Operating Instructions
Contents
1. WARNING LIGHTS OIL PRESS WATER TEMP SOLENOID SWITCH 1 OIL PRESS SWITCH ALTERNATOR 35AMP SWITCH GLOW PLUG O 9 GLOWSIGNAL KEY SWITCH 1 MAX CURRENT DRAW FOR STANDARD OIL PRESSURE SWITCH 15 0 42 amps 5 Watt max bulb TYPICAL WIRING DIAGRAM 103 12 103 13 103 15 104 19 104 22 2 DIODE WATER TEMP OIL PRESS SOLENOID SWITCH 2 DIODE GLOW PLUG 104 19 FOUR PCS GLOWSIGNAL KEY SWITCH 7C BATTERY 7 STARTER MOTOR 2 REMARKS DIODE Capacity Current 3 Reverse voltage 600 LOCATION OF ENGINE PARTS Right hand side view 1 Filler cap for lubricating oil 2 Atomiser 3 Oil pressure switch 4 Position of engine number label 5 Fuel injection pump 6 Mechanical stop control Electrical stop control at rear of pump 7 Throttle lever 8 Coolant drain tap 9 Lubricating oil dipstick 10 Lubricating oil drain plug 11 Lubricating oil filter 12 Fuel lift pump 13 Open engine breather Left hand side view 14 Induction manifold 15 Exhaust manifold 16 Starter motor 17 Alternator 18 Crankshaft pulley 19 Fan mounted on water pump 20 Water temperature switch 21 Water outlet 22 Heater connections PREVENTIVE MAINTENANCE The schedules which follow must be applied at the interval hours or months which occurs first Every Day or every 8 hours First Service 20 50 hours2. SYSTEM NUMBER OF CYLINDERS CUBIC CAPACITY LITRES 041 0451 061 06 089 0 954 1 267 133 1 496 1 995 2 216 CAPACITY INDUSTRIAL OIL SUMP AND FILTER LITRES 2 3 MAXIMUM 1 9 26 8 35 25 sT al 1 65 n 2 2 MINIMUM 13 2 1 23 4i 45 45 4 5 5 1 6 1 TYPICAL LUBRICATING API CC SE OR CD SE VISCOSITY SAE IOW 30 Depending on temperature OIL SPECIFICATION Not recommended during first 50 hours of operation COOLANT SYSTEM CAPACITY engine only LITRES 098 0 1 25 1 25 1 70 1 70 2 50 2 50 2 65 3 3 3 6 COOLANT Cleansoftwater with no more than 50 antifreeze concentration ethanediolbase SPECIFICATION 1 ethylene glycol corrosion inhibitor to BS 6850 1985 or ASTMD 3306 74 or AS 2108 1977 DIESEL FUEL SPECIFICATION Minimum cetane number 45 Aviation fuel JP4 must not be used DIRECTION OF ROTATION Clockwise viewed from the front Water pump end CYLINDER HEAD TORQUES Kgfm Ibf ft 3 5 4 0 25 29 5 0 5 3 36 38 L 9 0 9 5 65 69 4 TAPPET SETTINGS COLD INLET EXHAUST 0 2mm 0 008 inch 1 FOR THOSE LOCATIONS WHERE THERE IS NO RISK OF FREEZING IT IS NOT ESSENTIAL TO USE ANTIFREEZE HOWEVER ANTIFREEZE DOES HAVE USEFUL INHIBITING PROPERTIES FOR FROST PROTECTION DOWN TO 38 C A MAXIMUM CONCENTRATION OF 50 ANTIFREEZE MAY BE USED HOWEVER ANTIFREEZE MIXTURE CAN ELEVATE COOLANT TEMPERATURES THE EFFECT OF WHICH WILL GENERA
3. Every 100 hrs or 3 months Every 200 hrs or 6 months Every 400 hrs or 12 months Every 600 hrs or 18 months Check level of coolant Top up with coolant only Check concentration of coolant Renew coolant FILL SLOWLY ENSURE CORRECT QUANTITY IS USED Check engine lubricating oil level Renew engine lubricating oil FILL SLOWLY ENSURE CORRECT QUANTITY IS USED Renew engine oil filter Drain water from fuel filter and pre filter Renew fuel filter canister N B Air vent screws on filter and fuel pump Check tension of alternator drive belt Check alternator drive belt for wear Renew alternator drive belt Check and adjust idle speed Tighten cylinder head Check and adjust valve clearances Check electrical systems Check all nuts bolts for tightness Check injectors for performance Clean air filter earlier check may be necessary Renew air filter element Check and correct any leaks or engine damage Above operations to be carried out by trained personnel with reference to the workshop manual where necessary These preventive maintenance periods apply to average conditions of operation Check the periods given by the manufacturer of the equipment in which the engine is installed If necessary use shorter periods GENERAL DATA ENGINE 102 04 102 05 103 06 103 07 103 09 103 10 103 12 103 13 103 15 104 19 104 22 ENGINE CODE KA KN KB KL KC KD KG KH KE KF KR COMBUSTION
