Perkins Engine 1103D Service Manual

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Page 1

Operation and Maintenance Manual

SEBU8352

January 2008

1103D Industrial Engine

(Engine)

XK XL

(Engine)

Page 2

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product 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 premature failures, product damage, personal injury or

death.

Page 3

SEBU8352 3

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Messages .................................................... 5

General Hazard Information ................................... 6

Burn Prevention ...................................................... 8

Fire Prevention and Explosion Prevention .............. 8

Crushing Prevention and Cutting Prevention ........ 10

Mounting and Dismounting ................................... 10

Before Starting Engine .......................................... 10

Engine Starting ...................................................... 11

Engine Stopping .................................................... 11

Electrical System ................................................... 11

Index Section

Index ..................................................................... 73

Product Information Section

Model Views ......................................................... 13

Product Identiﬁcation Information ........................ 16

Operation Section

Lifting and Storage ................................................ 19

Gauges and Indicators .............................. ............ 22

Features and Controls .......................................... 23

Engine Starting ..................................................... 24

Engine Operation .................................................. 27

Engine Stopping ................................................... 28

Cold Weather Operation ....................................... 29

Maintenance Section

Reﬁll Capacities .................................................... 33

Maintenance Interval Schedule ............................ 46

Warranty Section

Warranty Information ............................................ 72

Page 4

4 SEBU8352 Foreword

Foreword

Literature Information

This manual con lubrication and maintenance information. This manual should be stored in or near the engine area in a literatur 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 consiste

Some photographs or illustrations in this manual show details from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvemen may have caused changes to your engine which are not included in this manual. Whenever a question arises reg 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 si precautions listed in the safety section before operating or performing lubrication, maintenance and repair on

this product.

tains safety, operation instructions,

e holder or literature storage area. Read,

ncy.

or attachments that may be different

t and advancement of product design

arding your engine, or this manual, please

tuations. Read and understand the basic

Recommended se appropriate intervals as indicated in the Maintenance Interval Schedule. The actual operating environment of the engine a Schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequen speciﬁed in the Maintenance Interval Schedule may be necessary.

The maintenance schedule items are organized for a preventive maintenance management program. If the prevent periodic tune-up is not required. The implementation of a preventive maintenance management program should mini avoidances resulting from reductions in unscheduled downtime and failures.

ive maintenance program is followed, a

mize operating costs through cost

rvice should be performed at the

lso governs the Maintenance Interval

t lubrication and maintenance than is

Maintenance Intervals

Perform maintenance on items at multiples of the original requirement. We recommend that the maintenan near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of

Your authorized Perkins dealer or your Perkins distribu maintenance schedule to meet the needs of your operating environment.

ce schedules be reproduced and displayed

the engine’s permanent record.

tor can assist you in adjusting your

Overhaul

Operatio

Operating techniques outlined in this manual are basic. Th techniques required to operate the engine more efﬁciently and economically. Skill and techniques develop engine and its capabilities.

The oper Photographs and illustrations guide the operator through procedures of inspecting, starting, operating and sto discussion of electronic diagnostic information.

ey assist with developing the skills and

as the operator gains knowledge of the

ation section is a reference for operators.

pping the engine. This section also includes a

Maintenance

The mai The illustrated, step-by-step instructions are grouped by service hours and/or calendar time maintenance interv referenced to detailed instructions that follow.

ntenance section is a guide to engine care.

als. Items in the maintenance schedule are

Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the i interval. Major repairs should only be carried out by Perkins authorized personnel. Your Perkins dealer or your P regarding overhaul programs. If you experience a major engine failure, there are also numerous after f your Perkins dealer or your Perkins distributor for information regarding these options.

nterval and the maintenance items in that

erkins distributor offers a variety of options

ailure overhaul options available. Consult with

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer,

defects, and other reproductive harm. Battery

birth posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Page 5

SEBU8352 5

Safety Section

Safety Messages

Safety Section

i02811420

Safety Messages

There may be s engine. The exact location and a description of the warning signs are reviewed in this section. Please become famil

Ensure that all of the warning signs are legible. Clean the warning s the words cannot be read or if the illustrations are not visible. Use a cloth, water, and soap to clean the warning other harsh chemicals. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the warning si could drop off of the engine.

Replace an missing.Ifawarningsignisattachedtoapartofthe engine that is replaced, install a new warning sign on the replac distributor can provide new warning signs.

everal speciﬁc warning signs on your

iar with all warning signs.

igns or replace the warning signs if

signs. Do not use solvents, gasoline, or

gns. The warning signs that are loosened

y warning sign that is damaged or

ement part. Your Perkins dealer or your

(1) Un iversal Warning

Do not operate or work on this equipment unless you have r and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the or death.

ead and understand the instructions

warnings could result in serious injury

Illustration 1

lexample

Typica

The Universal Warning label (2) is located on the rear end of t

he inlet manifold cover. Refer to illustration 2.

g01154807

Page 6

6 SEBU8352 Safety Section General Hazard Information

Illustration 2

(1) Ether

Warning Label

(2) Unive

rsal warning

(2) Ether

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and

ration 3

l injury.

g01154809

persona

Illust

Typical example

g01431463

i0232843

General Hazard Information

Illustration 4

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.

g00104

545

The ether warning label (1) is located on the front end of the inlet manifold cover. Refer to illustration 2.

Page 7

SEBU8352 7

Safety Section

General Hazard Information

Illustration 5

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.

g00702020

When pressuriz cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protectiv

The maximum air pressure for cleaning purposes must be below water pressure for cleaning purposes must be below 275 kPa (40 psi).

ed air and/or water is used for

efaceshield.

205 kPa (30 psi). The maximum

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydrau escape rapidly if the pressure is not relieved correctly.

Do not remove until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or personal injury may occur. Refer to the OEM information for any procedures that are required to relieve th

lic ﬂuid or items such as pipe plugs to

any hydraulic components or parts

or parts until pressure has been relieved

e hydraulic pressure.

Never put maintenance ﬂuids into glass containers. Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Report all necessary repairs.

Do not allow unauthorized personnel on the equipment.

Ensure that the power supply is disconnected before you work on the bus bar or the glow plugs.

Perform maintenance on the engine with the equipment in the servicing position. Refer to the OEM information for the procedure for placing the equipment in the servicing position.

Pressure Air and Water

Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury.

The direct application of pressurized air or pressurized water to the body could result in personal injury.

Illustration 6

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.

g00687600

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.

Only use the tools that are suitable for collecting

•

ﬂuids and equipment that is suitable for collecting ﬂuids.

Page 8

8 SEBU8352 Safety Section Burn Prevention

Only use the too

•

ﬂuids and equipment that is suitable for containing ﬂuids.

Obey all local regulations for the disposal of liquids.

ls that are suitable for containing

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 the lubrication system, in the fuel system, or in the cooling system before any lines, ﬁttings or related items are disconnected.

Coolant

When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained.

Check the coolant level after the engine has stopped and the engine has been allowed to cool.

i02813488

Fire Prevention and Explosion Prevention

on 7

Illustrati

All fuels, most lubricants, and some coolant mixtures are ﬂammabl

Flammable ﬂuids that are leaking or spilled onto hot surfaces or 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 emergen

onto electrical components can cause

cy shutdown.

g00704000

Ensure that the ﬁller cap is cool before removing the ﬁller cap. The ﬁller cap must be cool enough to touch withabarehand.Removetheﬁller 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.

Determinewhethertheenginewillbeoperatedinan environme drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, property

If the application involves the presence of combustible gases, co 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 engi materials or conductive materials to accumulate on the engine.

Store fuels and lubricants in correctly marked containers away from unauthorized persons. Store oily rag containers. Do not smoke in areas that are used for storing ﬂammable materials.

Do not expose the engine to any ﬂame.

nt that allows combustible gases to be

damage, or engine damage could result.

nsult your Perkins dealer and/or your

ne. Do not allow any ﬂammable combustible

s and any ﬂammable materials in protective

Page 9

SEBU8352 9

Safety Section

Fire Prevention and Explosion Prevention

Exhaust shield

s (if equipped) protect hot exhaust components from oil or fuel spray in case of a line, a tube, or a seal failure. Exhaust shields must be installed cor

rectly.

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 ﬂ a

me 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. Cle

an all electrical connections and tighten

all electrical connections.

Eliminate a

ll 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 cir

cuit breakers.

Arcing or sparking could cause a ﬁre. Secure connectio

ns, 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.

Use caution whe

n you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open ﬂames or sparks. Always stop the engin

Illustration 9

e before refueling.

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 ahydrometer.

Incorrect jumper cable connections can cause an explosion that can result in injury. Refer to the Operation Section of this manual for speciﬁc instructions.

Illustration 8

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.

g00704059

Page 10

10 SEBU8352 Safety Section Crushing Prevention and Cutting Prevention

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not install any lines that are bent or damaged. Do not clip any other items to the high pressure line

Repair any lines that are loose or damaged. Leaks can cause ﬁre Perkins distributor for repair or for replacement parts.

Check lines, your bare hand to check for leaks. Use a board or cardboard to check for leaks. Tighten all connections to the recomm

Replace the parts if any of the following conditions are present:

End ﬁttings are damaged or leaking.

•

Outer coverings are chafed or cut.

•

Wires are ex

•

Outer coverings are ballooning.

•

pressure lines. Do not strike high

s. Consult your Perkins dealer or your

tubes and hoses carefully. Do not use

ended torque.

posed.

When objects ar order to avoid injury to the eyes.

Chips or other are struck. Before objects are struck, ensure that no one will be injured by ﬂying debris.

e struck, wear protective glasses in

debris may ﬂy off objects when objects

i01372247

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.

Flexible part of the hoses are kinked.

•

Outer cover

•

End ﬁttings are displaced.

•

Make sure that all clamps, guards, and heat shields are installed correctly. During engine operation, this will help to parts, and excessive heat.

Crushing P

s have embedded armoring.

prevent vibration, rubbing against other

i02143194

revention and

Cutting Prevention

Support the component correctly when work beneath the compon

Unless other maintenance instructions are provided, never att running.

Stay clea parts. Leave the guards in place until maintenance is performed. After the maintenance is performed, reinstal

Keep objects away from moving fan blades. The fan blades w

ent is performed.

empt adjustments while the engine is

r of all rotating parts and of all moving

l the guards.

ill throw objects or cut objects.

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.

i02813489

Before Starting Engine

Before the initial start-up of an engine that is new, serviced or repaired, make provision to shut the engine off, in order to stop an overspeed. This may be accomplished by shutting off the air and/or fuel supply to the engine.

Overspeed shutdown should occur automatically for engines that are controlled electronically. If automatic shutdown does not occur, press the emergency stop button in order to cut the fuel and/or air to the engine.

Inspect the engine for potential hazards.

Before starting the engine, ensure that no one is on, underneath, or close to the engine. Ensure that the area is free of personnel.

Page 11

SEBU8352 11

Safety Section

Engine Starting

If equipped, en 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 se accident that is caused by parts in rotation, work around the parts carefully.

Do not bypass the automatic shutoff circuits. Do not disable the automatic shutoff circuits. The circuits are provided in o circuits are also provided in order to help prevent engine damage.

See the Service Manual for repairs and for adjustments.

sure that the lighting system for the

rvice procedures. To help prevent an

rder to help prevent personal injury. The

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.

Engine exhaust which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the en vent the engine exhaust to the outside.

Note: The eng device for cold starting for normal conditions of operation. If the engine will be operated in very cold conditions, 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 aidineachi air in order to improve starting.

contains products of combustion

gine is started in an enclosed area,

ine is equipped with an automatic

then an extra cold starting aid may be

ndividual cylinder that heats the intake

i01928905

Engine Stopping

Stop the engine according to the procedure in the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating of the engine and accelerated wear of the engine components.

Use the Emergency Stop Button (if equipped) ONLY in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency stop, DO NOT start the engine until the problem that caused the emergency stop has been corrected.

All protective guards and all protective covers must be installed if the engine must be started in order to perform service procedures. To help prevent an accident that is caused by parts in rotation, work around the parts carefully.

Start the engine from the operator’s compartment or from the engine start switch.

Always start the engine according to the procedure that is described in the Operation and Maintenance Manual, “Engine Starting” topic in the Operation Section. Knowing the correct procedure will help to 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.

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

Electr

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is oper gases that are produced by some batteries to ignite.

To help gases that are produced by some batteries, the negative “−” jump start cable should be connected last f “−” terminal of the starting motor. If the starting motor is not equipped with a negative “−” terminal, connect the ju

ical System

ating. A spark can cause the combustible

prevent sparks from igniting combustible

rom the external power source to the negative

mp start cable to the engine block.

Page 12

12 SEBU8352 Safety Section Electrical System

Check the elect loose or frayed. Tighten all loose electrical wires before the engine is started. Repair all frayed electrical wi the Operation and Maintenance Manual for speciﬁc starting instructions.

rical wires daily for wires that are

res before the engine is started. See

Grounding Practices

Correct grounding for the engine electrical system is necessary for optimum engine performance and reliabil 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 sur

Engines that are installed without engine-to-frame ground stra discharge.

To e ns u re t systems function correctly, an engine-to-frame ground strap with a direct path to the battery must be used. This engine ground to the frame.

ity. Incorrect grounding will result in

faces, and to aluminum components.

ps can be damaged by electrical

hat the engine and the engine electrical

path may be provided by way of a direct

All ground engine alternator must be grounded to the negative “-” battery terminal with a wire that is adequate to handle th

s should be tight and free of corrosion. The

e full charging current of the alternator.

Page 13

SEBU8352 13

Product Information Section

Model Views

Product Information Section

Model Views

i02869409

Model View Illustrations

1103D Engine Model Views

Illustration 10

Typical example

(1) Front lifting eye (2) Water temperature regulator housing

(horizontal outlet)

(3) Fuel priming pump

(4) Fuel ﬁlter (5) B reather tube (6) Water pump (7) S tarting motor

g01439632

(8) Oil ﬁlter (horizontal installation) (9) Cran kshaft pulley (10) Oil pan

Page 14

14 SEBU8352 Product Information Section Model Views

Illustration 11

Typical example

(11) Inlet manifold adapter (12) Top cover (13) Exhaust manifold

(14) Turbocharger (if equipped) (15) Turbocharger oil supply (if equipped) (16) Turbocharger oil return (if equipped)

i02813494

Engine Description

Perkins Engines are designed for the following applications: machine and industrial mobile equipment. The engines are available in the following types of aspiration:

Turbocharged aftercooled

•

Turbocharged

•

Naturally aspirated

•

g01434352

(17) Rear lifting eye (18) F lywheel housing (19) Flywheel

Engine Speciﬁcations

Note: The front end of the engine is opposite the

ﬂywheel end of the engine. The left and the right sides of the engine are determined from the ﬂywheel end. The number 1 cylinder is the front cylinder.

