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1. 52 Alternator Inspect 53 Engine Mounts InSpect L UU asa 64 Starting Motor Inspect 76 Turbocharger Inspect 76 Water Pump Inspect 78 Every 2 Years Cooling System Coolant Change 58 Every 3000 Service Hours Fuel Injector Test Change 68 Every 3000 Service Hours or 2 Years Cooling System Coolant Commercial Heavy Duty Chango occi seenen Eirene ERRE 55 Every 4000 Service Hours Aftercooler Core Clean Test 52 Every 6000 Service Hours or 3 Years Cooling System Coolant Extender ELC Add 59 Every 12 000 Service Hours or 6 Years Cooling System Coolant ELC Change 57 52 Maintenance Section Aftercooler Core Clean Test SEBU7833 03 i02322260 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 ps
2. 13 Model Views 13 Mounting and Dismounting 10 O Operation Section 24 P Product Identification Information 19 Product Information Section 13 R Radiator Clea Mccann a 75 Reference Numbers 19 Record for Reference 19 Refill Capacities 37 Cooling Sysfelfi u u uu sassa saaskaussus 37 Lubrication System 37 s Safety Mess8g808S uu aaa aykaataqass 5 1 Universal Warning L u ai 5 2 BUN GF asne 5 Safety Section uuu uuu assay aassaassysssssakassaqsaswuq 5 Serial Number Plate 19 Severe Service Application Check 75 Environmental Factors 76 Incorrect Maintenance Procedures 76 Incorrect Operating Procedures 76 Starting Motor INSPCCt sesser 76 Starting the EngIB L ul aa 29 Starting with Jump Start Cables 30 Stopping the Engine cccceeeseceeeeeeeeeeeeeeeees 32 T Table of Contents
3. 54 Engine Air Cleaner Element Single Element Battery or Battery Cable Disconnect 55 INSPECt REPIACE cccceceecccceeeeseececeeteteeeeenenneeeee 63 Before Starting Engine 10 28 Engine Air Cleaner Service Indicator Inspect 63 B rn PreventiOM inaidai ia 7 Test the Service Indicator 63 Bale ri u uu u E S sss 8 Engine Description aaa sassa 16 CO llu u a asas 8 Engine Cooling and Lubrication 18 kl y 2 uuu 5 Susa 8 Engine Service Llfe uu uuu aaasasssss 18 Engine Specifications 16 Engine Ground Inspect Clean 64 C Engine Identification 19 Engine LINDO uuu aaa aaa 24 Cold Weather Operation 33 Engine Mounts Inspect 64 Hints for Cold Weather Operation 33 Engine Oil and Filter Change 65 Idling the Engine 1 34 Drain the Engine Oll 65 Recommendations for Coolant Warm Up 34 Fill the Engine Crankcase 67 Recommendations for the Coolant 33 Replace the Element for the Oil
4. 80 SEBU7833 03 Index Section Index A E After Starting Engine uuu u uu ukasa 30 Electrical SySLUemm uU ienai 11 After Stopping Engin U UU sa 32 Grounding Practices u ua asassssassssa 12 Aftercooler Core Clean Test 52 Emergency Stoppindg 32 Aftercooler Core Inspect 52 Emissions Certification Film 20 Alternator Inspect 53 Label for compliant engines 20 Alternator and Fan Belts Inspect Adjust Label for engines that comply with MSHA Replace 53 emiISSIOnS u L LULU I aaa sasaqa ba 22 Adus timen esn 53 Label for engines that do not comply with nSp Gti9ori u u u U devs coatesaceanesasaadenaaeesters 53 SIMISSIONS ssececcccrianteedcuatnadecdenasseuseeeusasedaacranaredes 22 Replacement jes uuu uu a g q sa acerca 54 Emissions Warranty Information 79 Engine Cleafenccerocesiner i 60 Engine Air Cleaner Element Dual Element B Clean Replace uuu uuu uu uu haapa sbykayaqsssa 61 Cleaning the Primary Air Cleaner Elements 62 Battery Replac u aa sasas s saessapss wass 54 Servicing the Air Cleaner Elements 61 Battery Electrolyte Level Check
5. 3 Turbocharger Inspect If Equipped 76 Spec iN esre uuu case u Z uu u ss 77 Removal and Installation 76 82 Index Section SEBU7833 03 w Walk Around Inspection Inspect the Engine for Leaks and for Loose ConHectionS u uuu uusha ahasqaaasaasqutaassssss Warranty Information Warranty Section cccccccccccceesesecceeeeseseceeeeeteneees Water Pump Inspect 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 2008 Perkins Engines Company Limited Printed in U K All Rights Reserved
6. u u aY 69 Fuel System Primary Filter Water Separator Element Replace 70 Fuel System Primary Filter Water Separator Drain scinni saidara anaa a aat 70 Fuel System Secondary Filter Replace 71 Element fiter uru u u nn uha Sisku asas 71 Spin on filter 72 Fuel Tank Water and Sediment Drain 73 Drain the Water and the Sediment 73 Fuel Storage Tank8 u u uu asses 73 Fuel Tank u uu uuu s asasssuassmqassuyaaaiasqus 73 G Gauges and Indicators 27 General Hazard Information 6 Containing Fluid Spillage 7 Fluid Penetration 7 Pressure Air and Water 7 H Hoses and Clamps Inspect Replace 74 Replace the Hoses and the Clamps 74 l Important Safety Information 2 L Ging and Storag u uu u asqa 24 M Maintenance Interval Schedule 51 Maintenance Section 37 Model View lllustrations 13 1103 Engine Model Views 15 1104 Engine Model Views
7. JP8 T83133 Avtur FSII NATO F34 Jet A Jet A1 NATO F35 XF63 Low temperature fuels Special fuels for use in cold weather may be available for engine operation at temperatures below 0 C 32 F These fuels limit the formation of wax in the fuel oil at low temperatures If wax forms in the fuel oil this could stop the flow of fuel oil through the filter Note These fuels that lack lubricity may cause the following problems e Low engine power Difficult starting in hot conditions or in cold conditions e White smoke Deterioration of emissions and misfire at certain operating conditions Biofuel Specification Biofuel A 5 mix of RME to EN14214 in conventional fuel is permitted The preferred fuels provide maximum engine service life and performance The preferred fuels are distillate fuels These fuels are commonly called diesel fuel or gas oil The permissible fuels are crude oils or blended fuels Use of these fuels can result in higher maintenance costs and in reduced engine service life Diesel fuels that meet the specifications in Table 14 will help to provide maximum engine service life and performance In North America diesel fuel that is identified as No 2 D in ASTM D975 generally meets the specifications Table 14 is for diesel fuels that are distilled from crude oil Diesel fuels from other sources could exhibit detrimental properties that are not defined or controlled by t
8. Inspecting the Primary Air Cleaner Elements Illustration 35 g00281693 SEBU7833 03 63 Maintenance Section Engine Air Cleaner Element Single Element Inspect Replace 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 Engine Air Cleaner Element Single Element Inspect Replace Refer to Operation and Maintenance Manual Engine Air Cleaner Service Indicator Inspect NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged pleats gaskets or seals Dirt entering the engine causes premature wear and damage to engine components Air cleaner elements help to prevent air borne debris from entering
9. NOTICE Do not bend or strike high pressure lines Do not in stall bent or damaged lines tubes or hoses Repair any loose or damaged fuel and oil lines tubes and hoses Leaks can cause fires Inspect all lines tubes and hoses carefully Tighten all connections to the rec ommended torque Do not clip any other item to the high pressure lines Check for the following conditions e End fittings that are damaged or leaking e Outer covering that is chafed or cut e Exposed wire that is used for reinforcement e Outer covering that is ballooning locally 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 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
10. SEBU7833 03 er ins September 2008 Operation and Maintenance Manual 1103 and 1104 Industrial Engines DC Engine DD Engine DJ Engine DK Engine RE Engine RG Engine RJ Engine RR Engine RS Engine RT Engine DF Engine DG 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
11. Fill the fuel tank after operating the engine in order to drive out moist air This will help prevent condensation Do not fill the tank to the top The fuel expands as the fuel gets warm The tank may overflow Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pipe Some fuel tanks use supply lines that take fuel directly from the bottom of the tank If the engine is equipped with this system regular maintenance of the fuel system filter is important Fuel Storage Tanks Drain the water and the sediment from the fuel storage tank at the following intervals e Weekly e Service intervals e Refill of the tank This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank If a bulk storage tank has been refilled or moved recently allow adequate time for the sediment to settle 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 74 Maintenance Section Hoses and Clamps Inspect Replace SEBU7833 03 i02813964 Hoses and Clamps Inspect Replace Inspect all hoses for leaks that are caused by the following conditions e Cracking e Softness e Loose clamps Replace hoses that are cracked or soft Tighten any loose clamps
12. 106 C 223 F 60 Percent 51 C 60 F 111 C 232 F NOTICE Do not use propylene glycol in concentrations that ex ceed 50 percent glycol because of propylene glycol s reduced heat transfer capability Use ethylene glycol in conditions that require additional protection against boiling or freezing Table 18 Propylene Glycol Freeze Anti Boil Protection Protection 29 C 20 F 106 C 223 F Concentration 50 Percent To check the concentration of glycol in the coolant measure the specific gravity of the coolant Coolant Recommendations The following two coolants are used in Perkins diesel engines Preferred Perkins Extended Life Coolant ELC Acceptable A commercial heavy duty coolant antifreeze that meets ASTM D4985 specifications NOTICE Do not use a commercial coolant antifreeze that on ly meets the ASTM D3306 specification This type of coolant antifreeze is made for light automotive appli cations Perkins recommends a 1 1 mixture of water and glycol This mixture of water and glycol will provide optimum heavy duty performance as a coolant antifreeze This ratio may be increased to 1 2 water to glycol if extra freezing protection is required Note A commercial heavy duty coolant antifreeze that meets ASTM D4985 specifications MAY require a treatment with an SCA at the initial fill Read the label or the instructions
13. 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 Fan Drive Belt Alternator Belt 102758852 Emissions Certification Film Label for compliant engines Typical examples of emissions labels SEBU7833 03 21 Product Information Section Product Identification Information IMPORTANT ENGINE INFORMATION Engine Family 5PKXL04 4RH2 List Displacement 4 4 2 Refer to List RH37881 Manufacturer EPA Advertised kw 86 Ps g 2372 2500 3 O Family Max Fuel Rate 0 mm3 stk e11 97 68FA Engine Type Factory Reset if setting Applicable Values Init Timing DEG ATDC idle RPM 2001 63 0247 00 BI 2372 2500 DL Settings are to be made with engine at normal operating temperature with transmission in neutral This engine conforms to 2004 U S EPA non road and California off road Regulations for large C I engines and is certified to operate on commercially available diesel fuel Emission Control System Valve Lash Cold inch Engine Label Use Service Tool ECM Exhaust 0 0 Inlet 0 00 to verify current Hanger No position Label No 3181A081 Qe settings Illustration 17 g01173630 This typical example of a label i
14. Lubricants for Cold Weather When an engine is started and an engine is operated in ambient temperatures below 20 C 4 F use multigrade oils that are capable of flowing in low temperatures These oils have lubricant viscosity grades of SAE OW or SAE 5W When an engine is started and operated in ambient temperatures below 30 C 22 F use a synthetic base stock multigrade oil with an OW viscosity grade or with a 5W viscosity grade Use an oil with a pour point that is lower than 50 C 58 F The number of acceptable lubricants is limited in cold weather conditions Perkins recommends the following lubricants for use in cold weather conditions First Choice Use oil with an EMA DHD 1 Recommended Guideline Use a CH 4 oil that has an API license The oil should be either SAE 0W20 SAE 0W30 SAE OW40 SAE 5W30 or SAE 5W40 lubricant viscosity grade Second Choice Use an oil that has a CH 4 additive package Although the oil has not been tested for the requirements of the API license the oil must be either SAE OW20 SAE 0W30 SAE 0W40 SAE 5W30 or SAE 5W40 NOTICE Shortened engine service life could result if second choice oils are used Aftermarket Oil Additives Perkins does not recommend the use of aftermarket additives in oil 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
15. Obey all local regulations for the disposal of liquids Use all cleaning solutions with care SEBU7833 03 7 Safety Section Burn Prevention 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 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 o
16. 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 Ensure that the drive belts are correctly adjusted The drive belts should be in good condition Ensure that all of the connections of the hoses are tight The connections should not leak Ensure that the driven equipment is in good working order Cold 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 32 Operation Section Engine Stopping SEBU7833 03 Engine Stopping i01929389 Stopping the Engine NOTICE Stopping the engine immediately after it has been working under load can result in overheating and ac celerated wear of the engine components If the engine has been operating at high rpm and or high loads run at low idle for at least three minutes to reduce and stabilize internal engine temperature before stopping the engine Avoiding hot engine shutdowns will maximize tur bocharger shaft and bearing life Prior to stopping an engine that is being operated at low loads operate the engine at low idle for
17. g01012280 Illustration 11 7 Water pump 8 Fan pulley 9 Water temperature regulator housing 4 Fuel injection pump 5 Engine oil filter 6 Crankshaft pulley 1 Valve mechanism cover 2 Crankcase breather 3 Fuel filter SEBU7833 03 14 Product Information Section Model Views g01012281 Illustration 12 7 Flywheel 8 Air intake 4 Turbocharger 5 Starter motor 2 Exhaust manifold 1 Oil filler cap 3 Alternator 6 Flywheel housing SEBU7833 03 15 Product Information Section Model Views 1103 Engine Model Views Illustration 13 g01011348 1 Alternator 3 Turbocharger oil supply 5 Turbocharger 2 Fan pulley 4 Turbocharger oil drain 6 exhaust manifold 16 Product Information Section Model Views SEBU7833 03 Illustration 14 1 Fuel transfer pump 5 Dipstick 2 Oil filler cap 6 Oil filter 3 Fuel filter 7 Oil pan 4 Starter motor 8 Crankshaft pulley 102196981 Engine Description Perkins Engines are designed for the following applications machine genset and industrial mobile equipment The engines are available in the following types of aspiration e Turbocharged aftercooled e Turbocharged g01011349 9 Water pump 10 Water temperature regulator housing e Naturally aspirated Engine Specifications Note The front end of the engine is opposite the flywhe
18. 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 wires or cables that are smaller than the recommended gauge Do not bypass any fuses and or circuit breakers SEBU7833 03 9 Safety Section Fire Prevention and Explosion Prevention Arcing or sparking could cause a fire Secure connections recommended wiring and correctly maintained battery cables will help to prevent arcing or sparking Inspect all lines and hoses for wear or for deterioration The hoses must be correctly routed The lines and hoses must have adequate support and secure clamps Tighten all connections to the recommended torque Leaks can cause fires Oil filters and fuel filters must be correctly installed The filter housings must be tightened to the correct torque Illustration 9 g00704059 Use caution when you are refueling an engine Do not smok
19. reduced service life of the fuel system de posits in the combustion chamber and reduced ser vice life of the engine NOTICE Heavy Fuel Oil HFO Residual fuel or Blended fuel must NOT be used in Perkins diesel engines Severe component wear and component failures will result if HFO type fuels are used in engines that are configured to use distillate fuel In extreme cold ambient conditions you may use the distillate fuels that are specified in Table 15 However the fuel that is selected must meet the requirements that are specified in Table 14 These fuels are intended to be used in operating temperatures that are down to 54 C 65 F Table 15 Distillate Fuels Specification Grade MIL T 5624R JP 5 ASTM D1655 Jet A 1 MIL T 83133D JP 8 1 The fuels that are listed in this Table may not meet the requirements that are specified in the Perkins Specifications for Distillate Diesel Fuel Table Consult the supplier for the recommended additives in order to maintain the correct fuel lubricity These fuels are lighter than the No 2 grades of fuel The cetane number of the fuels in Table 15 must be at least 40 If the viscosity is below 1 4 cSt at 38 C 100 F use the fuel only in temperatures below 0 C 32 F Do not use any fuels with a viscosity of less than 1 2 cSt at 38 C 100 F Fuel cooling may be required in order to maintain the minimum visco
20. 30 seconds before stopping If the engine has been operating at highway speeds and or at high loads operate the engine at low idle for at least three minutes This procedure will cause the internal engine temperature to be reduced and stabilized Ensure that the engine stopping procedure is understood Stop the engine according to the shutoff system on the engine or refer to the instructions that are provided by the OEM To stop the engine turn the ignition key switch to the OFF position i01903586 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 i01903608 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 e Check the crankcase oil level Maintain the oil level between the ADD mark and the FULL mark on the oil level dipstick If necessary perform minor adjustments Repair any leaks and tighten any loose bolts e Note the required service interval Perform the maintenance that is in the
21. Adding The SCA To The Heavy Duty Coolant For Maintenance Total Volume Multiplication Amount of SCA of the Cooling Factor that is Required System V X 15 L 4 US gal x 0 014 0 2 L 7 oz 50 Maintenance Section Refill Capacities SEBU7833 03 Cleaning the System of Heavy Duty Coolant Antifreeze Perkins cooling system cleaners are designed to clean the cooling system of harmful scale and corrosion Perkins cooling system cleaners dissolve mineral scale corrosion products light oil contamination and sludge e Clean the cooling system after used coolant is drained or before the cooling system is filled with new coolant e Clean the cooling system whenever the coolant is contaminated or whenever the coolant is foaming SEBU7833 03 51 Maintenance Section Maintenance Interval Schedule i03302982 Maintenance Interval Schedule When Required Battery Replace uu u nasaq 54 Battery or Battery Cable Disconnect 55 Engi CEAI ull l l usss 60 Engine Air Cleaner Element Dual Element Clean Replace 61 Engine Air Cleaner Element Single Element Inspect Replace 63 Engine Oil Sample Obtain 64 Fuel Injector Test Change 68 Fuel System Prime ccceeececeeeeeeeeeeeeeeseneeeees 69
22. Filter 66 Viscosity of the Engine Lubrication Oil 33 Replace the Spin on Oil Filter 66 Cold Weather Starting 29 Engine Oil Level Check 64 Cooling System Coolant Change 58 Engine Oil Sample Obtain 64 Cooling System Coolant Commercial Heavy Duty Obtain the Sample and the Analysis 65 Change serioso eai aaa eaaa sehenuandineeen Engine Operation 31 Ear u uu L uD uu ss 55 Engine SlarftIng u u nna 11 28 E aa E kaqqa qana da maakanawnapakasa 56 Engine Stopping 11 32 FlUS R1Lu a E E EE 56 Engine Storage eos A 24 Cooling System Coolant ELC Change 57 COOLING Systane usu u sas 25 DRAMA eona 57 Exhaust SYSlOM ces A 25 Fila u uu ua E u retraces tree 58 General tems Uu uu u u ans asss 26 US iia aulia E ta stant dddheatedageets 57 Induction Systerm LLL a 25 Cooling System Coolant Extender ELC Add 59 Lubrication System occi 24 Cooling System Coolant Level Check 59 Engine Valve Lash Inspect Adjust 67 Engines With a Coolant Recovery Tank 59 Engine Warm UDcesccesiseccirnii 31 Engines Without a Coolant Recovery Tank 59 Crushing Prevention and Cutting Prev
