is a general description of the unit and the necessary information for
61. Coolant at the Initial Fill Commercial heavy duty coolant antifreeze that meets ASTM D4985 specifications MAY require an addition of SCA at the initial fill Read the label or the instructions that are provided by the OEM of the product Use the equation that is in Table 23 to determine the amount of Perkins SCA that is required when the cooling system is initially filled Table 23 Equation For Adding The SCA To The Heavy Duty Coolant At The Initial Fill V x 0 045 X V is the total volume of the cooling system X is the amount of SCA that is required 49 Maintenance Section Refill Capacities Table 24 is an example for using the equation that is in Table 23 Table 24 Example Of The Equation For Adding The SCA To The Heavy Duty Coolant At The Initial Fill Total Volume Multiplication Amount of SCA of the Cooling Factor that is Required System V X 15 L 4 US gal x 0 045 0 7 L 24 oz Adding The SCA to The Heavy Duty Coolant For Maintenance Heavy duty coolant antifreeze of all tyoes REQUIRE periodic additions of an SCA Test the coolant antifreeze periodically for the concentration of SCA For the interval refer to the Operation and Maintenance Manual Maintenance Interval Schedule Maintenance Section Test the concentration of SCA Additions of SCA are based on the results of the test The size of the cooling system determines the amount of SCA that
62. ICE Failure to follow these oil recommendations can cause shortened engine service life due to deposits and or excessive wear Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines The Total Base Number TBN for an oil depends on the fuel sulfur level For direct injection engines that use distillate fuel the minimum TBN of the new oil must be 10 times the fuel sulfur level The TBN is defined by ASTM D2896 The minimum TBN of the oil is 5 regardless of fuel sulfur level Illustration 25 demonstrates the TBN a e a S E Fe e e e e CE Ga a a Fn ie Va a T A e ee a ee oe Oe ea Se aA a d CEA A a T CL AAA T TEE ZAA A Y X Illustration 25 g00799818 Y TBN by ASTM D2896 X Percentage of fuel sulfur by weight 1 TBN of new oil 2 Change the oil when the TBN deteriorates to 50 percent of the original TBN Use the following guidelines for fuel sulfur levels that exceed 1 5 percent e Choose an oil with the highest TBN that meets one of these classifications EMA DHD 1 and API CH 4 e Reduce the oil change interval Base the oil change interval on the oil analysis Ensure that the oil analysis includes the condition of the oil and a wear metal analysis Excessive piston deposits can be produced by an oil with a high TBN These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore NOTICE Operating Direct
63. LC Perkins provides Extended Life Coolant ELC for use in the following applications e Heavy duty spark ignited gas engines This document is printed from SPI Not for Resale SEBU7833 03 e Heavy duty diesel engines e Automotive applications The anti corrosion package for ELC is different from the anti corrosion package for other coolants ELC is an ethylene glycol base coolant However ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite Perkins ELC has been formulated with the correct amount of these additives in order to provide superior corrosion protection for all metals in engine cooling systems ELC extends the service life of the coolant to 12000 service hours or six years ELC does not require a frequent addition of a Supplemental Coolant Additive SCA An Extender is the only additional maintenance that is needed at 6000 service hours or one half of the ELC service life ELC is available in a 1 1 premixed cooling solution with distilled water The Premixed ELC provides freeze protection to 36 C 33 F The Premixed ELC is recommended for the initial fill of the cooling system The Premixed ELC is also recommended for topping off the cooling system ELC Concentrate is also available ELC Concentrate can be used to lower the freezing point to 51 C 60 F for arctic conditions Containers of several sizes are available Consult your Perkins dealer or your Perkin
64. Maintain the electrolyte level to the FULL mark on the battery If the addition of water is necessary use distilled water If distilled water is not available use clean water that is low in minerals Do not use artificially softened water 2 Check the condition of the electrolyte with a Suitable battery tester 3 Install the caps 4 Keep the batteries clean Clean the battery case with one of the following cleaning solutions e Use a solution of 0 1 kg 0 2 Ib baking soda and 1 L 1 qt of clean water e Use a solution of ammonium hydroxide Thoroughly rinse the battery case with clean water This document is printed from SPI Not for Resale SEBU7833 03 102323088 Battery or Battery Cable Disconnect Ay WARNING The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Turn the start switch to the OFF position Turn the ignition switch if equipped to the OFF position and remove the key and all electrical loads 2 Disconnect the negative battery terminal Ensure that the cable cannot contact the terminal When four 12 volt batteries are involved two negative connection must be disconnected 3 Remove the positive connection 4 Clean all disconnected
65. Manual Fuel System Prime for more information on priming the fuel system Ay WARNING Engine exhaust contains products of combustion which may be harmful to your health Always start and operate the engine in a well ventilated area and if in an enclosed area vent the exhaust to the outside SEBU7833 03 Do not start the engine or move any of the controls if there is a DO NOT OPERATE warning tag or similar warning tag attached to the start switch or to the controls Ensure that the areas around the rotating parts are clear All of the guards must be put in place Check for damaged guards or for missing guards Repair any damaged guards Replace damaged guards and or missing guards Disconnect any battery chargers that are not protected against the high current drain that is created when the electric starting motor is engaged Check electrical cables and check the battery for poor connections and for corrosion Reset all of the shutoffs or alarm components if equipped Check the engine lubrication oil level Maintain the oil level between the ADD mark and the FULL mark on the engine oil level gauge Check the coolant level Observe the coolant level in the header tank if equipped Maintain the coolant level to the FULL mark on the header tank If the engine is not equipped with a header tank maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe If the
66. Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi This document is printed from SPI SEBU7833 03 Illustration 34 g00281692 Note When the primary air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements Inspecting the Primary Air Cleaner Elements g00281693 Not for Resale Illustration 35 SEBU7833 03 63 Maintenance Section Engine Air Cleaner Element Single Element Inspect Replace Inspect the clean dry
67. Prevention and Explosion Prevention 8 Fite EXUnQuisne hacntwiswemiwwe a 9 Lines Tubes and HOSES ccceeceeceececeeeeeeeeeees 9 This document is printed from SPI Not for Resale SEBU7833 03 Fluid RecomMMendatiOns cccsseceeeeeeeeeeeeeeees Cooling System Specifications cccceceeee ELC Cooling System Maintenance 00 Enone ON tis cadraiia E R Fuel SPe cifications ccccccccsecceseeeeeeeeeeeeeeeeees General Lubricant Information ceccee OVO WONG ici Nic vaca tae he a a tas California Proposition 65 Warning 008 Literature INformatiOn c cccceeceececeeeececeeeeeeees WiGITOTI ANIC Ci sisisi e aa Maintenance Intervals cccceseeeececeeeeeeeeeees Operation a eee OV Sr aU ls xr sre etree tetieos ss nsensn urate nla aes a CLY erecta E E sates ee E TE T acest Fuel and the Effect from Cold Weather Fuel Conservation PractiCes cccccssseceseeeeeeees Fuel Injector Test Change cccccseeeeceseeeeeeees Removal and Installation of the Fuel Injectors Fuel Related Components in Cold Weather FUGLE MEIO sechecsout certo hau aise ek UCI IFICQICMS naaras a a Fuel TANKS ana Fuel System Prime cccccceeecccseseeeeeseeeeeeeeeeaees Fuel System Primary Filter Water Separator Element Replace ccccssececseseesesseeseeneesneees Fuel System Primary Filter W
68. Starting ccccccseecceeseeeeeeceeeeeeesaeeeeesaeesees 11 Engine Stopping cccccseeeceeceeeeeeeesaeeeeeeeeeeeeeeaeees 11 Electrical System sssrinin eaaa 11 Product Information Section ModelVIEWS cao tee tec eeeet aa ee TA i 13 Product Identification Information 0 19 Operation Section Gftingand Storage deiacnoeii incre tveede Mel dele teicl cee 24 Gauges and Indicators cccceeeeeeseeeeeeeeeeeeeeees 27 ENGINS SLUNG renn a 28 Engine Operation nisiisnuiae 31 Engine Stopping ccccceeeeeecceeeseeeeeeeeeeesaeeeeeeeaeas 32 Cold Weather Operation ccccceesssseeeeeeeeeeees 33 Maintenance Section ETM CAP AaGuleS sanra aa 37 Maintenance Interval Schedule ceeee 51 Warranty Section Warranty Information ccccccccseeeeeeeseeeeeeeeeeaeees 79 Index Section This document is printed from SPI Not for Resale 4 Foreword Foreword Literature Information This manual contains safety operation instructions lubrication and maintenance information This manual should be stored in or near the engine area in a literature holder or literature storage area Read study and keep it with the literature and engine information English is the primary language for all Perkins publications The English used facilitates translation and consistency Some photographs or illustrations in this manual show details or attachments that may be different f
69. TRICAL GENERATOR z POWER Indicates that the screen display information refers to the Electrical Generator Indicates that the Event Log reading is being accessed Flashing Indicates that the Programming Mode is being accessed Indicates that the Electrical Generator is idle Indicates that the Electrical Generator s system date and time is being shown This icon indicates a stoppage or alarm Warning D Stoppage Indicates the percentage of fuel remaining in the generator s tank Indication related to the Battery Indicate Battery level outside established limits Indicates keypad is locked kW and kVAr indicate units of current power Cos Indicates power factor C Measurement given in degrees Celsius F Measurement given in degrees Fahrenheit Measurement related to Alternating Current V Measurement of Voltage A Measurement of Intensity Amperes Indicates Direct Current If Lx Lx is displayed Indicates measurement of phase phase Voltage If Lx N is displayed Indicates measurement of phase neutral Voltage Bar rpm PSI Hz kPa indicate measurement units for the corresponding parameter The lock icon indicates keypad is locked USERS MANUAL Page 29 of 62 RENTAL SERIES ELECTRICAL GENERATOR To view the different parameter readings press and the LCD indicator 8 will display these readings in the following order e RPM of generator frequency Hz e L
70. VoRap and Frequency are comeci i i Poclthon E Bet Electrical Power sahici io CLOSED poston 5 COnn ec cables to connecion team inals on cmuk breaker Image 15 Placing in operation Image 16 Caution with generator Image 17 General warning startup Image 18 Undefined Warning Image 19 Electrical Hazard 230 Image 20 Electrical Hazard Notice Volts 400 Volts Image 21 Lifting point Image 22 Possible battery leakage Image 23 Electrical grounding Image 24 Noise output 90 dB Image 25 Noise output 114 dB Image 26 Use of hearing protection required z 70 mrm 3 LX Image 27 Coolant Flush Image 28 Oil draining Image 29 Fuel draining BATTERY ISOLATOR Image 30 Battery isolator USERS MANUAL Page 61 of 62 POWER RENTAL SERIES ELECTRICAL GENERATOR 13 APPENDIX 2 IMAGE INDEX Image 1 ELECTRICAL GENERATOR WITH CANOPY 5 Image 2 Detailed view of Image 1 6 Image 3 INTERIOR OF A SOUNDPROOFED ELECTRICAL GENERATOR 7 Image 4 GENERIC CONTROL PANEL 8 Image 5 CONTROL PANEL FOR THE GPM 2 CONTROL MODULE 9 Image 6 CONTROL PANEL FOR THE DEEP SEA CONTROL MODULE 10 Image 7 CONTROL PANEL FOR THE INTELIGEN CONTROL MODULE 11 Image 8 TRAILER 12 Image 9 LIFTING FRAME 13 Image 10 GPM 2 CONTROL MODULE 21 Image 11 DEEP SEA 5210 CONTROL MODULE 26 Image 12 DEEP SEA 5210 CONTROL MODULE 26 Image 13 DEEP SEA 5310 CONTROL MODULE 35 Image 14 INTELIGEN CONTROL MODULE 46 Image 16 Placi
71. ain Screen press 11 Note Warning alarms are not logged DISPLAYING INFORMATION Press this button 11 Page order e Status display e Instrument display e Alarms display e Event Log It is possible to scroll through the different display screens by pressing the Next Page button o 10 Once selected the instrument will remain on the screen until the user selects a different instrument or after a period of inactivity for the Control module at which point the default display appears Alternatively by holding down on o 10 the user can autoscroll through all of the instruments on a particular screen To disable scrolling stop pressing the page down USERS MANUAL Page 42 of 62 RENTAL SERIES ELECTRICAL GENERATOR button then either press it again for a few seconds or press 11 When autoscroll is disabled if no buttons are pressed the display will return to the Alarms page If an alarm becomes activated while viewing instruments the Alarms page will be automatically displayed Instrument page content e Engine speed e Oil pressure e Coolant temperature e Engine hours run e Number of starts e DC battery voltage e Generator AC voltage L N e Generator AC voltage L L e Generator Line Current e Fuel level e Nominal voltage L N e Nominal voltage L L e Nominal frequency Hz If the following appears in an instrument display this means that the Engine cannot provi
72. al Solids 340 mg L Acidity DH of 5 5 to 9 0 For a water analysis consult one of the following sources e Local water utility company e Agricultural agent e Independent laboratory Additives Additives help to protect the metal surfaces of the cooling system A lack of coolant additives or insufficient amounts of additives enable the following conditions to occur e Corrosion e Formation of mineral deposits e Rust e Scale e Foaming of the coolant Many additives are depleted during engine operation These additives must be replaced periodically Additives must be added at the correct concentration Overconcentration of additives can cause the inhibitors to drop out of solution The deposits can enable the following problems to occur e Formation of gel compounds e Reduction of heat transfer e Leakage of the water pump seal e Plugging of radiators coolers and small passages This document is printed from SPI Not for Resale 46 Maintenance Section Refill Capacities Glycol Glycol in the coolant helps to provide protection against the following conditions e Boiling e Freezing e Cavitation of the water pump For optimum performance Perkins recommends a 1 1 mixture of a water glycol solution Note Use a mixture that will provide protection against the lowest ambient temperature Note 100 percent pure glycol will freeze at a temperature of 23 C 9 F Most conventional coolant antif
73. al regulations Then fill the cooling system with premixed ELC This should lower the contamination to less than 10 percent e Maintain the system as a conventional Heavy Duty Coolant Treat the system with an SCA Change the coolant at the interval that is recommended for the conventional Heavy Duty Coolant This document is printed from SPI Not for Resale SEBU7833 03 Commercial Heavy Duty Coolant Antifreeze and SCA NOTICE Commercial Heavy Duty Coolant which contains Amine as part of the corrision protection system must not be used NOTICE Never operate an engine without water temperature regulators in the cooling system Water temperature regulators help to maintain the engine coolant at the correct operating temperature Cooling system prob lems can develop without water temperature regula tors Check the coolant antifreeze glycol concentration in order to ensure adequate protection against boiling or freezing Perkins recommends the use of a refractometer for checking the glycol concentration Perkins engine cooling systems should be tested at 500 hour intervals for the concentration of Supplemental Coolant Additive SCA Additions of SCA are based on the results of the test An SCA that is liquid may be needed at 500 hour intervals Refer to Table 22 for part numbers and for quantities of SCA Table 22 Perkins Liquid SCA Part Number Quantity 21825735 Adding the SCA to Heavy Duty
74. alarm and the Common alarm LED By default the information screen will display the following message Running in auto If an alarm occurs the screen will display the following Alarm Type Shutdown or Warning Alarm Description Example High engine temperature The warning alarms do not entail generator unit shutdown If shutdown occurs while a warning is active the screen will cycle through the active alarms USERS MANUAL Page 38 of 62 RENTAL SERIES ELECTRICAL GENERATOR ae POWER Battery Charge alternator voltage not detected Battery voltage beyond established limits After shutdown command Engine continues running Could also indicate faulty oil pressure sender Low fuel level Low oil pressure Engine temperature beyond established limits Engine speed beyond established limits Alternator Frequency beyond established limits Alternator Voltage beyond established limits Intensity of the Alternator output beyond established limits USERS MANUAL Page 39 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER Engine does not start three attempts made Controlled shutdown of the unit It will not be functional until the emergency stop button has been reset Low oil pressure High Engine temperature Engine speed beyond established limits Alternator Frequency beyond established limits Alternator Voltage beyond established limit Faulty oil pressure sender Inten
75. and the Effect from Cold Weather Note Only use grades of fuel that are recommended by Perkins Refer to this Operation and Maintenance Manual Fluid Recommendations The following fuels can be used in this series of engine e Group 1 e Group 2 e Group 3 e Special Fuels Perkins prefer only Group 1 and Group 2 fuels for use in this series of engines Group 1 fuels are the preferred Group of Fuels for general use by Perkins Group 1 fuels maximize engine life and engine performance Group 1 fuels are usually less available than Group 2 fuels Frequently Group 1 fuels are not available in colder climates during the winter Note Group 2 fuels must have a maximum wear scar of 650 micrometers HFRR to ISO 12156 1 Group 2 fuels are considered acceptable for issues of warranty This group of fuels may reduce the life of the engine the engine s maximum power and the engine s fuel efficiency 35 Operation Section Cold Weather Operation When Group 2 diesel fuels are used the following components provide a means of minimizing problems in cold weather e Glow plugs if equipped e Engine coolant heaters which may be an OEM option e Fuel heaters which may be an OEM option e Fuel line insulation which may be an OEM option There are three major differences between Group 1 fuels and Group 2 fuels Group 1 fuels have the following different characteristics to Group 2 fuels e A lower cloud point e A lower pour
76. ant is contaminated e The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is needed Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure This document is printed from SPI Not for Resale 56 Maintenance Section Cooling System Coolant Commercial Heavy Duty Change 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap VY Illustration 28 g01003928 2 Open the drain cock or remove the drain plug 1 on the engine Open the drain cock or remove the drain plug on the radiator Allow the coolant to drain NOTICE Dispose of used engine coolant or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Perkins to reclaim the c
77. anufacturer Also excluded are breakdowns and damages caused by prolonged or improper storage In the latter case check the manufacturer s user manuals e The warranty for the electrical generator shall cover ONLY the replacement parts and labor necessary for the repair of the generator by personnel authorized by the manufacturer Traveling kilometers traveled and other expenses deriving from the repair of a generator under warranty are excluded from the warranty coverage and in no case shall the manufacturer be responsible for these covering these expenses which shall be paid in cash e The decision to accept or reject a warranty shall be made by the manufacturer In the case of engine and alternator breakdowns the warranty shall be granted by the provider of said components according to the particular warranty conditions of those components The manufacturer reserves the option to request that the faulty element be returned In such case all costs related to said return shall be covered by the customer e The warranty for a repair made during the warranty period shall have the same expiration date as the warranty for the electrical generator e The warranty does not cover damage caused by terrorist attacks natural disasters sabotage or incidents of a similar nature USERS MANUAL Page 57 of 62 RENTAL SERIES ELECTRICAL GENERATOR e If any of the provisions set out does not comply with the legislation of a certain
