Perkins Engine 1104D Service Manual

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Page 1

Operation and Maintenance Manual

SEBU8172-02

July 20 12

1104D Industrial Engine

(Engine)

NH NJ (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

SEBU8172-02 3

Table of Contents

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

Safety Section

Safety Messages .................................................... 6

General Hazard Information ................................... 9

Burn Prevention .................................................... 10

Fire Prevention and Explosion Prevention ............. 11

Crushing Prevention and Cutting Prevention ........ 13

Mounting and Dismounting ................................... 13

High Pressure Fuel Lines ..................................... 13

Before Starting Engine .......................................... 15

Engine Starting ..................................................... 15

Engine Stopping ................................................... 16

Maintenance In

Warranty Sect

Warranty Information .......................................... 105

terval Schedule ............................ 69

ion

Index Section

Index ................................................................... 106

Electrical System .................................................. 16

Engine Electronics ................................................ 17

Product Information Section

Model Views ......................................................... 18

Product Identiﬁcation Information ........................ 23

Operation Section

Lifting and Storage ................................................ 25

Gauges and Indicators .......................................... 27

Features and Controls .......................................... 29

Engine Diagnostics ............................................... 36

Engine Starting ..................................................... 40

Engine Operation .................................................. 43

Engine Stopping ................................................... 44

Cold Weather Operation ....................................... 46

Maintenance Section

Reﬁll Capacities .................................................... 50

Maintenance Recommendations .......................... 67

Page 4

4 SEBU8172-02 Foreword

Foreword

Literature Information

This manual co lubrication and maintenance information. This manual should be stored in or near the engine area in a literatu 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 consist

Some photographs or illustrations in this manual show detai from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improveme may have caused changes to your engine which are not included in this manual. Whenever a question arises re consult with your Perkins dealer for the latest available information.

ntains safety, operation instructions,

re holder or literature storage area. Read,

ency in electronic media delivery.

ls or attachments that may be different

nt and advancement of product design

garding your engine, or this manual, please

Use fuel consum intervals. Calendar intervals shown (daily, annually, etc.) may be used instead of service meter intervals if they provid approximate the indicated service meter reading.

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

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

nimize operating costs through cost

ption or service hours to determine

e more convenient schedules and

service should be performed at the

e also governs the Maintenance Interval

nt lubrication and maintenance than is

tive maintenance program is followed, a

Maintenance Intervals

Safety

This safety section lists basic safety precautions. In addition, this section identiﬁes hazardous,

g situations. Read and understand the basic

warnin precautions listed in the safety section before operating or performing lubrication, maintenance and

on this product.

repair

Opera

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

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

tion

. They assist with developing the skills and

lop as the operator gains knowledge of the

peration section is a reference for operators.

stopping the engine. This section also includes a

Maintenance

e maintenance section is a guide to engine care.

Th The illustrated, step-by-step instructions are grouped by fuel consumption, service hours and/or calendar

me maintenance intervals. Items in the maintenance

ti schedule are referenced to detailed instructions that follow.

Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in depending upon your speciﬁc maintenance practices, operation and application. We recommend that the mai displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maint

See the section in the Operation and Maintenance Manua regarding documents that are generally accepted as proof of maintenance or repair. Your authorized Perkins dealer can assist you in adjusting your maintena operating environment.

each level should be shifted ahead or back

ntenance schedules be reproduced and

ained as part of the engine's permanent record.

l, “Maintenance Records” for information

chedule to meet the needs of your

nce s

Overhaul

Major engine overhaul details are not covered in the Operation and Maintenance Manual except for the

erval and the maintenance items in that interval.

int Major repairs are best left to trained personnel or an authorized Perkins dealer. Your Perkins

ler offers a variety of options regarding overhaul

dea programs. If you experience a major engine failure, there are also numerous after failure overhaul options

ailable from your Perkins de

dealer for information regarding these options.

your

aler. Consult with

Page 5

SEBU8172-02 5

Foreword

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands

after handling.

Page 6

6 SEBU8172-02 Safety Section Safety Messages

Safety Section

i02864025

Safety Me ssages

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

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

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

lacement part. Your Perkins dealer or your

several speciﬁc warning signs on your

iliar with all warning signs.

g signs or replace the warning signs if

ng signs. Do not use solvents, gasoline, or

signs. The warning signs that are loosened

any warning sign that is damaged or

The Universal W sides of the valve mechanism cover base. Refer to illustration 1.

arning label (1) is located on both

(1) Universal Warning

Do not operate or work on this equipment unless

ave read and understand the instructions

you h and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or

the warnings could result in serious injury

heed or death.

Illustration 1

ypical example

g01154807

Page 7

SEBU8172-02 7

Safety Section

Safety Messages

Illustration 2

ersal warning

(1) Univ

(2) Han

d (High Pressure)

Contact with high pressure fuel may cause ﬂuid penetration and burn hazards. High pressure fu-

ay may cause a ﬁre hazard. Failure to fol-

el spr low these inspection, maintenance and service instructions may cause personal injury or death.

g01268960

Page 8

8 SEBU8172-02 Safety Section Safety Messages

Illustration 3

(2) Hand

Illustration 4

Typical example

(High Pressure)

(3) Ethe

g01154858

The warning label for the Hand (High Pressure) (2) is located on the top of the fuel manifold. Refer to illustration 4.

(3) Ether

g01426636

Illustration 5

Typical example

g01154809

The ether warning label (3) is located on the cover of the inlet manifold. Refer to illustration 4.

Note: The location of this label will depend on the application of the engine.

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

Page 9

SEBU8172-02 9

Safety Section

General Hazard Information

i02328435

General Hazard Information

Illustration 6

Attach a “Do Not Operate” warning tag or a similar warning tag to the start switch or to the controls before y

ou service the equipment or before you

repair the equipment.

g0010454

Report all nece

ssary repairs.

Do not allow unauthorized personnel on the equipment.

Ensure that the power supply is disconnected before youworkonth

e bus bar or the glow plugs.

Perform maintenance on the engine with the equipment i

ntheservicingposition.Refertothe 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 i

The direct application of pressurized air or pressuri injury.

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

njury.

zed water to the body could result in personal

surized air and/or water is used for

ective face shield.

02020

Illustration 7

g007

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

lkways, and from steps.

The maximum air pressure for cleaning purposes must be b

elow 205 kPa (30 psi). The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can

hydraulic ﬂuid or items such as pipe plugs to

cause escape rapidly if the pressure is not relieved correctly.

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

remove any hydraulic components or parts

onents or parts until pressure has been relieved

eve the hydraulic pressure.

Never put maintenance ﬂuids into glass containers.

rain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care.

Page 10

10 SEBU8172-02 Safety Section Burn Prevention

Contact with high pressure fuel may cause ﬂuid penetration and burn hazards. High pressure fuel spray may cause a ﬁre hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

Illustration 8

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 ﬂuidwitha 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.

Only use the tools that are suitable for containing

•

ﬂuids and equipment that is suitable for containing ﬂuids.

Allow the pressure to be purged in the air system, in the hydraulic system, in the lubrication system, or in the cooling system before any lines, ﬁttings or related items are disconnected.

Coolant

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

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

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

Ensure that the ﬁller cap is cool before removing the ﬁller cap. The ﬁller cap must be cool enough to touch with a bare hand. Remove the ﬁller cap slowly in order to relieve pressure.

Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

Obey all local regulations for the disposal of liquids.

i02334785

n P revention

Bur

Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is

rformed on the engine.

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.

Page 11

SEBU8172-02 11

Safety Section

Fire Prevention and Explosion Prevention

i04823662

Fire Prevention and Explosio n Prevention

tion 9

Illustra

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

Flammable ﬂuids that are leaking or spilled onto hot surface a ﬁre. Fire may cause personal injury and property damage.

After the emergency stop button is operated, ensure that you allow 15 minutes, before the engine covers are rem

Determine whether the engine will be operated in an envir drawn into the air inlet system. These gases could cause the engine to overspeed. Personal injury, prop

If the application involves the presence of combustible gase 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 materials or conductive materials to accumulate on the engine.

able.

s or onto electrical components can cause

oved.

onment that allows combustible gases to be

erty damage, or engine damage could result.

s, consult your Perkins dealer and/or your

engine. Do not allow any ﬂammable combustible

g00704000

Exhaust shield components from oil or fuel spray in a line, a tube, or a seal failure. Exhaust shields must be installed correctly.

Do not weld on lines or tanks that contain ﬂammable

ﬂuids. Do not ﬂammable ﬂuid. Clean any such lines or tanks

thoroughly with a nonﬂammable solvent prior to welding or ﬂ

Wiring must be kept in good condition. Ensure that all electri attached. Check all electrical wires daily. Repair any wires that are loose or frayed before you operate the engine. Cl all electrical connections.

Eliminate Do not use any wires or cables that are smaller than the recommended gauge. Do not bypass any fuses and/or ci

Arcing or sparking could cause a ﬁre. Secure connecti maintained battery cables will help to prevent arcing or sparking.

Contac penetration and burn hazards. High pressure fuel spray may cause a ﬁre hazard. Failure to follow the structions may cause personal injury or death.

After order to allow the fuel pressure to be purged from the high-pressure fuel lines before any service or repair is pe

Ensure that the engine is stopped. Inspect all lines and h route all hoses. The lines and hoses must have adequate support and secure clamps.

Properly install oil ﬁlters and fuel ﬁlters. The ﬁlter housings must be tightened to the correct torque. Ref more information.

t with high pressure fuel may cause ﬂuid

se inspection, maintenance and service in-

the engine has stopped, wait for 60 seconds in

rformed on the engine fuel lines.

oses for wear or for deterioration. Properly

er to the Disassembly and Assembly manual for

s (if equipped) protect hot exhaust

ﬂame cut lines or tanks that contain

ame cutting.

cal wires are correctly routed and securely

ean all electrical connections and tighten

all wiring that is unattached or unnecessary.

rcuit breakers.

ons, recommended wiring, and correctly

Store fuels and lubricants in correctly marked containers away from unauthorized persons. Store

ly rags and any ﬂammable materials in protective

oi containers. Do not smoke in areas that are used for storing ﬂammable materials.

Do not expose the engine to any ﬂame.

Page 12

12 SEBU8172-02 Safety Section Fire Prevention and Explosion Prevention

Illustration 10

Use caution when you are refueling an engine. Do not smoke while you are refueling an engine. Do not refuel an engine near open ﬂames or sparks. Always stop the engine before refueling.

g00704059

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

Do not charge a frozen battery.Charging a frozen battery may c

The batteries must be kept clean. The covers (if equippe recommended cables, connections, and battery box covers when the engine is operated.

er cable connections can cause

ause an explosion.

d) must be kept on the cells. Use the

Fire Extinguisher

Make sure that a ﬁre extinguisher is available. Be familiar with the operation of the ﬁre extinguisher. Inspect th extinguisher regularly. Obey the recommendations on the instruction plate.

e ﬁre extinguisher and service the ﬁre

Lines, Tubes, and Hoses

Do not bend high-pressure lines. Do not strike high-pressure lines. Do not install any lines that are damaged

Illustration 11

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.

g02298225

Leaks can cause ﬁres. Consult your Perkins dealer or your P

Replace the parts if any of the following conditions are pre

High-pressure fuel line or lines are removed.

•

End ﬁttings are damaged or leaking.

•

Outer

•

Wires are exposed.

•

Outer coverings are ballooning.

•

Flex

•

Outer covers have embedded armoring.

•

End ﬁttings are displaced.

•

Mak are installed correctly in order to prevent vibration, rubbing against other parts, and excessive heat.

erkins distributor for replacement parts.

sent:

coverings are chafed or cut.

ible parts of the hoses are kinked.

e sure that all clamps, guards, and heat shields

Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or ahydrometer.

Page 13

SEBU8172-02 13

Safety Section

Crushing Prevention and Cutting Prevention

i02143194

Crushing Prevention and Cutting Preve

Support the component correctly when work beneath the component is performed.

Unless other maintenance instructions are provided, never attempt adjustments while the engine is running.

Stay clear of all rotating parts and of all moving parts. Lea is performed. After the maintenance is performed, reinstall the guards.

Keep objects away from moving fan blades. The fan blades will throw objects or cut objects.

When objects are struck, wear protective glasses in order to avoid injury to the eyes.

Chips or other debris may ﬂy off objects when objects are struck. Before objects are struck, ensure that no one will

ve the guards in place until maintenance

be injured by ﬂying debris.

ntion

i02861106

High Pressure Fuel Lines

Contact with high pressure fuel may cause ﬂuid penetration and burn hazards. High pressure fuel spray may low these inspection, maintenance and service instructions may cause personal injury or death.

cause a ﬁre hazard. Failure to fol-

i02235492

Mounting and Dismounting

Inspect the steps, the handholds, and the work area before mounting the engine. Keep these items clean and keep these items in good repair.

Mount the engine and dismount the engine only at locations that have steps and/or handholds. Do not climb on the engine, and do not jump off the engine.

Face the engine in order to mount the engine or dismount the engine. Maintain a three-point contact with the steps and handholds. Use two feet and one hand or use one foot and two hands. Do not use any controls as handholds.

Do not stand on components which cannot support your weight. Use an adequate ladder or use a work platform. Secure the climbing equipment so that the equipment will not move.

Do not carry tools or supplies when you mount the engine or when you dismount the engine. Use a hand line to raise and lower tools or supplies.

Page 14

14 SEBU8172-02 Safety Section High Pressure Fuel Lines

Illustration 12

(1)Highpressureline (2)Highpressureline

(3) High pre ssure line (4) High pre ssure line

The high pressure fuel lines are the fuel lines that are between the high pressure fuel pump and the high pressure fuel manifold and the fuel lines that are between the fuel manifold and cylinder head. These fuel lines are different from fuel lines on other fuel systems.

This is because of the following differences:

The high pressure fuel lines are constantly charged

•

with high pressure.

The internal pressures of the high pressure fuel

•

lines are higher than other types of fuel system.

The high pressure fuel lines are formed to shape

•

and then strengthened by a special process.

Do not step on the high pressure fuel lines. Do not deﬂect the high pressure fuel lines. Do not bend or strike the high pressure fuel lines. Deformation or damage of the high pressure fuel lines may cause a point of weakness and potential failure.

g01425090

(5) High pressure fuel manifold (rail) (6) High pressure line

Do not check the high pressure fuel lines with the engine or the starting motor in operation. After the engine has stopped allow 60 seconds to pass in order to allow the pressure to be purged before any service or repair is performed on the engine fuel lines.

Do not loosen the high pressure fuel lines in order to remove air from the fuel system. This procedure is not required.

Visually inspect the high pressure fuel lines before the engine is started. This inspection should be each day.

If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a ﬂuid penetration hazard. Refer to Operation and Maintenance Manual, “General Hazard Information”.

Inspect the high pressure for the following:

•

damage, deformation, a nick, a cut, a crease, or adent

Page 15

SEBU8172-02 15

Safety Section

Before Starting Engine

Do not operate t

•

isaleakdonottightentheconnectioninorder to stop the leak. The connection must only be tightened to t Disassembly and Assembly Manual, “Fuel Injection Lines - Remove and Fuel Injection Lines - Install”.

If the high pressure fuel lines are torqued correctly

•

and the high pressure fuel lines are leaking the high pressu

Ensure that all clips on the high pressure fuel lines

•

areinplace that are damaged, missing or clips that are loose.

Do not atta

•

fuel lines.

Loosened h

•

replaced. Also removed high pressure fuel lines must be replaced. Refer to Disassembly and Assembly

he engine with a fuel leak. If there

he recommended torque. Refer to

re fuel lines must be replaced.

. Do not operate the engine with clips

ch any other item to the high pressure

igh pressure fuel lines must be

Manual, “ Fuel Injection Lines - Install”.

i02813489

Before Starting Engine

See the Service adjustments.

Manual for repairs and for

i02251260

Engine Starting

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

If a warning tag is attached to the engine start switch or to the controls DO NOT start the engine or move the controls. Consult with the person that attached the warning tag before the engine is started.

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

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.

If equipped, ensure that the lighting system for the engine is suitable for the conditions. Ensure that all lights work correctly, if equipped.

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

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/or the oil temperature gauge during the heater operation.

Engine exhaust contains products of combustion which can be harmful to your health. Always start the engine and operate the engine in a well ventilated area. If the engine is started in an enclosed area, vent the engine exhaust to the outside.

Note: The engine is equipped with a device for cold starting. If the engine will be operated in very cold conditions, then an extra cold starting aid may be required. Normally, the engine will be equipped with the correct type of starting aid for your region of operation.

These engines are equipped with a glow plug starting aid in each individual cylinder that heats the intake air in order to improve starting.

Page 16

16 SEBU8172-02 Safety Section Engine Stopping

i02234873

Engine Stopping

Stop the engin the Operation and Maintenance Manual, “Engine Stopping (Operation Section)” in order to avoid overheating the engine components.

Use the Emer in an emergency situation. Do not use the Emergency Stop Button for normal engine stopping. After an emergency problem that caused the emergency stop has been corrected.

Stop the engine if an overspeed condition occurs during the initial start-up of a new engine or an engine that has b

To stop an electronically controlled engine, cut the power to t to the engine.

e according to the procedure in

of the engine and accelerated wear of

gency Stop Button (if equipped) ONLY

stop, DO NOT start the engine until the

een overhauled.

he engine and/or shutting off the air supply

i02234878

Grounding Practices

Illustration 13

Typical example

(1) Starting motor to engine block (2) Ground to starting m otor (3) Ground to battery

g01162916

Electrical System

Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause the combustible gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible gases that are produced by some batteries, the negative “−” cable should be connected last from the external power source to the negative “−” terminal of the starting motor. If the starting motor is not equipped with a negative “−” terminal, connect the cable to the engine block.

Check the electrical wires daily for wires that are loose or frayed. Tighten all loose electrical connections before the engine is started. Repair all frayed electrical wires before the engine is started. See the Operation and Maintenance Manual for speciﬁc starting instructions.

Illustration 14

Typical example

(4) Ground to engine (5) Ground to battery

g01162918

Correct grounding for the engine electrical system is necessary for optimum engine performance and reliability. Incorrect grounding will result in uncontrolled electrical circuit paths and in unreliable electrical circuit paths.

Page 17

SEBU8172-02 17

Safety Section

Engine Electronics

Uncontrolled e damage to the crankshaft bearing journal surfaces and to aluminum components.

Engines that are installed without engine-to-frame ground straps can be damaged by electrical discharge.

To ensure that the engine and the engine electrical systems fun ground strap with a direct path to the battery must be used. This path may be provided by way of a direct engine grou

The connections for the grounds should be tight and free of cor grounded to the negative “-” battery terminal with a wire that is adequate to handle the full charging current of

The power supply connections and the ground connecti be from the isolator to the battery.

lectrical circuit paths can result in

ction correctly, an engine-to-frame

nd to the frame.

rosion. The engine alternator must be

the alternator.

ons for the engine electronics should always

i02650954

Engine Electronics

Derate

•

Shutdown

•

The following monitored engine operating conditions have the ability to limit engine speed and/or the engine power

Engine Coolant Temperature

•

Engine Oil Pressure

•

Engine Spee

•

Intake Manifold Air Temperature

•

The Engine Monitoring package can vary for different engine models and different engine applications. However, t monitoring control will be similar for all engines.

Note: Man modules that are available for Perkins Engines will work in unison with the Engine Monitoring System. Together monitoring function for the speciﬁc engine application. Refer to Troubleshooting for more information on the Engine M

d/Timing

he monitoring system and the engine

y of the engine control systems and display

, the two controls will provide the engine

onitoring System.

Tampe or the OEM wiring installation can be dangerous and could result in personal injury or death and/or engin

Electrical Shock Hazard. The electronic unit injectors use DC voltage. The ECM sends this voltage to the electronic unit injectors. Do not come in contact with the harness connector for the electronic unit injectors while the engine is operating. Failure to follow this instruction could result in personal injury or death.

This engine has a comprehensive, programmable Engine Monitoring System. The Electronic Control Module (ECM) has the ability to monitor the engine operating conditions. If any of the engine parameters extend outside an allowable range, the ECM will initiate an immediate action.

The following actions are available for engine monitoring control:

ring with the electronic system installation

e damage.

Warning

•

Page 18

18 SEBU8172-02 Product Information Section Model Views

Product Information Section

Model Views

i02861104

Model View Illustrations

The following model views show typical features of the engine. Due to individual applications, your engine may appear different from the illustrations.

Illustration 15

The 1104D NJ engine is turbocharged and aftercooled.

g01425089

Page 19

SEBU8172-02 19

Product Information Section

Model Views

Illustration 16

The 1104D NH engine is turbocharged.