23. Injectors The fuel injector 1 will need to be removed and the injector will need to be checked for performance The fuel injectors should not be cleaned as cleaning with incorrect tools can damage the nozzle The fuel injectors should be renewed only if a fault with the fuel injectors occurs Some of the problems that may indicate that new fuel injectors are needed are listed below e The engine will not start or the engine is difficult to start Not enough power e The engine misfires or the engine runs erratically e High fuel consumption e Black exhaust smoke e The engine knocks or there is vibration in the engine e Excessive engine temperature SEBU7833 03 69 Maintenance Section Fuel System Prime Removal and Installation of the Fuel Injectors Work carefully around an engine that is running Engine parts that are hot or parts that are moving can cause personal injury Make sure that you wear eye protection at all times during testing When fuel injection nozzles are tested test fluids travel through the orifices of the nozzle tip with high pressure Under this amount of pressure the test fluid can pierce the skin and cause serious injury to the operator Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension NOTICE Ifyour skin comes into contact with high pressure fuel obtain medical assistence immediately Operate t
24. No 1509 Engine oils that bear the API symbol are authorized by API Illustration 24 g00546535 Typical API symbol Diesel engine oils CC CD CD 2 and CE have not been API authorized classifications since 1 January 1996 Table 11 summarizes the status of the classifications Table 11 API Classifications Current Obsolete CF 4 CG 4 CH 4 CE CF CC CD CF 2 1 CD 20 1 The classifications CD 2 and American Petroleum Institute CF 2 are for two cycle diesel engines Perkins does not sell engines that utilize CD 2 and API CF 2 oils Terminology Certain abbreviations follow the nomenclature of SAE J754 Some classifications follow SAE J183 abbreviations and some classifications follow the EMA Recommended Guideline on Diesel Engine Oil In addition to Perkins definitions there are other definitions that will be of assistance in purchasing lubricants Recommended oil viscosities can be found in this publication Fluid Recommendations Engine Oil topic Maintenance Section SEBU7833 03 39 Maintenance Section Refill Capacities Engine Oil Commercial Oils The performance of commercial diesel engine oils is based on American Petroleum Institute API classifications These API classifications are developed in order to provide commercial lubricants for a broad range of diesel engines that operate at various conditions Only use commercial oils that meet th
25. This is important if the sys tem is drained after it has been flushed with water or if an antifreeze solution too weak to protect the system from frost has been used Illustration 23 g01003928 1 Ensure that the vehicle is on level ground 2 Remove the filler cap of the cooling system 3 Remove the drain plug 1 from the side of the cylinder block in order to drain the engine Ensure that the drain hole is not restricted 4 Open the tap or remove the drain plug at the bottom of the radiator in order to drain the radiator If the radiator does not have a tap or a drain plug disconnect the hose at the bottom of the radiator 5 Flush the cooling system with clean water 6 Fit the drain plugs and the filler cap Close the tap or connect the radiator hose 7 Fill the cooling system with an approved antifreeze mixture because this gives protection against corrosion The maximum flow rate is 1 L 0 2200 Imp gal per minute in order to fill the system Note Certain corrosion inhibitors could cause damage to some engine components Contact the Service Department of Perkins for advice 8 Operate the engine for a short period in order to circulate the lubricating oil and the coolant in the engine 9 Disconnect the battery Put the battery into safe storage in a fully charged condition Before the battery is put into storage protect the terminals against corrosion 1734115 POWERPART Lay U
26. This non road engine does not comply with either federal non road or California off road engine emission regulation requirement Sale or installation of this engine can only be for STATIONARY ENGINE Use only as defined by CFR 40 PART 89 2 Hanger No Position 81 Label 318A081 Illustration 21 g01157127 This typical example of a label is installed on engines that are stationary engines 24 Operation Section Lifting and Storage SEBU7833 03 Operation Section Lifting and Storage i02164186 Engine Lifting SSS iss e b sss Illustration 22 g01097527 NOTICE Never bend the eyebolts and the brackets Only load the eyebolts and the brackets under tension Remem ber that the capacity of an eyebolt is less as the angle between the supporting members and the object be comes less than 90 degrees When it is necessary to 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 desig
27. Your Safety is Involved The message that appears under the warning explains the hazard and can be either written or pictorially presented Operations that may cause product damage are identified by NOTICE labels on the product and in this publication Perkins cannot anticipate every possible circumstance that might involve a potential hazard The warnings in this publication and on the product are therefore not all inclusive If a tool procedure work method or operating technique that is not specifically recommended by Perkins is used you must satisfy yourself that it is safe for you and for others You should also ensure that the product will not be damaged or be made unsafe by the operation lubrication maintenance or repair procedures that you choose The information specifications and illustrations 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 prod
28. 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 disconnect an electric type of fuel heater in warm weather in order to prevent overheating of the fuel If the type of fuel heater is a heat exchanger the OEM should have included a bypass for warm weather Ensure that the bypass is operational during warm weather in order to prevent overheating of the fuel For more information about fuel heaters if equipped refer to the OEM information SEBU7833 03 37 Maintenance Section Refill Capacities Maintenance Section Refill Capacities i02198350 Refill Capacities Lubrication System The refill capacities for the engine crankcase reflect the approximate capacity of the crankcase or sump plus standard oil filters Auxiliary oil filter systems will require additional oil Refer to the OEM specifications for the capacity of the auxiliary oil filter Refer to the Operation and Maintenance Manual Maintenance Section for more information on Lubricant Specifications 1104 Engine Table 5 1104 Engine Compartment or System Liters Quarts Standard Oil Sump for the Engine 6 5 7 Crankcase 0 1 These values are the approximate capacities for the crankcase oil sump which include th
29. applications that require multiple drive belts replace the belts in matched sets Replacing only one belt of a matched set will cause the new belt to carry more load because the older belt is stretched The additional load on the new belt could cause the new belt to break If the belts are too loose vibration causes unnecessary wear on the belts and pulleys Loose belts may slip enough to cause overheating To accurately check the belt tension a suitable gauge should be used Illustration 26 g01003936 Typical example 1 Burroughs Gauge Fit the gauge 1 at the center of the longest free length and check the tension The correct tension is 535 N 120 Ib If the tension of the belt is below 250 N 56 Ib adjust the belt to 535 N 120 Ib If twin belts are installed check and adjust the tension on both belts k 2 g01003939 Adjustment Illustration 27 1 Loosen The alternator pivot bolt 2 and the bolt 3 54 Maintenance Section Battery Replace SEBU7833 03 2 Move the alternator in order to increase or decrease the belt tension Tighten the alternator pivot bolt and the link bolt to 22 N m 16 lb ft 1 Replacement Refer to the Disassembly and Assembly Manual for the installation procedure and the removal procedure for the belt 102322315 Battery Replace Batteries give off combustible gases which can explode A spark can cause the combustible gas es to ignite Th
30. 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 02322311 Alternator Inspect Perkins recommends a scheduled inspection of the alternator Inspect the alternator for loose connections and correct battery charging Check the ammeter if equipped during engine operation in order to ensure correct battery performance and or correct performance of the electrical system Make repairs as required Check the alternator and the battery charger for correct operation If the batteries are correctly charged the ammeter reading should be very near zero All batteries should be kept charged The batteries should be kept warm because temperature affects the cranking power If the battery is too cold the battery will not crank the engine When the engine is not run for long periods of time or if the engine is run for short periods the batteries may not fully charge A battery with a low charge will freeze more easily than a battery with a full charge 101929797 Alternator and Fan Belts Inspect Adjust Replace Inspection To maximize the engine performance inspect the belts for wear and for cracking Replace belts that are worn or damaged For
31. electrolyte level of the batteries unless the engine is equipped with a maintenance free battery e Check the condition of the gauges Replace any gauges that are cracked Replace any gauge that can not be calibrated 101907756 Water Pump Inspect A failed water pump may cause severe engine overheating problems that could result in the following conditions e Cracks in the cylinder head e A piston seizure e Other potential damage to the engine Note The water pump seal is lubricated by the coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and parts contract Visually inspect the water pump for leaks Renew the water pump seal or the water pump if there is an excessive leakage of coolant Refer to the Disassembly and Assembly Manual Water Pump Remove and Install for the disassembly and assembly procedure SEBU7833 03 79 Warranty Section Warranty Information Warranty Section Warranty Information i01903596 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
32. engine Inspect the cooling system for leaks SEBU7833 03 75 Maintenance Section Radiator Clean i02335774 Radiator Clean The radiator is not usually supplied by Perkins The following text describes a typical cleaning procedure for the radiator Refer to the OEM information for further information on cleaning the radiator Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the radiator for these items Damaged fins corrosion dirt grease insects leaves oil and other debris Clean the radiator if necessary 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 degr
33. filled with normal fuel This fuel must be discarded at the end of the storage period together with the fuel filter elements Operate the engine until the engine reaches normal operating temperature Stop any leaks from fuel lubricating oil or air systems Stop the engine and drain the lubricating oil from the oil pan SEBU7833 03 25 Operation Section Lifting and Storage e Renew the canister s of the lubricating oil filter e Fill the oil pan to the Full Mark on the dipstick with new clean lubricating oil Add 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 Cooling System To help prevent excessive engine wear use the following guidelines NOTICE Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged If freezing temperatures are expected check the cooling system for adequate protection against freezing See this Operation and Maintenance Manual General Coolant Information Maintenance Section NOTICE To prevent frost damage ensure that all the coolant is removed from the engine
34. 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 101929323 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 Do not drain the oil when the engine is cold As the oil cools suspended waste particles settle on the bottom of the oil pan The waste particles are not removed with the draining cold oil Drain the crankcase with the engine stopped Drain the crankcase with the oil warm This draining method allows the waste particles that are suspended in the oil to be drained properly Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil Drain the Engine Oil andr Illustration 38 g01003623 Oil drain plug After the engine has been run at the normal operating temperature stop the engine
35. illustration 2 Note The location of this label will depend on the application of the engine gt AN 7 lt Q al Cc ox lt J Illustration 2 g01682734 Typical example 2 Ether Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury 6 Safety Section General Hazard Information SEBU7833 03 A WARNING A Illustration 3 g01682820 The ether warning label 2 is located on the cover of the inlet manifold Refer to illustration 4 Illustration 4 g01682833 Typical example 102328435 General Hazard Information Illustration 5 g00104545 Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment al 4 98 3 BESSA Illustration 6 g00702020 Wear a hard hat protective glasses and other protective equipment as required Do not wear loose clothing or jewelry that can snag on controls or on other parts of the engine Make sure that all protective guards and all covers are secured in place on the engine Keep the engine free from foreign material Remove debris oil tools and other items from the deck from walkways and from steps Never put maintenance fluids into glass containers Drain all liquids into a suitable container
36. position Turn off all the engine s accessories 2 Connect one positive end of the jump start cable to the positive cable terminal of the discharged battery Connect the other positive end of the jump start cable to the positive cable terminal of the electrical source 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 stalled engine is started disconnect the jump start cables in reverse order After jump starting the alternator may not be able to fully recharge batteries that are severely discharged The batteries must be replaced or charged to the correct voltage with a battery charger after the engine is stopped Many batteries which are considered unusable are still rechargeable Refer to Operation and Maintenance Manual Battery Replace and Testing and Adjusting Manual Battery Test i01903609 After Starting Engine Note In temperatures from 0 to 60 C 32 to 140 F the warm up time is approximately three minutes In temperatures below 0 C 32 F additional warm up time may be required When the engine idles during warm up observe the following conditions e Check for an
37. possible injury turn the start switch off when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE The water separator is not a filter The water separa tor separates water from the fuel The engine should never be allowed to run with the water separator more than half full Engine damage may result NOTICE The water separator is under suction during normal engine operation Ensure that the drain valve is tight ened securely to help prevent air from entering the fuel system SEBU7833 03 71 Maintenance Section Fuel System Secondary Filter Replace Illustration 46 g01118416 1 Screw 2 Element 3 Glass bowl Sensor connection 5 Drain 6 Bottom cover 1 Place a suitable container below the water separator 2 Open the drain 5 Allow the fluid to drain into the container 3 When clean fuel drains from the water separator close the drain 5 Tighten the drain by hand pressure only Dispose of the drained fluid correctly 102469473 Fuel System Secondary Filter Replace 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 Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disc
38. 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 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
39. system plus the capacity for the external cooling system Enter the total in this row Table 10 1103 Naturally Aspirated Engines and Turbocharged Engines with an oil cooler Compartment or System Liters Quarts Engine Only 4 43 4 02 External cooling system capacity OEM recommendation Total Cooling System 1 The external cooling system includes a radiator or an expansion tank with the following components heat exchanger aftercooler and piping Refer to the OEM specifications Enter the value for the external system capacity in this row 2 The Total Cooling System includes the capacity for the engine cooling system plus the capacity for the external cooling system Enter the total in this row 102280119 Fluid Recommendations General Lubricant Information Because of government regulations regarding the certification of exhaust emissions from the engine the lubricant recommendations must be followed Engine Manufacturers Association EMA Oils The Engine Manufacturers Association Recommended Guideline on Diesel Engine Oil is recognized by Perkins For detailed information about this guideline see the latest edition of EMA publication EMA DHD 1 API Oils The Engine Oil Licensing and Certification System by the American Petroleum Institute API is recognized by Perkins For detailed information about this system see the latest edition of the API publication
40. that are provided by the OEM of the product In stationary engine applications and marine engine applications that do not require anti boil protection or freeze protection a mixture of SCA and water is acceptable Perkins recommends a six percent to eight percent concentration of SCA in those cooling systems Distilled water or deionized water is preferred Water which has the recommended properties may be used Engines that are operating in an ambient temperature above 43 C 109 4 F must use SCA and water Engines that operate in an ambient temperature above 43 C 109 4 F and below 0 C 32 F due to seasonal variations consult your Perkins dealer or your Perkins distributor for the correct level of protection Table 19 Coolant Service Life Service Life 12 000 Service Hours or Six Years Coolant Type Perkins ELC Commercial Heavy Duty Coolant Antifreeze that meets ASTM D4985 Perkins POWERPART SCA 3000 Service Hours or Two Years 3000 Service Hours or Two Years Commercial SCA and 3000 Service Hours or Water Two Years Extended Life Coolant ELC Perkins provides Extended Life Coolant ELC for use in the following applications e Heavy duty spark ignited gas engines SEBU7833 03 47 Maintenance Section Refill Capacities e Heavy duty diesel engines e Automotive applications The anti corrosion package for ELC is different from the anti corrosio
41. the lubrication system in the fuel system or in the cooling system before any lines fittings or related items are disconnected 8 Safety Section Fire Prevention and Explosion Prevention SEBU7833 03 Coolant When the engine is at operating temperature the engine coolant is hot The coolant is also under pressure The radiator and all lines to the heaters or to the engine contain hot coolant Any contact with hot coolant or with steam can cause severe burns Allow cooling system components to cool before the cooling system is drained Check the coolant level after the engine has stopped and the engine has been allowed to cool Ensure that the filler cap is cool before removing the filler cap The filler cap must be cool enough to touch with a bare hand Remove the filler cap slowly in order to relieve pressure Cooling system conditioner contains alkali Alkali can cause personal injury Do not allow alkali to contact the skin the eyes or the mouth Oils Hot oil and hot lubricating components can cause personal injury Do not allow hot oil to contact the skin Also do not allow hot components to contact the skin Batteries Electrolyte is an acid Electrolyte can cause personal injury Do not allow electrolyte to contact the skin or the eyes Always wear protective glasses for servicing batteries Wash hands after touching the batteries and connectors Use of gloves is recommended 102813488 Fire Preventi
42. 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 chance of system contamination NOTICE For any type of leak coolant lube or fuel clean up the fluid If leaking is observed find the source and correct the leak If leaking is suspected check the fluid levels more often than recommended until the leak is found or fixed or until the suspicion of a leak is 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 Ensure that the cooling system hoses are correctly clamped and that the cooling system hoses are tight Check for leaks Check the condition of all pipes Inspect the water pump for coolant leaks Note The water pump seal is lubricated by the coolant in the cooling system It is normal for a small amount of leakage to occur as the engine cools down and the parts contract Excessive coolant leakage may indicate the need to replace the water pump seal For the removal of the water pump and the installation of water pump and or se
43. 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 prevent major damage to the engine components Knowing the procedure will also help to prevent personal injury To ensure that the jacket water heater if equipped and or the lube oil heater if equipped is working correctly check the water temperature gauge and the oil temperature gauge during the heater operation Engine exhaust contains products of combustion which can be harmful to your health Always start the engine and operate the engine in a well ventilated area If the engine is started in an enclosed area vent the engine exhaust to the outside Note The engine is equipped with an automatic device for cold starting for normal conditions of operation If the engine will be operated in very cold conditions then an extra cold starting aid may be required Normally the engine will be equipped with the correct type of starting aid for your region of operation The engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting i01928905 Engine Stopping Stop the engine according to the procedure in the Operation and Maintenance Manual Engine Stopping Operation Sect
44. the following steps NOTICE Care must be taken to ensure that all fluids are contained during performance of inspection main tenance testing adjusting and the repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or dis assembling any component containing fluids Dispose of all fluids according to local regulations and mandates 1 Drain the coolant into a suitable container 2 Dispose of the coolant according to local regulations 3 Flush the system with clean water in order to remove any debris 4 Use Perkins cleaner to clean the system Follow the instruction on the label 5 Drain the cleaner into a suitable container Flush the cooling system with clean water 6 Fill the cooling system with clean water and operate the engine until the engine is warmed to 49 to 66 C 120 to 150 F NOTICE Incorrect or incomplete flushing of the cooling system can result in damage to copper and other metal com ponents To avoid damage to the cooling system make sure to completely flush the cooling system with clear water Continue to flush the system until all the signs of the cleaning agent are gone 7 Drain the cooling system into a suitable container and flush the cooling system with clean water Note The cooling system cleaner must be thoroughly flushed from the cooling system Cooling system cleaner that is left in the system will contamin
45. warning signs are legible Clean the warning signs or replace the warning signs if the words cannot be read or if the pictures are not visible When the warning signs are cleaned use a cloth water and soap Do not use solvent gasoline or other harsh chemicals to clean the warning signs Solvents gasoline or harsh chemicals could loosen the adhesive that secures the warning signs The warning signs that are loosened could drop off of the engine Replace any damaged warning signs or missing warning signs If a warning sign is attached to a part of the engine that is replaced install a new warning sign on the replacement part Perkins dealers or Perkins distributors can provide new warning signs Do not work on the engine and do not operate the engine unless the instructions and warnings in the Operation and Maintenance Manual are understood Correct care is your responsibility Failure to follow the instructions or failure to heed the warnings could result in injury or in death 1 Universal Warning 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 aS A WARNING L Illustration 1 g01154807 Typical example The Universal Warning label 1 may be located on the valve mechanism cover or the inlet manifold Refer to
46. your Perkins dealer or your Perkins distributor in order to determine if the engine is operating within the defined parameters Severe service operation can accelerate component wear Engines that operate under severe conditions may need more frequent maintenance intervals in order to ensure maximum reliability and retention of full service life Due to individual applications it is not possible to identify all of the factors which can contribute to severe service operation Consult your Perkins dealer or your Perkins distributor for the unique maintenance that is necessary for the engine The operating environment incorrect operating procedures and incorrect maintenance procedures can be factors which contribute to a severe service application 76 Maintenance Section Starting Motor Inspect SEBU7833 03 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 Compoun
47. 0 C 104 F e Density 0 835 to 0 855 Kg liter e Sulfur 0 2 of mass maximum e Distillation 85 at 350 C 662 F e Lubricity 460 micrometers maximum wear scar on ISO 12156 1 Cetane number This indicates the properties of ignition of the fuel Fuel with a low cetane number can be the root cause of problems during cold start This will affect combustion Viscosity This is the resistance to flow of a fluid If this resistance is outside the limits the engine and the engine starting performance in particular can be affected Sulfur High sulfur content of the fuel is not normally found in Europe North America or Australasia This can cause engine wear When only high sulfur fuels are available it will be necessary that high alkaline lubricating oil is used in the engine or that the lubricating oil change interval is reduced Distillation This is an indication of the mixture of different hydrocarbons in the fuel A high ratio of light weight hydrocarbons can affect the characteristics of combustion Lubricity This is the capability of the fuel to prevent pump wear Diesel engines have the ability to burn a wide variety of fuels These fuels are divided into four general groups e Group 1 preferred fuels e Group 2 permissible fuels e Group 3 aviation kerosene fuels e Other fuels Group 1 preferred fuels Specification DERV to EN590 Note Only use Arctic fuels when the temperature is belo
48. 2 X V is the total capacity of the cooling system X is the amount of ELC Extender that is required Table 21 is an example for using the formula that is in Table 20 Table 21 Example Of The Equation For Adding ELC Extender To ELC Total Volume Multiplication Amount of ELC of the Cooling Factor Extender that is System V Required X 0 18 L 9 L 2 4 US gal x 0 02 0 05 US gal or 6 fl oz NOTICE When using Perkins ELC do not use standard SCA s or SCA filters 48 Maintenance Section Refill Capacities SEBU7833 03 ELC Cooling System Cleaning Note If the cooling system is already using ELC cleaning agents are not required to be used at the specified coolant change interval Cleaning agents are only required if the system has been contaminated by the addition of some other type of coolant or by cooling system damage Clean water is the only cleaning agent that is required when ELC is drained from the cooling system After the cooling system is drained and after the cooling system is refilled operate the engine while the cooling system filler cap is removed Operate the engine until the coolant level reaches the normal operating temperature and until the coolant level stabilizes As needed add the coolant mixture in order to fill the system to the specified level Changing to Perkins ELC To change from heavy duty coolant antifreeze to the Perkins ELC perform
49. 23 Equation For Adding The SCA To The Heavy Duty Coolant At The Initial Fill V x 0 045 X V is the total volume of the cooling system X is the amount of SCA that is required Table 24 is an example for using the equation that is in Table 23 Table 24 Example Of The Equation For Adding The SCA To The Heavy Duty Coolant At The Initial Fill Total Volume Multiplication Amount of SCA of the Cooling Factor that is Required System V X 15 L 4 US gal x 0 045 0 7 L 24 oz Adding The SCA to The Heavy Duty Coolant For Maintenance Heavy duty coolant antifreeze of all types REQUIRE periodic additions of an SCA Test the coolant antifreeze periodically for the concentration of SCA For the interval refer to the Operation and Maintenance Manual Maintenance Interval Schedule Maintenance Section Test the concentration of SCA Additions of SCA are based on the results of the test The size of the cooling system determines the amount of SCA that is needed Use the equation that is in Table 25 to determine the amount of Perkins SCA that is required if necessary Table 25 Equation For Adding The SCA To The Heavy Duty Coolant For Maintenance V x 0 014 X V is the total volume of the cooling system X is the amount of SCA that is required Table 26 is an example for using the equation that is in Table 25 Table 26 Example Of The Equation For
50. 6 Install the air cleaner cover 7 Reset the air cleaner service indicator 62 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace SEBU7833 03 Cleaning the Primary Air Cleaner Elements NOTICE Observe the following guidelines if you attempt to clean the filter element Do not tap or strike the filter element in order to re move dust Do not wash the filter element Use low pressure compressed air in order to remove the dust from the filter element Air pressure must not exceed 207 kPa 30 psi Direct the air flow up the pleats and down the pleats from the inside of the filter element Take extreme care in order to avoid damage to the pleats Do not use air filters with damaged pleats gaskets or seals Dirt entering the engine will cause damage to engine components Refer to the OEM information in order to determine the number of times that the primary filter element can be cleaned When the primary air cleaner element is cleaned check for rips or tears in the filter material The primary air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings NOTICE Do not clean the air cleaner elements by bumping or tapping This could damage the seals Do not use el ements with damaged pleats gaskets or seals Dam aged elements will allow dirt to pass through Engine damage could result Visually
51. Operation and Maintenance Manual Maintenance Interval Schedule Fill the fuel tank in order to help prevent accumulation of moisture in the fuel Do not overfill the fuel tank NOTICE Only use antifreeze coolant mixtures recommended in the Coolant Specifications that are in the Operation and Maintenance Manual Failure to do so can cause engine damage Allow the engine to cool Check the coolant level If freezing temperatures are expected check the coolant for the correct antifreeze protection The cooling system must be protected against freezing to the lowest expected outside temperature Add the correct coolant water mixture if necessary Perform all required periodic maintenance on all driven equipment This maintenance is outlined in the instructions from the OEM SEBU7833 03 33 Operation Section Cold Weather Operation Cold Weather Operation i02717265 Cold Weather Operation Perkins Diesel Engines can operate effectively in cold weather During cold weather the starting and the operation of the diesel engine is dependent on the following items e The type of fuel that is used e The viscosity of the engine oil e The operation of the glow plugs e Optional Cold starting aid e Battery condition This section will cover the following information e Potential problems that are caused by cold weather operation e Suggest steps which can be taken in order to minimize starting problems and o
52. S oil analysis will complement the preventive maintenance program The S O S oil analysis is a diagnostic tool that is used to determine oil performance and component wear rates Contamination can be identified and measured through the use of the S O S oil analysis The S O S oil analysis includes the following tests 42 Maintenance Section Refill Capacities SEBU7833 03 e The Wear Rate Analysis monitors the wear of the engine s metals The amount of wear metal and type of wear metal that is in the oil is analyzed The increase in the rate of engine wear metal in the oil is as important as the quantity of engine wear metal in the oil e Tests are conducted in order to detect contamination of the oil by water glycol or fuel e The Oil Condition Analysis determines the loss of the oil s lubricating properties An infrared analysis is used to compare the properties of new oil to the properties of the used oil sample This analysis allows technicians to determine the amount of deterioration of the oil during use This analysis also allows technicians to verify the performance of the oil according to the specification during the entire oil change interval Fuel Specifications Fuel Recommendations To get the correct power and performance from the engine use a fuel of the correct quality The recommended fuel specification for Perkins engines is shown below e Cetane number 45 minimum Viscosity 2 0 to 4 5 cSt at 4
53. Severe Service Application Check 75 Daily Alternator and Fan Belts Inspect Adjust Replace ansiar iernii aaea ana aaan aAa a 53 Cooling System Coolant Level Check 59 Driven Equipment Check 60 Engine Air Cleaner Service Indicator Inspect 63 Engine Oil Level Check 64 Fuel System Primary Filter Water Separator Dr8ifk2 ua rere retce peerer aA 70 Walk Around Inspection 77 Every 50 Service Hours or Weekly Fuel Tank Water and Sediment Drain 73 Every 500 Service Hours or 1 Year Battery Electrolyte Level Check 54 Engine Air Cleaner Element Dual Element Clean Replace 61 Engine Air Cleaner Element Single Element Inspect Replace isinin 63 Engine Ground Inspect Clean 64 Engine Oil and Filter Change 65 Fuel System Primary Filter Water Separator Element Replace 70 Fuel System Secondary Filter Replace 71 Hoses and Clamps Inspect Replace 74 Radiator Cleg UL U uu u u uu uses 75 Every 1000 Service Hours Engine Valve Lash Inspect Adjust 67 Every 2000 Service Hours Aftercooler Core Inspect
54. Turbocharger Install for further information Inspecting NOTICE The compressor housing for the turbocharger must not be removed from the turbocharger for cleaning The actuator linkage is connected to the compressor housing If the actuator linkage is moved or disturbed the engine may not comply with emmissions legisla tion 1 Remove the pipe from the turbocharger exhaust outlet and remove the air intake pipe to the turbocharger Visually inspect the piping for the presence of oil Clean the interior of the pipes in order to prevent dirt from entering during reassembly 2 Check for the presence of oil If oil is leaking from the back side of the compressor wheel there is a possibility of a failed turbocharger oil seal The presence of oil may be the result of extended engine operation at low idle The presence of oil may also be the result of a restriction of the line for the intake air clogged air filters which causes the turbocharger to slobber 3 Inspect the bore of the housing of the turbine outlet for corrosion 4 Fasten the air intake pipe and the exhaust outlet pipe to the turbocharger housing i02177973 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
55. Use one of the following methods to drain the engine crankcase oil 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 If the engine is not equipped with a drain valve remove the oil drain plug 1 in order to allow the oil to drain If the engine is equipped with a shallow sump remove the bottom oil drain plugs from both ends of the oil pan 66 Maintenance Section Engine Oil and Filter Change SEBU7833 03 After the oil has drained the oil drain plugs should be cleaned and installed If necessary renew the O ring seal on the drain plug Some types of oil pans have oil drain plugs that are on both sides of the oil pan because of the shape of the pan This type of oil pan requires the engine oil to be drained from both plugs Replace the Spin on Oil Filter NOTICE Perkins oil filters are manufactured to Perkins speci fications Use of an oil filter that is not recommended by Perkins could result in severe damage to the en gine bearings crankshaft etc as a result of the larger waste particles from unfiltered oil entering the engine lubricating system Only use oil filters recommended by Perkins 1 Remove the oil filter with a suitable tool Note The following actions can be carried out as part of the preventive maintenance program 2 Cut th
56. al refer to the Disassembly and Assembly Manual Water Pump Remove and Install for more information or consult your Perkins dealer or your Perkins distributor Inspect the lubrication system for leaks at the front crankshaft seal the rear crankshaft seal the oil pan the oil filters and the rocker cover Inspect the fuel system for leaks Look for loose fuel line clamps and or tie wraps Inspect the piping for the air intake system and the elbows for cracks and for loose clamps Ensure that hoses and tubes are not contacting other hoses tubes wiring harnesses etc Inspect the alternator belts and any accessory drive belts for cracks breaks or other damage 78 Maintenance Section Water Pump Inspect SEBU7833 03 Belts for multiple groove pulleys must be replaced as matched sets If only one belt is replaced the belt will carry more load than the belts that are not replaced The older belts are stretched The additional load on the new belt could cause the belt to break e Drain the water and the sediment from the fuel tank on a daily basis in order to ensure that only clean fuel enters the fuel system Inspect the wiring and the wiring harnesses for loose connections and for worn wires or frayed wires Inspect the ground strap for a good connection and for good condition Disconnect any battery chargers that are not protected against the current drain of the starting motor Check the condition and the