4. LLY INCREASE AS THE ANTI FREEZE CONCENTRATION INCREASES IT IS THERFORE IMPORTANT THAT THE ORIGINAL RADIATOR SELECTION TAKES ALL INTENDED OPERATING CONDITIONS INTO ACCOUNT 2 With Balancer aa Without Balancer ENGINE TYPE 104 19 04 22 Maximum 7 8 2 Minimum 5 3 6 3 SAFETY PRECAUTIONS These safety precautions are important You must refer also to the local regulations in the couniry of use Do not use these engines in marine applications Do not change the specification of the engine Do not smoke when you put fuel in the tank Clean away fuel which has been spilt Material which has been contaminated by fuel must be moved to a safe place Do not us fuel in the tank while the engine runs unless it is absolutely necessary Do not clean add lubricating oil or adjust the engine while it runs unless you have had the correct training even extreme caution must be used to prevent injury Do not make adjustments that you do not understand Ensure that the engine does not run in a location where it can cause a concentration of toxic emissions Other persons must be kept at a safe distance while the engine or equipment is in operation Do not permit loose clothing or long hair near moving parts Keep away from moving parts during engine operation Attention The fan cannot be seen clearly while the engine runs Do not operate the engine if a safety guard has been removed Do not remove t
5. e of California to cause cancer birth defects and other reproductive harm COOLANT IF A MACHINE WHICH HAS BEEN PREPARED FOR LOW AMBIENT TEMPERTURE 15 MOVED TO A HIGH AMBIENT AREA 20 C THE CONCENTRATION OF ANTIFREEZE SHOULD BE REVIEWED Lowest temperature of protection needed 12 C 10 F 18C 0 25 C 13 F 37 C 34 F 88 Perkins Engines Volume of POWERPART antifreeze 25 33 40 50 Mixture ratio by volume POWERPART antifreeze water UE 5 1 1 1 Perkins Engines Limited Peterborough PE1 5NA England 100816243 0695
6. erkins Operating Instructions PLEASE READ THIS DOCUMENT CAREFULLY BEFORE STARTING THE ENGINE STARTING THE ENGINE Move throttle lever to full speed position Turn key anticlockwise to HEAT and hold itthere for 20to 30 seconds maximum 60 seconds until the glow signal starts glowing red With the signal glowing red turn the key clockwise all the way to START and crank the engine maximum 20 seconds When the engine fires release the key which will spring back to ON Turn throttle lever down slowly to allow the engine to idle of N Note Ifthe glow signal fails to glow in 20 to 30 seconds or glows rapidly 2 to 3 seconds this indicates a malfunction of the cold start system A Ether or other starting fluids must not be used with these engines TYPICAL WIRING DIAGRAM 102 04 102 05 103 06 103 07 103 09 103 10 eni Bak 2 DIODE WARNING LIGHTS gin S OIL PRESS WATER TEMP Ss SOLENOID SWITCH ki GLOW PLUG o oN OIL PRESS ON THERMO 102 04 TWO PCS SWITCH SWITCH e B ALTERNATOR 15AMP E 6 Ot FUSIBLE LINK OR CIRCUIT BREAKER 5 GLOWSIGNAL 12V KEY SWITCH BATTERY STARTER MOTOR MAX CURRENT DRAW FOR STANDARD OIL PRESSURE SWITCH 15 0 42amps 5WaET max bulb Lr DIODE Capacity Current 3 Reverse Voltage 600V TYPICAL WIRING DIAGRAMS TYPICAL WIRING DIAGRAM 103 09 10 2 DIODE
7. he fill r cap of the cooling system while the engine is hot and while the coolant is under pressure because dangerous hot coolant can be discharged Do not use salt water or any other coolant which can cause corrosion in the cooling system Do not allow sparks or fire near the batteries especially when the batteries are on charge because the gases from the electrolyte are highly flammable The battery fluid is dangerous to the skin and especially to the eyes Disconnect the battery terminals before a repair is made to the electrical system Only one person must control the engine Ensure that the engine is operated only from the control panel or from the operator s position If your skin comes into contact with high pressure fuel obtain medical assistance immediately Diesel fuel and used engine oils can damage the skin of certain persons Protect your hands with gloves or a special solution to protect the skin Do not move mobile equipment if the brakes are not in good condition Ensure that the control lever of the transmission drive is in the out of drive position before the engine is started Fit only genuine Perkins parts Do not use ether or other starting fluids to start these engines Do noi use more than 50 antifreeze concentration by volume at high ambients otherwise engine damage will result CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the Stat
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