78. ase to both the towing vehicle s coupling and the trailer s hitch ring Before towing again repeat de process Install safety chains on units with Site Trailer USERS MANUAL Page 14 of 62 2 RENTAL SERIES ELECTRICAL GENERATOR 3 2 INSTALLATION OF PORTABLE UNITS Portable units are defined as those moved to different work sites at least twice yearly 3 2 1 PLACEMENT This type of unit must be installed in well ventilated areas in order to ensure sufficient flow of coolant air and preventing combustion smoke from sitting in the Engine s exhaust The unit must be placed in a location that can safely bear the full weight of the generator unit and guarantee its stability both horizontally and vertically It should always remain at a distance that allows access to the interior of the Electrical Generator at least 1 meter away from any building or wall Avoid installing in areas with moisture or locations where water could get into the interior of the unit Note Exhaust can be supplied with optional spark arrester in the exhaust tube 3 2 2 FUEL As diesel fuel is used keep in mind the safety instructions previously mentioned in point 2 BASIC SAFETY RULES Before operating check the fuel level to ensure that the tank has the amount needed by the generator unit for an entire work day There is a optional of quick connectors for external fuel tank We can connect them with conductors through canopy fuel poi
79. at which includes a frame with a single lifting point Image 9 LIFTING FRAME If your unit includes a trailer one of the following may apply Trailer 1 Site trailer Connected with a DIN hitch ring and safety chains to the rear of the towing vehicle Use of this Trailer is not authorized on public roads Use the safety brake whenever necessary Trailer 2 Road trailer Keep in mind the legal considerations detailed in point 3 3 USERS MANUAL Page 13 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER A Always perform the following precautionary steps Make sure the hitch ring and coupling connecting the towing vehicle to the Trailer have the adequate towing capacity supporting a weight equal to or greater than the gross trailer weight Make sure there is no wear or damage to the hitch system or coupling never tow the generator if there is excessive wear or if any piece is damaged Make sure the coupling is properly fastened to the towing vehicle Check the condition of the trailer s tires Connect the safety cable to the bumper or rear part of the towing vehicle never attach it to the generator unit or to the hitch ring itself Check to make sure the brake systems on both the Trailer and towing vehicle are in perfect condition Make sure the trailer s turn signal indicators and brake lights are correctly installed and functioning properly After each transport apply a light coat of gre
80. ater Separator Dralans a a nS Fuel System Secondary Filter Replace Element TTS cca A SPINON TINET oeseri a a T Fuel Tank Water and Sediment Drain Drain the Water and the Sediment 0 Fuel Storage Tanks orenera in Fuel Tank 00 cccccececeeceeeeeseeceeeeeeeeeeeeeeeeeseeeeeeeenes G Gauges and Indicators cecccceeccceeeeeeeeeeeeeeaeees General Hazard Information 0cceceeeceeeeeeeeeees Containing Fluid Spillage ccccccsseceeeeeeeeees FIUIC PENCWAON incense visite aetna aa Pressure Air and Water ccccccceeeceececeeeeeeees H Hoses and Clamps Inspect Replace Replace the Hoses and the Clamps Important Safety Information ccccceeeeeeeeeeeees L Liingand Storage ieres iea 81 Index Section M Maintenance Interval Schedule cceceeeeeee 51 Maintenance Section ccccecececcececececececececeeees 37 Model View lllustrationS c ccccecececcecececececeeees 13 1103 Engine Model VieWS 0ccccseeeeeeeeees 15 1104 Engine Model VieWS ccccceeeeseeeeeees 13 Model VIEWS ccccececcccccecececececaceceececececececaeacaenes 13 Mounting and DISMOUNTING cccecseeeeeeeeeeeeees 10 O Operation SECON asena hector taedcctwredees 24 P Product Identification Information aaaaaaaaaaan0ann 19 Product Informati
81. ation 43 g01110422 Typical fuel Injectors The fuel injector 1 will need to be removed and the injector will need to be checked for performance The fuel injectors should not be cleaned as cleaning with incorrect tools can damage the nozzle The fuel injectors should be renewed only if a fault with the fuel injectors occurs Some of the problems that may indicate that new fuel injectors are needed are listed below e The engine will not start or the engine is difficult to start Not enough power e The engine misfires or the engine runs erratically e High fuel consumption e Black exhaust smoke e The engine knocks or there is vibration in the engine Excessive engine temperature This document is printed from SPI Not for Resale SEBU7833 03 Removal and Installation of the Fuel Injectors Ay WARNING Work carefully around an engine that is running Engine parts that are hot or parts that are moving can cause personal injury Ay WARNING Make sure that you wear eye protection at all times during testing When fuel injection nozzles are tested test fluids travel through the orifices of the nozzle tip with high pressure Under this amount of pressure the test fluid can pierce the skin and cause serious injury to the operator Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension NOTICE If your skin comes into contact with high pressure
82. atus measurements given are correct For units with trailer take to specialized maintenance shop annually Check the Alternator manufacturer s manual for specific tasks Check the Engine manufacturer s manual for specific tasks Check the condition and tightness of the antivibration feet EVERY 3000 HRS l EVERY 2 YRS Change coolant does not apply to the oil cooled DZR range Notes DAILY Check your Engine and Alternator manuals for specific maintenance tasks Make sure maintenance is performed by qualified personnel Be sure to comply with local legislation on environmental protection Batteries filters and used fluids as well as replaced electrical material and packaging should be taken to an authorized recycling center USERS MANUAL Page 53 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER When cleaning the generator do not use pressurized water as it could damage components USERS MANUAL Page 54 of 62 ae RENTAL SERIES ELECTRICAL GENERATOR ra POWER 7 TROUBLESHOOTING M Defective battery Replace the battery 4 Starter does notturi Battery isolator open Close battery isolator O a Defective Starting os S Contact Technical Svcs Loe ystem a g Starter functioning rauy air o Contact Technical Svcs S properly on contro module S Lacking fuel Refill the fuel tank 2 Stops with cause emergency NAS Take appropriate measures occurred D 9 Emergency not a S SoU noappareni indicated
83. aw sovuedsaniiadverwnecabuaws 15 3 2 2 FPOe A A snusawanasesinindcueasncaeaes 15 3 2 3 PRIOR TO STARTING GENERATOR 0 cc1cccccecocceccececeececceccececsecsecessecseseess 16 3 2 4 ELECTRICAL CONNECTION 1 1ccccoccecceccecceccececcececeesecsecsesscersesecsecsseess 16 3 3 STOR AGE water carte Suceins citation enatasunsnaleai contin tina ssa eusctoaeenincaueeutshadsnineuseanmediatawcae issues 17 STARTING AND STOPPING THE UNIT 0c ccccccececceccececcecceccececceccececuccecaeeeeaess 18 OPERATION MANUAL 0c cccccccceccececcecceccecccecceccecuccuecucueceececsecuececsecuccseaeceecutseeaeaeees 19 5 1 ELECTRICAL PANEL COMPONENTS 2ccsceccecceccececcecceccececcuccuceecauaececeueeuees 19 5 2 GPM 2 ANALOG CONTROL MODULE cc cccccccceccecccecceccececcuccuceecucaececeueeass 21 5 3 DEEP SEA 5210 DIGITAL CONTROL MODULE ccccceccececcececcececcecuceecueaecueauaeeueaeees 26 5 4 DEEP SEA 5310 DIGITAL CONTROL MODULE ccccceccececcececceceececuccecutecucaeaeeeeaeees 35 5 5 INTELIGEN DIGITAL CONTROL MODULE 0c cccccececcececcccecccececcecacaecececaeceuaeceeaeees 46 6 MAINTENANCE OF ELECTRICAL GENERATOR 2 cccecceccecceccecceccesccceeceecessaeees 50 6 1 PRIOR TO MAINTENANCE 2c cccccecceccecccecceccececceccuccecuccuccececeucueaecaeaeseeeensaees 50 6 2 DURING MAINTENANCE 2ccccccceccecccceccecceccccecceccecccuceuceecueaucesausueaeseeseeseees 50 6 3 MAINTENANCE CH
84. ay not have been provided by Perkins The procedure that follows is for a typical air filter system Refer to the OEM information for the correct procedure lf the air cleaner element becomes plugged the air can split the material of the air cleaner element Unfiltered air will drastically accelerate internal engine wear Refer to the OEM information for the correct air cleaner elements for your application e Check the precleaner if equipped and the dust bowl daily for accumulation of dirt and debris Remove any dirt and debris as needed e Operating conditions dust dirt and debris may require more frequent service of the air cleaner element e The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes 61 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace Dual Element Air Cleaners The dual element air cleaner contains a primary air cleaner element and a secondary air cleaner element The primary air cleaner element can be used up to six times if the element is properly c
85. bocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rom up at no load do not continue engine operation until the turbocharger is renewed A visual inspection of the turbocharger can minimize unscheduled downtime A visual inspection of the turbocharger can also reduce the chance for potential damage to other engine parts Removal and Installation Note The turbochargers that are supplied are nonserviceable This document is printed from SPI Not for Resale SEBU7833 03 For options regarding the removal installation and replacement consult your Perkins dealer or your Perkins distributor Refer to the Disassembly and Assembly Manual Turbocharger Remove and Turbocharger Install for further information Inspecting NOTICE The compressor housing for the turbocharger must not be removed from the turbocharger for cleaning The actuator linkage is connected to the compressor housing If the actuator linkage is moved or disturbed the engine may not comply with emmissions legisla tion 1 Remove the pipe from the turbocharger exhaust outlet and remove the air intake pipe to the turbocharger Visually inspect the piping for the presence of oil Clean the interior of the pipes in order to prevent dirt from entering during reassembly 2 Check for the presence of oil If oil is leaking from the back side of the compressor wheel there is a possibility of a failed
86. bottom of the filler pipe If the engine is equipped with a sight glass maintain the coolant level to the correct level in the sight glass 3 Clean the cooling system filler cap and inspect the gasket If the gasket is damaged discard the old filler cap and install a new filler cap If the gasket is not damaged use a Suitable pressurizing pump in order to pressure test the filler cap The correct pressure is stamped on the face of the filler cap If the filler cap does not retain the correct pressure install a new filler cap 4 Inspect the cooling system for leaks 100174798 Driven Equipment Check Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment e Inspection e Adjustment SEBU7833 03 e Lubrication e Other maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM 01930350 Engine Clean Personal injury or death can result from high volt age Moisture can create paths of electrical conductiv ity Make sure that the electrical system is OFF Lock out the starting controls and tag the controls DO NOT OPERATE NOTICE Accumulated grease and oil on an engine is a fire haz ard Keep the engine clean Remove debris and fluid spills whenever a significant quantity accumulates on the engine NOTICE Failure to protect some engine components from washing may make your engi
87. case disconnect an electric type of fuel heater in warm weather in order to prevent overheating of the fuel If the type of fuel heater is a heat exchanger the OEM should have included a bypass for warm weather Ensure that the bypass is operational during warm weather in order to prevent overheating of the fuel For more information about fuel heaters if equipped refer to the OEM information This document is printed from SPI Not for Resale SEBU7833 03 Maintenance Section Refill Capacities 102198350 Refill Capacities Lubrication System The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters Auxiliary oil filter systems will require additional oil Refer to the OEM specifications for the capacity of the auxiliary oil filter Refer to the Operation and Maintenance Manual Maintenance Section for more information on Lubricant Specifications 1104 Engine Table 5 1104 Engine Compartment or System Liters Quarts Standard Oil Sump for the Engine 6 5 7 Crankcase 1 1 These values are the approximate capacities for the crankcase oil sump which include the standard factory installed oil filters Engines with auxiliary oil filters will require additional oil Refer to the OEM specifications for the capacity of the auxiliary oil filter 1103 Engine Table 6 1103 Engine Compartment or System Liter
88. cates low Low level Coolant level and module issues unit stop command If light is flashing indicates High Coolant Temperature and the control module issues unit stop command Light will flash and indicate that the Overload protection switch is open module issues unit stop command If light is flashing indicates WARNING Low fuel level If light is flashing module issues unit stop command If light is continuous module issues unit stop command indicating an Emergency Stop emergency button If the light is flashing module issues Overspeed unit stop command indicating Engine High Speed If the light is continuous indicates Programmable WARNING alarm If light is flashing module issues unit stop command Note If at any point 3 or more LED indicators turn on it could indicate low battery level Unit startup failure 1 Battery charge Alternator failure 3 High coolant temperature Emergency Stop 17 USERS MANUAL Page 25 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER 5 3 DEEP SEA 5210 DIGITAL CONTROL MODULE Image 11 DEEP SEA 5210 CONTROL MODULE MODULE 5210 Image 12 DEEP SEA 5210 CONTROL MODULE USERS MANUAL Page 26 of 62 RENTAL SERIES ELECTRICAL GENERATOR Stop button Control module connection ReO LED MANUAL mode button Red LED Settings Settings AUTOMATIC mode button Settings ENTER Startup button for Electrical
89. ccceeeeeeeeeeeeeeeeeeneeeees 77 Inspect the Engine for Leaks and for Loose COMING CUOINS a aa eter ce a Geet as 77 Warranty Information ccccccceeeeeeeeseeeseeeesneeees 79 Warranty SeCtON sesir e 79 Water Pump INSPECt cccceeeeeeeeseeeeeseeeeaeeees 78 This document is printed from SPI Not for Resale Product and Dealer Information Note For product identification plate locations see the section Product Identification Information in the Operation and Maintenance Manual Delivery Date Product Information Model Product Identification Number Engine Serial Number Transmission Serial Number Generator Serial Number Attachment Serial Numbers Attachment Information Customer Equipment Number Dealer Equipment Number Dealer Information Name CBr Address Dealer Contact Phone Number Hours Sales Parts Service This document is printed from SPI Not for Resale Copyright 2008 Perkins Engines Company Limited Printed in U K All Rights Reserved This document is printed from SPI Not for Resale
90. ce section If an engine is out of operation and if use of the engine is not planned special precautions should be made If the engine will be stored for more than one month a complete protection procedure is recommended Use the following guidelines Completely clean the outside of the engine Drain the fuel system completely and refill the system with preservative fuel 1772204 POWERPART Lay Up 1 can be mixed with the normal fuel in order to change the fuel into preservative fuel If preservative fuel is not available the fuel system can be filled with normal fuel This fuel must be discarded at the end of the storage period together with the fuel filter elements Operate the engine until the engine reaches normal operating temperature Stop any leaks from fuel lubricating oil or air systems Stop the engine and drain the lubricating oil from the oil pan This document is printed from SPI Not for Resale SEBU7833 03 e Renew the canister s of the lubricating oil filter e Fill the oil pan to the Full Mark on the dipstick with new clean lubricating oil Add 176281 1 POWERPART Lay Up 2 to the oil in order to protect the engine against corrosion If 1762811 POWERPART Lay Up 2 is not available use a preservative of the correct specification instead of the lubricating oil If a preservative is used this must be drained completely at the end of the storage period and the oil pan must be refilled to the correct level
91. ceeit cana neuty ect adusecaadenmusianen 16 Engine Cooling and Lubrication 068 18 Engine Service Life ccccsssccceessssseeeeeeessneeees 18 Engine Specifications cccccccccecssssseeeeeeeeeeeens 16 Engine Ground Inspect Clean 0 64 Engine Identification cccccseccceeeeeseeeeseeeeeeeeaees 19 ENONSE LINN Ger n 24 Engine Mounts INSPe Ct ccceseeeeeeeeeeeeseeeeees 64 Engine Oil and Filter Change cccsseeeeeeeeees 65 Drain the Engine Oll ccccsssecceseeesseeeeeseeees 65 Fill the Engine Crankcase cesseeeeeeeeeeees 67 Replace the Element for the Oil Filter 66 Replace the Spin on Oil Filter eee 66 Engine Oil Level Check ccccceeseeeeseeeeeeeeaees 64 Engine Oil Sample Obtain ccccceeeeeeeeeeeeees 64 Obtain the Sample and the Analysis 65 Engine QperalOh serna n canes 31 ENJINS Starin aaa 11 28 Engine Stopping ccccsseeeceeeeeeeeeeeeeeeeesseeeees 11 32 EMOING SIOraAJE riar ia seawsaandestortee ties 24 Cooling SYSTEM cccseeeececeeeeceeeeeeeeeeeseeeeeeeeeaees 25 EXHAUST SYSTEM seeded dcat E dentdaaticceumde 25 General Items ccccceeeeecceeeeeeeeeeeeeeeeseaseeeeseaees 26 IMGUCHON System serei 25 Lubrication SySteM ceccar 24 Engine Valve Lash Inspect Adjust 00 67 Engine Wam UD casera en hate avin sdeedsuanes 31 F Fire
92. connection and battery terminals 5 Use a fine grade of sandpaper to clean the terminals and the cable clamps Clean the items until the surfaces are bright or shiny DO NOT remove material excessively Excessive removal of material can cause the clamps to not fit correctly Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly 6 Tape the cable connections in order to help prevent accidental starting 7 Proceed with necessary system repairs 8 In order to connect the battery connect the positive connection before the negative connector 55 Maintenance Section Battery or Battery Cable Disconnect 102203590 Cooling System Coolant Commercial Heavy Duty Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Dispose of all fluids according to Local regulations and mandates NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the cool
93. ct abnormal operating developments Significant changes in the readings should be investigated This document is printed from SPI Not for Resale SEBU7833 03 Engine Operation 102176671 Engine Operation Correct operation and maintenance are key factors in obtaining the maximum life and economy of the engine If the directions in the Operation and Maintenance Manual are followed costs can be minimized and engine service life can be maximized The engine can be operated at the rated rom after the engine reaches operating temperature The engine will reach normal operating temperature sooner during a low engine speed rom and during a low power demand This procedure is more effective than idling the engine at no load The engine should reach operating temperature in a few minutes Gauge readings should be observed and the data should be recorded frequently while the engine is operating Comparing the data over time will help to determine normal readings for each gauge Comparing data over time will also help detect abnormal operating developments Significant changes in the readings should be investigated 101929404 Engine Warm up 1 Run the engine at low idle for three to five minutes or run the engine at low idle until the jacket water temperature starts to rise More time may be necessary when the temperature is below 18 C 0 F 2 Check all of the gauges during the warm up period 3 Perform a walk aro
94. d Weather Fuel Tanks Condensation can form in partially filled fuel tanks Top off the fuel tanks after you operate the engine Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Drain the water and sediment from any fuel storage tank at the following intervals weekly oil changes and refueling of the fuel tank This will help prevent water and or sediment from being pumped from the fuel storage tank and into the engine fuel tank Fuel Filters It is possible that a primary fuel filter is installed between the fuel tank and the engine fuel inlet After you change the fuel filter always prime the fuel system in order to remove air bubbles from the fuel system Refer to the Operation and Maintenance Manual in the Maintenance Section for more information on priming the fuel system The micron rating and the location of a primary fuel filter is important in cold weather operation The primary fuel filter and the fuel supply line are the most common components that are affected by cold fuel Fuel Heaters Note The OEM may equip the application with fuel heaters If this is the
95. de this parameter the Control Module however can display this instrument If the following appears in an instrument display with the Electrical Generator in OFF AUTOMATIC Mode with the Engine stopped this means that the Control Module is not connected to the Engine Press this button 6 to display the given value USERS MANUAL Page 43 of 62 gt u RENTAL SERIES ELECTRICAL GENERATOR ALARM LED Remote start on load Overload pre alarm Common alarms Common shutdown EDITING THE CURRENT DATE AND TIME The date and time are adjustable When the battery is disconnected the date and time are frozen when the battery is reconnected the date and time shown will be from the time the battery was disconnected The date and time reflected in the Event Log will be taken from the configuration according to the following steps Press 1 and ie 11 simultaneously then enter the correct PIN number Press When Date and Time screen appears press the button 4 The minutes will _ Oo start to flash Press 3 or 2 to adjust to the desired setting Press the 10 button to confirm the value entered The hour will begin to flash Press 3 or 2 again to adjust to the desired setting USERS MANUAL Page 44 of 62 RENTAL SERIES ELECTRICAL GENERATOR Press the button 10 to confirm the value entered and select the day The day will begin to flash Press i 3