Front left engine view

(1) Front lifting eye (2) Water outlet (3) Rear lifting eye (4) Fuel manifold (rail) (5) Electronic control module

(6) Secondary fuel ﬁlter (7) Water pump (8) Oil Filler (9) Oil gauge (10) Oil sampling valve

g01428165

(11) Oil ﬁlter (12) Crankshaft pulley (13) Drive Belt (14) Belt tensioner

Page 20

20 SEBU8172-02 Product Information Section Model Views

Illustration 17

Rear right engine view

(15) Alternator (16) Exhaust manifold (17) Turbocharger (18) Wastegate solenoid

(19) Drain plug or coolant sampling valve (20) Starting Motor (21) Oil drain plug (22) Primary fuel ﬁlter

Note: The primary fuel ﬁlter may be mounted off the engine.

i04925801

Engine Description

The 1104 Electronic Engine models NH and NJ are designed for the following applications: machine and industrial mobile equipment. The engine is available in the following type of aspiration:

Turbocharged

•

Turbocharged aftercooled

•

In-line 4 cylinder

•

g01428176

(23) Hand fuel priming pump (24) Flywheel (25) Flywheel housing

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.

Emissions Control Systems

NH - Direct Diesel Injection, Turbocharger, and Engine Control Module

NJ - Direct Diesel Injection, Turbocharger with Air to Air Charge Cooler and Engine Control Module

Page 21

SEBU8172-02 21

Product Information Section

Model Views

Illustration 18

(A) Exhaust valves (B) Inlet valves

Table 1

1104 Electronic Engine Speciﬁcations

Operating Range (rpm)

Number of Cylinders

Bore

Stroke 127 mm (5.0 inch)

Aspiration NH Turbocharged engine

Compression Ratio 16.2:1

Displacement

Firing Order 1,3,4,2

Rotation (ﬂywheel end) Counterclockwise

Valve Lash Setting (Inlet) 0.35 mm (0.013 inch)

lve Lash Setting

Va (Exhaust)

(1)

The operating rpm is dependent on the engine rating, the

application, and the conﬁguration of the throttle.

750 to 2640

4 In-Line

105 mm (4.13 inch)

NJ Turbocharged engine

that is aftercooled

4.4 L (269 in

0.35 mm (0.013 inch)

g01187485

(1)

)

Electronic Engine Features

The engine operating conditions are monitored. The Electronic Control Module (ECM) controls the response of the engine to these conditions and to the demands of the operator. These conditions and operator demands determine the precise control of fuel injection by the ECM. The electronic engine control system provides the following features:

Engine monitoring

•

Engine speed go

•

Control of the injection pressure

•

Cold start strategy

•

Automatic ai

•

Torque rise shaping

•

Injection timing control

•

System diag

•

verning

r/fuel ratio co ntrol

nostics

For more information on electronic engine features, refer to th

e Operation and Maintenance Manual,

“Features and Controls” topic (Operation Section).

Engine Diagnostics

The engin that the engine systems are functioning correctly. The operator will be alerted to the condition by a “Stop or Warning” horsepower and the vehicle speed may be limited. Theelectronicservicetoolmaybeusedtodisplay the diag

There are three types of diagnostic codes: active, logged,

Most of the diagnostic codes are logged and stored in the E the Operation and Maintenance Manual, “Engine Diagnostics” topic (Operation Section).

The ECM provides an electronic governor that controls the injector output in order to maintain the desir

Engin

The cooling system consists of the following comp

Gear-driven centrifugal water pump

•

Water temperature regulator which regulates the

•

engine coolant temperature

Gear-driven rotor type oil pump

•

Oil

•

The engine lubricating oil is supplied by a rotor type

l pump. The engine lubricating oil is cooled and the

oi engine lubricating oil is ﬁltered. The bypass valves can provide unrestricted ﬂow of lubrication oil to

e engine if the oil ﬁlter element should become

th plugged.

e has built-in diagnostics in order to ensure

lamp. Under certain conditions, the engine

nostic codes.

and event.

CM. For additional information, refer to

ed engine rpm.

e Cooling and Lubrication

onents:

cooler

Page 22

22 SEBU8172-02 Product Information Section Model Views

Engine efﬁcien engine performance depend on adherence to proper operation and maintenance recommendations. Engine perfor the use of recommended fuels, lubrication oils, and coolants. Refer to this Operation and Maintenance Manual, “Mai information on maintenance items.

cy, efﬁciency of emission controls, and

mance and efﬁciency also depend on

ntenance Interval Schedule” for more

Page 23

SEBU8172-02 23

Product Information Section

Product Identiﬁcation Information

Plate Locations and Film Locations

i02378644

Perkins dealer these numbers in order to determine the components that were included with the engine. This permits accurate iden

The numbers for fuel setting information for electronic engines are s These numbers can be read by using the Electronic Service Tool.

s or Perkins distributors need all of

tiﬁcation of replacement part numbers.

tored within the personality module.

Serial Number Plate (1)

The engine serial number plate is located on the left side of the cylinder block to the rear of the engine.

Illustration 19

Location of the serial number plate

Perkins engines are identiﬁed by an engine serial number.

An example of an engine number is NH*****U000001J.

*****

____________________The list number for the engine

_____________________ _____________ _______Type of engine

____________________________Built in the United Kingdom

000001

___________________________Engine Serial Number

_____________________________________ Year of Manufacture

g01248563

Illustration 20

Serial number plate

g01094203

i02164876

Reference N umbers

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

Record for Reference

Engine Model _ ______________________________________________

Engine Serial number _____________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

Primary Fuel Filter _________________________________________

Water Separator Element ________________________________

Secondary Fuel Filter Element __________________________

Page 24

24 SEBU8172-02 Product Information Section Product Identiﬁcation Information

Lubrication Oi

l Filter Element

___________________________

Auxiliary Oil Filter Element _______________________________

Total Lubrication System Capacity _____________________

Total Coolin

g System Capacity

_________________________

Air Cleaner Element _______________________________________

Fan Drive Belt ______________________________________________

______________________________________________

Alternator

Emissions

Belt

i02861254

Certiﬁcation Film

Illustration 21

Typical e xample

g01440937

Page 25

SEBU8172-02 25

Operation Section

Lifting and Storage

Operation Section

Lifting and Storage

Engine Lifting

i02164186

Some removals r obtain correct balance and safety.

To re m o ve th e e are on the engine.

Lifting eyes engine arrangements. Alterations to the lifting eyes and/or the engine make the lifting eyes and the lifting ﬁxtures obs that correct lifting devices are provided. Consult your Perkins dealer or your Perkins distributor for informatio lifting.

n regarding ﬁxtures for correct engine

equire lifting the ﬁxtures in order to

ngine ONLY, use the lifting eyes that

are designed and installed for speciﬁc

olete. If alterations are made, ensure

i02308881

Engine Storage

If the engine is not started for a month or longer the lubricating oil will drain from the cylinder walls and from the piston rings. Rust can form on the cylinder walls. Rust on the cylinder walls will cause increased engine wear and a reduction in engine service life.

Illustration 22

NOTICE

Never bend the eyebolts and the brackets. Only load

eyebolts and the brackets under tension. Remem-

the ber that the capacity of an eyebolt is less as the angle between the supporting members and the object be-

es less than 90 degrees.

com

When it is necessary to remove a component at an

gle, only use a link bracket that is properly rated for

an the weight.

se a hoist to remove heavy components. Use

U an adjustable lifting beam to lift the engine. All supporting members (chains and cables) should be

arallel to each other. The chains and cables should

p be perpendicular to the top of the object that is being lifted.

g01097527

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.

If an engine is out of operation and if use of the engine is not planned for more than one month, a complete protection procedure is recommended.

To help prevent excessive engine wear and corrosion to the engine, use the following guidelines:

1. Completely clean the outside of the engine.

2. Ensure that the vehicle is on level ground.

3. Drain the fuel system completely and reﬁll

thesystemwithpreservativefuel.1772204 POWERPARTLay-Up1canbemixedwith 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.

Page 26

26 SEBU8172-02 Operation Section Lifting and Storage

Personal injury can result from hot coolant. Any contact with hot coolant or with steam c an cause severe burns. Allow cooling system components to cool before the cooling system is drained.

4. Drain and reﬁll the cooling system. Refer to this

Operation and Maintenance Manual, “Cooling System coolant (Commercial Heavy Duty Change or Cooling System coolant (ELC) Change” for information on draining, ﬂushing and reﬁlling the cooling system.

5. Operate the engine until the engine reaches

normal operating temperature. Stop the engine. After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, “Fuel Injection Lines - Install”.

6. Drain the lubricating oil from the oil pan.

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

9. If equipped, re

element. Seal the end of the breather pipe.

10. Remove the val

1762811 POWERPART Lay-Up 2 around the rocker shaft assembly.

11. Remove the glow plugs. Slowly rotate the

crankshaft. By checking the valves, position the piston at BD Lay-Up 2 for two seconds into the cylinder bore. This procedure must be carried out on each cylinder.

12. Install the glow plugs. Install the valve mechanism

cover.

13. Remove the pipes that are installed between

the air ﬁlt Spray 1762811 POWERPART Lay-Up 2 into the turbocharger. The duration of the spray is printed o with waterproof tape.

14. Remove th

the turbocharger. Spray 1762811 POWERPART Lay-Up 2 into the turbocharger. The duration of the spra turbocharger with waterproof tape.

15. Seal the

with waterproof tape.

16. Remove

belt into storage.

17. In o rd

of the engine, spray the engine with 1734115 POWERPART Lay-Up 3. Do not spray the area insid

y is printed on the container. Seal the

er to prevent corrosion to the outside

e the alternator.

place the crankcase breather

ve mechanism cover. Spray

C. Spray 1762811 POWERPART

er assembly and the turbocharger.

n the container. Seal the turbocharger

e exhaust pipe from the output side of

vent of the fuel tank or the fuel ﬁller cap

the alternator drive belt and put the drive

Fill the oil pan to the Full Mark on the engine oil level gauge with new, clean lubricating oil. Add 1762811 POWERPARTLay-Up2totheoilin order to protect the engine against corrosion. If 1762811 POWERPART Lay-Up 2 is not available, use a preservative of the correct speciﬁcation instead of the lubricating oil. If a preservative is used, this must be drained completely at the end of the storage period and the oil pan must be reﬁlled to the correct level with normal lubricating oil.

7. Operate the engine in order to circulate engine oil.

8. Disconnect the battery. Ensure that the battery is

in a fully charged condition. Protect the terminals against corrosion. 1734115 POWERPART Lay-Up 3 can be used on the terminals. Put the battery into safe storage.

Page 27

SEBU8172-02 27

Operation Section

Gauges and Indicators

Gauges and Ind icators

i02861754

Gauges and Indicators

Your engine the gauges that are described. For more information about the gauge package, see the OEM information.

Gauges provide indications of engine performance. Ensure that the gauges are in good working order. Determine the gauges over a period of time.

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

Some engine applications are equipped with Indicator Lamps. aid. There are two lamps. One lamp has an orange lens and the other lamp has a red lens.

These indicator lamps can be used in two ways:

The in

•

current operational status of the engine. The indicator lamps can also indicate that the engine has a f via the ignition switch.

The i

•

diagnostic codes. This system is activated by pressing the Flash Code button.

Refer to the Troubleshooting Guide, “Indicator Lamps” for further information.

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

SAE10W40is350to450kPa(50to65psi)atrated rpm.

A lower oil pressure is normal at low idle. If the load is stable and the gauge reading changes, perform the following procedure:

may not have the same gauges or all of

the normal operating range by observing

le changes in gauge readings indicate

he readings are within speciﬁcations.

erkins distributor for assistance.

Indicator lamps can be used as a diagnostic

dicatorlampscanbeusedtoidentifythe

ault. This system is automatically operated

ndicator lamps can be used to identify active

NOTICE

Engine Oil Pressure – Th e oil pressure should be greatest after a cold engine is started. The typical engine oil pressure with

1. Remove the load

2. Stop the engine.

3. Check and maintain the oil level.

Jacket Water

Typical temperature range is 83° to 95°C

(181.4° to 171°F). The maximum allowable temperatur system at 48 kPa (7 psi) is 103 °C (217.4 °F). Higher temperatures may occur under certain conditions. The water te to load. The temperature reading should never exceed 7 °C (44.6 °F) below the boiling point for the pressuriz

A 100 kPa (14.5 psi) radiator cap may be installed on the cooling system. The temperature of this cooling system mus

If the engine is operating above the normal range and steam procedure:

1. Reduce t

2. Determine if the engine must be shut down

immedia reducing the load.

3. Inspec

load, the engine is running at high idle. The engine is runni 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. Operation at speeds exceeding high idle rpm should be kept to a minimum.

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

is in the “on” position.

e at sea level with the pressurized cooling

mperature reading may vary according

ed system that is being used.

t not exceed 112 °C (233.6 °F).

becomes apparent, perform the following

he load and the engine rpm.

tely or if the engine can be cooled by

t the cooling system for leaks.

Tachometer – This gauge indicates engine

speed (

ismovedtothefullthrottlepositionwithout

ng at the full load rpm when the throttle control

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

Coolant Temperature –

rpm). When the throttle control lever

NOTICE

Page 28

28 SEBU8172-02 Operation Section Gauges and Indicators

Service Hour Meter – The gauge indicates total operating hours of the engine.

Page 29

SEBU8172-02 29

Operation Section

Features and Controls

i02651062

Monitoring System

If the Shutdown mode has been selected and the warning in take as little as 20 seconds from the time the warning indicator is activated. Depending on the application avoid personal injury. The engine can be restarted following shutdown for emergency maneuvers, if necessar

The Engine Monitoring System is not a guarantee against catastrophic failures. Programmed delays and derate schedules are designed to minimize false alarms and provide time for the operator to stop the engine.

The following parameters are monitored:

Coolant temperature

•

Intake air temperature

•

Engine intake manifold pressure

•

Engine Oil pressure

•

Pressure in the fuel rail

•

dicator activates, engine shutdown may

, special precautions should be taken to

NOTICE

“Warning”

The “Warning” lamp and the warning signal (orange lamp) turn “ON continuously in order to alert the operator that one or more of the engine parameters is not within normal operating ra

” and the warning signal is activated

nge.

“Warning/Derate”

The “Diagnostic” lamp turns “ON” and the warning signal (red lamp) is activated. After the warning, the engine powe begin to ﬂash when the derating occurs.

The engine preset operational limits. The engine derate is achieved by restricting the amount of fuel that is available reduction of fuel is dependent on the severity of the fault that has caused the engine derate, typically up to a limit predetermined reduction in engine power.

“Warnin

The “Diagnostic” lamp turns “ON” and the warning signal ( the engine power will be derated. The engine will continue at the rpm of the set derate until a shutdown of the e after a shutdown for use in an emergency.

Ashutd as 20 seconds. The engine can be restarted after a shutdown for use in an emergency. However, the ca Theenginemayshutdownagaininaslittleas20 seconds.

r will be derated. The warning lamp will

will be derated if the engine exceeds

for each injection. The amount of this

of 50%. This reduction in fuel results in a

g/Derate/Shutdown”

red lamp) is activated. After the warning,

ngine occurs. The engine can be restarted

own of the engine may occur in as little

use of the initial shutdown may still exist.

Engine speed/timing

•

Programmable O ptions and Systems Operation

If the Warning/Derate/Shutdown mode has been selected and the warning indicator activates, bring the engine to a stop whenever possible. Depending on the application, special precautions should be taken to avoid personal injury.

The engine can be programmed to the following modes:

If there is a signal for low oil pressure or for coolant temperature, there will be a two second delay in

r to verify the condition.

orde

For each of the programmed modes, refer to

bleshooting , “Indicator Lamps” for more

Trou information on Indicator Lamps.

more information or assistance for repairs, consult

For your Perkins dealer or your Perkins distributor.

Page 30

30 SEBU8172-02 Operation Section Features and Controls

i02296746

Monitoring System

Table 2

Warning

Lamp

ON ON

OFF OFF

ON OFF

ON FLASHING

FLASHING OFF

FLASHING FLASHING

ON ON

Shutdown

Lamp

Lamp Status Description of lamp status Engine Status

Lamp check When the engine start switch is turned to the

“ON” position both lamps will illuminate for 2 seconds only.

No faults There are no active diagnostic faults.

Active diagnostic fault

Warning One or more of the engine protection values

Derate and warning

Engine shutdown

An active diagnostic fault has been detected.

A serious active diagnostic fault has been detected and an engine derate has been invoked.

has been exceeded.

One or more of the engine protection values has been exceeded.

One or more of the engine protection values has been exceeded or a serious active diagnostic

as been detected.

fault h

The engine has not been started.

Theengineisrunning normally.

Theengineisrunning but the engine has been derated.

Theengineisrunning normally.

Theengineisrunning but the engine has been derated.

The engine is shutdown or shutdown is imminent.

i02861773

Sensors and Electrical Components

Sensor Locations

ustration 23 shows the typical locations of the

Ill sensors and the ECM on the engine. Speciﬁcengines may appear different from the illustration due to

ferences in applications.

dif

Page 31

SEBU8172-02 31

Operation Section

Features and Controls

Illustration 23

(1) Coolant temperature sensor (2) Intake manifold pressure sensor (3) Inlet air temperature sensor

(4) Fuel pressure sensor (5) Electronic control m odule (6) Primary position sensor

Illustration 24 shows the sensors and the ECM in position on the engine.

g01425443

(7) Secondary position sensor (8) Engine oil pressure sensor

Page 32

32 SEBU8172-02 Operation Section Features and Controls

Illustration 24

Failure of Sensors

All Sensors

A failure of any of the sensors may be caused by one of the following malfunctions:

Sensor output is open.

•

Sensor output is shorted to “- battery” or “+ battery”.

•

Measured reading of the sensor is out of the

•

speciﬁcation.

g01425468

Programmable Monitoring System (PMS)

The Programmable Monitoring System determines the level of action that is taken by the Electronic Control Module (ECM) in response to a condition that can damage the engine. These conditions are identiﬁed by the ECM from the signals that are produced from the following sensors.

Coolant Temperature Sensor

•

Intake manifold Air Temperature Sensor

•

Intake manifold Pressure Sensor

•

Fuel Pressure Sensor

•

Page 33

SEBU8172-02 33

Operation Section

Features and Controls

Engine Oil Pres

•

Primary Speed/Timing Sensor

•

Secondary Speed/Timing Sensor

•

sure Sensor

Coolant Temperature Sensor 1

The coolant t coolant temperature. The output of the ECM (5) can indicate a high coolant temperature through a relay or a lamp. Th by the ECM to determine initiation of the Cold Start Condition.

Failure of the Coolant Temperature Sensor

The ECM (5) will detect a failure of the coolant temperature sensor. The diagnostic lamp will warn the operator sensor. A failure of the coolant temperature sensor will not cause a shutdown of the engine or any horsepow operation of the sensor, refer to Troubleshooting, “Engine Temperature Sensor Circuit - Test”.

emperature sensor monitors engine

e coolant temperature sensor is used

about the status of the coolant temperature

er change. In order to check the correct

Electronic Control Module 5

The ECM is the control computer of the engine. The ECM provides power to the electronics. The ECM monitors data that is input from the sensors of the engine. The ECM acts as a governor in order to control the speed and the power of the engine.

The ECM adjusts injection timing and fuel pressure for the best engine performance, the best fuel economy and the best control of exhaust emissions.

Primary Speed/Timing Sensor 6

If the ECM (5) does not receive a signal from the primary speed/timing sensor , the “DIAGNOSTIC” lamp will indicate a diagnostic fault code which will be logged in the ECM memory.

If the ECM does not receive a signal from the primary speed/timing sensor (7), the ECM will read the signal from the secondary speed/timing sensor (8). The ECM continually checks in order to determine if there is a signal from both sensors.

Intermittent failure of the sensors will cause erratic engine control.

Intake Manifold Air Temperature Sensor 2

Note: T

The location will depend on the type of engine.

The in the intake air temperature. A signal is sent to the ECM (5). The intake manifold air temperature sensor is als Cold Start Strategy.

In ord refer to Troubleshooting, “EngineTemperature Sensor Circuit - Test”.

his sensor can have two different locations.

take manifold air temperature sensor measures

o used by the ECM to determine initiation of the

er to check the correct operation of the sensor,

Intake Man ifold Pressure Sensor 3

The intake manifold pressure sensor measures pressure in the manifold. A signal is sent to the ECM

(5)

l Pressure Sensor 4

Fue

The fuel pressure sensor measures the fuel pressure

the fuel manifold. A signal is sent to the ECM (5).

Failure of the Primary Speed/Timing Sensor

Correct operation of the primary speed/timing sensor is essential. Software in the ECM protects against reverse running of the engine. If the primary speed/timing sensor fails there is no automatic protection against reverse running. In some applications, it is possible for the transmission to run the engine in reverse. In this event, Stop the engineimmediately.Turnthekeyswitchtothe“OFF” position.

In order to check the correct operation of the sensor, refer to Troubleshooting, “Engine speed/Timing sensor - Test”.

Secondary Speed/Timing Sensor 7

The signal from the secondary speed/timing sensor is used by the ECM (5) on engine start-up in order to check the stroke of the pistons. The secondary speed/timing sensor may be used by the ECM in order to operate the engine if the primary speed/timing sensor is faulty.

In order to check the correct operation of the sensor, refer to Troubleshooting, “Engine speed/Timing sensor-Test”.

Page 34

34 SEBU8172-02 Operation Section Features and Controls

Engine Oil Pressure Sensor 8

Note: This sensor can have two different locations.

The location will depend on the type of engine.

The engine oil pressure sensor is an absolute pressure sensor that measures the engine oil pressure in the main oil gallery. The engine oil pressure sensor detects engine oil pressure for diagnostic purposes. The engine oil pressure sensor sends a signal to the ECM (5).

Low Oil Pressure Warning

The setpoint for the low pressure warning is dependent upon the engine speed. The fault will be active and logged only if the engine has been running for more than 8 seconds.

Very Low Oil Pressure Warning

The very low oil pressure setpoint is dependent upon the engine speed. If the DERATE mode of the engine monitoring system is selected, the ECM (5) will derate the engine power. The engine horsepower will be limited.

Operating leve

•

Operating rpm

•

The particular shutoff may need to be reset before theenginewillstart.

Always determine the cause of the engine shutdown. Make necessary repairs before attempting to restart the engine.

Be familiar with the following items:

Types and locations of shutoff

•

Condition

•

The resetting procedure that is required to restart

•

the engin

NOTICE

s which cause each shutoff to function

Alarms

The alarms are electrically operated. The operation of the al

arms are controlled by the ECM.

Failure of the Engine Oil Pressure Sensor

The ECM (5) will detect failure of the engine oil pressure sensor. The diagnostic lamp warns the user about the status of the engine oil pressure sensor. The engine oil pressure related strategies will be disabled in the event of a failure of the engine oil pressure sensor. A failure of the engine oil pressure sensor will not cause a shutdown of the engine or any horsepower change. In order to check the correct operation of the sensor, refer to Troubleshooting, “5 Volt Sensor Supply Circuit - Test”.

58345

i028

Engine Shutoffs and Engine

rms

Ala

Shutoffs

The shutoffs are electrically operated or mechanically operated. The electrically operated shutoffs are

ntrolled by the ECM.

The alarm is operated by a sensor or by a switch. When th is sent to the ECM. An event code is created by the ECM. The ECM will send a signal in order to illumi

Your engine may be equipped with the following senso

Coolant level – The low coolant level switch indic

Coolant temperature – The coolant temperature sens temperature.

Inta

manifold air temperature sensor indicates high intake air temperature.

Intake manifold pressure – The intake manifold pressure sensor checks the rated pressure in the eng

Fuel rail pressure – The fuel rail pressure sensor ch rail.

e sensor or the switch is activated a signal

nate the lamp.

rs or switches:

ates when the coolant level is low.

or indicates high jacket water coolant

ke manifold air temperature – The intake

ine manifold.

ecks for high pressure or low pressure in the fuel

Shutoffs are set at critical levels for the following

tems:

Operating temperature

•

Operating pressure

•

gine oil pressure – The engine oil pressure

sensor indicates when oil pressure drops below rated system pressure, at a set engine speed.

Page 35

SEBU8172-02 35

Operation Section

Features and Controls

Engine overspe

sensor checks the engine speed. The alarm is activated at 3000 RPM.

Air ﬁlter restriction – The switch checks the air ﬁlter when the engine is operating.

User deﬁned switch – This switch can shut down the engine remotely.

Water in fuel switch – This switch checks for water in the primary fuel ﬁlter when the engine is operating.

Note: The sensing element of the coolant temperature switch must be submerged in coolant in order to

Engines may be equipped with alarms in order to alert th conditions occur.

When an alarm is activated, corrective measures must be taken in order to avoid possible engine damage.

e operator when undesirable operating

before the situation becomes an emergency

ed – The primary speed/timing

operate.

NOTICE

If corre reasonable time, engine damage could result. The alarm will continue until the condition is corrected. The ala

Testin

Turning the keyswitch to the ON position will check the in indicator lights will be illuminated for two seconds after the keyswitch is operated. Replace suspect bulb

Refer to Troubleshooting for more information.

ctive measures are not taken within a

rmmayneedtobereset.

dicator lights on the control panel. All the

s immediately.

i02237393

Overspeed

An overspeed condition is detected by the Electronic Control Module (ECM). The event code will be logged if the engine speed exceeds 3000 rpm. The “DIAGNOSTIC” lamp will indicate a diagnostic active code. The diagnostic active code will remain active until the engine speed drops to 2800 rpm.

Page 36

36 SEBU8172-02 Operation Section Engine Diagnostics

Engine Diagnostics

i02651093

Self-Diagnostics

Perkins electronic engines have the capability to perform a self-diagnostics test. When the system detects an active problem, a diagnostic lamp is activated. Diagnostic codes will be stored in permanent memory in the Electronic Control Module (ECM). The diagnostic codes can be retrieved by using the electronic service tool. Refer to Troubleshooting , “Electronic Service Tools” for further information.

Some installations have electronic displays that provide direct readouts of the engine diagnostic codes. Refer to the manual that is provided by the OEM for more information on retrieving engine diagnostic codes. Alternatively refer to Troubleshooting , “Indicator Lamps” for further information.

Active codes represent problems that currently exist. These problems should be investigated ﬁrst.

Logged codes represent the following items:

Intermittent problems

•

Recorded events

•

Performance history

•

The problems may have been repaired since the logging of the code. These codes do not indicate that a repair is needed. The codes are guides or signals when a situation exists. Codes may be helpful to troubleshoot problems.

When the problems have been corrected, the corresponding logged fault codes should be cleared.

i02651107

Diagnostic Lamp

A diagnostic lamp is used to indicate the existence of

active fault. Refer to Troubleshooting , “Indicator

an Lamps” for more information. A fault diagnostic code will remain active until the problem is repaired.

he diagnostic code may be retrieved by using the

T electronic service tool. Refer to Troubleshooting , “Electronic Service Tools” for more information.

i02855276

Diagnostic Flash Code Retrieval

“Diagnostic” Lamp

Use the “DIAGNOSTIC” Lamp or an electronic service tool to determine the diagnostic ﬂash code.

Usethefollowingproceduretoretrievetheﬂash codes if the engine is equipped with a “DIAGNOSTIC” lamp:

1. Turn the keyswitch “ON/OFF” two times within 3

seconds.

A ﬂashing“YELLOW” lamp indicates a 3 digit code for the engin system diagnostic message. Count the ﬁrst sequence of ﬂashes in order to determine the ﬁrst digit of the ﬂash code sequence of ﬂashes will identify the second digit of the ﬂash code. After the second pause, the third sequenc

Any additional ﬂash codes will follow after a pause. These co Flash Code 551 indicates that No Detected Faults have occurred since the ignition keyswitch has been turned

For further information, assistance for repairs, or troub consult an authorized Perkins dealer.

Table a brief description of the ﬂash codes.

Note

performance with “ACTIVE” ﬂash codes.

Some may also indicate that a mechanical system needs attention. Troubleshooting is not required for code “55 codes will limit the operation or the performance of the engine.

Table 3 indicates the potential effect on the engine performance with active ﬂash codes. Table 3 also

rms a list of Electronic diagnostic codes and

fo descriptions.

e. The sequence of ﬂashes represents the

. After a two second pause, the second

eofﬂashes will identify the ﬂash code.

des will be displayed in the same manner.

to the ON position.

leshooting, refer to the Service Manual or

3 lists the ﬂash codes and the table also gives

: Table 3indicates the potential effect on engine

codes record events. Also, some codes

1”. Code 001 will not display a ﬂash code. Some

Page 37

SEBU8172-02 37

Operation Section

Engine Diagnostics

Table 3

Flash Codes for the Industrial Engine

Effect On Engine Performance

Diagnostic Flash Code

Engine Misﬁre

Low

Power

Reduced

Engine

Speed

111 Cylinder 1 Fault X X X

112 Cylinder 2 Fault X X X

113 Cylinder 3 Fault X X X

114 Cylinder 4 Fault X X X

Intake Ma

133

Temperature sensor fault

Primary Speed/

141

Timing Sensor Fault

nifold

(5)

Secondary

142

Speed/Timing Sensor Fault

Timing Calibration

143

Fault

X X

Engine Operation

144

Mode Selector Switc

High Air Filter

151

Restriction

Thro

154

sensor Fault

hFault

ttle Position

Secondary Throttle

155

Position sensor

Fault

Oil Pressure Sensor

157

Fault

Fuel Rail Pressure

159

Sensor Fault

High Pressure Fuel

162

(5)

Pump Fault

XX X X X

XX X

Coolant

168

Temperature Sensor

XX X

Fault

169 Low Engine Coolant X X

Wastegate Solenoid

177

185

Fault

High Exhaust Temperature

Intake Manifold

197

Pressure Sensor

Fault

Glow Plug Start

199

Relay Fault

(1)

Engine

Shutdown

Suggested Operator Action

Shut

Down the

Engine

Service

(2)

(3)

Schedule a

Service.

(4)

(continued)

Page 38

38 SEBU8172-02 Operation Section Engine Diagnostics

(Table 3, contd)

Flash Codes for the Industrial Engine

Effect On Engine Performance

Diagnostic Flash Code

Incorrect Engine

415

Software

Machine Sec

426

System Module

(6)

Fault

429 Keyswitch

Intermittent Battery

511

Power to ECM

SAE J1939 Data

514

Link Fault

urity

Fault

Engine Misﬁre

Low

Power

XX X X

Reduced

Engine

Speed

XX X

5VoltSensorDC

516

Power Supply Fault

8VoltSensorDC

517

Power Supply Fault

(5)

Check Customer Parameters or

527

(1)

An “X” indicates that the effect on engine performance may occur if the code is active.

(2)

Shut Down the Engine: Operate the engine c autiously. Get im mediate service. Severe engine damage ma y result.

(3)

The o

(4)

Schedule Service: T he problem should be investigated when the operator has access to a qualiﬁed service program.

(5)

These Flash Codes may affect the system under s peciﬁc environmental conditions s uch a s engine start-up at cold temperature and

cold weather operation at high altitudes.

(6)

The e

m Parameters

Syste

(5)

perator should go to the nearest location that has a qualiﬁed se rvice program .

ngine will not start.

XX X

(1)

Engine

Shutdown

Suggested Operator Action

Shut

Down the

Engine

Service

(2)

(3)

Schedule a

Service.

(4)

i01902949

lt Logging

Fau

The system provides the capability of Fault Logging. When the Electronic Control Module (ECM)

nerates an active diagnostic code, the code will

ge be logged in the memory of the ECM. The codes that have been logged by the ECM can be identiﬁed

the electronic service tool. The active codes that

by have been logged will be cleared when the fault has been rectiﬁed or the fault is no longer active.

he following logged faults can not be cleared from

T the memory of the ECM without using a factory password: Overspeed, low engine oil pressure, and

igh engine coolant temperature.

Page 39

SEBU8172-02 39

Operation Section

Engine Diagnostics

i02651197

Engine Operation with Active Diagnostic Co

If a diagnostic lamp illuminates during normal engine operation, the system has identiﬁed a situation that is not within t tool to check the active diagnostic codes.

he speciﬁcation. Use the electronic service

des

The active d The cause of the problem should be corrected as soon as possible. If the cause of the active diagnostic code is rep diagnostic code, the diagnostic lamp will turn off.

Operation engine can be limited as a result of the active diagnostic code that is generated. Acceleration rates may be sig be automatically reduced. Refer to Troubleshooting , “Troubleshooting with a Diagnostic Code” for more informa diagnostic code and the possible effect on engine performance.

iagnostic code should be investigated.

aired and there is only one active

of the engine and performance of the

niﬁcantly slower and power outputs may

tion on the relationship between each active

i01902995

Engine O peration with Intermittent Diagnostic Codes

agnostic lamp illuminates during normal engine

If a di operation and the diagnostic lamp shuts off, an intermittent fault may have occurred. If a fault has

rred, the fault will be logged into the memory of

occu the Electronic Control Module (ECM).

st cases, it is not necessary to stop the engine

In mo because of an intermittent code. However, the operator should retrieve the logged fault codes

the operator should reference the appropriate

and information in order to identify the nature of the event. The operator should log any observation that could

e caused the lamp to light.

hav

Low power

•

Limits of the engine speed

•

cessive smoke, etc

•

This information can be useful to help troubleshoot

he situation. The information can also be used for

t future reference. For more information on diagnostic codes, refer to the Troubleshooting Guide for this

ngine.

Page 40

40 SEBU8172-02 Operation Section Engine Starting

Engine Starting

i02322201

Before Starting Engine

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

Open the fu

•

All valves in the fuel return line must be open before and durin pressure. High fuel pressure may cause ﬁlter housing failure or other damage.

If the engine has not been started for several weeks, fuel may have drained from the fuel system. Air may hav ﬁlters have been changed, some air pockets will be trapped in the engine. In these instances, prime the fuel sy Manual, “Fuel System - Prime” for more information on priming the fuel system.

ngine is started, perform the required

nance Manual, “Maintenance Interval

el supply valve (if equipped).

NOTICE

g engine operation to help prevent high fuel

e entered the ﬁlter housing. Also, when fuel

stem. Refer to the Operation and Maintenance

i02322203

Starting the Engine

Note: Do not ad

start-up. The electronic control module (ECM) will control the engine speed during start-up.

Starting the Engine

1. Disengage any equipment that is driven by the

engine.

2. Turn the keyswitch to the RUN position. Leave the

keyswitchintheRUNpositionuntilthewarning light for t

3. When the warning light for the glow plugs is

extingui position in order to engage the electric starting motor and crank the engine.

Note: The operating period of the warning light for the glow plugs will change due to the temperature of the en

Do not engage the starting motor when ﬂywheel is turnin

gine.

g. Do not start the engine under load.

justtheenginespeedcontrolduring

he glow plugs is extinguished.

shed turn the keyswitch to the START

NOTICE

ne exhaust contains products of combustion

Engi which may be harmful to your health. Always start and operate the engine in a well ventilated area

if in an enclosed area, vent the exhaust to the

and, outside.

ot start the engine or move any of the controls

Do n

•

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

the controls.

Reset all of the shutoffs or alarm components (if

•

uipped).

Ensure that any equipment that is driven by the

•

ngine has been disengaged from the engine.

e Minimize electrical loads or remove any electrical loads.

If the engine fails to start within 30 seconds, release the sta allow the starting motor to cool before attempting to start the engine again.

4. Allow the keyswitch to return to the RUN position

5. Repeat step 2 through step 4 if the engine fails

rter switch or button and wait two minutes to

after the engine starts.

to start.

i02

325155

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.

Page 41

SEBU8172-02 41

Operation Section

Engine Starting

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.

Note: Do not start-up. The electronic control module (ECM) will control the engine speed during start-up.

1. Disengage any driven equipment.

2. Turn the ke

keyswitch in the RUN position until the warning light for the glow plugs is extinguished.

Do not engage the starting motor when ﬂywheel is turning. Do not start the engine under load.

If the engine fails to start within 30 seconds, release the starter switch or button and wait two minutes to allow th start the engine again.

e starting motor to cool before attempting to

sel fuel is used, the following items

et water heaters, fuel heaters, and fuel

dure that follows for cold weather

adjust the engine speed control during

yswitch to the RUN position. Leave the

NOTICE

i02322204

Starting with Jump Start Cables

Improper jump start cable connections can cause an explosion resulting in personal injury.

Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jump start cable ends to contact each other or the e ngine.

Note: If it is possible, ﬁrst diagnose the reason for

the starting failure. Refer to Troubleshooting, “Engine Will Not Crank and Engine Cranks But Will Not Start” for further information. Make any necessary repairs. If the engine will not start only due to the condition of the battery, either charge the battery, or start the engine by using another battery with jump start cables. The condition of the battery can be rechecked after the engine has been switched OFF.

3. When th extinguished turn the keyswitch to the START position in order to engage the electric starting motor a

Note: The operating period of the warning light for the gl of the engine.

4. Allo after the engine starts.

5. Repe to start.

Note

speed up the warm up process.

6. All allow the engine to idle until the water temperature indicator begins to rise. When idling after the en engine rpm from 1000 to 1200 rpm. This will warm up the engine more quickly. Maintaining an will be easier with the installation of a hand throttle. Allow the white smoke to disperse before pr

e warning light for the glow plugs is

nd crank the engine.

ow plugs will change due to the temperature

w the keyswitch to return to the RUN position

at step 2 through step 4 if the engine fails

: The engine should not be “raced” in order to

ow the engine to idle for three to ﬁve minutes, or

gine has started in cold weather, increase the

elevated low idle speed for extended periods

oceeding with normal operation.

NOTICE

Using a battery source with the same voltage as the

ic starting motor. Use ONLY equal voltage for

electr jump starting. The use of higher voltage will damage the electrical system.

Do not reverse the battery cables. The alternator can be damaged. Attach ground cable last and remove ﬁrst.

Turn all electrical accessories OFF before attaching

ump start cables.

the j

Ensure that the main power switch is in the OFF posi-

before attaching the jump start cables to the en-

tion gine being started.

n the start switch on the stalled engine to the

1. Tur OFF position. Turn off all the engine's accessories.

2. Con

nect one positive end of the jump start cable to the positive cable terminal of the discharged battery. Connect the other positive end of the jump

art cable to the positive cable terminal of the

st electrical source.

7. Operate the engine at low load until all systems each operating temperature. Check the gauges

r during the warm-up period.

Page 42

42 SEBU8172-02 Operation Section Engine Starting

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

ies must be replaced or charged to the

re 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.

i02330138

After Starting Engine

Note: In ambient temperatures from 0 to 60°C

(32 to 140°F), the warm-up time is approximately three minutes. In temperatures below 0°C (32°F), additional warm-up time may be required.

When the engine idles during warm-up, observe the following conditions:

Do not check the high pressure fuel lines with the engine or the starting motor in operation. If you inspect the engine in operation, always use the proper inspection procedure in order to avoid a ﬂuid penetration hazard. Refer to Operation and Maintenance Manual, “General hazard Information”.

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.

Allow the engine to idle for three to ﬁve minutes, or

•

allow the engine to idle until the water temperature indicator begins to rise. Check all gauges during the warm-up period.

Note: Gauge readings should be observed and the data should be recorded frequently while the engine is operating. Comparing the data over time will help to determine normal readings for each gauge.Comparingdataovertimewillalsohelp detect abnormal operating developments. Signiﬁcant changes in the readings should be investigated.

Page 43

SEBU8172-02 43

Operation Section

Engine Operation

i02330143

Engine Operation

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

The engine engine reaches operating temperature. The engine will reach normal operating temperature if the engine is operat light load. This procedure is more effective than idling the engine at no load. The engine should reach operati

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

ration and maintenance are key factors

ce Manual are followed, costs can be

can be operated at the rated rpm after the

ed at low idle speed and operated with a

ng temperature in a few minutes.

e recorded frequently while the engine

ingdataovertimewillalsohelpdetect

i02330149

Fuel Conservation Practices

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

Avoid spilling fuel.

•

Fuel expan 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 t time.

Observe

•

Keep the air cleaner elements clean.

Maintai

•

of the engine can affect the fuel

ions. Follow the recommended procedures

ds when the fuel is warmed up. The fuel

he engine rather than idle for long periods of

the air cleaner service indicator frequently.

n the electrical systems.

One damaged battery cell will overwork the alternator. This wi

•

ll consume excess power and excess fuel.

Ensure that the drive belts are correctly adjusted.

ive belts should be in good condition.

The dr

Ensure that all of the connections of the hoses are

. The connections should not leak.

tight

Ensure that the driven equipment is in good

ing order.

work

Cold engines consume excess fuel. Utilize heat

the jacket water system and the exhaust

from system, when possible. Keep cooling system components clean and keep cooling system

ponents in good repair. Never operate the

com engine without water temperature regulators. All of these items will help maintain operating

peratures.

tem

Page 44

44 SEBU8172-02 Operation Section Engine Stopping

Engine Stopping

i02334873

Stopping the Eng ine

NOTICE Stopping the engine immediately after it has been working under load, can result in overheating and accelerated wear of the engine components.

Avoid accelerating the engine prior to shutting it down.

Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life.

Note: Individual applications will have different control systems. Ensure that the shutoff procedures are understood. Use the following general guidelines in order to stop the engine.

1. Remove the load from the engine. Reduce the

engine speed (rpm) to low idle. Allow the engine to idle for ﬁve minutes in order to cool the engine.

2. Stop the engine after the cool down period

according to the shutoff system on the engine and turn the ignition key switch to the OFF position. If necessary, refer to the instructions that are provided by the OEM.

i01903586

Emer

gency Stopping

i02330274

After Stopping Engine

Note: Before y

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

Contact wit penetration and burn hazards. High pressure fuel spray may cause a ﬁre hazard. Failure to follow these i structions may cause personal injury or death.

After the

•

60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any servi fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system a systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual,

Check the crankcase oil level. Maintain the oil level

•

betwee the engine oil level gauge.

If the e

•

note the reading. Perform the maintenance that is in the Operation and Maintenance Manual,

tenance Interval Schedule”.

“Main

ou check the engine oil, do not operate

h high pressure fuel may cause ﬂuid

nspection, maintenance and service in-

engine has stopped, you must wait for

ce or repair is performed on the engine

nd from the cooling, lubrication or air

“Fuel Injection Lines - Install”.

n the “MIN” mark and the “MAX” mark on

ngine is equipped with a service hour meter,

NOTICE Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use emergency shutoff devices or controls for normal stopping procedure.

The OEM may have equipped the application with an emergency stop button. For more information about the emergency stop button, refer to the OEM information.

Ensure that any components for the external system that support the engine operation are secured after the engine is stopped.

Fill the fuel tank in order to help prevent

•

Only use antifreeze/coolant mixtures recommended in the and Maintenance Manual. Failure 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.

•

mulation of moisture in the fuel. Do not overﬁll

accu the fuel tank.

NOTICE

Coolant Speciﬁcations that are in the Operation

Allow the engine to cool. Check the coolant level.

Page 45

SEBU8172-02 45

Operation Section

Engine Stopping

Check the coola

•

and the correct corrosion protection. Add the correct coolant/water mixture, if necessary.

Perform all required periodic maintenance on all

•

driven equipment. This maintenance is outlined in the instruct

nt for correct antifreeze protection

ions from the OEM.

Page 46

46 SEBU8172-02 Operation Section Cold Weather Operation

Cold Weather Operation

i02717265

Cold Weather Operation

Perkins Diesel Engines can operate effectively in cold weather. During cold weather, the starting and the operation of the diesel engine is dependent on the following items:

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 ele

•

fraying or damaged insulation.

Keep all bat

•

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 Te

-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 prope

rect speciﬁcation of engine lubricant

er parts (hoses, fan drive belts, etc)

ctrical wiring and connections for any

teries fully charged and warm.

sting and Adjusting Manual, “Glow Plug

rty 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 47

SEBU8172-02 47

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

Startability is improved.

•

Warm up time

•

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

Idling th

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

heaters (if equipped) heat the

is reduced.

is stopped. An effective block heater

on.

e Engine

increase the engine rpm from 1000 to 1200

will be easier with the installation of a hand

m operating temperature. The minimum

Recommendations for Coolant Warm U

Warm up an engine that has cooled below normal opera be performed before the engine is returned to full operation. During operation in very cold temperature

itions, damage to engine valve mechanisms can

cond result from engine operation for short intervals. This can happen if the engine is started and the engine is

ped many times without being operated in order

stop to warm up completely.

n the engine is operated below normal operating

Whe temperatures, fuel and oil are not completely burned in the combustion chamber. This fuel and oil causes

t carbon deposits to form on the valve stems.

sof Generally, the deposits do not cause problems and the deposits are burned off during operation at

rmal engine operating temperatures.

When the engine is started and the engine is stopped

ny times without being operated in order to warm

ma up completely, the carbon deposits become thicker. This can cause the following problems:

ting temperatures due to inactivity. This should

Free operation

•

Valves become stuck.

•

Pushrods may become bent.

•

Other damage

•

result.

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

rvice life for the engine bearings, the piston

ary fuel consumption.

of the valves is prevented.

to valve train components can

son, when the engine is started,

the valve stems will be kept at a minimum

vicelifeoftheenginewillbegenerally

The Water Temperature Regulator and Insulat

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

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

Note: Perkins discourages the use of all air ﬂow re Restriction of the air ﬂow can result in the following: high exhaust temperatures, power loss, excessive

n usage, and reduction in fuel economy.

ed Heater Lines

tor. When the engine coolant is below the

cylinder head. The coolant then returns to the

es that coolant ﬂows around the engine under

has reached the correct minimum operating

r temperature regulator opens further allowing

ass passage between the cylinder block and

sipation.

striction devices such as radiator shutters.

Page 48

48 SEBU8172-02 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 is located in the engine compartment may be speciﬁed. An air cleaner that is located in the engine compartmen 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.

encountered, an air cleaner inlet that

t may also minimize the entry of snow

i02685960

Fuel an d the Effect from Cold Weather

Note: Only use grades of fuel that are recommended

by Perkins. Refer to this Operation and Maintenance Manual, “Fl

The following components provide a means of minimizing

Glow plugs (if equipped)

•

Engine coolant heaters, which may be an OEM

•

option

Fuel heaters, which may be an OEM option

•

Fuel line

•

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

uid Recommendations”.

problems in cold weather:

insulation, which may be an OEM option

s to form in the fuel. These crystals can cause

The pour 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 temper are fueled in one climate may not operate well if the engines are moved to another climate. Problems can resul

Before troubleshooting for low power or for poor perfo

Low temperature fuels may be available for engine oper 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 Wea Cold Weather”.

point is the temperature when diesel fuel

ature for the engine's application. Engines that

t due to changes in temperature.

rmance in the winter, check the fuel for waxing.

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

ther Operation and Fuel Related Components in

Page 49

SEBU8172-02 49

Operation Section

Cold Weather Operation

i02323237

Fuel Related Components in Cold Weather

Fuel Tanks

Condensation can form in partially ﬁlled fuel tanks. Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks.

Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel supply pip

Some fuel tanks use supply lines that take fuel directly equipped with this system, regular maintenance of the fuel system ﬁlter is important.

from the bottom of the tank. If the engine is

Drain the water and sediment from any fuel storage tank at the following intervals: weekly, service

ls, and refueling of the fuel tank. This will help

interva prevent water and/or sediment from being pumped from the fuel storage tank and into the engine fuel tank.

Fuel Fi

A primary fuel ﬁlter is installed between the fuel tank a the fuel ﬁlter, always prime the fuel system in order to remove air bubbles from the fuel system. Refer to the Maintenance Section for more information on priming the fuel system.

The location of a primary fuel ﬁlter is important in cold weather operation. The primary fuel ﬁlter and the fuel supp are affected by cold fuel.

lters

nd the engine fuel inlet. After you change

Operation and Maintenance Manual in the

ly line are the most common components that

Fuel Heaters

e: The OEM may equip the application with fuel

Not

heaters. If this is the case, the temperature of the fuel must not exceed 73 °C (163 °F) at the fuel transfer

pum

For more information about fuel heaters (if equipped),

fer to the OEM information.

Page 50

50 SEBU8172-02 Maintenance Section Reﬁll Capacities

Maintenance Section

Reﬁll Capacities

i04262329

Reﬁll C apacities

Lubrication System

The reﬁll capacities for the engine crankcase reﬂect the approximate capacity of the crankcase or sump plus standard oil ﬁlters. Auxiliary oil ﬁ lter systems will require additional oil. Refer to the OEM speciﬁcations for the capacity of the auxiliary oil ﬁ lter. Refer to the Operation and Maintenance Manual, “Maintenance Section” for more information on Lubricant Speciﬁcations.

Table 4

Engine

Reﬁll Capacities

Compartment or System

Crankcase Oil Sump

(1)

The minimum value is the approximate capac ity for the crankcase oil sump (aluminum) which includes the standard factory installed oil ﬁlters. Engines with auxiliary oil ﬁlters w ill require additional oil. Refer to the OEM speciﬁcations for the capacity of the auxiliary oil ﬁ lter. The design of the oil pan can change the oil capacity of the oil pan.

(2)

Approximate c apacity of the largest crankcase oil sump. Refer to OEM for more information.

Minimum

(1)

6L(1.32

Imp gal)

Maximum

(2)

14L(3.1

Imp gal)

Cooling System

Refer to the OEM speciﬁcations for the External System capacity. This capacity information will be needed in order to determine the amount of coolant/antifreeze that is required for the Total Cooling System.

Page 51

SEBU8172-02 51

Maintenance Section

Reﬁll Capacities

Table 5

Engine

Reﬁll Capacities

Compartment or System

Engine Engine

(1)

Engine Only

External System Per OEM

(1)

Single Turbocharger

(2)

Series Turbochargers

(3)

The External System includes a radiator or an expansion tank with the following components: heat exchanger and p iping. Refer to the OEM speciﬁcations. Enter the value for the c apacity of the External System in this row.

(3)

i02865363

9 L (1.97 Imp gal) 9.4 L (2.07 Imp gal)

Liters

TTA

(2)

Fluid Recommendations

General Lubricant Information

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

EMA____________ Engine Manufacturers Association

•

API_____________________ American Petroleum Institute

•

SAE___________________________________________ Society Of

•

Automotive Engineers Inc.

EMA Guidelines

The “Engine Manufacturers Association Recommended Guideline on Diesel Engine Oil” is recognized by Perkins. For detailed information about this guideline, see the latest edition of EMA publication, “EMA DHD -1”.

API Licensing

The Engine Oil Licensing and Certiﬁcation System by theAmericanPetroleumInstitute(API)isrecognized 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.

ration 25

Illust

Typical API symbol

g00546535

Terminology

in abbreviations follow the nomenclature of

Certa “SAE J754”. Some classiﬁcations follow “SAE J183” abbreviations, and some classiﬁcations follow the

Recommended Guideline on Diesel Engine

“EMA Oil”.InadditiontoPerkinsdeﬁnitions, there are other deﬁnitions that will be of assistance in purchasing

icants. Recommended oil viscosities can be found

lubr in this publication, “Fluid Recommendations/Engine Oil” topic (Maintenance Section).

Engine Oil

Commercial Oils

NOTICE

For applications above 168 kW CI-4 oil must be used.

Page 52

52 SEBU8172-02 Maintenance Section Reﬁll Capacities

Table 6

API Classiﬁcations for the 1104D Industrial Engine

Oil Speciﬁcation Maintenance

CH-4/CI-4

CI-4

CG-4

Interval

500 Hours

250 Hours

Maintenance intervals for engines that use biodiesel – The oil change interval can be adversely

affected b

y the use of biodiesel. Use oil analysis in order to monitor the condition of the engine oil. Use oil analysis also in order to determine the oil change interval t

hat is optimum.

Note: These engine oils are not approved by perkins a

nd these engine oils must not be used:CC, CD, CD-2, and CF-4.

The perf

ormance of commercial diesel engine oils is based on API classiﬁcations. These API classiﬁcations are developed in order to provide commerc

ial lubricants for a broad range of diesel

engines that operate at various conditions.

Only us

e commercial oils that meet the following

classiﬁcations:

API___

•

_________________________________________

CH-4 CI-4

In order to make the correct choice of a commercial

efer to the following explanations:

oil, r

EMA DHD-1 – The EMA has developed lubricant

mendations as an alternative to the API oil

recom classiﬁcation system. DHD-1 is a Recommended Guideline that deﬁnes a level of oil performance for

e types of diesel engines: high speed, four stroke

thes cycle, heavy-duty, and light duty. DHD-1 oils may be used in Perkins engines when the following oils

ecommended: API CH-4 and API CG-4. DHD-1

are r oils are intended to provide superior performance in comparison to API CG-4.

DHD-1 oils will meet the needs of high performance Perkins diesel engines that are operating in many

lications. The tests and the test limits that are

app used to deﬁne DHD-1 are similar to the new API CH-4 classiﬁcation. Therefore, these oils will also

et the requirements for diesel engines that require

me low emissions. DHD-1 oils are designed to control the harmful effects of soot with improved wear resistance

dimprovedresistancetopluggingoftheoilﬁlter.

an These oils will also provide superior piston deposit control for engines with either two-piece steel pistons

raluminumpistons.

All DHD-1 oils m

ust complete a full test program with the base stock and with the viscosity grade of the ﬁnishedcommercialoil.Theuseof“APIBase Oil Interchan

ge Guidelines” are not appropriate for DHD-1 oils. This feature reduces the variation in performance that can occur when base stocks are changed in co

mmercial oil formulations.

DHD-1 oils are recommended for use in extended oil change inte

rval programs that optimize the life of the oil. These oil change interval programs are based on oil analysis. DHD-1 oils are recommended for conditions

that demand a premium oil. Your Perkins distributor has the speciﬁc guidelines for optimizing oil change intervals.

API CH-4 – API CH-4 oils were developed in order to meet the requirements of the new high performance diesel eng

ines. Also, the oil was designed to meet the requirements of the low emissions diesel engines. API CH-4 oils are also acceptable for use in older d

iesel engines and in diesel engines that use high sulfur diesel fuel. API CH-4 oils may be used in Perkins engines that use API CG-4 and API CF-4 oils

. API CH-4 oils will generally exceed the performance of API CG-4 oils in the following criteria: deposits on pistons, control of oil consumption, wear of pisto

n rings, valve train wear, viscosity control,

and corrosion.

Three ne

w engine tests were developed for the API CH-4 oil. The ﬁrst test speciﬁcally evaluates deposits on pistons for engines with the two-piece steel piston.

st (piston deposit) also measures the control

This te of oil consumption. A second test is conducted with moderate oil soot. The second test measures

llowing criteria: wear of piston rings, wear of

the fo cylinder liners, and resistance to corrosion. A third new test measures the following characteristics with

evels of soot in the oil: wear of the valve train,

high l 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

rate high soot. The oils also have improved

gene oxidation resistance. API CH-4 oils must pass an additional test (piston deposit) for engines that use

minum pistons (single piece). Oil performance is

alu 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

e recommended for use in extended oil change

ar intervals. API CH-4 oils are recommended for conditions that demand a premium oil. Your Perkins

stributor has speciﬁc guidelines for optimizing oil

di change intervals.

Page 53

SEBU8172-02 53

Maintenance Section

Reﬁll Capacities

Some commercia

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

ndition of the oil and perform a wear

metal analysis.

NOTICE

Failuretof

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

Total Bas e

Number (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines

The Total Base Number (TBN) for an oil depends on the fuel sulfur level. For direct injection engines that use disti must be 10 times the fuel sulfur level. The TBN is deﬁned by “ASTM D2896”. The minimum TBN of the oil is 5 r demonstrates the TBN.

llate fuel, the minimum TBN of the new oil

egardless of fuel sulfur level. Illustration 26

NOTICE

Operating Dir

ect 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 protecti

Table 7

Percentage of Sulfur in the fuel

Lower than 0.5 Normal

0.5to1.0

Greater than 1.0 0.50 of normal

on.

Oil change interval

0.75 of normal

Lubricant Viscosity Recommendations for Direct Injection (DI) Diesel Engines

The correct SAE viscosity grade of oil is determined by the minimum ambient temperature during cold engine start-up, and the maximum ambient temperature during engine operation.

Refer to Table 8 (minimum temperature) in order to determine the required oil viscosity for starting a cold engine.

Illustration 26

(Y) TBN by “ASTM D2896” (X) Percentage of fuel sulfur by weight (1) TBN of new oil (2) Change the oil when the TBN deteriorates to 50 perc ent 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.

Excessivepistondepositscanbeproducedbyanoil with a high TBN. These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore.

RefertoTable8(maximumtemperature)inorderto select the oil viscosity for engine operation at the highest ambient temperature that is anticipated.

Generally, use the highest oil viscosity that is available to meet the requirement for the temperature at start-up.

Table 8

Engine Oil Viscosity

Ambient TemperatureEMA 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)

AE 5W40

SAE 10W30 −20 °C (−4 °F) 40 °C (104 °F)

SAE 15W40 −10 °C (14 °F) 50 °C (122 °F)

Minimum Maximum

30 °C (−22 °F)

−

0°C(104°F)

Synthetic Base Stock Oils

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

Page 54

54 SEBU8172-02 Maintenance Section Reﬁll Capacities

Synthetic base conventional oils in the following two areas:

Synthetic bas

•

temperatures especially in arctic conditions.

Synthetic ba

•

stability especially at high operating temperatures.

Some synthe characteristics that enhance the service life of the oil. Perkins does not recommend the automatic extending o oil.

Re-reﬁned

Re-reﬁned base stock oils are acceptable for use in Perk performance requirements that are speciﬁed by Perkins. Re-reﬁned base stock oils can be used exclusiv base stock oils. The speciﬁcation for the US military and the speciﬁcations of other heavy equipment manufac stock oils that meet the same criteria.

The proc stock oil should adequately remove all wear metals that are in the used oil and all the additives that areint make re-reﬁned base stock oil generally involves the process of vacuum distillation and hydrotreating the used oi high quality, re-reﬁned base stock oil.

ely in ﬁnished oil or in a combination with new

turers also allow the use of re-reﬁned base

he used oil. The process that is used to

l. Filtering is adequate for the production of

oils generally perform better than

eoilshaveimprovedﬂow at low

se oils have improved oxidation

tic base oils have performance

f the oil change intervals for any type of

Base Stock O ils

ins engines if these oils meet the

ess that is used to make re-reﬁned base

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 hel characteristics that meet industry standards.

There are no the performance or the compatibility of aftermarket additives in ﬁnished oil. Aftermarket additives may not be comp package, which could lower the performance of the ﬁnished oil. The aftermarket additive could fail to mix with th 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 O

See the appropriate “Lubricant Viscosities” table in

•

order to engine.

At the s

•

new oil and install a new oil ﬁlter.

pprovideﬁnished oils with performance

e ﬁnished oil. This could produce sludge

il” or the recommended API classiﬁcation.

ﬁnd the correct oil viscosity grade for your

peciﬁed interval, service the engine. Use

l Additives

il. It is not necessary to use aftermarket

consist of base oils and of commercial

industry standard tests that evaluate

atible with the ﬁnished oil's additive

cants for Cold Weather

Lubri

When an engine is started and an engine is operated in amb multigrade oils that are capable of ﬂowing in low 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 bas or with a 5W viscosity grade. Use an oil with a pour point that is lower than −50 °C (−58 °F).

Perkins recommends the following lubricants for use in cold weather conditions:

Use a commercial oil that is API:CI-4, CI-4 PLUS, CH-4, and CG-4. The oil must have one of the fo 0W-30, SAE 0W-40, SAE 5W-30, and SAE 5W-40

ient temperatures below −20 °C (−4°F),use

e stock multigrade oil with an 0W viscosity grade

llowing lubricant viscosity grades: SAE 0W-20, SAE

rm maintenance at the intervals that are

Perfo

•

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

Oil analysis

engines may be equipped with an oil sampling

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

ysis will complement the preventive maintenance

anal program.

oil analysis is a diagnostic tool that is used to

The determine oil performance and component wear rates. Contamination can be identiﬁed and measured

ough the use of the oil analysis. The oil analysis

thr includes the following tests:

e Wear Rate Analysis monitors the wear of the

•

engine's metals. The amount of wear metal and type of wear metal that is in the oil is analyzed. The

crease in the rate of engine wear metal in the

in oil is as important as the quantity of engine wear metal in the oil.

Page 55

SEBU8172-02 55

Maintenance Section

Reﬁll Capacities

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 oftheoilaccordingtothespeciﬁcation during the entire oil change interval.

cted in order to detect

ion Analysis determines the loss of

f the used oil sample. This analysis

technicians to verify the performance

i02788820

Fluid Recommendations (Fuel Speciﬁcation )

Glossary

•

ISO International Standards Organization

•

ASTM American Society for Testing and Materials

•

Diesel Fuel Req uirements

Satisfactory the use of a good quality fuel. The use of a good quality fuel will give the following results: long engine life and accep fuel must meet the minimum requirements that are stated in table 9.

The footnot tion for Distillate Diesel Fuel Table. Read ALL of the footnotes.

engine performance is dependent on

table exhaust emissions levels. The

NOTICE

es are a key part of the Perkins Speciﬁca-

HFRR High Frequency Reciprocating Rig for

•

Lubricity testing of diesel fuels

FAME Fatty Acid Methyl Esters

•

CFR Co-ordinating Fuel Research

•

LSD Low Sulfur Diesel

•

ULSD Ultra Low Sulfur Diesel

•

RME Rape Methyl Ester

•

SME Soy Methyl Ester

•

EPA Environmental Protection Agency of the

•

United States

General Information

NOTICE Every attempt is made to provide accurate, up to date information. By use of this document you agree that Perkins Engines Company Limited is not responsible for errors or omissions.

TICE

NO These recommendations are subject to change without notice. Contact your local Perkins distributor for

he most up to date recommendations.

Page 56

56 SEBU8172-02 Maintenance Section Reﬁll Capacities

Table 9

Perkins Speciﬁcation for Distillate Diesel Fuel

Property UNITS Requirements “ASTM”Test “ISO”Test

Aromatics %Volume 35% maximum D1319 “ISO”3837

Ash

Carbon Residue on

%Weight 0.01% maxim

%Weight 0.35% maximum

um D482

D524

10% Bottoms

Cetane Number

(2)

Cloud Point °C

40 minimum

The cloud point must

D613/D6890 “ISO”5165

D2500 not exceed the lowest expected ambient temperature.

Copper Strip

No. 3 maximum D130 “ISO”2160

Corrosion

Density at 15 °C (59 °F)

Distill

(3)

ation

Kg / M

°C 10% at 282 °C

801 minimum and 876 maximum

No equivalent test

D86 “ISO”3405 (539.6 °F) maximum 90% at 360 °C (680 °F) maximum

Flash Point °C legal limit D93 “ISO”2719

Thermal Stability

Minimum of 80%

D6468 No equivalent test reﬂectance after aging for 180 minutes at 150 °C (302 °F)

Pour Point

°C 6 °C (

42.8 °F) minimum

D97 below ambient temperature

(1)(4)

Sulfur

Kinematic Viscosity

%mass 1% maximum D5453/D26222 “ISO 20846 ”“ISO 20884”

(5)

“MM”2“/S (cSt)” The viscosity of the

D445 “ISO”3405 fuel that is delivered to the fuel injection pump. “1.4 minimum/4.5 maximum”

Water and sediment

Water

% weight 0.1% maximum

Sediment % weight 0.05% maximum

Gums and Resins

(6)

mg/100mL

10 mg per 100 mL

D1796

D1744 No equivalent test

D473

D381 maximum

(1)

“ISO”6245

“ISO”4262

“ISO”3015

“ISO 3675 ”“ISO 12185”

”3016

“ISO

“ISO”3734

“ISO”3735

“ISO”6246

(continued)

Page 57

SEBU8172-02 57

Maintenance Section

Reﬁll Capacities

(Table 9, contd)

Lubricity corrected wear scar diam 60 °C (140 °F).

(1)

This speciﬁcation includes the requirem ents for Ultra Low Sulfur Diesel (ULSD). ULSD fuel will have ≤ 15 ppm (0.0015%) sulfur. Refer to “ASTM D5453”, “ASTM D2622”, or “ISO 20846, ISO 20884” test methods. This speciﬁcation includes the requirements for Low Sulfur Diesel (LSD). LSD fuel will have ≤500 ppm (0.05%) sulfur. Refer to following:“ASTM 54 53, ASTM D262 2”, “ISO 20846”, and “ISO 20884 test methods”.

(2)

A fuel with a h igher cetane number is recommende d in order to operate at a higher altitude or in cold weather.

(3)

“Via standa maximum den

(4)

Regional regulations, national regulations or international regulations can require a fuel with a speciﬁc sulfur limit. Consult all applicable regulations before selecting a fuel for a given engine application. Per kins 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 co rrosion of internal com ponents. Fuel sulfur levels above 0.5% may signiﬁcantly shorten the oil change interval. For additional information, refer to this manual, “Fluid recommendations (General lubricant Information)”.

(5)

The values of the fuel viscosity are the values as the fuel is delivered to the fuel injection pumps. F uel should a lso m eet the minimum viscosity r equirement and the fuel should meet the maximum viscosity requirements at 40 °C (104 °F) of either the “AST M D445” test method or the “ISO 3104” test method. If a fuel with a low v iscosity is used, cooling of the fuel ma y be required to maintain 1.4 c St or greater viscosity at the fuel injection pump. Fuels with a high v iscosity might require fuel heaters in order to lower the viscosity to 4.5 cSt at the fuel injection pump.

(6)

Follow the

(7)

The lubricity of a fuel is a concern with low sulfur and ultra low sulfur fuel. To determine the lubricity of the fuel, use the “ISO 12156-1 or 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 problem s in the fuel system.

eter at

(7)

rds tables, the equivalent API gravity for the minimum density of 801 kg / m

sity of 876 kg / m

test conditions and procedures for gasoline (motor).

is 30”.

0.52 maximum D6079

“ISO”12156-1

(kilograms per cubic meter) is 45 and for the

NOTICE Operating with fuels that do not meet the Perkins recommenda

tions can cause the following effects: Starting difﬁculty, poor combustion, deposits in the fuel injectors, reduced service life of the fuel system, de-

in the combustion chamber, and reduced ser-

posits vice life of the engine.

Diesel Fuel Characteristics

ns Recommendation

Perki

Cetane Number

Fuel that has a high cetane number will give a shorter ignition delay. This will produce a better ignition

ity. Cetane numbers are derived for fuels against

qual proportions of cetane and heptamethylnonane in the standard CFR engine. Refer to “ISO 5165” for the

t method.

tes

Cetane numbers in excess of 45 are normally

ected from current diesel fuel. However, a cetane

exp number of 40 may be experienced in some territories. The United States of America is one of the territories

at can have a low cetane value. A minimum cetane

th value of 40 is required during average starting conditions. A higher cetane value may be required

r operations at high altitudes or in cold weather

fo operations.

Viscosity

Viscosity is the property of a liquid of offering resistance to shear or ﬂow. Viscosity decreases with increas follows a logarithmic relationship for normal fossil fuel. The common reference is to kinematic viscosity. This is divided by the density. The determination of kinematic viscosity is normally by readings from gravity ﬂow visco 3104” for the test method.

The vi serves as a lubricant for the fuel system components. Fuel must have sufﬁcient viscosity in order to lubricate the fu and extremely hot temperatures. If the kinematic viscosity of the fuel is lower than 1.4 cSt at the fuel inje can occur. This damage can be excessive scufﬁng and seizure. Low viscosity may lead to difﬁcult hot rest viscosity may result in seizure of the pump.

Per

4.5 mm2/sec that is delivered to the fuel injection pump.

ing temperature. This decrease in viscosity

the quotient of the dynamic viscosity that is

meters at standard temperatures. Refer to “ISO

scosity of the fuel is signiﬁcant because fuel

el system in both extremely cold temperatures

ction pump damage to the fuel injection pump

arting, stalling and loss of performance. High

kins recommends kinematic viscosities of 1.4 and

uel with a low cetane number can be the root cause

F of problems during cold start.

Page 58

58 SEBU8172-02 Maintenance Section Reﬁll Capacities

Density

Density is the mass of the fuel per unit volume at a speciﬁcte direct inﬂuence on engine performance and a direct inﬂuence on emissions. This determines the heat output from a is generally quoted in the following kg/m at 15 °C (59 °F).

Perkins recommends a value of density of 841 kg/m in order to obtain the correct power output. Lighter fuels are ac the rated power.

mperature. This parameter has a

given injected volume of fuel. This

ceptable but these fuels will not produce

Sulfur

The level of sulfur is governed by emissions legislati or international regulations can require a fuel with a speciﬁc sulfur limit. The sulfur content of the fuel and the fu regulations for emissions.

By using D2622, or ISO 20846 ISO 20884”, the content of sulfur in low sulfur diesel (LSD) fuel must be below 500 PPM 0 D5453, ASTM D2622, or ISO 20846 ISO 20884”, the contentofsulfurinultralowsulfur(ULSD)fuelmust be belo the use of ULSD fuel are acceptable provided that the fuels meet the minimum requirements that are stated exceed wear scar diameter of 0.52 mm (0.0205 inch). The fuel lubricity test must be performed on a HFRR, opera

In some parts of the world and for some applications, high s be available. Fuel with very high sulfur content can cause engine wear. High sulfur fuel will have a neg High sulfur fuel can be used provided that the local emissions legislation will allow the use. High sulfur fuel emissions.

ons. Regional regulation, national regulations

el quality must comply with all existing local

the test methods “ASTM D5453, ASTM

.05%. By using the test methods “ASTM

w 15 PPM 0.0015%. The use of LSD fuel and

in table 9. The lubricity of these fuels must not

ted at 60 °C (140 °F). Refer to “ISO 12156-1 ”.

ulfur fuels above 0.5% by mass might only

ative impact on emissions of particulates.

can be used in countries that do not regulate

Lubricity

This is the capability of the fuel to prevent pump wear. The ﬂuid ﬂuid to reduce the friction between surfaces that are under load. This ability reduces the damage that is caused by fri lubricating properties of the fuel. Until fuel sulfur limits were mandated, the fuel's lubricity was generally believed to

The lubricity has particular signiﬁcance to the current low viscosi fossil fuel. These fuels are made in order to meet stringent exhaust emissions. A test method for measuring developed and the test is based on the HFRR method that is operated at 60 °C (140 °F). Refer to “ISO 12156 the test method.

Lubricit MUST NOT be exceeded. The fuel lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Refer to “

Fuel additives can enhance the lubricity of a fuel. Contact when fuel additives are required. Your fuel supplier can make recommendations for additives to use and for the p

y wear scar diameter of 0.52 mm (0.0205 inch)

's lubricity describes the ability of the

ction. Fuel injection systems rely on the

beafunctionoffuelviscosity.

ty fuel, low sulfur fuel and low aromatic

the lubricity of diesel fuels has been

part 1 and CEC document F06-A-96” for

ISO 12156-1 ”.

your fuel supplier for those circumstances

roper level of treatment.

Distillation

This is an indication of the mixture of different hydrocarbons in the fuel. A high ratio of light weight

carbons can affect the characteristics of

hydro combustion.

Class

Diesel engines have the ability to burn a wide variety of fu groups: Ref to table 10

iﬁcation of the Fuels

els. These fuels are divided into four general

n only high sulfur fuels are available, it will

Whe be necessary that high alkaline lubricating oil is used in the engine or that the lubricating oil change

erval is reduced. Refer to this Operation and

int Maintenance Manual, “Fliud Recommendations (Genernal Lubrication Information)” for information

sulfur in fuel.

Page 59

SEBU8172-02 59

Maintenance Section

Reﬁll Capacities

Table 10

Fuel Groups Classiﬁcation

Group 1 Preferred fuels Full life of the

Product

Group 2

Group 3

Group 4

Permissible fuels with an appropriate fuel additive

Biodiesel

These fuels MAY cause reduced engine life and performance

These fuels WILL cause reduced engine life and performan

Group 1 Speciﬁcations (Preferred Fuels)

This group of fuel speciﬁcations is considered acceptable:

EN590 DERV Grade A, B, C, E, F, Class, 0, 1, 2,

•

3, and 4

“BS2869 Class A2” Off-Highway Gas Oil Red

•

Diesel

“ASTM D975”, Class 1D , and Class 2D

•

“JP7 (MIL-T-38

•

“NATO F63”

•

JP8

•

JP5

•

“Jet A1 (ASTM D1655)”

•

“Jet A (ASTM D1655)”

•

“NATO F34 ”

•

Note: These fuels are only acceptable provided that these fuel These fuels must meet the requirements that are stated in table 9. Fuel samples should be analyzed for the com lubricity wear scar diameter of 0.52 mm (0.0205 inch). The fuel lubricity test must be performed on a HFRR, ope 12156-1 ”. Fuels must have minimum viscosity of

1.4 centistokes that is delivered to the fuel injection pump. Fue maintain minimum viscosity of 1.4 centistokes that is delivered to the fuel injection pump.

s are used with an appropriate fuel additive.

pliance. These fuels MUST NOT exceed

ratedat60°C(140°F).Referto“ISO

l cooling may be required in order to

219)”

Group 3 Speciﬁcations (Permissible Fuels)

“JIS K2204 Grades 1,2,3 and Special Grade 3”

•

This grade of fuel must meet the minimum lubricity requirements that are stated in table 9.

5% FAME to “EN14214” can be mixed with the fuel

•

that meets the requirements that are stated in table

9. This blend is commonly known as B5.

Note: The use of LSD fuel and the use of ULSD fuel is acceptable provided that the fuels meet the minimum requirements that are stated in table 9. The lubricity of these fuels must not exceed wear scar diameter of 0.52 mm (0.0205 inch). The lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Refer to “ISO 12156-1 ”. By using the test methods “ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884”, the content of sulfur in LSD fuel must be below 500 PPM 0.05%. By using the test methods “ASTM D5453, ASTM D2622, or ISO 20846 ISO 20884”, the content of sulfur in ULSD fuel must be below 15 PPM 0.0015%.

Group 2 Speciﬁcations (Permissible Fuels)

This group of fuel speciﬁcations is considered acceptable, but only with an appropriate fuel additive, but these fuels MAY reduce the engine life and performance.

This group of fuel speciﬁcation must be used only with the appropriate fuel additive. This fuel WILL reduce

“JIS 2203#1 and #2 Toyu”

Note: These fuels are only acceptable provided that these fuels are used with an appropriate fuel additive. These stated in table 9. Fuel samples should be analyzed for the compliance. These fuels MUST NOT exceed lubr The fuel lubricity test must be performed on a HFRR, operated at 60 °C (140 °F). Refer to “ISO 1215

1.4 centistokes that is delivered to the fuel injection pump. Fuel cooling may be required in order to mai delivered to the fuel injection pump.

engine life and performance.

fuels must meet the requirements that are

icity wear scar diameter of 0.52 mm (0.0205 inch).

6-1 ”. Fuels must have minimum viscosity of

ntain minimum viscosity of 1.4 centistokes that is

Page 60

60 SEBU8172-02 Maintenance Section Reﬁll Capacities

Group 4 Biodies

Biodiesel is a fuel that can be deﬁned as mono-alkyl esters of fatt be made from a variety of feedstock. The most commonly available biodiesel in europe is Rape Methyl Ester rapeseed oil. Soy Methyl Ester (SME) is the most common biodiesel in the United States. This biodiesel is derived f oil are the primary feedstocks. These fuels are together known as Fatty Acid Methyl Esters (FAME).

Raw pressed vegetable oils are NOT acceptable for use as a fuel in any concentration in compression engines. W crankcase and the fuel tank. These fuels may not be compatible with many of the elastomers that are used in engines forms, these oils are not suitable for use as a fuel in compression engines. Alternate base stocks for biodiese oils, or a variety of other feedstocks. In order to use any of the products that are listed as fuel, the oil must be es

Note: Engines that are manufactured by Perkins are cert Protection Agency (EPA) and European Certiﬁcation fuels. Perkins does not certify engines on any other fuel. Th of using the correct fuel that is recommended by the manufacturer and allowed by the EPA and other approp

Recommendation for the use of biodiesel

Use of FAME fuels is permissible. However, the following conditions apply:

y acids. Biodiesel is a fuel that can

(REM). This biodiesel is derived from

rom soybean oil. Soybean oil or rapeseed

ithout esteriﬁcation, these oils gel in the

that are manufactured today. In original

l may include animal tallow, waste cooking

teriﬁed.

iﬁed by use of the prescribed Environmental

e user of the engine has the responsibility

riate regulatory agencies.

The oil change i

•

of biodiesel. Use Services Oil Analysis in order to monitor the condition of the engine oil. Use Services Oil A oil change interval that is optimum.

Conﬁrm that b

•

the manufacturer of the fuel ﬁlters.

Inacompari

•

biodiesel provides less energy per gallon by 5% to 7%. Do NOT change the engine rating in order to compensate engine problems when the engine is converted back to 100 percent distillate diesel fuel.

The compatibility of the elastomers with biodiesel

•

is being monitored. The condition of seals and hoses shou

Biodiesel may pose low ambient temperature

•

problems ambient temperatures, fuel may need to be stored in a heated building or a heated storage tank. The fuel syst and tanks. Filters may plug and fuel in the tank may solidify at low ambient temperatures if precautions are not t assistance in the blending and attainment of the proper cloud point for the fuel.

Biodiesel has poor oxidation stability, which

•

can result in long term problems in the storage of biod accelerate fuel oxidation in the fuel system. This is especially true in engines with electronic fuel s higher temperatures. Consult the fuel supplier for oxidation stability additives.

em may require heated fuel lines, ﬁlters,

aken. Consult your biodiesel supplier for

iesel. The poor oxidation stability may

ystems because these engines operate at

nterval can be affected by the use

nalysis also in order to determine the

iodiesel is acceptable for use with

son of distillate fuels to biodiesel,

for the power loss. This will help avoid

ld be monitored regularly.

for both storage and operation. At low

The FAME fuel must comply with “EN14214”.

•

imum of 5% mixture of FAME can be used

Amax

•

in mineral oil diesel fuel, provided that the fuel complies with the fuel speciﬁcation that is listed in

e 9. This blend is commonly known as B5. No

tabl mixture above 5% is acceptable. Concentrations above 5% will lead to reduced product service life

potential failure of the fuel injection equipment.

and

Note: When biodiesel, or any blend of biodiesel is

d, the user has the responsibility for obtaining the

use proper local exemptions, regional exemptions, and/or national exemptions that are required for the use

biodiesel in any Perkins engine that is regulated

of by emissions standards. Biodiesel that meets EN 14214 is acceptable. The biodiesel must be blended

th an acceptable distillate diesel fuel at the

wi maximum stated percentages. However, the following operational recommendations must be followed:

Biodiesel is a fuel that can be made from a variety

•

of feedstock. The feedstock that is used can

cttheperformanceoftheproduct.Twoofthe

affe characteristics of the fuel that are affected are cold ﬂow and oxidation stability. Contact your fuel

lier for guidance.

supp

Biodiesel or biodiesel blends are not recommended

•

engines that will operate occasionally. This

for is due to poor oxidation stability. If the user is prepared to accept some risk, then limit biodiesel

maximum of B5. Examples of applications that

to a should limit the use of biodiesel are the following: Standby Generator sets and certain emergency

hicles

Page 61

SEBU8172-02 61

Maintenance Section

Reﬁll Capacities

Biodiesel is an

•

excellent medium for microbial contamination and growth. Microbial contamination and growth can cause corrosion in the fuel system and premature

plugging of the fuel ﬁlter. The use of conventionalanti-microbial additives and the effectiveness of conventional anti-microbial additives in

biodiesel is not known. Consult your

supplier of fuel and additive for assistance.

Care must be

•

takeninordertoremovewater from fuel tanks. Water accelerates microbial contamination and growth. When biodiesel is compared to

distillate fuels, water is naturally more

likely to exist in the biodiesel.

Fuel for Co

ld Weather Operation

The European standard “EN590” contains climate dependant

requirements and a range of options. The options can be applied differently in each country. There are 5 classes that are given to arctic climates and sever

e winter climates. 0, 1, 2, 3, and 4.

Fuel that complies with “EN590 ” CLASS 4 can be used at t

emperatures as low as −44 °C (−47.2 °F). Refer to “EN590” for a detailed discretion of the physical properties of the fuel.

The diesel fuel “ASTM D975 1-D” that is used in the united states of america may be used in very cold temper

atures that are below −18 °C (−0.4 °F).

In extreme cold ambient conditions, you may also use fue

ls that are listed in the table 11. These fuels are intended to be used in temperatures that can be as low as −54 °C (−65.2 °F).

Table

Distillate Fuels

Light

Speciﬁcation Grade

“MIL-T-5624R”

“MIL-T-83133D”

“ASTM D1655”

(1)

The use of these fuels is acceptable with an appropriate fuel additive and the fuels must meet minimum requirements that are stated in Table 9. Fuel samples should be analyzed for the compliance. Fuels MUST NOT e xceed 0.52 mm lubricity wear s car diameter that is tested on a HFFR . T he test must be performed at 60 °C. Refer to “ISO 12156-1”. Fuels must have minimum viscosity of 1.4 centistokes that is deliver ed to the fuel injection pump. Fuel cooling may be required in order to maintain minimum viscosity of 1.4 centistokes that is delivered to the fuel injection pump.

JP-5

JP-8

Jet-A-1

(1)

Mixing alcohol or gas oline with diesel fuel can produce an explosive mi xture in the engine crankcase or the fuel tank. Alcohol or gasoline must not be used in order to dilute diesel fuel. Failure to follow this instruction may result in death or personal injury.

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 table 9. To ensure optimum engine performance, a complete fuel analysis should be obtained before engine operation. The fuel analysis should include all of the properties thatarestatedinthetable9.

Fuel Additive

Supplemental diesel fuel additives are not generally recommended. This is due to potential damage to the fuel system or the engine. Your fuel supplier or the fuel manufacturer will add the appropriate supplemental diesel fuel additives.

Perkins recognizes the fact that additives may be required in some special circumstances. Fuel additives need to be used with caution. Contact your fuel supplier for those circumstances when fuel additives are required. Your fuel supplier can recommend the appropriate fuel additive and the correct level of treatment.

Note: For the best results, your fuel supplier should treat the fuel when additives are required. The treated fuel must meet the requirements that are stated in table 9.

i02962446

Fluid Recommendations (Coolant Speciﬁcations)

General Coolant Information

NOTICE Never add coolant to an overheated engine. Engine damage could result. Allow the engine to cool ﬁrst.

NOTICE

the engine is to be stored in, or shipped to an area

If with below freezing temperatures, the cooling system must be either protected to the lowest outside temper-

ture or drained completely to prevent damage.

Page 62

62 SEBU8172-02 Maintenance Section Reﬁll Capacities

Table 12

NOTICE Frequently ch 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.

eck 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 engine cooling systems.

DO NOT use the following types of water in cooling systems: Hard water, softened water that has been conditioned with salt, and sea water.

If distilled water or deionized water is not available, use water with the properties that are listed in Table

12.

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 63

SEBU8172-02 63

Maintenance Section

Reﬁll Capacities

Freezing

•

NOTICE

Cavitation of the water pump

•

Do not use a com

mercial 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

, ethylene and propylene glycol provide similar protection against freezing and boiling. See Tables 13 and 14.

Table 13

Ethylene Glycol

Concentration Freeze Protection

50 Percent −36 °C (−33 °F)

60 Percent

−51 °C (−

60 °F)

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 14

Propylene Glycol

Concentration Freeze Protection

50 Percent −29 °C (−20 °F)

To check the concentration of glycol in the coolant, measure the speciﬁc gravity of the coolant.

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

vy-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

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

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

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

systems. Distilled water or deionized water is preferred. Water which has the recommended properties may be used.

Table 15

Coolant Service Life

Coolant Type Service Life

Perkins ELC

Commercial Heavy-Duty

Antifreeze that meets

Perkins POWERPART

Commercial SCA and

“AST

M D4985”

SCA

Water

6,000 Service Hours or

Three Years

ervice Hours or

3000 S

Two Years

3000 Service Hours or

Two Years

3000 Service Hours or

Two Years

Coolant Recommendations

ELC____________________________ Extended Life Coolant

•

SCA___________________Supplement Coolant Additive

•

ASTM__________________________________________ American

•

Society for Testing and Materials

The following two coolants are used in Perkins diesel engines:

Preferred – Perkins ELC

Acceptable – A commercial heavy-duty antifreeze

that meets “ASTM D4985” speciﬁcations

ELC

Perkins provides ELC for use in the following applications:

Heavy-duty spark ignited gas engines

•

Heavy-duty diesel engines

•

Automotive applications

•

Page 64

64 SEBU8172-02 Maintenance Section Reﬁll Capacities

The anti-corro the anti-corrosion package for other coolants. ELC is an ethylene glycol base coolant. However, ELC contains orga agents with low amounts of nitrite. Perkins ELC has been formulated with the correct amount of these additi protection for all metals in engine cooling systems.

ELC is avail distilled water. ELC is a 1:1 mixture. The Premixed ELC provides freeze protection to −36 °C (−33 °F). The Premixe ﬁll of the cooling system. The Premixed ELC is also recommended for topping off the cooling system.

Containers of several sizes are available. Consult your Perkins distributor for the part numbers.

sion package for ELC is different from

nic corrosion inhibitors and antifoam

ves in order to provide superior corrosion

able in a premixed cooling solution with

d ELC is recommended for the initial

ELC Cooling 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 Cooling 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 when ELC is drained from the cooling system.

Before the c (if equipped) must be set to the hot position. Refer to the OEM in order to set the heater control. After the coolin is reﬁlled, operate the engine until the coolant level reaches the normal operating temperature and until the c the coolant mixture in order to ﬁll the system to the speciﬁed level.

ts are not required to be used at

d by the addition of some other type of

is the only cleaning agent that is required

ooling system is ﬁlled, the heater control

g system is drained and the cooling system

oolant level stabilizes. As needed, add

tem Cleaning

Changing to Perkins ELC

To chang ELC, perform the following steps:

Care m u contained during performance of inspection, maintenance, testing, adjusting and the repair of the produc containers before opening any compartment or disassembling any component containing ﬂuids.

e from heavy-duty antifreeze to the Perkins

NOTICE

stbetakentoensurethatallﬂuids are

t. Be prepared to collect the ﬂuid with suitable

In order to maintain the correct balance between

tifreeze and the additives, you must maintain

the an the recommended concentration of ELC. Lowering the proportion of antifreeze lowers the proportion of

tive. This will lower the ability of the coolant to

addi protect the system from pitting, from cavitation, from erosion, and from deposits.

NOTICE Do not use a conventional coolant to top-off a cooling system that is ﬁlled with Extended Life Coolant (ELC).

Do not use standard supplemental coolant additive (SCA).

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

Dispose of all ﬂuids according to local regulations and mandates.

1. Drai

2. Dispose of the coolant according to local

3. Flush the system with clean water in order to

4. Use Perkins cleaner to clean the system. Follow

5. Drain the cleaner into a suitable container. Flush

6. Fill the cooling system with clean water and

n the coolant into a suitable container.

lations.

regu

ove any debris.

rem

instruction on the label.

the

e cooling system with clean water.

erate the engine until the engine is warmed to

op 49° to 66°C (120° to 150°F).

Page 65

SEBU8172-02 65

Maintenance Section

Reﬁll Capacities

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

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

7. Drain the co

and ﬂush the cooling system with clean water.

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

8. Repeat St

completely clean.

9. Fill the

ELC.

ELC Cool

ncomplete ﬂushing of the cooling system

ush the system until all the signs of the

oling system into a suitable container

ooling system cleaner must be thoroughly

he cleaner may also corrode the cooling

eps 6 and 7 until the system is

cooling system with the Perkins Premixed

ing System Contamination

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

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

Perkins engine cooling systems should be tested at 500 hour

Additions of SCA are based on the results of the test. An SCA t intervals.

te an engine without water temperature

erating temperature. Cooling system prob-

antifreeze (glycol concentration) in

ometer for checking the glycol concentration.

intervals for the concentration of SCA.

hat is liquid may be needed at 500 hour

NOTICE 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.

o Table 16 for part numbers and for quantities

Refer t of SCA.

Table 16

Perkins Liquid SCA

Part Number

21825735 10

Quantity

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 17 to determine the amount of Perkins SCA that is required when the cooling system is initially ﬁlled.

Table 17

Equation For Adding The SCA To The Heavy-Duty

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Coolant At The Initial Fill

V×0.045=X

Page 66

66 SEBU8172-02 Maintenance Section Reﬁll Capacities

Table18isanex

ample for using the equation that

is in Table 17.

Table 18

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant At The Initial Fill

Total Vol u m e

of the Cooling

System (V)

15 L (4 US gal)

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 H eavy-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 co

•

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

oling system after used coolant is

Use the equation that is in Table 19 to determine the amount of Perkins SCA that is required, if necessary:

Table 19

on For Adding The SCA To The Heavy-Duty

Equati

V is the total volume of the cooling system.

X is the amount of SCA that is required.

Coolant For Maintenance

V × 0.014 = X

Table20isanexampleforusingtheequationthat is in Table 19.

Table 20

Example Of The Equation For Adding The SCA To

The Heavy-Duty Coolant For Maintenance

Total Vol u m e

of the Cooling

System (V)

15 L (4 US gal)

Multiplication

Factor

× 0.014

Amount of

SCA that is

quired (X)

0.2 L (7 oz)

Page 67

SEBU8172-02 67

Maintenance Section

Maintenance Recommendations

i04103075

Welding on Engines with Electronic

Because th some manufacturers do not recommend welding onto a chassis frame or rail. Consult the OEM of the equipment or you achas

Proper welding procedures are necessary in order to avoid associated components. When possible, remove the component from the unit and then weld the compone possible, the following procedure must be followed whenyouweldonaunitequippedwithanElectronic Engine the safest procedure to weld on a component. This procedure should provide a minimum risk of damage to elec

frameorrail.

sis

damage to the engines ECM, sensors, and

nt. If removal of the component is not

. The following procedure is considered to be

tronic components.

Controls

NOTICE

e strength of the frame may decrease,

r Perkins dealer regarding welding on

Electronic com

•

ECM

•

Sensors

•

Electronica

•

Relays

•

Aftertreatment ID module

•

Do not use electrical components (ECM or ECM sensors)orel grounding the welder.

ectronic component grounding points for

ponents for the driven equipment

lly controlled valves

NOTICE

NOTICE Do not ground the welder to electrical components such as the ECM or sensors. Improper grounding can cause damage to the drive train bearings, hydraulic components, electrical components, and other components.

Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. This will help reduce the possibility of damage.

Note: Perform the welding in areas that are free from explosive hazards.

1. Stop the engine. Turn the switched power to the

OFF position.

2. Ensure that the fuel supply to the engine is turned

off.

3. Disconnect the negative battery cable from the

battery. If a battery disconnect switch is provided, open the switch.

4. Disconnect all electronic components from

the wiring harnesses. Include the following components:

Illustration 27

Use the example above. The current ﬂ ow from the welder to the ground clamp of the welder will not damage any associated components.

(1) Engine (2) Welding electrode (3) Keyswitch in the OFF position (4) Battery disconn ect switch in the open position (5) Disconnected battery cables (6) Batte ry (7) Electrical/Electronic component (8) Minimum distance between the compo nent that is being welded

and any electrical/electronic component (9) The component that is being welded (10) Current path of the welder (11) Ground clamp for the welder

g01075639

Page 68

68 SEBU8172-02 Maintenance Section Maintenance Recommendations

5. Connect the wel the part that will be welded. Place the ground cable as close as possible to the weld in order to reduce the pos to the following components. Bearings, hydraulic components, electrical components, and ground straps.

Note: If electrical/electronic components are used as a ground f components are located between the welder ground and the weld, current ﬂow from the welder could severely da

6. Protect the wiring harness from welding debris and spatte

7. Use standard welding practices to weld the materials

mage the component.

ding ground cable directly to

sibility of welding current damage

or the welder, or electrical/electronic

Page 69

SEBU8172-02 69

Maintenance Section

Maintenance Interval Schedule

i04949917

Maintenance Interval Schedule

When Required

Battery - Replace .................................................. 71

Battery or Battery Cable - Disconnect .................. 72

Engine - Cle Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 80

Engine Oil S

Fuel System - Prime ............................................. 89

Severe Service Application - Check ..................... 99

Daily

Alternator Belt - Inspect/Adjust/Replace ............... 71

Cooling Sy

Driven Equipment - Check .................................... 79

Engine Air Cleaner Service Indicator - Inspect ..... 82

Engine Ai

Engine Oil Level - Check ...................................... 83

Fuel System Primary Filter/Water Separator -

Drain ................................................................... 93

V-Belts - Inspect/Adjust/Replace ........................ 101

Walk-Around Inspection ...................................... 102

Every 50

Fuel Tank Water and Sediment - Drain ................. 97

Every 2

an ...................................................... 79

ample - Obtain .................................. 84

stem Coolant Level - Check ................ 77

r Precleaner - Check/Clean ................... 83

Service Hours or Weekly

50 Service Hours

Every 1000 Serv

Engine Valve Lash - Inspect/Adjust ...................... 87

Every 2000 Ser

Aftercooler Core - Inspect ..................................... 70

Alternator -

Belt Tensioner - Inspect ........................................ 73

Engine Mounts - Inspect ....................................... 83

Exhaust Man

Starting Motor - Inspect ...................................... 100

Turbocharger - Inspect ........................................ 100

Water Pump -

Inspect ............................................... 71

ice Hours

vice Hours

ifold - Inspect ................................... 87

Inspect ......................................... 104

Every 3000 Service Hours

Alternato

r Belt - Inspect/Adjust/Replace ............... 71

Every 3000 Service Hours or 2 Years

Cooling S

Change ............................................................... 73

ystem Coolant (Commercial Heavy-Duty) -

Every 4000 Service Hours

Aftercooler Core - Clean/Test ............................... 70

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 75

Commissioning

Fan Cle arance - Check ......................................... 88

Engine Oil and Filter - Change ............................. 87

al 500 Service Hours

Initi

Engine Valve Lash - Inspect/Adjust ...................... 87

Every

Fan Clearance - Check ......................................... 88

V-Be

500 Service Hours

lts - Inspect/Adjust/Replace ........................ 101

Every 500 Service Hours or 1 Year

tery Electrolyte Level - Check .......................... 72

Bat Cooling System Supplemental Coolant Additive

(SCA) - Test/Add ................................................. 78

nkcase Breather (Canister) - Replace ............. 79

Cra Engine Air Cleaner Element (Dual Element) -

Clean/Replace .................................................... 80

gine O il and Filter - Change ............................. 84

En Fuel System Primary Filter (Water Separator)

Element - Replace .............................................. 90

el System Secondary Filter - Replace .............. 94

Hoses and Clamps - Inspect/Replace .................. 97

Radiator - Clean .................................................... 98

Page 70

70 SEBU8172-02 Maintenance Section Aftercooler Core - Clean/Test

i02322260

Aftercooler C ore - C lean /Test

1. Remove the cor

for the correct procedure.

2. Turn the afte

remove debris.

Personal injury can result from air pressure.

Personal i 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 opposit nozzle approximately 6 mm (.25 inch) away from the ﬁns. Slowly move the air nozzle in a direction that is debris that is between the tubes.

njury can result without following prop-

e direction of the fan's air ﬂow. Hold the

parallel with the tubes. This will remove

e. Refer to the OEM information

rcooler core upside-down in order to

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.

295

i02322

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

Do not use a high concentration of caustic cleaner to clea can attack the internal metals of the core and cause leakage. Only use the recommended concentration of clea

5. Back ﬂush the core with a suitable cleaner.

6. Ste

residue. Flush the ﬁ ns of the aftercooler core. Remove any other trapped debris.

7. Wash the core with hot, soapy water. Rinse the core thoroughly with clean water.

rized water may also be used for cleaning.

urized water in order to soften mud. Clean

NOTICE

n the core. A high concentration of caustic cleaner

ner.

am clean the core in order to remove any

Aftercooler Core - Inspect

Adjust the frequency of cleaning according to

Note:

the effects of the operating environment.

ect the aftercooler for these items: damaged ﬁns,

Insp 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.

sonal injury can result from air pressure.

Per

Personal injury can result without following prop-

procedure. When using pressure air, wear a pro-

er tective face shield and protective clothing.

ximum air pressure at the nozzle must be less

Ma than 205 kPa (30 psi) for cleaning purposes.

Page 71

SEBU8172-02 71

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.

, start the engine and accelerate the

b behind the core in order to inspect

Make 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 belt o

•

and splitting.

Illustration 28

Typical example

f cracks, splits, glazing, grease,

g01251375

Adjustment

This type of belt has an automatic belt tensioner.

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.

i02491869

ernator Belt -

Alt Inspect/Adjust/Replace (Poly V-Belt)

Inspection

o maximize the engine performance, inspect the belt

T (1) for wear and for cracking. Replace the belt if the belt is worn or damaged.

Replace

Refer to Disassembly and Assembly manual, “Alternator Belt - Remove and Install”.

i02322315

Battery - Replace

Batteries give off combustible gases which can explode. A spark can cause the combustible gases 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 order to help prevent electrical arcs and/or sparks near batteries. Do not smoke when batteries are serviced.

If the belt (1) has more than four cracks per

•

25.4000 mm (1 inch) the belt must be replaced.

Page 72

72 SEBU8172-02 Maintenance Section Battery Electrolyte Level - Check

The battery cables or the batteries 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.

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

5. Remove the used battery.

All lead-acid batteries contain sulfuric acid which can burn the skin and clothing. Always wear a face shield and protective clothing when working on or near batteries.

1. Remove the ﬁller caps. Maintain the electrolyte

level to the “FULL” mark on the battery.

If the addition of water is necessary, use distilled water. If distilled water is not available use clean water that is low in minerals. Do not use artiﬁcially softened water.

2. Check the condition of the electrolyte with a suitable battery tester.

3. Install the caps.

4. Keep the batteries clean.

Clean the battery case with one of the following cleaning solutions:

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.

•

Thoroughly rinse the battery case with clean water.

6. Install the new battery.

Note: Before the cables are connected, ensure that

the engine start switch is OFF.

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

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

i02747977

tery Electrolyte Level -

Bat Check

When the engine is not run for long periods of time or

en the engine is run for short periods, the batteries

wh may not fully recharge. Ensure a full charge in order to help prevent the battery from freezing. If batteries

re correctly charged, the ammeter reading should

a be very near zero, when the engine is in operation.

i02323088

Batte

ry or Battery Cable -

Disconnect

battery cables or the batteries should not be

The removed with the battery cover in place. The battery cover should be removed before any servic-

is attempted.

ing

Removing the battery cables or the batteries with

e cover in place may cause a battery explosion

th resulting in personal injury.

rn the start switch to the OFF position. Turn the

1. Tu ignition switch (if equipped) to the OFF position and remove the key and all electrical loads.

2. Disconnect the negative battery terminal. Ensure that the cable cannot contact the terminal. When

our 12 volt batteries are involved, two negative

f connection must be disconnected.

Page 73

SEBU8172-02 73

Maintenance Section

Belt Tensioner - Inspect

3. Remove the posi

4. Clean all disconnected connection and battery

terminals.

5. Use a ﬁne grade of sandpaper to clean the terminals an until the surfaces are bright or shiny. DO NOT remove material excessively. Excessive removal of material correctly. Coat the clamps and the terminals with a suitable silicone lubricant or petroleum jelly.

6. Tape the cable connections in order to help prevent accidental starting.

7. Proceed with necessary system repairs.

8. In order to

positive connection before the negative connector.

tive connection.

dthecableclamps.Cleantheitems

cancausetheclampstonotﬁt

connect the battery, connect the

i02870187

Belt Tensioner - Inspect

Install the bel “Alternator Belt - Remove and Install”.

t. Refer to Disassembly and Assembly,

i02854855

Cooling System Coolant (Commercial Heavy-Duty) 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.

Illustration 29

Typical example

Remove the belt. Refer to Disassembly and Assembly, “Alternator Belt - Remove and Install”.

Ensure that the belt tensioner is securely installed. Visually inspect the belt tensioner (1) for damage. Check that the roller on the tensioner rotates freely. Some engines have a guide roller (2). Ensure that the guide roller is securely installed. Visually inspect the guide roller for damage. Ensure that the guide roller can rotate freely.

g01429637

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 of the coolant 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.

Drain

Page 74

74 SEBU8172-02 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 30

Typical example

and allow the engine to cool.

ap.

g01244659

3. Fill the coolin cooling system ﬁller cap.

4. Start and run t temperature reaches 49 to 66 °C (120 to 150 °F).

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

g system with clean water. Install the

he engine at low idle until the

ne and allow the engine to cool.

r cap. Open the drain cock or remove

drain. Flush the cooling system with

Fill

1. Close the d

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.

rain cock or install the drain plug on the

NOTICE

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.

NOTICE Dispose of used engine coolant or recycle. Various methods have been proposed to reclaim used coolant for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Perkins to reclaim the coolant.

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

Flush

1. Flush the cooling system with clean water in order

to remove any debris.

2. Close the drain cock or install the drain plug in the

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

2. Fill th

3. Start

4. Chec

e cooling system with Commercial Heavy-Duty Coolant. Add Supplemental Coolant Additive to the coolant. For the correct amount,

o the Operation and Maintenance Manual,

refer t “Fluid Recommendations” topic (Maintenance Section) for more information on cooling system

ﬁcations. Do not install the cooling system

speci ﬁller cap.

and run the engine at low idle. Increase the engine rpm to high idle. Run the engine at high idle for one minute in order to purge the air from

avities of the engine block. Decrease the

the c engine speed to low idle. Stop the engine.

k the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for ﬁlling. Maintain the coolant level in the

ansion bottle (if equipped) at the correct level.

exp

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.

Page 75

SEBU8172-02 75

Maintenance Section

Cooling System Coolant (ELC) - Change

Illustration 31

Filler cap

5. Clean the cooling system ﬁller cap and inspect the

gasket. If the gasket is damaged, discard the old ﬁller cap and install a new ﬁller cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the ﬁller cap. The correct pressure is stamped on the face of the ﬁ ller cap. If the ﬁller cap does not retain the correct pressure, install a new ﬁller cap.

6. Start the engine. Inspect the cooling system for

leaks and for correct operating temperature.

g00103639

Foaming of the c

•

The oil has entered the cooling system and the

•

coolant is con

The fuel has entered the cooling system and the

•

coolant is co

Note: When the cooling system is cleaned, only clean water replaced.

Note: Inspe temperature regulator after the cooling system has been drained. This is a good opportunity to replace the water p the hoses, if necessary.

is needed when the ELC is drained and

ct the water pump and the water

ump, the water temperature regulator and

oolant is observed.

taminated.

ntaminated.

Drain

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

zed System: Hot coolant can cause seri-

nts are cool. Loosen the cooling system

i02490917

Cooling System Coolant (ELC)

- Change

Dispose of all ﬂuids according to Local regulations and mandates.

TICE

NO Keep all parts clean from contaminants.

ntaminants may cause rapid wear and shortened

Co component life.

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

1. Stop the engine and allow the engine to cool. Loosen the cooling system ﬁller cap slowly in

o relieve any pressure. Remove the cooling

order t system ﬁller cap.

Illustration 32

Typical example

g01244659

The engine overheats frequently.

•

Page 76

76 SEBU8172-02 Maintenance Section Cooling System Coolant (ELC) - Change

2. Open the drain c 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 hav for reuse in engine cooling systems. The full distillation procedure is the only method acceptable by Perkins to reclaim the

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

e been proposed to reclaim used coolant

coolant.

kins distributor.

ock or remove the drain plug (1)

NOTICE

Flush

1. Flush the cooling system with clean water in order

to remov

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

e any debris.

Close the drain cock or install the drain

2. Fill the coolin Coolant (ELC). Refer to the Operation and Maintenance Manual, “Fluid Recommendations” topic (Mainte on cooling system speciﬁcations. Do not install the cooling system ﬁller cap.

3. Start and run the engine at low idle. Increase the engine rpm to high idle. Run the engine at high idle for one the cavities of the engine block. Decrease the engine speed to low idle. Stop the engine.

4. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for ﬁl expansion bottle (if equipped) at the correct level.

g system with Extended Life

nance Section) for more information

minute in order to purge the air from

ling. Maintain the coolant level in the

NOTICE Do not ﬁ (1.3 US gal) per minute to avoid air locks.

Cooli

3. Fill the cooling system with clean water. Install the

cool

4. Start and run the engine at low idle until the

temp

5. Stop the engine and allow the engine to cool.

Loo order to relieve any pressure. Remove the cooling system ﬁller cap. Open the drain cock or remove the or remove the drain plug on the radiator. Allow the water to drain. Flush the cooling system with cle

1. Close the drain cock or install the drain plug on the

en plug on the radiator.

ll the cooling system faster than 5 L

ng system air locks may result in engine damage.

ing system ﬁller cap.

erature reaches 49 to 66 °C (120 to 150 °F).

sen the cooling system ﬁller cap slowly in

drain plug on the engine. Open the drain cock

an water.

gine. Close the drain cock or install the drain

Illustration 33

Filler cap

5. Clean the cooling system ﬁller cap and inspect the gasket. If the gasket is damaged, discard the old ﬁller cap and install a new ﬁller cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the ﬁller cap. The correct pressure is stamped on the face of the ﬁller cap. If the ﬁller cap does not retain the correct pressure, install a new ﬁller cap.

6. Start the engine. Inspect the cooling system for leaks and for correct operating temperature.

g00103639

NOTICE

onotﬁll the cooling system faster than 5 L

D (1.3 US gal) per minute to avoid air locks.

Cooling system air locks may result in engine damage.

Page 77

SEBU8172-02 77

Maintenance Section

Cooling System Coolant Level - Check

i04408743

Cooling System Coolant Level

- Check

Engines With a Coolant Recovery Tank

Note: The co

provided by Perkins. The procedure that follows is for typical cooling systems. Refer to the OEM informatio

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

When any servicing or repair of the engine cooling system is performed, the procedure must be performed wi you to accurately check the coolant level. This will also help in avoiding the risk of introducing an air lock into the

1. Observe the coolant level in the coolant recovery tank. M mark on the coolant recovery tank.

Pressurized System: Hot coolant can cause serious bu stop the engine and wait until the cooling system components are cool. Loosen the cooling system

sure cap slowly in order to relieve the pres-

pres sure.

oling system may not have been

n for the correct procedures.

NOTICE

th the engine on level ground. This will allow

coolant system.

aintain the coolant level to “COLD FULL”

rns. To open the cooling system ﬁller cap,

Illustration 34

Filler cap

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.

g02590196

Engines Without a Coolant Recovery Tank

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

2. Loos

3. Pou

en ﬁller cap slowly in order to relieve any

pressure. Remove the ﬁller cap.

r the correct coolant mixture into the tank. Refer to the Operation and Maintenance Manual, “Reﬁll Capacities and Recommendations” for

ormation on the correct mixture and type of

inf coolant. Refer to the Operation and Maintenance Manual, “Reﬁll Capacities and Recommendations”

r the cooling system capacity. Do not ﬁll the

fo coolant recovery tank above “COLD FULL” mark.

Illustration 35

Cooling system ﬁller cap

g00285520

Page 78

78 SEBU8172-02 Maintenance Section Cooling System Supplemental Coolant Additive (SCA) - Test/Add

Add the SCA, If Necessary

1. Remove the cooling system ﬁller cap slowly in

order to relieve pressure.

2. Maintain the coolant level at the maximum mark that is correct for your application. If the engine is equipped with a sight glass, maintain the coolant level to the correct level in the sight glass.

3. Clean the cooling system ﬁller cap and inspect the gasket. If the gasket is damaged, discard the old ﬁller cap and install a new ﬁller cap. If the gasket is not damaged, use a suitable pressurizing pump in order to pressure test the ﬁller cap. The correct pressure is stamped on the face of the ﬁ ller cap. If the ﬁller cap does not retain the correct pressure, install a new ﬁller cap.

4. Inspect the cooling system for leaks.

NOTICE Do not exceed the recommended amount of supplemental coolant additive concentration. Excessive supplemental coolant additive concentration can form deposits on the higher temperature surfaces of the cooling system, reducing the engine's heat transfer characteristics. Reduced heat transfer could cause cracking of the cylinder head and other high temperature components. Excessive supplemental coolant additive concentration could also result in radiator tube blockage, overheating, and/or accelerated water pump seal wear. Never use both liquid supplemental coolant additive and the spin-on element (if equipped) at the same time. The use of those additives together could result in supplemental coolant additive concentration exceeding the recommended maximum.

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

e engine and wait until the cooling system

948

i03644

Cooling System Supplemental Coolan

t Additive (SCA) -

Test/Add

Cooling system coolant additive contains alkali. To help prevent personal injury, avoid contact with the skin and the eyes. Do not drink cooling system coolant additive.

Test for SCA Concentration

Heavy-Duty Coolant/Antifreeze and SCA

NOTICE

not exceed the recommended six percent supple-

Do mental coolant additive concentration.

NOTICE When any servicing or repair of the engine cooling system is performed the procedure must be performed with the engine on level ground. This will allow you to accurately check the coolant level. This will also help in avoiding the risk of introducing an air lock into the coolant system.

1. Slowly loosen the cooling system ﬁller cap in

order to relieve the pressure. Remove the cooling system ﬁller cap.

Note: Always discard drained ﬂuids according to local regulations.

2. If necessary, drain some coolant from the cooling

system into a suitable container in order to allow space for the extra SCA.

3. AddthecorrectamountofSCA.Refertothe

Operation and Maintenance Manual, “Reﬁll Capacities and Recommendations” for more information on SCA requirements.

Use a Coolant Conditioner Test Kit in order to check

he concentration of the SCA.

Page 79

SEBU8172-02 79

Maintenance Section

Crankcase Breather (Canister) - Replace

4. Clean the cooli gasket. If the gasket is damaged, discard the old ﬁller cap and install a new ﬁller cap. If the gasket is not damaged in order to pressure test the ﬁller cap. The correct pressure is stamped on the face of the ﬁ ller cap. If the ﬁller cap install a new ﬁller cap.

Crankcase

ng system ﬁller cap and inspect the

,useasuitablepressurizingpump

does not retain the correct pressure,

i02866782

Breather (Canister)

- Replace

NOTICE Ensure that the engine is stopped before any servicing or repair is performed.

Note: The breather assembly is not installed on all engines.

1. Place a container under the canister (1).

3. Lubricate the O

(3) with clean engine lubricating oil. Install the new canister. Tighten the canister to 12 N·m (8 lb ft). Do not overti g

4. Remove the container. Dispose of the old canister and any split

ring seal (2) on the new canister

hten the canister.

oil in a safe place.

i02151646

Driven Equipmen t - Check

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

Inspection

•

Adjustment

•

Lubrication

•

Other maintenance recommendations

•

2. Clean the outside of the canister. Use a suitable tool in order to remove the canister.

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

i01909392

Engine - Clean

onal injury or death can r esult from high volt-

Pers age.

sture can create paths of electrical conductiv-

Moi ity.

e sure that the electrical system is OFF. Lock

Mak out the starting controls and tag the controls “DO NOT OPERATE”.

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

Illustration 36

Typical example

g01428096

NOTICE

ailure to protect some engine components from

F washing may make your engine warranty invalid. Allow the engine to cool for one hour before washing the engine.

Page 80

80 SEBU8172-02 Maintenance Section Engine Air Cleaner Element (Dual Element) - Clean/Replace

Periodic clean 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 main

•

Note: Cautionmustbeusedinordertoprevent electrical excessive water when the engine is cleaned. Pressure washers and steam cleaners should not be directed a cables into the rear of the connectors. Avoid electrical components such as the alternator, the starter, and the ECM. Pr in order to wash the engine.

ing of the engine is recommended.

tenance

components from being damaged by

t any electrical connectors or the junction of

otect the fuel injection pump from ﬂuids

i02334355

Engine Air Cleaner Elemen t (Dual Element) - Clean/Replace

Operating in di

•

frequent service of the air cleaner element.

The air cleane

•

one time per year. This replacement should be performed regardless of the number of cleanings.

Replace the dirty air cleaner elements with clean air cleaner elements. Before installation, the air cleaner elements sh and/or holes in the ﬁlter material. Inspect the gasket or the seal of the air cleaner element for damage. Maintain a s for replacement purposes.

Dual Eleme

The dual element air cleaner contains a primary air cleaner el

The primary air cleaner element can be used up to six tim properly inspected. The primary air cleaner element should be replaced at least one time per year. This replace number of cleanings.

ement and a secondary air cleaner element.

es if the element is properly cleaned and

ment should be performed regardless of the

rty conditions may require more

r element should be replaced at least

ould be thoroughly checked for tears

upply of suitable air cleaner elements

nt Air C leaners

NOTICE

Never run the engine without an air cleaner element

led. Never run the engine with a damaged air

instal cleaner element. Do not use air cleaner elements with damaged pleats, gaskets or seals. Dirt entering the

e causes premature wear and damage to engine

engin components. Air cleaner elements help to prevent airborne debris from entering the air inlet.

NOTICE Never service the air cleaner element with the engine running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

Note: The air ﬁlter system may not have been

provided by Perkins. The procedure that follows is for a typical air ﬁlter system. Refer to the OEM information for the correct procedure.

If the air cleaner element becomes plugged, the air can split the material of the air cleaner element. Unﬁltered air will drastically accelerate internal engine wear. Refer to the OEM information for the correct air cleaner elements for your application.

Check the precleaner (if equipped) and the dust

•

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

The seco Refer to the OEM information for instructions in order to replace the secondary air cleaner element.

When the engine is operating in environments that are dusty or dirty, air cleaner elements may require more fr

Illustration 37

) Cover

) Primary air cleaner element

) Secondary air cleaner element

) Air inlet

1. Remove the cover. Remove the primary air

2. The secondary air cleaner element should be

ndary air cleaner element is not serviceable.

equent replacement.

g00736431

eaner element.

emoved and discarded for every three cleanings

r of the primary air cleaner element.

Page 81

SEBU8172-02 81

Maintenance Section

Engine Air Cleaner Element (Dual Element) - Clean/Replace

Note: Refer to “ Elements”.

3. Cover the air i

out.

4. Clean the ins

with a clean, dry cloth.

5. Remove the t

secondary air cleaner element. Install a primary air cleaner element that is new or cleaned.

6. Install the air cleaner cover.

7. Reset the a

Cleaning t

Cleaning the Primary Air Cleaner

nlet with tape in order to keep dirt

ide of the air cleaner cover and body

apefrom the air inlet. Install the

ir cleaner service indicator.

he Primary Air Cleaner

Elements

Refer to the OEM information in order to determine the number of times that the primary ﬁlter element can be cleane cleaned, check for rips or tears in the ﬁlter material. The primary air cleaner element should be replaced at least be performed regardless of the number of cleanings.

d. When the primary air cleaner element is

one time per year. This replacement should

Two methods may primary air cleaner element:

pressurized a

•

Vacuum cleaning

•

be used in order to clean the

Pressurized Air

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.

Pressurized air can be used to clean primary air cleaner elements that have not been cleaned more than three times. Use ﬁltered, dry air with a maximum pressure of 207 kPa (30 psi). Pressurized air will not remove deposits of carbon and oil.

NOTICE Do not t

Do not wash the primary air cleaner element.

Use low pressure (207 kPa; 30 psi maximum) pressurised air or vacuum cleaning to clean the primary air cl

Take extreme care in order to avoid damage to the air clean

Do not use air cleaner elements that have damaged plea

Refer to the OEM information in order to determine the element can be cleaned. Do not clean the primary air ﬁlter element more than three times. The primary air time per year.

Cl of the air ﬁlter element.

Vi before cleaning. Inspect air cleaner elements for damage to the pleats, the seals, the gaskets and

he outer cover. Discard any damaged air cleaner

t element.

ap or strike the air cleaner element.

eaner element.

er elements.

ts, gaskets or seals.

number of times that the primary air cleaner

cleaner element must be replaced at least one

eaning the air ﬁlter element will not extend the life

sually inspect the primary air cleaner element

Illustration 38

Note: When the primary air cleaner elements are cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside).

Aim the air hose so that air ﬂows along the length of the ﬁlter. Follow the direction of the paper pleats in order to prevent damage to the pleats. Do not aim the air directly at the face of the paper pleats.

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

g00281692

Page 82

82 SEBU8172-02 Maintenance Section Engine Air Cleaner Service Indicator - Inspect

Vacuum Cleanin

Vacuum cleaning is a good method for removing accumulated d primary air cleaner element. Vacuum cleaning is especially useful for cleaning primary air cleaner elements whi dry, dusty environment.

Cleaning fr air is recommended prior to vacuum cleaning the dirty side (outside) of a primary air cleaner element.

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

ch require daily cleaning because of a

om the clean side (inside) with pressurized

irt from the dirty side (outside) of a

Inspecting the Primary Air Cleaner Elements

i02335405

Engine Air C lean er Service Indicator - In

Some engines may be equipped with a different service indicator.

Some engines are equipped with a differential gauge for inlet air pressure. The differential gauge for inlet air pressur that is measured before the air cleaner element and the pressure that is measured after the air cleaner element. A the pressure differential rises. If your engine is equipped with a different type of service indicator, follow the the air cleaner service indicator.

The servi cleaner element or in a remote location.

e displays the difference in the pressure

s the air cleaner element becomes dirty,

OEM recommendations in order to service

ce indicator may be mounted on the air

spect

693

Illustration 39

Inspect the clean, dry primary air cleaner element. Usea60wattbluelightinadarkroomorinasimilar

ity. Place the blue light in the primary air cleaner

facil element. Rotate the primary air cleaner element. Inspect the primary air cleaner element for tears

or holes. Inspect the primary air cleaner element

and/ for light that may show through the ﬁlter material. If it is necessary in order to conﬁrm the result, compare

rimary air cleaner element to a new primary air

the p cleaner element that has the same part number.

ot use a primary air cleaner element that has

Do n any tears and/or holes in the ﬁlter material. Do not use a primary air cleaner element with damaged

ats, gaskets or seals. Discard damaged primary

ple air cleaner elements.

g00281

Illustration 40

Typical service indicator

Observe the service indicator. The air cleaner element should be cleaned or the air cleaner element should be replaced when one of the following conditions occur:

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 at the greatest vacuum that is attained.

Page 83

SEBU8172-02 83

Maintenance Section

Engine Air Precleaner - Check/Clean

If the service i yellow core does not latch at the greatest vacuum, the service indicator should be replaced. If the new service indic indicator may be restricted.

The service i frequently in environments that are severely dusty.

ndicator does not reset easily, or if the

ator will not reset, the hole for the service

ndicator may need to be replaced

i02343354

Engine Air Pre cleane r Check/Clean

Incorrect moun

•

Deterioration of the engine mounts

•

Loose engine mounts

•

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

ting of the engine

unt that shows deterioration should

i02335785

Engine Oil Level - Check

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

d hot components can cause personal

Illustration 41

Typical example

(1) Wing nut (2) Cover (3) Body

Remove wing nut (1) and cover (2). Check for an accumulation of dirt and debris in body (3). Clean the body, if necessary.

After cleaning the precleaner, install cover (2) and wing nut (1).

Note: When the engine is operated in dusty applications, more frequent cleaning is required.

gine Mounts - Inspect

Note: The engine mounts may not have been

supplied by Perkins. Refer to the OEM information

or further information on the engine mounts and the

f correct bolt torque.

g00287039

i02323089

65836

Illustration 42

(Y) “Min” mark. (X) “Max” mark.

NOTICE

Perform this maintenance with the engine stopped.

Note: Ensure that the engine is either level or that the engine is in the normal operating position in order to obtain a true level indication.

Note: After the engine has been switched OFF, wait for ten minutes in order to allow the engine oil to drain to the oil pan before checking the oil level.

1. Maintain the oil level between the “ADD” mark (Y) and the “FULL” mark (X) on the engine oil dipstick. Do not ﬁll the crankcase above the “FULL” mark (X).

g011

nspect the engine mounts for deterioration and for

I correct bolt torque. Engine vibration can be caused by the following conditions:

Page 84

84 SEBU8172-02 Maintenance Section Engine Oil Sample - Obtain

NOTICE Operating you “FULL” mark could cause your crankshaft to dip into the oil. The air bubbles created from the crankshaft dipping into t 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.

r engine when the oil level is above the

he oil reduces the oil's lubricating char-

i01907674

Engine Oil Sample - Obtain

The condition of the engine lubricating oil may be checked at regular intervals as part of a preventive maintenance program. Perkins include an oil sampling valve as an option. The oil sampling valve (if equipped) is included in order to regularly sample the engine lubricating oil. The oil sampling valve is positioned on the oil ﬁlter head or the oil sampling valve is positioned on the cylinder block.

Perkins recommends using a sampling valve in order to obtain oil samples. The quality and the consistency of the samples are better when a sampling valve is used. The location of the sampling valve allows oil that is ﬂowing under pressure to be obtained during normal engine operation.

Obtain the Sample and the Analysis

Ensure that the dry. Also ensure that the container for the sample is clearly labelled.

To ensure that the sample is representative of the oil in the crankcase, obtain a warm, well mixed oil sample.

To avoid contamination of the oil samples, the tools and the supp samples must be clean.

The sample c quality of the oil, the existence of any coolant in the oil, the existence of any ferrous metal particles in the oil, an particles in the oil.

Engine Oi

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.

Care must be taken to ensure that ﬂuids are contained

g performance of inspection, maintenance, test-

durin ing, adjusting and repair of the product. Be prepared to collect the ﬂuid with suitable containers before open-

ny compartment or disassembling any compo-

ing a nent containing ﬂuids.

container for the sample is clean and

lies that are used for obtaining oil

an be checked for the following: the

d the existence of any nonferrous metal

i02867741

l and Filter - Cha nge

NOTICE

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

•

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

ose of all ﬂuids according to local regulations and

Disp mandates.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Do not drain the engine lubricating oil when the

gine is cold. As the engine lubricating oil cools,

en suspended waste particles settle on the bottom of the oil pan. The waste particles are not removed with

rainingcoldoil.Draintheoilpanwiththeengine

d stopped. Drain the oil pan with the oil warm. This draining method allows the waste particles that are

uspended 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 85

SEBU8172-02 85

Maintenance Section

Engine Oil and Filter - Change

Drain the Engine Lub ricating Oil

Note: Ensure that the vessel that will be used is large

enough to collect the waste oil.

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

Replace the Oil Filter

NOTICE Perkins oil ﬁ ﬁcations.Useofanoilﬁlter that is not recommended by Perkins could result in severe damage to the engine bearin waste particles from unﬁltered oil entering the engine lubricating system. Only use oil ﬁlters recommended by Perkins.

1. Remove the oil ﬁlterwithasuitabletool.A

horizonta before removal.

Note: The part of the preventive maintenance program.

2. Cut the oi

apart the pleats and inspect the oil ﬁlter for metal debris. An excessive amount of metal debris in the oil ﬁ failure.

Useama metals and the nonferrous metals that are found in the oil ﬁlter element. Ferrous metals may indicate wear on

lters are manufactured to Perkins speci-

gs, crankshaft, etc., as a result of the larger

lly installed oil ﬁltercanbedrained

following actions can be carried out as

l ﬁlter open with a suitable tool. Break

lter may indicate early wear or a pending

gnet to differentiate between the ferrous

the steel and cast iron parts of the engine.

Illustration 43

Typical example

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 oil pan, 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, replace the O ring seal. Tighten the drain plug to 34 N·m (25 lb ft).

g01428532

Nonferrous metals may indicate wear on the

num parts, brass parts or bronze parts of the

alumi engine. Parts that may be affected include the following items: main bearings, rod bearings, and

charger bearings.

turbo

Due to normal wear and friction, it is not

mmon to ﬁnd small amounts of debris in the

unco oil ﬁlter.

Page 86

86 SEBU8172-02 Maintenance Section Engine Oil and Filter - Change

Horizontal Oil Filter

Illustration 44

Typical example

g01187802

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

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

NOTICE Do not ﬁll the oil ﬁlters with oil before installing them. This oil would not be ﬁltered and could be contaminated. Contaminated oil can cause accelerated wear to engine components.

5. Install the oil ﬁlter. Tighten the oil ﬁlter to 12 N·m

(8.8 lb ft). Do not overtighten the oil ﬁlter.

Illustration 45

Typical example

g01428535

Note: Some oil ﬁlters may be installed horizontally. Refer to illustration 45. This type of oil ﬁlter assembly canbedrainedbeforetheﬁlter is removed. Start at step1inordertoremovetheoilﬁlter and install the oil ﬁlter.

Fill the Oil Pan

1. Remove the oil ﬁller cap. Refer to this

Operation and Maintenance Manual, “Fluid Recommendations” for more information on suitable oils. Fill the oil pan with the correct amount of new engine lubricating oil. Refer to this Operation and Maintenance Manual, “Reﬁll Capacities” for more information on reﬁll capacities.

NOTICE

If equipped with an auxilliary oil ﬁlter system or a re-

te ﬁlter system, follow the OEM or the ﬁlter manu-

mo facture's remonmendations. Under ﬁlling or over ﬁ lling the crankcase with oil can cause engine damage.

2. Start the engine and run the engine at “LOW IDLE” for two minutes. Perform this procedure in

rder to ensure that the lubrication system has

o oil and that the oil ﬁlters are ﬁlled. Inspect the oil ﬁlter for oil leaks.

Page 87

SEBU8172-02 87

Maintenance Section

Engine Oil and Filter - Change

3. Stop the engine the oil pan for a minimum of ten minutes.

Illustration 46

(Y) “Min” mark. (X) “Max” mark.

4. Remove th check the oil level. Maintain the oil level between the “MIN” and “MAX” marks on the engine oil level gauge.

and allow the oil to drain back to

g01165836

e engine oil level gauge in order to

i02869394

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 ca use 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.

i02862580

Exhaust Manifold - Inspect

Engine Oil and Filter - Change (CG-4 Oil)

CG-4 engine oil may be used. If this grade of engine oil is used a 250 hour service interval is required for theengineoilandtheengineoilﬁlter.

i02503009

Eng

ine Valve Lash -

Inspect/Adjust

This maintenance is recommended by Perkins as

rt of a lubrication and preventive maintenance

pa schedule in order to help provide maximum engine life.

NOTICE

nly qualiﬁed service personel should perform this

O maintenance. Refer to the Service Manual or your authorized Perkins dealer or your Perkins distributor for

he complete valve lash adjustment procedure.

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

Illustration 47

1. Inspect the exhaust manifold for damage. If necessary, replace the exhaust manifold. Refer to Disassembly and Assembly, “Exhaust Manifold

- Remove and Install”.

2. Check the torque on all the bolts (1). The bolts must be tightened in the sequence that is shown in illustration 48.

g01425829

Page 88

88 SEBU8172-02 Maintenance Section Fan Clearance - Check

Illustration 48

g01363916

3. Tighten the bolts to the following torque 40 N·m (29.5lbft).

i0268333

Fan Clearan ce - Ch eck

There ar the OEM for information on clearance for the fan.

Ensure cooling system is full. The clearance between the cover (1) and the fan (2) will require checking. The gap (A) the fan blade must be checked in four equally spaced positions.

e different types of cooling systems. Refer to

that the engine is stopped. Ensure that the

between the edge of the cover and the tip of

Page 89

SEBU8172-02 89

Maintenance Section

Fuel System - Prime

Illustration 49

Adjustment of the cover will change the clearance (gap) between the edge of the cover and the tip of the fan blade. Ensure that the cover is centralized to the fan.

The maximum clearance is 12.5 mm (0.4921 inch). The minimum clearance is 6 mm (0.2362 inch).

i02871014

Fuel Sy stem - Prime

g01348394

Refer to the Operation and Maintenance Manual , “General Hazard Information and High Pressure Fuel Lines” before adjustments and repairs are performed.

Note: Refer to Systems Operation, Testing and Adjusting, “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

Ensure that all adjustments and repairs are performed by authorized personnel that have had the correct training.

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

If air enters the fuel system, the air must be purged from the fuel system before the engine can be started. Air can enter the fuel system when the following events occur:

Page 90

90 SEBU8172-02 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace

The fuel tank is

•

partially drained.

The low pressu

•

A leak exists in the low pressure fuel system.

•

The fuel ﬁlter has been replaced.

•

empty or the fuel tank has been

re fuel lines are disconnected.

Hand Fuel Priming Pump

Use the foll from the fuel system:

1. Ensure that Check that the fuel supply valve (if equipped) is in the “ON” position.

owing procedures in order to remove air

the fuel system is in working order.

Note: Operatin help ensure that the fuel system is free of air.

Note: Do not lo in order to purge air from the fuel system. This procedure is not required.

After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and Assembly Manual, “Fuel Injection Lines - Install”.

g the engine for this period of time will

osen the high pressure fuel line

Illustration 50

Typical example

2. Operate the fuel priming pump (1). Count the number of operations of the fuel priming pump. After 100 depressions of the fuel priming pump stop.

3. The engine fuel system should now be primed and the engine should now be able to start.

4. Operate the engine starter and crank the engine. After the engine has started, operate the engine at low idle for a minimum of ﬁve minutes, immediately after air has been removed from the fuel system.

g01476592

i02869425

Fuel System Primary Filter (Water Separa tor) Element Replace

Type O ne Filter

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. Cleanupfuelspillsimmediately.

Note: Refer to Testing and Adjusting M anual , “Cleanliness of Fuel System Components” for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

Page 91

SEBU8172-02 91

Maintenance Section

Fuel System Primary Filter (Water Separator) Element - Replace

NOTICE

Ensure that th

e engine is stopped before any servicing

or repair is performed.

After the engine has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the cooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, “Fuel Injection Lines - Install”.

1. Turn the fuel supply valve (if equipped) to the OFF position before performing this maintenance.

2. Place a suitable container under the water separator in order to catch any fuel that might spill. Clean up any spilled fuel. Clean the outside of the water separator.

7. Use a suitable t

ool in order to remove canister (4). Discard the old seals (5 and 6) and the canister in asafeplace.

8. Clean glass bowl (3).

Illustration 52

Typical example

g01259366

Illustration 51

Typical example

g01259363

3. Install a suitable tube onto drain (1). Open the drain (1). Allow the ﬂuid to drain into the container. Remove the tube.

4. Tighten drain (1) by hand pressure only.

5. If equipped, remove the wiring harness from the

sensor on the bottom of the glass bowl.

6. Hold glass bowl (3) and remove screw (2). Remove glass bowl (3) from canister (4).

9. Install the new canister. Do not use a tool in order to install the canister. Tighten the canister by hand.

10. Install new O ring seal (5) onto setscrew (2). Install new O ring seal (6) into the glass bowl.

11. Align the glass bowl to the canister. Ensure that the sensor (if equipped) is in the correct position. Install setscrew (2). Tighten the setscrew to a torqueof5N·m(44lbin).

12. If equipped, install the wiring harness to the sensor.

13. Remove the container and dispose of the fuel in asafeplace.

14. The secondary ﬁlter must be replaced at the same time as th e primary ﬁlter. Refer to the Operation and Maintenance Manual , “Fuel System Filter Replace”.

Type Tw o Fil ter

Page 92

92 SEBU8172-02 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace

After the engin

e has stopped, you must wait for 60 seconds in order to allow the fuel pressure to be purged from the high pressure fuel lines before any service or

repair is performed on the engine fuel lines. If necessary, perform minor adjustments. Repair any leaks from the low pressure fuel system and from the c

ooling, lubrication or air systems. Replace any high pressure fuel line that has leaked. Refer to Disassembly and assembly Manual, “Fuel Injection L

ines - Install”.

NOTICE Ensure that the engine is stopped before any servicing or repair i

sperformed.

1. Turn the fuel supply valve (if equipped) to the OFF

position before performing this maintenance.

2. Place a suitable container under the water

separator in order to catch any fuel that might spill. Clean up any spilled fuel. Clean the outside of the water separator.

Illustration 53

stall a suitable tube onto drain (1). Open drain

3. In

(1). Allow the ﬂuid to drain into the container. Remove the tube.

g01429124

Illustration 54

6. Rotate b

owl (3) counterclockwise in order to remove the bowl. Remove O ring seal (2). Clean the bowl.

g01429125

4. Tighten drain (1) by hand pressure only.

f equipped, remove the wiring harness from the

5.I

sensor on the bottom of the bowl .

Illustration 55

g01429126

Page 93

SEBU8172-02 93

Maintenance Section

Fuel System Primary Filter/Water Separator - Drain

7. Useasuitablet (4).

Illustration 56

ool in order to remove old canister

g01429127

i02869410

Fuel System Primary Filter/Water

Ensure that the engine is stopped before any servicing or repair is performed.

Separator - Drain

NOTICE

8. Lubric

9. Remov

10. Lubricate O ring seal (7) with clean engine oil.

11. If equipped, install the wiring harness to the

12. Remove the container and dispose of the ﬂuid in

13. The secondary ﬁlter must be replaced at the same

ate O ring seal (5 ) with clean engine oil on the new canister. Install new canister (6). Spin on the canister until the O ring seal contacts the

ng surface. Then rotate the canister 360

seali degree in order to tighten the canister correctly.

e cap (8) from the threaded end of the new canister and remove new O ring seal (7). Install thenewOringsealintobowl(3).

Install the bowl onto the new canister. Tighten the

to 15 N·m (11 lb ft).

bowl

sor. Open the fuel supply valve.

sen

fe place.

asa

me as the primary ﬁlter. Refer to the Operation

ti and Maintenance Manual , “Fuel System Filter Replace”.

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

1. Place a suitable container under the water

separator in order to catch any fuel that might spill. Cleanupanyspilledfuel.

Page 94

94 SEBU8172-02 Maintenance Section Fuel System Secondary Filter - Replace

Illustration 57

Typical example

2. Install a suitable tube onto the drain (1). Open the drain (1). Allow the ﬂuid to drain into the container.

3. Tighten the drain (1) by hand pressure only. Remove the tube and dispose of the drained ﬂuid inasafeplace.

g01476633

1. Install a suita screw (2).

2. Open drain (1) container.

3. Tighten drai the tube and dispose of the drained ﬂuidinasafe place.

4. Tighten vent screw to 6 N·m (53 lb in).

ble tube onto drain (1). Loosen vent

.Allowtheﬂuidtodrainintothe

n (1) by hand pressure only. Remove

i02869989

Fuel System Seco nd ary Filter Replace

Type One

Primary Filter with a Vent Screw

Illustration 58

Typical example

Note: Not all primary ﬁlters require vent screw (2). This primary fuel ﬁlter that has a vent screw may be installed on a fuel system that has a low fuel tank.

g01371846

NOTICE Ensure that the engine is stopped before any servicing or repair is performed.

This fuel ﬁltercanbeidentiﬁed by the six drain holes in the ﬁlter. Refer to illustration 59.

Page 95

SEBU8172-02 95

Maintenance Section

Fuel System Secondary Filter - Replace

Illustration 59

Typical example

g01429525

1. Ensure that the fuel supply valve (if equipped) is in the OFF position. Place a suitable container under the fuel ﬁlter in order to catch any fuel that might spill. Clean up any spilled fuel.

Illustration 60

Typical example

g01429517

2. Clean the outside of the fuel ﬁlter. Use a suitable tool in order to remove the canister (2) from the engine and dispose of the canister in a safe place.

3. Ensure that dirt can not enter the new canister. Do not ﬁll the canister with fuel before the canister is installed. Lubricate the O ring seal (1) with clean engine oil on the new canister.

4. Install the new canister. Do not use a tool in order to install the canister. Tighten the canister by hand.

5. Spin on the canister until the O ring seal contacts the sealing surface. The canister will require a ¾ of a full turn in order to tighten the canister correctly .

6. Prime the fuel system. Refer to the Operation and Maintenance Manual, “Fuel System - Prime” for more information.

Type Two

Page 96

96 SEBU8172-02 Maintenance Section Fuel System Secondary Filter - Replace

NOTICE

Ensure that th

e engine is stopped before any servicing

or repair is performed.

Illustration 61

g01429532

This fue l ﬁltercanbeidentiﬁed by the 12 drain holes in the ﬁlter. Refer to illustration 61.

1. Ensure that the fuel supply valve (if equipped) is in the OFF position. Place a suitable container under the fuel ﬁlter in order to catch any fuel that might spill. Clean up any spilled fuel.

Illustration 62

Typical example

g01429516

2. Clean the outside of the fuel ﬁlter. Use a suitable tool in order to remove the canister (2) from the engine and dispose of the canister in a safe place.

3. Ensure that dirt can not enter the new canister. Do not ﬁll the canister with fuel before the canister is installed. Lubricate the O ring seal (1) with clean engine oil on the new canister.

4. Install the new canister. Do not use a tool in order to install the canister. Tighten the canister by hand.

5. Spin on the canister until the O ring seal contacts the sealing surface. Then rotate the canister 360 degree in order to tighten the canister correctly.

6. Remove the container and dispose of the fuel in a safe place. If equipped, open the fuel supply valve.

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

Page 97

SEBU8172-02 97

Maintenance Section

Fuel Tank Water and Sediment - Drain

i02335436

Fuel Tank Water and Sediment

-Drain

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.

Fuel Tank

Fuel quality is critical to the performance and to the service life of the engine. Water in the fuel can cause excessive wear to the fuel system.

Water can be introduced into the fuel tank when the fuel tank is being ﬁlled.

Condensation occurs during the heating and cooling of fuel. The condensation occurs as the fuel passes through the fuel system and the fuel returns to the fuel tank. This causes water to accumulate in fuel tanks. Draining the fuel tank regularly and obtaining fuel from reliable sources can help to eliminate water in the fuel.

Some fuel tanks and sediment to settle below the end of the fuel supply pipe. Some fuel tanks use supply lines that take fuel dire the engine is equipped with this system, regular maintenance of the fuel system ﬁlter is important.

use supply pipes that allow water

ctly from the bottom of the tank. If

Fuel Storage Ta nks

Drain the water and the sediment from the fuel storage tank at the following intervals:

Weekly

•

Service int

•

Reﬁll of the tank

•

This will help prevent water or sediment from being pumped from the storage tank into the engine fuel tank.

If a bulk storage tank has been reﬁlled or moved recently settle before ﬁlling the engine fuel tank. Internal bafﬂes in the bulk storage tank will also help trap sedimen storage tank helps to ensure the quality of the fuel. When possible, water separators should be used.

ervals

, allow adequate time for the sediment to

t. Filtering fuel that is pumped from the

i02349879

Hoses and Clamps Inspect/Replace

Drain the Water and the Sediment

Fuel tanks should contain some provision for draining water and draining sediment from the bottom of the fuel tanks.

Open the drain valve on the bottom of the fuel tank in order to drain the water and the sediment. Close the drain valve.

Check the fuel daily . Allow ﬁve minutes after the fuel tank has been ﬁlled before draining water and sediment from the fuel tank.

Fill the fuel tank after operating the engine in order to drive out moist air. This will help prevent condensation. Do not ﬁll the tank to the top. The fuel expands as the fuel gets warm. The tank may overﬂow.

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

Cracking

•

Softness

•

Loose clamps

•

Page 98

98 SEBU8172-02 Maintenance Section Radiator - Clean

Replace hoses t loose clamps.

Check for the f

End ﬁttings that are damaged or leaking

•

Outer covering that is chafed or cut

•

Exposed wir

•

Outer covering that is ballooning locally

•

Flexible part of the hose that is kinked or crushed

•

Armoring t

•

A constant torque hose clamp can be used in place of any stan torque hose clamp is the same size as the standard clamp.

Due to extreme temperature changes, the hose will harden. Hardening of the hoses will cause hose clamps to torque hose clamp will help to prevent loose hose clamps.

Each installation application can be different. The differences depend on the following factors:

Type of hose

•

Type of

•

hat are cracked or soft. Tighten any

ollowing conditions:

e that is used for reinforcement

hat is embedded in the outer covering

dard hose clamp. Ensure that the constant

loosen. This can result in leaks. A constant

ﬁtting material

1. Stop the engine

2. Loosen the cooling system ﬁller cap slowly in

order to relie system ﬁller cap.

Note: Drain t container. The coolant can be reused.

3. Drain the co level that is below the hose that is being replaced.

4. Remove the h

5. Disconnect the old hose.

6. Replace the old hose with a new hose.

7. Install th

Note: For the correct coolant, see this Operation and

Maintena

8. Reﬁll the cooling system. Refer to the OEM informat cooling system.

9. Clean th cooling system ﬁller cap's seals. Replace the cooling system ﬁller cap if the seals are damaged. Install

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

e hose clamps with a torque wrench.

nce Manual, “Fluid Recommendations”.

ion for further information on reﬁlling the

ecoolingsystemﬁller cap. Inspect the

the cooling system ﬁller cap.

. Allow the engine to cool.

ve any pressure. Remove the cooling

he coolant into a suitable, clean

olant from the cooling system to a

ose clamps.

Anticipated expansion and contraction of the hose

•

Anticipated expansion and contraction of the

•

ﬁttings

Replace the Hoses and the Clamps

Refer to the OEM information for further information on removing and replacing fuel hoses (if equipped).

The coolant system and the hoses for the coolant system are not usually supplied by Perkins. The

lowing text describes a typical method of replacing

fol coolant hoses. Refer to the OEM information for further information on the coolant system and the

es for the coolant system.

hos

Pressurized System: Hot coolant can cause serious burns. To open the cooling system ﬁller cap,

op the engine and wait until the cooling system

st components are cool. Loosen the cooling system pressure cap slowly in order to relieve the pres-

ure.

i02335774

Radia

The radiator is not usually supplied by Perkins. The following text describes a typical cleaning procedure for t further information on cleaning the radiator.

Note

the effects of the operating environment.

pect the radiator for these items: Damaged ﬁns,

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

tor - Clean

he radiator. Refer to the OEM information for

: Adjust the frequency of cleaning according to

Page 99

SEBU8172-02 99

Maintenance Section

Severe Service Application - Check

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.

Pressurized air is the preferred method for removing loose debris. Direct the air in the opposite direction to the fan's air ﬂow. Hold the nozzle approximately 6 mm (0.25 inch) away from the radiator ﬁns. Slowly move the air nozzle in a direction that is parallel with the radiator tube assembly. This will remove debris that is between the tubes.

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

Use a degreaser and steam for removal of oil and grease. Clean both sides of the core. Wash the core with detergent and hot water. Thoroughly rinse the core with clean water.

If the radiator is blocked internally, refer to the OEM Manual for information regarding ﬂushing the cooling system.

After cleaning the radiator, start the engine. Allow the engine to operate at low idle speed for three to ﬁve minutes. Accelerate the engine to high idle. This will help in the removal of debris and the drying of the core. Slowly reduce the engine speed to low idle and then stop the engine. Use a light bulb behind the core in order to inspect the core for cleanliness. Repeat the cleaning, if necessary.

Inspect the ﬁns for damage. Bent ﬁns may be opened with a “comb”. Inspect these items for good condition: Welds, mounting brackets, air lines, connections, clamps, and seals. Make repairs, if necessary.

i02335775

Performance su

•

and fuel consumption

Fuel quality

•

Operational Altitude

•

Maintenance intervals

•

Oil selecti

•

Coolant type and maintenance

•

Environmental qualities

•

Installat

•

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 determin parameters.

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

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

The op procedures and incorrect maintenance procedures can be factors which contribute to a severe service appli

Envi

Ambient temperatures – Theenginemaybe

expo cold environments or hot environments. Valve components can be damaged by carbon buildup if the cold temperatures. Extremely hot intake air reduces engine performance.

ion

e if the engine is operating within the deﬁned

rvice operation can accelerate component

ensure maximum reliability and retention of

dividual applications, it is not possible

or your Perkins distributor for the unique

erating environment, incorrect operating

cation.

ronmental Factors

sed to extended operation in extremely

engine is frequently started and stopped in very

ch as power range, speed range,

on and maintenance

Severe Service Application Check

evere service is the application of an engine that

S exceeds the current published standards for that engine. Perkins maintains standards for the following

ngine parameters:

Quality of the air – The engine may be exposed to extended operation in an environment that is

rty or dusty, unless the equipment is cleaned

di regularly. Mud, dirt and dust can encase components. Maintenance can be very difﬁcult. The buildup can

ntain corrosive chemicals.

Buildup – Compounds, elements, corrosive

emicals and salt can damage some components.

Page 100

100 SEBU8172-02 Maintenance Section Starting Motor - Inspect

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

Incorrect Ope

Extended operation at low idle

•

Frequent hot shutdowns

•

Operating a

•

Operating at excessive speeds

•

Operating outside the intended application

•

lems can arise when the engine is

rating Procedures

t excessive loads

Incorrect Maintenance Procedures

Extendin

•

Failure to use recommended fuel, lubricants and

•

coolant/

Startin

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

g the maintenance intervals

antifreeze

i02177969

g Motor - Inspect

start in an emergency situation.

NOTICE Turbocharger ties of oil to enter the air intake and exhaust systems. Loss of engine lubricant can result in serious engine damage.

Minor leakage of oil into a turbocharger under extended low idle op 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 eng engine operation until the turbocharger is renewed.

Avisualin unscheduled downtime. A visual inspection of the turbocharger can also reduce the chance for potential damage to

Removal

For options regarding the removal, installation, and repl your Perkins distributor. Refer to the Disassembly and Assembly, “Turbocharger - Remove and Turboc Testing and Adjusting, “Turbocharger - Inspect” for further information.

harger - Install” and Systems Operation,

bearing failures can cause large quanti-

eration should not cause problems as

ine rpm up at no load), do not continue

spection of the turbocharger can minimize

other engine parts.

and Installation

acement, consult your Perkins dealer or

Inspecting

Check the starting motor for correct operation. Check

ectrical connections and clean the electrical

the el connections. Refer to the Systems Operation, Testing and Adjusting Manual, “Electric Starting System -

for more information on the checking procedure

Tes t” and for speciﬁcations or consult your Perkins dealer or your Perkins distributor for assistance.

i04149590

Turboc harger - Inspect

A regular visual inspection of the turbocharger is recommended. If the turbocharger fails during engine operation, damage to the turbocharger compressor wheel and/or to the engine may occur. Damage to the turbocharger compressor wheel can cause additional damage to the pistons, the valves, and the cylinder head.

NOTIC The compressor housing for the turbocharger must not be removed from the turbocharger for inspection

moved for the cleaning of the compressor.

or re

1. Remove the pipe from the turbocharger exhaust

let and remove the air intake pipe to the

out turbocharger. Visually inspect the piping for the presence of oil. Clean the interior of the pipes

rder to prevent dirt from entering during

in o reassembly.

eck for obvious heat discoloration of the

2. Ch

turbocharger. Check for any loose bolts or any missing bolts. Check for damage to the oil supply

ne and the oil drain line. Check for cracks in

li the housing of the turbocharger. Ensure that the compressor wheel can rotate freely.

3. Check for the presence of oil. If oil is leaking from

the back side of the compressor wheel, there is a

ossibility of a failed turbocharger oil seal.

Perkins Engine 1104D Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual