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1. y EX is AKRE y Ve 3 o_o ok k 8 LN Illustration 23 el 1 Coolant temperature sensor 4 Fuel pressure sensor 2 Intake manifold air temperature sensor 5 Electronic control module ECM 3 Intake manifold pressure sensor 6 Oil pressure sensor 7 Primary position sensor 8 Secondary position sensor SEBU8387 31 Operation Section Features and Controls aa Gi ara Le AO US Saas RO Illustration 24 901330220 1 Coolant temperature sensor 3 Intake manifold pressure sensor 5 Electronic control module ECM 2 Intake manifold air temperature sensor 4 Fuel pressure sensor Illustration 25 g01330325 6 Engine oil pressure sensor 7 Primary speed timing sensor 8 Secondary speed timing sensor 32 Operation Section Features and Controls SEBU8387 Illustration 24 and illustration 25 shows the sensors and the ECM in position on the engine Failure of Sensors All Sensors A failure of any of the sensors may be caused by one of the following malfunctions e Sensor output is open e Sensor output is shorted t
2. O Oo A Wh a j T 1 Illustration 52 901370515 Illustration 53 901370722 Typical example Typical example 3 Install a suitable tube onto the drain 1 Open the 6 Rotate the bowl 3 counterclockwise in order to drain 1 Allow the fluid to drain into the container remove the bowl Remove the O ring seal 2 Remove the tube Clean the bowl 4 Tighten the drain 1 by hand pressure only 5 If equipped remove the wiring harness from the sensor on the bottom of the bowl 3 78 Maintenance Section SEBU8387 Fuel System Primary Filter Water Separator Element Replace Y Illustration 54 g01370724 Typical example 7 Use a suitable tool in order to remove the old canister 4 Illustration 55 g01371107 Typical example 8 Lubricate the O ring seal 5 with clean engine oil on the new canister Install the new canister 6 Spin on the canister until the O ring seal contacts the sealing surface Then rotate the canister 360 degree in order to tighten the canister correctly 9 Remove the cap 8 from the threaded end of the new canister and remove the new O ring seal 7 Install the new O ring seal into the bowl 3 10 L
3. 439 Ignition Key Switch X Fault 514 SAE J1939 Data Link X X Fault 516 5 Volt Sensor DC X X Power Supply Fault 517 8 Volt Sensor DC X X Power Supply Fault 527 Customer System X X X Parmeter Fault 1 If warning lamps are installed refer to this table For installations that have electronic displays refer to the OEM for information 2 An X indicates that the effect on engine performance may occur if the code is active 3 The operator should go to the nearest location that has a qualified service program cold weather operation at high altitudes 4 Schedule Service The problem should be investigated when the operator has access to a qualified service program 5 These Flash Codes may affect the system under specific environmental conditions such as engine start up at cold temperature and 6 If the primary engine speed timing sensor fails there is no automatic protection against reverse running In this event Stop the engine immediately Turn the keyswitch to the OFF position In order to check the correct operation of the sensor refer to Troubleshooting Engine speed Timing sensor Test 101902949 Fault Logging The system provides the capability of Fault Logging When the Electronic Control Module ECM generates an active diagnostic code the code will be logged in the memory of the ECM The codes that have been logged by the ECM can be identified by the electroni
4. 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 Additive 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 Decrease the engine speed to low idle 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 Illustration 30 g00103639 Filler cap SEBU8387 59 Maintenance Section Cooling System Coolant ELC Change 5 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 inst
5. 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 SAE10W40 is 350 to 450 kPa 50 to 65 psi at rated rpm 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 Stop the engine 3 Check and maintain the oil level Jacket Water Coolant Temperature Typical temperature range is 83 to 95 C 181 4 to 171 F The maximum allowable temperature at sea level with the pressurized cooling system at 48 kPa 7 psi is 103 C 217 4 F Higher temperatures may occur under certain conditions The water temperature reading may vary according to load The temperature reading should never exceed 7 C 44 6 F below the boiling point for the pressurized system that is being used A 100 kPa 14 5 psi radiator cap may be installed on the cooling system The temperature of this cooling system must not exceed 112 C 233 6 F If the engine is operating above the normal range and steam becomes apparent perform the following procedure 1 Reduce the load and the engine rpm 2 Determine if the engine must be shut down immediately or if the engine can be cooled by reducing the load 3 Inspect the
6. Check the crankcase oil level Maintain the oil level between the MIN mark and the MAX mark on the engine oil level gauge If the engine is equipped with a service hour meter note the reading 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 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 e Allow the engine to cool Check the coolant level SEBU8387 43 Operation Section Engine Stopping e Check the coolant for correct antifreeze protection and the correct corrosion protection Add the correct coolant water mixture if necessary e Perform all required periodic maintenance on all driven equipment This maintenance is outlined in the instructions from the OEM 44 Operation Section Cold Weather Operation SEBU8387 Cold Weather Operation 102717265 Cold Weather Operation Perkins Diesel Engines can operate effectively in cold weather Dur
7. Typical example The ether warning label 2 is located on the cover of the inlet manifold g01329365 SEBU8387 7 Safety Section General Hazard Information IN S FN 2 a vy it WR MS N alll gt Illustration 4 991329366 Location of labels 2 Ether 3 Hand High Pressure 3 Hand High Pressure The warning label for the Hand High Pressure 3 is located on the top of the fuel manifold A WARNING 102328435 Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu General Hazard Information el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death A WARNING g00104545 Illustration 6 g01154858 N 7 l Lee Illustration 5 Attach a Do Not Operate warning tag or a similar Typical example warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment 8 Safety Section General Hazard Information SEBU8387 Gan E amp Y X 3d 3D P Illustration 7 g00702020 Wear a hard hat protective glasses and other protective equipment as required Do not wear loose clothing or jewelry that can sn
8. cecceeeceeeeeeeeenees 44 Engine LING essione 24 Hints for Cold Weather Operation 44 Engine Mounts Inspect 67 Idling the Engine eeeeceeeeseeeeeeeetteeeeeeeeaes 45 Engine Oil and Filter Change 0 cece 68 Recommendations for Coolant Warm Up 45 Drain the Engine Lubricating Oil 69 Recommendations for the Coolant 000 44 Fillthe OW P an eea a a a eee ie 70 Viscosity of the Engine Lubrication Oil 44 Replace the Oil Filter eeeeeeeeeeeeeeeeeeenees 69 Cold Weather Starting cceeeeeceeeeeeeeeeeeneees 38 Engine Oil Level Check cceccceecceeeeeeeeteeeeeeeees 67 Cooling System Coolant Commercial Heavy Duty Engine Oil Sample Obtain eceeteeeeeeees 68 Change ena n E E T 57 Obtain the Sample and the Analysis 68 DAI Ss esas cate A EEEE E 57 Engine Operation ececcceceteeeeeesecieeeeeeeteeeeerees 41 Pills OE ESA ETET A S EET 58 Engine Operation with Active Diagnostic Codes 36 FUS aa A TRAO cette 58 Engine Operation with Intermittent Diagnostic Cooling System Coolant ELC Change 59 COdeS eie a r r eee 37 Dra aaun teteeee a tne ads 59 Engine Starting 0 ceceeeeeeeeeeettteeeeeeenaees 13 38 BNNs dente ca ease Alea ave ce ndcaeden E ES 60 Engine Stopping cceeeeeeeeeeeeceeeeeeeeeeeeeees 14 42 PUSH i aaa e Adie eae 60 Engine Storage oiee ren ie r aE Mie eaeeetie 24 Cooling System Cool
9. Check that the fuel supply valve if equipped is in the ON position Illustration 47 g01333855 typical example 2 Operate fuel priming pump 1 Count the number of operations of the fuel priming pump After 100 depressions of the fuel priming pump stop 3 The engine fuel system should now be primed and the engine should now be able to start 4 Operate the engine starter and crank the engine After the engine has started operate the engine at low idle for a minimum of five minutes immediately after air has been removed from the fuel system Note Operating the engine for this period of time will help ensure that the fuel system is free of air Note Do not loosen the high pressure fuel line in order to purge air from the fuel system This procedure is not required Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air
10. Inspect eee eee eee 84 INSPOCUNG ieena A ENE 84 Removal and Installation 0 cceeeeeeeeeee 84 Ww Walk Around Inspection cccccceeeeeeeeeeeeereeeees 85 High Pressure Fuel Lines 85 Inspect the Engine for Leaks and for Loose CONN CHIONS 1 1 22 ceetecneeseceeeededetiedbeeedeteeeeeedeeneae 85 Warranty Information cccceeeeeseeeeeeeeeteeeeeeeeeaaes 87 Warranty Section eee eee ee eeeeaes 87 Water Pump INSPeCt cccccceeeeeeeeeeeeeeeeeees 86 Welding on Engines with Electronic Controls 17 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 Branch Address Dealer Contact Phone Number Hours Sales Parts Service Copyright 2007 Perkins Engine Company Limited All Rights Reserved Printed in U K
11. el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death 5 Operate the engine until the engine reaches normal operating temperature Stop the engine After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install e gt Drain the lubricating oil from the oil pan Renew the canister s of the lubricating oil filter Fill the oil pan to the Full Mark on the engine oil level gauge with new clean lubricating oil Add 1762811 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 with normal lubricating oil 7 Operate the engine in order to circulate engine oil 8 Disconnect the battery Ensure that the battery is in a fully charg
12. 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 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 causes 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 directl
13. 1 Starting motor to engine block 2 Ground to starting motor 3 Ground to battery loo o Illustration 14 g01162918 Typical example 4 Ground to engine 5 Ground to battery 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 the 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 The connections for the 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 The power supply connections and the ground connections for th
14. Service Hours or 6 Years Cooling System Coolant ELC Change 59 Commissioning Fan Clearance Check eccceeeeceeeeeeeeetteeeeeeeeee 71 54 Maintenance Section Aftercooler Core Clean Test SEBU8387 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 r
15. 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 150 F 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
16. cooling system for leaks Tachometer This gauge indicates engine speed rpm When the throttle control lever a 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 rpm Overspeeding can result in serious damage to the engine Operation at speeds exceed ing high idle rom should be kept to a minimum amount of charge or discharge in the battery charging circuit Operation of the indicator should be to the side of 0 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 4 Ammeter This gauge indicates the SEBU8387 7 Operation Section Gauges and Indicators Service Hour Meter The gauge indicates total operating hours of the engine 28 Operation Section Features and Controls SEBU8387 Features and Controls 102651062 Monitoring System If the Shutdown mode has been selected and the warning indicator activates engine shutdown may take as little as 20 seconds from the time the warn ing indicator is activated Depending on the ap plication special precautions should be taken to avoid personal injury The engine can be restarted followin
17. diagnostic lamp shuts off an intermittent fault may have occurred If a fault has occurred the fault will be logged into the memory of the Electronic Control Module ECM In most cases it is not necessary to stop the engine because of an intermittent code However the operator should retrieve the logged fault codes and the operator should reference the appropriate information in order to identify the nature of the event The operator should log any observation that could have caused the lamp to light e Low power e Limits of the engine speed e Excessive smoke etc This information can be useful to help troubleshoot the situation The information can also be used for future reference For more information on diagnostic codes refer to the Troubleshooting Guide for this engine 38 Operation Section Engine Starting SEBU8387 Engine Starting 102322201 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 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
18. 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 engine 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 the starter and the ECM Protect the fuel injection pump from fluids in order to wash the engine 64 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace SEBU8387 102334355 Engine Air Cleaner Element Dual Element Clean Replace NOTICE Never run the engine without an air cleaner element installed Neve
19. 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 102320721 Fire Prevention and Explosion Prevention Illustration 9 g00704000 All fuels most lubricants and some coolant mixtures are flammable Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire Fire may cause personal injury and property damage After the emergency stop button is operated ensure that you allow 15 minutes before the engine covers are removed 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 If the application involves the presence of combustible
20. 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 SEBU8387 11 Safety Section Crushing Prevention and Cutting Prevention 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 damaged Leaks can cause fires Consult your Perkins dealer or your Perkins distributor for replacement parts Replace the parts if any of the following conditions are present e High pressure fuel line or lines are removed End fittings are damaged or leaking e Outer coverings are chafed or cut e Wires are exposed e Outer coverings are ballooning Flexible part of the hoses are kinked e Ou
21. fuel filter in order to catch any fuel that might spill Clean up any spilled fuel Sn 4 y je Illustration 59 g01333960 Typical example 2 Clean the outside of the fuel filter Use a suitable tool in order to remove the canister 2 from the engine and dispose of the canister in a safe place 3 Ensure that dirt can not enter the new canister Do not fill the canister with fuel before the canister is installed Lubricate the O ring seal 1 with clean engine oil on the new canister 4 Install the new canister Do not use a tool in order to install the canister Tighten the canister by hand 5 Spin on the canister until the O ring seal contacts the sealing surface Then rotate the canister 360 degree in order to tighten the canister correctly 6 Remove the container and dispose of the fuel in a safe place If equipped open the fuel supply valve 7 Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime for more information SEBU8387 81 Maintenance Section Fuel Tank Water and Sediment Drain 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
22. 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 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 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 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
23. i02747977 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 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 SEBU8387 57 Maintenance Section Battery or Battery Cable Disconnect 102323088 Battery or Battery Cable Disconnect The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed be
24. nor mal engine operation Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system 1 Place a suitable container under the water separator in order to catch any fuel that might spill Clean up any spilled fuel 4 O Illustration 48 g01334411 Typical example 2 Install a suitable tube onto drain 1 Open drain 1 Allow the fluid to drain into the container 3 Tighten drain 1 by hand pressure only Remove the tube and dispose of the drained fluid in a safe place Illustration 49 g01371846 Typical example Note Not all primary filters require vent screw 2 This primary fuel filter that has a vent screw may be installed on a fuel system that has a low fuel tank 1 Install a suitable tube onto drain 1 Loosen vent screw 2 SEBU8387 75 Maintenance Section Fuel System Primary Filter Water Separator Element Replace 2 Open drain 1 Allow the fluid to drain into the container 3 Tighten drain 1 by hand pressure only Remove the tube and dispose of the drained fluid in a safe place 4 Tighten vent screw to 6 N m 53 Ib in i02668803 Fuel System Primary Filter Water Separator Element Replace Type One Filter 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
25. 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 50 Maintenance Section Refill Capacities SEBU8387 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 also 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 fue
26. or in a combination with new base stock oils The specification for the US military and the specifications of other heavy equipment manufacturers also allow the use of re refined base stock oils 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 distillation 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 SW viscosity grade Use an oil with a pour point that is lower than 50 C 58 F Perkins recommends the following lubricants for use in cold weather conditions Use a commercial oil that is API Cl 4 Cl 4 PLUS CH 4 and CG 4 The oil must have one of the following lubricant viscosity grades SAE OW 20 SAE OW 30 SAE OW 40 SAE 5W 30 and SAE 5W 40 Aftermarket Oil Additives Perkins
27. 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 below 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 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 freque
28. starting motor and crank the engine Note The operating period of the warning light for the glow plugs will change due to the temperature of the engine NOTICE Do not engage the starting motor when flywheel is turning Do not start the engine under load If the engine fails to start within 30 seconds release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again 4 Allow the keyswitch to return to the RUN position after the engine starts 5 Repeat step 2 through step 4 if the engine fails to start 102325155 Cold Weather Starting 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 SEBU8387 39 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 Note Do not adjust the engine speed control during start up The electronic control module ECM will control the engine speed during start up 1 Disengage any driven equipment 2 Turn the keyswitch to the RUN position Le
29. suitable for containing fluids and equipment that is suitable for containing fluids Obey all local regulations for the disposal of liquids 102334785 Burn Prevention Do not touch any part of an operating engine Allow the engine to cool before any maintenance is performed on the engine Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines Allow the pressure to be purged in the air system in the hydraulic system in the lubrication system or in the cooling system before any lines fittings or related items are disconnected 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
30. 00 Maintenance Interval Schedule When Required Battery Replace 0 ccceceeceeeeeeeeeseeeeeeeneneeeees 56 Battery or Battery Cable Disconnect 57 Engine ClOany sendi uga aang eedten uae dent 63 Engine Air Cleaner Element Dual Element Clean Replace 00 ccccccccceeeeeececeeeeeeeeeeeetteeenees 64 Engine Air Cleaner Element Single Element Inspect Replace eeceeeeeceeeeeeeeeeeeeeteeesenteeaeees 66 Engine Oil Sample Obtain 0 eee 68 Fuel System Prime cccccceceeeeeeeeeeeeneeeeeeeenaeees 72 Severe Service Application Check n 83 Daily Cooling System Coolant Level Check 60 Driven Equipment Check c cecceeeettteteee 63 Engine Air Cleaner Service Indicator Inspect 66 Engine Air Precleaner Check Clean 67 Engine Oil Level Check ec cceeeeeeeseeeeeeenneeees 67 Fuel System Primary Filter Water Separator DAU testes eee ae E E EEE 74 Walk Around Inspection ccccceeeeeeeeeseneeeeees 85 Every Week Alternator and Fan Belts Inspect 06 55 Hoses and Clamps Inspect Replace 81 Every 50 Service Hours or Weekly Fuel Tank Water and Sediment Drain 81 Initial 500 Service Hours Engine Valve Lash Inspect Adjust cee 70 Every 500 Service Hours Fan Clearance Check c0cccccccccseeeeeeeeeeeeeeeeees 71 Every 500 Ser
31. 453 1 Weep hole 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 Visually inspect the water pump for leaks The water pump is not a serviceable item In order to install a new water pump refer to the Disassembly and Assembly Manual Water Pump Remove and Install SEBU8387 87 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 88 SEBU8387 Index Section Index A E After Starting Engine ccceeeteeeeeeeetteeeeereee 40 Electrical Systemi asteiden ia nS raii Ri 14 After Stopping Engine 42 Grounding Practices eceeeeeeeeeeeeeeenteeeeeeees 15 Aftercooler Core Clean TeSt ccccceeeeeteeeeeee 54 Emergency Stopping cccccccceeeeeeetieeeeerees 42 Aftercooler Core INSp Ct cccceeeeeeeeteeeeeee 54 Emissions Certification Film 0 ccceeceeees 23 Al
32. 8 Perkins soap Operation and Maintenance Manual 1106C Genset PK Engine 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 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 dama
33. Association e API American Petroleum Institute e SAE Society Of Automotive Engineers Inc EMA Guidelines 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 API Licensing 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 No 1509 Engine oils that bear the API symbol are authorized by API Illustration 26 g00546535 Typical API symbol SEBU8387 49 Maintenance Section Refill Capacities 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 Engine Oil Commercial Oils NOTICE For applications above 168 kWCI 4 oil must be used Table 6 API Classifications for the 1106C Genset Engine Power Oil Maintenance Specification Interval Less than CH 4 C
34. For air to air aftercoolers use the same methods that are used for cleaning radiators 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 SEBU8387 55 Maintenance Section Alternator Inspect After cleaning start the engine and accelerate the engine to high idle rpm 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 t
35. I 4 500 Hours 168 kW 225 hp More than Cl 4 500 Hours 168 kW 225 hp Less than CG 4 250 Hours 168 kW 225 hp Maintenance intervals for engines that use biodiesel The oil change interval can be adversely affected by the use of biodiesel Use oil analysis in order to monitor the condition of the engine oil Use oil analysis also in order to determine the oil change interval that is optimum Note These engine oils are not approved by perkins and these engine oils must not be used CC CD CD 2 and CF 4 The performance of commercial diesel engine oils is based on 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 the following classifications e API CH 4 Cl 4 In order to make the correct choice of a commercial oil refer to the following explanations EMA DHD 1 The 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 and API CG 4 DHD 1 oils are intended to provide superior performance in comparison to API CG 4 DHD 1 oils will meet the needs of
36. 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 Consult the OEM information for the correct procedure to replace the air cleaner 102335405 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 39 g00103777 Typical service indicato
37. 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 instructions that follow 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 recomm
38. ae L D o de al ASHIK IG D J oo ah 5 ad ey or A k et a t G A O V Illustration 43 g01333549 Typical example 70 Maintenance Section Engine Valve Lash Inspect Adjust SEBU8387 3 Clean sealing surface 2 4 Apply clean engine oil to O ring seal 3 for the new 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 new oil filter Spin on the oil filter until the O ring contacts the sealing surface 2 Then rotate the oil filter of a full turn Note Some oil filters may be installed horizontally Refer to illustration 44 This type of oil filter assembly can be drained before the filter is removed The torque for this drain plug 4 is 12 N m 8 Ib ft If necessary install a new O ring seal 5 Start at step 1 in order to remove the oil filter and install the oil filter Illustration 44 g01169166 Typical example Fill the Oil Pan 1 Remove the oil filler cap Refer to this Operation and Maintenance Manual Fluid Recommendations for more information on suitable oils Fill the oil pan with the correct amount of new engine lubricating oil Refer to this Operation and Maintenance Manual Refill Capacities for more information on refill capacities NOTICE If equipped with
39. ag 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 Report all necessary repairs Do not allow unauthorized personnel on the equipment Ensure 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
40. ain the coolant level in the expansion bottle if equipped at the correct level Illustration 32 g00103639 Filler cap 5 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 6 Start the engine Inspect the cooling system for leaks and for correct operating temperature 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 1 Observe the coolant level in the coolant recovery tank Maintain the coolant level to COLD FULL mark on the coolant recovery tank SEBU8387 61 Maintenance Section Cooling System Coolant Level Check 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 slow
41. all a new filler cap 6 Start the engine Inspect the cooling system for leaks and for correct operating temperature 102238084 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 of the coolant 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 sys
42. an auxilliary oil filter system or a re mote filter system follow the OEM or the filter manu facture s remonmendations Under filling or over filling the crankcase with oil can cause engine damage 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 oil pan for a minimum of ten minutes Illustration 45 g01165836 Y Min mark X Max mark 4 Remove the engine oil level gauge in order to check the oil level Maintain the oil level between the MIN and MAX marks on the engine oil level gauge 102348484 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 reduce engine efficiency and also reduce engine component life SEBU8387 71 Maintenance Section Fan Clearance Check Ensure that the engine can not be started while this mainte
43. aning is required 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 mounting 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 102335785 Engine Oil Level Check Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin lt ei Illustration 41 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 68 Maintenance Section Engine Oil Sample Obtain SEBU8387 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 Op
44. ant Level Check 60 Engine Valve Lash Inspect Adjust eee 70 Engines With a Coolant Recovery Tank 60 Engines Without a Coolant Recovery Tank 61 Cooling System Supplemental Coolant Additive F SCA TeSt Ad ecccececeeeeeeeeceeeeeeeeeeeteeeeeneees 62 Add the SCA If Necessary ceceeeeeees 62 Fan Clearance Check ccsceccceeceeeeeeeeeeanes 71 Test for SCA Concentration s 62 Fault LOGGING cissi iia diteet aweetenbet 36 Crankcase Breather Canister Replace 62 Features and Controls ccccceceeeeeeeeeeeeneees 28 Crushing Prevention and Cutting Prevention 11 Fire Prevention and Explosion Prevention 9 Fire Extinguisher 0 ccccccccccccsseeceeesssteeeeeseneaes 11 Lines Tubes and HOSES ccccseseceeeeeeeaeneees 11 D Fluid Recommendations ccccecceeeeeeeeeeeeeeeeees 48 Engine GW ecur e e tacos dad cenehiddang 49 Diagnostic Flash Code Retrieval eeeeeee 34 General Lubricant Information 0 eeeeeee 48 Diagnostic Lampie aecicen a a 34 Diagnostic Lampa arcieri AA 34 Driven Equipment Check cccceeeeeeteeeees 63 SEBU8387 89 Index Section FOre WOM isra a a ai i Eaa e 4 M California Proposition 65 Warning e 4 Literature Information cceeeeeeeeeeeeeeeeeeeeeees 4 Maintenance Interval Schedule ee
45. at transfer characteristics Reduced heat transfer could cause cracking of the cylinder head and other high temper ature components Excessive supplemental coolant additive concentration could also result in radiator tube blockage overheating and or accelerated water pump seal wear Never use both liquid supplemental coolant additive and the spin on element if equipped at the same time The use of those additives together could result in supplemental coolant additive concen tration exceeding the recommended maximum 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 Slowly loosen the cooling system filler cap in order to relieve the pressure Remove the cooling system filler cap Note Always discard drained fluids according to local regulations 2 If necessary drain some coolant from the cooling system into a suitable container in order to allow space for the extra SCA 3 Add the correct amount of SCA Refer to the Operation and Maintenance Manual Refill Capacities and Recommendations for more information on SCA requirements 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 suitab
46. aterial Inspect the gasket or the seal of the air cleaner element for damage Maintain a supply of suitable air cleaner elements for replacement purposes 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 cleaned 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 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 36 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 tapefrom the air inlet Install the secondary air cleane
47. ave the keyswitch in the RUN position until the warning light for the glow plugs is extinguished NOTICE Do not engage the starting motor when flywheel is turning Do not start the engine under load If the engine fails to start within 30 seconds release the starter switch or button and wait two minutes to allow the starting motor to cool before attempting to start the engine again 3 When the warning light for the glow plugs is extinguished turn the keyswitch to the START position in order to engage the electric starting motor and crank the engine Note The operating period of the warning light for the glow plugs will change due to the temperature of the engine 4 Allow the keyswitch to return to the RUN position after the engine starts 5 Repeat step 2 through step 4 if the engine fails to start Note The engine should not be raced in order to speed up the warm up process 6 Allow the engine to idle for three to five minutes or allow the engine to idle until the water temperature indicator begins to rise When idling after the engine has started in cold weather increase the engine rpm from 1000 to 1200 rpm This will warm up the engine more quickly Maintaining an elevated low idle speed for extended periods will be easier with the installation of a hand throttle Allow the white smoke to disperse before proceeding with normal operation 7 Operate the engine at low load until all systems reach opera
48. c service tool The active codes that have been logged will be cleared when the fault has been rectified or the fault is no longer active The following logged faults can not be cleared from the memory of the ECM without using a factory password Overspeed low engine oil pressure and high engine coolant temperature 102651197 Engine Operation with Active Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation the system has identified a situation that is not within the specification Use the electronic service tool to check the active diagnostic codes The active diagnostic code should be investigated The cause of the problem should be corrected as soon as possible If the cause of the active diagnostic code is repaired and there is only one active diagnostic code the diagnostic lamp will turn off Operation of the engine and performance of the engine can be limited as a result of the active diagnostic code that is generated Acceleration rates may be significantly slower and power outputs may be automatically reduced Refer to Troubleshooting Troubleshooting with a Diagnostic Code for more information on the relationship between each active diagnostic code and the possible effect on engine performance SEBU8387 37 Operation Section Engine Diagnostics 101902995 Engine Operation with Intermittent Diagnostic Codes If a diagnostic lamp illuminates during normal engine operation and the
49. 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 Illustration 8 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 SEBU8387 9 Safety Section Burn Prevention e Only use the tools that are
50. ce Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods If an engine is out of operation and if use of the engine is not planned for more than one month a complete protection procedure is recommended To help prevent excessive engine wear and corrosion to the engine use the following guidelines 1 Completely clean the outside of the engine 2 Ensure that the vehicle is on level ground 3 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 SEBU8387 25 Operation Section Lifting and Storage Personal injury can result from 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 D Drain and refill the cooling system Refer to this Operation and Maintenance Manual Cooling System coolant Commercial Heavy Duty Change or Cooling System coolant ELC Change for information on draining flushing and refilling the cooling system Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu
51. ce Manual Fuel System Prime for more information 80 Maintenance Section Fuel System Secondary Filter Replace SEBU8387 Type Two filter 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 Note Refer to Testing and Adjusting Manual Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system NOTICE Ensure that the engine is stopped before any servicing or repair is performed This fuel filter can be identified by the 12 drain holes in the filter Refer to illustration 58 Illustration 58 g01375926 Typical example After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install 1 Ensure that the fuel supply valve if equipped is in the OFF position Place a suitable container under the
52. ch injection The amount of this reduction of fuel is dependent on the severity of the fault that has caused the engine derate typically up to a limit of 50 This reduction in fuel results in a predetermined reduction in engine power Warning Derate Shutdown The Diagnostic lamp turns ON and the warning signal red lamp is activated After the warning the engine power will be derated The engine will continue at the rpm of the set derate until a shutdown of the engine occurs The engine can be restarted after a shutdown for use in an emergency A shutdown of the engine may occur in as little as 20 seconds The engine can be restarted after a shutdown for use in an emergency However the cause of the initial shutdown may still exist The engine may shut down again in as little as 20 seconds If there is a signal for low oil pressure or for coolant temperature there will be a two second delay in order to verify the condition For each of the programmed modes refer to Troubleshooting Indicator Lamps for more information on Indicator Lamps For more information or assistance for repairs consult your Perkins dealer or your Perkins distributor SEBU8387 29 Operation Section Features and Controls Monitoring System 102296746 Table 2 Warning Shutdown ae i Lamp Lamp Lamp Status Description of lamp status Engine Status Lamp check When the engine start switch is tur
53. 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 Inspect the fins for damage Bent fins may be opened with a comb Inspect these 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 Fuel quality Operational Altitude e Maintenance intervals Oil selection and maintenance Coolant type and maintenance e Environmental qualities 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 en
54. ction Gauges and Indicators SEBU8387 Gauges and Indicators 102717240 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 engine 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 Some engine applications are equipped with Indicator Lamps Indicator lamps can be used as a diagnostic aid There are two lamps One lamp has an orange lens and the other lamp has a red lens These indicator lamps can be used in two ways e The indicator lamps can be used to identify the current operational status of the engine The indicator lamps can also indicate that the engine has a fault This system is automatically operated via the ignition switch The indicator lamps can be used to identify active diagnostic codes This system is activated by pressing the Flash Code button Refer to the Troubleshooting Guide Indicator Lamps for further information
55. does not recommend the use of aftermarket additives in oil 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 52 Maintenance Section Refill Capacities SEBU8387 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 e 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 e At the specified interval service the engine Use new oil and install a new oil filter e Perform maintenance at the int
56. e Sensor The ECM 5 will detect failure of the engine oil pressure sensor The diagnostic lamp warns the user about the status of the engine oil pressure sensor The engine oil pressure related strategies will be disabled in the event of a failure of the engine oil pressure sensor A failure of the engine oil pressure sensor will not cause a shutdown of the engine or any horsepower change In order to check the correct operation of the sensor refer to Troubleshooting 5 Volt Sensor Supply Circuit Test Primary Speed Timing Sensor 7 If the ECM 5 does not receive a signal from the primary speed timing sensor the DIAGNOSTIC lamp will indicate a diagnostic fault code which will be logged in the ECM memory If the ECM does not receive a signal from the primary speed timing sensor 7 the ECM will read the signal from the secondary speed timing sensor 8 The ECM continually checks in order to determine if there is a signal from both sensors Intermittent failure of the sensors will cause erratic engine control Failure of the Primary Speed Timing Sensor Correct operation of the primary speed timing sensor is essential Software in the ECM protects against reverse running of the engine If the primary speed timing sensor fails there is no automatic protection against reverse running In some applications it is possible for the transmission to run the engine in reverse In this event Stop the engine immediately T
57. e engine PK Type of engine U Built in the United Kingdom 000001 Engine Serial Number J Year of Manufacture Perkins dealers or Perkins distributors need all of these numbers in order to determine the components that were included with the engine This permits accurate identification of replacement part numbers The numbers for fuel setting information for electronic engines are stored within the flash file These numbers can be read by using the electronic service tool Serial Number Plate 1 The engine serial number plate is located on the left side of the cylinder block to the rear of the front engine mounting 88Perkins ENGLAND TPLNol O O SERIAL No TYPE LIST No Illustration 20 g01094203 Serial number plate 102164876 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 copy of this list for a record Keep the information for future reference Record for Reference Engine Model Engine Serial number Engine Low Idle rpm Engine Full Load rpm 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 SEBU8387 23 Product Information Section Product Identification Information Fan Drive Belt Alt
58. e engine electronics should always be from the isolator to the battery 102650954 Engine Electronics Tampering with the electronic system installation or the OEM wiring installation can be dangerous and could result in personal injury or death and or engine damage Electrical Shock Hazard The electronic unit injec tors use DC voltage The ECM sends this voltage to the electronic unit injectors Do not come in contact with the harness connector for the elec tronic unit injectors while the engine is operating Failure to follow this instruction could result in personal injury or death This engine has a comprehensive programmable Engine Monitoring System The Electronic Control Module ECM has the ability to monitor the engine operating conditions If any of the engine parameters extend outside an allowable range the ECM will initiate an immediate action The following actions are available for engine monitoring control e Warning 16 Safety Section Engine Electronics SEBU8387 e Derate e Shutdown The following monitored engine operating conditions have the ability to limit engine speed and or the engine power e Engine Coolant Temperature e Engine Oil Pressure e Engine Speed Timing e Intake Manifold Air Temperature The Engine Monitoring package can vary for different engine models and different engine applications However the monitoring system and the engine monitoring control will be similar f
59. e pos sibility of damage 1 Stop the engine Turn the switched power to the OFF position 2 Disconnect the negative battery cable from the battery If a battery disconnect switch is provided open the switch 3 Disconnect the J1 P1 connectors from the ECM Move the harness to a position that will not allow the harness to accidentally move back and make contact with any of the ECM pins O 0 ers i AYE g00765012 Illustration 15 Use the example above The current flow from the welder to the ground clamp of the welder will not cause damage to any associated components 1 Engine Battery disconnect switch in the open position Disconnected battery cables Battery Electrical Electronic component Maximum distance between the component that is being welded and any electrical electronic component 9 The component that is being welded 10 Current path of the welder 11 Ground clamp for the welder 4 Connect the welding ground cable directly to the part that will be welded Place the ground cable as close as possible to the weld in order to reduce the possibility of welding current damage to bearings hydraulic components electrical components and ground straps Note If electrical electronic components are used as a ground for the welder or electrical electronic components are located between the welder ground and the weld current flow
60. ecommended concentration of cleaner 5 Back flush the core with a suitable cleaner 6 Steam clean the core in order 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 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 rpm 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
61. ective 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 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 102251260 Engine Starting 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 14 Safety Section Engine Stopping SEBU8387 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 engine 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 preve
62. ed condition Protect the terminals against corrosion 1734115 POWERPART Lay Up 3 can be used on the terminals Put the battery into safe storage 9 If equipped replace the crankcase breather element Seal the end of the breather pipe 10 Remove the valve mechanism cover Spray 1762811 POWERPART Lay Up 2 around the rocker shaft assembly 11 Remove the glow plugs Slowly rotate the crankshaft By checking the valves position the piston at BDC Spray 1762811 POWERPART Lay Up 2 for two seconds into the cylinder bore This procedure must be carried out on each cylinder 12 Install the glow plugs Install the valve mechanism cover 13 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 14 Remove the exhaust pipe from the output side of 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 15 Seal the vent of the fuel tank or the fuel filler cap with waterproof tape 16 Remove the alternator drive belt and put the drive belt into storage 17 In order to prevent corrosion to the outside of the engine spray the engine with 1734115 POWERPART Lay Up 3 Do not spray the area inside the alternator 26 Operation Se
63. eeeee 53 Maitena Oe e aas aee aaae e raa ea a aaaea 4 Maintenance Section cccceccecsseeeeeeeessteeeeerees 48 Maintenance Intervals cceeeeeeeeeestteeeees 4 Model View Illustrations cecceeeeeeeeeeeeenes 18 Operation an a e ei 4 Model VieWS ccccecceceeeeeeeeeceeceeeeeeeeeeeeeeeeteees 18 Ovemaul ence nah alee ae vedios 4 Monitoring System 0 ees 28 29 Safety ree as ar a aaeeea asna T ETE d 4 Programmable Options and Systems Fuel and the Effect from Cold Weather 46 Operation seise a a a a 28 Fuel Conservation Practices 41 Mounting and DisMmounting 0 ceeceeeseeeeeeeeeee 11 Fuel Related Components in Cold Weather 47 Fuel EIEEE atiere tata tn eaters 47 Fuel Heaters sists a ahead haiti ee 47 O Fuel TANKS E E E A 47 Fuel System Prime ccceceeceeeeeeeeeeeeeeeeeeeeeneeees 72 Operation SechON esiet iias ai at 24 Electric Fuel Priming Pump ccccceeeee 73 OVErSPeeU iiien inea eiei aiai 33 Hand Fuel Priming PUMP 73 Fuel System Primary Filter Water Separator Element Replace ccccceeeeeeeeeeeeeeseeeaeees 75 P Type One Filter aaaaiaenieesnneisrrrnsrerrrneenrrrnsea 75 Type Two Ferari eieaa 76 Plate Locations and Film Locations 08 22 Fuel System Primary Filter Water Separator Serial Number Plate 1 oaase 22 Da a eet ce AES 74 Product Identification Information 008 22 Fuel S
64. eeeeeeeeeeeeeeeeeeeeeeneeeeteeeaeees 5 General Hazard Information s s 7 Burn Prevention secerni e naaa a a 9 Fire Prevention and Explosion Prevention 9 Crushing Prevention and Cutting Prevention 11 Mounting and Dismounting sssini 11 High Pressure Fuel Lines i e 12 Before Starting Engine n se 13 Engine Starting sorsara ma a a TAN 13 Engine StOpping eree T aAA 14 Electrical System ssssseesiseseesirrisernresreirneeseensns 14 Engine Electronics eceeeeeeeeeeeeeeeeeneeeeeeeeneaeees 15 Product Information Section General Information eceeeeeeeeseneeeeeaee 17 Model VIEWS ictecetiescdcdhccs sidonnat anata oina 18 Product Identification Information a 22 Operation Section Lifting and Storage 00 0 ceeeeeeeeeeeeeeeeeeeeeeeeeeneeees 24 Gauges and Indicators cceeeeeeeeeestteeeeeeenaes 26 Features and Controls s es 28 Engine Diagnostics 0 ce eeeeeeeeeeeeeeeeeeeeeneenees 34 Engine Starting eese 38 Engine Operation eanan EEEE 41 Engine Stopping es iere 42 Cold Weather Operation eeeeeeeeeeettees 44 Maintenance Section Refill Capacities 2 0 2 0 ccccccceeeeceeeeeececeeeeeeeeeeeeeeees 48 Maintenance Interval Schedule 53 Warranty Section Warranty Information cccceeeeeeeeeeeeeetteeeeeeenaeees 87 Index Section 4 SEBU8387 Foreword Foreword Recommended service should be performed at the Literature Information This manual contai
65. efer to Disassembly and Assembly Fuel injection lines Remove and Fuel injection lines Install If the high pressure fuel lines are torqued correctly and the high pressure fuel lines are leaking the high pressure fuel lines must be replaced Ensure that all clips on the high pressure fuel lines are in place Do not operate the engine with clips that are damaged missing or loose e Do not attach any other item to the high pressure fuel lines Loosened high pressure fuel lines must be replaced Also removed high pressure fuel lines must be replaced Refer to Disassembly and assembly manual Fuel Injection Lines Install 102322199 Before Starting Engine 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 engine 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 prot
66. el System Primary Filter Water Separator Drain SEBU8387 Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install If you inspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information 102656272 Fuel System Primary Filter Water Separator Drain 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 NOTICE Ensure that the engine is stopped before any servicing or repair is performed NOTICE The water separator can be under suction during
67. el 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 SEBU8387 47 Operation Section Cold Weather Operation 102323237 Fuel Related Components in Cold 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 impor
68. end 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 interval 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 SEBU8387 5 Safety Section Safety Messages Safety Section 102648377 Safety Messages There may be several specific warning signs on your engine The exact location and a description of the warning signs are reviewed in this section Please become familiar with all warning signs Ensure that all of the warning signs are legible Clean the war
69. erating temperature if the engine is operated at low idle speed and operated with a light load 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 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 e 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 e Be aware of the properties of the different fuels Use only the recommended fuels e Avoid unnecessary idling Shut off the engine rather than idle for long periods of time e Observe the air cleaner service indicator frequently Keep the air cleaner elements clean e Maintain the electrical systems One damaged battery cell will overwork the alternator This will consume excess power and excess fuel Ens
70. erating 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 101907674 Engine Oil Sample Obtain The condition of the engine 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 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 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 Ser
71. ernator Belt 102648170 Emissions Certification Film Label for compliant engines Typical examples of emissions labels a N IMPORTANT ENGINE INFORMATION Engine Type Engine Family H 12 HHH Displacement 4 E 120R H6HH Factory Reset if HHHH SAI 2a EPA Family dH iH N setting Applicable EPA Advertised kw 5 MLIT HHTHH Family Fuel Rate 4 mm3 stk EA EA ARE CRAG enna ee Max Values Init Timing HAHAIHHHHE HAHAH HHAH HAHHA SIHHHHHE una Settings are to be made with engine at normal operating temperature with transmission in neutral This engine conforms to 2004 U S EPA o H HHAHIHHAH O oO non road and California off road Regulations for large C l engines HHAHIHHAH and is certified to operate on commercially available diesel fuel Emission Control System Valve Lash Cold inch HEHHE HHHH Use Service Tool HHHHHH1 GHHHHHHH Exhaust 5 Inlet 5 Label to verify current Hanger No ese position 4 Label No 3181A081 engine settings Illustration 21 g01329012 24 Operation Section Lifting and Storage SEBU8387 Operation Section Lifting and Storage 102164186 Engine Lifting C5 lm a ra a me SS ise ee Illustration 22 g01097527 NOTICE Never bend the eyebolts and the brackets Only load the eyebolts and the brackets under tension Remem ber that
72. ervals that are specified in the Operation and Maintenance Manual Maintenance Interval Schedule Oil analysis Some engines may be equipped with an oil sampling valve If oil analysis is required the oil sampling valve is used to obtain samples of the engine oil The oil analysis will complement the preventive maintenance program The 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 oil analysis The oil analysis includes the following tests 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 SEBU8387 53 Maintenance Section Maintenance Interval Schedule 1027610
73. es 12 Sensors and Electrical Components 2006 29 Hoses and Clamps Inspect Replace 81 Coolant Temperature Sensor 1 00 00e 32 Replace the Hoses and the Clamps 82 Engine Oil Pressure Sensor 6 cccceeeees 32 Failure Of S NSOMS ccccccceeeeeeeeeeeeecteeeeeeeeees 32 Fuel Pressure Sensor 4 e eeceeeeeeeeeees 32 l Intake Manifold Air Temperature Sensor 2 32 Intake Manifold Pressure Sensor 3 006 32 Important Safety Information ce eeeeeeeenees 2 Primary Speed Timing Sensor 7 na se 33 Programmable Monitoring System PMS 32 Secondary Speed Timing Sensor 8 08 33 L Sensor Locations 2 ccccceceeeeeeeeeeeeeeeseeees 29 Severe Service Application Check 065 83 Lifting and Storage 0 eee eee eeeeeeeeeeeeeteeeeeeeeneeeees 24 Environmental Factors ccccceeseseeeeeeenees 83 Incorrect Maintenance Procedures 005 84 Incorrect Operating Procedures 84 Starting Motor Inspect eee ee eeeteeeeeeeneee 84 90 Index Section SEBU8387 Starting the Engine ee eee eres 38 Starting the Engine 0 0 0 eceeeeeeeeeeeeeeeeeeeeeeeee 38 Starting with Jump Start Cables ee 39 Stopping the Engine cc ceceeeeeeeeeeeennteeeeeeeaes 42 T Table of Content ccc ccceeeceeeeeeeeneeeeeeeeeneeeeeeeaas 3 Turbocharger
74. es or cables that are smaller than the recommended gauge Do not bypass any fuses and or circuit breakers Arcing or sparking could cause a fire Secure connections recommended wiring and correctly maintained battery cables will help to prevent arcing or sparking Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines Ensure that the engine is stopped 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 Oil filters and fuel filters must be correctly installed The filter housings must be tightened to the correct torque Refer to the Disassembly and Assembly manual for more information OO Illustration 10 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 OOQ Illustration 11 g00704135 Gases from a battery can explode Keep any open flames or sparks away
75. essure only 5 If equipped remove the wiring harness from the sensor on the bottom of the bowl 6 Hold bowl 3 and remove screw 2 Remove the bowl from canister 4 7 Use a suitable tool in order to remove the canister 4 Discard old seals 5 and 6 and the canister in a safe place 8 Clean bowl 3 76 Maintenance Section SEBU8387 Fuel System Primary Filter Water Separator Element Replace Illustration 51 g01333552 Typical example 9 Lubricate the O ring seal 7 with clean engine oil on the new canister Install the new canister Do not use a tool in order to install the canister Tighten the canister by hand Spin on the canister until the O ring seal contacts the sealing surface Then rotate the canister of a turn in order to tighten the canister correctly 10 Install new O ring seal 5 onto setscrew 2 Install new O ring seal 6 into bowl 3 11 Align the bowl to the canister Ensure that the sensor if equipped is in the correct position Install setscrew 2 Tighten the setscrew to a torque of 5 N m 44 Ib in 12 If equipped install the wiring harness to the sensor 13 Remove the container and dispose of the fluid in a safe place 14 The secondary filter must be replaced at the same time as the primary filter Refer to the Operation and Maintenance Manual Fuel System Filter Replace Type Two Fil
76. est oil viscosity that is available to meet the requirement for the temperature at start up Table 8 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 0W30 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 C 104 F SAE 10W30 20 C 4 F 40 C 104 F SAE 15W40 10 C 14 F 50 C 122 F Synthetic Base Stock Oils 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 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 oil Re refined Base Stock Oils Re refined base stock oils are acceptable for use in Perkins engines if these oils meet the performance requirements that are specified by Perkins Re refined base stock oils can be used exclusively in finished oil
77. fore any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install 1 Ensure that the fuel supply valve if equipped is in the OFF position Place a suitable container under the fuel filter in order to catch any fuel that might spill Clean up any spilled fuel Sn a y je Illustration 57 g01333960 Typical example 2 Clean the outside of the fuel filter Use a suitable tool in order to remove the canister 2 from the engine and dispose of the canister in a safe place 3 Ensure that dirt can not enter the new canister Do not fill the canister with fuel before the canister is installed Lubricate the O ring seal 1 with clean engine oil on the new canister 4 Install the new canister Do not use a tool in order to install the canister Tighten the canister by hand 5 Spin on the canister until the O ring seal contacts the sealing surface The canister will require a of a full turn in order to tighten the canister correctly 6 Remove the container and dispose of the fuel in a safe place If equipped open the fuel supply valve 7 Prime the fuel system Refer to the Operation and Maintenan
78. fore 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 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 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 com
79. fore cleaning Inspect air cleaner elements for damage to the pleats the seals the gaskets and the outer cover Discard any damaged air cleaner element Two methods may be used in order to clean the primary air cleaner element e pressurized air e Vacuum cleaning Pressurized Air 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 Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than three times Use filtered dry air with a maximum pressure of 207 kPa 30 psi Pressurized air will not remove deposits of carbon and oil Illustration 37 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 air hose so that air flows along the length of the filter Follow the direction of the paper pleats in order to prevent damage to the pleats Do not aim the air directly at the face of the paper pleats Note Refer to Inspecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for removing accumulated dirt from the dirty side outside of a primary air cleaner element Vacu
80. 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 Manual Fuel System Prime for more information on priming the fuel system 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 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 Reset all of the shutoffs or alarm components if equipped Ensure that any equipment that is driven by the engine has been disengaged from the engine Minimize electrical loads or remove any electrical loads 102322203 Starting the Engine Note Do not adjust the engine speed control during start up The electronic control module ECM will control the engine speed during start up Starting the Engine 1 Disengage any equipment that is driven by the engine 2 Turn the keyswitch to the RUN position Leave the keyswitch in the RUN position until the warning light for the glow plugs is extinguished 3 When the warning light for the glow plugs is extinguished turn the keyswitch to the START position in order to engage the electric
81. from the welder could severely damage the component 5 Protect the wiring harness from welding debris and spatter 6 Use standard welding practices to weld the materials 18 Product Information Section Model Views SEBU8387 Model Views 102649396 Model View Illustrations The following model views show typical features of the engine Due to individual applications your engine may appear different from the illustrations Note Only major components are identified on the following illustrations EZ re ROE NS SZ UE A E 7 A A SASAK nA A A SSF r h ANE EN A Illustration 16 Front left engine view 1 Fuel manifold Rail 2 Canister for the crankcase breather 3 Electronic control module 4 P2 connector 5 Secondary fuel filter RN 6 Hand primer 7 Primary fuel filter 8 Oil sampling valve 9 Oil filter 10 Fuel pump g01329939 Fan pulley Belt tensioner SEBU8387 19 Product Information Section Model Views Illustration 17 Rear right engine view 16 Oil gauge 17 Air intake 18 Oil filler 19 Front lifting eye 20 Alternator 21 Exhaust manifold 22 Exhaust elbow 23 Turbocharger 24 Wastegate solenoid 25 Starting motor 102715685 Engine Description The 1106 Electronic Engine model PK is designed for the following applications machine and industrial mobile equipment The e
82. g shutdown for emergency maneuvers if necessary NOTICE The Engine Monitoring System is not a guarantee against catastrophic failures Programmed delays and derate schedules are designed to minimize false alarms and provide time for the operator to stop the engine The following parameters are monitored e Coolant temperature e Intake air temperature e Engine intake manifold pressure e Engine Oil pressure e Pressure in the fuel rail e Engine speed timing Programmable Options and Systems Operation If the Warning Derate Shutdown mode has been selected and the warning indicator activates bring the engine to a stop whenever possible De pending on the application special precautions should be taken to avoid personal injury The engine can be programmed to the following modes Warning The Warning lamp and the warning signal orange lamp turn ON and the warning signal is activated continuously in order to alert the operator that one or more of the engine parameters is not within normal operating range Warning Derate The Diagnostic lamp turns ON and the warning signal red lamp is activated After the warning the engine power will be derated The warning lamp will begin to flash when the derating occurs The engine will be derated if the engine exceeds preset operational limits The engine derate is achieved by restricting the amount of fuel that is available for ea
83. g 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 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 Decrease the engine speed to low idle 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 Maint
84. gases consult your Perkins dealer and or your Perkins distributor for additional information about suitable protection devices 10 Safety Section Fire Prevention and Explosion Prevention SEBU8387 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 contain 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 wir
85. ge 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 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 SEBU8387 Table of Contents Table of Contents FOFE WOM itis faved eect nenton eden 4 Safety Section Safety Messages ee e
86. hance 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 proved 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 e 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 e 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 Remove the water pump Refer to Disassembly and Assembly Water Pump Remove and Install For more information consult your Perkins dealer or your Perkins distributor e 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 piping for the air intake system and the elbows for cracks and for loose clamps Ensure that hoses and
87. he batteries are correctly charged the ammeter reading should be very near zero 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 i02680086 Alternator and Fan Belts Inspect NOTICE Ensure that the engine is stopped before any servicing or repair is performed To maximize the engine performance inspect the belt 1 for wear and for cracking Replace the belt if the belt is worn or damaged e If the belt 1 has more than four cracks per 25 4000 mm 1 inch the belt must be replaced e Check the belt for cracks splits glazing grease and splitting Illustration 28 g01347573 Typical example 102680137 Alternator and Fan Belts Replace Refer to Disassembly and Assembly Manual Alternator Belt Remove and Install 56 Maintenance Section Battery Replace SEBU8387 102322315 Battery Replace 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 i
88. he capacity of the auxiliary oil filter Refer to the Operation and Maintenance Manual Maintenance Section for more information on Lubricant Specifications Table 4 Engine Refill Capacities Minimum Maximum 13 5 L 16 5 L Crankcase Oil Sump 2 9696 3 6295 Imp gal Imp gal 1 These values are the approximate capacities for the crankcase oil sump aluminum which includes 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 Compartment or System Cooling System 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 Table 5 Engine Refill Capacities Compartment or System Liters Engine Only 9 ra External System Per OEM 1 The External System includes a radiator or an expansion tank with the following components heat exchanger and piping Refer to the OEM specifications Enter the value for the capacity of the External System in this row 102761894 Fluid Recommendations General Lubricant Information Because of government regulations regarding the certification of exhaust emissions from the engine the lubricant recommendations must be followed e EMA Engine Manufacturers
89. iller 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 62 Maintenance Section SEBU8387 Cooling System Supplemental Coolant Additive SCA Test Add 102335389 Cooling System Supplemental Coolant Additive SCA Test Add Cooling system coolant additive contains alkali To help prevent personal injury avoid contact with the skin and the eyes Do not drink cooling system coolant additive Test for SCA Concentration Heavy Duty Coolant Antifreeze and SCA NOTICE Do not exceed the recommended six percent supple mental coolant additive concentration Use a Coolant Conditioner Test Kit in order to check the concentration of the SCA Add the SCA If Necessary NOTICE Do not exceed the recommended amount of sup plemental coolant additive concentration Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system reducing the engine s he
90. ing 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 e 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 operation Hints for Cold Weather Operation e If 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 Install the correct specification of e
91. ired engine rpm 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 rotor type oil pump e Oil cooler The engine lubricating oil is supplied by a rotor type oil pump The engine lubricating oil is cooled and the engine lubricating oil is filtered The bypass valve can provide unrestricted flow of lubrication oil to the engine if the oil filter element should become plugged SEBU8387 21 Product Information Section Model Views 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 this Operation and Maintenance Manual Maintenance Interval Schedule for more information on maintenance items 22 Product Information Section Product Identification Information SEBU8387 Product Identification Information i02761892 Plate Locations and Film Locations SS y 9 ri 0 NG es TE 1 au ES g01331472 Illustration 19 Location of the serial number plate Perkins engines are identified by an engine serial number An example of an engine number is PK U000001 J kkkkk The list number for th
92. l 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 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 NOTICE 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 27 demonstrates the TBN Illustration 27 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 e
93. l 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 operating 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 temperat
94. ld 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 e Free operation of the valves is 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 oi
95. le 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 102667594 Crankcase Breather Canister Replace NOTICE Ensure that the engine is stopped before any servicing or repair is performed 1 Place a container under canister 2 2 Clean the outside of the canister Use a suitable tool in order to remove the canister SEBU8387 63 Maintenance Section Driven Equipment Check Illustration 35 g01340520 Typical example 3 Lubricate O ring seal 1 on the new canister with clean engine lubricating oil 4 Install the new canister Spin on the canister until the O ring seal contacts the sealing surface 3 Then rotate the canister of a full turn 5 Remove the container Dispose of the old canister and any split oil in a safe place 102151646 Driven Equipment Check Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment e Inspection e Adjustment e Lubrication e Other maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM 101909392 Engine Clean Personal injury or death can result from high volt age Moisture can create paths of
96. lugs should be cleaned and installed If necessary replace the O ring seal Tighten the drain plug to 34 N m 25 Ib ft Replace the 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 tool 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 and turbocharger bearings Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter ae are
97. luid penetration hazard Refer to Operation and Maintenance Manual General hazard Information Visually inspect the high pressure fuel lines for damage or signs of fuel leakage Replace any damaged high pressure fuel lines or high pressure fuel lines that have leaked Ensure that all clips on the high pressure fuel lines are in place and that the clips are not loose e Inspect the rest of the fuel system for leaks Look for loose fuel line clamps 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 Check for any loose tie wraps or missing tie wraps 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 Check the condition of the gauges Replace any gauges that are cracked Replace any gauge that can not be calibrated 102499304 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 Illustration 60 g01249
98. ly in order to relieve any pressure Remove the filler 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 33 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 4 Illustration 34 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 bottom of the f
99. mendations for the recommended coolant mixture SEBU8387 45 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 rpm from 1000 to 1200 rpm This will warm up the engine more 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 co
100. n 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 _ Switch the engine to the OFF position Remove all electrical loads N Turn off any battery chargers Disconnect any battery chargers oo The NEGATIVE cable connects the NEGATIVE battery terminal to the NEGATIVE terminal on the starting motor Disconnect the cable from the NEGATIVE battery terminal D 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 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
101. nance 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 102683336 Fan Clearance Check There are different types of cooling systems Refer to the OEM for information on clearance for the fan Ensure that the engine is stopped Ensure that the cooling system is full The clearance between the cover 1 and the fan 2 will require checking The gap A between the edge of the cover and the tip of the fan blade must be checked in four equally spaced positions 72 Maintenance Section Fuel System Prime SEBU8387 Illustration 46 Adjustment of the cover will change the clearance gap between the edge of the cover and the tip of the fan blade Ensure that the cover is centralized to the fan The maximum clearance is 12 5 mm 0 4921 inch The minimum clearance is 6 mm 0 2362 inch 102668315 Fuel System Prime Contact with high pressure fuel ma
102. ncy 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 SEBU8387 83 Maintenance Section Severe Service Application Check 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 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
103. ncy 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 To stop an electronically controlled engine cut the power to the engine and or shutting off the air supply to the engine 102234878 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 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 cable to the engine block Check the electrical wires daily for wires that are loose or frayed Tighten all loose electrical connections before the engine is started Repair all frayed electrical wires before the engine is started See the Operation and Maintenance Manual for specific starting instructions SEBU8387 15 Safety Section Engine Electronics Grounding Practices Illustration 13 g01162916 Typical example
104. nd 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 12 Safety Section High Pressure Fuel Lines SEBU8387 i02668808 High Pressure Fuel Lines Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death Illustration 12 1 High pressure line 2 High pressure line 3 High pressure line The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head These fuel lines are different from fuel lines on other fuel systems This is because of the following differences 4 High pressure line 5 High pressure line 6 High pressure line g01341328 7 High pressure fuel manifold rail 8 High pressure line e The high pressure fuel lines are constantly charged with high pressure e The internal pressures of the high
105. ned to the The engine has not been ON ON ON position both lamps will illuminate for 2 started seconds only OFF OFF No faults There are no active diagnostic faults The engine is running normally Active An active diagnostic fault has been detected The engine is running ON OFF diagnostic normally fault Active A serious active diagnostic fault has been The engine is running ON FLASHING diagnostic detected and an engine derate has been but the engine has been fault invoked derated Warning One or more of the engine protection values The engine is running FEASHING OFF has been exceeded normally Derate and One or more of the engine protection values The engine is running FLASHING FLASHING warning has been exceeded but the engine has been derated Engine One or more of the engine protection values has The engine is shutdown or ON ON shutdown been exceeded or a serious active diagnostic shutdown is imminent fault has been detected Sensors and Electrical Components Sensor Locations 102649763 Illustration 23 shows the typical locations of the sensors on the engine Specific engines may appear different from the illustration due to differences in applications The location of the Electronic Control Module ECM is illustrated 30 SEBU8387 Operation Section Features and Controls
106. ngine is available in the following type of aspiration e Turbocharged aftercooled e Four stroke cycle e In line 6 cylinder g01329941 26 Oil pan 27 Drain plug oil 28 Drain plug or coolant sampling valve 29 Breather 30 Rear lifting eye Engine Specifications Note The front end of the engine is opposite the flywheel end of the engine The left and the right sides of the engine are determined from the flywheel end The number 1 cylinder is the front cylinder 20 Product Information Section Model Views SEBU8387 3 QO DOH Illustration 18 g01127295 1106 Electronic Engine model PK A Exhaust valves B Inlet valves Table 1 1106 Electronic Engine Model PK Specifications Operating Range rpm 900 to 28000 Number of Cylinders 6 In Line Bore 105 mm 4 13 inch Stroke 127 mm 5 0 inch Aspiration Turbocharged aftercooled Compression Ratio 16 2 1 Displacement 6 6 L 403 in Firing Order 1 5 3 6 2 4 Rotation flywheel end Counterclockwise Valve Lash Setting Inlet 0 35 mm 0 013 inch Valve Lash Setting Exhaust 0 35 mm 0 013 inch 1 The operating rpm is dependent on the engine rating the application and the configuration of the throttle Electronic Engine Fea
107. ngine is equipped with a DIAGNOSTIC lamp 1 Move the keyswitch from the on off two times within three seconds A flashing YELLOW lamp indicates a 3 digit code for the engine The sequence of flashes represents the system diagnostic message Count the first sequence of flashes in order to determine the first digit of the flash code After a two second pause the second sequence of flashes will identify the second digit of the flash code After the second pause the third sequence of flashes will identify the flash code Any additional flash codes will follow after a pause These codes will be displayed in the same manner Flash Code 551 indicates that No Detected Faults have occurred since the ignition keyswitch has been turned to the ON position For further information assistance for repairs or troubleshooting refer to the Service Manual or consult your Perkins distributor Table3 lists the flash codes and the table also gives a brief description of the flash codes Note Table3 indicates the potential effect on engine performance with ACTIVE flash codes Some codes record events Also some codes may also indicate that a mechanical system needs attention Troubleshooting is not required for code 551 Code 001 will not display a flash code Some codes will limit the operation or the performance of the engine Table3 indicates the potential effect on the engine performance with active flash codes Table 3 al
108. ngine 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 Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury e For jump starting 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 Recom
109. ning signs or replace the warning signs if the words cannot be read or if the illustrations are not visible Use a cloth water and soap to clean the warning signs Do not use solvents gasoline or other harsh chemicals Solvents gasoline or harsh chemicals could loosen the adhesive that secures the warning signs The warning signs that are loosened could drop off of the engine Replace any warning sign that is damaged or missing If a warning sign is attached to a part of the engine that is replaced install a new warning sign on the replacement part Your Perkins dealer or your distributor can provide new warning signs 1 Universal 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 A WARNING LL Illustration 1 g01154807 Typical example The Universal Warning label 1 is located on both sides of the valve mechanism cover base 6 Safety Section Safety Messages SEBU8387 J i YP Vie ACK Le 7 Illustration 2 Location of label 1 Universal warning 2 Ether Warning A WARNING Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury A WARNING Ly A Illustration 3 g01154809
110. ns have electronic displays that provide direct readouts of the engine diagnostic codes Refer to the manual that is provided by the OEM for more information on retrieving engine diagnostic codes Alternatively refer to Troubleshooting Indicator Lamps for further information Active codes represent problems that currently exist These problems should be investigated first Logged codes represent the following items e Intermittent problems e Recorded events e Performance history The problems may have been repaired since the logging of the code These codes do not indicate that a repair is needed The codes are guides or signals when a situation exists Codes may be helpful to troubleshoot problems When the problems have been corrected the corresponding logged fault codes should be cleared 102651107 Diagnostic Lamp A diagnostic lamp is used to indicate the existence of an active fault Refer to Troubleshooting Indicator Lamps for more information A fault diagnostic code will remain active until the problem is repaired The diagnostic code may be retrieved by using the electronic service tool Refer to Troubleshooting Electronic Service Tools for more information 102761893 Diagnostic Flash Code Retrieval Diagnostic Lamp Use the DIAGNOSTIC lamp or an electronic service tool to determine the diagnostic flash code Use the following procedure to retrieve the flash codes if the e
111. ns 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 from 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
112. nt 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 or 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 Note The engine is equipped with a device for cold starting 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 These engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting 102234873 Engine Stopping Stop the engine according to the procedure in the Operation and Maintenance Manual Engine Stopping Operation Section in order to avoid 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 emerge
113. o battery or battery e Measured reading of the sensor is out of the specification Programmable Monitoring System PMS The Programmable Monitoring System determines the level of action that is taken by the Engine Control Module ECM 5 in response to a condition that can damage the engine These conditions are identified by the ECM from the signals that are produced from the following sensors e Coolant Temperature Sensor e Intake manifold Air Temperature Sensor e Intake manifold Pressure Sensor e Fuel Pressure Sensor Engine Oil Pressure Sensor Primary Speed Timing Sensor Secondary Speed Timing Sensor Coolant Temperature Sensor 1 The coolant temperature sensor monitors engine coolant temperature The output of the ECM 5 can indicate a high coolant temperature through a relay or a lamp The coolant temperature sensor is used by the ECM to determine initiation of the Cold Start Condition Failure of the Coolant Temperature Sensor The ECM 5 will detect a failure of the coolant temperature sensor The diagnostic lamp will warn the operator about the status of the coolant temperature sensor A failure of the coolant temperature sensor will not cause a shutdown of the engine or any horsepower change In order to check the correct operation of the sensor refer to Troubleshooting Engine Temperature Sensor Circuit Test Intake Manifold Air Temperature Sensor 2 The intake manifold air tem
114. off when changing fuel filters or water separator elements Clean up fuel spills immediately Note Refer to Testing and Adjusting Manual Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system NOTICE Ensure that the engine is stopped before any servicing or repair is performed After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install 1 Turn the fuel supply valve if equipped to the OFF position before performing this maintenance Clean the fuel filter assembly 2 Place a suitable container under the water separator in order to catch any fuel that might spill Clean up any spilled fuel Clean the outside of the water separator pe Illustration 50 g01333866 Typical example 3 Install a suitable tube onto the drain 1 Open the drain 1 Allow the fluid to drain into the container Remove the tube 4 Tighten the drain 1 by hand pr
115. on Engine Oil and Filter Change Do not drain the engine lubricating oil when the engine is cold As the engine lubricating oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with draining cold oil Drain the oil pan with the engine stopped Drain the oil pan 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 Lubricating Oil Note Ensure that the vessel that will be used is large enough to collect the waste oil After the engine has been run at the normal operating temperature stop the engine Use one of the following methods to drain the engine oil pan Illustration 42 901333817 Typical example e If 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 oil pan remove the bottom oil drain plugs from both ends of the oil pan After the oil has drained the oil drain p
116. or all engines Note Many of the engine control systems and display modules that are available for Perkins Engines will work in unison with the Engine Monitoring System Together the two controls will provide the engine monitoring function for the specific engine application Refer to Troubleshooting for more information on the Engine Monitoring System SEBU8387 17 Product Information Section General Information Product Information Section General Information 101889424 Welding on Engines with Electronic Controls NOTICE Proper welding procedures are necessary in order to avoid damage to the engine s ECM sensors and associated components When possible remove the component from the unit and then weld the compo nent If removal of the component is not possible the following procedure must be followed when you weld with a unit that is equipped with an Electronic Engine The following procedure is considered to be the safest procedure to weld a component This pro cedure should provide a minimum risk of damage to electronic components NOTICE Do not ground the welder to electrical components such as the ECM or sensors Improper grounding can cause damage to the drive train bearings hydraulic components electrical components and other com ponents Clamp the ground cable from the welder to the com ponent that will be welded Place the clamp as close as possible to the weld This will help reduce th
117. partment 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 of the coolant 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 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 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 58 Maintenance Section Cooling System Coolant Commercial Heavy Duty Change SEBU8387 y aaa TE yy Q alts Illustration 29 g01144180 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
118. peration 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 the engine may not start in an emergency situation 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 102718318 Turbocharger Inspect A regular visual inspection of the turbocharger is recommended 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 o
119. peration should not cause problems as long as a turbocharger bearing failure has not oc cured When a turbocharger bearing failure is accompanied by a significant engine performance loss exhaust smoke or engine rpm 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 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 inspection or removed for the cleaning of the compressor 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 obvious heat discoloration of the turbocharger Check for any loose bolts or any missing bolts Check for damage to the oil supply line and the oil drain line Check for cracks in the ho
120. perature sensor measures the intake air temperature A signal is sent to the ECM 5 The intake manifold air temperature sensor is also used by the ECM to determine initiation of the Cold Start Strategy In order to check the correct operation of the sensor refer to Troubleshooting EngineTemperature Sensor Circuit Test Intake Manifold Pressure Sensor 3 The intake manifold pressure sensor measures pressure in the manifold A signal is sent to the ECM 5 Fuel Pressure Sensor 4 The fuel pressure sensor measures the fuel pressure in the fuel manifold A signal is sent to the ECM 5 Engine Oil Pressure Sensor 6 The engine oil pressure sensor is an absolute pressure sensor that measures the engine oil pressure in the main oil gallery The engine oil pressure sensor detects engine oil pressure for diagnostic purposes The engine oil pressure sensor sends a signal to the ECM 5 Low Oil Pressure Warning The setpoint for the low pressure warning is dependent upon the engine speed The fault will be active and logged only if the engine has been running for more than 8 seconds SEBU8387 33 Operation Section Features and Controls Very Low Oil Pressure Warning The very low oil pressure setpoint is dependent upon the engine speed If the DERATE mode of the engine monitoring system is selected the ECM 5 will derate the engine power The engine horsepower will be limited Failure of the Engine Oil Pressur
121. pressure fuel lines are higher than other types of fuel system e The high pressure fuel lines are formed to shape and then strengthened by a special process SEBU8387 13 Safety Section Before Starting Engine Do not step on the high pressure fuel lines Do not deflect the high pressure fuel lines Do not bend or strike the high pressure fuel lines Deformation or damage of the high pressure fuel lines may cause a point of weakness and potential failure Do not check the high pressure fuel lines with the engine or the starting motor in operation After the engine has stopped allow 60 seconds to pass in order to allow the pressure to be purged before any service or repair is performed on the engine fuel lines Do not loosen the high pressure fuel lines in order to remove air from the fuel system This procedure is not required Visually inspect the high pressure fuel lines before the engine is started This inspection should be each day If you inspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information e Inspect the high pressure fuel lines for damage deformation a nick a cut a crease or a dent e Do not operate the engine with a fuel leak If there is a leak do not tighten the connection in order to stop the leak The connection must only be tightened to the recommended torque R
122. r 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 SEBU8387 67 Maintenance Section Engine Air Precleaner Check Clean 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 at the greatest vacuum that is attained If 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 102343354 Engine Air Precleaner Check Clean 1 LJ Illustration 40 g00287039 Typical example 1 Wing nut 2 Cover 3 Body Remove wing nut 1 and cover 2 Check for an accumulation of dirt and debris in body 3 Clean the body if necessary After cleaning the precleaner install cover 2 and wing nut 1 Note When the engine is operated in dusty applications more frequent cle
123. r 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 SEBU8387 65 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace Cleaning the Primary Air Cleaner Elements 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 tap or strike the air cleaner element Do not wash the primary air cleaner element Use low pressure 207 kPa 30 psi maximum pres surised air or vacuum cleaning to clean the primary air cleaner element Take extreme care in order to avoid damage to the air cleaner elements Do not use air cleaner elements that have damaged pleats gaskets or seals Refer to the OEM information in order to determine the number of times that the primary air cleaner element can be cleaned Do not clean the primary air filter element more than three times The primary air cleaner element must be replaced at least one time per year Cleaning the air filter element will not extend the life of the air filter element Visually inspect the primary air cleaner element be
124. r 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 may 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 If 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 Operating in dirty conditions 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 m
125. ressure fuel lines with the engine or the starting motor in operation If you inspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information e Check for any fluid or for any air leaks at idle rom and at one half full rpm no load on the engine before operating the engine under load This is not possible in some applications e Allow the engine to idle for three to five minutes or allow the engine to idle until the water temperature indicator begins to rise 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 detect abnormal operating developments Significant changes in the readings should be investigated SEBU8387 41 Operation Section Engine Operation Engine Operation 102330143 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 rpm after the engine reaches operating temperature The engine will reach normal op
126. so forms a list of Electronic diagnostic codes and descriptions SEBU8387 35 Operation Section Engine Diagnostics Table 3 Flash Codes for 1106C Genset Diagnostic Effect On Engine Performance 2 Suggested Operator Flash Code Action Description Engine Low Reduced Engine Service Schedule Misfire Power Engine Shutdown a Service Speed 4 111 No 1 Injector Fault X X X 112 No 2 Injector Fault X X X 113 No 3 Injector Fault X X X 114 No 4 Injector Fault X X X 115 No 5 Injector Fault X X X 116 No 6 Injector Fault X X X 133 Intake Manifold Air X X Temperature sensor fault 135 Intake Manifold Boost X X Pressure Fault 141 Primary Engine X X Speed Timing Sensor Fault 142 Secondary Engine X Speed Timing Sensor Fault 143 Engine Timing X X Calibration Fault 144 Engine Operation Mode X X Selector Switch Fault 154 Throttle Position sensor X X Fault 155 Secondary Throttle X X Position sensor Fault 157 Engine Oil Pressure X X Sensor Fault 159 Fuel Rail Pressure X X Sensor Fault 162 Fuel Rail Pressure X X X Valve Solenoid Fault 168 Engine Coolant X Temperature Sensor Faul 177 Turbo Wastegate X Actuator Fault 199 Glow Plug Start Relay X Fault 415 Software Mismatch X X 422 ECM Power Supply X X X Voltage Fault continued 36 Operation Section Engine Diagnostics SEBU8387 Table 3 contd
127. sure 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 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 84 Maintenance Section Starting Motor Inspect SEBU8387 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 o
128. systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install If you inspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information Electric Fuel Priming Pump 1 Ensure that the fuel system is in working order Check that the fuel supply valve if equipped is in the ON position NOTICE The electric fuel priming pump will operate for 90 sec onds If necessary the electric fuel priming pump can be stopped during the 90 seconds of operation by op eration of the switch 2 Turn the keyswitch to the RUN position Operate the switch for the electric priming pump After 90 seconds of the electric fuel priming pump operation the fuel system will be primed and the electric fuel priming pump will turn off 3 The engine should now be able to start 4 Operate the engine starter and crank the engine After the engine has started operate the engine at low idle for a minimum of five minutes immediately after air has been removed from the fuel system Note Operating the engine for this period of time will help ensure that the fuel system is free of air Note Do not loosen the high pressure fuel line in order to purge air from the fuel system This procedure is not required 74 Maintenance Section Fu
129. t 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 40 Operation Section Engine Starting SEBU8387 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 igniting the combustible gases that are produced by some batteries 4 Start the engine 5 Immediately after the 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 proper 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 102330138 After Starting Engine Note In ambient 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 Do not check the high p
130. tant Drain the water and sediment from any fuel storage tank at the following intervals weekly service intervals 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 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 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 case the temperature of the fuel must not exceed 73 C 163 F at the fuel transfer pump For more information about fuel heaters if equipped refer to the OEM information 48 Maintenance Section Refill Capacities SEBU8387 Maintenance Section Refill Capacities 102237872 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 t
131. tem 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 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 y JAT TL Os Wass aA Illustration 31 g01144180 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 60 Maintenance Section Cooling System Coolant Level Check SEBU8387 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 coolin
132. ter 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 Note Refer to Testing and Adjusting Manual Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install NOTICE Ensure that the engine is stopped before any servicing or repair is performed 1 Turn the fuel supply valve if equipped to the OFF position before performing this maintenance 2 Place a suitable container under the water separator in order to catch any fuel that might spill Clean up any spilled fuel Clean the outside of the water separator SEBU8387 77 Maintenance Section Fuel System Primary Filter Water Separator Element Replace
133. ter 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 102235492 Mounting and Dismounting 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 a
134. ternator Inspect ceeeceeeseeceeeeeeeeeeeeeteeeeeees 55 Label for compliant engines cceeee 23 Alternator and Fan Belts Inspect 55 Emissions Warranty Information 87 Alternator and Fan Belts Replace 208 55 Engine Cleans irae A 63 Engine Air Cleaner Element Dual Element Clean Replace cccccccceeeeeeeeeeceeceeeeeeeeeeeeeetees 64 B Cleaning the Primary Air Cleaner Elements 65 Servicing the Air Cleaner Elements 0 64 Battery Replace cccccessceeeeeesseeeeeeeeeeneeeees 56 Engine Air Cleaner Element Single Element Battery Electrolyte Level Check n se 56 Inspect ReEplace eceeceecceeeeeeeeeeeeeeeenenaeees 66 Battery or Battery Cable Disconnect 57 Engine Air Cleaner Service Indicator Inspect 66 Before Starting Engine s es 13 38 Test the Service Indicator 67 Burn Prevention cccccccscceeeeecneceeeeeeaeeetesseceeeeeeees 9 Engine Air Precleaner Check Clean 0 67 Batterie Sedii ii attack uee ecole eee 9 Engine Description ceccceeceeceeeeeeeeeeeeeeeeees 19 Coa ern arer era 9 Electronic Engine Features 20 e E A E hee 9 Engine Cooling and Lubrication e 20 Engine Diagnostics 0 ccceeeeeeeeeeeeeeteeeeeeeenaes 20 Engine Specifications 19 c Engine Diagnostics eeren 34 Engine ElettroNiCS esde arie aa 15 Cold Weather Operation
135. that are cracked or soft Tighten any loose clamps 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 e 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 changes 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 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 Pressurized System Hot coolant can cause
136. the OFF position If necessary refer to the instructions that are provided by the OEM 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 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 Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install
137. 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 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 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 102308881 Engine Storage If the engine is not started for a month or longer 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 Perkins are not responsible for damage which may occur when an engine is in storage after a period in servi
138. ting temperature Check the gauges during the warm up period 102322204 Starting with Jump Start Cables 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 Refer to Troubleshooting Engine Will Not Crank and Engine Cranks But Will Not Start for further information Make any necessary repairs If the engine will not start only due to the condition of the battery either charge the battery or start the engine by using another battery 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 Turn all electrical accessories OFF before 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 on the stalled engine to the OFF position Turn off all the engine s accessories 2 Connec
139. tubes are not contacting other hoses tubes wiring harnesses etc Ensure that the areas around the rotating parts are clear Inspect the alternator belts and any accessory drive belts for cracks breaks or other damage e Inspect the wiring harness for damage 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 High Pressure Fuel Lines Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines If necessary perform minor adjustments Repair any leaks from the low pressure fuel system and from the cooling lubrication or air systems Replace any high pressure fuel line that has leaked Refer to Disassembly and assembly Manual Fuel Injection Lines Install 86 Maintenance Section Water Pump Inspect SEBU8387 If you inspect the engine in operation always use the proper inspection procedure in order to avoid a f
140. tures The engine operating conditions are monitored The Electronic Control Module ECM controls the response of the engine to these conditions and to the demands of the operator These conditions and operator demands determine the precise control of fuel injection by the ECM The electronic engine control system provides the following features e Engine monitoring e Engine speed governing e Control of the injection e Cold start strategy pressure e Automatic air fuel ratio control e Torque rise shaping e Injection timing control e System diagnostics For more information on electronic engine features refer to the Operation and Maintenance Manual Features and Controls topic Operation Section Engine Diagnostics The engine has built in diagnostics in order to ensure that the engine systems are functioning correctly The operator will be alerted to the condition by a Stop or Warning lamp Under certain conditions the engine horsepower and the vehicle speed may be limited The electronic service tool may be used to display the diagnostic codes There are three types of diagnostic codes active logged and event Most of the diagnostic codes are logged and stored in the ECM For additional information refer to the Operation and Maintenance Manual Engine Diagnostics topic Operation Section The ECM provides an electronic governor that controls the injector output in order to maintain the des
141. ubricate the O ring seal 7 with clean engine oil Install the bowl onto the new canister Tighten the bowl to 15 N m 11 Ib ft 11 If equipped install the wiring harness to the sensor Open the fuel supply valve 12 Remove the container and dispose of the fluid in a safe place 13 The secondary filter must be replaced at the same time as the primary filter Refer to the Operation and Maintenance Manual Fuel System Filter Replace SEBU8387 79 Maintenance Section Fuel System Secondary Filter Replace 102690522 Fuel System Secondary Filter Replace Type One Filter 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 Note Refer to Testing and Adjusting Manual Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system NOTICE Ensure that the engine is stopped before any servicing or repair is performed This fuel filter can be identified by the six drain holes in the filter Refer to illustration 56 Illustration 56 g01375918 Typical example After the engine has stopped you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines be
142. um cleaning is especially useful for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning from the clean side inside with pressurized air is recommended prior to vacuum cleaning the dirty side outside of a primary air cleaner element 66 Maintenance Section SEBU8387 Engine Air Cleaner Element Single Element Inspect Replace Note Refer to Inspecting the Primary Air Cleaner Elements Inspecting the Primary Air Cleaner Elements Illustration 38 g00281693 Inspect the clean dry 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
143. ure 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 engines 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 42 SEBU8387 Operation Section Engine Stopping Engine Stopping i02330274 102334873 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 Avoid accelerating the engine prior to shutting it down Avoiding hot engine shutdowns will maximize tur bocharger shaft and bearing life Note Individual applications will have different control systems Ensure that the shutoff procedures are understood Use the following general guidelines in order to stop the engine 1 Remove the load from the engine Reduce the engine speed rpm to low idle Allow the engine to idle for five minutes in order to cool the engine 2 Stop the engine after the cool down period according to the shutoff system on the engine and turn the ignition key switch to
144. ures power loss excessive fan usage and reduction in fuel economy 46 Operation Section Cold Weather Operation SEBU8387 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 i02685960 Fuel 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 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 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 fu
145. urn the keyswitch to the OFF position In order to check the correct operation of the sensor refer to Troubleshooting Engine speed Timing sensor Test Secondary Speed Timing Sensor 8 The signal from the secondary speed timing sensor is used by the ECM 5 on engine start up in order to check the stroke of the pistons The secondary speed timing sensor may be used by the ECM in order to operate the engine if the primary speed timing sensor is faulty In order to check the correct operation of the sensor refer to Troubleshooting Engine speed Timing sensor Test 102237393 Overspeed An overspeed condition is detected by the Electronic Control Module ECM The event code will be logged if the engine speed exceeds 3000 rpm The DIAGNOSTIC lamp will indicate a diagnostic active code The diagnostic active code will remain active until the engine speed drops to 2800 rpm 34 Operation Section Engine Diagnostics SEBU8387 Engine Diagnostics 102651093 Self Diagnostics Perkins electronic engines have the capability to perform a self diagnostics test When the system detects an active problem a diagnostic lamp is activated Diagnostic codes will be stored in permanent memory in the Electronic Control Module ECM The diagnostic codes can be retrieved by using the electronic service tool Refer to Troubleshooting Electronic Service Tools for further information Some installatio
146. using of the turbocharger Ensure that the compressor wheel can rotate freely 3 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 turbocharger oil seal SEBU8387 85 Maintenance Section Walk Around Inspection 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 4 Inspect the bore of the housing of the turbine outlet for corrosion 5 Fasten the air intake pipe and the exhaust outlet pipe to the turbocharger housing Ensure that all clamps are installed correctly and that all clamps are tightened securely 102323090 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 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 c
147. vice Hours or 1 Year Battery Electrolyte Level Check n se 56 Cooling System Supplemental Coolant Additive SCA Test Add 0 eect ceeds ie caneaeeteenees 62 Crankcase Breather Canister Replace 62 Engine Air Cleaner Element Dual Element Clean Replace 0 0 00 cccccececeeeeeceeeeeeeeeeeeeeeeeteeeeees 64 Engine Air Cleaner Element Single Element Inspect Replace eeeeeeecceeceeeeeeeeeeeteeeeentneaees 66 Engine Oil and Filter Change n e 68 Fuel System Primary Filter Water Separator Element Replace cccccceeeeeeeeeeeeeseeeaeees 75 Fuel System Secondary Filter Replace 79 Radiator Cl6an haen haan aee 82 Every 1000 Service Hours Engine Valve Lash Inspect Adjust eee 70 Water Pump Inspect ec ceeeeeeeeeeeeeeecteeeeeeeeees 86 Every 2000 Service Hours Aftercooler Core Inspect ccceeeeeeeeeeeeteeeteees 54 Alternator Inspect ececceeceeeeeeeeeeeteeteenaeees 55 Engine Mounts Inspect ieser 67 Starting Motor Inspect 0 eee 84 Turbocharger Inspect eee eeceeeeneeeeeeeesteeeeeeeaes 84 Every 3000 Service Hours Alternator and Fan Belts Replace 2 55 Every 3000 Service Hours or 2 Years Cooling System Coolant Commercial Heavy Duty Change e aain eaa ni aeran a ceed neater 57 Every 4000 Service Hours Aftercooler Core Clean Test acncnnen 54 Every 12 000
148. vice 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 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 102667766 Engine Oil and Filter Change Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin 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 SEBU8387 69 Maintenance Secti
149. xceed 1 5 percent e Choose an oil with the highest TBN that meets one of these classifications EMA DHD 1 and API CH 4 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 anda 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 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 Table 7 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 SEBU8387 51 Maintenance Section Refill Capacities Refer to Table 8 minimum temperature in order to determine the required oil viscosity for starting a cold engine Refer to Table 8 maximum temperature in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated Generally use the high
150. y cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death g01348394 Refer to the Operation and Maintenance Manual General Hazard Information and High Pressure Fuel Lines before adjustments and repairs are performed Note Refer to Testing and Adjusting Manual Cleanliness of Fuel System Components for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training 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 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 SEBU8387 73 Maintenance Section Fuel System Prime 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 has been replaced Hand Fuel Priming Pump Use the following procedures in order to remove air from the fuel system 1 Ensure that the fuel system is in working order
151. y 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 before 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 102349879 Hoses and Clamps Inspect Replace Contact with high pressure fuel may cause fluid penetration and burn hazards High pressure fu el spray may cause a fire hazard Failure to fol low these inspection maintenance and service in structions may cause personal injury or death If you inspect the engine in operation always use the proper inspection procedure in order to avoid a fluid penetration hazard Refer to Operation and Maintenance Manual General hazard Information Inspect all hoses for leaks that are caused by the following conditions e Cracking e Softness e Loose clamps 82 Maintenance Section Radiator Clean SEBU8387 Replace hoses
152. ystem Secondary Filter Replace 79 Product Information Section ceeeceeeeeeeees 17 Type One Filter 2 cecceeecseececetesseecdeneeeeeecenees 79 Type TWO MMOP eeii eni aaa ia N 80 Fuel Tank Water and Sediment Drain 81 R Drain the Water and the Sediment 0 81 Fuel Storage Tanks 81 Radiator Clean ee ccccieecceeeeseeneeeeeeeeeeeeeeeeeenaeeees 82 F el Tanka saaa Teede aaa anada a Era R Aa 81 Reference Numbers ee eececeeeeeeeeeeteteees 22 Record for Reference 22 Refill Capacities nnsneenenennn nenne eeee eee nrrnrnnnseeerrene 48 G COOlING Syst eee ceeeeeeeeeetteeeeeetneeeeetes 48 Lubrication System eceeeeeeeeeeeeeeeetteeeeeeenaas 48 Gauges and Indicators cceeeeeeeeeeeseteeeeeeeaes 26 General Hazard Information 00 eceeeeeeees 7 Containing Fluid Spillage 0 00 ceeeeeeeeeeeeeee 8 S Fluid Penetration ccccceceeeseeeeeesetceeeeeeeeees 8 Pressure Air and Water 8 Safety Messages asssssseesrneseerrressrsnnnesrrnnnesennnn 5 General Information cceccceeeeeeeeeeeeeeeteeeeeeeaes 17 1 Universal Warning cceeeseeeeeetteeeeeeeees 5 2 Ether Warning ccccceceeeceeeesseeeeseenieeeeeeeeaas 6 3 Hand High Pressure 7 H Safety Section s aea a an 5 Self DiagnostiCS societan sina aiaa 34 High Pressure Fuel Lines cceceeeeseeeeeeeenteee

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