Page 15

SEBU8352 15

Product Information Section

Model Views

Illustration 12

A typical example of the layout of the valves

(A) Inlet valv es (B) Exhaust v alves

Table 1

1103D Industrial Engine Speciﬁcations

Number of Cylinders

Bore

Stroke 127 mm (5.0 inch)

Aspiration Turbocharged

Compression Ratio

Displacement 3.3 L (201 in3)

Firing Order

Rotation (ﬂywheel end) Counterclockwise

Valve Lash Setting (Inlet) 0.20 mm (0.008 inch)

Valve Lash Setting (Exhaust)

3 In-Line

105 mm (4.134 inch)

Naturally aspirated

NA 19.25:1

T 18.25:1

123

0.45 mm (0.018 inch)

g01222531

The engine lubr

icating oil is supplied to the engine by a gear-driven pump. The engine lubricating oil is cooled and the engine lubricating oil is ﬁltered. Bypass valves

provide unrestricted ﬂow of lubrication oil to the engine parts when oil viscosity is high. Bypass valves can also provide unrestricted ﬂow of lubricati

on 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 a

nd maintenance recommendations. Engine performance and efﬁciency also depend on the use of recommended fuels, lubrication oils, and coolants. R

efer 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 addition, use recommended fuels, coolants and lubricants. Use the Operation and Maintenance Manual as

Expected engine life is generally predicted by the average p that is demanded is based on fuel consumption of the engine over a period of time. Reduced hours of operatio throttle settings result in a lower average power demand. Reduced hours of operation will increase the leng overhaul is required.

and maintenance recommendations. In

a guide for required engine maintenance.

ower that is demanded. The average power

n at full throttle and/or operating at reduced

th of operating time before an engine

Engine Cooling and Lubrication

The cooling system consists of the following components:

Gear-driven centrifugal water pump

•

Water temperature regulator which regulates the

•

engine coolant temperature

Gear-driven oil pump (gear type)

•

Oil cooler

•

Page 16

16 SEBU8352 Product Information Section Product Identiﬁcation Information

Product Identiﬁcation Information

i02813999

Engine Identiﬁcation

Perkins engines are identiﬁed by a serial number. This number is shown on a serial number plate that is mounted on the left hand side of the engine block.

An example of an engine number is XK12345U090001P.

__________________________________________ Type of engine

XK12345

____________________________ Built in the United Kingdom

090001

_____________________________________ Year of Manufacture

____________________________ Engine List Number

___________________________ Engine Serial Number

Perkins distributors need these numbers in order to determine the components that were included with the engine. This permits accurate identiﬁcation of replacement part numbers.

i02875212

Serial Number Plate

The Serial Number Plate is located on the upper left side of the engine block above the fuel injection pump.

Illustration 13

Location of serial number plate

Illustration 14

Typical serial number plate

(1) Temporary Parts List number (2) List numb er (3) Serial number (4) Type

g01431025

g01431032

The following information is stamped on the Serial Number Plate: Engine serial number, Model, and Arrangement number.

Page 17

SEBU8352 17

Product Information Section

Product Identiﬁcation Information

i02164876

Reference Numbers

S/N: XK11-Up

S/N: XL11-Up

Information for the following items may be needed to order parts. Locate the information for your engine. Record the inf Make a copy of this list for a record. Keep the information for future reference.

Record for Reference

Engine Model _______________________________________________

ormation in the appropriate space.

Engine Serial

number

_____________________________________

Engine Low Idle rpm ______ ________________________________

Engine Full Load rpm _____________________________________

_________________________________________

Primary Fuel

Filter

Water Separator Element ________________________________

Secondary Fuel Filter Element __________________________

Lubrication

Oil Filter Element

___________________________

Auxiliary Oil Filter Element _______________________________

Total Lubrication System Capacity _____________________

Total Coolin

g System Capacity

_________________________

Air Cleaner Element _______________________________________

Fan Drive Belt _ _____________________________________________

______________________________________________

Alternator B

elt

Page 18

18 SEBU8352 Product Information Section Product Identiﬁcation Information

i02869408

Emissions Certiﬁcation Film

Illustration 15

Typical example

g01350379

Page 19

SEBU8352 19

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

i02677363

Product Lifting

Illustration 16

NOTICE Never bend the eyebolts and the brackets. Only load the eyebolts and the brackets under tension. Remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes 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.

g00103219

i02677364

Product Storage

Table 2

Required Tools

Part

Tool

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.

Number Part Descript

1772204

1762811

1734115

POWERPART Lay-Up 1

POWERPART Lay-Up 2

POWERPART Lay-Up 3

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 :

ion

Qty

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 proper balance and safety.

ToremovetheengineONLY,usetheliftingeyesthat are on the engine.

Lifting eyes are designed and installed for speciﬁc engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting ﬁxtures obsolete. If alterations are made, ensure that proper lifting devices are provided. Consult your Perkins dealer for information regarding ﬁxtures for proper engine lifting.

Completely clean the outside of the engine.

•

Drain the fuel system completely and reﬁll the

•

system with preservative fuel. Tooling (A) can be mixed with the normal fuel in order to change the fuel into preservative fuel.

If preservative fuel is not available, the fuel system

•

can be ﬁlled with normal fuel. This fuel must be discarded at the end of the storage period together with the fuel ﬁlter elements.

Operate the engine until the engine reaches normal

•

operating temperature. Stop any leaks from fuel, lubricating oil or air systems. Stop the engine and drain the lubricating oil from the oil pan.

Renew the canister(s) of the lubricating oil ﬁlter.

•

Page 20

20 SEBU8352 Operation Section Lifting and Storage

Fill the oil pan

•

new, clean lubricating oil. Add Tooling (B) to the oil in order to protect the engine against corrosion. If Tooling (B) is the correct speciﬁcation instead of the lubricating oil. If a preservative is used, this must be drained completely a theoilpanmustbereﬁlled to the correct level with normal lubricating oil.

to the Full Mark on the dipstick with

not available, use a preservative of

t the end of the storage period and

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

If freezing temperatures are expected, check the cooling sys freezing. See this Operation and Maintenance Manual, “General Coolant Information” (Maintenance Section).

To prevent frost damage, ensure that all the coolant is removed fro tem is drained after it has been ﬂushed with water, or if an antifreeze solution too weak to protect the system from frost

be discharged.

tem for adequate protection against

NOTICE

m the engine. This is important if the sys-

has been used.

3. Remove the drai 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 radiat disconnect the hose at the bottom of the radiator.

5. Flush the coo

6. Fit the drain plugs and the ﬁller cap. Close the tap

or connect th

7. Fill the cooling system with an approved antifreeze mixture beca corrosion.

Note: Certai 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 battery is put into storage, protect the terminals against corrosion. Tooling (C) can be used on the terminals

10. Clean the crankcase breather if one is installed. Seal the en

n corrosion inhibitors could cause

nplug(1)fromthesideofthe

or does not have a tap or a drain plug,

ling system with clean water.

e radiator hose.

use this gives protection against

fully charged condition. Before the

d of the pipe.

Illustration 17

1. Ensure that the vehicle is on level ground.

2. Remove the ﬁller cap of the cooling system.

g01356026

11. Remove the fuel injector nozzles and spray To o li ng ( cylinder bore with the piston at BDC.

12. Slowly ro revolution and then replace the fuel injector nozzles.

B) for one or two seconds into each

tate the crankshaft for one complete

Induction System

Remove the air ﬁlter assembly. If necessary,

•

remove the pipes that are installed between the air ﬁlter ass (B) into the turbocharger. The duration of the spray is printed on the container. Seal the turbocharger with wat

Exhaust

Remove the exhaust pipe. Spray Tooling (B) into

•

the turb printed on the container. Seal the turbocharger with waterproof tape.

embly and the turbocharger. Spray Tooling

erproof tape.

System

ocharger. The duration of the spray is

Page 21

SEBU8352 21

Operation Section

Lifting and Storage

General Items

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 Tooling (B) around the rocker shaft assembly. Replace the ﬁller cap or the rocker cover.

Seal the vent of the fuel tank or the fuel ﬁller cap

•

with waterproof tape.

Remove the alternator drive belts and put the drive

•

belts into storage.

In order to prevent corrosion, spray the engine

•

with Tooling (C). Do not spray the area inside the alternator.

When the engine protection has been completed in accordance with these instructions, this ensures that no corrosion will occur. Perkins are not responsible for damage which may occur when an engine is in storage after a period in service.

Your Perkins dealer or your Perkins distributor can assist in preparing the engine for extended storage periods.

Page 22

22 SEBU8352 Operation Section Gauges and Indicators

Gauges and Ind icators

i02164190

Gauges and Indicators

Your engine m 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 th the gauges over a period of time.

Noticeable c potential gauge or engine problems. Problems may also be indicated by gauge readings that change even if the r Determine and correct the cause of any signiﬁcant change in the readings. Consult your Perkins dealer or your Per

If no oil pressure is indicated, STOP the engine. If maximum co the engine. Engine damage can result.

SAE10W30 rpm.

ay not have the same gauges or all of

e normal operating range by observing

hanges in gauge readings indicate

eadings are within speciﬁcations.

kins distributor for assistance.

NOTICE

olant temperature is exceeded, STOP

Engine Oil

should be greatest after a cold engine is started. The typical engine oil pressure with

is 207 to 413 kPa (30 to 60 psi) at rated

Pressure – The oil pressure

1. Reduce the load

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 l

Tachometer – This gauge indicates engine speed (rpm). W

ismovedtothefullthrottlepositionwithout load, the engine is running at high idle. The engine is running at th lever is at the full throttle position with maximum rated load.

To help prevent engine damage, never exceed the high 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 allowedtoexceedhighidlerpm.

indicator should be to the right side of “0” (zero).

is in the “ON” position.

efullloadrpmwhenthethrottlecontrol

Ammeter – This gauge indicates the

amount of charge or discharge in the

battery charging circuit. Operation of the

Fuel Level – This gauge indicates the fuel

level in the fuel tank. The fuel level gauge

operates when the “START/STOP” switch

Service Hour Meter – The gauge indicates

operating time of the engine.

and the engine rpm.

oad.

hen the throttle control lever

NOTICE

A lower oil pressure is normal at low idle. If the load is stable the following procedure:

1. Remove th

2. Reduce engine speed to low idle.

3. Check and maintain the oil level.

tempera 48 kPa (7 psi) is 110°C (230°F). Higher temperatures may occur under certain conditions. The water tempera reading should never exceed the boiling point for the pressurized system that is being used.

If the en and steam becomes apparent, perform the following procedure:

and the gauge reading changes, perform

e load.

Jacket Wa

Typical temperature range is 71 to 96°C (160 to 205°F). The maximum allowable

ture with the pressurized cooling system at

ture reading may vary according to load. The

gine is operating above the normal range

ter Coolant Temperature –

Page 23

SEBU8352 23

Operation Section

Features and Controls

i02690464

Fuel Shutoff

The fuel shutoff solenoid is located on the fuel injection pump.

When the fuel shutoff solenoid is activated, the solenoid moves to the “Open” position.

When the fuel shutoff solenoid is deactivated, the solenoid moves to the “Closed” position.

Page 24

24 SEBU8352 Operation Section Engine Starting

Engine Starting

i02675151

Before Starting Engine

Before the en daily maintenance and any other periodic maintenance that is due. Refer to the Operation and Maintena Schedule” for more information.

For the maxim

•

thorough inspection within the engine compartment before the engine is started. Look for the following items: oil l excessive dirt and/or grease. Remove any excess dirt and/or grease buildup. Repair any faults that were ident

Inspect the cooling system hoses for cracks and

•

for loose c

Inspect the alternator and accessory drive belts for

•

cracks, br

Inspect the wiring for loose connections and for

•

worn wires

Check the fuel supply. Drain water from the water

•

separator (if equipped).

All valve and during engine operation to help prevent high fuel pressure. High fuel pressure may cause ﬁlter housing failure o

gine is started, perform the required

nce Manual, “Maintenance Interval

um service life of the engine, make a

eaks, coolant leaks, loose bolts, and

iﬁed during the inspection.

lamps.

eaks, and other damage.

or frayed wires.

(if equipped). Open the fuel supply valve

NOTICE

s in the fuel return line must be open before

r other damage.

Do not start the

•

if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or to the control

Ensure that the areas around the rotating parts are

•

clear.

All of the guards must be put in place. Check for

•

damaged guar any damaged guards. Replace damaged guards and/or missing guards.

Disconnect any battery chargers that are not

•

protected against the high current drain that is created wh 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 “MIN” mark and the “MAX” mark on the

Check the coolant level. Observe the coolant level

•

in the head 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 bott 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 diaphrag piston locks in the visible position.

m enters the red zone, or when the red

engine or move any of the controls

ds or for missing guards. Repair

en the electric starting motor is

engine oil level gauge.

er tank (if equipped). Maintain the

om of the ﬁller pipe. If the engine is

If the engine has not been started for several weeks, fuel may h may have entered the ﬁlter housing. Also, when fuel ﬁlters have been changed, some air pockets will be trapped fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information on primi

Engine exhaust contains products of combustion which may be harmful to your health. Always start and ope and, if in an enclosed area, vent the exhaust to the outside.

ave drained from the fuel system. Air

in the engine. In these instances, prime the

ng the fuel system.

rate the engine in a well ventila ted area

Ensure t

•

engine has been disengaged from the engine. Minimize electrical loads or remove any electrical loads.

hat any equipment that is driven by the

Page 25

SEBU8352 25

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 position before you start the engine.

NOTICE Do not crank the engine for more than 30 seconds. Allow the electric starting motor to cool for two minutes before cranking the engine again.

2. Turn the engine start switch to the START position.

Hold the engine start switch in the START position and crank the engine.

3. When the engine starts, release the engine start

switch.

4. If equipped, slowly move the throttle lever to the

low idle position and allow the engine to idle. Refer to the Operation and Maintenance Manual, “After Starting Engine” topic.

When Group 2 die provide a means of minimizing starting problems and fuel problems in cold weather: engine oil pan heaters, jack line insulation.

Use the proce starting.

1. If equipped, throttle position before you start the engine.

2. If equipped, HEAT position. Hold the engine start switch in the HEAT position for 6 seconds until the glow plug indicator li glow plugs and aid in the starting of the engine.

Do not crank t 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 th

Note: If the glow plug indicator light illuminates rapidly for light fails to illuminate, a malfunction exists in the cold start system. Do not use ether or other starting ﬂuids to start th

4. When the engine starts, release the engine start switch key

2 to 3 seconds, or if the glow plug indicator

e engine.

sel fuel is used, the following items

et water heaters, fuel heaters, and fuel

dure that follows for cold weather

move the throttle lever to the full

turn the engine start switch to the

ght illuminates. This will activate the

NOTICE

he engine for more than 30 seconds.

e engine.

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.

i02198092

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.

5. If the engine does not start, release the engine start swi Then, repeat steps 2 through step 4.

6. If the eng enginetoidleforthreetoﬁve minutes, or allow the engine to idle until the water temperature indicator begins to smoothly until speed is gradually increased to high idle. Allow the white smoke to disperse before proceed

7. Operate the engine at low load until all systems reach op during the warm-up period.

8. Turn the order to stop the engine.

tch and allow the starter motor to cool.

ine is equipped with a throttle allow the

rise. The engine should run at low idle

ing with normal operation.

erating temperature. Check the gauges

engine start switch to the OFF position in

Page 26

26 SEBU8352 Operation Section Engine Starting

i02177935

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 e xplode. 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.

3. Connect one neg to the negative cable terminal of the electrical source. Connect the other negative end of the jump start cab chassis ground. This procedure helps to prevent potential sparks from igniting the combustible gases that ar

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 batterie correct voltage with a battery charger after the engine is stopped. Many batteries which are considered unusable ar and Maintenance Manual, “Battery - Replace” and Testing and Adjusting Manual, “Battery - Test”.

s must be replaced or charged to the

e still rechargeable. Refer to Operation

ative end of the jump start cable

le to the engine block or to the

e produced by some batteries.

i01903609

After Starting Engine

NOTICE Using a battery source with the same voltage as the electric st 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, tu “OFF” position. Turn all electrical accessories OFF before attaching the jump start cables.