96. e f the engine is equipped with a drain valve turn the drain valve knob counterclockwise in order to drain the oil After the oil has drained turn the drain valve Knob clockwise in order to close the drain valve e If the engine is not equipped with a drain valve remove the oil drain plug 1 in order to allow the oil to drain If the engine is equipped with a shallow sump remove the bottom oil drain plugs from both ends of the oil pan This document is printed from SPI Not for Resale 66 Maintenance Section Engine Oil and Filter Change After the oil has drained the oil drain plugs should be cleaned and installed If necessary renew the O ring seal on the drain plug Some types of oil pans have oil drain plugs that are on both sides of the oil pan because of the shape of the pan This type of oil pan requires the engine oil to be drained from both plugs Replace the Spin on Oil Filter NOTICE Perkins oil filters are manufactured to Perkins speci fications Use of an oil filter that is not recommended by Perkins could result in severe damage to the en gine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Perkins 1 Remove the oil filter with a suitable tool Note The following actions can be carried out as part of the preventive maintenance program 2 Cut the oil filter open with a suitable too
97. e electric starting motor to cool Then repeat steps 2 through step 4 6 Turn the engine start switch to the OFF position in order to stop the engine 102198092 Cold Weather Starting Ay WARNING Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury Startability will be improved at temperatures below 18 C 0 F from the use of a jacket water heater or extra battery capacity 29 Operation Section Engine Starting When Group 2 diesel fuel is used the following items provide a means of minimizing starting problems and fuel problems in cold weather engine oil pan heaters jacket water heaters fuel heaters and fuel line insulation Use the procedure that follows for cold weather starting 1 If equipped move the throttle lever to the full throttle position before you start the engine 2 If equipped turn the engine start switch to the HEAT position Hold the engine start switch in the HEAT position for 6 seconds until the glow plug indicator light illuminates This will activate the glow plugs and aid in the starting of the engine NOTICE Do not crank the engine for more than 30 seconds Allow the electric starting motor to cool for two minutes before cranking the engine again 3 While the glow plug indicator light is illuminated turn the engine start switch to the START position and crank the engine Note If the glow plug indicator light illumi
98. e lubricating oil may be checked at regular intervals as part of a preventive maintenance program Perkins include an oil sampling valve as an option The oil sampling valve if equipped is included in order to regularly sample the engine lubricating oil The oil sampling valve is positioned on the oil filter head or the oil sampling valve is positioned on the cylinder block This document is printed from SPI Not for Resale SEBU7833 03 Perkins recommends using a sampling valve in order to obtain oil samples The quality and the consistency of the samples are better when a sampling valve is used The location of the sampling valve allows oil that is flowing under pressure to be obtained during normal engine operation Obtain the Sample and the Analysis Ay WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin In order to help obtain the most accurate analysis record the following information before an oil sample is taken e The date of the sample e Engine model e Engine number e Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change Ensure that the container for the sample is clean and dry Also ensure that the container for the sample is clearly labelled To ensure that the sample is representative of the oil in the crankcase obtain a
99. e optimum heavy duty performance as a coolant antifreeze This ratio may be increased to 1 2 water to glycol if extra freezing protection is required Note A commercial heavy duty coolant antifreeze that meets ASTM D4985 specifications MAY require a treatment with an SCA at the initial fill Read the label or the instructions that are provided by the OEM of the product In stationary engine applications and marine engine applications that do not require anti boil protection or freeze protection a mixture of SCA and water is acceptable Perkins recommends a six percent to eight percent concentration of SCA in those cooling systems Distilled water or deionized water is preferred Water which has the recommended properties may be used Engines that are operating in an ambient temperature above 43 C 109 4 F must use SCA and water Engines that operate in an ambient temperature above 43 C 109 4 F and below 0 C 32 F due to seasonal variations consult your Perkins dealer or your Perkins distributor for the correct level of protection Table 19 Coolant Service Life Coolant Type Service Life 12 000 Service Hours Perkins ELC ap Sie Weare Commercial Heavy Duty Coolant Antifreeze that meets ASTM D4985 Perkins POWERPART 3000 Service Hours or SCA Two Years Commercial SCA and 3000 Service Hours or Water Two Years 3000 Service Hours or Two Years Extended Life Coolant E
100. e spray is printed on the container Seal the turbocharger with waterproof tape This document is printed from SPI Not for Resale 26 SEBU7833 03 Operation Section Lifting and Storage General Items e lf the lubricating oil filler is installed on the rocker cover remove the filler cap If the lubricating oil filler cap is not installed on the rocker cover remove the rocker cover Spray 1762811 POWERPART Lay Up 2 around the rocker shaft assembly Replace the filler cap or the rocker cover e Seal the vent of the fuel tank or the fuel filler cap with waterproof tape e Remove the alternator drive belts and put the drive belts into storage In order to prevent corrosion spray the engine with 1734115 POWERPART Lay Up 3 Do not spray the area inside the alternator When the engine protection has been completed in accordance with these instructions this ensures that no corrosion will occur Perkins are not responsible for damage which may occur when an engine is in storage after a period in service Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods This document is printed from SPI Not for Resale SEBU7833 03 Gauges and Indicators 102164190 Gauges and Indicators Your engine may not have the same gauges or all of the gauges that are described For more information about the gauge package see the OEM information Gauges provide indications of en
101. efore filling the engine fuel tank Internal baffles in the bulk storage tank will also help trap sediment Filtering fuel that is pumped from the storage tank helps to ensure the quality of the fuel When possible water separators should be used This document is printed from SPI Not for Resale 74 Maintenance Section Hoses and Clamps Inspect Replace 102813964 Hoses and Clamps Inspect Replace Inspect all hoses for leaks that are caused by the following conditions e Cracking e Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque Do not clip any other item to the high pressure lines Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally Flexible part of the hose that is kinked or crushed e Armoring that is embedded in the outer covering A constant torque hose clamp can be used in place of any standard hose clamp Ensure that the constant torque hose clamp is the same size as the standard clamp Due to extreme temperature change
102. electrical wires before the engine is started See the Operation and Maintenance Manual for specific Starting instructions Grounding Practices Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability Incorrect grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths Uncontrolled electrical circuit paths can result in damage to main bearings to crankshaft bearing journal surfaces and to aluminum components Engines that are installed without engine to frame ground straps can be damaged by electrical discharge To ensure that the engine and the engine electrical systems function correctly an engine to frame ground strap with a direct path to the battery must be used This path may be provided by way of a direct engine ground to the frame All grounds should be tight and free of corrosion The engine alternator must be grounded to the negative battery terminal with a wire that is adequate to handle the full charging current of the alternator This document is printed from SPI Not for Resale SEBU7833 03 13 Product Information Section Model Views Product Information Section Model Views 101928892 Model View Illustrations 1104 Engine Model
103. els that meet the specifications in Table 14 will help to provide maximum engine service life and performance In North America diesel fuel that is identified as No 2 D in ASTM D975 generally meets the specifications Table 14 is for diesel fuels that are distilled from crude oil Diesel fuels from other sources could exhibit detrimental properties that are not defined or controlled by this specification Table 14 Perkins Specifications for Distillate Diesel Fuel Specifications Requirements ASTM Test Aromatics 35 maximum D1319 0 02 maximum i i Ash weight D482 Carbon Residue 0 35 maximum D524 on 10 Bottoms weight 40 minimum DI Cetane Number engines D613 The cloud point must not exceed the Cloud Point lowest expected ambient temperature continued This document is printed from SPI Not for Resale 44 Maintenance Section Refill Capacities Table 14 contd Copper Strip No 3 maximum D130 Corrosion 10 at 282 C 540 F maximum Distillation D86 90 at 360 C 680 F maximum Flash Point legal limit D93 30 minimum API Gravity D287 45 maximum 6 C 10 F minimum i Pour Point S D97 temperature 0 2 maximum D3605 Sulfur or D1552 2 0 cSt minimum Kinematic and 4 5 cSt i Viscosity 2 maximum at pane 40 C 104 F Water and 0 1 maximum
104. ention and Explosion Prevention Coolant When the engine is at operating temperature the engine coolant is hot The coolant is also under pressure The radiator and all lines to the heaters or to the engine contain hot coolant Any contact with hot coolant or with steam can cause severe burns Allow cooling system components to cool before the cooling system is drained Check the coolant level after the engine has stopped and the engine has been allowed to cool Ensure that the filler cap is cool before removing the filler cap The filler cap must be cool enough to touch with a bare hand Remove the filler cap slowly in order to relieve pressure Cooling system conditioner contains alkali Alkali can Cause personal injury Do not allow alkali to contact the skin the eyes or the mouth Oils Hot oil and hot lubricating components can cause personal injury Do not allow hot oil to contact the skin Also do not allow hot components to contact the skin Batteries Electrolyte is an acid Electrolyte can cause personal injury Do not allow electrolyte to contact the skin or the eyes Always wear protective glasses for servicing batteries Wash hands after touching the batteries and connectors Use of gloves is recommended 102813488 Fire Prevention and Explosion Prevention Illustration 8 g00704000 SEBU7833 03 All fuels most lubricants and some coolant mixtures are flammable Flammable fluids that are leaking
105. er and performance from the engine use a fuel of the correct quality The recommended fuel specification for Perkins engines is shown below e Cetane number 45 minimum e Viscosity 2 0 to 4 5 cSt at 40 C 104 F e Density 0 835 to 0 855 Kg liter e Sulfur 0 2 of mass maximum e Distillation 85 at 350 C 662 F e Lubricity 460 micrometers maximum wear scar on ISO 12156 1 Cetane number This indicates the properties of ignition of the fuel Fuel with a low cetane number can be the root cause of problems during cold start This will affect combustion Viscosity This is the resistance to flow of a fluid If this resistance is outside the limits the engine and the engine starting performance in particular can be affected Sulfur SEBU7833 03 High sulfur content of the fuel is not normally found in Europe North America or Australasia This can cause engine wear When only high sulfur fuels are available it will be necessary that high alkaline lubricating oil is used in the engine or that the lubricating oil change interval is reduced Distillation This is an indication of the mixture of different hydrocarbons in the fuel A high ratio of light weight hydrocarbons can affect the characteristics of combustion Lubricity This is the capability of the fuel to prevent pump wear Diesel engines have the ability to burn a wide variety of fuels These fuels are divided into four general groups e Group 1
106. erval Major repairs should only be carried out by Perkins authorized personnel Your Perkins dealer or your Perkins distributor offers a variety of options regarding overhaul programs If you experience a major engine failure there are also numerous after failure overhaul options available Consult with your Perkins dealer or your Perkins distributor for information regarding these options California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Battery posts terminals and related accessories contain lead and lead compounds Wash hands after handling This document is printed from SPI Not for Resale SEBU7833 03 Safety Section 103299360 Safety Messages There may be several specific warning signs on an engine The exact location of the hazards and the description of the hazards are reviewed in this section Please become familiar with all warning Signs Ensure that all of the warning signs are legible Clean the warning signs or replace the warning signs if the words cannot be read or if the pictures are not visible When the warning signs are cleaned use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the warning signs Solvents gasoline or harsh chemicals could loosen the adhesive that secures the warning signs The warning signs that are loosened cou
107. es consume excess fuel Utilize heat from the jacket water system and the exhaust system when possible Keep cooling system components clean and keep cooling system components in good repair Never operate the engine without water temperature regulators All of these items will help maintain operating temperatures This document is printed from SPI Not for Resale 32 Operation Section Engine Stopping Engine Stopping 101929389 Stopping the Engine NOTICE Stopping the engine immediately after it has been working under load can result in overheating and ac celerated wear of the engine components If the engine has been operating at high rom and or high loads run at low idle for at least three minutes to reduce and stabilize internal engine temperature before stopping the engine Avoiding hot engine shutdowns will maximize tur bocharger shaft and bearing life Prior to stopping an engine that is being operated at low loads operate the engine at low idle for 30 seconds before stopping If the engine has been operating at highway speeds and or at high loads operate the engine at low idle for at least three minutes This procedure will cause the internal engine temperature to be reduced and stabilized Ensure that the engine stopping procedure is understood Stop the engine according to the shutoff system on the engine or refer to the instructions that are provided by the OEM e To stop the engine turn the ignition ke
108. esale SEBU7833 03 23 Product Information Section Product Identification Information EMISSIONS CONTROL INFORMATION ENGINE FAMILY 1104C 44TA MODEL YEAR 2005 ENGINE DISPLACEMENT 4 400 FOLLOWING INFORMATION APPLICABLE TO USA ONLY This non road engine does not comply with either federal non road or California off road engine emission regulation requirement Sale or installation of this engine can only be for STATIONARY ENGINE Use only as defined by CFR 40 PART 89 2 Hanger No Position 81 Label 318A081 Illustration 21 g01157127 This typical example of a label is installed on engines that are stationary engines This document is printed from SPI Not for Resale 24 Operation Section Lifting and Storage Operation Section Lifting and Storage 102164186 Engine Lifting gE ey l i E N a oe ee oo Is i F gE i EE ee gs es a a a a ee ee ee Cee 2 el ee ee 2 ee ee a ee ee ee ee ee 2 ie Illustration 22 g01097527 NOTICE Never bend the eyebolts and the brackets Only load the eyebolts and the brackets under tension Remem ber that the capacity of an eyebolt is less as the angle between the supporting members and the object be comes less than 90 degrees When it is necessary to
109. f 650 micrometers wear scar and the reliability of the fuel Injection pump will be reduced The fuel injection pump is not covered by a warranty even when the additives are included JP5 MIL T5624 Avcat FSII NATO F44 JP8 183133 Avtur FSII NATO F34 Jet A Jet A1 NATO F35 XF63 Low temperature fuels Special fuels for use in cold weather may be available for engine operation at temperatures below 0 C 32 F These fuels limit the formation of wax in the fuel oil at low temperatures If wax forms in the fuel oil this could stop the flow of fuel oil through the filter Note These fuels that lack lubricity may cause the following problems e Low engine power Difficult starting in hot conditions or in cold conditions e White smoke Deterioration of emissions and misfire at certain operating conditions Biofuel Specification Biofuel A 5 mix of RME to EN14214 in conventional fuel is permitted NOTICE Water emulsion fuels These fuels are not permitted Refer to the following fuel specifications for North America 43 Maintenance Section Refill Capacities The preferred fuels provide maximum engine service life and performance The preferred fuels are distillate fuels These fuels are commonly called diesel fuel or gas oil The permissible fuels are crude oils or blended fuels Use of these fuels can result in higher maintenance costs and in reduced engine service life Diesel fu
110. f a circuit breaker for protection against earth leakage ELCB 8 Do not operate the unit with the doors open Risk of electrocution burns or entrapment 9 The exhaust system produces enough heat to ignite certain materials 10 Do not inhale exhaust gases produced by the unit 11 Do not touch the Engine nor the Exhaust while the Electrical Generator is operating as this could produce severe burns 12 Ensure proper ventilation in the area where the Generator is installed in order to guarantee sufficient flow of coolant air 13 Do not refuel while the engine is running or in poorly ventilated areas 14 Know how to stop the unit in case of emergency 15 The fuel used is flammable and volatile 16 Do not overfill the tank and make sure it is closed properly after filling Use extreme precaution if fuel is spilled the vapors and the fuel itself are flammable Clean the area completely before starting up the unit USERS MANUAL Page 3 of 62 2 RENTAL SERIES ELECTRICAL GENERATOR 17 Do not smoke or bring any flames or sparks in the vicinity of the Electrical Generator risk of explosion 18 If you notice abnormal behavior by the Electrical Generator stop the unit and locate examine and resolve the potential failure of the unit prior to restarting 19 Keep the unit at least one meter away from buildings or other units 20 Be cautious when switching or installing batteries as they contain acids which are highl
111. g of the engine e Deterioration of the engine mounts e Loose engine mounts Any engine mount that shows deterioration should be replaced Refer to the OEM information for the recommended torques 02335785 Engine Oil Level Check Ay WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin SEBU7833 03 Illustration 37 g01165836 Y Min mark X Max mark NOTICE Perform this maintenance with the engine stopped Note Ensure that the engine is either level or that the engine is in the normal operating position in order to obtain a true level indication Note After the engine has been switched OFF wait for ten minutes in order to allow the engine oil to drain to the oil pan before checking the oil level 1 Maintain the oil level between the ADD mark Y and the FULL mark X on the engine oil dipstick Do not fill the crankcase above the FULL mark X NOTICE Operating your engine when the oil level is above the FULL mark could cause your crankshaft to dip into the oil The air bubbles created from the crankshaft dipping into the oil reduces the oil s lubricating char acteristics and could result in the loss of power 2 Remove the oil filler cap and add oil if necessary Clean the oil filler cap Install the oil filler cap i02202699 Engine Oil Sample Obtain The condition of the engin
112. g with cables in cold weather refer to the Operation and Maintenance Manual Starting with Jump Start Cables for instructions Viscosity of the Engine Lubrication Oil Correct engine oil viscosity is essential Oil viscosity affects the amount of torque that is needed to crank the engine Refer to this Operation and Maintenance Manual Fluid Recommendations for the recommended viscosity of oil Recommendations for the Coolant Provide cooling system protection for the lowest expected outside temperature Refer to this Operation and Maintenance Manual Fluid Recommendations for the recommended coolant mixture This document is printed from SPI Not for Resale 34 Operation Section Cold Weather Operation In cold weather check the coolant often for the correct glycol concentration in order to ensure adequate freeze protection Engine Block Heaters Engine block heaters if equipped heat the engine jacket water that surrounds the combustion chambers This provides the following functions e Startability is improved e Warm up time is reduced An electric block heater can be activated once the engine is stopped An effective block heater is typically a 1250 1500 W unit Consult your Perkins dealer or your Perkins distributor for more information Idling the Engine When idling after the engine is started in cold weather increase the engine rom from 1000 to 1200 rom This will warm up the engine more
113. ge 50 of 62 a RENTAL SERIES ELECTRICAL GENERATOR added The battery should be recharged if the terminal voltage is below 12 3 V 9 If the battery needs recharging after being taken out of the unit remove the vent caps and charge battery with direct current only Connect the charger s positive cable to the battery s positive terminal and the charger s negative cable to the battery s negative terminal Recharge battery with a current equaling 1 10 the nominal capacity Ah Battery is fully charged when acid density is 1 28 Before completing recharging process turn off charger before disconnecting battery and check electrolyte level 10 Ifthe battery is discharged and you want to perform an emergency startup with the battery from another generator first check the tightness of the discharged battery s terminals Stop the engines of both units and connect the two positive terminals of the batteries first and then connect the negative terminal of the charged battery to a metal area on the disabled unit ground Start up the auxiliary unit and then the unit being repaired Disconnect the cables in reverse order to avoid a short circuit Finally fully charge the battery 11 Installation of the fuel filter in all units means that the operator must constantly monitor the water buildup and drain as it becomes filled This does not entail an inconvenience but rather simply keeping an eye on the transparent tank i
114. generator unit It also logs the opening and closing of the Mains circuit breaker as well as the starting and shutting down of the generator unit STARTUP Start l Press the START button A 5 to start up the Electrical Generator When the Generator voltage is within the established limits the LED indicator e 7 will be lit Next press the GCB ON OFF button 10 The loads will be transferred Stop 0 directly to the Electrical Generator To stop the unit press STOP 6 LOAD TEST MODE MANUAL This operating Mode is used to allow the Electrical Generator to check the state of the Mains Power or to disconnect from the Mains when an imminent mains failure is detected When this operating Mode is selected the unit starts up at no load To USERS MANUAL Page 48 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER 12 and then press the GCB ON OFF button between the Electrical Generator and the Mains for 60 seconds to assume the loads 10 At this time synchronization occurs OFF MODE Start i The Electrical Generator will not start Even if we press the buttons START 5 STOP 6 GCB ON OFF 10 the Generator will not respond USERS MANUAL Page 49 of 62 POWER RENTAL SERIES ELECTRICAL GENERATOR 6 MAINTENANCE OF ELECTRICAL GENERATOR You must make sure that the person who will perform this duty is qualified to do so and utilizes the appropriate individual protection equ
115. gine performance Ensure that the gauges are in good working order Determine the normal operating range by observing the gauges over a period of time Noticeable changes in gauge readings indicate potential gauge or engine problems Problems may also be indicated by gauge readings that change even if the readings are within specifications Determine and correct the cause of any significant change in the readings Consult your Perkins dealer or your Perkins distributor for assistance NOTICE If no oil pressure is indicated STOP the engine If maximum coolant temperature is exceeded STOP the engine Engine damage can result Engine Oil Pressure The oil pressure should be greatest after a cold engine is started The typical engine oil pressure with SAE10WS30 is 207 to 413 kPa 30 to 60 psi at rated rom A lower oil pressure is normal at low idle If the load is stable and the gauge reading changes perform the following procedure 1 Remove the load 2 Reduce engine speed to low idle 3 Check and maintain the oil level Jacket Water Coolant Temperature Typical temperature range is 71 to 96 C 160 to 205 F The maximum allowable temperature with the pressurized cooling system at 48 kPa 7 psi is 110 C 230 F Higher temperatures may occur under certain conditions The water temperature reading may vary according to load The reading should never exceed the boiling point for the pressurized system that is being
116. he following classifications e EMA DHD 1 multigrade oil preferred oil e API CH 4 multigrade oil preferred oil e ACEAE3 In order to make the correct choice of a commercial oil refer to the following explanations EMA DHD 1 The Engine Manufacturers Association EMA has developed lubricant recommendations as an alternative to the API oil classification system DHD 1 is a Recommended Guideline that defines a level of oil performance for these types of diesel engines high speed four stroke cycle heavy duty and light duty DHD 1 oils may be used in Perkins engines when the following oils are recommended API CH 4 API CG 4 and API CF 4 DHD 1 oils are intended to provide superior performance in comparison to API CG 4 and API CF 4 DHD 1 oils will meet the needs of high performance Perkins diesel engines that are operating in many applications The tests and the test limits that are used to define DHD 1 are similar to the new API CH 4 classification Therefore these oils will also meet the requirements for diesel engines that require low emissions DHD 1 oils are designed to control the harmful effects of soot with improved wear resistance and improved resistance to plugging of the oil filter These oils will also provide superior piston deposit control for engines with either two piece steel pistons or aluminum pistons All DHD 1 oils must complete a full test program with the base stock and with the viscosity grade of the
117. his row 2 The Total Cooling System includes the capacity for the engine cooling system plus the capacity for the external cooling system Enter the total in this row Table 8 1104 Turbocharged Engine Compartment or System Liters Quarts Engine Only 11 4 12 External cooling System capacity OEM recommendation Total Cooling System 1 The external cooling system includes a radiator or an expansion tank with the following components heat exchanger aftercooler and piping Refer to the OEM specifications Enter the value for the external cooling system capacity in this row 2 The Total Cooling System includes the capacity for the engine cooling system plus the capacity for the external cooling system Enter the total in this row This document is printed from SPI Not for Resale 38 Maintenance Section Refill Capacities 1103 Engine Table 9 1103 Naturally Aspirated Engine without an oil cooler Compartment or System Liters Quarts Engine Only 4 21 4 External cooling system capacity OEM recommendation Total Cooling System 1 The external cooling system includes a radiator or an expansion tank with the following components heat exchanger aftercooler and piping Refer to the OEM specifications Enter the value for the external system capacity in this row 2 The Total Cooling System includes the capacity for the engine cooling system plus the capacit
118. icator Make sure the Electrical Generator s outlet cables are in perfect condition Make sure machine is properly grounded and that the earth leakage circuit breaker is working press Test button Perform a general inspection and make sure there are no fluid leaks Check the Engine manufacturer s manual for specific tasks Every 50 hrs WEEKLY Water and sediment in fuel tank Drain Review the connections of the startup battery clean and cover with Vaseline Change the filtering element of the water separator filter Start up the Engine 3 times noting the voltage readings each time Make sure EVERY 250 HRS battery voltage is correct on each startup EVERY 6 MONTHS Make sure all of the electrical panel lights are functioning properly Check the state of all of the gauges and indicators on the electrical panel Clean the interior of the electrical generator Check the Engine manufacturer s manual for specific tasks Make sure there are no leaks in the coolant tubes EVERY 500 HRS Make sure that all of the unit s alarms display correctly YEARLY Thoroughly clean the engine radiator Check the Engine manufacturer s manual for specific tasks Fully charge the battery and check the electrolyte level Thoroughly clean the Generator Unit Clean the control panel and tighten its connections Clean the electrical power panel and socket panel and tighten its EVERY 1000 HRS connections YEARLY Make sure the control appar
119. if unit voltage is present and within limits Flashes during synchronization with Mains Flashing Red LED indicates alarm Green when GCB is closed Flashes during synchronization with Mains Opens and closes GCB in Manual mode Green is MCB is closed Flashes during synchronization with Mains Green if Mains Power is correct Red light flashes if Mains Failure occurs and generator stops continuous if generator is operating turns off when Mains power restored Confirms on screen value Increases value Decreases value Cycles through MEASUREMENT ADJUSTMENT HISTORY display screens Page 47 of 62 RENTAL SERIES ELECTRICAL GENERATOR The InteliGen module contains the following three menu screens e Measurement e Adjustment e History Page Can be selected using the following button 18 To display the different instruments on each screen menu press E 17 and ies 16 The Measurement screen displays the parameters measured by the Engine if the Engine uses an electronic management system many additional parameters can be displayed In addition to these parameters measurements can be displayed for fuel level oil pressure current voltage frequency run hours and battery charge level The Adjustment menu screen displays the adjustment parameters already configured it is not necessary to edit any of these The History screen menu displays the log of alarms that have occurred in the
120. ine Neutral AC Voltage of generator e Line Line AC Voltage of generator e Oil pressure e Coolant temperature e Fuel level e Engine operating hours e DC voltage of battery e AC line current e Total kW e Voltage V e Phase angle cos USERS MANUAL Page 30 of 62 2 RENTAL SERIES ELECTRICAL GENERATOR POWER The following is an example of what the LCD screen 8 will look like when the various parameters are displayed Initial screen in which Engine speed and generator Mo are measured To measure the next parameter press x Then the second measurement screen appears indicating the Voltage readings between each Phase and Neutral To measure the next parameter press The third measurement screen will appear indicating the Voltage readings between Phases To measure the next parameter press Pressing afterwards we move from one parameter to the next in the order specified on the previous page Turns on to indicate a set alarm displayed along with the icons detailed on the preceding page Warning state Stoppage LCD screen will appear as follows when a configurable alarm is activated USERS MANUAL Page 31 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER ALARMS The following chart describes each alarm Fuel level below minimum Low battery voltage Emergency Stop Engine overspeed Low oil pressure High Engine temperature If Engine does not start afte
121. ine start switch Always start the engine according to the procedure that is described in the Operation and Maintenance Manual Engine Starting topic in the Operation Section Knowing the correct procedure will help to prevent major damage to the engine components Knowing the procedure will also help to prevent personal injury To ensure that the jacket water heater if equipped and or the lube oil heater if equipped is working correctly check the water temperature gauge and the oil temperature gauge during the heater operation Engine exhaust contains products of combustion which can be harmful to your health Always start the engine and operate the engine in a well ventilated area If the engine is started in an enclosed area vent the engine exhaust to the outside 11 Safety Section Engine Starting Note The engine is equipped with an automatic device for cold starting for normal conditions of operation If the engine will be operated in very cold conditions then an extra cold starting aid may be required Normally the engine will be equipped with the correct type of starting aid for your region of operation The engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting 101928905 Engine Stopping Stop the engine according to the procedure in the Operation and Maintenance Manual Engine Stopping Operation Section in order to a
122. ing temperature As the jacket water coolant temperature rises above the minimum operating temperature the water temperature regulator opens further allowing more coolant through the radiator to dissipate excess heat The progressive opening of the water temperature regulator operates the progressive closing of the bypass passage between the cylinder block and head This ensures maximum coolant flow to the radiator in order to achieve maximum heat dissipation Note Perkins discourages the use of all air flow restriction devices such as radiator shutters Restriction of the air flow can result in the following high exhaust temperatures power loss excessive fan usage and reduction in fuel economy This document is printed from SPI Not for Resale SEBU7833 03 A cab heater is beneficial in very cold weather The feed from the engine and the return lines from the cab should be insulated in order to reduce heat loss to the outside air Insulating the Air Inlet and Engine Compartment When temperatures below 18 C 0 F will be frequently encountered an air cleaner inlet that is located in the engine compartment may be specified An air cleaner that is located in the engine compartment may also minimize the entry of snow into the air cleaner Also heat that is rejected by the engine helps to warm the intake air Additional heat can be retained around the engine by insulating the engine compartment 102322217 Fuel
123. ion QOQ Illustration 10 g00704135 Gases from a battery can explode Keep any open flames or sparks away from the top of a battery Do not smoke in battery charging areas Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter or a hydrometer Incorrect jumper cable connections can cause an explosion that can result in injury Refer to the Operation Section of this manual for specific instructions Do not charge a frozen battery This may cause an explosion The batteries must be kept clean The covers if equipped must be kept on the cells Use the recommended cables connections and battery box covers when the engine is operated Fire Extinguisher Make sure that a fire extinguisher is available Be familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher regularly Obey the recommendations on the instruction plate Lines Tubes and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install any lines that are bent or damaged Do not clip any other items to the high pressure lines This document is printed from SPI Not for Resale 10 Safety Section Crushing Prevention and Cutting Prevention Repair any lines that are loose or damaged Leaks can cause fires Consult your Perkins dealer or your Perkins distributor for repair or for replacement parts Check lines tubes and h
124. ion Control System Valve Lash Cold inch Engine Label Use Service Tool Se ee ECM Exhaust 0 0 Inlet 0 00 to verify current Hanger No position Label No 3181A081 ngine settings Illustration 17 g01173630 This typical example of a label is installed on engines that have electronic fuel injection systems and installed on engines that have electronic fuel injection pumps IMPORTANT ENGINE INFORMATION Engine Family 5PKXL04 0AJ1 List RE81372 Engine Type 2160 2200 Displacement 4 400 Advertised kw 62 RPM 2200 Fuel Rate at adv kw 64 2 mm3 stk Init Timing DEG BTDC idle RPM e11 97 68CA 00 000 0089701 Manufacturer settings are to be made with engine at normal operating temperature with transmission in neutral This engine conforms to 2005 U S EPA non road and California off road Regulations for large C I engines and is certified to operate on commercially available diesel fuel Emission Control System Valve Lash Cold inch Engine Label DDI Exhaust 0 0 Inlet 0 00 Hanger No position Label No 3181A081 Illustration 18 g01156733 This typical example of a label is installed on engines that have mechanical fuel injection pumps This document is printed from SPI Not for Resale 22 SEBU7833 03 Product Information Section Product Identification Information Label for engines that comply with MSHA emissions LABEL NUMBER MSHA APPR NO ENGINE MODEL CURVE NO W _
125. ipment 6 1 PRIOR TO MAINTENANCE You must first e Switch Control Module to the STOP position e Press the emergency stop button e Open the battery isolator 6 2 DURING MAINTENANCE Preventive maintenance tasks are necessary to preserve the unit doing so will result in optimum performance Be sure to verify the following items 1 While the Engine is cold the oil level should be between the minimum and maximum values If it is below the minimum add Engine oil Note With the GPM 2 and InteliGen modules after running 50 hours notice will be given to change the oil The recommended oil is 15W40 2 The radiator water level should be adequate 3 The fuel level in the tank should be sufficient for the service to be performed The generator control panel is equipped with a fuel gauge which will be functional whenever the electrical panel is receiving power 4 Always refuel in a well ventilated area with the engine stopped 5 Closely inspect the connections and the electrical circuit for both the mechanical and electrical sections 6 Check carefully for possible liquid leaks If a leak is detected find its source and resolve the problem 7 The air inlet and outlet vents should be completely unobstructed to allow for free circulation of cooling air 8 Check the battery s connection terminals and electrolyte level if necessary add demineralized or distilled water Acid should never be USERS MANUAL Pa
126. irs If the engine will not start only due to the condition of the battery either charge the battery or start the engine with jump start cables The condition of the battery can be rechecked after the engine has been switched OFF NOTICE Using a battery source with the same voltage as the electric starting motor Use ONLY equal voltage for jump starting The use of higher voltage will damage the electrical system Do not reverse the battery cables The alternator can be damaged Attach ground cable last and remove first When using an external electrical source to start the engine turn the generator set control switch to the OFF position Turn all electrical accessories OFF be fore attaching the jump start cables Ensure that the main power switch is in the OFF posi tion before attaching the jump start cables to the en gine being started 1 Turn the start switch to the OFF position Turn off all the engine s accessories 2 Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source SEBU7833 03 3 Connect one negative end of the jump start cable to the negative cable terminal of the electrical source Connect the other negative end of the jump start cable to the engine block or to the chassis ground This procedure helps to prevent potential sparks from ign
127. isually inspect the water pump for leaks Renew the water pump seal or the water pump if there is an excessive leakage of coolant Refer to the Disassembly and Assembly Manual Water Pump Remove and Install for the disassembly and assembly procedure This document is printed from SPI Not for Resale SEBU7833 03 79 Warranty Section Warranty Information Warranty Section Warranty Information 101903596 Emissions Warranty Information This engine may be certified to comply with exhaust emission standards and gaseous emission standards that are prescribed by the law at the time of manufacture and this engine may be covered by an Emissions Warranty Consult your authorized Perkins dealer or your authorized Perkins distributor in order to determine if your engine is emissions certified and if your engine is subject to an Emissions Warranty This document is printed from SPI Not for Resale 80 Index Section Index A After Stanin ENGINE ssseeciiccdsteaid obeckcodk eames tectinas 30 After Stopping Engine cccccsescceesseeseeeeeeeeeees 32 Aftercooler Core Clean Test
128. iting the combustible gases that are produced by some batteries 4 Start the engine 5 Immediately after the stalled engine is started disconnect the jump start cables in reverse order After jump starting the alternator may not be able to fully recharge batteries that are severely discharged The batteries must be replaced or charged to the correct voltage with a battery charger after the engine is stopped Many batteries which are considered unusable are still rechargeable Refer to Operation and Maintenance Manual Battery Replace and Testing and Adjusting Manual Battery Test 101903609 After Starting Engine Note In temperatures from 0 to 60 C 32 to 140 F the warm up time is approximately three minutes In temperatures below 0 C 32 F additional warm up time may be required When the engine idles during warm up observe the following conditions e Check for any fluid or for any air leaks at idle rom and at one half full rom no load on the engine before operating the engine under load This is not possible in some applications Operate the engine at low idle until all systems achieve operating temperatures Check all gauges during the warm up period Note Gauge readings should be observed and the data should be recorded frequently while the engine is operating Comparing the data over time will help to determine normal readings for each gauge Comparing data over time will also help dete
129. l Break apart the pleats and inspect the oil filter for metal debris An excessive amount of metal debris in the oil filter may indicate early wear or a pending failure Use a magnet to differentiate between the ferrous metals and the nonferrous metals that are found in the oil filter element Ferrous metals may indicate wear on the steel and cast iron parts of the engine Nonferrous metals may indicate wear on the aluminum parts brass parts or bronze parts of the engine Parts that may be affected include the following items main bearings rod bearings turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter SEBU7833 03 Illustration 39 g01003628 2 Filter head 3 O ring seal 3 Clean the sealing surface of the oil filter head 2 Ensure that the union not shown in the oil filter head is secure 4 Apply clean engine oil to the O ring seal 3 on the oil filter NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 5 Install the oil filter Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Replace the Element for the Oil Filter Illustration 40 g010
130. ld drop off of the engine Replace any damaged warning signs or missing warning signs If a warning sign is attached to a part of the engine that is replaced install a new warning sign on the replacement part Perkins dealers or Perkins distributors can provide new warning signs Do not work on the engine and do not operate the engine unless the instructions and warnings in the Operation and Maintenance Manual are understood Correct care is your responsibility Failure to follow the instructions or failure to heed the warnings could result in injury or in death 1 Universal Warning Ay WARNING Do not operate or work on this equipment unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals Failure to follow the instructions or heed the warnings could result in serious injury or death 5 Safety Section Safety Messages Illustration 1 g01154807 Typical example The Universal Warning label 1 may be located on the valve mechanism cover or the inlet manifold Refer to illustration 2 Note The location of this label will depend on the application of the engine Illustration 2 g01682734 Typical example 2 Ether Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury
131. leaned and properly inspected The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings The secondary air cleaner element is not serviceable or washable Refer to the OEM information for instructions in order to replace the secondary air cleaner element When the engine is operating in environments that are dusty or dirty air cleaner elements may require more frequent replacement Illustration 33 g00736431 1 Cover 2 Primary air cleaner element 3 Secondary air cleaner element 4 Air inlet 1 Remove the cover Remove the primary air cleaner element 2 The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element Note Refer to Cleaning the Primary Air Cleaner Elements 3 Cover the air inlet with tape in order to keep dirt out 4 Clean the inside of the air cleaner cover and body with a clean dry cloth 5 Remove the tape for the air inlet Install the secondary air cleaner element Install a primary air cleaner element that is new or cleaned 6 Install the air cleaner cover 7 Reset the air cleaner service indicator This document is printed from SPI Not for Resale 62 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace Cleaning the Primary Air Cleaner Elements NOTICE Observe the following guideline
132. low the hose that is being replaced 4 Remove the hose clamps 5 Disconnect the old hose 6 Replace the old hose with a new hose 7 Install the hose clamps with a torque wrench Note For the correct coolant see this Operation and Maintenance Manual Fluid Recommendations 8 Refill the cooling system Refer to the OEM information for further information on refilling the cooling system 9 Clean the cooling system filler cap Inspect the cooling system filler cap s seals Replace the cooling system filler cap if the seals are damaged Install the cooling system filler cap 10 Start the engine Inspect the cooling system for leaks This document is printed from SPI Not for Resale SEBU7833 03 102335774 Radiator Clean The radiator is not usually supplied by Perkins The following text describes a typical cleaning procedure for the radiator Refer to the OEM information for further information on cleaning the radiator Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the radiator for these items Damaged fins corrosion dirt grease insects leaves oil and other debris Clean the radiator if necessary Ay WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the n
133. lso measures the control of oil consumption A second test is conducted with moderate oil soot The second test measures the following criteria wear of piston rings wear of cylinder liners and resistance to corrosion A third new test measures the following characteristics with high levels of soot in the oil wear of the valve train resistance of the oil in plugging the oil filter and control of sludge In addition to the new tests API CH 4 oils have tougher limits for viscosity control in applications that generate high soot The oils also have improved oxidation resistance API CH 4 oils must pass an additional test piston deposit for engines that use aluminum pistons single piece Oil performance is also established for engines that operate in areas with high sulfur diesel fuel All of these improvements allow the API CH 4 oil to achieve optimum oil change intervals API CH 4 oils are recommended for use in extended oil change intervals API CH 4 oils are recommended for conditions that demand a premium oil Your Perkins dealer or your Perkins distributor has specific guidelines for optimizing oil change intervals Some commercial oils that meet the API classifications may require reduced oil change intervals To determine the oil change interval closely monitor the condition of the oil and perform a wear metal analysis This document is printed from SPI Not for Resale 40 Maintenance Section Refill Capacities NOT
134. make sure to completely flush the cooling system with clear water Continue to flush the system until all the signs of the cleaning agent are gone 7 Drain the cooling system into a suitable container and flush the cooling system with clean water Note The cooling system cleaner must be thoroughly flushed from the cooling system Cooling system cleaner that is left in the system will contaminate the coolant The cleaner may also corrode the cooling system 8 Repeat Steps 6 and 7 until the system is completely clean 9 Fill the cooling system with the Perkins Premixed ELC ELC Cooling System Contamination NOTICE Mixing ELC with other products reduces the effective ness of the ELC and shortens the ELC service life Use only Perkins Products for premixed or concen trate coolants Use only Perkins ELC extender with Perkins ELC Failure to follow these recommenda tions can result in shortened cooling system compo nent life ELC cooling systems can withstand contamination to a maximum of ten percent of conventional heavy duty coolant antifreeze or SCA If the contamination exceeds ten percent of the total system capacity perform ONE of the following procedures e Drain the cooling system into a suitable container Dispose of the coolant according to local regulations Flush the system with clean water Fill the system with the Perkins ELC e Drain a portion of the cooling system into a suitable container according to loc
135. n flammable fluid Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting Wiring must be kept in good condition All electrical wires must be correctly routed and securely attached Check all electrical wires daily Repair any wires that are loose or frayed before you operate the engine Clean all electrical connections and tighten all electrical connections Eliminate all wiring that is unattached or unnecessary Do not use any wires or cables that are smaller than the recommended gauge Do not bypass any fuses and or circuit breakers This document is printed from SPI Not for Resale SEBU7833 03 Arcing or sparking could cause a fire Secure connections recommended wiring and correctly maintained battery cables will help to prevent arcing or sparking Inspect all lines and hoses for wear or for deterioration The hoses must be correctly routed The lines and hoses must have adequate support and secure clamps Tighten all connections to the recommended torque Leaks can cause fires Oil filters and fuel filters must be correctly installed The filter housings must be tightened to the correct torque i Illustration 9 g00704059 Use caution when you are refueling an engine Do not smoke while you are refueling an engine Do not refuel an engine near open flames or sparks Always stop the engine before refueling 9 Safety Section Fire Prevention and Explosion Prevent
136. n order to know when to drain If the filter were to become worn out it should be replaced 12 The oil draining pump improves the draining process saves time and facilitates maintenance 13 The fuel tank includes a drain hatch to provide quick access and a safety valve to prevent fuel from being extracted through the outlet on the base frame 14 The radiator is drained through the base frame outlet 15 For maintaining the canopy we recommend cleaning periodically to avoid dirt buildup The unit s galvanized canopy prevents corrosion and rust Note While performing preventive maintenance tasks it is advisable to wear protective eyewear and gloves during all operations involving the handling of battery acid USERS MANUAL Page 51 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER Note Remember to always perform all operations with the utmost precaution and safety as indicated in this Manual Pay special attention to the risk of short circuits that could be caused by coming in contact with the unit s metallic objects USERS MANUAL Page 52 of 62 RENTAL SERIES ELECTRICAL GENERATOR POWER 6 3 MAINTENANCE CHART After 50 hrs Perform 250 hr maintenance Check fuel level on the main tank Check coolant fluid level Check the oil level see engine s user manual Drain water separator filter Make sure the radiator inlets and outlets are unobstructed Inspect the air filter service ind
137. n the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a Suitable pressurizing pump in order to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 6 Start the engine Inspect the cooling system for leaks and for correct operating temperature SEBU7833 03 101929799 Cooling System Coolant Change ho aat Illustration 30 g01003928 Drain plug NOTICE Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged Note The radiator may not have been provided by Perkins The following is a general procedure for changing the coolant Refer to the OEM information for the correct procedure 1 Ensure that the vehicle is on level ground 2 Remove the filler cap of the cooling system 3 Remove the drain plug 1 from the side of the cylinder block in order to drain the engine Ensure that the drain hole is not
138. nates rapidly for 2 to 3 seconds or if the glow plug indicator light fails to illuminate a malfunction exists in the cold start system Do not use ether or other starting fluids to start the engine 4 When the engine starts release the engine start switch key 5 If the engine does not start release the engine start switch and allow the starter motor to cool Then repeat steps 2 through step 4 6 If the engine is equipped with a throttle allow the engine to idle for three to five minutes or allow the engine to idle until the water temperature indicator begins to rise The engine should run at low idle smoothly until soeed is gradually increased to high idle Allow the white smoke to disperse before proceeding with normal operation 7 Operate the engine at low load until all systems reach operating temperature Check the gauges during the warm up period 8 Turn the engine start switch to the OFF position in order to stop the engine This document is printed from SPI Not for Resale 30 Operation Section Engine Starting 102177935 Starting with Jump Start Cables Ay WARNING Improper jump start cable connections can cause an explosion resulting in personal injury Prevent sparks near the batteries Sparks could cause vapors to explode Do not allow jump start cable ends to contact each other or the engine Note If it is possible first diagnose the reason for the starting failure Make any necessary repa
139. ne The left and the right applications machine genset and industrial mobile sides of the engine are determined from the flywheel equipment The engines are available in the following end The number 1 cylinder is the front cylinder types of aspiration e Turbocharged aftercooled e Turbocharged This document is printed from SPI Not for Resale SEBU7833 03 Illustration 15 goo984281 A typical example of the layout of the valves A Inlet valves B Exhaust valves Table 1 Table 2 17 Product Information Section Model Views 1103 Industrial Engine Specifications Number of Cylinders 3 In Line Bore 105 mm 4 134 inch Stroke 127 mm 5 0 inch Aspiration Turbocharged Naturally aspirated Compression Ratio NA 19 25 1 T 18 25 1 Displacement 3 3 L 201 in Firing Order 123 Rotation flywheel end Counterclockwise Valve Lash Setting Inlet 0 20 mm 0 008 inch Valve Lash Setting Exhaust 1104 Industrial Engine Specifications Number of Cylinders 4 In Line Bore 105 mm 4 134 inch Stroke 127 mm 5 0 inch Aspiration Turbocharged aftercooled Turbocharged Naturally aspirated Compression Ratio NA 19 25 1 NA T 18 23 1 T TA Displacement 4 4 L 268 in Firing Order 1342 Rotation flywheel end Counterclockwise Valve Lash Setting Inlet 0 20 mm 0 008 inch Valve Lash Setting Exhaust 0 4
140. ne warranty invalid Allow the engine to cool for one hour before washing the engine Periodic cleaning of the engine is recommended Steam cleaning the engine will remove accumulated oil and grease A clean engine provides the following benefits e Easy detection of fluid leaks e Maximum heat transfer characteristics e Ease of maintenance Note Caution must be used in order to prevent electrical components from being damaged by excessive water when the engine is cleaned Pressure washers and steam cleaners should not be directed at any electrical connectors or the junction of cables into the rear of the connectors Avoid electrical components such as the alternator and the starter Protect the fuel injection pump from fluids in order to wash the engine This document is printed from SPI Not for Resale SEBU7833 03 101915869 Engine Air Cleaner Element Dual Element Clean Replace NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine Servicing the Air Cleaner Elements Note The air filter system m
141. ng in operation 61 Image 17 Caution with generator startup 61 Image 18 General warning 61 Image 19 Undefined Warning Notice 61 Image 20 Electrical Hazard 230 Volts 61 Image 21 Electrical Hazard 400 Volts 61 Image 22 Lifting point 61 Image 23 Possible battery leakage 61 Image 24 Electrical grounding 61 Image 25 Noise output 90 dB 61 Image 26 Noise output 114 dB 61 Image 27 Use of hearing protection required 61 Image 28 Coolant Flush 61 Image 29 Oil draining 61 Image 30 Fuel draining 61 Image 31 Battery isolator 61 USERS MANUAL Page 62 of 62 23 Perkins aoe Operation and Maintenance Manual 1103 and 1104 Industrial Engines 0 O JJ Q OR AES OO DA Ae m m m m m m ms Se gy oe UO w gt gt eaegecacacacad 3 5 5 J 5 5 7 Sw ws SS Sw N N NT N DK DG Te l This document is printed from SPI Not for Resale Important Safety Information Most accidents that involve product operation maintenance and repair are caused by failure to observe basic safety rules or precautions An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs A person must be alert to potential hazards This person should also have the necessary training skills and tools to perform these functions properly Improper operation lubrication maintenance or repair of this product can be dangerous and could result in injury or death Do not operate
142. ng temperatures are expected check the coolant for the correct antifreeze protection The cooling system must be protected against freezing to the lowest expected outside temperature Add the correct coolant water mixture if necessary Perform all required periodic maintenance on all driven equipment This maintenance is outlined in the instructions from the OEM Not for Resale SEBU7833 03 Cold Weather Operation 102717265 Cold Weather Operation Perkins Diesel Engines can operate effectively in cold weather During cold weather the starting and the operation of the diesel engine is dependent on the following items e The type of fuel that is used e The viscosity of the engine oil e The operation of the glow plugs e Optional Cold starting aid e Battery condition This section will cover the following information e Potential problems that are caused by cold weather operation Suggest steps which can be taken in order to minimize starting problems and operating problems when the ambient air temperature is between 0 to 40 C 32 to 40 F The operation and maintenance of an engine in freezing temperatures is complex This is because of the following conditions e Weather conditions e Engine applications Recommendations from your Perkins dealer or your Perkins distributor are based on past proven practices The information that is contained in this section provides guidelines for cold weather operati
143. ngine Ensure that the area is free of personnel If equipped ensure that the lighting system for the engine is suitable for the conditions Ensure that all lights work correctly if equipped All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures To help prevent an accident that is caused by parts in rotation work around the parts carefully This document is printed from SPI Not for Resale SEBU7833 03 Do not bypass the automatic shutoff circuits Do not disable the automatic shutoff circuits The circuits are provided in order to help prevent personal injury The circuits are also provided in order to help prevent engine damage See the Service Manual for repairs and for adjustments 102207232 Engine Starting Ay WARNING Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury If a warning tag is attached to the engine start switch or to the controls DO NOT start the engine or move the controls Consult with the person that attached the warning tag before the engine is started All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures To help prevent an accident that is caused by parts in rotation work around the parts carefully Start the engine from the operator s compartment or from the eng
144. nnect 55 ENOING Gla xsi nce Mean edt iuleltatverhanetnidtanar 60 Engine Air Cleaner Element Dual Element Clean Replace cccccssseeececeeeeeeeeeeeeeeesaeseeeeeeas 61 Engine Air Cleaner Element Single Element Inspect Replace ceeeccccseeeeeeeeseeeeceeeeeeeesaaeeeees 63 Engine Oil Sample Obtain cccceeeseeeeeeeeeees 64 Fuel Injector Test Change scccceceseeeeeeeeeees 68 FUG Syst m PME suraia ied 69 Severe Service Application Check ccc 75 Daily Alternator and Fan Belts Inspect Adjust Repl Ce eeoa 53 Cooling System Coolant Level Check 59 Driven Equipment Check cccccceeeseeeeeeseeees 60 Engine Air Cleaner Service Indicator Inspect 63 Engine Oil Level Check ccceccseeeesseeeeeeeeeeees 64 Fuel System Primary Filter Water Separator LAN wifee ath cecean tS icaute ato taneaisee E esncSaebacassaece 70 Walk Around Inspection ceecccceeeeeceeeeeseeeeees 77 Every 50 Service Hours or Weekly Fuel Tank Water and Sediment Drain 73 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check c cceee 54 Engine Air Cleaner Element Dual Element Cleam AC DIA CS ndrinta iorra i ea iat 61 Engine Air Cleaner Element Single Element Inspect Replace grasa tater ce ade 63 Engine Ground Inspect Clean ccccseeeeee 64 Engine Oil and Filter
145. nnect any battery chargers amp The NEGATIVE cable connects the NEGATIVE battery terminal to the NEGATIVE terminal on the starting motor Disconnect the cable from the NEGATIVE battery terminal A The POSITIVE cable connects the POSITIVE battery terminal to the POSITIVE terminal on the starting motor Disconnect the cable from the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Dispose of used batteries to an appropriate recycling facility SEBU7833 03 5 Remove the used battery 6 Install the new battery Note Before the cables are connected ensure that the engine start switch is OFF 7 Connect the cable from the starting motor to the POSITIVE battery terminal 8 Connect the NEGATIVE cable to the NEGATIVE battery terminal 102747977 Battery Electrolyte Level Check When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing If batteries are correctly charged the ammeter reading should be very near zero when the engine is in operation All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps
146. nt for replenishing the generator base tank You should consider this series of points e inorder to connect or disconnect you should move backwards the female lock fitting e Make sure that the external tank aspiration circuit does not contain air e Inthe external tank the aspiration connector should be male and the return connector female both are 3 8 BSP connectors e Return should be correctly connected e Connectors have to be watertight they lock when they are disconnected e The distance between tank and genset has to be as shorter as possible If you observe engine anomalous behaviour lack of power for aspiration problems you should have to reduce distance or increase the hose diameter USERS MANUAL Page 15 of 62 POWER RENTAL SERIES ELECTRICAL GENERATOR 3 2 3 PRIOR TO STARTING GENERATOR Before starting up the generator inspect the consumer power supply conductors to make sure they are in perfect condition and that the consumers are disconnected the unit should always be started up at no load Make sure that there is nothing obstructing the ventilation ducts and that there are no foreign objects inside the unit Make sure the fluid levels of the Electrical Generator are adequate for the service the unit will be providing and that there are no leaks or spillage 3 2 4 ELECTRICAL CONNECTION The connecting of cables that supply consumers must be performed by qualified personnel these conductors should
147. nthetic Base Stock Oil synthetic base oils are acceptable for use in these engines if these oils meet the performance requirements that are specified for the engine synthetic base oils generally perform better than conventional oils in the following two areas e Synthetic base oils have improved flow at low temperatures especially in arctic conditions e Synthetic base oils have improved oxidation Stability especially at high operating temperatures This document is printed from SPI Not for Resale SEBU7833 03 Some synthetic base oils have performance characteristics that enhance the service life of the oil Perkins does not recommend the automatic extending of the oil change intervals for any type of oll Re refined base stock oil Re refined base stock oil are acceptable for use in Perkins engines if these oils meet the performance requirements that are specified by Perkins Re refined base stock oil can be used exclusively in finished oil or in a combination with new base stock oil The US military specifications and the specifications of other heavy equipment manufacturers also allow the use of re refined base stock oil that meet the same criteria The process that is used to make re refined base stock oil should adequately remove all wear metals that are in the used oil and all the additives that are in the used oil The process that is used to make re refined base stock oil generally involves the process of vacuum di
148. on Hints for Cold Weather Operation e f the engine will start operate the engine until a minimum operating temperature of 81 C 177 8 F is achieved Achieving operating temperature will help prevent the intake valves and exhaust valves from sticking e The cooling system and the lubrication system for the engine do not lose heat immediately upon shutdown This means that an engine can be shut down for a period of time and the engine can still have the ability to start readily 33 Operation Section Cold Weather Operation Install the correct specification of engine lubricant before the beginning of cold weather Check all rubber parts hoses fan drive belts etc weekly Check all electrical wiring and connections for any fraying or damaged insulation Keep all batteries fully charged and warm Fill the fuel tank at the end of each shift Check the air cleaners and the air intake daily Check the air intake more often when you operate In SNOW Ensure that the glow plugs are in working order Refer to Testing and Adjusting Manual Glow Plug Test Personal injury or property damage can result from alcohol or starting fluids Alcohol or starting fluids are highly flammable and toxic and if improperly stored could result in injury or property damage Ay WARNING Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury e For jump startin
149. on Section c cceceeeececececeees 13 R Radiator Cled n ee O 75 Reference Numbers ccccececcecececececececececceaececes 19 Record for Reference ccccececececececeeeeeeeeeees 19 Refill C pacties sirarne iona i 37 COOlING SYSTEM iaie cerieeoetsl eines 37 Lubrication System cccccseeceeeeeeeeeeeeeeeeeeeeaees 37 S Safety Messages cccccccsesseeeceeseeeeeeeeeeeeeseeeeeeeas 5 1 Universal Warning cccccseseeeeeeeeeeeeeeeenees 5 02 eNO hs e a taming nonin oienplashtean 5 DAISY SOCUON aina a abi iaee cae 5 Serial Number Plate ccccccceccececeecececeeaeceeaes 19 Severe Service Application Check 0008 75 Environmental Factors cccccecececececececececenes 76 Incorrect Maintenance Procedures 0 76 Incorrect Operating Procedures ccccee 76 Starting Motor INSP Ct ccccceeceeeeeeeeeeeeeeeeees 76 Starting the Engine ceisia i 29 Starting with Jump Start Cables cccceeeeeees 30 Stopping the Engine seers 32 T Table of Contents c cccccececcecececcececeecececeeaeneceeaees 3 Turbocharger Inspect If Equipped 76 INSPOCTING cccccecccsececeeeeeseeeeseeeeseeseseeeeseeesees 77 Removal and Installation ccccccecececeeeeenees 76 This document is printed from SPI Not for Resale 82 SEBU7833 03 Index Section W Walk Around INSPECTION c
150. oolant For information regarding the disposal and the recycling of used coolant consult your Perkins dealer or your Perkins distributor Flush 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain cock or install the drain plug in the engine Close the drain cock or install the drain plug on the radiator NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 3 Fill the cooling system with clean water Install the cooling system filler cap 4 Start and run the engine at low idle until the temperature reaches 49 to 66 C 120 to 150 F SEBU7833 03 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain cock or remove the drain plug on the engine Open the drain cock or remove the drain plug on the radiator Allow the water to drain Flush the cooling system with clean water Fill 1 Close the drain cock or install the drain plug on the engine Close the drain cock or install the drain plug on the radiator NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 2 Fill the cooling system with Commercial Heavy Duty Coolant Add Supplemental Coolant Addi
151. oses carefully Do not use your bare hand to check for leaks Use a board or cardboard to check for leaks Tighten all connections to the recommended torque Replace the parts if any of the following conditions are present e End fittings are damaged or leaking e Outer coverings are chafed or cult e Wires are exposed e Outer coverings are ballooning Flexible part of the hoses are kinked e Outer covers have embedded armoring e End fittings are displaced Make sure that all clamps guards and heat shields are installed correctly During engine operation this will help to prevent vibration rubbing against other parts and excessive heat 102143194 Crushing Prevention and Cutting Prevention Support the component correctly when work beneath the component is performed Unless other maintenance instructions are provided never attempt adjustments while the engine is running Stay clear of all rotating parts and of all moving parts Leave the guards in place until maintenance is performed After the maintenance is performed reinstall the guards Keep objects away from moving fan blades The fan blades will throw objects or cut objects When objects are struck wear protective glasses in order to avoid injury to the eyes Chips or other debris may fly off objects when objects are struck Before objects are struck ensure that no one will be injured by flying debris SEBU7833 03 101372247 Mounting and Dismo
152. oved to be unwarranted NOTICE Accumulated grease and or oil on an engine is a fire hazard Remove the accumulated grease and oil Re fer to this Operation and Maintenance Manual En gine Clean for more information Ensure that the cooling system hoses are correctly clamped and that the cooling system hoses are tight Check for leaks Check the condition of all pipes Inspect the water pump for coolant leaks Note The water pump seal is lubricated by the coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of the water pump and the installation of water pump and or seal refer to the Disassembly and Assembly Manual Water Pump Remove and Install for more information or consult your Perkins dealer or your Perkins distributor Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the rocker cover Inspect the fuel system for leaks Look for loose fuel line clamps and or tie wraps Inspect the piping for the air intake system and the elbows for cracks and for loose clamps Ensure that hoses and tubes are not contacting other hoses tubes wiring harnesses etc Inspect the alternator belts and any accessory drive belts for cracks breaks or other damage Thi
153. ozzle must be less than 205 kPa 30 psi for cleaning purposes Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction to the fan s air flow Hold the nozzle approximately 6 mm 0 25 inch away from the radiator fins Slowly move the air nozzle in a direction that is parallel with the radiator tube assembly This will remove debris that is between the tubes Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides Use a degreaser and steam for removal of oil and grease Clean both sides of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water If the radiator is blocked internally refer to the OEM Manual for information regarding flushing the cooling system After cleaning the radiator start the engine Allow the engine to operate at low idle speed for three to five minutes Accelerate the engine to high idle This will help in the removal of debris and the drying of the core Slowly reduce the engine speed to low idle and then stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary 75 Maintenance Section Radiator Clean Inspect the fins for damage Bent fins may be opened with a comb Inspect the
154. preferred fuels e Group 2 permissible fuels e Group 3 aviation kerosene fuels e Other fuels Group 1 preferred fuels Specification DERV to EN590 Note Only use Arctic fuels when the temperature is below 0 C 32 F Do not use Arctic fuels when the ambient temperature is above 0 C 32 F To ensure that the time period between cranking the engine and first fire is Kept to a minimum only use fuel of the correct viscosity and at the correct temperature Gas oil to BS2869 Class A2 ASTM D975 91 Class 2D This can only be used if the fuel has the correct specification of lubricity JIS K2204 1992 Grades 1 2 3 and Special Grade 3 This can only be used if the fuel has the correct specification of lubricity Note If low sulfur or low sulfur aromatic fuels are used then fuel additives can be used to Increase lubricity Group 2 permissible fuels Specification These fuel specifications are considered acceptable for issues of warranty However these fuels may reduce the life of the engine the engine s maximum power and the engine s fuel efficiency This document is printed from SPI Not for Resale SEBU7833 03 ASTM D975 91 Class 1D JP7 Mil T38219 NATO F63 NOTICE These fuels should have a wear scar value of 650 micrometers maximum HFRR to ISO 12156 1 Group 3 aviation kerosene fuels Specification These fuels need additives to achieve lubricity o
155. prevented e Valves become stuck e Pushrods may become bent e Other damage to valve train components can result For this reason when the engine is started the engine must be operated until the coolant temperature is 71 C 160 F minimum Carbon deposits on the valve stems will be kept at a minimum and the free operation of the valves and the valve components will be maintained In addition the engine must be thoroughly warmed in order to keep other engine parts in better condition and the service life of the engine will be generally extended Lubrication will be improved There will be less acid and less sludge in the oil This will provide longer service life for the engine bearings the piston rings and other parts However limit unnecessary idle time to ten minutes in order to reduce wear and unnecessary fuel consumption The Water Temperature Regulator and Insulated Heater Lines The engine is equipped with a water temperature regulator When the engine coolant is below the correct operating temperature jacket water circulates through the engine cylinder block and into the engine cylinder head The coolant then returns to the cylinder block via an internal passage that bypasses the valve of the coolant temperature regulator This ensures that coolant flows around the engine under cold operating conditions The water temperature regulator begins to open when the engine jacket water has reached the correct minimum operat
156. primary air cleaner element Use a 60 watt blue light in a dark room or in a similar facility Place the blue light in the primary air cleaner element Rotate the primary air cleaner element Inspect the primary air cleaner element for tears and or holes Inspect the primary air cleaner element for light that may show through the filter material If it is necessary in order to confirm the result compare the primary air cleaner element to a new primary air cleaner element that has the same part number Do not use a primary air cleaner element that has any tears and or holes in the filter material Do not use a primary air cleaner element with damaged pleats gaskets or seals Discard damaged primary air cleaner elements 102152042 Engine Air Cleaner Element Single Element Inspect Replace Refer to Operation and Maintenance Manual Engine Air Cleaner Service Indicator Inspect NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering the air inlet NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine A wide variety of air cleaners may be installed for use with this engine
157. quickly Maintaining an elevated low idle speed for extended periods will be easier with the installation of a hand throttle The engine should not be raced in order to speed up the warm up process While the engine is idling the application of a light load parasitic load will assist in achieving the minimum operating temperature The minimum operating temperature is 82 C 179 6 F Recommendations for Coolant Warm Up Warm up an engine that has cooled below normal operating temperatures due to inactivity This should be performed before the engine is returned to full operation During operation in very cold temperature conditions damage to engine valve mechanisms can result from engine operation for short intervals This can happen if the engine is started and the engine is stopped many times without being operated in order to warm up completely When the engine is operated below normal operating temperatures fuel and oil are not completely burned in the combustion chamber This fuel and oil causes soft carbon deposits to form on the valve stems Generally the deposits do not cause problems and the deposits are burned off during operation at normal engine operating temperatures When the engine is started and the engine is stopped many times without being operated in order to warm up completely the carbon deposits become thicker This can cause the following problems SEBU7833 03 e Free operation of the valves is
158. r s responsibility to adjust and seal the ELCB according to the current regulations USERS MANUAL Page 20 of 62 RENTAL SERIES ELECTRICAL GENERATOR 5 2 GPM 2 ANALOG CONTROL MODULE Image 10 GPM 2 CONTROL MODULE USERS MANUAL Page 21 of 62 RENTAL SERIES ELECTRICAL GENERATOR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 USERS MANUAL Unit startup failure Alternator failure Battery charge Alternator failure Low oil level Low level High Coolant Temperature Overload Low fuel level Emergency Stop Overspeed Remote Startup Mode Unit heating Stop signal Maintenance Signal Maintenance reset button Unit startup button Manual Mode Key position for stopping unit Automatic Mode Programmable alarm Flashing red light three failed startup attempts Continuous red light Voltage failure or low Frequency Flashing red light Battery charge Alternator failure Continuous red light unit stopped Indicates Contact Flashing red light Low oil level Continuous red light unit stopped Indicates Contact Flashing red light High temperature Continuous red light Low coolant level Flashing red light Unit overload Red Low fuel level Continuous flashing red light Stopped warning Flashing red light Emergency Stop Continuous red light Engine overspeed Green LED Yellow
159. r 3 attempts the unit will be stopped and this icon will be displayed Z Y X W V U T S Low engine speed T Alternator Frequency beyond established limits Alternator Voltage beyond established limits If it is detected that the Generator s output current exceeds the A At established value for an extended period of time this warning will be displayed If the cutoff point for overcurrent is exceeded by 10 for one hour the unit will be stopped Note If the established limits defined as Warning or Stop are exceeded the module will display the corresponding alarm None of these will be shown if not detected by the System Note The Deep Sea 5210 module will display a Warning by lighting up the icon as well as the identifying alarm icon If the warning causes the unit to stop this icon will turn on as well as the corresponding icon both of which will be flashing USERS MANUAL Page 32 of 62 RENTAL SERIES ELECTRICAL GENERATOR EVENT LOG To view the event log press the following button repeatedly 10 This icon will flash A screen similar to this will be shown On November 1 2002 at 08 17 the system detected that the Oil pressure was below the minimum level and shut down the generator To move from one event to the next press 9 To exit the Main Screen press 10 Note Warning alarms are not logged ADJUST DATE AND TIME The date and time are adjustable When the batter
160. r cap 3 Pour the correct coolant mixture into the tank Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations for information on the correct mixture and type of coolant Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations for the cooling system capacity Do not fill the coolant recovery tank above COLD FULL mark Illustration 31 g00103639 4 Clean filler cap and the receptacle Reinstall the filler cap and inspect the cooling system for leaks Note The coolant will expand as the coolant heats up during normal engine operation The additional volume will be forced into the coolant recovery tank during engine operation When the engine is stopped and cool the coolant will return to the engine Engines Without a Coolant Recovery Tank Check the coolant level when the engine is stopped and cool This document is printed from SPI Not for Resale 60 Maintenance Section Driven Equipment Check Illustration 32 g00285520 Cooling system filler cap Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Remove the cooling system filler cap slowly in order to relieve pressure 2 Maintain the coolant level within 13 mm 0 5 inch of the
161. r system follow the OEM or filter manu facturer s recommendations Under filling or overfilling the crankcase with oil can cause engine damage 67 Maintenance Section Engine Valve Lash Inspect Adjust NOTICE To prevent crankshaft bearing damage crank the en gine with the fuel OFF This will fill the oil filters before starting the engine Do not crank the engine for more than 30 seconds 2 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 3 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes X T T lt g00998024 Illustration 42 Y ADD mark X FULL mark 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL marks on the engine oil dipstick 102171102 Engine Valve Lash Inspect Adjust This maintenance is recommended by Perkins as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life NOTICE Only qualified service personel should perform this maintenance Refer to the Service Manual or your au thorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure Operation of Perkins engines with incorrect valve lash can
162. r the capacity of the cooling system for your engine Refer to this Operation and Maintenance Manual Fluid Recommendations information for the Perkins ELC Extender 4 Clean the cooling system filler cap and inspect the gasket If the gasket is damaged discard the old filler cap and install a new filler cap If the gasket is not damaged use a Suitable pressurizing pump in order to pressure test the filler cap The correct pressure is stamped on the face of the filler cap If the filler cap does not retain the correct pressure install a new filler cap 102335378 Cooling System Coolant Level Check Engines With a Coolant Recovery Tank Note The cooling system may not have been provided by Perkins The procedure that follows is for typical cooling systems Refer to the OEM information for the correct procedures Check the coolant level when the engine is stopped and cool 59 Maintenance Section Cooling System Coolant Extender ELC Add 1 Observe the coolant level in the coolant recovery tank Maintain the coolant level to COLD FULL mark on the coolant recovery tank Ay WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 2 Loosen filler cap slowly in order to relieve any pressure Remove the fille