57. ank Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 2 Loosen filler cap slowly in order to relieve any pressure Remove the 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 31 g00103639 4 Clean filler cap and the receptacle Reinstall the filler cap and inspect the cooling system for leaks Note The coolant will expand as the coolant heats up during normal engine operation The additional volume will be forced into the coolant recovery tank during engine operation When the engine is stopped and cool the coolant will return to the engine Engines Without a Coolant Recovery Tank Check the coolant level when the engine is stopped and cool 60 Maintenance Section Driven Equipment Check SEBU7833 03 Illustration 32 g00285520 Cooling system filler cap Pressurized System Hot coolant can cause seri ous burn
58. ate the coolant The cleaner may also corrode the cooling system 8 Repeat Steps 6 and 7 until the system is completely clean 9 Fill the cooling system with the Perkins Premixed ELC ELC Cooling System Contamination NOTICE Mixing ELC with other products reduces the effective ness of the ELC and shortens the ELC service life Use only Perkins Products for premixed or concen trate coolants Use only Perkins ELC extender with Perkins ELC Failure to follow these recommenda tions can result in shortened cooling system compo nent life ELC cooling systems can withstand contamination to a maximum of ten percent of conventional heavy duty coolant antifreeze or SCA If the contamination exceeds ten percent of the total system capacity perform ONE of the following procedures Drain the cooling system into a suitable container Dispose of the coolant according to local regulations Flush the system with clean water Fill the system with the Perkins ELC Drain a portion of the cooling system into a suitable container according to local regulations Then fill the cooling system with premixed ELC This should lower the contamination to less than 10 percent Maintain the system as a conventional Heavy Duty Coolant Treat the system with an SCA Change the coolant at the interval that is recommended for the conventional Heavy Duty Coolant SEBU7833 03 49 Maintenance Section Refill Capacities Commercial Heavy Duty C
59. atteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury 1 Turn the start switch to the OFF position Turn the ignition switch if equipped to the OFF position and remove the key and all electrical loads 2 Disconnect the negative battery terminal Ensure that the cable cannot contact the terminal When four 12 volt batteries are involved two negative connection must be disconnected 3 Remove the positive connection 4 Clean all disconnected 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 102203590 Cooling System Coolant Commercial Heavy Duty Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing ad
60. base oils and of commercial additive packages These additive packages are blended into the base oils at precise percentages in order to help provide finished oils with performance characteristics that meet industry standards There are no industry standard tests that evaluate the performance or the compatibility of aftermarket additives in finished oil Aftermarket additives may not be compatible with the finished oil s additive package which could lower the performance of the finished oil The aftermarket additive could fail to mix with the finished oil This could produce sludge in the crankcase Perkins discourages the use of aftermarket additives in finished oils To achieve the best performance from a Perkins engine conform to the following guidelines Select the correct oil or a commercial oil that meets the EMA Recommended Guideline on Diesel Engine Oil or the recommended API classification See the appropriate Lubricant Viscosities table in order to find the correct oil viscosity grade for your engine At the specified interval service the engine Use new oil and install a new oil filter Perform maintenance at the intervals that are specified in the Operation and Maintenance Manual Maintenance Interval Schedule S O S Oil analysis Some engines may be equipped with an oil sampling valve If S O S oil analysis is required the oil sampling valve is used to obtain samples of the engine oil The S O
61. battery terminal 8 Connect the NEGATIVE cable to the NEGATIVE battery terminal 102747977 Battery Electrolyte Level Check When the engine is not run for long periods of time or when the engine is run for short periods the batteries may not fully recharge Ensure a full charge in order to help prevent the battery from freezing If batteries are correctly charged the ammeter reading should be very near zero when the engine is in operation All lead acid batteries contain sulfuric acid which can burn the skin and clothing Always wear a face shield and protective clothing when working on or near batteries 1 Remove the filler caps 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 SEBU7833 03 55 Maintenance Section Battery or Battery Cable Disconnect i02323088 Battery or Battery Cable Disconnect The battery cables or the b
62. ccur 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 7 g00687600 Always use a board or cardboard when you check for a leak Leaking fluid that is under pressure can penetrate body tissue Fluid penetration can cause serious injury and possible death A pin hole leak can cause severe injury If fluid is injected into your skin you must get treatment immediately Seek treatment from a doctor that is familiar with this type of injury Containing Fluid Spillage Care must be taken in order to ensure that fluids are contained during performance of inspection maintenance testing adjusting and repair of the engine Make provision to collect the fluid with a suitable container before any compartment is opened or before any component is disassembled e Only use the tools that are suitable for collecting fluids and equipment that is suitable for collecting fluids e Only use the tools that are suitable for containing fluids and equipment that is suitable for containing fluids Obey all local regulations for the disposal of liquids i02143195 Burn Prevention Do not touch any part of an operating engine Allow the engine to cool before any maintenance is performed on the engine Relieve all pressure in the air system in the hydraulic system in
63. dditives or insufficient amounts of additives enable the following conditions to occur e Corrosion e Formation of mineral deposits e Rust Scale e Foaming of the coolant Many additives are depleted during engine operation These additives must be replaced periodically Additives must be added at the correct concentration Overconcentration of additives can cause the inhibitors to drop out of solution The deposits can enable the following problems to occur e Formation of gel compounds e Reduction of heat transfer e Leakage of the water pump seal e Plugging of radiators coolers and small passages 46 Maintenance Section Refill Capacities SEBU7833 03 Glycol Glycol in the coolant helps to provide protection against the following conditions e Boiling e Freezing e Cavitation of the water pump For optimum performance Perkins recommends a 1 1 mixture of a water glycol solution Note Use a mixture that will provide protection against the lowest ambient temperature Note 100 percent pure glycol will freeze at a temperature of 23 C 9 F Most conventional coolant antifreezes use ethylene glycol Propylene glycol may also be used In a 1 1 mixture with water ethylene and propylene glycol provide similar protection against freezing and boiling See Tables 17 and 18 Table 17 Ethylene Glycol Concentration Freeze Boil Protection Protection 50 Percent 36 C 33 F
64. ds elements corrosive chemicals and salt can damage some components Altitude Problems can arise when the engine is operated at altitudes that are higher than the intended settings for that application Necessary adjustments should be made Incorrect Operating Procedures e Extended operation at low idle e Frequent hot shutdowns e Operating at excessive loads e Operating at excessive speeds e Operating outside the intended application Incorrect Maintenance Procedures e Extending the maintenance intervals e Failure to use recommended fuel lubricants and coolant antifreeze 102177969 Starting Motor Inspect Perkins recommends a scheduled inspection of the starting motor If the starting motor fails 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 102184788 Turbocharger Inspect If Equipped A regular visual inspection of the turbocharger is recommended Any fumes from the crankcase are filtered through the air inlet system Therefore by products from oil and from combustion can collect in the turbocharger compressor housing Over time this bui
65. e Bore 105 mm 4 134 inch Stroke 127 mm 5 0 inch Aspiration Turbocharged aftercooled Turbocharged Naturally aspirated Compression Ratios NA 19 25 1 T 17 25 1 T 18 23 1 TA 18 23 1 Displacement 4 4 L 268 in Firing Order 1342 Rotation flywheel end Counterclockwise Valve Lash Setting Inlet 0 20 mm 0 008 inch Valve Lash Setting Exhaust 0 45 mm 0 018 inch 18 Product Information Section Model Views SEBU7833 03 Table 4 1103 Genset Specifications Number of Cylinders 3 In Line Bore 105 mm 4 134 inch Stroke 127 mm 5 0 inch Aspiration Turbocharged Naturally aspirated Compression Ratio NA 19 25 1 T 17 25 1 Displacement 3 3 L 201 in Firing Order 123 Rotation flywheel end Counterclockwise Valve Lash Setting Inlet 0 20 mm 0 008 inch Valve Lash Setting Exhaust 0 45 mm 0 018 inch Engine Cooling and Lubrication The cooling system consists of the following components e Gear driven centrifugal water pump e Water temperature regulator which regulates the engine coolant temperature e Gear driven oil pump gear type e Oil cooler The engine lubricating oil is supplied by a gear type pump The engine lubricating oil is cooled and the engine lubricating oil is filtered Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity i
66. e 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 58 Maintenance Section Cooling System Coolant Change SEBU7833 03 5 Stop the engine and allow the engine to cool Loosen the cooling system filler cap slowly in order to relieve any pressure Remove the cooling system filler cap Open the drain cock or remove the drain plug on the engine Open the drain cock or remove the drain plug on the radiator Allow the water to drain Flush the cooling system with clean water Fill 1 Close the drain cock or install the drain plug on the engine Close the drain cock or install the drain plug on the radiator NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 2 Fill the cooling system with 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
67. e 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 i01929404 Engine Warm up 1 Run the engine at low idle for three to five minutes or run the engine at low idle until the jacket water temperature starts to rise More time may be necessary when the temperature is below 18 C 0 F 2 Check all of the gauges during the warm up period 3 Perform a walk around inspection Check the engine for fluid leaks and air leaks 4 Increase the rpm to the rated rpm Check for fluid leaks and air leaks The engine may be operated at full rated rpm and at full load when the temperature of the water jacket reaches 60 C 140 F i02330149 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
68. e drain plug on the engine Open the drain cock or remove the drain plug on the radiator Allow the water to drain Flush the cooling system with clean water Fill 1 Close the drain cock or install the drain plug on the engine Close the drain cock or install the drain plug on the radiator NOTICE Do not fill the cooling system faster than 5 L 1 3 US gal per minute to avoid air locks Cooling system air locks may result in engine damage 2 Fill the cooling system with Commercial Heavy Duty Coolant Add Supplemental Coolant 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 Stop the engine 4 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level in the expansion bottle if equipped at the correct level 5 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system fille
69. e engine is started See the Operation and Maintenance Manual for specific starting instructions Grounding Practices Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability Incorrect grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths Uncontrolled electrical circuit paths can result in damage to main bearings to crankshaft bearing journal surfaces and to aluminum components Engines that are installed without engine to frame ground straps can be damaged by electrical discharge To ensure that the engine and the engine electrical systems function correctly an engine to frame ground strap with a direct path to the battery must be used This path may be provided by way of a direct engine ground to the frame All grounds should be tight and free of corrosion The engine alternator must be grounded to the negative battery terminal with a wire that is adequate to handle the full charging current of the alternator SEBU7833 03 o z 2 gt O p O xe D N Cc Re x D O A N N NSS 7 We Ss yy N 5 6 lt oN 101928892 SE SS lt lt x 552 A PA a E 1104 Engine Model Views Product Information Model View Illustrations Section Model Views
70. e following classifications e EMA DHD 1 multigrade oil preferred oil e API CH 4 multigrade oil preferred oil e ACEAE3 In order to make the correct choice of a commercial oil refer to the following explanations EMA DHD 1 The Engine Manufacturers Association EMA has developed lubricant recommendations as an alternative to the API oil classification system DHD 1 is a Recommended Guideline that defines a level of oil performance for these types of diesel engines high speed four stroke cycle heavy duty and light duty DHD 1 oils may be used in Perkins engines when the following oils are recommended API CH 4 API CG 4 and API CF 4 DHD 1 oils are intended to provide superior performance in comparison to API CG 4 and API CF 4 DHD 1 oils will meet the needs of high performance Perkins diesel engines that are operating in many applications The tests and the test limits that are used to define DHD 1 are similar to the new API CH 4 classification Therefore these oils will also meet the requirements for diesel engines that require low emissions DHD 1 oils are designed to control the harmful effects of soot with improved wear resistance and improved resistance to plugging of the oil filter These oils will also provide superior piston deposit control for engines with either two piece steel pistons or aluminum pistons All DHD 1 oils must complete a full test program with the base stock and with the viscosity grade of the fi
71. e life due to deposits and or excessive wear Total Base Number TBN and Fuel Sulfur Levels for Direct Injection DI Diesel Engines The Total Base Number TBN for an oil depends on the fuel sulfur level For direct injection engines that use distillate fuel the minimum TBN of the new oil must be 10 times the fuel sulfur level The TBN is defined by ASTM D2896 The minimum TBN of the oil is 5 regardless of fuel sulfur level Illustration 25 demonstrates the TBN 7 Illustration 25 g00799818 Y TBN by ASTM D2896 X Percentage of fuel sulfur by weight 1 TBN of new oil 2 Change the oil when the TBN deteriorates to 50 percent of the original TBN Use the following guidelines for fuel sulfur levels that exceed 1 5 percent e Choose an oil with the highest TBN that meets one of these classifications EMA DHD 1 and API CH 4 e Reduce the oil change interval Base the oil change interval on the oil analysis Ensure that the oil analysis includes the condition of the oil and a wear metal analysis Excessive piston deposits can be produced by an oil with a high TBN These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore NOTICE Operating Direct Injection DI diesel engines with fuel sulphur levels over 0 5 percent will require shortened oil change interva
72. e 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 turbocharger bearings and cylinder heads Due to normal wear and friction it is not uncommon to find small amounts of debris in the oil filter Illustration 39 g01003628 2 Filter head 3 O ring seal 3 Clean the sealing surface of the oil filter head 2 Ensure that the union not shown in the oil filter head is secure 4 Apply clean engine oil to the O ring seal 3 on the oil filter NOTICE Do not fill the oil filters with oil before installing them This oil would not be filtered and could be contaminat ed Contaminated oil can cause accelerated wear to engine components 5 Install the oil filter Tighten the oil filter by hand according to the instructions that are shown on the oil filter Do not overtighten the oil filter Replace the Element for the Oil Filter Illustration 40
73. e standard factory installed oil filters Engines with auxiliary oil filters will require additional oil Refer to the OEM specifications for the capacity of the auxiliary oil filter 1103 Engine Table 6 1103 Engine Compartment or System Liters Quarts Standard Oil Sump for the Engine 6 5 7 Crankcase 0 1 These values are the approximate capacities for the crankcase oil sump which include the standard factory installed oil filters Engines with auxiliary oil filters will require additional oil Refer to the OEM specifications for the capacity of the auxiliary oil filter Cooling System To maintain the cooling system the Total Cooling System capacity must be known The approximate capacity for the engine cooling system is listed below External System capacities will vary among applications Refer to the OEM specifications for the External System capacity This capacity information will be needed in order to determine the amount of coolant antifreeze that is required for the Total Cooling System 1104 Engine Table 7 1104 Naturally Aspirated Engine Compartment or System Liters Quarts Engine Only 10 4 11 External cooling system capacity OEM recommendation 0 Total Cooling System 1 The external cooling system includes a radiator or an expansion tank with the following components heat exchanger aftercooler and piping Refer to the OEM specifications Enter the
74. e while you are refueling an engine Do not refuel an engine near open flames or sparks Always stop the engine before refueling OQO Illustration 10 g00704135 Gases from a battery can explode Keep any open flames or sparks away from the top of a battery Do not smoke in battery charging areas Never check the battery charge by placing a metal object across the terminal posts Use a voltmeter or a hydrometer Incorrect jumper cable connections can cause an explosion that can result in injury Refer to the Operation Section of this manual for specific instructions Do not charge a frozen battery This may cause an explosion The batteries must be kept clean The covers if equipped must be kept on the cells Use the recommended cables connections and battery box covers when the engine is operated Fire Extinguisher Make sure that a fire extinguisher is available Be familiar with the operation of the fire extinguisher Inspect the fire extinguisher and service the fire extinguisher regularly Obey the recommendations on the instruction plate Lines Tubes and Hoses Do not bend high pressure lines Do not strike high pressure lines Do not install any lines that are bent or damaged Do not clip any other items to the high pressure lines 10 Safety Section Crushing Prevention and Cutting Prevention SEBU7833 03 Repair any lines that are loose or damaged Leaks can cause fires Consult your Perkins d