Ensure that the main power switch is in the OFF position before attaching the jump start cables to the engine bein

1. Turn the start switch to the OFF position. Turn off

all the en

2. Connect one positive end of the jump start cable

to the pos battery. Connect the other positive end of the jump start cable to the positive cable terminal of the electri

arting motor. Use ONLY equal voltage for

rn the generator set control switch to the

g started.

gine’s accessories.

itive cable terminal of the discharged

cal source.

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:

Check for any ﬂuid or for any air leaks at idle rpm

•

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.

Page 27

SEBU8352 27

Operation Section

Engine Operation

i02176671

Engine Operation

Correct oper in obtaining the maximum life and economy of the engine. If the directions in the Operation and Maintenance minimized and engine service life can be maximized.

The engine ca engine reaches operating temperature. The engine will reach normal operating temperature sooner during a low power demand. This procedure is more effective than idling the engine at no load. The engine should reach operating

Gauge readings should be observed and the data should be r is operating. Comparing the data over time will help to determine normal readings for each gauge. Comparing abnormal operating developments. Signiﬁcant changes in the readings should be investigated.

ation and maintenance are key factors

Manual are followed, costs can be

n be operated at the rated rpm after the

engine speed (rpm) and during a low

temperature in a few minutes.

ecorded frequently while the engine

data over time will also help detect

i02330149

Fuel Conservation Practices

The efﬁciency o economy. Perkins design and technology in manufacturing provides maximum fuel efﬁciency in all applicati in order to attain optimum performance for the life of the engine.

Avoid spilling fuel.

•

Fuel expands may overﬂow from the fuel tank. Inspect fuel lines for leaks. Repair the fuel lines, as needed.

Be aware of the properties of the different fuels.

•

Use only the recommended fuels.

Avoid unnecessary idling.

•

Shut off the time.

Observe the

•

Keep the air cleaner elements clean.

Maintain th

•

f the engine can affect the fuel

ons. Follow the recommended procedures

when the fuel is warmed up. The fuel

engine rather than idle for long periods of

air cleaner service indicator frequently.

e electrical systems.

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. Chec k for

ﬂuidleaksandairleaks.Theenginemaybe operated at full rated rpm and at full load when the temperature of the water jacket reaches 60°C (140°F).

One damaged battery cell will overwork the alternator. This will co

Ensure that the drive belts are correctly adjusted.

•

The drive be

Ensure that all of the connections of the hoses are

•

tight. The

Ensure that the driven equipment is in good

•

working or

Cold engines consume excess fuel. Utilize heat

•

from the ja system, when possible. Keep cooling system components clean and keep cooling system component engine without water temperature regulators. All of these items will help maintain operating temperat

nsume excess power and excess fuel.

lts should be in good condition.

connections should not leak.

der.

cket water system and the exhaust

s in good repair. Never operate the

ures.

Page 28

28 SEBU8352 Operation Section Engine Stopping

Engine Stopping

i01929389

Stopping the Engine

NOTICE Stopping the engine immediately after it has been working under load can result in overheating and accelerated 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 turbocharger shaft and bearing life.

Prior to stopping an engine that is being operated at low loads, operate the engine at low idle for 30 seconds before stopping. If the engine has been operating at highway speeds and/or at high loads, operate the engine at low idle for at least three minutes. This procedure will cause the internal engine temperature to be reduced and stabilized.

Ensure that the engine stopping procedure is understood. Stop the engine according to the shutoff system on the engine or refer to the instructions that are provided by the OEM.

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.

i02818879

After Stopping Engine

Note: Before yo

the engine for at least 10 minutes in order to allow the engine oil to return to the oil pan.

Check the crankcase oil level. Maintain the oil level

•

between the “ADD” mark and the “FULL” mark on the oil level d

If necessary, perform minor adjustments. Repair

•

any leaks and

Note the required service interval. Perform

•

the maintena 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 tan

Only use antifreeze/coolant mixtures recommended in the Reﬁll Capacities and Recommendations topic that is in this Op to do so can cause engine damage.

Pressurized System: Hot coolant can cause serious 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 pressure.

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.

u check the engine oil, do not operate

ipstick.

tighten any loose bolts.

nce that is in the Operation and

NOTICE

eration and Maintenance Manual. Failure

The OEM may have equipped the application with an emerge 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 engi

ncy stop button. For more information

ne is stopped.

Perform all required periodic maintenance on all

•

driven equipment. This maintenance is outlined in the instructions from the OEM.

Page 29

SEBU8352 29

Operation Section

Cold Weather Operation

i02717265

Cold Weather O perat ion

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:

The type of fuel that is used

•

The viscosity of the engine oil

•

The operation of the glow plugs

•

Optional Cold starting aid

•

Battery condition

•

This section will cover the following information:

Potential problems that are caused by cold weather

•

operation

Suggest steps which can be taken in order to

•

minimize starting problems and operating problems when the ambient air temperature is between 0° to−40 °C (32° to 40 °F).

Install the cor

•

before the beginning of cold weather.

Check all rubb

•

weekly.

Check all elec

•

fraying or damaged insulation.

Keep all batte

•

Fill the fuel tank at the end of each shift.

•

Check the air cleaners and the air intake daily.

•

Check the air intake more often when you operate in snow.

Ensure that the glow plugs are in working order.

•

Refer to Test

-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

rect speciﬁcation of engine lubricant

er parts (hoses, fan drive belts, etc)

trical wiring and connections for any

ries fully charged and warm.

ing and Adjusting Manual, “Glow Plug

damage.

The operation and maintenance of an engine in freezing temperatures is complex . This is because of the following conditions:

Weather conditions

•

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

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.

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 downforaperiodoftimeandtheenginecanstill have the ability to start readily.

Do not use aerosol types of starting aids such as ether. Such use could result in an explosion and personal injury.

Forjumpstartingwithcablesincoldweather,

•

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.

Page 30

30 SEBU8352 Operation Section Cold Weather Operation

In cold weather correct glycol concentration in order to ensure adequate freeze protection.

, check the coolant often for the

Engine Block Heaters

Engine block h engine jacket water that surrounds the combustion chambers. This provides the following functions:

Startability is improved.

•

Warm up time i

•

An electric block heater can be activated once the engine is is typically a 1250/1500 W unit. Consult your Perkins dealer or your Perkins distributor for more information

Idling the E

When idling after the engine is started in cold weather, in rpm. This will warm up the engine more quickly. Maintaining an elevated low idle speed for extended periods wil 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 op operating temperature is 82 °C (179.6 °F).

eaters (if equipped) heat the

s reduced.

stopped. An effective block heater

ngine

crease the engine rpm from 1000 to 1200

l be easier with the installation of a hand

erating temperature. The minimum

Recommendations for Coolant Warm Up

Warm up an engine that has cooled below normal operatin be performed before the engine is returned to full operation. During operation in very cold temperature conditio result from engine operation for short intervals. This can happen if the engine is started and the engine is stopped to warm up completely.

When the temperatures, fuel and oil are not completely burned in the combustion chamber. This fuel and oil causes soft ca Generally, the deposits do not cause problems and the deposits are burned off during operation at normal

When the engine is started and the engine is stopped many ti up completely, the carbon deposits become thicker. This can cause the following problems:

g temperatures due to inactivity. This should

ns, damage to engine valve mechanisms can

many times without being operated in order

engine is operated below normal operating

rbon deposits to form on the valve stems.

engine operating temperatures.

mes without being operated in order to warm

Free operation

•

Valves become stuck.

•

Pushrods may become bent.

•

Other damage t

•

result.

For this reaso the engine must be operated until the coolant temperature is 71 °C (160 °F) minimum. Carbon deposits on t 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 servi extended. Lubrication will be improved. There will be less acid and less sludge in the oil. This will provide longer serv rings, and other parts. However, limit unnecessary idle time to ten minutes in order to reduce wear and unnecessa

of the valves is prevented.

o valve train components can

n, when the engine is started,

he valve stems will be kept at a minimum

celifeoftheenginewillbegenerally

ice life for the engine bearings, the piston

ry fuel consumption.

The Water Temperature Regulator and Insulated

The engine is equipped with a water temperature regulator correct operating temperature jacket water circulates through the engine cylinder block and into the engine cy cylinder block via an internal passage that bypasses the valve of the coolant temperature regulator. This ensures t cold operating conditions. The water temperature regulator begins to open when the engine jacket water ha temperature. As the jacket water coolant temperature rises above the minimum operating temperature the water te more coolant through the radiator to dissipate excess heat.

The progressive opening of the water temperature regulator operates the progressive closing of the bypass head. This ensures maximum coolant ﬂow to the radiator in order to achieve maximum heat

pation.

dissi

Note: Perkins discourages the use of all air ﬂow

iction devices such as radiator shutters.

restr Restriction of the air ﬂow can result in the following: high exhaust temperatures, power loss, excessive fan us

Heater Lines

. When the engine coolant is below the

linder head. The coolant then returns to the

hat coolant ﬂ ows around the engine under

s reached the correct minimum operating

mperature regulator opens further allowing

passage between the cylinder block and

age, and reduction in fuel economy.

Page 31

SEBU8352 31

Operation Section

Cold Weather Operation

A cab heater is b feed from the engine and the return lines from the cab should be insulated in order to reduce heat loss to the outside

eneﬁcial in very cold weather. The

air.

Insulating the Air Inlet and Engine Compartment

When temperatures below −18 °C (−0°F)willbe frequently e is located in the engine compartment may be speciﬁed. An air cleaner that is located in the engine compartment 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.

ncountered, an air cleaner inlet that

may also minimize the entry of snow

i02322217

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.

Group 1

•

Group 2

•

Group 3

•

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 die components provide a means of minimizing problems in cold weather:

Glow plugs (if equipped)

•

Engine coolan

•

option

Fuel heaters,

•

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 di

A lower cloud point

•

A lower pour point

•

A higher ener

•

Note: Group 3 fuels reduce the life of the engine. The use of Group 3 warranty.

Group3fuels Aviation Kerosene Fuels.

Special fuel

The cloud point is a temperature that allows wax crystals to the fuel ﬁlters to plug.

The pour poi 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 temperatu that are fueled in one climate may not operate well if the engines are moved to another climate. Problems can result

Before troubleshooting for low power or for poor performan

Low temperature fuels may be available for engine operatio fuels limit the formation of wax in the fuel at low temperatures.

For more information on cold weather operation, refer to the Operation and Maintenance Manual, “Cold Weather O Cold Weather”.

fferent characteristics to Group 2 fuels.

s include Biofuel.

form in the fuel. These crystals can cause

re for the engine’s application. Engines

due to changes in temperature.

ce in the winter, check the fuel for waxing.

n at temperatures below 0 °C (32 °F). These

peration and Fuel Related Components in

sel fuels are used the following

t heaters, which may be an OEM

which may be an OEM option

gy per unit volume of fuel

fuelsisnotcoveredbythePerkins

include Low Temperature Fuels and

nt is the temperature when diesel fuel

Page 32

32 SEBU8352 Operation Section Cold Weather Operation

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 tan 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 wi the fuel system ﬁlter is important.

ks use supply pipes that allow water

th this system, regular maintenance of

Drain the wa tank at the following intervals: weekly, oil changes, and refueling of the fuel tank. This will help prevent water and/o fuel storage tank and into the engine fuel tank.

ter and sediment from any fuel storage

r sediment from being pumped from the

Fuel Filters

It is possi between the fuel tank and the engine fuel inlet. After you change the fuel ﬁlter, always prime the fuel system in o system. Refer to the Operation and Maintenance Manual in the Maintenance Section for more informat

The micron rating and the location of a primary fuel ﬁlter is i primary fuel ﬁlter and the fuel supply line are the most common components that are affected by cold fuel.

ble that a primary fuel ﬁlter is installed

rder to remove air bubbles from the fuel

ion on priming the fuel system.

mportant in cold weather operation. The

Fuel Heaters

Note: The OEM may equip the application with fuel

heaters. If this is the case, disconnect an electric type of fuel h overheating of the fuel. If the type of fuel heater is a heat exchanger, the OEM should have included a bypass f operational during warm weather in order to prevent overheating of the fuel.

eater in warm weather in order to prevent

or warm weather. Ensure that the bypass is

For more information about fuel heaters (if equipped), refer to the OEM information.

Page 33

SEBU8352 33

Maintenance Section

Reﬁll Capacities

Maintenance Section

Reﬁll Capacities

i02814021

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.

1103D Engine

Table 3

1103D Engine

Compartment or System

Standard Oil Sump for the Engine Crankcase

(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.

(1)

Cooling System

To ma int a System capacity must be known. The approximate capacity for the engine cooling system is listed below. Ex applications. Refer to the OEM speciﬁcations for the External System capacity. This capacity information will be n of coolant/antifreeze that is required for the Total Cooling System.

in the cooling system, the Total Cooling

ternal System capacities will vary among

eeded in order to determine the amount

Liters

6.5 7

Quarts

1103D Engine

Table 4

1103D Naturally Aspirated Engine without

an oil cooler

Compartment or System

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 exc hanger, aftercooler, and piping. Refer to the OEM speciﬁcations. En te r 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 c ooling system. Enter the total in this row.

Table 5

1103D Naturally Aspirated Engines and

Turbocharged Engines with an oil cooler

Compartment or System

Engine Only 4.43 4.02

External cooling system capacity (OEM recommendation)

Total Cooling System

(1)

(2)

The Total Cooling System includes the capacity for the engine cooling system plus the capacity for the external c ooling system. Enter the total in this row.

(1)

(2)

(1)

(2)

Liters

4.21 4

Liters

Quarts

i02883944

Fluid Recommendations

Cooling System Speciﬁcations

General Coolant Information

NOTICE Never add co damage could result. Allow the engine to cool ﬁrst.

olant to an overheated engine. Engine

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 temperature or drained completely to prevent damage.

Page 34

34 SEBU8352 Maintenance Section Reﬁll Capacities

Table 6

NOTICE Frequently che proper freeze protection or for anti-boil protection.

Clean the cooling system for the following reasons:

Contamination of the cooling system

•

Overheating of the engine

•

Foaming of the coolant

•

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 problems can develop without water temperature regulators.

ck the speciﬁc gravity of the coolant for

NOTICE

Acceptable Wat

Property Maximum Limit

Chloride (Cl) 40 mg/L

Sulfate (SO4)100mg/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:

Local water utility company

•

Agricultural agent

•

Independent laboratory

•

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 e ngine 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 6.

Additives

Additives help to protect the metal surfaces of the cooling system. A lack of coolant additives or insufﬁcient amounts of additives enable the following conditions to occur:

Corrosion

•

Formation of mineral deposits

•

Rust

•

Scale

•

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:

Formation of gel compounds

•

Reduction of heat transfer

•

Leakage of the water pump seal

•

Plugging of radiators, coolers, and small passages

•

Glycol

Glycol in the coolant helps to provide protection against the following conditions:

Boiling

•

Page 35

SEBU8352 35

Maintenance Section

Reﬁll Capacities

Freezing

•

NOTICE

Cavitation of the water pump

•

Do not use a comm

ercial coolant/antifreeze that on-

ly meets the ASTM D3306 speciﬁcation. This type of

For optimum performance, Perkins recommends a 1:1 mixture of a water/glycol solution.

coolant/antifreeze is made for light automotive applications.

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 antifreezes use ethylene glycol. Propylene glycol may also be used. In a 1:1 mixture with water, e

thylene and propylene glycol provide similar protection against freezing and boiling. See Tables 7 and 8.

Table 7

Ethylene Glycol

Concentration

50 Percent −36 °C (−33 °F) 106 °C (223 °F)

60 Percent −51 °C (−60 °F) 111 °C (232 °F)

Freeze

Protection

Boil

Protection

NOTICE Do not use propylene glycol in concentrations that exceed 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 8

Propylene Glycol

Concentration

50 Percent −29 °C (−20 °F) 106 °C (223 °F)

Freeze

Protection

Anti-Boil

Protection

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:

Perkins recommends a 1:1 mixture of water and glycol. This mixture of water and glycol will provide optimum heavy

-duty performance as a antifreeze. This ratio may be increased to 1:2 water to glycol if extra freezing protection is required.

Note: A commercial heavy-duty antifreeze that meets “ASTM D4985” speciﬁcations MAY require a treatment wi

th an SCA at the initial ﬁll. Read the label or the instructions that are provided by the OEM of the product.

In stationary engine applications and marine engine applications that do not require anti-boil protection or freeze pr

otection, a mixture of SCA and water is acceptable. Perkins recommends a six percent to eight percent concentration of SCA in those cooling sy

stems. 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 th

at 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 Pe

rkins distributor for the correct level of

protection.

Table 9

Coolant Service Life

Coolant Type Service Life

Perkins ELC

Commercial Heavy-Duty

eze that meets

Antifre

“ASTM D4985”

Perkins POWERPART

Commercial SCA and

SCA

Water

6,000 Service Hours or

Three Years

3000 Service Hours or

Two Years

3000 Service Hours or

Two Years

3000 Service Hours or

Two Years

Preferred – Perkins Extended Life Coolant (ELC)

Acceptable – A commercial heavy-duty antifreeze

that meets “ASTM D4985” speciﬁcations

Extended Life Coolant (ELC)

Perkins provides Extended Life Coolant (ELC) for use in the following applications:

Heavy-duty spark ignited gas engines

•

Heavy-duty diesel engines

•

Page 36

36 SEBU8352 Maintenance Section Reﬁll Capacities

Automotive app

•

The anti-corrosion package for ELC is different from the anti-corr is an ethylene glycol base coolant. However, ELC contains organic corrosion inhibitors and antifoam agents with l has been formulated with the correct amount of these additives in order to provide superior corrosion protection f

ELC is available in a 1:1 premixed cooling solution with distill freeze protection to −36 °C (−33 °F). The Premixed ELC is recommended for the initial ﬁll of the cooling system. The topping off the cooling system.

ELC Concent canbeusedtolowerthefreezingpointto−51 °C (−60 °F) for arctic conditions.

Containers of several sizes are available. Consult your Perkins dealer or your Perkins distributor for the part numbe

or all metals in engine cooling systems.

ed water. The Premixed ELC provides

ELC Coolin

lications

osion package for other coolants. ELC

ow amounts of nitrite. Perkins ELC

Premixed ELC is also recommended for

rate is also available. ELC Concentrate

rs.

g System Maintenance

Correct additions to the Extended Life Coolant

NOTICE Use only Perkins products for pre-mixed or concentrated coolants.

Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. Failure to follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed.

ELC Co oling Sys

Note: If the cooling system is already using ELC,

cleaning agen the speciﬁed coolant change interval. Cleaning agents are only required if the system has been contaminate coolant or by cooling system damage.

Clean water i when ELC is drained from the cooling system.

After the coo cooling system is reﬁlled, operate the engine while the cooling system ﬁller cap is removed. Operate the engine un operating temperature and until the coolant level stabilizes. As needed, add the coolant mixture in order to ﬁll

ts are not required to be used at

d by the addition of some other type of

s the only cleaning agent that is required

ling system is drained and after the

til the coolant level reaches the normal

the system to the speciﬁed level.

tem Cleaning

Changing to Perkins ELC

To change from heavy-duty antifreeze to the Perkins ELC, perform the following steps:

NOTICE Caremustbetakentoensurethatallﬂuids are contained during performance of inspection, maintenance, t product. Be prepared to collect the ﬂuid with suitable containers before opening any compartment or disassemblin

Dispose of all ﬂuids according to local regulations and mandates

1. Drain the coolant into a suitable container.

2. Dispose of

regulations.

esting, adjusting and the repair of the

g any component containing ﬂuids.

the coolant according to local

In order t the antifreeze and the additives, you must maintain the recommended concentration of Extended Life Coolant lowers the proportion of additive. This will lower the ability of the coolant to protect the system from pitting, from cav

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).

When using Perkins ELC, do not use standard SCA’s or SCA ﬁlters.

o maintain the correct balance between

(ELC). Lowering the proportion of antifreeze

itation, from erosion, and from deposits.

NOTICE

3. Flush the

remove any debris.

4. Use Perki

the instruction on the label.

5. Drain the

the cooling system with clean water.

6. Fill the c

operate the engine until the engine is warmed to 49° to 66°C (120° to 150°F).

system with clean water in order to

ns cleaner to clean the system. Follow

cleaner into a suitable container. Flush

ooling system with clean water and

Page 37

SEBU8352 37

Maintenance Section

Reﬁll Capacities

NOTICE Incorrect or in can result in damage to copper and other metal components.

To avoid damage to the cooling system, make sure to completely ﬂushthecoolingsystemwithclearwater. Continue to ﬂu cleaning agent are gone.

7. Drain the cool

and ﬂush the cooling system with clean water.

Note: The cool ﬂushed from the cooling system. Cooling system cleaner that is left in the system will contaminate the coolant. The system.

8. Repeat Step

completely clean.

9. Fill the coo

ELC.

complete ﬂushing of the cooling system

sh the system until all the signs of the

ing system into a suitable container

ing system cleaner must be thoroughly

cleaner may also corrode the cooling

s 6 and 7 until the system is

ling system with the Perkins Premixed

Commercial Hea

vy-Duty 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 a regulators in the cooling system. Water temperature regulators help to maintain the engine coolant at the correct opera lems can develop without water temperature regulators.

Check the anti order to ensure adequate protection against boiling or freezing. Perkins recommends the use of a refractomet

Perkins engine cooling systems should be tested at 500 hour in Supplemental Coolant Additive (SCA).

n engine without water temperature

ting temperature. Cooling system prob-

freeze (glycol concentration) in

er for checking the glycol concentration.

tervals for the concentration of

ELC Cooling

Mixing ELC with other products reduces the effectiveness of the ELC and shortens the ELC service life. Use only Perkins Products for premixed or concentrate coolants. Failure to follow these recommendations can result in shortened cooling system component life.

ELC cooling systems can withstand contamination to a maximum of ten percent of conventional heavy-duty 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.

System Contamination

NOTICE

Additions of An SCA that is liquid may be needed at 500 hour intervals.

Refer to Table 10 for part numbers and for quantities of SCA.

Table 10

SCA are based on the results of the test.

Perkins Liquid SCA

Part Number Quantity

21825735 10

Adding the SCA to Heavy-Duty Coolant at the Initial Fill

Commercial heavy-duty 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 11 to determine the amount of Perkins SCA that is required when the cooling system is initially ﬁlled.

Table 11

Equation For Adding The SCA To The Heavy-Duty

Visthetot

X is the amount of SCA that is required.

Coolant At The Initial Fill

V×0.045=X

al volume of the cooling system.

Page 38

38 SEBU8352 Maintenance Section Reﬁll Capacities

Table12isanex

ample for using the equation that

is in Table 11.

Table 12

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant At The Initial Fill

Total Volume

of the Cooling

System (V)

15L(4USgal)

Multiplication

Factor

×0.045

Amount of SCA

that is Required

(X)

0.7 L (24 oz)

Adding The SCA to The Heavy-Duty Coolant For Maintenance

Heavy-duty antifreeze of all types REQUIRE periodic additions of an SCA.

Test the 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.

Cleaning the Sy

stem of Heavy-Duty

Antifreeze

Perkins cooli to clean the cooling system of harmful scale and corrosion. Perkins cooling system cleaners dissolve min contamination and sludge.

Clean the coo

•

drained or before the cooling system is ﬁlled with new coolant.

Clean the cooling system whenever the coolant is

•

contaminated or whenever the coolant is foaming.

ng system cleaners are designed

eral scale, corrosion products, light oil

ling system after used coolant is

i02883885

Fluid Recommendations

General Lubricant Info rmation

Because of government regulations regarding the certiﬁcation of exhaust emissions from the engine, the lubricant recommendations must be followed.

Use the equation that is in Table 13 to determine the amount of Perkins SCA that is required, if necessary:

Table 13

Equation Fo

V is the total volume of the cooling system.

X is the amount of SCA that is required.

r Adding The SCA To The Heavy-Duty Coolant For Maintenance

V × 0.014 = X

Table14isanexampleforusingtheequationthat is in Table 13.

Table 14

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant For Maintenance

Total Volume

of the Cooling

System (V)

15L(4USgal)

Multiplication

Factor

×0.014

Amount of SCA that is Required

(X)

0.2 L (7 oz)

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 No. 1509”. Engine oils that bear the API symbol are authorized by API.

Page 39

SEBU8352 39

Maintenance Section

Reﬁll Capacities

Illustration 18

Typical API symbol

g00546535

Diesel engine oils CC, CD, CD-2, and CE have not been API authorized classiﬁcations since 1 January 1996. Table 15 summarizes the status of the classiﬁcations.

Table 15

API Classiﬁcations

Current Obsolete

CH-4, , CI-4 CE, CC, CD

(1)

The oil CD-2 is for a two-cycle diesel engine. Perkins does not

sell engines that utilize CD-2 oil.

CD-2

(1)

Termin olo gy

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).

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 classiﬁcati

on 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 applicatio

ns. 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 re

quirements for diesel engines that require low emissions. DHD-1 oils are designed to control the harmful effects of soot with improved wear resistance and impro

ved resistance to plugging of the oil ﬁlter. These oils will also provide superior control of piston deposits for engines with either two-piece steel pistons o

r aluminum pistons.

All DHD-1 oils must complete a full test program with the b

ase stock and with the viscosity grade of the ﬁnishedcommercialoil.Theuseof“APIBase Oil Interchange Guidelines” are not appropriate for DHD-1 oi

ls. 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

ese oil change interval programs are based

oil. Th 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.

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 the following classiﬁcations:

API CH-4 CI-4

•

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

he requirements of the low emissions diesel

meet t engines. API CH-4 oils are also acceptable for use in older diesel engines and in diesel engines that

igh sulfur diesel fuel. API CH-4 oils may be

use h used in Perkins engines that use API CG-4 and API CF-4 oils. API CH-4 oils will generally exceed the

ormance of API CG-4 oils in the following criteria:

perf deposits on pistons, control of oil consumption, wear of piston rings, valve train wear, viscosity control,

orrosion.

and c

Page 40

40 SEBU8352 Maintenance Section Reﬁll Capacities

Three new engin

e tests were developed for the API CH-4 oil. The ﬁrsttestspeciﬁcally evaluates deposits on pistons for engines with the two-piece steel piston. This test (pis

ton deposit) also measures the control of oil consumption. A second test is conducted with moderate oil soot. The second test measures the followin

g criteria: wear of piston rings, wear of cylinder liners, and resistance t o 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 hi

gh soot. The oils also have improved oxidation resistance. API CH-4 oils must pass an additional test (piston deposit) for engines that use aluminum p

istons (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 d

ealer or your Perkins distributor has speciﬁc

guidelines for optimizing oil change intervals.

Some comm

ercial oils that meet the API classiﬁcations may require reduced oil change intervals. To determine the oil change interval, closely monitor

the condition of the oil and perform a wear

metal analysis.

NOTICE

Failure

to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.

Total Ba

se Number (TBN) and Fuel Sulfur Levels for D irect Injection (DI) Diesel Engines

The Total Base Number (TBN) for an oil depends on the fuel sulfur level. For direct injection engines that use dis must be 10 times the fuel sulfur level. The TBN is deﬁned by “ASTM D2896”. The minimum TBN of the oil is demonstrates the TBN.

tillate fuel, the minimum TBN of the new oil

5 regardless of fuel sulfur level. Illustration 19

Illustration 19

(Y) TBN by “ASTM D2896” (X) P ercentage 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.

g00799818

Use the following guidelines for fuel sulfur levels that exceed 1.5 percent:

Choose an oil with the highest TBN that meets one

•

of these classiﬁcations: EMA DHD-1 and API CH-4.

Reduce the oil change interval. Base the oil

•

change interval on the oil analysis. Ensure that the oil analysis includes the condition of the oil and a wear metal analysis.

Excessive piston deposits can be produced by an oil withahighTBN.Thesedepositscanleadtoaloss of control of the oil consumption and to the polishing of the cylinder bore.

NOTICE Operating Direct Injection (DI) diesel engines with fuel sulphur levels over 0.5 percent will require shortened oil change intervals in order to help maintain adequate wear protection.

Table 16

Percentage of Sulfur in the fuel

Lower than 0.5 Normal

0.5 to 1.0 0.75 of normal

Greater than 1.0 0.50 of normal

Oil change interval

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.

Page 41

SEBU8352 41

Maintenance Section

Reﬁll Capacities

Refer to Table 1

7 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.

Refer to Table 17 (maximum temperature) in order to select the oil viscosity for engine operation at the highest ambi

ent temperature that is anticipated.

Generally, use the highest oil viscosity that is available to

meet the requirement for the temperature

at start-up.

Table 17

Engine Oil Viscosity

EMA LRG-1

API CH-4

Viscosity Grade

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)

Ambient Temperature

Minimum Maximum

Synthetic Base Stock Oils

Synthetic base oils are acceptable for use in these engines if these oils meet the performance requirements that are speciﬁed for the engine.

Synthetic base oils generally perform better than conventional oils in the following two areas:

Synthetic base oils have improved ﬂow at low

•

temperatures especially in arctic conditions.

Synthetic base oils have improved oxidation

•

stability especially at high operating temperatures.

Some synthetic base oils have performance characteristics that enhance the service life of the oil. Perkins does not recommend the automatic extending of the oil change intervals for any type of oil.

Re-reﬁned Base

Stock Oils

Re-reﬁned base stock oils are acceptable for use in Perkins

engines if these oils meet the performance requirements that are speciﬁed by Perkins. Re-reﬁnedbasestockoilscanbeused exclusively

in ﬁnished oil or in a combination with new base stock oils. The US military speciﬁcations and the speciﬁcations of other heavy equipment manufacture

rs also allow the use of re-reﬁned base

stock oils that meet the same criteria.

The process t

hatisusedtomakere-reﬁned base stock oil should adequately remove all wear metals that are in the used oil and all the additives that areintheus

ed 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. Fi

ltering is adequate for the production of

high quality, re-reﬁned base stock oil.

Lubricant

s 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 ﬂowinginlow temperatures.

These oils have lubricant viscosity grades of SAE 0W or SAE 5W.

When an engine is started and operated in ambient temperatures below −30 °C (−22 °F), use a synthetic base stoc

k multigrade oil with an 0W viscosity grade orwitha5Wviscositygrade.Useanoilwithapour point that is lower than −50 °C (−58 °F).

The number of acceptable lubricants is limited in cold weather conditions. Perkins recommends the

ng lubricants for use in cold weather conditions:

followi

First Choice – Use oil with an EMA DHD-1 Recomme

nded Guideline. Use a CH-4 oil that has an API license. The oil should be either SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W30, or SAE 5W40

nt viscosity grade.

lubrica

Second Choice – Use an oil that has a CH-4

ve package. Although the oil has not been

additi tested for the requirements of the API license, the oil must be either SAE 0W20, SAE 0W30, SAE 0W40, SAE 5W3

0, or SAE 5W40.

NOTICE Shortened engine service life could result if second choice oils are used.

Page 42

42 SEBU8352 Maintenance Section Reﬁll Capacities

Aftermarket Oi

Perkins does not recommend the use of aftermarket additives in o additives in order to achieve the engine’s maximum service life or rated performance. Fully formulated, ﬁnished oils additive packages. These additive packages are blended into the base oils at precise percentages in order to help characteristics that meet industry standards.

There are no i the performance or the c ompatibility of aftermarket additives in ﬁnished oil. Aftermarket additives may not be compa package, which could lower the performance of the ﬁnished oil. The aftermarket additive could fail to mix with the 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 Oi

l” or the recommended API classiﬁcation.

l Additives

il. It is not necessary to use aftermarket

consist of base oils and of commercial

provide ﬁnished oils with performance

ndustry standard tests that evaluate

tible with the ﬁnished oil’s additive

ﬁnished oil. This could produce sludge

Tests are condu

•

contamination of the oil by water, glycol or fuel.

The Oil Condit

•

the oil’s lubricating properties. An infrared analysis is used to compare the properties of new oil to the properties o allows technicians to determine the amount of deterioration of the oil during use. This analysis also allows t of the oil according to the speciﬁcation during the entire oil change interval.

cted in order to detect

ion Analysis determines the loss of

f the used oil sample. This analysis

echnicians to verify the performance

i02883936

Fluid Recommendations

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:

See the appropriate “Lubricant Viscosities” table in

•

order to ﬁ engine.

At the spe

•

new oil and install a new oil ﬁlter.

Perform m

•

speciﬁed in the Operation and Maintenance Manual, “Maintenance Interval Schedule”.

nd the correct oil viscosity grade for your

ciﬁed interval, service the engine. Use

aintenance at the intervals that are

Oil analysis

Some eng valve. If oil analysis is required the oil sampling valve is used to obtain samples of the engine oil. The oil analysi program.

The oil a determine oil performance and component wear rates. Contamination can be identiﬁed and measured throug includes the following tests:

The Wea

•

engine’s metals. The amount of wear metal and type of wear metal that is in the oil is analyzed. The increa oil is as important as the quantity of engine wear metal in the oil.

ines may be equipped with an oil sampling

s will complement the preventive maintenance

nalysis is a diagnostic tool that is used to

h the use of the oil analysis. The oil analysis

r Rate Analysis monitors the wear of the

se in the rate of engine wear metal in the

Cetane number___________________________ 45 minimum

•

Viscosity___________ 2,0to4.5cStat40°C(104°F)

•

Density_______________________ _0.835 to 0.855 Kg/liter

•

Sulfur_______________________ 0.2% of mass, maximum

•

Distillation___________________ 85% at 350 °C (662 °F)

•

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

Thisistheresistancetoﬂow of a ﬂuid. If this resistance is outside the limits, the engine and the engine starting performance in particular can be affected.

Sulfur

Page 43

SEBU8352 43

Maintenance Section

Reﬁll Capacities

High sulfur con in Europe, North America or Australasia. This can cause engine wear. When only high sulfur fuels are available lubricating oil is used in the engine or that the lubricating oil change interval is reduced.

Distillation

This is an ind 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 engin of fuels. These fuels are divided into four general groups:

Group 1 (preferred fuels)

•

Group2(per

•

Group 3 (aviation kerosene fuels)

•

Other fuels

•

Group 1 (pre

“DERV to EN590”

Note: Only use Arctic fuels when the temperature is below 0 °C (32 °F). Do not use Arctic fuels when the ambient te that the time period between cranking the engine and ﬁrst ﬁre is kept to a minimum, only use fuel of the correct vi

Gas oil to “BS2869 Class A2”

tent of the fuel is not normally found

, it will be necessary that high alkaline

ication of the mixture of different

es have the ability to burn a wide variety

missible fuels)

ferred fuels): Speciﬁcation

mperature is above 0 °C (32 °F). To ensure

scosity and at the correct temperature.

“ASTM D975 - 91 C

“JP7, Mil T38219”

“NATO F63”

These fuels should have a wear scar value of 650 micrometers m

Group 3 (aviation kerosene fuels): Speciﬁcation

These fuels ne micrometers wear scar and the reliability of the fuel pump and fuel injectors will be reduced. The fuel injection pum when the additives are included.

“JP5 MIL T5624

“JP8 T83133 (Avtur FSII, NATO F34”

“Jet A”

“Jet A1, NATO

Low temperature fuels

Special fuels for use in cold weather may be available for engine operation at temperatures below 0 °C (32 °F). Thes 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:

Low engine power

•

Difﬁcult st

•

conditions

e fuels limit the formation of wax in the

arting in hot conditions or in cold

lass 1D”

NOTICE

aximum *HFRR to ISO 12156 - 1.*

ed additives to achieve lubricity of 650

p is not covered by a warranty, even

(Avcat FSII, NATO F44”

F35, XF63”

“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 speciﬁcat

Note: If low sulfur or low sulfur aromatic fuels are used, the lubricity.

Group 2 (p

These fuel speciﬁcations are considered acceptable for issue reduce the life of the engine, the engine’s maximum power and the engine’s fuel efﬁciency.

ion of lubricity.

n fuel additives can be used to increase

ermissible fuels): Speciﬁcation

s of warranty. However,these fuels may

White smoke

•

Deterioration of emissions and misﬁre at certain

•

operating c

Biofuel: Speciﬁcation

Biofuel: A 5% mix of RME to EN14214 in conventional fuel is permitted.

Water emulsion fuels: These fuels are not permitted

Refer to the following fuel speciﬁcations for North Amer

onditions

NOTICE

ica.

Page 44

44 SEBU8352 Maintenance Section Reﬁll Capacities

The preferred f

uels 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 f

uels can result in higher maintenance

costs and in reduced engine service life.

Diesel fuels

that meet the speciﬁcations in Table 18 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 18 is for diesel fuels that are distilled from crude oil. Diesel fuels from other sourc

es could exhibit detrimental properties

that are not deﬁned or controlled by this speciﬁcation.

Table 18

Perkins Speciﬁcations for Distillate Diesel Fuel

Speciﬁcations

Aromatics

Ash

Carbon Residue on 10% Bottoms

Cetane Number

Cloud Point

Requirements

ASTM Test

35% maximum “D1319”

0.02% maximum (weight)

0.35% maximum (weight)

40 minimum (DI engines)

“D482”

“D524”

“D613”

The cloud point must not exceed the lowest expected

ambient temperature.

(continued)

(Table 18, contd)

Copper Strip Corrosion

No. 3 maximum

“D130”

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)

Pour Point

minimum below ambient

“D97”

temperature

0.2% maximum “D3605”

(1)

Sulfur

“D1552”

2.0 cSt minimum Kinematic Viscosity

(2)

and 4.5 cSt maximum at

“D445”

40 °C (104 °F)

Water and Sediment

Water

Sediment

Gum and Resins

(3)

0.1% maximum

“D1796”

0.1% maximum “D1744”

0.05% maximum

(weight)

10 mg per 100 mL maximum

“D473”

“D381”

0.38 mm

Lubricity

(4)

(0.015 inch) maximum at

“D6079”

25 °C (77 °F)

(1)

Perkins fuel systems and engine components can operate on high sulfur fuels. Fuel sulfur levels affect exhaust emissions. High sulfur fuels also increase the potential for corrosion of internal com ponents. 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 v iscosity are the v alues as the fuel is delivered to the fuel injection pumps. If a fuel with a low viscosity is used, cooling of the fuel m ay 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.

Page 45

SEBU8352 45

Maintenance Section

Reﬁll Capacities

NOTICE

Operating with

fuels that do not meet the Perkins recommendations can cause the following effects: Starting difﬁculty, poor combustion, deposits in the fuel injectors, redu

ced service life of the fuel system, deposits in the combustion chamber, and reduced service 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 19. However, the fuel that is selected must meet the requirements that are speciﬁed in Table 18. These fuels are intended to be used in operating temperatures that aredownto−54 °C (−65 °F).

Table 19

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 sp eciﬁed in the “Perkins Speciﬁcations for Distillate Diesel Fuel” Table. Consult the sup plier for the recommended additives in order to maintain the correct fuel lubricity.

(1)

These fuels are lighter than the No. 2 grades of fuel. The cetane number of the fuels in Table 19 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 mayberequiredinordertomaintaintheminimum viscosity of 1.4 cSt at the fuel injection pump.

There are many other diesel fuel speciﬁcations that are published by governments and by technological societies. Usually, those speciﬁcations do not review all the requirements that are addressed in this speciﬁcation. To ensure optimum engine performance, a complete fuel analysis should be obtained before engine operation. The fuel analysis should include all of the properties that are listed in Table 18.

Page 46

46 SEBU8352 Maintenance Section Maintenance Interval Schedule

i02818827

Maintenance Interval Schedule

When Required

Battery - Replace .................................................. 49

Battery or Battery Cable - Disconnect .................. 50

Engine - Clean ...................................................... 5

Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 55

Engine Air Clea

Inspect/Replace .................................................. 57

Engine Oil Sample - Obtain .................................. 59

Fuel Injector -

Fuel System - Prime ............................................. 63

Severe Service Application - Check ..................... 68

Daily

Alternator and Fan Belts - Inspect/Adjust/Replace Cooling System

Driven Equipment - Check .................................... 54

Engine Air Cleaner Service Indicator - Inspect ..... 57

Engine Oil Level Fuel System Primary Filter/Water Separator -

Drain ................................................................... 64

Walk-Around Ins

ner Element (Single Element) -

Test/Change ................................... 62

Coolant Level - Check ................ 53

- Check ...................................... 58

pection ........................................ 70

Every 4000 Serv

Aftercooler Core - Clean/Test ............................... 47

Every 6000 Serv

Cooling System Coolant Extender (ELC) - Add .... 53

Every 12 000 Se

Cooling System Coolant (ELC) - Change ............. 52

ice Hours

iceHoursor3Years

rviceHoursor6Years

Every 500 Service Hours or 1 Year

Battery Electro Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 55

Engine Air Clean

Inspect/Replace .................................................. 57

Engine Oil and Filter - Change ............................. 59

Fuel System Prim

Element - Replace .............................................. 65

Fuel System Secondary Filter - Replace .............. 65

Hoses and Clamps

Radiator - Clean .................................................... 67

lyte Level - Check .......................... 49

er Element (Single Element) -

ary Filter (Water Separator)

- Inspect/Replace .................. 66

Every 1000 Service Hours

Engine Valve Lash - Inspect/Adjust ...................... 61

Every 2000 Service Hours

Aftercooler Core - Inspec t ..................................... 47

Alternator - Inspect ............................................... 48

Engine Mounts - I

Starting Motor - Inspect ........................................ 69

Turbocharger - Inspect .......................................... 69

Water Pump - Inspe

nspect ....................................... 58

ct ........................................... 71

Every 3000 Service Hours or 2 Years

Cooling System Co

Change ............................................................... 50

olant (Commercial Heavy-Duty) -

Page 47

SEBU8352 47

Maintenance Section

Aftercooler Core - Clean/Test

i02690449

Aftercooler Core - Clean /Test

1. Remove the core

for the correct procedure.

2. Turn the after

remove debris.

Personal injury can result from air pressure.

Personal inju er procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

3. Pressurized air is the preferred method for

removing loose debris. Direct the air in the opposite dir nozzle approximately 6 mm (.25 inch) away from the ﬁns. Slowly move the air nozzle in a direction that is para debris that is between the tubes.

. Refer to the OEM information

cooler core upside-down in order to

ry can result without following prop-

ection of the fan’s air ﬂow. Hold the

llel with the tubes. This will remove

Personal injury can result from air pressure.

Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing.

Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

8. Dry the core with compressed air. Direct the air in

the reverse direction of the normal ﬂow.

9. Inspect the core in order to ensure cleanliness. Pressure test the core. If necessary, repair the core.

10. Install the core. Refer to the OEM information for the correct procedure.

11. After cleaning, start the engine and accelerate theenginetohighidlerpm.Thiswillhelpinthe 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.

i02690450

4. Pressurize The maximum water pressure for cleaning purposes must be less than 275 kPa (40 psi). Use pressuriz thecorefrombothsides.

Do not use a high concentration of caustic cleaner to clean the c 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 clea

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.

d water may also be used for cleaning.

ed water in order to soften mud. Clean

NOTICE

ore. A high concentration of caustic cleaner

n the core in order to remove any

Aftercooler C ore - Inspect

Note: Adju

the effects of the operating environment.

Inspect th 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

Personal injury can result without following proper proced tective face shield and protective clothing.

Maximum a than 205 kPa (30 psi) for cleaning purposes.

st the frequency of cleaning according to

e aftercooler for these items: damaged ﬁns,

injury can result from air pressure.

ure. When using pressure air, wear a pro-

ir pressure at the nozzle must be less

Page 48

48 SEBU8352 Maintenance Section Alternator - Inspect

After cleaning engine to high idle rpm. This will help in the removal of debris and drying of the core. Stop the engine. Use a light bul the core for cleanliness. Repeat the cleaning, if necessary.

Inspect the ﬁns for damage. Bent ﬁns may be opened with a “comb”.

Note: If parts of the aftercooler system are repaired or replaced, a leak test is highly recommended.

Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps, and seals. Ma

, start the engine and accelerate the

b behind the core in order to inspect

ke repairs, if necessary.

i02322311

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.

For applicatio replace the belts in matched sets. Replacing only one belt of a matched set will cause the new belt to carry more loa 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 sli

To accurately check the belt tension, a suitable gauge shouldbeuse

Illustration 20

Typical example

(1) Dial G auge

Fit the gauge (1) at the center of the longest free length and check the tension. The correct tension is 535 N (120 lb). If the tension of the belt is below 250 N (56 lb) adjust the belt to 535 N (120 lb).

If twin belts are installed, check and adjust the tensiononbothbelts.

ns that require multiple drive belts,

d because the older belt is stretched.

p enough to cause overheating.

g01003936

Adjustment

i01929797

Altern

ator and Fan Belts -

Inspect/Adjust/Replace

Inspec

To maximize the engine performance, inspect the belts f worn or damaged.

tion

or wear and for cracking. Replace belts that are

Illustration 21

1. Loosen The alternator pivot bolt (2) and the bolt (3).

g010039

Page 49

SEBU8352 49

Maintenance Section

Battery - Replace

2. Move the altern decrease the belt tension. Tighten the alternator pivot bolt and the link bolt to 22 N·m (16 lb ft).(1).

ator in order to increase or

Replacement

Refer to the Disassembly and Assembly Manual for the installation procedure and the removal procedure for the belt.

i02322315

Battery - Rep

Batteries give off combustible gases which can explode. A s es to ignite. This can result in severe personal injury or death.

Ensure proper ventilation for batteries that are in an enclosure. Follow the proper procedures in ordertohelpp near batteries. Do not smoke when batteries are serviced.

park can cause the combustible gas-

revent electrical arcs and/or sparks

lace

5. Remove the used

6. Install the new battery.

Note: Before the cables are connected, ensure that

theenginestartswitchisOFF.