163. re that the power supply is disconnected before you work on the bus bar or the glow plugs Perform maintenance on the engine with the equipment in the servicing position Refer to the OEM information for the procedure for placing the equipment in the servicing position Pressure Air and Water Pressurized air and or water can cause debris and or hot water to be blown out This could result in personal injury The direct application of pressurized air or pressurized water to the body could result in personal injury When pressurized air and or water is used for cleaning wear protective clothing protective shoes and eye protection Eye protection includes goggles or a protective face shield The maximum air pressure for cleaning purposes must be below 205 kPa 30 psi The maximum water pressure for cleaning purposes must be below 275 kPa 40 psi Fluid Penetration Pressure can be trapped in the hydraulic circuit long after the engine has been stopped The pressure can cause hydraulic fluid or items such as pipe plugs to escape rapidly if the pressure Is not relieved correctly Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur Refer to the OEM information for any procedures that are required to relieve the hydraulic pressure 7 Safety Section Burn
164. reezes use ethylene glycol Propylene glycol may also be used In a 1 1 mixture with water ethylene and propylene glycol provide similar protection against freezing and boiling See Tables 17 and 18 Table 17 Ethylene Glycol r Freeze Boil Concentration Protection Protection 50 Percent 36 C 33 F 106 C 223 F 60 Percent 51 C 60 F 111 C 232 F NOTICE Do not use propylene glycol in concentrations that ex ceed 50 percent glycol because of propylene glycol s reduced heat transfer capability Use ethylene glycol in conditions that require additional protection against boiling or freezing Table 18 Propylene Glycol Freeze Anti Boil Concentration Protection Protection 50 Percent 29 C 20 F 106 C 223 F To check the concentration of glycol in the coolant measure the specific gravity of the coolant Coolant Recommendations The following two coolants are used in Perkins diesel engines Preferred Perkins Extended Life Coolant ELC SEBU7833 03 Acceptable A commercial heavy duty coolant antifreeze that meets ASTM D4985 specifications NOTICE Do not use a commercial coolant antifreeze that on ly meets the ASTM D3306 specification This type of coolant antifreeze is made for light automotive appli cations Perkins recommends a 1 1 mixture of water and glycol This mixture of water and glycol will provid
165. relieve the pres sure 57 Maintenance Section Cooling System Coolant ELC Change 1 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Illustration 29 g01003928 Typical example 2 Open the drain cock or remove the drain plug 1 on the engine Open the drain cock or remove the drain plug on the radiator Allow the coolant to drain NOTICE Dispose of used engine coolant or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Perkins to reclaim the coolant For information regarding the disposal and the recycling of used coolant consult your Perkins dealer or your Perkins distributor Flush 1 Flush the cooling system with clean water in order to remove any debris 2 Close the drain cock or install the drain plug in the engine Close the drain cock or install the drain plug on the radiator NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 3 Fill the cooling system with clean water Install the cooling system filler cap 4 Start and run the engine at low idle until the temperature reaches 49 to 66 C 120 to
166. rmation on maintenance items This document is printed from SPI Not for Resale SEBU7833 03 Product Identification Information 102280116 Engine Identification Perkins engines are identified by a serial number This number is shown on a serial number plate that is mounted on the left hand side of the engine block An example of an engine number is RE12345U090001H RE Type of engine RE12345 Engine List Number U Built in the United Kingdom 090001 Engine Serial Number H Year of Manufacture Perkins dealers need these numbers in order to determine the componenis that were included with the engine This permits accurate identification of replacement part numbers 19 Product Information Section Product Identification Information 101940474 Serial Number Plate g8Perkins ENGLAND mreng 1 bas aa 4 3 2 g00994966 Illustration 16 Typical serial number plate 1 Temporary Parts List number 2 Type 3 Serial number 4 List number The Serial Number Plate is located on the left side of the cylinder block behind the high pressure pipes of the Fuel injection pump The following information is stamped on the Serial Number Plate Engine serial number Model and Arrangement number 02164876 Reference Numbers Information for the following items may be needed to order parts Locate the information for your engine Record the information in the appropriate space Make a
167. rom your engine Guards and covers may have been removed for illustrative purposes Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual Whenever a question arises regarding your engine or this manual please consult with your Perkins dealer or your Perkins distributor for the latest available information Safety This safety section lists basic safety precautions In addition this section identifies hazardous warning situations Read and understand the basic precautions listed in the safety section before operating or performing lubrication maintenance and repair on this product Operation Operating techniques outlined in this manual are basic They assist with developing the skills and techniques required to operate the engine more efficiently and economically Skill and techniques develop as the operator gains knowledge of the engine and its capabilities The operation section is a reference for operators Photographs and illustrations guide the operator through procedures of inspecting starting operating and stopping the engine This section also includes a discussion of electronic diagnostic information Maintenance The maintenance section is a guide to engine care The illustrated step by step instructions are grouped by service hours and or calendar time maintenance intervals Items in the maintenance schedule are referenced to detailed
168. s some engines may be equipped with an oil sampling valve If S O S oil analysis is required the oil sampling valve is used to obtain samples of the engine oil The S O S oil analysis will complement the preventive maintenance program The S O S oil analysis is a diagnostic tool that is used to determine oil performance and component wear rates Contamination can be identified and measured through the use of the S O S oil analysis The S O S oil analysis includes the following tests This document is printed from SPI Not for Resale 42 Maintenance Section Refill Capacities e The Wear Rate Analysis monitors the wear of the engine s metals The amount of wear metal and type of wear metal that is in the oil is analyzed The increase in the rate of engine wear metal in the oil is as important as the quantity of engine wear metal in the oil e Tests are conducted in order to detect contamination of the oil by water glycol or fuel e The Oil Condition Analysis determines the loss of the oil s lubricating properties An infrared analysis is used to compare the properties of new oil to the properties of the used oil sample This analysis allows technicians to determine the amount of deterioration of the oil during use This analysis also allows technicians to verify the performance of the oil according to the specification during the entire oil change interval Fuel Specifications Fuel Recommendations To get the correct pow
169. s Quarts Standard Oil Sump for the Engine 6 5 7 Crankcase 1 1 These values are the approximate capacities for the crankcase oil sump which include the standard factory installed oil filters Engines with auxiliary oil filters will require additional oil Refer to the OEM specifications for the capacity of the auxiliary oil filter 37 Maintenance Section Refill Capacities Cooling System To maintain the cooling system the Total Cooling System capacity must be known The approximate capacity for the engine cooling system is listed below External System capacities will vary among applications Refer to the OEM specifications for the External System capacity This capacity information will be needed in order to determine the amount of coolant antifreeze that is required for the Total Cooling System 1104 Engine Table 7 1104 Naturally Aspirated Engine Compartment or System Liters Quarts Engine Only 10 4 11 External cooling system capacity OEM recommendation Total Cooling System 1 The external cooling system includes a radiator or an expansion tank with the following components heat exchanger aftercooler and piping Refer to the OEM specifications Enter the value for the external system capacity in t
170. s the hose will harden Hardening of the hoses will cause hose clamps to loosen This can result in leaks A constant torque hose clamp will help to prevent loose hose clamps Each installation application can be different The differences depend on the following factors e Type of hose e Type of fitting material SEBU7833 03 e Anticipated expansion and contraction of the hose e Anticipated expansion and contraction of the fittings Replace the Hoses and the Clamps Refer to the OEM information for further information on removing and replacing fuel hoses if equipped The coolant system and the hoses for the coolant system are not usually supplied by Perkins The following text describes a typical method of replacing coolant hoses Refer to the OEM information for further information on the coolant system and the hoses for the coolant system Ay WARNING Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 1 Stop the engine Allow the engine to cool 2 Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Note Drain the coolant into a suitable clean container The coolant can be reused 3 Drain the coolant from the cooling system to a level that is be
171. s being heated Wait before starting up the unit STOP 10 Indicates Stop Signal Flashing Indicates Engine cooling period Continuous The control module issues a stop command to the Engine stays lit for 20 seconds following the complete stopping of the Engine bl 11 Indicates Maintenance flashing light the first time the light turns on after 50 operating hours and afterwards every 150 hours To reset the Maintenance hour meter the Electrical Generator must be running Turn 7 12 until the control the key to the STOP position while pressing the button module becomes completely deactivated USERS MANUAL Page 24 of 62 POWER RENTAL SERIES ELECTRICAL GENERATOR ALARMS The following is a chart describing the possible alarms of the GPM 2 module If the light is flashing an audible signal will be given and generator is shut down If light is continuous indicates low Alternator failure frequency If it runs below nominal level for over 30 seconds unit is shut down If light is continuous and the engine is Contact stopped indicates contact not an alarm If light is flashing indicates failure and the control module issues unit stop command If light is continuous and the engine is Contact stopped indicates contact not an alarm If light is flashing indicates failure and Low oil pressure the control module issues unit stop command If light is continuous indi
172. s distributor for the part numbers ELC Cooling System Maintenance Correct additions to the Extended Life Coolant NOTICE Use only Perkins products for pre mixed or concen trated coolants Use only Perkins Extender with Extended Life Coolant Mixing Extended Life Coolant with other products re duces the Extended Life Coolant service life Failure to follow the recommendations can reduce cooling sys tem components life unless appropriate corrective ac tion is performed In order to maintain the correct balance between the antifreeze and the additives you must maintain the recommended concentration of Extended Life Coolant ELC Lowering the proportion of antifreeze lowers the proportion of additive This will lower the ability of the coolant to protect the system from pitting from cavitation from erosion and from deposits This document is printed from SPI 47 Maintenance Section Refill Capacities NOTICE Do not use a conventional coolant to top off a cooling system that is filled with Extended Life Coolant ELC Do not use standard supplemental coolant additive SCA Only use ELC Extender in cooling systems that are filled with ELC Perkins ELC Extender ELC Extender is added to the cooling system halfway through the ELC service life Treat the cooling system with ELC Extender at 6000 hours or three years Use Table 20 in order to determine the correct amount of ELC Extender that is required Containers of
173. s document is printed from SPI Not for Resale 76 Maintenance Section Starting Motor Inspect Environmental Factors Ambient temperatures The engine may be exposed to extended operation in extremely cold environments or hot environments Valve components can be damaged by carbon buildup if the engine is frequently started and stopped in very cold temperatures Extremely hot intake air reduces engine performance Quality of the air The engine may be exposed to extended operation in an environment that is dirty or dusty unless the equipment is cleaned regularly Mud dirt and dust can encase components Maintenance can be very difficult The buildup can contain corrosive chemicals Buildup Compounds elements corrosive chemicals and salt can damage some components Altitude Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application Necessary adjustments should be made Incorrect Operating Procedures e Extended operation at low idle e Frequent hot shutdowns e Operating at excessive loads e Operating at excessive speeds e Operating outside the intended application Incorrect Maintenance Procedures e Extending the maintenance intervals e Failure to use recommended fuel lubricants and coolant antifreeze 102177969 Starting Motor Inspect Perkins recommends a scheduled inspection of the starting motor If the starting motor fails
174. s document is printed from SPI Not for Resale 78 SEBU7833 03 Maintenance Section Water Pump Inspect Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break e Drain the water and the sediment from the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the electrolyte level of the batteries unless the engine is equipped with a maintenance free battery e Check the condition of the gauges Replace any gauges that are cracked Replace any gauge that can not be calibrated 101907756 Water Pump Inspect A failed water pump may cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure e Other potential damage to the engine Note The water pump seal is lubricated by the coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and parts contract V
175. s if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components Refer to the OEM information in order to determine the number of times that the primary filter element can be cleaned When the primary air cleaner element is cleaned check for rips or tears in the filter material The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually inspect the primary air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean primary air cleaner elements e
176. s water to accumulate in fuel tanks Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel Drain the Water and the Sediment Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment Close the drain valve Check the fuel daily Allow five minutes after the fuel tank has been filled before draining water and sediment from the fuel tank Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank at the following intervals e Weekly e Service intervals e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle b
177. se items for good condition Welds mounting brackets air lines connections clamps and seals Make repairs if necessary 102335775 Severe Service Application Check Severe service is the application of an engine that exceeds the current published standards for that engine Perkins maintains standards for the following engine parameters e Performance such as power range speed range and fuel consumption e Fuel quality e Operational Altitude e Maintenance intervals e Oil selection and maintenance e Coolant type and maintenance e Environmental qualities e Installation e The temperature of the fluid in the engine Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the defined parameters severe service operation can accelerate component wear Engines that operate under severe conditions may need more frequent maintenance intervals in order to ensure maximum reliability and retention of full service life Due to individual applications it is not possible to identify all of the factors which can contribute to severe service operation Consult your Perkins dealer or your Perkins distributor for the unique maintenance that is necessary for the engine The operating environment incorrect operating procedures and incorrect maintenance procedures can be factors which contribute to a severe service application Thi
178. ses of the Electrical Generator FREQUENCY METER Indicates the Frequency of the Electrical Generator Hz VOLTMETER WITH ATS Indicates the Voltage V by means of a switch of the different phases of the Electrical Generator HOUR METER Indicates number of hours worked by the Electrical Generator The two digits in red on the right indicate hundredths of hours Hours are indicated in white from the third digit on EMERGENCY STOP BUTTON Pressing this button brings the Electrical Generator to an immediate stop To cancel turn to the left when the end of the emergency situation has been confirmed On soundproofed units the emergency stop button is installed apart from the electrical panel built into the canopy USERS MANUAL Page 19 of 62 RENTAL SERIES ELECTRICAL GENERATOR GAUGES INDICATING ENGINE PARAMETERS Oil Pressure Intensity of Battery Voltae Engine Temperature Fuel Level DIAGNOSTIC BUTTON Allows Engine parameters to be checked when Electrical Generator is stopped electronically controlled Engines Also gives a readout of the generator s different alarms oO EARTH LEAKAGE CIRCUIT BREAKER ELCB Protection against earth leakage of one phase setting off the Electrical Generator s primary protection switch Configured to be activated when voltage is exceeded by 3 mA with a time delay of Os Includes a TEST button for checking the state of the ELCB It is the installe
179. sity of the Alternator output beyond established limits Note If the established limit for shutdown is exceeded a corresponding alarm screen will be displayed and on the configurable LED indicator 8 the Common Shutdown alarm will appear USERS MANUAL Page 40 of 62 POWER TYPICAL INFORMATION SCREEN MESSAGES Running in auto Indicates Electrical Generator running normally in Automatic Mode Also indicates the average line to neutral voltage L N the highest of the three phase currents the nominal frequency average line to line voltage L L and total kilowatts MEASUREMENT PARAMETER DISPLAY SCREENS p Coolant temperature Coolant temperature in degrees C Celsius and degrees Fahrenheit F Oil pressure Displays Engine oil pressure in Bar PSI and T a kPa Generator Amps C gt All three generator line currents USERS MANUAL Page 41 of 62 ae RENTAL SERIES ELECTRICAL GENERATOR RENTAL SERIES ELECTRICAL GENERATOR EVENT LOG To view the event log press the following button repeatedly 11 Register of Shutdown alarms occurring in the generator unit the most recent occurrences can be stored A screen similar to this is shown Event log 21 15 00 On September 10 2003 at 21 15 the system detected that the Oil pressure was below the minimum level and shut down the generator To scroll from one event to the next press o 10 To exit the M
180. stem Coolant ELC Change 57 LR ANN aene E A 57 AEA AEA EEE A naa AE A ET 58 EE S EEE E E E E E aude 57 Cooling System Coolant Extender ELC Add 59 Cooling System Coolant Level Check 59 Engines With a Coolant Recovery Tank 59 Engines Without a Coolant Recovery Tank 59 Crushing Prevention and Cutting Prevention 10 D Driven Equipment Check ccccccceesseeseeeseeees 60 SEBU7833 03 E Electrical SYSt MM essri eaa a a 11 Grounding Practices cccccceesseeeeeesseeeeeeeeaees 12 Emergency Stopping ccccsssececeeesseeesseeeeeeeeaees 32 Emissions Certification Film cccccsseeeeeeeeees 20 Label for compliant engines cccceeeeeeeeees 20 Label for engines that comply with MSHA EMISSIONS cccccseeeeceeseeceessecceeseceeseessanseeseuess 22 Label for engines that do not comply with CIMIS SIOMS sesa a a T 22 Emissions Warranty Information c ccccceeeee 79 Engine CleaNa ainn ial a tian ene lcutirennes 60 Engine Air Cleaner Element Dual Element Clean R place siioni a G 61 Cleaning the Primary Air Cleaner Elements 62 Servicing the Air Cleaner Elements 61 Engine Air Cleaner Element Single Element HSpeCUREpII CE naa 63 Engine Air Cleaner Service Indicator Inspect 63 Test the Service INdICAtOl ccccceeeeeeeseeeeees 63 Engine Description aciiw ccd
181. stillation and hydrotreating the used oil Filtering is adequate for the production of high quality re refined base stock oil Lubricants for Cold Weather When an engine is started and an engine is operated in ambient temperatures below 20 C 4 F use multigrade oils that are capable of flowing in low temperatures These oils have lubricant viscosity grades of SAE OW or SAE 5W When an engine is started and operated in ambient temperatures below 30 C 22 F use a synthetic base stock multigrade oil with an OW viscosity grade or with a 5W viscosity grade Use an oil with a pour point that is lower than 50 C 58 F The number of acceptable lubricants is limited in cold weather conditions Perkins recommends the following lubricants for use in cold weather conditions First Choice Use oil with an EMA DHD 1 Recommended Guideline Use a CH 4 oil that has an API license The oil should be either SAE OW20 SAE OW30 SAE 0OW40 SAE 5W30 or SAE 5W40 lubricant viscosity grade Second Choice Use an oil that has a CH 4 additive package Although the oil has not been tested for the requirements of the API license the oil must be either SAE 0W20 SAE OWS30 SAE OW40 SAE 5W30 or SAE 5W40 41 Maintenance Section Refill Capacities NOTICE Shortened engine service life could result if second choice oils are used Aftermarket Oil Additives Perkins does not recommend the use of aftermarket additives in oil
182. stration 44 Typical example 3 Crank the engine with the throttle lever in the CLOSED position until the engine starts Note If necessary loosen the union nuts 1 on the fuel injection lines at the connection with the fuel injector until fuel is evident Stop cranking the engine Tighten the union nuts 1 to a torque of 30 N m 22 lb ft 4 Start the engine and run the engine at idle for one minute NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 5 Cycle the throttle lever from the low idle position to the high idle position three times The cycle time for the throttle lever is one second to six seconds for one complete cycle Note In order to purge air from the fuel injection pump on Perkins engines with a fixed throttle the engine should be run at full load for thirty seconds The load should then be decreased until the engine is at high idle This should be repeated three times This will assist in removing trapped air from the fuel injection pump 6 Check for leaks in the fuel system This document is printed from SPI Not for Resale 70 Maintenance Section SEBU7833 03 Fuel System Primary Filter Water Separator Element Replace 102206563 Fuel System Primary Filter Water Separator Element Replace Fuel leaked or spilled onto hot surfaces or elec trical components can cause a fire To
183. system is refilled operate the engine while the cooling system filler cap is removed Operate the engine until the coolant level reaches the normal operating temperature and until the coolant level stabilizes As needed add the coolant mixture in order to fill the system to the specified level Changing to Perkins ELC To change from heavy duty coolant antifreeze to the Perkins ELC perform the following steps NOTICE Care must be taken to ensure that all fluids are contained during performance of inspection main tenance testing adjusting and the repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or dis assembling any component containing fluids Dispose of all fluids according to local regulations and mandates 1 Drain the coolant into a suitable container 2 Dispose of the coolant according to local regulations 3 Flush the system with clean water in order to remove any debris 4 Use Perkins cleaner to clean the system Follow the instruction on the label 5 Drain the cleaner into a suitable container Flush the cooling system with clean water 6 Fill the cooling system with clean water and operate the engine until the engine is warmed to 49 to 66 C 120 to 150 F SEBU7833 03 NOTICE Incorrect or incomplete flushing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system
184. tal Regulations it is advisable to take them to an authorized recycling center For a cleaner environment recycle all possible items and be sure to not throw electrical components in with the regular garbage so as to comply with European Directive 2002 96 EC These items should be stored separately until being taken for ecological recycling USERS MANUAL Page 56 of 62 ae RENTAL SERIES ELECTRICAL GENERATOR 9 WARRANTY e The electrical generator warranty covers an entire year starting from the date it is installed This should be communicated to SE POWER hereinafter the manufacturer in writing via fax or email The following information must be included MODEL SERIAL NUMBER and INSTALLATION DATE e If the manufacturer is not informed of the installation within a maximum of sixty days from the invoice date the latter shall be considered the effective start date of the warranty period If for any reason the installation is not possible within the first sixty days following the invoice date the manufacturer must be informed thereof in writing Thus no warranty claims shall be accepted if the manufacturer does not possess the aforementioned correspondence e The warranty of the electrical generator will cover any faulty components or assembly not caused by improper use handling or modification The warranty does not cover breakdowns caused by connecting the electrical generator to devices not installed or supplied by the m
185. the filter head 1 Ensure that the fuel drain 3 on the new spin on filter is closed This document is printed from SPI Not for Resale SEBU7833 03 Illustration 50 g01121723 4 Lubricate the sealing ring 4 with clean fuel oil 5 Install the spin on filter 2 into the top of the filter head 1 6 Tighten the spin on filter by hand until the sealing ring contacts the filter head Rotate the spin on filter through 90 degrees 7 Prime the fuel system Refer to Operation and Maintenance Manual Fuel System Prime 102335436 Fuel Tank Water and Sediment Drain NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Dispose of all fluids according to local regulations and mandates Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system 73 Maintenance Section Fuel Tank Water and Sediment Drain Water can be introduced into the fuel tank when the fuel tank is being filled Condensation occurs during the heating and cooling of fuel The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank This cause
186. the steps listed below 1 Check the levels of oil coolant and fuel 2 Close the battery isolator 3 Release the emergency shutoff switch if it has been pressed 4 Check the Electrical Generator s automatic switch levers should be in the lowered position 5 To perform the startup of your Electrical Generator please refer to point 6 OPERATION MANUAL taking into account the control panel model of your unit 6 Once the unit has been started connect the Electrical Generator s automatic switch 7 Make sure the earth leakage circuit breaker ELCB is functioning properly by pressing the TEST button 8 Turn on the electromagnetic circuit breaker once again and use the Electrical Generator normally To stop the unit 1 Disconnect the loads 2 Turn off the electromagnetic circuit breaker 3 Leave the engine running at no load for 2 minutes to cool down the generator unit A Stop the Engine completely by switching the control module switch to the OFF position USERS MANUAL Page 18 of 62 POWER RENTAL SERIES ELECTRICAL GENERATOR 5 OPERATION MANUAL The generator you purchased has been designed for manual service and thus starting and stopping the unit will be done manually The following is a description of the different elements according to the Electrical Generator chosen 5 1 ELECTRICAL PANEL COMPONENTS AMMETER Measures the Intensity A by means of a switch of the different pha
187. tive to the coolant For the correct amount refer to the Operation and Maintenance Manual Fluid Recommendations topic Maintenance section for more information on cooling system specifications Do not install the cooling system filler cap 3 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 4 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level in the expansion bottle if equipped at the correct level 5 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a Suitable pressurizing pump in order to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 6 Start the engine Inspect the cooling system for leaks and for correct operating temperature This document is printed from SPI Not for Resale SEBU7833
188. to remove any residue Flush the fins of the aftercooler core Remove any other trapped debris 7 Wash the core with hot soapy water Rinse the core thoroughly with clean water SEBU7833 03 Ay WARNING Personal injury can result from air pressure Personal injury can result without following prop er procedure When using pressure air wear a pro tective face shield and protective clothing Maximum air pressure at the nozzle must be less than 205 kPa 30 psi for cleaning purposes 8 Dry the core with compressed air Direct the air in the reverse direction of the normal flow 9 Inspect the core in order to ensure cleanliness Pressure test the core If necessary repair the core 10 Install the core Refer to the OEM information for the correct procedure 11 After cleaning start the engine and accelerate the engine to high idle rom This will help in the removal of debris and drying of the core Stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary 102322295 Aftercooler Core Inspect Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the aftercooler for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the aftercooler if necessary For air to air aftercoolers use the same methods that are used for cleaning radiators Ay WARNING
189. und inspection Check the engine for fluid leaks and air leaks 4 Increase the rpm to the rated rom Check for fluid leaks and air leaks The engine may be operated at full rated rom and at full load when the temperature of the water jacket reaches 60 C 140 F 31 Operation Section Engine Operation 102330149 Fuel Conservation Practices The efficiency of the engine can affect the fuel economy Perkins design and technology in manufacturing provides maximum fuel efficiency in all applications Follow the recommended procedures in order to attain optimum performance for the life of the engine Avoid spilling fuel Fuel expands when the fuel is warmed up The fuel may overflow from the fuel tank Inspect fuel lines for leaks Repair the fuel lines as needed Be aware of the properties of the different fuels Use only the recommended fuels Avoid unnecessary idling Shut off the engine rather than idle for long periods of time Observe the air cleaner service indicator frequently Keep the air cleaner elements clean Maintain the electrical systems One damaged battery cell will overwork the alternator This will consume excess power and excess fuel Ensure that the drive belts are correctly adjusted The drive belts should be in good condition Ensure that all of the connections of the hoses are tight The connections should not leak Ensure that the driven equipment is in good working order Cold engin
190. unting Inspect the steps the handholds and the work area before mounting the engine Keep these items clean and keep these items in good repair Mount the engine and dismount the engine only at locations that have steps and or handholds Do not climb on the engine and do not jump off the engine Face the engine in order to mount the engine or dismount the engine Maintain a three point contact with the steps and handholds Use two feet and one hand or use one foot and two hands Do not use any controls as handholds Do not stand on components which cannot support your weight Use an adequate ladder or use a work platform Secure the climbing equipment so that the equipment will not move Do not carry tools or supplies when you mount the engine or when you dismount the engine Use a hand line to raise and lower tools or supplies 02813489 Before Starting Engine Before the initial start up of an engine that is new serviced or repaired make provision to shut the engine off in order to stop an overspeed This may be accomplished by shutting off the air and or fuel supply to the engine Overspeed shutdown should occur automatically for engines that are controlled electronically If automatic shutdown does not occur press the emergency stop button in order to cut the fuel and or air to the engine Inspect the engine for potential hazards Before starting the engine ensure that no one is on underneath or close to the e
191. ves are not compatible These additives can cause problems in the fuel system SEBU7833 03 NOTICE Operating with fuels that do not meet the Perkins rec ommendations can cause the following effects Start ing difficulty poor combustion deposits in the fuel in jectors reduced service life of the fuel system de posits in the combustion chamber and reduced ser vice life of the engine NOTICE Heavy Fuel Oil HFO Residual fuel or Blended fuel must NOT be used in Perkins diesel engines Severe component wear and component failures will result if HFO type fuels are used in engines that are configured to use distillate fuel In extreme cold ambient conditions you may use the distillate fuels that are specified in Table 15 However the fuel that is selected must meet the requirements that are specified in Table 14 These fuels are intended to be used in operating temperatures that are down to 54 C 65 F Table 15 Distillate Fuels Specification Grade MIL T 5624R JP 5 ASTM D1655 Jet A 1 MIL T 83133D JP 8 1 The fuels that are listed in this Table may not meet the requirements that are specified in the Perkins Specifications for Distillate Diesel Fuel Table Consult the supplier for the recommended additives in order to maintain the correct fuel lubricity These fuels are lighter than the No 2 grades of fuel The cetane number of the fuels in Table 15 must be
192. void overheating of the engine and accelerated wear of the engine components Use the Emergency Stop Button if equipped ONLY in an emergency situation Do not use the Emergency Stop Button for normal engine stopping After an emergency stop DO NOT start the engine until the problem that caused the emergency stop has been corrected Stop the engine if an overspeed condition occurs during the initial start up of a new engine or an engine that has been overhauled This may be accomplished by shutting off the fuel supply to the engine and or shutting off the air supply to the engine 02176668 Electrical System Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating A spark can cause the combustible gases that are produced by some batteries to ignite To help prevent sparks from igniting combustible gases that are produced by some batteries the negative jump start cable should be connected last from the external power source to the negative terminal of the starting motor If the starting motor is not equipped with a negative terminal connect the jump start cable to the engine block This document is printed from SPI Not for Resale 12 SEBU7833 03 Safety Section Electrical System Check the electrical wires daily for wires that are loose or frayed Tighten all loose electrical wires before the engine is started Repair all frayed
193. warm well mixed oil sample To avoid contamination of the oil samples the tools and the supplies that are used for obtaining oil samples must be clean The sample can be checked for the following the quality of the oil the existence of any coolant in the oil the existence of any ferrous metal particles in the oil and the existence of any nonferrous metal particles in the oil 65 Maintenance Section Engine Oil and Filter Change 101929323 Engine Oil and Filter Change Ay WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase with the engine stopped Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil Drain the Engine Oil Re p ay A A A v 1 Illustration 38 g01003623 Oil drain plug After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine crankcase oil
194. y for the external cooling system Enter the total in this row Table 10 1103 Naturally Aspirated Engines and Turbocharged Engines with an oil cooler Compartment or System Liters Quarts Engine Only 4 43 4 02 External cooling system capacity OEM recommendation Total Cooling System 1 The external cooling system includes a radiator or an expansion tank with the following components heat exchanger aftercooler and piping Refer to the OEM specifications Enter the value for the external system capacity in this row 2 The Total Cooling System includes the capacity for the engine cooling system plus the capacity for the external cooling system Enter the total in this row 102280119 Fluid Recommendations General Lubricant Information Because of government regulations regarding the certification of exhaust emissions from the engine the lubricant recommendations must be followed Engine Manufacturers Association EMA Oils The Engine Manufacturers Association Recommended Guideline on Diesel Engine Oil is recognized by Perkins For detailed information about this guideline see the latest edition of EMA publication EMA DHD 1 SEBU7833 03 API Oils The Engine Oil Licensing and Certification System by the American Petroleum Institute API is recognized by Perkins For detailed information about this system see the latest edition of the API publication
195. y hazardous Avoid spills and use protection to avoid contact with the skin and eyes In case of contact rinse thoroughly with water and contact a doctor immediately 21 Incase of ingestion of battery acid drink large amounts of water and milk and contact a doctor immediately 22 Use only distilled water in the battery tap water reduces its life cycle 23 Ifa battery is filled above the maximum level the electrolytes will spill out if this happens clean the area quickly to avoid corrosion of the parts it has come in contact with 24 Frequently clean the unit to avoid obstructions or the entry of foreign elements into the unit dust moisture etc 25 Regularly inspect the unit s electrical cords 26 Prolonged contact with the used oil can cause skin cancer Wash your hands after working with the generator 27 Avoid oil spills on both the inside and outside of the generator In case of an oil spill on the inside of the unit clean it properly as it could potentially become a flammable material USERS MANUAL Page 4 of 62 ea RENTAL SERIES ELECTRICAL GENERATOR A POWER 2 INSTALLATION OF THE ELECTRICAL GENERATOR General overview of the Electrical Generator and its different configurations manufactured by SE POWER Note this image corresponds to the detailed view of Image 2 Image 1 ELECTRICAL GENERATOR WITH CANOPY AND OPTIONAL TRAILER FOR UNITS WITHOUT DRIP PAN USERS MANUAL Page 5 of 62 RENTAL
196. y is disconnected the date and time are frozen when the battery is reconnected the date and time shown will be from the time the battery was disconnected The date and time reflected in the Event Log will be taken from the configuration according to the following steps USERS MANUAL Page 33 of 62 RENTAL SERIES ELECTRICAL GENERATOR EN Press L 1 and 10 simultaneously This icon will flash indicating that configuration mode is active The calendar will be shown Press 4 and the hour will start flashing To adjust to the desired setting press SmS Once the desired value has been set press 4 to save LIST OF POSSIBLE ALARMS 1 Low Pressure 17 Low Voltage 2 High temperature 18 High Voltage 3 Fuel level 19 Low Frequency 4 Date time 20 High Frequency 5 Mains transient delay 21 Generator Under Voltage 6 Start delay nN 7 Warming up 22 Generator Over Voltage 23 Generator Under Frequency 8 Crank attempt 9 Crank rest 24 Generator Over Frequency 10 Safety delay 25 Delayed Overcurrent 11 Overspeed overshoot 26 Under Speed 12 Warming up 27 Over Speed 13 Transfer delay 28 Low Voltage 14 Return delay 29 High Voltage 15 Cooling run 30 Alternator failure 16 Energize to stop USERS MANUAL Page 34 of 62 RENTAL SERIES ELECTRICAL GENERATOR 5 4 DEEP SEA 5310 DIGITAL CONTROL MODULE Image 13 DEEP SEA 5310 CONTROL MODULE
197. y predicted by the average power that is demanded The average power that is demanded is based on fuel consumption of the engine over a period of time Reduced hours of operation at full throttle and or operating at reduced throttle settings result in a lower average power demand Reduced hours of operation will increase the length of operating time before an engine overhaul is required Exhaust Engine Cooling and Lubrication The cooling system consists of the following components e Gear driven centrifugal water pump e Water temperature regulator which regulates the engine coolant temperature e Gear driven oil pump gear type e Oil cooler The engine lubricating oil is supplied by a gear type pump The engine lubricating oil is cooled and the engine lubricating oil is filtered Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high Bypass valves can also provide unrestricted flow of lubrication oil to the engine parts if the oil cooler should become plugged or if the oil filter element should become plugged Engine efficiency efficiency of emission controls and engine performance depend on adherence to proper operation and maintenance recommendations Engine performance and efficiency also depend on the use of recommended fuels lubrication oils and coolants Refer to the Operation and Maintenance Manual Maintenance Interval Schedule for more info
198. y switch to the OFF position 101903586 Emergency Stopping NOTICE Emergency shutoff controls are for EMERGENCY use ONLY DO NOT use emergency shutoff devices or controls for normal stopping procedure The OEM may have equipped the application with an emergency stop button For more information about the emergency stop button refer to the OEM information Ensure that any components for the external system that support the engine operation are secured after the engine is stopped This document is printed from SPI SEBU7833 03 101903608 After Stopping Engine Note Before you check the engine oil do not operate the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan Check the crankcase oil level Maintain the oil level between the ADD mark and the FULL mark on the oil level dipstick If necessary perform minor adjustments Repair any leaks and tighten any loose bolts Note the required service interval Perform the maintenance that is in the Operation and Maintenance Manual Maintenance Interval Schedule Fill the fuel tank in order to help prevent accumulation of moisture in the fuel Do not overfill the fuel tank NOTICE Only use antifreeze coolant mixtures recommended in the Coolant Specifications that are in the Operation and Maintenance Manual Failure to do so can cause engine damage Allow the engine to cool Check the coolant level If freezi

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