75. ealer or your Perkins distributor for repair or for replacement parts Check lines tubes and hoses carefully Do not use your bare hand to check for leaks Use a board or cardboard to check for leaks Tighten all connections to the recommended torque Replace the parts if any of the following conditions are present e End fittings are damaged or leaking e Outer coverings are chafed or cut e Wires are exposed e Outer coverings are ballooning Flexible part of the hoses are kinked e Outer covers have embedded armoring e End fittings are displaced Make sure that all clamps guards and heat shields are installed correctly During engine operation this will help to prevent vibration rubbing against other parts and excessive heat 102143194 Crushing Prevention and Cutting Prevention Support the component correctly when work beneath the component is performed Unless other maintenance instructions are provided never attempt adjustments while the engine is running Stay clear of all rotating parts and of all moving parts Leave the guards in place until maintenance is performed After the maintenance is performed reinstall the guards Keep objects away from moving fan blades The fan blades will throw objects or cut objects When objects are struck wear protective glasses in order to avoid injury to the eyes Chips or other debris may fly off objects when objects are struck Before objects are struck ensure
76. easer and steam for removal of oil and grease Clean both sides of the core Wash the core with detergent and hot water Thoroughly rinse the core with clean water If the radiator is blocked internally refer to the OEM Manual for information regarding flushing the cooling system After cleaning the radiator start the engine Allow the engine to operate at low idle speed for three to five minutes Accelerate the engine to high idle This will help in the removal of debris and the drying of the core Slowly reduce the engine speed to low idle and then stop the engine Use a light bulb behind the core in order to inspect the core for cleanliness Repeat the cleaning if necessary 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 i02335775 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
77. econd test is conducted with moderate oil soot The second test measures the following criteria wear of piston rings wear of cylinder liners and resistance to corrosion A third new test measures the following characteristics with high levels of soot in the oil wear of the valve train resistance of the oil in plugging the oil filter and control of sludge In addition to the new tests API CH 4 oils have tougher limits for viscosity control in applications that generate high soot The oils also have improved oxidation resistance API CH 4 oils must pass an additional test piston deposit for engines that use aluminum pistons single piece Oil performance is also established for engines that operate in areas with high sulfur diesel fuel All of these improvements allow the API CH 4 oil to achieve optimum oil change intervals API CH 4 oils are recommended for use in extended oil change intervals API CH 4 oils are recommended for conditions that demand a premium oil Your Perkins dealer or your Perkins distributor has specific guidelines for optimizing oil change intervals Some commercial oils that meet the API classifications may require reduced oil change intervals To determine the oil change interval closely monitor the condition of the oil and perform a wear metal analysis 40 Maintenance Section Refill Capacities SEBU7833 03 NOTICE Failure to follow these oil recommendations can cause shortened engine servic
78. educed 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 rom 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 cold temperature conditions damage to engine valve mechanisms can result from engine operation for short intervals This can happen if the engine is started and the engine is stopped many times without being operated in order to warm up completely When the engine is operated below normal operating temperatures fuel and oil are not completely burned in the combustion chamber This fuel and oil causes soft carbon deposits to form on the valve stems Gene
79. el 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 SEBU7833 03 17 Product Information Section Model Views I i O e A B Illustration 15 g00984281 A typical example of the layout of the valves A Inlet valves B Exhaust valves Table 1 1104 Industrial Engine Specifications Number of Cylinders 4 In Line Bore 105 mm 4 134 inch Stroke 127 mm 5 0 inch Aspiration Turbocharged aftercooled Turbocharged Naturally aspirated Compression Ratio NA 19 25 1 NA T 18 23 1 T TA Displacement 4 4 L 268 in Firing Order 1342 Rotation flywheel end Counterclockwise Valve Lash Setting Inlet 0 20 mm 0 008 inch Valve Lash Setting Exhaust 0 45 mm 0 018 inch Table 2 1103 Industrial Engine Specifications Number of Cylinders 3 In Line Bore 105 mm 4 134 inch Stroke 127 mm 5 0 inch Aspiration Turbocharged Naturally aspirated Compression Ratio NA 19 25 1 T 18 25 1 Displacement 3 3 L 201 in Firing Order 123 Rotation flywheel end Counterclockwise Valve Lash Setting Inlet 0 20 mm 0 008 inch Valve Lash Setting Exhaust 0 45 mm 0 018 inch Table 3 1104 Genset Specifications Number of Cylinders 4 In Lin
80. em or a re mote oil filter system follow the OEM or filter manu facturer s recommendations Under filling or overfilling the crankcase with oil can cause engine damage NOTICE To prevent crankshaft bearing damage crank the en gine with the fuel OFF This will fill the oil filters before starting the engine Do not crank the engine for more than 30 seconds 2 Start the engine and run the engine at LOW IDLE for two minutes Perform this procedure in order to ensure that the lubrication system has oil and that the oil filters are filled Inspect the oil filter for oil leaks 3 Stop the engine and allow the oil to drain back to the sump for a minimum of ten minutes m Illustration 42 Y ADD mark X FULL mark X g00998024 4 Remove the oil level gauge in order to check the oil level Maintain the oil level between the ADD and FULL marks on the engine oil dipstick i02171102 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 effic
81. ent reminder We also recommend that a maintenance record be maintained as part of the engine s permanent record Your authorized Perkins dealer or your Perkins distributor can assist you in adjusting your maintenance schedule to meet the needs of your operating environment Overhaul Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the interval and the maintenance items in that 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 SEBU7833 03 5 Safety Section Safety Messages Safety Section i03299360 Safety Messages There may be several specific warning signs on an engine The exact location of the hazards and the description of the hazards are reviewed in this section Please become familiar with all warning signs Ensure that all of the
82. ention 10 F D Fire Prevention and Explosion Prevention 8 Fire EXxtinQuiShe rs uuu uu anu makasha 9 Driven Equipment Check 60 Lines Tubes and Hoses 9 SEBU7833 03 81 Index Section Fluid Recommendations 38 Cooling System Specifications 45 ELC Cooling System Maintenancoe 47 ENGIN Oll enancia R 39 Fuel Specifications 42 General Lubricant Information 38 FoOreWold u Susu cide da eed A EENE 4 California Proposition 65 Warning 4 Literature Information 4 Maintenance cccecceceeeeeeeeeeeeesencecaeeeeeeenees 4 Maintenance Intervals 4 Operation Lu uuu ias N a Eaa EA 4 Overhaul u uuu umu uu saa aaa 25 4 Salo ly lu 2 2 E S S 4 Fuel and the Effect from Cold Weather 35 Fuel Conservation Practices 31 Fuel Injector Test Change 68 Removal and Installation of the Fuel Injectors 69 Fuel Related Components in Cold Weather 36 Fuel Filters erince 36 Fuel Heaters 7 36 Fuel Tank au un usus sasana aqha cada 36 Fuel System Priffl
83. equirements 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 SEBU7833 03 41 Maintenance Section Refill Capacities 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 oil Re refined base stock oil are acceptable for use in Perkins engines if these oils meet the performance requirements that are specified by Perkins Re refined base stock oil can be used exclusively in finished oil or in a combination with new base stock oil The US military specifications and the specifications of other heavy equipment manufacturers also allow the use of re refined base stock oil that meet the same criteria The process that is used to make re refined base stock oil should adequately remove all wear metals that are in the used oil and all the additives that are in the used oil The process that is used to make re refined base stock oil generally involves the process of vacuum distillation and hydrotreating the used oil Filtering is adequate for the production of high quality re refined base stock oil
84. er 2 Remove the oil filler cap and add oil if necessary Clean the oil filler cap Install the oil filler cap 102202699 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 SEBU7833 03 65 Maintenance Section Engine Oil and Filter Change 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 Service hours on the engine e The number of hours that have accumulated since the last oil change e The amount of oil that has been added since the last oil change Ensure that the container
85. ervice indicator should reset in less than three pushes Check the movement of the yellow core when the engine is accelerated to the engine rated speed The yellow core should latch approximately at the greatest vacuum 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 64 Maintenance Section Engine Ground Inspect Clean SEBU7833 03 i01941505 Engine Ground Inspect Clean Inspect the wiring harness for good connections Perkins use the starter motor in order to ground the engine Check the connection on the starter motor at every oil change Ground wires and straps should be combined at engine grounds All grounds should be tight and free of corrosion e Clean the grounding stud on the starter motor and the terminals with a clean cloth e f the connections are corroded clean the connections with a solution of baking soda and water e Keep the grounding stud and the strap clean and coated with suitable grease or petroleum jelly 102323089 Engine Mounts Inspect Note The engine mounts may not have been supplied by Perkins Refer to the OEM information for further information on the engine mounts a
86. g01003662 1 Drain plug 2 Square hole 3 Filter bowl 1 Place a suitable container under the oil filter Remove the drain plug 1 and the seal from the oil filter SEBU7833 03 67 Maintenance Section Engine Valve Lash Inspect Adjust 2 Locate a suitable wrench into the square hole 2 in order to remove the filter bowl 3 3 Remove the filter bowl 3 and remove the element from the filter bowl Clean the filter bowl g01003675 Illustration 41 4 O ring seal 5 Element 6 Filter head 4 Install a new O ring 4 onto the filter bowl and lubricate the O ring with clean engine oil Install the filter element 5 into the filter bowl 5 Install the filter bowl into the oil filter head 6 Tighten the filter bowl to the following torque 25 N m 18 Ib ft 6 Install a new seal onto the drain plug 1 and install the drain plug into the oil filter Tighten the drain plug to the following torque 12 N m 8 lb ft Note Some engines may have a horizontally mounted oil filter This oil filter has a drain plug that is located in the oil filter head Fill the Engine Crankcase 1 Remove the oil filler cap Refer to the Operation and Maintenance Manual for more information on lubricant specifications Fill the crankcase with the proper amount of oil Refer to the Operation and Maintenance Manual for more information on refill capacities NOTICE If equipped with an auxiliary oil filter syst
87. h idle rpm Overspeeding can result in serious damage to the engine The engine can be operated at high idle without damage but should never be allowed to exceed high idle rpm amount of charge or discharge in the battery charging circuit Operation of the indicator should be to the right side of 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 Service Hour Meter The gauge indicates operating time of the engine 4 Ammeter This gauge indicates the 28 Operation Section Engine Starting SEBU7833 03 Engine Starting 102194223 Before Starting Engine Before the engine is started perform the required daily maintenance and any other periodic maintenance that is due Refer to the Operation and Maintenance Manual Maintenance Interval Schedule for more information e For the maximum service life of the engine make a thorough inspection within the engine compartment before the engine is started Look for the following items oil leaks coolant leaks loose bolts and excessive dirt and or grease Remove any excess dirt and or grease buildup Repair any faults that were identified during the inspection Inspect the cooling system hoses for cracks and for loose clamps Inspect the alternator and accessory drive belts for cracks breaks and other damage Inspect the wiring for
88. he engine at a fast idle speed in order to identify the faulty fuel injector Individually loosen and tighten the union nut for the high pressure pipe to each fuel injector Do not loosen the union nut more than half a turn There will be little effect on the engine speed when the union nut to the faulty fuel injection nozzle is loosened Refer to the Disassembly and Assembly Manual for more information Consult your authorized Perkins dealer or your Perkins distributor for assistance 102890360 Fuel System Prime If air enters the fuel system the air must be purged from the fuel system before the engine can be started Air can enter the fuel system when the following events occur e The fuel tank is empty or the fuel tank has been partially drained e The low pressure fuel lines are disconnected e A leak exists in the low pressure fuel system e The fuel filter is replaced e A new injection pump is installed Use the following procedure in order to remove air from the fuel system 1 Ensure that all low pressure fuel connections and high pressure fuel lines are installed correctly 2 Turn the ignition key to the RUN position Leave the ignition key in the RUN position for three minutes If a manual purging screw is installed the purging screw should be slackened during priming the fuel system g01003929 Illustration 44 Typical example 3 Crank the engine wi
89. he warm up period 8 Turn the engine start switch to the OFF position in order to stop the engine 30 Operation Section Engine Starting SEBU7833 03 102177935 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 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 with jump start cables The condition of the battery can be rechecked after the engine has been switched OFF NOTICE Using a battery source with the same voltage as the electric starting motor Use ONLY equal voltage for jump starting The use of higher voltage will damage the electrical system Do not reverse the battery cables The alternator can be damaged Attach ground cable last and remove first When using an external electrical source to start the engine turn the generator set control switch to the OFF position Turn all electrical accessories OFF be fore attaching the jump start cables Ensure that the main power switch is in the OFF posi tion before attaching the jump start cables to the en gine being started 1 Turn the start switch to the OFF
90. his specification NOTICE Water emulsion fuels These fuels are not permitted Refer to the following fuel specifications for North America Table 14 Perkins Specifications for Distillate Diesel Fuel Specifications Requirements ASTM Test Aromatics 35 maximum D1319 z Ash 0 02 maximum D482 weight Carbon Residue 0 35 maximum D524 on 10 Bottoms weight 40 minimum DI X Cetane Number engines D613 The cloud point must not exceed the Cloud Point lowest expected ambient temperature continued 44 Maintenance Section Refill Capacities SEBU7833 03 Table 14 contd Copper Strip No 3 maximum D130 Corrosion 10 at 282 C 540 F maximum Distillation D86 90 at 360 C 680 F maximum Flash Point legal limit D93 30 minimum API Gravity D287 45 maximum 6 C 10 F minimum Pour Point below ambient D97 temperature 0 2 maximum D3605 Sulfur 0 or D1552 2 0 cSt minimum Kinematic and 4 5 cSt D445 Viscosity maximum at 40 C 104 F Water and 0 1 maximum i a Sediment D17906 Water 0 1 maximum D1744 0 05 maximum Sediment weight D473 Gum and Resins 10 mg per 100 D381 3 mL maximum 0 38 mm z a 0 015 inch 7 7 Lubricity maximun at D6079 25 C 77 F 1 Perkins fuel systems and engine co
91. i for cleaning purposes 3 Pressurized air is the preferred method for removing loose debris Direct the air in the opposite direction of the fan s air flow Hold the nozzle approximately 6 mm 25 inch away from the fins Slowly move the air nozzle in a direction that is parallel with the tubes This will remove debris that is between the tubes 4 Pressurized water may also be used for cleaning The maximum water pressure for cleaning purposes must be less than 275 kPa 40 psi Use pressurized water in order to soften mud Clean the core from both sides NOTICE Do not use a high concentration of caustic cleaner to clean the core A high concentration of caustic cleaner can attack the internal metals of the core and cause leakage Only use the recommended concentration of cleaner 5 Back flush the core with a suitable cleaner 6 Steam clean the core in order 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 f
92. ication Perkins engines are identified by a serial number This number is shown on a serial number plate that is mounted on the left hand side of the engine block An example of an engine number is RE12345U090001H RE Type of engine RE12345 Engine List Number U Built in the United Kingdom 090001 Engine Serial Number H Year of Manufacture Perkins dealers need these numbers in order to determine the components that were included with the engine This permits accurate identification of replacement part numbers i01940474 Serial Number Plate Perkins ENGLAND 1 vure 4 3 2 g00994966 Illustration 16 Typical serial number plate 1 Temporary Parts List number 2 Type 3 Serial number 4 List number The Serial Number Plate is located on the left side of the cylinder block behind the high pressure pipes of the Fuel injection pump The following information is stamped on the Serial Number Plate Engine serial number Model and Arrangement number 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 20 Product Information Section Product Identification Information SEBU7833 03
93. ich may be an OEM option e Fuel heaters which may be an OEM option e Fuel line insulation which may be an OEM option There are three major differences between Group 1 fuels and Group 2 fuels Group 1 fuels have the following different characteristics to Group 2 fuels e A lower cloud point e A lower pour point e A higher energy per unit volume of fuel Note Group 3 fuels reduce the life of the engine The use of Group 3 fuels is not covered by the Perkins warranty Group 3 fuels include Low Temperature Fuels and Aviation Kerosene Fuels Special fuels include Biofuel The cloud point is a temperature that allows wax crystals to form in the fuel These crystals can cause the fuel filters to plug The pour point is the temperature when diesel fuel will thicken The diesel fuel becomes more resistant to flow through fuel lines fuel filters and fuel pumps Be aware of these facts when diesel fuel is purchased Consider the average ambient air temperature for the engine s application Engines that are fueled in one climate may not operate well if the engines are moved to another climate Problems can result due to changes in temperature Before troubleshooting for low power or for poor performance in the winter check the fuel for waxing Low temperature fuels may be available for engine operation at temperatures below 0 C 32 F These fuels limit the formation of wax in the fuel at low temperatures For more infor
94. iency and also reduce engine component life 68 Maintenance Section Fuel Injector Test Change SEBU7833 03 Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance Ensure that the engine is stopped before measuring the valve lash The engine valve lash can be inspected and adjusted when the temperature of the engine is hot or cold Refer to Systems Operation Testing and Adjusting Engine Valve Lash Inspect Adjust for more information 102198352 Fuel Injector Test Change Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component NOTICE If a fuel injector is suspected of operating outside of normal parameters it should be removed by a qualified technician The suspect fuel injector should be taken to an authorised agent for inspection The fuel injector 1 in illustration 43 has no fuel return The fuel injector 2 has a fuel return a aC Lt oA Illustration 43 g01110422 Typical fuel
95. ine Safety and Health Administration MSHA emissions Approved diesel engines shall be identified by an approved mark that is legible and permanent The approved mark is scribed with the approved MSHA number The label should be securely attached to the diesel engine Label for engines that do not comply with emissions EMISSIONS CONTROL INFORMATION ENGINE FANMILY ENGINE DISPLACEMENT This non road engine may be used as aREPLACEMENT engine within the EU as per the provisions of Directive 97 68 EC INFORMATION APPLICABLE TO USA ONLY This non road engine does not comply with either federal non road or California off road engine emission regulation requirements Sale or installation of this engine is a violation of federal and Californian law subject to civil penalty for any purpose other than as an EXPORT ONLY or REPLACEMENT engine Export only engine is indicated by an additional attached tag Hanger No Position 8 amp 3 Perkins MODEL YEAR 2005 Label No 3181A081 Illustration 20 This typical example of a label is installed on engines that do not comply with emissions g01156734 SEBU7833 03 23 Product Information Section Product Identification Information EMISSIONS CONTROL INFORMATION ENGINE FAMILY 1104C 44TA MODEL YEAR 2005 ENGINE DISPLACEMENT 4 400 FOLLOWING INFORMATION APPLICABLE TO USA ONLY
96. inspect the primary air cleaner elements before cleaning Inspect the air cleaner elements for damage to the seal the gaskets and the outer cover Discard any damaged air cleaner elements There are two common methods that are used to clean primary air cleaner elements e Pressurized air e Vacuum cleaning Pressurized Air Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than two times Pressurized air will not remove deposits of carbon and oil Use filtered dry air with a maximum pressure of 207 kPa 30 psi Illustration 34 g00281692 Note When the primary air cleaner elements are cleaned always begin with the clean side inside in order to force dirt particles toward the dirty side outside Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats Do not aim the stream of air directly at the primary air cleaner element Dirt could be forced further into the pleats Note Refer to Inspecting the Primary Air Cleaner Elements Vacuum Cleaning Vacuum cleaning is a good method for cleaning primary air cleaner elements which require daily cleaning because of a dry dusty environment Cleaning with pressurized air is recommended prior to vacuum cleaning Vacuum cleaning will not remove deposits of carbon and oil Note Refer to Inspecting the Primary Air Cleaner Elements
97. ion 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 emergency stop has been corrected Stop the engine if an overspeed condition occurs during the initial start up of a new engine or an engine that has been overhauled This may be accomplished by shutting off the fuel supply to the engine and or shutting off the air supply to the engine i02176668 Electrical System Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating A spark can cause the combustible gases that are produced by some batteries to ignite To help prevent sparks from igniting combustible gases that are produced by some batteries the negative jump start cable should be connected last from the external power source to the negative terminal of the starting motor If the starting motor is not equipped with a negative terminal connect the jump start cable to the engine block 12 Safety Section Electrical System SEBU7833 03 Check the electrical wires daily for wires that are loose or frayed Tighten all loose electrical wires before the engine is started Repair all frayed electrical wires before th
98. ion before you start the engine NOTICE Do not crank the engine for more than 30 seconds Allow the electric starting motor to cool for two minutes before cranking the engine again 2 Turn the engine start switch to the START position Hold the engine start switch in the START position and crank the engine 3 When the engine starts release the engine start switch 4 If equipped slowly move the throttle lever to the low idle position and allow the engine to idle Refer to the Operation and Maintenance Manual After Starting Engine topic 5 If the engine does not start release the engine start switch and allow the electric starting motor to cool Then repeat steps 2 through step 4 6 Turn the engine start switch to the OFF position in order to stop the engine 102198092 Cold Weather Starting 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 When Group 2 diesel fuel is used the following items provide a means of minimizing starting problems and fuel problems in cold weather engine oil pan heaters jacket water heaters fuel heaters and fuel line insulation Use the procedure that follows for cold weather starting 1 If equipped move the throttle lever to the full throttle position before you sta
99. is can result in severe personal in jury or death Ensure proper ventilation for batteries that are in an enclosure Follow the proper procedures in or der to help prevent electrical arcs and or sparks near batteries Do not smoke when batteries are serviced The battery cables or the batteries should not be removed with the battery cover in place The bat tery cover should be removed before any servic ing is attempted Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury _ Switch the engine to the OFF position Remove all electrical loads N Turn off any battery chargers Disconnect any battery chargers o The NEGATIVE cable connects the NEGATIVE battery terminal to the NEGATIVE terminal on the starting motor Disconnect the cable from the NEGATIVE battery terminal A The POSITIVE cable connects the POSITIVE battery terminal to the POSITIVE terminal on the starting motor Disconnect the cable from the POSITIVE battery terminal Note Always recycle a battery Never discard a battery Dispose of used batteries to an appropriate recycling facility 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
100. justing and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Dispose of all fluids according to Local regulations and mandates NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contaminated Note When the cooling system is cleaned only clean water is needed Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to relieve the pres sure 56 Maintenance Section Cooling System Coolant Commercial Heavy Duty Change SEBU7833 03 1 Stop the engine and allow the engine to cool Loosen the cooling system fille
101. la tors Many engine failures are related to the cooling system The following problems are related to cooling system failures Overheating leakage of the water pump and plugged radiators or heat exchangers These failures can be avoided with correct cooling system maintenance Cooling system maintenance is as important as maintenance of the fuel system and the lubrication system Quality of the coolant is as important as the quality of the fuel and the lubricating oil Coolant is normally composed of three elements Water additives and glycol Water Water is used in the cooling system in order to transfer heat Distilled water or deionized water is recommended for use in engine cooling systems DO NOT use the following types of water in cooling systems Hard water softened water that has been conditioned with salt and sea water If distilled water or deionized water is not available use water with the properties that are listed in Table 16 Table 16 Perkins Minimum Acceptable Water Requirements Property Maximum Limit Chloride Cl 40 mg L Sulfate SO 100 mg L Total Hardness 170 mg L Total Solids 340 mg L Acidity pH of 5 5 to 9 0 For a water analysis consult one of the following sources e Local water utility company e Agricultural agent e Independent laboratory Additives Additives help to protect the metal surfaces of the cooling system A lack of coolant a
102. ldup can contribute to loss of engine power increased black smoke and overall loss of engine efficiency If the turbocharger fails during engine operation damage to the turbocharger compressor wheel and or to the engine may occur Damage to the turbocharger compressor wheel can cause additional damage to the pistons the valves and the cylinder head NOTICE Turbocharger bearing failures can cause large quanti ties of oil to enter the air intake and exhaust systems Loss of engine lubricant can result in serious engine damage Minor leakage of oil into a turbocharger under extend ed low idle operation should not cause problems as long as a turbocharger bearing failure has not oc cured When a 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 SEBU7833 03 77 Maintenance Section Walk Around Inspection 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
103. leats 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 conditions dust dirt and debris may require more frequent service of the air cleaner element e The air cleaner element should be replaced at least one time per year This replacement should be performed regardless of the number of cleanings Replace the dirty air cleaner elements with clean air cleaner elements Before installation the air cleaner elements should be thoroughly checked for tears and or holes in the filter material Inspect the gasket or the seal of the air cleaner element for damage Main
104. loose connections and for worn wires or frayed wires e Check the fuel supply Drain water from the water separator if equipped Open the fuel supply valve if equipped NOTICE All valves in the fuel return line must be open before and during engine operation to help prevent high fuel pressure High fuel pressure may cause filter housing failure or other damage If the engine has not been started for several weeks fuel may have drained from the fuel system Air may have entered the filter housing Also when fuel filters have been changed some air pockets will be trapped in the engine In these instances prime the fuel system Refer to the Operation and Maintenance 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 Ensure that the areas around the rotating parts are clear All of the guards must be put in place Check for damaged guards or for missing guards Repair any damaged guards Replace damaged guards and or missing guards Disconnect any battery chargers that are not protected against the high curren
105. low 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 i02322295 Aftercooler Core Inspect Note Adjust the frequency of cleaning according to the effects of the operating environment Inspect the aftercooler for these items damaged fins corrosion dirt grease insects leaves oil and other debris Clean the aftercooler if necessary For air to air aftercoolers use the same methods that are used for cleaning radiators 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 SEBU7833 03 53 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
106. ls in order to help maintain adequate wear protection Table 12 Percentage of Sulfur in Oil change interval the fuel Lower than 0 5 Normal 0 5 to 1 0 0 75 of normal Greater than 1 0 0 50 of normal Lubricant Viscosity Recommendations for Direct Injection DI Diesel Engines The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start up and the maximum ambient temperature during engine operation Refer to Table 13 minimum temperature in order to determine the required oil viscosity for starting a cold engine Refer to Table 13 maximum temperature in order to select the oil viscosity for engine operation at the highest ambient temperature that is anticipated Generally use the highest oil viscosity that is available to meet the requirement for the temperature at start up Table 13 Engine Oil Viscosity EMA LRG 1 Ambient Temperature API CH 4 Viscosity Grade Minimum Maximum SAE 0W20 40 C 40 F 10 C 50 F SAE 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 Oil Synthetic base oils are acceptable for use in these engines if these oils meet the performance r
107. mation on cold weather operation refer to the Operation and Maintenance Manual Cold Weather Operation and Fuel Related Components in Cold Weather 36 Operation Section Cold Weather Operation SEBU7833 03 i01903588 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 important Drain the water and sediment from any fuel storage tank at the following intervals weekly oil changes and refueling of the fuel tank This will help prevent water and or sediment from being pumped from the fuel storage tank and into the engine fuel tank Fuel Filters It is possible that a primary fuel filter is installed between the fuel tank and the engine fuel inlet After you change the fuel filter always prime the fuel system in order to remove air bubbles from the fuel system Refer to the Operation and Maintenance Manual in the Maintenance Section for more information on priming the fuel system The micron rating and the location of
108. mponents can operate on high sulfur fuels Fuel sulfur levels affect exhaust emissions High sulfur fuels also increase the potential for corrosion of internal components Fuel sulfur levels above 0 5 percent may significantly shorten the oil change interval For additional information see this publication Fluid Recommendations Engine Oil topic Maintenance Section 2 The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps If a fuel with a low viscosity is used cooling of the fuel may be required to maintain a 1 4 cSt viscosity at the fuel injection pump Fuels with a high viscosity might require fuel heaters in order to bring down the viscosity to a 20 cSt viscosity 3 Follow the test conditions and procedures for gasoline motor 4 The lubricity of a fuel is a concern with low sulfur fuel To determine the lubricity of the fuel use either the ASTM D6078 Scuffing Load Wear Test SBOCLE or the ASTM D6079 High Frequency Reciprocating Rig HFRR test If the lubricity of a fuel does not meet the minimum requirements consult your fuel supplier Do not treat the fuel without consulting the fuel supplier Some additives are not compatible These additives can cause problems in the fuel system NOTICE Operating with fuels that do not meet the Perkins rec ommendations can cause the following effects Start ing difficulty poor combustion deposits in the fuel in jectors
109. n 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 a reference for ope
110. n package for other coolants ELC is an ethylene glycol base coolant However ELC contains organic corrosion inhibitors and antifoam agents with low amounts of nitrite Perkins ELC has been formulated with the correct amount of these additives in order to provide superior corrosion protection for all metals in engine cooling systems ELC extends the service life of the coolant to 12000 service hours or six years ELC does not require a frequent addition of a Supplemental Coolant Additive SCA An Extender is the only additional maintenance that is needed at 6000 service hours or one half of the ELC service life ELC is available in a 1 1 premixed cooling solution with distilled water The Premixed ELC provides freeze protection to 36 C 33 F The Premixed ELC is recommended for the initial fill of the cooling system The Premixed ELC is also recommended for topping off the cooling system ELC Concentrate is also available ELC Concentrate can be used to lower the freezing point to 51 C 60 F for arctic conditions Containers of several sizes are available Consult your Perkins dealer or your Perkins distributor for the part numbers ELC Cooling System Maintenance Correct additions to the Extended Life Coolant NOTICE Use only Perkins products for pre mixed or concen trated coolants Use only Perkins Extender with Extended Life Coolant Mixing Extended Life Coolant with other products re duces the Ex
111. nated Note When the cooling system is cleaned only clean water is needed when the ELC is drained and replaced Note Inspect the water pump and the water temperature regulator after the cooling system has been drained This is a good opportunity to replace the water pump the water temperature regulator and the hoses if necessary Drain Pressurized System Hot coolant can cause seri ous burns To open the cooling system filler cap stop the engine and wait until the cooling system components are cool Loosen the cooling system pressure cap slowly in order to 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 ye Illustration 29 Typical example 2 Open the drain cock or remove the drain plug 1 on the engine Open the drain cock or remove the drain plug on the radiator Allow the coolant to drain NOTICE Dispose of used engine coolant or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Perkins to reclaim the coolant For information regarding the disposal and the recycling of used coolant consult your Perkins dealer or your Perkins distributor Flush 1 Flush the cooling system with clean water in order to remov
112. nd cool 1 Loosen the cooling system filler cap slowly in order to relieve pressure Remove the cooling system filler cap 2 It may be necessary to drain enough coolant from the cooling system in order to add the Extender 3 Add Extender according to the requirements for your engine s cooling system capacity Refer to this Operation and Maintenance Manual Refill Capacities in the Maintenance Section for the capacity of the cooling system for your engine Refer to this Operation and Maintenance Manual Fluid Recommendations information for the Perkins ELC Extender 4 Clean the cooling system filler cap and inspect the gasket If the gasket is damaged discard the old filler cap and install a new filler cap If the gasket is not damaged use a suitable pressurizing pump in order to pressure test the filler cap The correct pressure is stamped on the face of the filler cap If the filler cap does not retain the correct pressure install a new filler cap 102335378 Cooling System Coolant Level Check Engines With a Coolant Recovery Tank Note The cooling system may not have been provided by Perkins The procedure that follows is for typical cooling systems Refer to the OEM information for the correct procedures Check the coolant level when the engine is stopped and cool 1 Observe the coolant level in the coolant recovery tank Maintain the coolant level to COLD FULL mark on the coolant recovery t
113. nd 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 temperatures power loss excessive fan usage and reduction in fuel economy SEBU7833 03 35 Operation Section Cold Weather Operation 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 inle
114. nd 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 I Illustration 37 g01165836 Y Min mark X Max mark NOTICE Perform this maintenance with the engine stopped Note Ensure that the engine is either level or that the engine is in the normal operating position in order to obtain a true level indication Note After the engine has been switched OFF wait for ten minutes in order to allow the engine oil to drain to the oil pan before checking the oil level 1 Maintain the oil level between the ADD mark Y and the FULL mark X on the engine oil dipstick Do not fill the crankcase above the FULL mark X NOTICE Operating your engine when the oil level is above the FULL mark could cause your crankshaft to dip into the oil The air bubbles created from the crankshaft dipping into the oil reduces the oil s lubricating char acteristics and could result in the loss of pow
115. ned 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 101930351 Engine Storage If the engine will not be started for several weeks the lubricating oil will drain from the cylinder walls and from the piston rings Rust can form on the cylinder walls Rust on the cylinder walls will cause increased engine wear and a reduction in engine service life Lubrication System To help prevent excessive engine wear use the following guidelines Complete all of the lubrication recommendations that are listed in this Operation and Maintenance Manual Maintenance Interval Schedule Maintenance Section If an engine is out of operation and if use of the engine is not planned special precautions should be made If the engine will be stored for more than one month a complete protection procedure is recommended Use the following guidelines Completely clean the outside of the engine Drain the fuel system completely and refill the system with preservative fuel 1772204 POWERPART Lay Up 1 can be mixed with the normal fuel in order to change the fuel into preservative fuel If preservative fuel is not available the fuel system can be
116. nished 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 dealer or your Perkins distributor has the specific guidelines for optimizing oil change intervals API CH 4 API CH 4 oils were developed in order to meet the requirements of the new high performance diesel engines Also the oil was designed to meet the requirements of the low emissions diesel engines API CH 4 oils are also acceptable for use in older diesel engines and in diesel engines that use high sulfur diesel fuel API CH 4 oils may be used in Perkins engines that use API CG 4 and API CF 4 oils API CH 4 oils will generally exceed the performance of API CG 4 oils in the following criteria deposits on pistons control of oil consumption wear of piston rings valve train wear viscosity control and corrosion Three new engine tests were developed for the API CH 4 oil The first test specifically evaluates deposits on pistons for engines with the two piece steel piston This test piston deposit also measures the control of oil consumption A s
117. on and Explosion Prevention Illustration 8 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 A flash fire may result if the covers for the engine crankcase are removed within fifteen minutes after an emergency shutdown Determine whether the engine will be operated in an environment that allows combustible gases to be drawn into the air inlet system These gases could cause the engine to overspeed Personal injury property damage or engine damage could result If the application involves the presence of combustible gases consult your Perkins dealer and or your Perkins distributor for additional information about suitable protection devices Remove all flammable combustible materials or conductive materials such as fuel oil and debris from the engine Do not allow any flammable combustible materials or conductive materials to accumulate on the engine Store fuels and lubricants in correctly marked containers away from unauthorized persons Store oily rags and any flammable materials in protective containers Do not smoke in areas that are used for storing flammable materials Do not expose the engine to any flame Exhaust shields if equipped protect hot exhaust components from oil or fuel spray in case of a line a tube
118. onnected Fit a suitable cover over discon nected fuel system component Element filter Turn the valves for the fuel lines if equipped to the OFF position before performing this maintenance Place a tray under the fuel filter in order to catch any fuel that might spill Clean up any spilled fuel immediately W I TTT D 2o Fs O N x ERAR Illustration 47 1 Drain 2 Filter bowl g01010637 1 Close the valves for the fuel lines if equipped 2 Clean the outside of the fuel filter assembly Open the fuel drain 1 and drain the fuel into a suitable container 72 Maintenance Section Fuel System Secondary Filter Replace SEBU7833 03 Illustration 48 g01010595 3 O ring seal 4 Element 5 Filter head 3 Remove the filter bowl 2 from the filter head 5 Press on the element 4 Rotate the element counterclockwise in order to release the element for the filter bowl and remove the element from the bowl Discard the used element 4 Remove the O ring 3 from the filter bowl and clean the filter bowl Check that the threads of the filter bowl are not damaged 5 Install a new O ring seal 3 to the filter bowl 2 6 Locate a new filter element 4 into the filter bowl Press on the element and rotate the element clockwise in order to lock the element into the filter b
119. oolant Antifreeze and SCA NOTICE Commercial Heavy Duty Coolant which contains Amine as part of the corrision protection system must not be used NOTICE Never operate an engine without water temperature regulators in the cooling system Water temperature regulators help to maintain the engine coolant at the correct operating temperature Cooling system prob lems can develop without water temperature regula tors Check the coolant antifreeze glycol concentration in order to ensure adequate protection against boiling or freezing Perkins recommends the use of a refractometer for checking the glycol concentration Perkins engine cooling systems should be tested at 500 hour intervals for the concentration of Supplemental Coolant Additive SCA Additions of SCA are based on the results of the test An SCA that is liquid may be needed at 500 hour intervals Refer to Table 22 for part numbers and for quantities of SCA Table 22 Perkins Liquid SCA Part Number Quantity 21825735 Adding the SCA to Heavy Duty Coolant at the Initial Fill Commercial heavy duty coolant antifreeze that meets ASTM D4985 specifications MAY require an addition of SCA at the initial fill Read the label or the instructions that are provided by the OEM of the product Use the equation that is in Table 23 to determine the amount of Perkins SCA that is required when the cooling system is initially filled Table
120. ore 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 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 SEBU7833 03 11 Safety Section Engine Starting 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 i02207232 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 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
121. owl 7 Install the filter bowl 4 into the top of the filter head 5 8 Tighten the filter bowl by hand until the filter bowl contacts the filter head Rotate the filter bowl through 90 degrees Note Do not use a tool to tighten the filter bowl 9 Open the valves for the fuel lines if equipped Spin on filter Turn the valves for the fuel lines if equipped to the OFF position before performing this maintenance Place a tray under the fuel filter in order to catch any fuel that might spill Clean up any spilled fuel immediately Illustration 49 g01121396 1 Filter Head 2 Spin on filter 3 Drain 1 Clean the outside of the fuel filter assembly Open the fuel drain 3 and drain the fuel into a suitable container 2 Use a suitable tool in order to remove the spin on filter 2 from the filter head 1 3 Ensure that the fuel drain 3 on the new spin on filter is closed SEBU7833 03 73 Maintenance Section Fuel Tank Water and Sediment Drain Illustration 50 g01121723 4 Lubricate the sealing ring 4 with clean fuel oil 5 Install the spin on filter 2 into the top of the filter head 1 6 Tighten the spin on filter by hand until the sealing ring contacts the filter head Rotate the spin on filter through 90 degrees 7 Prime the fuel system Refer to Opera
122. p 3 can be used on the terminals 10 Clean the crankcase breather if one is installed Seal the end of the pipe 11 Remove the fuel injector nozzles and spray 1762811 POWERPART Lay Up 2 for one or two seconds into each cylinder bore with the piston at BDC 12 Slowly rotate the crankshaft for one complete revolution and then replace the fuel injector nozzles Induction System Remove the air filter assembly If necessary remove the pipes that are installed between the air filter assembly and the turbocharger Spray 1762811 POWERPART Lay Up 2 into the turbocharger The duration of the spray is printed on the container Seal the turbocharger with waterproof tape Exhaust System e Remove the exhaust pipe 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 26 Operation Section Lifting and Storage SEBU7833 03 General Items e If the lubricating oil filler is installed on the rocker cover remove the filler cap If the lubricating oil filler cap is not installed on the rocker cover remove the rocker cover Spray 1762811 POWERPART Lay Up 2 around the rocker shaft assembly Replace the filler cap or the rocker cover e Seal the vent of the fuel tank or the fuel filler cap with waterproof tape e Remove the alternator drive belts and put the drive belts into storage 1734115 POWERPART Lay Up 3 Do not s
123. perating 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 engine lubricant before the beginning of cold weather Check all rubber parts hoses fan drive belts etc weekly Check all electrical wiring and connections for any fraying or damaged insulation Keep all batteries fully charged and warm Fill the fuel tank at the end of each shift Check the air cleaners and the air intake daily Check the air intake more often when you operate in snow Ensure that the glow plugs are in working order Refer
124. pray the area inside the alternator When the engine protection has been completed in accordance with these instructions this ensures that no corrosion will occur Perkins are not responsible for damage which may occur when an engine is in storage after a period in service Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods In order to prevent corrosion spray the engine with SEBU7833 03 27 Operation Section Gauges and Indicators Gauges and Indicators i02164190 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 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 greate
125. r cap If the gasket that is on the cooling system filler cap is not damaged use a suitable pressurizing pump in order to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 6 Start the engine Inspect the cooling system for leaks and for correct operating temperature SEBU7833 03 57 Maintenance Section Cooling System Coolant ELC Change i02203595 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 ofthe product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Dispose of all fluids according to Local regulations and mandates NOTICE Keep all parts clean from contaminants Contaminants may cause rapid wear and shortened component life Clean the cooling system and flush the cooling system before the recommended maintenance interval if the following conditions exist e The engine overheats frequently e Foaming is observed e The oil has entered the cooling system and the coolant is contaminated e The fuel has entered the cooling system and the coolant is contami
126. r cap slowly in order to relieve any pressure Remove the cooling system filler cap WY Illustration 28 g01003928 2 Open the drain cock or remove the drain plug 1 on the engine Open the drain cock or remove the drain plug on the radiator Allow the coolant to drain NOTICE Dispose of used engine coolant or recycle Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems The full distillation procedure is the only method acceptable by Perkins to reclaim the 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 th
127. r elements Clean up fuel spills immediately NOTICE Do not allow dirt to enter the fuel system Thoroughly clean the area around a fuel system component that will be disconnected Fit a suitable cover over discon nected fuel system component Illustration 45 g01118416 1 Screw 2 Element 3 Glass bowl 4 Sensor connection 5 Drain 6 Bottom cover 1 Turn the fuel supply valve if equipped to the OFF position 2 Place a suitable container under the water separator Clean the outside of the water separator 3 Open the drain 5 Allow the fluid to drain into the container 4 Tighten the drain 5 by hand pressure only 5 Hold the element 2 and remove the screw 1 Remove the element and the glass bowl 3 from the base Discard the old element 6 Clean the glass bowl 4 Clean the bottom cover 6 7 Install the new O ring seal Install the bottom cover onto the new element Install the assembly onto the base 8 Install the screw 1 and tighten the screw to a torque of 8 N m 6 lb ft 9 Remove the container and dispose of the fuel safely 10 Open the fuel supply valve 1 Prime the fuel system Refer to the Operation and Maintenance Manual Fuel System Prime for more information i02211066 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
128. rally 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 oil This will provide longer service life for the engine bearings the piston rings and other parts However limit unnecessary idle time to ten minutes in order to reduce wear and unnecessary fuel consumption The Water Temperature Regulator and Insulated Heater Lines The engine is equipped with a water temperature regulator When the engine coolant is below the correct operating temperature jacket water circulates through the engine cylinder block a
129. rators 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 Recommended service should be performed at the appropriate intervals as indicated in the Maintenance Interval Schedule The actual operating environment of the engine also governs the Maintenance Interval Schedule Therefore under extremely severe dusty wet or freezing cold operating conditions more frequent lubrication and maintenance than is specified in the Maintenance Interval Schedule may be necessary The maintenance schedule items are organized for a preventive maintenance management program If the preventive maintenance program is followed a periodic tune up is not required The implementation of a preventive maintenance management program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures Maintenance Intervals Perform maintenance on items at multiples of the original requirement We recommend that the maintenance schedules be reproduced and displayed near the engine as a conveni
130. rt the engine 2 If equipped turn the engine start switch to the HEAT position Hold the engine start switch in the HEAT position for 6 seconds until the glow plug indicator light illuminates This will activate the glow plugs and aid in the starting of the engine NOTICE Do not crank the engine for more than 30 seconds Allow the electric starting motor to cool for two minutes before cranking the engine again 3 While the glow plug indicator light is illuminated turn the engine start switch to the START position and crank the engine Note If the glow plug indicator light illuminates rapidly for 2 to 3 seconds or if the glow plug indicator light fails to illuminate a malfunction exists in the cold start system Do not use ether or other starting fluids to start the engine 4 When the engine starts release the engine start switch key 5 If the engine does not start release the engine start switch and allow the starter motor to cool Then repeat steps 2 through step 4 6 If the engine is equipped with a throttle allow the engine to idle for three to five minutes or allow the engine to idle until the water temperature indicator begins to rise The engine should run at low idle smoothly until speed is gradually increased to high idle Allow the white smoke to disperse before proceeding with normal operation 7 Operate the engine at low load until all systems reach operating temperature Check the gauges during t
131. s 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 filler pipe If the engine is equipped with a sight glass maintain the coolant level to the correct level in the sight glass 3 Clean the cooling system filler cap and inspect the gasket If the gasket is damaged discard the old filler cap and install a new filler cap If the gasket is not damaged use a suitable pressurizing pump in order to pressure test the filler cap The correct pressure is stamped on the face of the filler cap If the filler cap does not retain the correct pressure install a new filler cap 4 Inspect the cooling system for leaks 100174798 Driven Equipment Check Refer to the OEM specifications for more information on the following maintenance recommendations for the driven equipment e Inspection e Adjustment e Lubrication e Other maintenance recommendations Perform any maintenance for the driven equipment which is recommended by the OEM 101930350 Engine Clean Personal injury or death can result from high volt age Moisture can create paths of electrical conductiv ity Make sure that the electrical system is OFF Lock out the star
132. s high Bypass valves can also provide unrestricted flow of lubrication oil to the engine parts if the oil cooler should become plugged or if the oil filter element should become plugged Engine efficiency efficiency of emission controls and engine performance depend on adherence to proper operation and maintenance recommendations Engine performance and efficiency also depend on the use of recommended fuels lubrication oils and coolants Refer to the Operation and Maintenance Manual Maintenance Interval Schedule for more information on maintenance items Engine Service Life Engine efficiency and maximum utilization of engine performance depend on the adherence to proper operation and maintenance recommendations In addition use recommended fuels coolants and lubricants Use the Operation and Maintenance Manual as a guide for required engine maintenance Expected engine life is generally predicted by the average power that is demanded The average power that is demanded is based on fuel consumption of the engine over a period of time Reduced hours of operation at full throttle and or operating at reduced throttle settings result in a lower average power demand Reduced hours of operation will increase the length of operating time before an engine overhaul is required SEBU7833 03 19 Product Information Section Product Identification Information Product Identification Information i02280116 Engine Identif
133. s installed on engines that have electronic fuel injection systems and installed on engines that have electronic fuel injection pumps IMPORTANT ENGINE INFORMATION 83 Perkins Engine Family 5PKXL04 0AJ1 List RE81372 En Refer to Manufacturer Engine Type 2160 2200 Displacement 4 400 Advertised kw 62 RPM 2200 Fuel Rate at adv kw 64 2 mm3 stk Init Timing DEG BTDC idle RPM e11 97 68CA 00 000 0089 01 Settings are to be made with engine at normal operating temperature with transmission in neutral This engine conforms to 2005 U S EPA non road and California off road Regulations for large C I engines and is certified to operate on commercially available diesel fuel Emission Control System Valve Lash Cold inch Engine Label DDI Exhaust 0 0 Inlet 0 00 Hanger No position Label No 3181A081 Illustration 18 g01156733 This typical example of a label is installed on engines that have mechanical fuel injection pumps 22 Product Information Section Product Identification Information SEBU7833 03 Label for engines that comply with MSHA emissions 3 e LABEL NUMBER Perkins 555 MSHA APPR NO ENGINE MODEL CURVE NO RATED HP RATED kW aa rpm cfm gt Illustration 19 g01381316 Typical example The label that is shown in illustration 19 is for engines that operate in underground coal mines in North America The label is installed on engines that comply with the M
134. sity of 1 4 cSt at the fuel injection pump There are many other diesel fuel specifications that are published by governments and by technological societies Usually those specifications do not review all the requirements that are addressed in this specification To ensure optimum engine performance a complete fuel analysis should be obtained before engine operation The fuel analysis should include all of the properties that are listed in Table 14 SEBU7833 03 45 Maintenance Section Refill Capacities Cooling System Specifications General Coolant Information NOTICE Never add coolant to an overheated engine Engine damage could result Allow the engine to cool first NOTICE If the engine is to be stored in or shipped to an area with below freezing temperatures the cooling system must be either protected to the lowest outside temper ature or drained completely to prevent damage NOTICE Frequently check the specific gravity of the coolant for proper freeze protection or for anti boil protection Clean the cooling system for the following reasons e Contamination of the cooling system e Overheating of the engine e Foaming of the coolant NOTICE Never operate an engine without water temperature regulators in the cooling system Water temperature regulators help to maintain the engine coolant at the proper operating temperature Cooling system prob lems can develop without water temperature regu
135. st after a cold engine is started The typical engine oil pressure with SAE10W30 is 207 to 413 kPa 30 to 60 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 Reduce engine speed to low idle 3 Check and maintain the oil level Jacket Water Coolant Temperature Typical temperature range is 71 to 96 C 160 to 205 F The maximum allowable temperature with the pressurized cooling system at 48 kPa 7 psi is 110 C 230 F Higher temperatures may occur under certain conditions The water temperature reading may vary according to load The reading should never exceed the boiling point for the pressurized system that is being used 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 Inspect the cooling system for leaks 3 Determine if the engine must be shut down immediately or if the engine can be cooled by reducing the load Tachometer This gauge indicates engine speed rpm When the throttle control lever is moved to the full throttle position without load the engine is running at high idle The engine is running at the full load rpm when the throttle control lever is at the full throttle position with maximum rated load NOTICE To help prevent engine damage never exceed the hig
136. t drain that is created when the electric starting motor is engaged Check electrical cables and check the battery for poor connections and for corrosion Reset all of the shutoffs or alarm components if equipped Check the engine lubrication oil level Maintain the oil level between the ADD mark and the FULL mark on the engine oil level gauge Check the coolant level Observe the coolant level in the header tank if equipped Maintain the coolant level to the FULL mark on the header tank If the engine is not equipped with a header tank maintain the coolant level within 13 mm 0 5 inch of the bottom of the filler pipe If the engine is equipped with a sight glass maintain the coolant level in the sight glass Observe the air cleaner service indicator if equipped Service the air cleaner when the yellow diaphragm enters the red zone or when the red piston locks in the visible position Ensure that any equipment that is driven by the engine has been disengaged from the engine Minimize electrical loads or remove any electrical loads SEBU7833 03 29 Operation Section Engine Starting i02198348 Starting the Engine Do not use aerosol types of starting aids such as ether Such use could result in an explosion and personal injury Refer to the OMM for your type of controls Use the following procedure to start the engine 1 If equipped move the throttle lever to the full throttle posit
137. t that is located in the engine compartment may be specified An air cleaner that is located in the engine compartment may also minimize the entry of snow into the air cleaner Also heat that is rejected by the engine helps to warm the intake air Additional heat can be retained around the engine by insulating the engine compartment 102322217 Fuel and the Effect from Cold Weather Note Only use grades of fuel that are recommended by Perkins Refer to this Operation and Maintenance Manual Fluid Recommendations The following fuels can be used in this series of engine e Group 1 e Group 2 e Group 3 e Special Fuels Perkins prefer only Group 1 and Group 2 fuels for use in this series of engines Group 1 fuels are the preferred Group of Fuels for general use by Perkins Group 1 fuels maximize engine life and engine performance Group 1 fuels are usually less available than Group 2 fuels Frequently Group 1 fuels are not available in colder climates during the winter Note Group 2 fuels must have a maximum wear scar of 650 micrometers HFRR to ISO 12156 1 Group 2 fuels are considered acceptable for issues of warranty This group of fuels may reduce the life of the engine the engine s maximum power and the engine s fuel efficiency When Group 2 diesel fuels are used the following components provide a means of minimizing problems in cold weather e Glow plugs if equipped e Engine coolant heaters wh
138. tain 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 or washable Refer to the OEM information for instructions in order to replace the secondary air cleaner element When the engine is operating in environments that are dusty or dirty air cleaner elements may require more frequent replacement Illustration 33 g00736431 1 Cover 2 Primary air cleaner element 3 Secondary air cleaner element 4 Air inlet 1 Remove the cover Remove the primary air cleaner element 2 The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element Note Refer to Cleaning the Primary Air Cleaner Elements 3 Cover the air inlet with tape in order to keep dirt out 4 Clean the inside of the air cleaner cover and body with a clean dry cloth 5 Remove the tape for the air inlet Install the secondary air cleaner element Install a primary air cleaner element that is new or cleaned
139. te The radiator may not have been provided by Perkins The following is a general procedure for changing the coolant Refer to the OEM information for the correct procedure 1 Ensure that the vehicle is on level ground 2 Remove the filler cap of the cooling system 3 Remove the drain plug 1 from the side of the cylinder block in order to drain the engine Ensure that the drain hole is not restricted 4 Open the radiator drain tap or remove the drain plug at the bottom of the radiator in order to drain the radiator If the radiator does not have a radiator drain tap or a drain plug disconnect the hose at the bottom of the radiator 5 Flush the coolant system with clean water 6 Install the drain plugs and close the radiator drain tap Install the radiator hose if the radiator hose was previously removed 7 Fill the system with an approved antifreeze mixture The maximum flow rate is 1 L 0 2200 Imp gal per minute in order to fill the system Install the filler cap 8 Run the engine and check for coolant leaks SEBU7833 03 59 Maintenance Section Cooling System Coolant Extender ELC Add i02335364 Cooling System Coolant Extender ELC Add The Perkins Extended Life Coolant ELC does not need the frequent addition of Supplemental Coolant Additives SCA that are associated with conventional coolants The Extender only needs to be added once Check the cooling system only when the engine is stopped a
140. tended Life Coolant service life Failure to follow the recommendations can reduce cooling sys tem components life unless appropriate corrective ac tion is performed In order to maintain the correct balance between the antifreeze and the additives you must maintain the recommended concentration of Extended Life Coolant ELC Lowering the proportion of antifreeze lowers the proportion of additive This will lower the ability of the coolant to protect the system from pitting from cavitation from erosion and from deposits NOTICE Do not use a conventional coolant to top off a cooling system that is filled with Extended Life Coolant ELC Do not use standard supplemental coolant additive SCA Only use ELC Extender in cooling systems that are filled with ELC Perkins ELC Extender ELC Extender is added to the cooling system halfway through the ELC service life Treat the cooling system with ELC Extender at 6000 hours or three years Use Table 20 in order to determine the correct amount of ELC Extender that is required Containers of several sizes are available Consult your Perkins dealer or your Perkins distributor for the part numbers Use the formula in Table 20 to determine the correct amount of ELC Extender for your cooling system Refer to Operation and Maintenance Manual Refill Capacities in order to determine the capacity of the cooling system Table 20 Formula For Adding ELC Extender To ELC V x 0 0
141. th the throttle lever in the CLOSED position until the engine starts Note If necessary loosen the union nuts 1 on the fuel injection lines at the connection with the fuel injector until fuel is evident Stop cranking the engine Tighten the union nuts 1 to a torque of 30 N m 22 Ib ft 4 Start the engine and run the engine at idle for one minute NOTICE Do not crank the engine continuously for more than 30 seconds Allow the starting motor to cool for two minutes before cranking the engine again 5 Cycle the throttle lever from the low idle position to the high idle position three times The cycle time for the throttle lever is one second to six seconds for one complete cycle Note In order to purge air from the fuel injection pump on Perkins engines with a fixed throttle the engine should be run at full load for thirty seconds The load should then be decreased until the engine is at high idle This should be repeated three times This will assist in removing trapped air from the fuel injection pump 6 Check for leaks in the fuel system 70 Maintenance Section SEBU7833 03 Fuel System Primary Filter Water Separator Element Replace i02206563 Fuel System Primary Filter Water Separator Element Replace 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 separato
142. that no one will be injured by flying debris 101372247 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 and handholds Use two feet and one hand or use one foot and two hands Do not use any controls as handholds Do not stand on components which cannot support your weight Use an adequate ladder or use a work platform Secure the climbing equipment so that the equipment will not move Do not carry tools or supplies when you mount the engine or when you dismount the engine Use a hand line to raise and lower tools or supplies 102813489 Before Starting Engine Before the initial start up of an engine that is new serviced or repaired make provision to shut the engine off in order to stop an overspeed This may be accomplished by shutting off the air and or fuel supply to the engine Overspeed shutdown should occur automatically for engines that are controlled electronically If automatic shutdown does not occur press the emergency stop button in order to cut the fuel and or air to the engine Inspect the engine for potential hazards Bef
143. the cooling system filler cap 3 Start and run the engine at low idle Increase the engine rpm to high idle Run the engine at high idle for one minute in order to purge the air from the cavities of the engine block Stop the engine 4 Check the coolant level Maintain the coolant level within 13 mm 0 5 inch below the bottom of the pipe for filling Maintain the coolant level in the expansion bottle if equipped at the correct level 5 Clean the cooling system filler cap Inspect the gasket that is on the cooling system filler cap If the gasket that is on the cooling system filler cap is damaged discard the old cooling system filler cap and install a new cooling system filler cap If the gasket that is on the cooling system filler cap is not damaged use a suitable pressurizing pump in order to pressure test the cooling system filler cap The correct pressure for the cooling system filler cap is stamped on the face of the cooling system filler cap If the cooling system filler cap does not retain the correct pressure install a new cooling system filler cap 6 Start the engine Inspect the cooling system for leaks and for correct operating temperature Cooling System Coolant Change x QS 8 bet je Illustration 30 Drain plug NOTICE Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant can be discharged No
144. 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 i01909507 Engine Air Cleaner Service Indicator Inspect Some engines may be equipped with a different service indicator Some engines are equipped with a differential gauge for inlet air pressure The differential gauge for inlet air pressure displays the difference in the pressure that is measured before the air cleaner element and the pressure that is measured after the air cleaner element As the air cleaner element becomes dirty the pressure differential rises If your engine is equipped with a different type of service indicator follow the OEM recommendations in order to service the air cleaner service indicator The service indicator may be mounted on the air cleaner element or in a remote location Illustration 36 g00103777 Typical service indicator Observe the service indicator The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur e The yellow diaphragm enters the red zone e The red piston locks in the visible position Test the Service Indicator Service indicators are important instruments Check for ease of resetting The s
145. ting 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 and the starter Protect the fuel injection pump from fluids in order to wash the engine SEBU7833 03 61 Maintenance Section Engine Air Cleaner Element Dual Element Clean Replace i01915869 Engine Air Cleaner Element Dual Element Clean Replace NOTICE Never run the engine without an air cleaner element installed Never run the engine with a damaged air cleaner element Do not use air cleaner elements with damaged p
146. tion and Maintenance Manual Fuel System Prime 102335436 Fuel Tank Water and Sediment Drain NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com ponent containing fluids Dispose of all fluids according to local regulations and mandates Fuel Tank Fuel quality is critical to the performance and to the service life of the engine Water in the fuel can cause excessive wear to the fuel system 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
147. 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 Recommendations for the recommended coolant mixture 34 Operation Section Cold Weather Operation SEBU7833 03 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 r
148. uct damage personal injury or death SEBU7833 03 Table of Contents Table of Contents FOE WONG sau uhaq aan ai r a A 4 Safety Section Safety Messages u uu aaa sssssssaeaess 5 General Hazard Information 6 Burn Prevention u uu en 7 Fire Prevention and Explosion Prevention 8 Crushing Prevention and Cutting Prevention 10 Mounting and Dismounting 10 Before Starting Engine 10 Engine Starting vvess u u u uuu 11 Engine StOPpPING Lu u u u ss 11 Electrical System uu u ion 11 Product Information Section Model Views 13 Product Identification Information 19 Operation Section Lifting ANd Storage u uuu usss 24 Gauges and Indicators 27 Engine SANING eesse 28 Engine Operation u uU L u ninnan 31 Engine Stopping uuu it 32 Cold Weather Operation 33 Maintenance Section Refill Capacities 37 Maintenance Interval Schedule 51 Warranty Section Warranty Information u L L L uuu u oa 79 Index Section 4 Foreword SEBU7833 03 Foreword Literature Information This manual contains safety operatio
149. value for the external system capacity in this row 2 The Total Cooling System includes the capacity for the engine cooling system plus the capacity for the external cooling system Enter the total in this row Table 8 1104 Turbocharged Engine Compartment or System Liters Quarts Engine Only 11 4 12 External cooling System capacity OEM recommendation Total Cooling System 1 The external cooling system includes a radiator or an expansion tank with the following components heat exchanger aftercooler and piping Refer to the OEM specifications Enter the value for the external cooling system capacity in this row 2 The Total Cooling System includes the capacity for the engine cooling system plus the capacity for the external cooling system Enter the total in this row 38 Maintenance Section Refill Capacities SEBU7833 03 1103 Engine Table 9 1103 Naturally Aspirated Engine without an oil cooler Compartment or System Liters Quarts 4 21 4 Engine Only External cooling system capacity OEM recommendation Total Cooling System 1 The external cooling system includes a radiator or an expansion tank with the following components heat exchanger aftercooler and piping Refer to the OEM specifications Enter the value for the external system capacity in this row 2 The Total Cooling System includes the capacity for the engine cooling
150. w 0 C 32 F Do not use Arctic fuels when the ambient temperature is above 0 C 32 F To ensure that the time period between cranking the engine and first fire is kept to a minimum only use fuel of the correct viscosity and at the correct temperature Gas oil to BS2869 Class A2 ASTM D975 91 Class 2D This can only be used if the fuel has the correct specification of lubricity JIS K2204 1992 Grades 1 2 3 and Special Grade 3 This can only be used if the fuel has the correct specification of lubricity Note If low sulfur or low sulfur aromatic fuels are used then fuel additives can be used to increase lubricity Group 2 permissible fuels Specification These fuel specifications are considered acceptable for issues of warranty However these fuels may reduce the life of the engine the engine s maximum power and the engine s fuel efficiency SEBU7833 03 43 Maintenance Section Refill Capacities ASTM D975 91 Class 1D JP7 Mil T38219 NATO F63 NOTICE These fuels should have a wear scar value of 650 micrometers maximum HFRR to ISO 12156 1 Group 3 aviation kerosene fuels Specification These fuels need additives to achieve lubricity of 650 micrometers wear scar and the reliability of the fuel injection pump will be reduced The fuel injection pump is not covered by a warranty even when the additives are included JP5 MIL T5624 Avcat FSII NATO F44
151. y 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 Operate the engine at low idle until all systems achieve operating temperatures Check all gauges during the warm up period Note Gauge readings should be observed and the data should be recorded frequently while the engine is operating Comparing the data over time will help to determine normal readings for each gauge Comparing data over time will also help detect abnormal operating developments Significant changes in the readings should be investigated SEBU7833 03 31 Operation Section Engine Operation Engine Operation i02176671 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 operating temperature sooner during a low engine speed rpm and during a low power demand This procedure is more effective than idling the engine at no load The engine should reach operating temperature in a few minutes Gauge readings should be observed and the data should be recorded frequently while the engine is operating Comparing th

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