7. Connect the cable from the starting motor to the POSITIVE “+” battery terminal.

8. Connect the NEGATIVE “-” cable to the NEGATIVE “-” battery terminal.

battery.

i02747977

Battery Electrolyte Level Check

When the engine is not run for long periods of time or when the engine is run for short periods, the batteries may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing. If batteries are correctly charged, the ammeter reading should be very near zero, when the engine is in operation.

The battery cables or the ba tteries should not be removed with the battery cover in place. The battery cover should be removed before any servicing is attempted.

Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in personal injury.

1. Switch the engine to the OFF position. Remove

all electrical loads.

2. Turn off any battery chargers. Disconnect any battery chargers.

3. The NEGATIVE “-” cable connects the NEGATIVE “-” battery terminal to the NEGATIVE “-” terminal on the starting motor. Disconnect the cable from the NEGATIVE “-” battery terminal.

4. The POSITIVE “+” cable connects the POSITIVE “+” battery terminal to the POSITIVE “+” terminal on the starting motor. Disconnect the cable from the POSITIVE “+” battery terminal.

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 ba ttery.

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:

Use a solution of 0.1 kg (0.2 lb) baking soda

•

and 1 L (1 qt) of clean water.

Use a solution of ammonium hydroxide.

•

Note: Always recycle a battery. Never discard a battery. Dispose of used batteries to an appropriate recycling facility.

Thoroughly rinse the battery case with clean water.

Page 50

50 SEBU8352 Maintenance Section Battery or Battery Cable - Disconnect

i02323088

Battery or Battery Cable Disconnect

The battery cables or the ba tteries should not be removed with tery cover should be removed before any servicing is attempted.

Removing the battery cables or the batteries with the cover in place may cause a battery explosion resulting in

1. Turn the start switch to the OFF position. Turn the

ignition sw and remove the key and all electrical loads.

2. Disconnect that the cable cannot contact the terminal. When four 12 volt batteries are involved, two negative connection

3. Remove the positive connection.

4. Clean all disconnected connection and battery

terminals.

the battery cover in place. The bat-

personal injury.

itch (if equipped) to the OFF position

the negative battery terminal. Ensure

must be disconnected.

i02203590

Cooling System Coolant (Commercial H

eavy-Duty) -

Change

NOTICE Care must be taken to ensure that ﬂuids are contained during performance of inspection, maintenance, testing, adjustingand repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compartment or disassembling any component containing ﬂuids.

Dispose of all ﬂuids according to Local regulations and mandates.

NOTICE Keep all part

Contaminants may cause rapid wear and shortened component li

Clean the cooling system and ﬂush the cooling system before the recommended maintenance interval if the following conditions exist:

The engine overheats frequently.

•

s clean from contaminants.

fe.

5. Use a ﬁne grade of sandpaper to clean the terminals and the cable clamps. Clean the items until the s remove material excessively. Excessive removal ofmaterialcancausetheclampstonotﬁt correctly a suitable silicone lubricant or petroleum jelly .

6. Ta pe t he c prevent accidental starting.

7. Proceed w

8. In order to connect the battery, connect the

positive

urfaces are bright or shiny. DO NOT

. Coat the clamps and the terminals with

able connections in order to help

ith necessary system repairs.

connection before the negative connector.

Foaming is observed.

•

The oil has entered the cooling system and the

•

coolant is contaminated.

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

Page 51

SEBU8352 51

Maintenance Section

Cooling System Coolant (Commercial Heavy-Duty) - Change

1. Stop the engine Loosen the cooling system ﬁller cap slowly in order to relieve any pressure. Remove the cooling system ﬁller c

Illustration 22

2. Open the drain cock or remove the drain plug (1) on the engine. Open the drain cock or remove the drainplugontheradiator.

Allow the coolant to drain.

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.

and allow the engine to cool.

ap.

g01003928

NOTICE

Flush

5. Stop the engine

Loosen the cooling system ﬁller cap slowly in order to relieve any pressure. Remove the cooling system ﬁller c the drain plug on the engine. Open the drain cock or remove the drain plug on the radiator. Allow the water to d clean water.

and allow the engine to cool.

ap. Open the drain cock or remove

rain. Flush the cooling system w ith

Fill

1. Close the dra

engine. Close the drain cock or install the drain plug on the radiator.

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 coo Heavy-Duty Coolant. Add Supplemental Coolant Additive to the coolant. For the correct amount, refer to the “Fluid Recommendations” topic (Maintenance Section) for more information on cooling system speciﬁcat ﬁller cap.

3. Start and r engine rpm to high idle. Run the engine at high idle for one minute in order to purge the air from the cavit

4. Check the coolant level. Maintain the coolant level within 13 pipe for ﬁlling. Maintain the coolant level in the expansion bottle (if equipped) at the correct level.

in cock or install the drain plug on the

NOTICE

ling system with Commercial

Operation and Maintenance Manual,

ions. Do not install the cooling system

un the engine at low idle. Increase the

ies of the engine block. Stop the engine.

mm (0.5 inch) below the bottom of the

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. Clean the cooling system ﬁller cap. Inspect the gasket that is on the cooling system ﬁller cap. If the gaske is damaged, discard the old cooling system ﬁller cap and install a new cooling system ﬁller cap. If the gask is not damaged, use a suitable pressurizing pump in order to pressure test the cooling system ﬁller cap. Th ﬁller cap is stamped on the face of the cooling system ﬁller cap. If the cooling system ﬁller cap does no cooling system ﬁller cap.

6. Start t leaks and for correct operating temperature.

t that is on the cooling system ﬁller cap

et that is on the cooling system ﬁller cap

e correct pressure for the cooling system

t retain the correct pressure, install a new

he engine. Inspect the cooling system for

Page 52

52 SEBU8352 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, testing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before opening any compartment or disassembling any component 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:

The engine overheats frequently.

•

Foaming is observed.

•

The oil has entered the cooling system and the

•

coolant is contaminated.

The fuel has entered the cooling system and the

•

coolant is contaminated.

1. Stop the engine Loosen the cooling system ﬁller cap slowly in order to relieve any pressure. Remove the cooling system ﬁller c

Illustration 23

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.

For information regarding the disposal and the recycling of used coolant, consult your Perkins dealer or your Perkins distributor.

and allow the engine to cool.

ap.

g01003928

NOTICE

Note: When the cooling system is cleaned, only clean water is needed when the ELC is drained and replaced.

Drain

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).

Page 53

SEBU8352 53

Maintenance Section

Cooling System Coolant Extender (ELC) - Add

5. Stop the engine Loosen the cooling system ﬁller cap slowly in order to relieve any pressure. Remove the cooling system ﬁller c the drain plug on the engine. Open the drain cock or remove the drain plug on the radiator. Allow the water to d clean water.

and allow the engine to cool.

ap. Open the drain cock or remove

rain. Flush the cooling system with

Fill

1. Close the dra

engine. Close the drain cock or install the drain plug on the radiator.

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 coo Coolant (ELC). Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic (Main 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 on the cavities of the engine block. Stop the engine.

4. Check the c within 13 mm (0.5 inch) below the bottom of the pipe for ﬁlling. Maintain the coolant level in the expansio

5. Clean the cooling system ﬁ ller cap. Inspect the gasket th the gasket that is on the cooling system ﬁller cap is damaged, discard the old cooling system ﬁller cap and in the gasket that is on the cooling system ﬁller cap is not damaged, use a suitable pressurizing pump in order cap. The correct pressure for the cooling system ﬁller cap is stamped on the face of the cooling system 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.

in cock or install the drain plug on the

NOTICE

ling system with Extended Life

tenance Section) for more information

e minute in order to purge the air from

oolant level. Maintain the coolant level

n bottle (if equipped) at the correct level.

at is on the cooling system ﬁller cap. If

stall a new cooling system ﬁller cap. If

to pressure test the cooling system ﬁller

ﬁller cap. If the cooling system ﬁller cap

i02335364

Cooling System Coolant Extender (ELC

The Perkins Extended Life Coolant (ELC) does not need the frequent addition of Supplemental Coolant Additives (SC coolants. The Extender only needs to be added once.

Check the coo stopped and cool.

1. Loosen the co 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 Operat Capacities” in the Maintenance Section for the capacity of the cooling system for your engine. Refer to thi “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 a is not damaged, use a suitable pressurizing pump in order to pressure test the ﬁller cap. The correct pressure the ﬁller cap does not retain the correct pressure, install a new ﬁller cap.

A) that are associated with conventional

ling system only when the engine is

oling system ﬁller cap slowly in

ion and Maintenance Manual, “Reﬁll

s Operation and Maintenance Manual,

nd install a new ﬁller cap. If the gasket

isstampedonthefaceoftheﬁller cap. If

)-Add

i02335378

Cooling System Co olan t Level

- Check

Engines With a Coolant Recovery Tank

Note: The cooling system may not have been

ed by Perkins. The procedure that follows

provid 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.

Page 54

54 SEBU8352 Maintenance Section Driven Equipment - Check

1. Observe the coo tank. Maintain the coolant level to “COLD FULL” mark on the coolant recovery tank.

Pressurized ous burns. To open the cooling system ﬁller cap, stop the engine and wait until the cooling system components a pressure cap slowly in order to relieve the pressure.

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 Capa information on the correct mixture and type of coolant. Refer to the Operation and Maintenance Manual, “R for the cooling system capacity. Do not ﬁll the coolant recovery tank above “COLD FULL” mark.

lant level in the coolant recovery

System: Hot coolant can cause seri-

re cool. Loosen the c ooling system

cities and Recommendations” for

eﬁll Capacities and Recommendations”

Illustration 25

Cooling system ﬁ ller cap

Pressurized System: Hot coolant can cause serious burns. To open the cooling system ﬁller cap, stop the eng components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pressure.

ine and wait until the cooling system

g00285520

Illustration 24

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.

g00103639

Engines Without a Coolant Recovery Tank

Check the coolant level when the engine is stopped and cool.

1. Remove the cooling system ﬁller cap slowly in order to rel

2. Maintain the coolant level within 13 mm (0.5 inch) of the bott 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 is not damaged, use a suitable pressurizing pump in order to pressure test the ﬁller cap. The correct pressure the ﬁller cap does not retain the correct pressure, install a new ﬁller cap.

4. Inspect the cooling system for leaks.

ieve pressure.

om of the ﬁller pipe. If the engine is

and install a new ﬁller cap. If the gasket

isstampedonthefaceoftheﬁller cap. If

i00174798

Driven Equipmen t - Check

Refer to the OEM speciﬁcations for more information on the following maintenance recommendations for thedrivenequipment:

Inspection

•

Adjustment

•

Page 55

SEBU8352 55

Maintenance Section

Engine - Clean

Lubrication

•

Other maintenance recommendations

•

Perform any maintenance for the driven equipment which is recommended by the OEM.

i01930350

Engine - Clean

Personal injury or death can result from high voltage.

Moisture can create paths of electrical conductivity.

Make sure that the electrical system is OFF. Lock out the starting controls and tag the controls “DO NOT OPERATE”.

NOTICE Accumulated ard. Keep the engine clean. Remove debris and ﬂuid spills whenever a signiﬁcant quantity accumulates on the engine.

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.

grease and oil on an engine is a ﬁre haz-

NOTICE

i01915869

Engine Air Cleaner Element (Dual Element

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 airborne debris from entering the air inlet.

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 typic information for the correct procedure.

If the air cle can split the material of the air cleaner element. Unﬁltered air will drastically accelerate internal engine wear correct air cleaner elements for your application.

Check the pr

•

bowl daily for accumulation of dirt and debris. Remove any dirt and debris, as needed.

al air ﬁlter system. Refer to the OEM

aner element becomes plugged, the air

. Refer to the OEM information for the

ecleaner (if equipped) and the dust

) - Clean /Replace

NOTICE

Periodic cleaning of the engine is recommended. Steam cleaning the engine will remove accumulated oil and grease. A clean engine provides the following beneﬁts:

Easy detection of ﬂuid leaks

•

Maximum heat transfer characteristics

•

Ease of maintenance

•

Note: Cautionmustbeusedinordertoprevent 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.

Operating conditions (dust, dirt and debris) may

•

require more frequent service of the air cleaner element.

The air cleaner element should be replaced at least

•

onetimepe performed regardless of the number of cleanings.

Replace th cleaner elements. Before installation, the air cleaner elements should be thoroughly checked for tears and/or ho or the seal of the air cleaner element for damage. Maintain a supply of suitable air cleaner elements for repla

r year. This replacement should be

e dirty air cleaner elements with clean air

les in the ﬁlter material. Inspect the gasket

cement purposes.

Page 56

56 SEBU8352 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace

Dual Element Ai

The dual element air cleaner contains a primary air cleaner eleme The primary air cleaner element can be used up to six times if the element is properly cleaned and properly ins should be replaced at least one time per year. This replacement should be performed regardless of the number of cle

The secondary air cleaner element is not serviceable or washable. instructions in order to replace the secondary air cleaner element. When the engine is operating in environmen elements may require more frequent replacement.

Illustration 26

(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.

pected. The primary air cleaner element

anings.

Refer to the OEM information for

ts that are dusty or dirty, air cleaner

rCleaners

nt and a secondary air cleaner element.

g00736431

Cleaning the Primary Air Cleaner Elements

NOTICE Observe the following guidelines if you attempt to clean the ﬁlter element:

Donottaporstriketheﬁlter element in order to remove 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 elements with damaged pleats, gaskets or seals. Damaged elements will allow dirt to pass through. Engine damage could result.

2. The secondary air cleaner element should be removed and discarded for every three cleanings of the primary air cleaner element.

Note: Refer to “Cleaning the Primary Air Cleaner Elements”.

3. Cover the air inlet with tape in order to keep dirt out.

4. Clean the inside of the air cleaner cover and body with a clean, dry cloth.

5. Remove the tape for the air inlet. Install the secondary air cleaner element. Install a primary air cleaner element that is new or cleaned.

6. Install the air cleaner cover.

7. Reset the air cleaner service indicator.

Visually inspect the primary air cleaner elements before cleaning. Inspect the air cleaner elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged air cleaner elements.

There are two common methods that are used to clean primary air cleaner elements:

Pressurized air

•

Vacuum cleaning

•

Pressurized A ir

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).

Page 57

SEBU8352 57

Maintenance Section

Engine Air Cleaner Element (Single Element) - Inspect/Replace

Illustration 27

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”.

g00281692

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. V acuum cleaning will not remove deposits of carbon and oil.

Inspect the cle 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. Rota Inspect the primary air cleaner element for tears and/or holes. Inspect the primary air cleaner element for light tha is necessary in order to conﬁrm the result, compare the primary air cleaner element to a new primary air cleaner ele

Do not use a primary air cleaner element that has any tears an use a primary air cleaner element with damaged pleats, gaskets or seals. Discard damaged primary air cleaner

Engine Air C

an, dry primary air cleaner element.

te the primary air cleaner element.

t may show through the ﬁlter material. If it

ment that has the same part number.

d/or holes in the ﬁlter material. Do not

elements.

i02152042

leaner Element (Single Element) Inspect/Replace

Refer to Op Air Cleaner Service Indicator-Inspect”.

eration and Maintenance Manual, “Engine

NOTICE

Note: Refer to “Inspecting the Primary Air Cleaner Elements”.

Inspecting the Primary Air Cleaner Elements

Illustration 28

g00281693

NOTICE Never ser running since this will allow dirt to enter the engine.

Awidevar with this engine. Consult the OEM information for the correct procedure to replace the air cleaner.

vice the air cleaner element with the engine

iety of air cleaners may be installed for use

i01909507

Engine Air C lean er Service Indicator - Inspect

Some eng service indicator.

ines may be equipped with a different

Page 58

58 SEBU8352 Maintenance Section Engine Mounts - Inspect

Some engines ar for inlet air pressure. The differential gauge for inlet air pressure displays the difference in the pressure that is measur the pressure that is measured after the air cleaner element. As the air cleaner element becomes dirty , the pressure equipped with a different type of service indicator, follow the OEM recommendations in order to service the air clea

The service indicator may be mounted on the air cleaner ele

e equipped with a differential gauge

ed before the air cleaner element and

differential rises. If your engine is

ner service indicator.

ment or in a remote location.

i02323089

Engine M o unts - Inspect

Note: The engin

supplied by Perkins. Refer to the OEM information for further information on the engine mounts and the correct bolt t

Inspect the engine mounts for deterioration and for correctboltt by the following conditions:

Incorrect mo

•

Deterioration of the engine mounts

•

Loose engine mounts

•

Any engine mo be replaced. Refer to the OEM information for the recommended torques.

e mounts may not have been

orque.

orque. Engine vibration can be caused

unting of the engine

unt that shows deterioration should

i02676018

Illustration 29

Typical se rvice 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:

The yellow diaphragm enters the red zone.

•

The red piston locks in the visible position.

•

g00103777

Test the Service Indicator

Service indicators are important instruments.

Check for ease of resetting. The service 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.

Engine Oil Level - Check

Hot oil and h injury. Do not allow hot oil or hot components to contact the skin.

Illustration 30

(Y) “MIN” mark. (X) “MAX” mark.

Perform this maintenance with the engine stopped.

ot components can cause personal

g0116583

NOTICE

The service indicator may need to be replaced frequently in environments that are severely dusty.

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.

Page 59

SEBU8352 59

Maintenance Section

Engine Oil Sample - Obtain

Note: After the the engine oil to drain to the oil pan before checking the oil level.

1. Maintain the oil level between the “MIN” mark (Y) and the “MAX” mark (X) on the engine oil dipstick. Do not ﬁll the (X).

Operating you “FULL” mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into acteristics and could result in the loss of power.

2. Remove the oil ﬁller cap and add oil, if necessary. Clean the oil ﬁller cap. Install the oil ﬁller cap.

engine has been switched OFF, allow

crankcase above the “MAX” mark

NOTICE

r engine when the oil level is above the

the oil reduces the oil’s lubricating char-

i02202699

Engine O il 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 o ption. 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.

Engine number

•

Service hours on the engine

•

The number of hours that have accumulated since

•

the last oil change

The amount of oil that has been added since the

•

last oil change

Ensure that the container for the sample is clean and dry. Also ensure that the container for the sample is clearly labe

To ensure that the sample is representative of the oil in the cra sample.

To avoid cont 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 exi the oil, and the existence of any nonferrous metal particles in the oil.

lled.

nkcase, obtain a warm, well mixed oil

amination of the oil samples, the tools

stence of any ferrous metal particles in

i02703306

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:

Thedateofthesample

•

Engine model

•

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.

Page 60

60 SEBU8352 Maintenance Section Engine Oil and Filter - Change

Drain the Engine Oil

Illustration 31

Oil drain plug

After the engine has been run at the normal operating temperature, stop the engine. Use one of the following methods to drain the engine crankcase oil:

g01356033

1. Remove the oil ﬁ

lter with a suitable tool.

Note: The following actions can be carried out as part of the pre

ventive maintenance program.

2. Cut the oil ﬁlter open with a suitable tool. Break apart the plea

ts 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 th

e 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.

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.

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 th e Spin-on Oil Filter

NOTICE Perkins oil ﬁlters are manufactured to Perkins speciﬁcations. Use of an oil ﬁlter that is not recommended by Perkins could result in severe damage to the engine 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.

Illustration 32

(2) Filter hea d (3) O ring seal

g01356034

3. Clean the sealing surface of the oil ﬁlter head (2). Ensure that the union (4) in the oil ﬁlter head is secure.

4. Apply clean engine oil to the O ring seal (3) on the oil ﬁlter.

Page 61

SEBU8352 61

Maintenance Section

Engine Valve Lash - Inspect/Adjust

NOTICE

Do not ﬁll the oi

l ﬁlters with oil before installing them. This oil would not be ﬁltered and could be contaminated. Contaminated oil can cause accelerated wear to engine compon

ents.

5. Install the oil ﬁlter. Tighten the oil ﬁlter by hand

according to t

he instructions that are shown on

the oil ﬁlter. Do not overtighten the oil ﬁlter.

Note: Some oil

ﬁlters may be installed vertically. Refer to illustration 33. Start at step (1) in order to remove the oil ﬁlter and install the oil ﬁlter.

2. Start the engin

e 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 th

eoilﬁlters are ﬁlled. Inspect the oil

ﬁlter for oil leaks.

3. Stop the engi

ne and allow the oil to drain back to

thesumpforaminimumoftenminutes.

Illustration 34

(Y) “MIN” mark. (X) “MAX” mark.

4. Remove the o

il level gauge in order to check the oil level. Maintain the oil level between the “MIN” and “MAX” marks on the engine oil dipstick.

g01165836

Illustration 33

Typical example

g01356074

Fill the Engine Crankcase

1. Remove the oil ﬁller cap. Refer to the Operation

and Maintenance Manual for more information on lubricant speciﬁcations. Fill the crankcase with the proper amount of oil. Refer to the Operation and Maintenance Manual for more information on reﬁll capacities.

NOTICE If equipped with an auxiliary oil ﬁlter system or a remote oil ﬁlter system, follow the OEM or ﬁlter manufacturer’s recommendations. Under ﬁlling or overﬁlling the crankcase with oil can cause engine damage.

NOTICE To prevent crankshaft bearing damage, crank the engine with the fuel OFF. This will ﬁll the oil ﬁlters before starting the engine. Do not crank the engine for more than 30 seconds.

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 authorized Perkins dealer or your Perkins distributor for the complete valve lash adjustment procedure.

Operation of Perkins engines with incorrect valve lash can reduce engine efﬁciency, and also reduce engine component life.

Page 62

62 SEBU8352 Maintenance Section Fuel Injector - Test/Change

Ensure that the engine can not be started while this maintenance is being performed. To help prevent 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 measuring/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.

i02198352

Fuel Injec tor - Test/Change

Fuel leaked cal components can cause a ﬁre.

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 disconnected fuel system component.

If a fuel injector is suspected of operating outside of normal para technician. The suspect fuel injector should be taken to an authorised agent for inspection.

The fuel injector (1) in illustration 35 has no fuel return. The fuel injector (2) has a fuel return.

or spilled onto hot surfaces or electri-

NOTICE

meters it should be removed by a qualiﬁed

Illustration 35

Typical fu

The fuel injector (1) will need to be removed and the injector

The fuel injectors should not be cleaned as cleaning with inco injectors should be renewed only if a fault with the fuel injectors occurs. Some of the problems that may indicat below:

•

el Injectors

will need to be checked for performance.

rrect tools can damage the nozzle. The fuel

e that new fuel injectors are needed are listed

The engi to start.

Not enou

Theenginemisﬁres or the engine runs erratically.

High fuel consumption

ne will not start or the engine is difﬁcult

gh power

g01110422

Black ex

•

The engine knocks or there is vibration in the

•

engine.

Excessive engine temperature

•

haust smoke

Page 63

SEBU8352 63

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 are tested, test ﬂuids travel through the oriﬁces of the nozzle tip with high pressure. Under this amount of pr skin and cause serious injury to the operator. Always keep the tip of the fuel injection nozzle pointed aw collector and extension.

If your skin comes into contact with high pressure fuel, obtain medical assistence immediately.

testing. When fuel injection nozzles

essure, the test ﬂuid can pierce the

ay from the operator and into the fuel

NOTICE

Use the followi from the fuel system:

1. Ensure that al

correctly.

2. Turn the keysw

keyswitch in the RUN position for three minutes. If a manual purging screw is installed, slacken the manual pu system.

3. Crank the eng

closed position until the engine starts.

ng procedure in order to remove air

l fuel connections are installed

itch to the RUN position. Leave the

rging screw during priming the fuel

ine with the throttle lever in the

Operate the engine at a fast idle speed in order to identify the faulty fuel injector. Individually loosen and tighten the union nut for the high pressure pipe to each fuel injector. Do not loosen the union nut more than half a turn. There will be little effect on the engine speed when the union nut to the faulty fuel injection nozzle is loosened. Refer to the Disassembly and Assembly Manual for more information. Consult your authorized Perkins dealer or your Perkins distributor for assistance.

i02869449

Fuel Sy stem - 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:

The fuel tank is empty or the fuel tank has been

•

partially drained.

The low pressure fuel lines are disconnected.

•

Illustration 36

Injector nuts

Note: If necessary, loosen the union nuts (1) on the fuelinjectionlinesattheconnectionwiththefuel injector until fuel is evident. Stop cranking the engine. Tightentheunionnutstoatorqueof27N·m(20lbft).

4. Start the engine and run the engine at idle for one

minute.

5. Cycle the throttle lever from the low idle position to

thehighidlepositionthreetimes.Thecycletime for the throttle lever is approximately 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. This should be repeated three times. This will assist in removing trapped air from the fuel injection pump.

6. Return the engine to no load condition. Check for

leaks in the fuel system.

g01228000

A leak exists in the low pressure fuel system.

•

The fuel ﬁlter is replaced.

•

A new injection pump is installed.

•

Page 64

64 SEBU8352 Maintenance Section Fuel System Primary Filter/Water Separator - Drain

i02873783

Fuel System Primary Filter/Water

Fuel leaked or spilled onto hot surfaces or electrical components can cause a ﬁre. To help prevent possible injury, turn the start switch off when changing fuel ﬁlters or water separator elements. Clean up fuel spills immediately.

The water separator is not a ﬁlter. The water separator separates water from the fuel. The engine should never be allo than half full. Engine damage may result.

wed to run with the water separator more

Separator - Drain

NOTICE

NOTICE The water separator is under suction during normal engine operation. Ensure that the drain valve is tightened securely to help prevent air from entering the fuel system.

Illustration 37

(1) Screw (2) Elemen (3) Glass b (4) Sensor (5) Drain (6) Bottom c

t owl

connection

over

g01118416

1. Place a suitable container below the water separator

2. Open the drain (5). Allow the ﬂuid to drain into the contai

ner.

3. When clean fuel drains from the water separator close the d

rain (5). Tighten the drain by hand pressure only. Dispose of the drained ﬂuid correctly.

Page 65

SEBU8352 65

Maintenance Section

Fuel System Primary Filter (Water Separator) Element - Replace

i02875191

Fuel System Primary Filter (Water Separa

tor) Element -

Replace

NOTICE Do not allow dirt to enter the fuel system. Thoroughly clean the are will be disconnected. Fit a suitable cover over disconnected fuel system component.

a around a fuel system component that

1. Turn the fuel su position.

2. Place a suitab 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 elem

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

9. Remove the container and dispose of the fuel safely.

pply valve (if equipped) to the OFF

le container under the water

ent (2) and remove the screw (1).

·m (6 lb ft).

Illustration 38

Typical example

(1) Screw (2) Element (3) Glass bowl (4) Sensor conne ction (5) Drain (6) Bottom cover

g01118416

10. Open the fuel supply valve.

11. Prime the fuel system. Refer to the Operation and

Maintenance Manual, “Fuel System - Prime” for more inform

Fuel Syste

ation.

i02873572

m Secondary Filter -

Replace

Fuel leake trical components can cause a ﬁre. To help prevent possible injury, turn the start switch off when changing Cleanupfuelspillsimmediately.

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 disconnected fuel system component.

d or spilled onto hot surfaces or elec-

fuel ﬁlters or water separator elements.

NOTICE

Page 66

66 SEBU8352 Maintenance Section Hoses and Clamps - Inspect/Replace

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 39

Typical example

(1) Fuel priming pump (2) Spin-on ﬁ lter (3) Drain

g01440509

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 fuel priming pump (1).

3. Ensure that the fuel drain (3) on the new spin-on ﬁlter is closed.

Illustration 40

Typical example

g01440510

4. Lubricate the sealing ring (4) with clean fuel oil.

5. Install the spin-on ﬁlter (2) into the top of the fuel

priming pump (1).

6. Tighten the spin-on ﬁlter by hand until the sealing ring contacts the fuel priming pump. Rotate the spin-on ﬁlter through 90 degrees.

7. Prime the fuel system. Refer to Operation and Maintenance Manual, “Fuel System - Prime”.

i02813964

Hoses and Clamps Inspect/Replace

Inspect all hoses for leaks that are caused by the following conditions:

Cracking

•

Softness

•

Loose clamps

•

Replace hoses that are cracked or soft. Tighten any loose clamps.

Page 67

SEBU8352 67

Maintenance Section

Radiator - Clean

NOTICE Do not bend or st stall bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks c and hoses carefully. Tighten all connections to the recommended torque. Do not clip any other item to the high pressur

rike high pressure lines. Do not in-

an cause ﬁres. Inspect all lines, tubes

e lines.

Check for the following conditions:

End ﬁttings that are damaged or leaking

•

Outer coverin

•

Exposed wire that is used for reinforcement

•

Outer covering that is ballooning locally

•

Flexible par

•

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 c clamp.

Duetoextrem harden. Hardening of the hoses will cause hose clamps to loosen. This can result in leaks. A constant torque hose clamps.

Each instal differences depend on the following factors:

Type of hose

•

Type of ﬁtting material

•

Anticipated expansion and contraction of the hose

•

g that is chafed or cut

t of the hose that is kinked or crushed

lamp is the same size as the standard

e temperature changes, the hose will

clamp will help to prevent loose hose

lation application can be different. The

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. Removethehoseclamps.

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install the hose clamps with a torque wrench.

Note: For the correct coolant, see this Operation and

Maintenance Manual, “Fluid Recommendations”.

8. Reﬁll the cooling system. Refer to the OEM information for further information on reﬁlling the cooling system.

9. Clean the cooling system ﬁller cap. Inspect the cooling system ﬁller cap’s seals. Replace the cooling system ﬁller cap if the seals are damaged. Install the cooling system ﬁller cap.

10. Start the engine. Inspect the cooling system for leaks.

Anticipate

•

ﬁttings

d expansion and contraction of the

Replace the Hoses and the Clamps

Refer to th on removing and replacing fuel hoses (if equipped).

The coolan system are not usually supplied by Perkins. The following text describes a typical method of replacing coolant h further information on the coolant system and the hoses for the coolant system.

e OEM information for further information

t system and the hoses for the coolant

oses. Refer to the OEM information for

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.

Page 68

68 SEBU8352 Maintenance Section Severe Service Application - Check

Inspect the rad corrosion, dirt, grease, insects, leaves, oil, and other debris. Clean the radiator, if necessary.

Personal inj

Personal injury can result without following proper procedure tective face shield and protective clothing.

Maximum air p than 205 kPa (30 psi) for cleaning purposes.

Pressurized loose debris. Direct the air in the opposite direction to the fan’s air ﬂow. Hold the nozzle approximately 6mm(0.25inc move the air nozzle in a direction that is parallel with the radiator tube assembly. This will remove debris that is betw

Pressurized water may also be used for cleaning. The maximum must be less than 275 kPa (40 psi). Use pressurized water in order to soften mud. Clean the core from both sides

Use a degreaser and steam for removal of oil and grease. Cl 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 engin ﬁve minutes. Accelerate the engine to high idle. This will help in the removal of debris and the drying of the core and then stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat t

iator for these items: Damaged ﬁns,

ury can result from air pressure.

. When using pressure air, wear a pro-

ressure at the nozzle must be less

air is the preferred method for removing

h) away from the radiator ﬁns. Slowly

een the tubes.

water pressure for cleaning purposes

ean both sides of the core. Wash the core

e to operate at low idle speed for three to

.Slowlyreducetheenginespeedtolowidle

he cleaning, if necessary.

i02335775

Severe Service Application Check

Severe service is the application of an engine that exceeds the current published standards for that engine. Perki engine parameters:

Performance

•

and fuel consumption

Fuel quality

•

Operational Altitude

•

Maintenance intervals

•

Oil selectio

•

Coolant type and maintenance

•

Environmental qualities

•

Installatio

•

The temperature of the ﬂuid in the engine

•

Refer to the standards for the engine or consult your Perkins dealer or your Perkins distributor in order to determine if parameters.

Severe serv wear. Engines that operate under severe conditions may need more frequent maintenance intervals in order to ens full service life.

Due to indiv to identify all of the factors which can contribute to severe service operation. Consult your Perkins dealer or y maintenance that is necessary for the engine.

ns maintains standards for the following

such as power range, speed range,

n and maintenance

the engine is operating within the deﬁned

ice operation can accelerate component

ure maximum reliability and retention of

idual applications, it is not possible

our Perkins distributor for the unique

Inspect the ﬁns for damage. Bent ﬁns may be opened with a “c Welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary.

omb”. Inspect these items for good condition:

The operat procedures and incorrect maintenance procedures can be factors which contribute to a severe service applicat

ing environment, incorrect operating

ion.

Page 69

SEBU8352 69

Maintenance Section

Starting Motor - Inspect

Environmental Factors

Ambient temper

exposed to extended operation in extremely cold environments or hot environments. Valve components ca the engine is frequently started and stopped in very cold temperatures. Extremely hot intake air reduces engine perfo

Quality of the air – The engine may be exposed to extended o dirty or dusty, unless the equipment is cleaned regularly. Mud, dirt and dust can encase components. Maintenanc contain corrosive chemicals.

Buildup – Co chemicals and salt can damage some components.

Altitude – P operated at altitudes that are higher than the intended settings for that application. Necessary adjustments should be m

Incorrect

Extended operation at low idle

•

Frequent hot shutdowns

•

Operating

•

Operating at excessive speeds

•

Operating outside the intended application

•

atures – The engine may be

n be damaged by carbon buildup if

rmance.

peration in an environment that is

e can be very difﬁcult. The buildup can

mpounds, elements, corrosive

roblems can arise when the engine is

ade.

Operating Procedures

at excessive loads

Check the start the electrical connections and clean the electrical connections. Refer to the Systems Operation, Testing and Adjusting Test” for more information on the checking procedure and for speciﬁcations or consult your Perkins dealer or your Perki

ing motor for correct operation. Check

Manual, “Electric Starting System -

ns distributor for assistance.

i02184788

Turbocharger - Inspect (If Equipped)

A regular visual inspection of the turbocharger is recommended. Any fumes from the crankcase are ﬁltered through the air inlet system. Therefore, by-products from oil and from combustion can collect in the turbocharger compressor housing. Over time, this buildup can contribute to loss of engine power, increased black smoke and overall loss of engine efﬁciency.

If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to the turbocharger compressor wheel can cause additional damage to the pistons, the valves, and the cylinder head.

NOTICE Turbocharger bearing failures can cause large quantities of oil to enter the air intake and exhaust systems. Loss of engine lubricant can result in serious engine damage.

Incorrect Maintenance Procedures

Extending

•

Failure to use recommended fuel, lubricants and

•

coolant/a

Starting M

Perkins recommends a scheduled inspection of the starting motor. If the starting motor fails, the engine may not st

the maintenance intervals

ntifreeze

i02177969

otor - Inspect

art in an emergency situation.

Minor leakage of oil into a turbocharger under extended low idle operation should not cause problems as long as a turbocharger bearing failure has not occured.

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.

Page 70

70 SEBU8352 Maintenance Section Walk-Around Inspection

For options reg replacement, consult your Perkins dealer or your Perkins distributor. Refer to the Disassembly and Assembly Manu Turbocharger - Install” for further information.

arding the removal, installation, and

al, “Turbocharger - Remove and

Inspecting

NOTICE The compress not be removed from the turbocharger for cleaning.

The actuator housing. If the actuator linkage is moved or disturbed the engine may not comply with emmissions legislation.

1. Remove the pipe from the turbocharger exhaust

outlet and remove the air intake pipe to the turbocharg 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 si possibility of a failed turbocharger oil seal.

or housing for the turbocharger must

linkage is connected to the compressor

er. Visually inspect the piping for the

de of the compressor wheel, there is a

The guards must

•

damaged guards or replace missing guards.

Wipe all caps a

•

serviced in order to reduce the chance of system contamination.

For any type of ﬂuid. If leaking is observed, ﬁnd the source and correct the leak. If leaking is suspected, check the ﬂuid levels more often th or ﬁxed, or until the suspicion of a leak is proved to be unwarranted.

Accumulated grease and/or oil on an engine is a ﬁre hazard. Remove the accumulated grease and oil. Refer to this Operation and Maintenance Manual, “Engine - 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.

•

be in the correct place. Repair

nd plugs before the engine is

NOTICE

leak (coolant, lube, or fuel) clean up the

an recommended until the leak is found

NOTICE

The presen engine operation at low idle. The presence of oil mayalsobetheresultofarestrictionoftheline for the int the turbocharger to slobber.

3. Inspect t

outlet for corrosion.

4. Fasten th

pipe to the turbocharger housing.

ce of oil may be the result of extended

ake air (clogged air ﬁlters), which causes

he bore of the housing of the turbine

e air intake pipe and the exhaust outlet

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 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:

Note: The water pump seal is lubricated by the coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and the parts contract.

Excessive coolant leakage may indicate the need to replace the water pump seal. For the removal of the water pump and the installation of water pump and/or seal, refer to the Disassembly and Assembly Manual, “Water Pump - Remove and Install” for more information or consult your Perkins dealer or your Perkins distributor.

Inspect the lubrication system for leaks at the front

•

crankshaft seal, the rear crankshaft seal, the oil pan, the oil ﬁlters and the rocker cover.

Inspect the fuel system for leaks. Look for loose

•

fuel line clamps and/or tie-wraps.

Inspect the piping for the air intake system and the

•

elbows for cracks and for loose clamps. Ensure that hoses and tubes are not contacting other hoses, tubes, wiring harnesses, etc.

Inspect the alternator belts and any accessory

•

drive belts for cracks, breaks or other damage.

Page 71

SEBU8352 71

Maintenance Section

Water Pump - Inspect

Belts for multi matched sets. If only one belt is replaced, the belt will carry more load than the belts that are not replaced. The older belt the new belt could cause the belt to break.

Drain the wat

•

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 cond

Disconnect any battery chargers that are not

•

protected a motor. Check the condition and the electrolyte level of the batteries, unless the engine is equipped with a maintena

Check the condition of the gauges. Replace any

•

gauges tha can not be calibrated.

ple groove pulleys must be replaced as

s are stretched. The additional load on

er and the sediment from the fuel

ition.

gainst the current drain of the starting

ncefreebattery.

t are cracked. Replace any gauge that

i01907756

Water Pump - Inspect

A failed water pump may cause severe engine overheati conditions:

Cracks in t

•

Apistonseizure

•

Other potential damage to the engine

•

Note: The w coolant in the cooling system. It is normal for a small amount of leakage to occur as the engine cools down and parts

Visually inspect the water pump for leaks. Renew the water is an excessive leakage of coolant. Refer to the Disassembly and Assembly Manual, “Water Pump

- Remove assembly procedure.

ng problems that could result in the following

he cylinder head

ater pump seal is lubricated by the

contract.

pump seal or the water pump if there

and Install” for the disassembly and

Page 72

72 SEBU8352 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 pre manufacture, and this engine may be covered by an Emissions Warranty. Consult your authorized Perkins dealer or yo to determine if your engine is emissions certiﬁed and if your engine is subject to an Emissions Warranty.

scribed by the law at the time of

ur authorized Perkins distributor in order

Page 73

SEBU8352 73

Index Section

Index

After Startin

After Stopping Engine............................................ 28

Aftercooler Core - Clean/Test ................................ 47

Aftercooler C

Alternator - Inspect ................................................ 48

Alternator and Fan Belts - Inspect/Adjust/

Replace................................................................ 48

Adjustment ......................................................... 48

Inspection........................................................... 48

Replacement...................................................... 49

Battery - Replace................................................... 49

Battery Elect

Battery or Battery Cable - Disconnect ................... 50

Before Starting Engine .................................... 10, 24

Burn Preventio

Batteries............................................................... 8

Coolant................................................................. 8

Oils....................................................................... 8

Cold Weather Operation ........................................ 29

Hints for Cold We

Idling the Engine ................................................ 30

Recommendations for Coolant Warm Up .......... 30

Recommendation

Viscosity of the Engine Lubrication Oil............... 29

Cold Weather Starting ........................................... 25

Cooling System C

Change ................................................................ 50

Drain .................................................................. 50

Fill ...................................................................... 51

Flush .................................................................. 51

Cooling System Coolant (ELC) - Change.............. 52

Drain .................................................................. 52

Fill ...................................................................... 53

Flush .................................................................. 52

Cooling System Co

Cooling System Coolant Level - Check ................. 53

Engines With a Coolant Recovery Tank............. 53

Engines Without a

Crushing Prevention and Cutting Prevention ........ 10

Driven Equipment

g Engine ............................................. 26

ore - Inspect...................................... 47

rolyte Level - Check .......................... 49

n....................................................... 8

ather Operation ...................... 29

s for the Coolant .................... 29

oolant (Commercial Heavy-Duty) -

olant Extender (ELC) - Add..... 53

Coolant Recovery Tank........ 54

- Check..................................... 54

Electrical Sy

Grounding Practices .......................................... 12

Emergency Stopping ............................................. 28

Emissions Cer

Emissions Warranty Information............................ 72

Engine - Clean....................................................... 55

Engine Air Clea

Clean/Replace ..................................................... 55

Cleaning the Primary Air Cleaner Elements ...... 56

Servicing the A Engine Air Cleaner Element (Single Element) -

Inspect/Replace ................................................... 57

Engine Air Clea

Test the Service Indicator................................... 58

Engine Description ................................................ 14

Engine Cooling

Engine Service Life ............................................ 15

Engine Speciﬁcations......................................... 14

Engine Identiﬁc

Engine Mounts - Inspect........................................ 58

Engine Oil and Filter - Change .............................. 59

Drain the Engine

Fill the Engine Crankcase .................................. 61

Replace the Spin-on Oil Filter ........................... 60

Engine Oil Level -

Engine Oil Sample - Obtain ................................... 59

Obtain the Sample and the Analysis.................. 59

Engine Operation

Engine Starting ................................................. 11, 24

Engine Stopping ............................................... 11, 28

Engine Valve Lash

Engine Warm-up.................................................... 27

Features and Cont

Fire Prevention and Explosion Prevention .............. 8

Fire Extinguisher .................................................. 9

Lines, Tubes and Ho

Fluid Recommendations ............................ 33, 38, 42

Cooling System Speciﬁcations........................... 33

ELC Cooling System M

Engine Oil .......................................................... 39

Fuel Speciﬁcations............................................. 42

General Lubricant

Foreword ..................................... ............................ 4

California Proposition 65 Warning ....................... 4

Literature Informa

Maintenance ........................................................ 4

Maintenance Intervals.......................................... 4

Operation ............................................................. 4

Overhaul .............................................................. 4

Safety................................................................... 4

Fuel and the Effect fr

Fuel Conservation Practices.................................. 27

stem .................................................... 11

tiﬁcation Film .................................. 18

ner Element (Dual Element) -

ir Cleaner Elements ................... 55

ner Service Indicator - Inspect...... 57

and Lubrication ......................... 15

ation .............................................. 16

Oil........................................... 60

Check ....................................... 58

................................................... 27

- Inspect/Adjust ....................... 61

rols ........................................... 23

ses .................................... 10

aintenance .................... 36

Information ........................... 38

tion........................................... 4

om Cold Weather ................. 31

Page 74

74 SEBU8352 Index Section

Fuel Injector -

Removal and Installation of the Fuel Injectors ... 63

Fuel Related Components in Cold Weather .......... 32

Fuel Filters ......................................................... 32

Fuel Heaters ...................................................... 32

Fuel Tanks.......................................................... 32

Fuel Shutoff ........................................................... 23

Fuel System - Prime .............................................. 63

Fuel System Primary Filter (Water Separator)

Element - Replac

Fuel System Primary Filter/Water Separator -

Drain .................................................................... 64

Fuel System Seco

Spin-on ﬁlter....................................................... 66

Gauges and Indic

General Hazard Information .................................... 6

Containing Fluid Spillage ..................................... 7

Fluid Penetrati

Pressure Air and Water........................................ 7

Hoses and Clamps

Replace the Hoses and the Clamps .................. 67

Important Safet

Test/Change ................................... 62

e ............................................... 65

ndary Filter - Replace ............... 65

ators .......................................... 22

on.................................................. 7

- Inspect/Replace ................... 66

y Information ................................... 2

Product Storag

Cooling System.................................................. 20

Exhaust System ................................................. 20

General Items .................................................... 2

Induction System ............................................... 20

Lubrication System ............................................ 19

Radiator - Clean .................................................... 67

Reference Numbers .............................................. 17

Record for Refe

Reﬁll Capacities..................................................... 33

Cooling System.................................................. 33

Lubrication Sys

Safety Messages ..................................................... 5

(1) Universal W

(2) Ether ............................................................... 6

Safety Section ......................................................... 5

Serial Number Pl

Severe Service Application - Check ...................... 68

Environmental Factors ....................................... 69

Incorrect Mainte

Incorrect Operating Procedures......................... 69

Starting Motor - Inspect ......................................... 69

Starting the Engi

Starting with Jump Start Cables ............................ 26

Stopping the Engine .............................................. 28

e..................................................... 19

rence......................................... 17

tem ............................................ 33

arning .......................................... 5

ate .............................................. 16

nance Procedures .................... 69

ne ................................................ 25

Lifting and Storage ................................................ 19

Maintenance Interval Schedule ............................. 46

Maintenance Section ............................................. 33

Model View Illus

1103D Engine Model Views ............................... 13

Model Views .......................................................... 13

Mounting and Dis

Operation Section.................................................. 19

Product Identiﬁcation Information .......................... 16

Product Information Section .................................. 13

Product Lifting

trations......................................... 13

mounting.................................... 10

........................................................ 19

Table of Contents..................................................... 3

Turbocharger - Inspect (If Equipped)..................... 69

Inspecting........................................................... 70

Removal and Installation.................................... 69

Walk-Around Insp

Inspect the Engine for Leaks and for Loose

Connections ..................................................... 70

Warranty Informat

Warranty Section ................................................... 72

Water Pump - Inspect............................................ 71

ection ........................................ 70

ion ............................................. 72

Page 75

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:

Page 76

Perkins Engine 1103D Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual